PVC Water Pumps

By: Joseph
Longenecker

September 2010

P V C WAT E R
PUMPS

Whats Inside:
Pump Design
Manufacturing Process
Pump Performance

I NTRODUCTION
The purpose of this document is to show several
water pump designs constructed from PVC pipe,

Appendix

explain how to manufacture them, and discuss

pump performance and how to improve on these
designs.

Copyright ECHO 2007. All rights reserved. This document may

be reproduced for training purposes if distributed free of charge or
at cost and credit is given to ECHO. For all other uses, contact
echo@echonet.org for written permission.

PVC Water Pumps

TableofContents
_____________________________________________________________________________

PumpPerformance
PumpDesigns
17
2
RowerPump
Definitionofterms
6
HandPressurePump
17
SomePrinciplesofwaterpumping
6
HandSuctionPump
18
RowerPumpPerformance
7
MarblePump
20
PerformanceofMarbleandInertiapumps
8
SockPump
20
Factorsthataffectpumpperformance
8
InertiaPump
21
DesigningaPump:Tradeoffs
8
ReciprocatingRopePump
22
Alternativedesignsforcomponents
9
TreadleSuctionPump
23
Testingmethodologyanddata

ManufacturingProcesses
Appendix
10
SoftenPVCbyheating
25
Imperialtometricconversions
11
FlarePVCpipe
25
Acknowledgments
11
MakePVCsheet
25
Bibliography
12
CompressPVCpipe
25
Contactformoreinformation

12
CutPVCdiscs

13
DrillPVCwithahanddrill

13
Tapthreadedholes

14
Markaradialvalveholepattern

14
Findtheexactcenterofacircle

15
Deburraholeorpipe

15
Punchaholeinrubbersheet

15
Cutadiscfromrubbersheet

16
CutPVCpipesquare

16
GluePVCpipe

16
GlueaPVCdisctotheendofapipe

16
GlueaPVCdiscinsidetheendofapipe

16
Makealargehoseclamp

16
HeatformaholeinPVC

16
BendPVCpipe

PVC Water Pumps

PumpDesigns

RowerPump

Therowerpumpisoperatedusingthearmandback
musclessimilartorowingaboat.Thecylinderis
mountedhorizontallyandthehandleisattacheddirectly
tothepistonrod.Itcanbepositionedeitherforstanding
orseatedoperation.Theergonomicposition,combined
withthe3footstroke,givestherowerpumpan
outputof1020gallonsperminute,muchhigherthan
otherhandpumps.Liftisupto27feetsuctionandat
least8feetpressurewiththeuseofarodseal.

Rowerpumpinstalledataborehole

Components

Dimensionsofallcomponentswilldependonsizesof
availablePVCpipe.Listedvaluesareforprototypes
builtatECHO.Criticalrelationshipsbetween
dimensionsarediscussed,allowingthedesignertobuild
apumpsuccessfullyfromanysizepipehedesires.

Thepumpcylinderisthebodyofthepumpinwhichthe
pistonslidesupanddown.Deburrbothendsofthe
pipeandglueaTeeontothetopend.Notethat
AmericanPVCismeasuredbytheinnerdiameter,while
WestAfricanPVCwhichismeasuredbyouterdiameter.
Sch.40ismediumwallpipe.

InletPipe

Theinletpipeextendsfromthefootofthecylinderinto
thewater.Thetopoftheinletmustbeequaltothe
pumpcylinderdiameter,butitcanbereducedtoa
smallerdiameterpipetosavecostandreducepriming
time.Asaruleofthumb,theinletpipediametershould
giveaflowareathatofthepumpcylinder.This
requiresaninletpipediameter0.707ofthecylinder.
Dontuseaninletpipelessthanthecylinderdiameter;
wastedenergyduetopipefrictionwillbecome
significant.However,ifyoubuildasurgechamber,
smallerinletpipecanbeused(seethetestingsection).

Theinletpipewillneedtobebentdependingonthe
watersourceandthemountingangleofthepump.See
themanufacturingsectiononbendingpipe.Ifasharp
bendisneeded,usea45or90degreefitting.

FootValve

Thefootvalveisacheckvalve(onewayvalve)that
allowswaterintothebottom(foot)ofthecylinderbut
notbackout.Arubberwasherisboltedtothecenterof
aPVCdiscwitharadialarrayofholes.ThePVCdiscis
gluedtothetopoftheinletpipeandthecylinderis
heatedandflaredovertheinletpipe.Therubberflaps
upwhenthepistonsuckswaterintothecylinder,but
bridgesovertheholeswhenthewaterreverses
direction.

Tightentheboltuntiltherubberjuststartstoliftatthe
edges.Iftherubberiscompressedtoomuchinthe
center,theedgeswillliftupinaconeshape.Thiswill
notpreventthevalvefromclosingduringoperation,but
canmakeitbounceopenandloseprime.

Rowerpumpcomponents

PumpCylinder

Material:2Sch.40PVCpipe
Length:43

Explodedviewoffootvalvecomponents

PVC Water Pumps

Assembledfootvalve

RubberValveFlap
Material:Truckinnertuberubber(orotherrubbersheet
1/16thick)
Useacircularpunchtomakethecenterhole;thiswill
keeptheflapcenteredandreducethechanceofit
pullingoffthebolt.Therubbershouldoverlapthevalve
holesbyatleast1/16topreventitfrombeingsucked
intotheholeattheedge,breakingtheseal.Itshouldbe
atleast1/16fromtheedgeofthePVCvalvediscto
preventitfromcatchingoninsideofthepumpcylinder
whereitflaresoutoverthefootvalve.Bicycletube
rubberisnotstiffenoughtobridgethevalveholes,
althoughlayeringseveralpiecesmaywork.

Footvalvediscdimensions

HoseClamp
Thefootvalveisheldinplacewithahoseclamponthe
footofthecylinder.Makeeightcuts1/2deepintothe
endofthecylindersotheplasticcanflexintogripthe
inletpipe.Beforeputtingonthehoseclamp,wrapthe
jointtightlywithastripofbicycleinnertube.This
providesadditionalsealagainstthesmallamountofair
thatwillbeabletoleakbetweentheinletpipeand
cylinderfoot.

Thefootvalvejoint,wrappedinrubberandhoseclamped

Rubbervalveflapdimensions

PVCValveDisc
Material:4Sch.40PVCpipe,flattened(aboutthick)
Togettheedgeexactlyflushwiththeinletpipe,cutthe
discslightlylarger,glueittotheinletpipe,andfileit
downtothepipe.Whentappingthecenterhole,only
runthetappartwaythroughsothattheboltstartseasily
buttightensup.Makesurethevalveholesareatfar
enoughfromtheedgesothattheinletpipeunderneath
doesnotblockthem.Seethesectiononalternative
checkvalvedesignsfortipsongettingthemostflow
areaforyourpipesizewithoutweakeningthevalve.

SurgeChamber

Material:4PVCpipeandreducers
Length:18
Thesurgechamber(optional)isbelowthefootvalve.It
absorbssharpvacuumspikescreatedbythepistonand
evensouttheflowofwateruptheinletpipe(seethe
sectiononpumpperformance).Thesurgechamber
shouldhaveavolume2xthepumpcylinder.The
diameterandlengtharenotimportantifthisvolumeis
maintained.

PVC Water Pumps

Surgechamberonrowerpump

HeadSeal

Theheadseal(rodseal)sealsaroundthepistonrodso
thatwatercanbepumpedtohigherelevation.Arubber
washerissandwichedbetweentwoPVCdiscs,witha
PVCbushingontoptokeeptherodcentered.These
componentsmustbeassembledonthepistonrodbefore
attachingthehandle.Theyshouldfitsnuglybutnot
tightlyintotheTeesotheyareeasytoremovefor
maintenance.

Explodedviewofheadsealcomponents

Rubberwasher
Material:truckinnertubeatleast1/16thick
Thecenteriscutusingacircularpunch.Itisvery
importantthatthecutissmooth,assmallcutsandtears
willpropagateunderthecyclicloading.Thediameter
shouldbe1/16smallerthantheroddiametertogivea
goodsealwithoutexcessivefrictionandstressonthe
rubber.Doubleuprubberwashersiftheyarenotthick
enough.

Rubbersupportdiscs[2]
Material:4PVCpipe,flattened(about1/4thick)
Thediscthicknessisrequiredsothatastherubberflexes
upanddownwiththerod,itisnotcaughtintherod
bushingaboveit.Theholediametershouldbeatleast
fourrubberthicknesslargerthantheroddiameterto

preventtherubberfrombindinginthegapasitflexes
upanddown.

Rodbushing
Material:PVCorHDPEplastic
Thepurposeofthebushingistokeeptherodcentered
soitdoesnotdeformtherubberandallowleaks.HDPE
(#2)plasticwearsmuchbetterthanPVCandhashigh
lubricity.Someplasticbarrelsaremadefromit.Itcan
beflattenedbyheatthesameasPVC.Woodisanother
option:Awoodbushingcanreplaceboththebushing
discandtheretainerring.Therodshouldslidethrough
thebushingwithaslittleclearanceaspossiblewithout
sticking.Ifyoulackprecisecuttingtools,seeHeat
formaholeinthemanufacturingsection.

RetainerRing
Thisisasmallsectionof2pipeinsertedabovethehead
sealcomponentstoholdtheminplaceandgivethehose
clampsomethingtogrip.Sizeittoleaveasmallamount
protrudingfromTeefittingtoallowatooltogripit
shoulditbecomestuck.

HoseClamp
Makeeightcuts1/2deepintothetopoftheTeesothe
plasticcanflexintogriptheretainerring.

Piston

Thepistonslidesupanddowninthecylindercreating
suctiontopullwaterintothepump.Inthispiston
design,therubberdiscsservebothasthepistonsealand
asthecheckvalveflap.Onthedownstroketherubber
foldsoutofthewayasthepistonmovesthroughthe
watercolumn.Ontheupstroke,therubberissucked
downagainstthePVCdiscandwaterpressureforcesit
outagainstthecylinderwall,sealing.Thisdesign
pumpssandverywellbecauseoneverystroketheseal
breakscontactwiththecylinder,allowingany
accumulatedsandparticlestobeflushedout.

Explodedviewofpistoncomponents

PistonValveDisc
Material:4PVCpipe,flattened(aboutthick)

PVC Water Pumps

Thediameterofthediscshouldbe1/8lessthanthe
cylinderdiameter,giving1/16clearancewiththe
cylinderonallsides.Itisimportantthatthediscbe
exactlycircularandthattheholebeexactlyinthecenter.
Waterleakageandfrictionwillincreaseastheprecision
ofthevalvediscdecreases.Whentappingthecenter
hole,onlyrunthetappartwaythroughsothatthebolt
startseasilybuttightensup.

Pistonvalvediscdimensions

RubberValveFlap[23]
Material:Truckinnertuberubber(orotherrubbersheet
1/16thick)
Thediametershouldbe1/16greaterthanthecylinder
diameter.Thisallowstherubbertofollowirregularities
inthecylinderwallwithoutbreakingcontactor
bunchingupattheedges.Itisimportantthattheflapbe
exactlycircularandthattheholebeexactlyinthecenter.
Waterleakageandfrictionwillincreaseastheprecision
ofthevalveflapdecreases.Useacircularpunchto
makethecenterhole;thiswillkeeptheflapcentered
andreducethechanceofitpullingoffthebolt.Dont
usebicycletuberubber;itwillstretchatthecenterhole
andtheflapswillbepulledoffcenterandbindbetween
thePVCdiscandcylinderwall.

Thenumberofrubberdiscswilldependonthethickness
oftherubberandthegapsizebetweenthevalvedisc
andcylinderwall.Asaruleofthumb,thetotalrubber
thicknessshouldbeequaltothegapdistance.Ifthe
rubberistoothin,waterwillleakpast;iftoothick,
frictionwillbeexcessiveandthepistonmaybindinthe
cylinder.Tip:addmorerubberdiscsuntilyoufeelthe
rubbergrabbingthecylinderwallwhenyoupullslowly
onthepiston,thenuseoneless.

PistonBolt
Thepistonboltis5/1618x1long.Usegalvanized,
stainless,orpaintedhardwaretoresistcorrosion.

Woodplug
Material:hardwood

ThewoodplugisinsertedintotheendofthePVCpiston
rodbyheatingit.Theplugistaperedwiththelargeend
insertedfirsttolockitinplace.Thesmallendisslightly
largerthanthepipediameter.Iftheendoftherodis
greaterthandiameter,bevelitsothepistonvalve
holesarenotblocked.Inthecenteroftheplug,a1/4
holeisdrilledthroughandtapped5/1618toreceivethe
pistonbolt.Tapasdeepasthetapwillgo.

PistonRodandTHandle

Material:PVCpipeandTee
Length:Rodis44,eachsideofhandleis5
Gluebothsidesofthehandle,butattachtherodwith
twoscrewsthroughthesideoftheTee.Therodmustbe
detachedtoreplacetheheadsealrubber.PVCpipeis
chosenbecauseitissmoothandwillwearslowlyonthe
headseal.Anaddedbenefitisthatthehighflexibilityof
thinpipeallowssidetosidemovementofthehandle
withoutputtingstressontheheadseal.Ifthepumpis
abused,thehandlewillbreakfirst,ratherthanbreaking
theheadsealorcylinder.Thepistonrodismosteasily
replaced.Seetheappendixforadditionalhandleand
pistonrodoptions.

Installation

Cylinderangle

Thebestangleforthecylinderwilldependonwhether
youhavearodseal.Ifyes,setthepumpcloseto
horizontal,withthefootvalvethreeinchesbelowthe
headseal(thiswillkeepwateronthefootvalvesoit
doesnotloseprime).Ahorizontalpullismost
ergonomicbothfromastandingandseatedposition.If
norodseal,mountthepumpatasteeperangle,30deg
fromhorizontal,toreducethedistancewatersplashes
outofthetopofthecylinder.

Securingthepump

Oneoptionistoburrythepumpinamoundofdirt.
Anotheristoplanttwosetsofpolesinthegroundatthe
headandfootofthecylinder.Insertapegthroughtwo
polessothepumpcanrestbetweenthemonit.Lashthe
polestogethertosecurethepump.

PVC Water Pumps

7
Thispumpworksmostefficientlyifsomewaterleaks
pastthepistonseal,providingawaterbarriersoair
cannotleakpastthesealontheupstroke.Toventthis
watersoitdoesnotblowoffthecap,aholeisdrilled
inthetopofthecylinderdirectlybelowthecap(onthe
darksideofthebelowphotograph).Thecylindercapis
onlytosupportthepistonrod.

Rowerpumpclampedbetweentwosetsofpoles

SunProtection

PVCdegradesinUVlightandbecomesbrittle.Paintthe
pump,coveritwithashelter,orburyitinamoundof
dirt.

OtherRowerDocumentation

TheMennoniteCentralCommittee(MCC)hasagood
constructionmanualfortheirversionoftherower
pump.Thisdocumentisavailableinelectronicformby
requestfromECHO.

HandPressurePump

Thehandpressurepumpisoperatedsimilartoabicycle
airpump.Itisintendedtobeplacednearawatersource
andforcewateruphilloroveragreatdistance.The
pistonissolid,pullingwaterintothecylinderthrough
onecheckvalveandexpellingitthroughanother.Check
valvesareradialflappervalvesinsertedinbothendsof
theTeeatthebottomofthecylinder.Theendsofthe
Teeareslottedsimilartotheheadandfootoftherower
pump;byremovingthehoseclampsthevalvediscsmay
beremoved.Thecylinderis2diameter.The1plastic
hoseandballvalvepicturedbelowarefortestingonly;
liketherowerpump,itisrecommendedtousesuction
anddischargepipingatleasttheareaofthecylinder.

Handpressurepump

Thepistonsealissimilartotherowerpump,buttwo
rubbersealsareused,oneoneithersideofthePVCdisc.
Thiscreatesasealwhenthepistonmovesineither
direction.ThepistonrodisPVCpipewithanendcap,
tappedtoaccepttheboltthatholdstherubberandPVC
discinplace.

Handpressurepumppiston

PVC Water Pumps

HandSuctionPump

Thehandsuctionpumpissimilarinconstructiontothe
rowerpump.Itismoreportableanddoesnotneedto
beanchoreddown.Outputisprobablysimilarbuthas
notbeenmeasured.Thepumppicturedbelowhasa3
cylinderand2suctionhoseforlargevolumeatlowlift.
Itismostcomfortabletooperatethispumpifthelength
ofthecylinderrequiresyoutobendslightlyattheknees
whenpumping.Thiswillallowyoutopumpwithyour
legs.

Marblepump

Thefootvalveismadebycompressingthe1.25pump
cylinderoverapipe,thengluingthesmallerpipein
placetomakeaseatfora1glassmarble.Themarbleis
heldinplacebyapinthroughthecylinder,permitting
themarbletoriseofftheseat.

Marblepumpfootvalve

Handsuctionpump

MarblePump

Themarblepumpisnamedfortheglassmarblesused
forballcheckvalvesinthepistonandfootvalve.Water
isdeliveredthroughthepistonrodonthedownstroke.
Aflexiblehoseisattachedtotheendoftherodfor
delivery.Thispumpdoesnotneedarodsealtopump
uphill.Thesmalldiametermakesitappropriatefor
wellsbelowthesuctionlimit.Itworksbestasalift
pump(thefootvalveandpistonshouldbesubmerged
inthewater).

TheplungerisPVCpipe.Ashortsectionofpipe
isinsertedintotheendbyheating.AringofPVC
pipeisinsertedovertheendofthepipe,creatinga
grooveinwhicharubberoringsits.Theoringshould
beloose,buthavenotravelupanddowninitsgroove.
Themarbleseatsontopofthepipeandisheldin
placebyapinthroughtherodthatpermitsittoraise
ofitsdiameterofftheseat.Inlieuofapin,therodmay
beheatedandcrimpedintoanovalshapetokeepthe
marbleinplace.

Marblepumppiston

PVC Water Pumps

SockPump

Thesockpumpisnamedforthesockvalveonthe
plunger.Abicycleinnertubeistiedtotheendofthe
plungeroverarowofholes.Theplungerpipeis
pluggedabovethevalveholes,andendoftheplungeris
flaredouttoslidelooselyinthepumpcylinder(a
woodenmoldwasturnedonalathetomakethisflare).
Thispumpusesthesamefootvalveasthemarblepump
(anytypeoffootvalvecanbeused).Onthedown
stroke,waterisforcedupthroughtheplungerandout
throughtheholes,butistrappedontheupstrokebythe
sockvalve.Theflaredplungerformsanimperfectseal,
butathighspeedtheleakageisnegligibleandis
compensatedforbylackofthemechanicalfrictionofa
rubberorleatherseal.Waterdeliveryisthroughthe
risingmain,nottheplunger.

Sockpumpplunger

InertiaPump

Theinertiapumphasnopistonvalve.Thepistonisa
PVCpipewithaplugintheend.Thecylinder/rising
mainis1.25pipe.Anytypeoffootvalvecanbeused,
butitmustbesubmergedatleast4feetbelowthewater.

Inertiapumpplunger

Theplungerisworkedrapidlyupanddown.Onthe
downstrokeandplungerdisplacesmostofthewaterin
thecylinder;thewatershootsrapidlyupinthesmall
gapbetweentheplungerandcylinder.Whenthe
plungerreversesdirection,theinertiaofthewaterkeeps
itmovingupwardforamoment,creatingapressure
dropinthecylinderthatpullsmorewaterthroughthe
footvalve.Thewaterwillloseitsmomentumandsome

ofitwillbepulledbackdownintothecylinder,butif
thespeedoftheplungerishigh,thiswillbelowenough
thatasignificantamountofwatermaybeliftedupthe
risingmain.

Thepumpingheadshouldnotchangetheamountof
waterthatfallsbackintothecylinderontheupstroke.
Objectsthrownupwardundertheinfluenceofgravity
willfallatthesamerateindependentoftheirmass.
Pumpingheadwillaffecttheforcerequiredtopushthe
plungerdown.

Thesmallerthegapbetweenplungerandcylinder,the
morequicklythispumpwillprime.However,atsome
point,frictionwillbecomesignificant.

ReciprocatingRopePump

Thereciprocatingropepumpisadeepwellpumpin
whichthepistonisattachedtoamassandraisedand
loweredonarope(ithasnopistonrod).Themass
providestheforcenecessaryforthedownstroke.Atthe
topofthepumpisapulleyorrollersothattheropecan
bepulledhorizontallyinarowingmotion.Thepiston
andfootvalvecomponentsareotherwisethesameas
therowerpump.Mymeasurementsoftherowerpump
haveshownaforceofaround14lbsisnecessaryforthe
pistondownstroke.Because14lbisalottoaddtothe
handleforceofapump,theweightonthepistoncanbe
reduced,withtheresultthatitreturnsmoreslowly.In
thephotographbelow,thepistonweighs10lbandthis
givesatolerablereturn.

Thispumpismostappropriatefordeepwellswhere
eliminatingthepistonrodcangreatlyreducethecost
andmakeextractingthepistonmucheasier.

PVC Water Pumps

10

Reciprocatingropepump

TreadleSuctionPump

Thisisanopentoptreadlepumpmostsuitedforfilling
irrigationcanals.Ithasnospouttodirecttheflowof
water.Ithasnobasetositon,butratherapostthatis
setintotheground.Withwaterpouringaroundit,the
soilquicklysettlesfirmlyaroundthepost.Ifthepump
canbesetdowninaditchsothatthebaseofthe
cylindersissubmergedinwater,itwilleliminateany
suctionairleaks.

Treadlesuctionpump

ThecylindersarePVCpipe.Thekeytosuccessfully
usingthisweakmaterialinatreadlepumpistoisolateit
fromanystructuralloads.Waterandpistonsealfriction
shouldbetheonlyforcesonthepipe.Inthemodel,the
cylindersareclampedtotheverticalframemember.
Thetreadlespivotona5/8steelrodwhichkeepsside
tosidewobblelow.Cotterpinsratherthannutsare
usedonthepivotrods.Theydontfreezeonandare
easytomakefromsteelwire.

Thebaseofthecylinderisa2Teeandelbowfitting
withringsof3pipecompressedoverthemtoexpand
thediameter.2pipeisgluedintothefittingsand
sawedoffflushtogiveawidesurfaceforthevalveseat.
Rubberflappervalvesarescrewedontotheseat(cutthe
rubberfromatiresidewall).The3cylindersarethen
flaredoverthefootvalves.

PVC Water Pumps

11
maximumtravelofthepistons;astheropestretches,the
pistonswillsitlowerinthecylindersandthestroke
lengthwillreduce.

Ropeattachmentdetail

ManufacturingProcesses

SoftenPVCbyHeating

PVCcylinderdetail

Pistonsaresimilartotherowerpump,butsizedfor3
pipe.

Pistondetail

Theropeisanchoredtothetreadlesbyhookingitover
protrudingpinsontheoutsideofthetreadleboard.
Thismakesiteasytoadjusttheropelengthtoallowthe

PVCbecomessoftandpliablewhenheatedbetween225
and275degF.Thisbehaviorcanbeexploitedtomake
flaredpipeconnectionsandflatPVCsheet,increasing
theversatilityofthismaterialinareaswherepipe
couplingsandflatsheetaredifficultorexpensiveto
obtain.Hotairandhotoilmaybothbeusedtoheat
PVC.Oilismoredesirablebecauseitgivessteady
uniformheat,butittakeslongertoreachworking
temperatureandisdangerousifspilledoraccidentally
heatedtoflashpoint.Caution:ifheatedbeyond275
degF,PVCwillscorchandthefumesgivenoffcontain
dioxins,neurotoxinsthatbioaccumulateinbodytissue.

Hotoilbath

Heattheoilslowly.Testthetemperaturewithapieceof
PVCwhileheating.Itshouldnotshowanysignsof
scorchingwhenheldintheoilforanylengthoftime.
Oilhasmuchbetterheattransferpropertiesthanairso
thedesiredoiltemperaturewillbeonlyslightlyhigher
thanthedesiredPVCtemperature.

HotAir

Aircanbeheatedbypropanetorch,electricheatgun,
fire,etc.Directingthisheatagainstthepipeisbest
accomplishedbyputtingaskirtaroundthepipe.Itis
importanttokeepeitherthepipeortheheatsource

PVC Water Pumps

12

movingconstantly,astheairtemperaturewillbevery
nonuniform.Airtemperaturewillalsobemuchhigher
thanthedesiredPVCtemperature.Airhaslowheat
transferpropertiesandunlessalargetemperature
differenceismaintained,thePVCwillheatveryslowly.
Herearesomeexamples:

1. Apropanetorchwithskirtmadefromatincan.The
torchheatstheairinthecanatthebottomandthe
pipeisinsertedthroughaholenearthetop.The
pipeshouldberotatedconstantlyforevenheating.
2. Anelectricheatgunwithatincan.Thepipeis
insertedintotheopentopofatincanandanelectric
heatgunisaimeddownintothecan.Keeptheheat
gunmovingtogiveevenheating.
3. Holdthepipeoverafire.Enoughheatisrisingover
alargeareasoaskirtisnotneededtocontainheat
aroundthepipe.Ittakespracticetoheatwithout
scorching.

HeatingPVCwithatorch

HeatingPVCwithanelectricheatgun

otherpipeandcontractitslightly.Toreducethiseffect,
coolthepipeeveryfewsecondsbypullingitoutofthe
flaredpipeanddunkinginwaterbriefly.Ifyouneedto
makealotofflaredends,itmaybeworthwhiletoturna
woodenmoldonalathe.Themoldcanbemadeafew
thousandthsofaninchlargerthanthepipediameterto
alloweasierinsertionofthepipe.

AflaredPVCjoint

MakePVCsheet
Cutashortsectionofpipelengthwisesoitcanbe
unfolded.Heatthepipeuntiluniformlysoftandspread
flatandpressbetweentwosmoothandrigidsurfaces.
Allowtocooluntilwellsolidified.Usealotofweight
whenpressingthesheetflat,otherwiseitwillhave
ridgesandripples.SoftPVCdoesnotflowlikepie
dough;itremainstoughandrubbery.PVCismadeof
chainsofpolymersthatcanslidepasteachotherwhile
abovetheglasstransitiontemperaturebutalways
remainpartiallyconnectedbycrosslinkmolecules.
Whenpressedbetweentwoperfectlyflatsurfaces,the
PVCsheetwillstillhaveaslightconvexshapewhen
removedduetoresidualstressesinvolvedinunbending
thepipe.Tomakeitperfectlyflat,trypressingbetween
twoslightlyconcavesurfaces,suchaswidewoodplanks
thathavewarpedorcupped.Havingbeenoverbent,
thesheetwillspringbackintoamoreflatstate.PVChas
amemoryandifyoureheatyourflatsheetagain,itwill
curlbackintoapipe.

FlarePVCpipe

Thisprocessstretchesthepipe,increasingitsdiameter
soitwillfitoveranotherpipe.Heattheendofonepipe
untiluniformlysoft,theninsertitovertheotherpipe.
Allowtocoolenoughtoholdinthehand,thenpullthe
twopipesapartwhilebendingthejointbackandforth
toloosenit.Onlyflareapipeusingthepipethatitwill
bejoinedto:Theheatfromtheflaredpipecansoftenthe

FlatPVCsheet

PVC Water Pumps

13

CompressPVCpipe

TheprincipleofflaringPVCpipecanalsobeappliedto
reducethepipediameter.Putahoseclamparoundthe
endofthepipe,heatthepipeuntiluniformlysoft
underneaththehoseclamp,insertthesmallerpipeand
tightenthehoseclampuntilthelargerpipehas
compressedagainstthesmaller.Smallerpipeswillbe
lopsidedwhencompressedbecausethehoseclamp
screwmechanismputsaflatdentinonesidethat
becomesincreasinglynoticeableinsmallerdiameters.

1.25pipecompressedonto3/4pipewithhoseclamp

CutPVCdiscs
Withalathe
DrillaholeinthecenterofapieceofPVCsheetandbolt
toasteelrodtoclamprodinlathechuck.
Note:5/8diametersteelrodistapped5/1618to
receiveaboltwhichclampsthediscagainsttheendof
therod.Thisprovidesagoodfrictiongriponthedisc
andresistsbendingforcesappliedbythecuttingtool.
Alternatively,astandardboltorthreadedrodwithtwo
nutsmaybeusedtoholdthePVC.

2.
3.

a) Ifanadjustableholesaw,loosenthenutand
rotatethetwohalvestoslidethecuttingteethin
andouttogivethecorrectdiameter(notethat
youneedaninnerdiameterbecauseyouwantto
keepthecenterofthecutout).Tightenthenut.
b) Ifafixeddiameterholesaw,findonethatis+/
1/8ofthedesireddiameter(rememberto
measuretheinsidediameterofthesaw).
ClampthePVCsheettoscrapwoodtosupportthe
sawasitcutsthroughthebacksideofthesheet.
Useeitherahanddrillordrillpresstocutthehole
a) Handdrill:Clampthescrapwoodtoasecure
object(workbench,vise).Holdthedrillwith
bothhandsandtakecaretokeepitsteadyand
straight,asthiswillreducethechangeofthe
sawcatchingandwrenchingthedrilloutof
yourhands.Runatamediumspeedandfeed
thesawslowlyintothework.Withdrawthe
sawfromtheworkoftenandcleantheteeth
withawirebrush,astheplasticmeltstothem
andclogsthesaw
b) Drillpress:Clampthescrapwoodinthedrill
pressviseandadjustthetableheighttobring
theworkclosetothesaw.Turnonthedrill
pressandadjustthespeedto600rpm.Feedthe
sawslowlyintothework
4.Removetheholecenterfromtheholesaw.

Fixedholesaw(left)andadjustableholesaw(right)

PVCdiscturnedonlathe

Withaholesaw
1. Selectholesawsize

HoleSawingusingahanddrill

PVC Water Pumps

14

HoleSawingusingadrillpress

Withasawandfile
1. MarkoutthediscdiameteronthePVCsheetwitha
compassorbytracinganobjectofthecorrectsize.
2. Cutoutsideofthislinewithmultiplesawcutsto
givetheapproximateshapebutleaveextramaterial
forthefiletoremove.
3. Filetheremainingpointsdowntotheline.Make
suretoholdthefileperpendiculartothediscsothe
edgeisnottapered.

Drillpressesholdboththeworkandthebitrigidly
andthereislittlebenefitfrompilotholes.
Twistdrillbitswillpullthemselvesrapidlythrough
asoftplasticlikePVC,particularlywhentheyhavea
pilotholetofollow.Thisrapidcuttingofalarge
chunkoutoftheplasticcancauseittocrack,
especiallyiftheholeisnearanedge.Trytodevelop
theskillofpushingthedrilltogetittobite,then
pullingbackonittodrilltheholeinaslow
controlledmanner.
Drillrpmdependsonthesizebit.Smallbitsmust
beturnedveryfasttoexpelthechipsfromtheflutes
onthebit.Largebitsshouldbeturnedslowly.The
speedofthecuttingsurfacesincreasesasthe
diameterincreasesandtherpmmustbedecreased
inthesameproportiontopreventexcessiveheat
buildupthatwilldamagethebit.Thisisvery
importantwhendrillingmetal,butwithsofter
plasticitisnotanissueandbitscanberunfaster.

Tapthreadedholes

Atapisusedtocutinternalthreadsinthehole.Tapping
apartofteneliminatestheneedforanutonthebolt.

1. Drillaholesmallerthanthethreadsize,
approximatelyequaltothediameteratthebaseof
thethreads.Tapdrillchartswillgivetheexactsize.
2. Twistthetapdownintothehole;pushtogetit
startedbutafterthatitwillpullitselfin.

Straightcutsaroundperimeterofdisc,edgefiledround

DrillPVCwithahanddrill

PVCissoft,andalargebitwillwanderaroundalot
beforeitgetsindeepenoughtokeepitselfcentered.
Tomakeastraightroundholeinthecorrect
location,drillasmallpilothole(1/8)first.Thiswill
doalottokeepthebitcentered.Forevenmore
accurateholes,stepupthediameterbyincrements
of1/8untilyoureachthedesireddiameter.Note:

TappingthreadsinaPVCdisc.

Iftappingmetal

Lubricatethetapheavilywithcuttingoil.Turnthetap1
turnforward,1/4turnbackwardtobreakthechipthatis
formedasmetalisshavedofftheinsideofthehole.This
willpreventthetapcuttingteethfromgettingclogged

PVC Water Pumps

andbinding.Veryeasytotwistatapinhalfifyoudont
followthisprocedureinmetal.Notanissuewithsofter
plasticandwood.

Ifthereisnotap...

Whenthreadingaboltintoplasticorwood,itisnot
necessarytotapthehole,themetalboltwillcutitsown
threads,althoughitwillgoinwithmuchmore
resistance.Ifyouhaveaveryhardwoodorplastic,
tappingisprobablynecessarytokeepfromsplittingthe
wood.Ifthereistoomuchresistance,theholecanbe
drilledoutlarger,butkeepinmindthatlessthreadwill
beincontactwiththewoodandthereforelessholding
power.

Acrudetapcanbemadefromasteelbolt.Cutaslitin
theendofthebolt;thecutedgesofthreadwillbesharp
cuttingsurfaces.Aluminumcanbetappedwiththis
method.

15

Markingholecenterswithacompass

Freehand

Drawdiameterlinesdividingthediscintosixroughly
equalsegments.Measurefromthecenteroredgeofthe
discandmarktheholecenters.

Makeatemplate

Cutadiscfromsheetmetalandmarkoutthehole
pattern.Punchasmallholetomarkthecenterofeach
hole.ThemarksareeasilytransferredtothePVCdisc
withacenterpunch.

Asteelboltslitattheend,usedtotapsoftermaterials

Markaradialvalveholepattern

Withacompass

Scribeacirclethatwillpassthroughthecentersofthe
holes.Keepingthecompassatthesameradius,place
thepointontheedgeofthecircleandsteparoundthe
circlemakingmarksateachstep.Thiswilldividethe
circleintosixequalsegmentsandmarkthecentersof
theholes.

Holepatterntemplate

Findtheexactcenterofacircle

Placethepointofasquareontheedgeofthecircleand
markwheretheedgesintersectthecircle.Drawaline
connectingthesetwomarks;itwillbeanexactdiameter.
Drawtwoorthreediametersandmarkwherethey
intersect.

PVC Water Pumps

16

Punchaholeinrubbersheet

Circularpunchesmakeacleancutinasoftmaterialsuch
asrubber.PlaceapieceofflatPVCorhardwood
underneaththerubbertocutagainst(dontusemetal,it
willdullthecuttingedge).

Indexcardusedtomarkendpointsofacirclediameter.

Deburraholeorpipe

Withadeburringtool

Dragthecuttingedgeclockwisearoundtheinsideedge
ofthehole,applyingfirmpressure.Deburringtoolscut
inonlyonedirection,mostlikelyclockwise.

Fromlefttoright:standardcircularpunch,metalpipe
sharpenedtoacuttingedge,valvestemsharpenedtoacutting
edge,drilledoutmetalstocksharpenedtoacuttingedge.

Cutadiscfromrubbersheet

Deburringtoolremovingburrsoninsideedgeofpipe

Withafile

Toavoidmakinggroovesincurvedsurfaces,movethe
filesidewaysaroundtheinsideofthepipe(drawfile).
Filescutonlyinonedirection,usuallyawayfromyou.
Dontcutbackwards,itdullstheteethandplugsthem
withfilings.

Option1:PVCtemplate

1. Tracethetemplate(centerholeandouterdiameter)
ontorubbersheetandcutoutsideoflinetoleave
1/8extramaterial
2. punchthecenterhole
3. bolttherubbertothetemplateandcutaroundit
withscissors.Makestraightcuts,keepingthe
scissorsbladevertical.Donottrytofollowthe
curveofthetemplate,asthiswillstretchtherubber
andthecutwillnotfollowthetemplate.

Filingtheinsideedgeofapipe

Rubberdiscbeingcutontemplate

PVC Water Pumps

Option2:freehand

1. Tracearoundanobjectofcorrectsize.Or,tracean
objectclosetothecorrectsizeandmeasurefromthis
lineandmakeseveralmarksaroundthe
circumferencetoguideyou.
2. Cutoutthediscwithscissors.
3. Findthecenterandpunchthehole.

CutPVCpipesquare

Constructamiterboxfromwood.Thisisachannelthat
willcradlethepipesecurelywhileyoucut.Ithasaslot
(cutwithyoursaw)perpendicularacrossittoguidethe
sawblade.Onevariationonthestandardmiterboxisto
hingeoneflangeofthechannel,makingthebox
adjustableforseveralsizesofpipe.

17

GlueaPVCdiscinsidetheendofapipe

Cutthedisctofitexactlyintothepipewithnolarge
gaps
Ifyouarenotsuccessfulatgettingagoodfit,heat
thepipeandcompressitaroundthedisc.Mark
theirpositionrelativetoeachother.
Useplentyofgluesothatgapsarefilled.

Makealargehoseclamp

GluePVCpipe

1.
2.

3.

Deburrtheedgesofthepipeandfittingsotheydo
notscrapeoffthegluewhenthepipeisinserted.
ApplyPVCprimertobothsurfacestocleanand
softenthepipesurface.Allowprimertodry,
leavingatackysurface.Donotgetprimeronparts
ofthepipethatwillnotbegluedtogether,ithas
beenfoundtoweakenthepipeleadingtofailure.
ApplyPVCcementtobothsurfaces.Insertthepipe
intothefittingwhilerotating1/4turntoevenly
distributetheglue.Holdfor30secondsuntilsetup.
Thejointwillcureoverafewhourstoreach
maximumstrength.

GlueaPVCdisctotheendofapipe

Makesuretheendofthepipeissquareandflatand
thediscisflat.Toresolveslightproblemswith
eithersurface,heatthediscandpressthepipedown
ontoituntilitsolidifiesagain.Marktheirposition
relativetoeachother.
Whengluing,applyfirmpressuretoholdthedisc
againstthepipeandholditforafewminutesat
least.Unlikeapipejoint,thereisnoforcetokeep
thepiecesfromspringingapartwhilethegluesets.
Letcureforseveralhoursbeforedoinganything
withthisassembly.

Twohoseclampslinkedendtoend

HeatformaholeinPVC

Ifyouneedaholeofexactsizeforarodbushing,butdo
nothavethenecessarytools,trythis:

1. Drillaholethenextsizesmallerthanthedesired
hole
2. Heattheedgeoftheholetosoftenit.
3. Inserttherodtospreadtheplastic.IftherodisPVC
pipe,keepitmovinginandouttoavoidsoftening
therod.

ThisworkswithPVCandHDPE(#2plastic).Ifthehole
hastobespreadsignificantly,itwillprobablybe
difficulttogettherodstarted.Trybevelingtheendof
therodormakingataperedmoldfromwood.

BendPVCpipe

Fillthepipewithsandandcapbothends.Heatthe
sectiontobebentandformitaroundabucketorlarge
pipe.

PVC Water Pumps

PumpPerformance

Definitionofterms

PressurePump:apumpthatmoveswaterby
raisingitspressureaboveatmospheric
SuctionPump:apumpthatmoveswaterby
loweringitspressure.Atmosphericpressureforces
waterintothepump.
LiftPump:apressurepumpsubmergedinawell
Head:verticaldistancetowhichwaterisbeing
raised.
PressureLoss(HeadLoss):adropinpressurewhen
waterpassesthrougharestrictionorlengthofpipe.
Thisislostenergy.
RisingMain:Inaliftpump,thepipeconnectingthe
pumpcylinderwiththepumphead
SuctionPipe:Inasuctionpump,thepipefromthe
pumpcylinderdowntothewater.
PumpHead:Theabovegroundmechanismfor
operatingaliftpump
SweptVolume:thevolumesweptbythepistonin
thecylinderduringtheextentofitsmotion.This
maybegreaterthanvolumeofwateroutputif
pistonleakageissignificant;itmaybelessthan
volumeoutputifinertiaofwaterkeepsitmoving
significantlyafterthepistonreverses.
DirectActionPump:Thepumphandleisdirectly
attachedtothepistonrod(nopivotinghandleto
generatedleverage).

SomePrinciplesofWaterPumping

Pumpsmovewaterbycreatingapressuredifference
thatisgreatenoughtoovercomegravityandfluid
resistance.Inapistonpumpthisisdonebypositive
displacement:Thewaterisforcedtomovebyaclose
fittingpistoninacylinder.Theflowrateisconstant
withthedisplacementofthepistonandthepressure
varieswiththeresistanceofthepipeline.Ina
centrifugalpumpthewaterisspunwithanimpellerto
raiseitspressurebycentrifugalforceagainstthe
impellerhousing.Thepressureisconstantwiththe
rotationspeedoftheimpellerandtheflowratevaries
withtheresistanceofthepipeline.Thepowerrequired
tooperateapumpisproportionaltothepressure

18
differenceandflowrate.Ifnotenoughpoweris
available,apistonpumpwillstallandacentrifugal
pumpwillspinbutnotdeliveranywater.

Asuctionpumplowersthepressurebelow
atmosphericairpressuresothattheatmospherepushes
waterintothepump.Forthisreason,suctionpumpsare
limitedintheorytoamaximumdepthof34feet.In
practicethismaximumsuctiondepthisreducedto
around27feetduetolossesfromfluidfrictionandfrom
acceleratingthewateroneachpumpingstroke.A
pressurepumpraisesthepressureaboveatmospheric
sothatwaterispushedoutofthepump;theheightis
onlylimitedtotheenergysuppliedbytheoperator.
Somepumpsarecapableofbothsuctionandpressure
pumping.

Reciprocatingpistonpumpsrequiretwocheckvalves;as
thepistonmovesupanddowninthecylinder,wateris
suckedintothecylinderthroughonevalveandexpelled
throughtheother.

Sourcesofwastedenergyinpumpsare:
Fluidfrictionaswaterincreasesspeedtoflow
thoughsmallorificesincheckvalves.
Mechanicalfrictionofsealsagainstmovingcylinder
wallsandpistonrods.
Forceneededtoopen(crack)checkvalves.
Pipefrictioninthesuctionordeliverypipe.

Pipefrictionisoftenthemostsignificantbecausepipeof
toosmalldiameterisusedbecauseitischeaper.Flow
frictionincheckvalvesandslidingfrictioninsealscan
behighinapoorlydesignedpump.

Asuctionpumpcannotallowairtoleakpastitspiston
oritwillfunctionverypoorly.Itismoredifficultto
makeasealairtightthanwatertightbecauseairisless
viscous(itflowsmoreeasily).Ifthesealhassmallgaps,
negligibleamountsofwaterwillleakthrough,but
significantamountsofair.Thisissueiseasilysolvedby
havingwateronbothsidesofthepistonseal.Inmany
suctionpumpdesigns,oneofthecheckvalvesispartof
thepiston.Onthedownstroke,thepistonmoves
throughthecolumnofwaterinthecylinder.Onthe
upstroke,thepistonsimultaneouslyexpelswaterfrom
thecylindertopandpullsmorewaterintothebottom
throughthefootvalve.

Theneedtocreatesuctioncanbeeliminatedbyplacing
thepumpcylinderbelowwater.Mostwellpumpsare

PVC Water Pumps

19

RowerPumpPerformance

Thefollowingtests(graphs14)usedatwoinchrower
pumpinaborehole.Thesuctionpipewas27feetlong
andthewaterlevelwas7feetbelowthepump.

1. Flow Rate from a 2" Rower Pump as a function of Handle

Force for Three Suction Pipe Options
20
18

Flow Rate (gpm)

16
14
12
10
8
6
4

2. Flow Rate from a 2" Rower Pump as a function of Work

Input for Three Suction Pipe Options
20
18
16
Flow Rate (gpm)

ofthistypeandarereferredtoasliftpumps.Mostso
calledpressuretreadlepumpshavepistonswhichonly
seewaterononeside.Thesearecapableofsuctionand
areadvertisedassuch,butwillworkmosteffectively
whenthepressureheadismuchgreaterthanthesuction
head.Watermustleakpastthesealsothateachpiston
haswatersittingontopofitanddoesnotsuckair.

Allofthepumpsdescribedinthisdocumentare
intendedtobeusedasdirectactionpumps,i.e.the
handleisdirectlyattachedtothepumprod.No
leverageisprovided.Thediameterofthepumpis
determinedbasedonthewaterdepth.Thismakesthe
mostsensewhenyouarebuildingthepumpyourself
andhaveawiderangeofdesignoptions.Nothingis
gainedbyusingalargercylinderandthenshortening
thestrokebyuseofalevertogainmechanical
advantage.Asmallercylinderwithalongerstrokecan
givethesamevolumeatlowercost.

14
12
10
8
6
4
2
0
0.06

0.08

0.10
0.12
Work Input (hp)

0.14

0.16

0.18

0.20

1" pipe with surge chamber

1" pipe
1.25" pipe

Theseflowratesseemgooduntilyouconsiderthatyou
areonlyliftingthewater7feet.Theforcerequiredto
holdupacolumnofwatercanbecalculatedasF=
ghA.
F=Force(lb)
=density1(slug/ft3=lbs2/ft4)
g=accelerationofgravity(ft/s2)
A=cylindercrosssectionalarea(ft2)

Forwater,g=62.4lb/ft3

62.4lb 7 ft 3.14in 2 ft 2
2 2 9.5lb

ft 3

12 in

Itshouldonlytake9.5lbofforcetoliftthiswater.This
isknownasthestatichead,theweightofthewater
columnatrest.Therestofthehandleforce(dynamic
head)islostasfrictionmovingthewaterthroughthe
suctionpipeandfootvalveandasforceneededto
acceleratethewateroneachstroke.

2
0
20

25

30

35

Handle Force (lb)

40

45

50

1" pipe with surge chamber

1" pipe
1.25" pipe

Density is defined as mass per unit volume. A slug is a unit

of mass, analogous to the kilogram.

PVC Water Pumps

20
fasttogivethesamevolume,thereforedynamiclosses
willbemuchlesssignificant.

Forlonghorizontalruns,pipefrictionlossesbecome
moresignificantthanvalvelosses.Thefollowingtests
(graph5)useda2rowerpumpinaboreholewith
varyinglengthsofhorizontalpipe.Thesuctionpipe
diameterwas1.25.Theverticalsuctionpipewas9feet
longandthewaterlevelat7feetbelowthepump.

3. Force lost to Friction in 2" Rower Pump as a fuction of Flow

Rate for Three Suction Pipe Options
45
Handle Force Lost (lb)

40
35
30
25
20
15
10
5
0
8

10

12

14

Flow Rate (gpm)

16

18

20

5. Flow Rate in a 2" Rower Pump as a function of Horizontal Run

1" pipe with surge chamber

20

1" pipe
18

1.25" pipe

16

14
Flow Rate (gpm)

4. Work Lost to Friction in 2" Rower Pump as a fuction of Flow

Rate for Three Suction Pipe Options
0.18

Work Lost (hp)

0.16

12
50 lb
10

40
30

8
6

0.14

0.12

0.10
0
0

0.08

20

40

60

Horizontal Run (ft)

0.04
8

10
12
Flow Rate (gpm)

14

16
18
1" pipe with surge chamber
1" pipe
1.25" pipe

20

Theseresultslookdepressing,butconsiderthatapump
thissizeisnotmeantforthehighflowratesseeninthis
test.Thetwoinchpumpisbettermatchedtodeeper
wellswhereitwillhavemorestaticheadandtheuser
willnotbeabletopumpasfast,reducingthedynamic
head.

Supposeawellis27feetdeep,apersoniscapableofa50
lbpull,andhispumphasasurgechamber:37lbof
handleforceisneededtoliftthewater(statichead),
leavingonly13lbtowasteasfriction(dynamichead).
Fromchart3,hecanpumpabout12gpm.

Forshallowerwells,usealargerdiameterpump.The
rowerpumpcaneasilybemadefrom3or4pipewith
correspondingchangesinthevalvedimensions.A3
pumpcanprobablybeusedupto15feetdeep(static
headatthisliftrequires46lbhandleforce),anda4
pumpusedupto8feetdeep(43lbhandleforce).The
largerdiameterpumpswillnotneedtobestrokedas

Fromthischartweseethattheamountofwateraperson
canpumpdecreasesabout3.5gallonsovera60footrun.
Asurgechamberandlargediameterpipearegood
investmentsforlongerruns.

Canwedecreasedynamiclossessignificantlybyusinga
lessrestrictivevalve?Thefollowingchartcompares
pumpswithdifferentfootvalves.Oneisaradialpattern
ofsix7/16holes,theotherisasideflappervalveovera
single1.5diameterhole.Theflappervalveallowsa
persontopumpfourmoregallonsperminutethandoes
theradialvalve.However,itmaystillbeinferiorforthe
applicationbecauseitismoreeasilydamaged.

Comparison of Radial and Flapper Check Valves

25

20
Flow Rate (gpm)

0.06

15

Radial
Valve

10

Flapper
Valve

0
25

30

35

40
45
Handle Force (lb)

50

55

PVC Water Pumps

Otherobservations:

IbuiltarowerpumpfromclearPVCpipeandobserved
thatifthepumpisstrokedfastenough,themomentum
ofthewaterwillkeepitmovingcontinuallyupward,
evenduringthedownstrokeofthepiston.Thefoot
valvewillneverclosecompletely.Thiseliminatesthe
problemofwaterleakingbackthroughthevalvewhileit
isclosing,andtheproblemofthevalveslammingshut
anddamagingtheseatortheflap.

Theorizingabouttheaboveresults,thesurgechamber
requireslessforceatthehandle,butvolumetric
efficiencyislowerbecauseasmallermassofwateris
accelerated.Morestrokesareneededtomovethesame
amountofwater,sothenetpowerrequiredissimilarto
thelargerpipe.The1.25piperequiredconsiderably
moreforceforagivenflowrate,butthisforcetakesthe
waterfurtherbecauseitsmomentumcontinuestomove
itupthepipeevenafterthepistonhasreversed
direction

Marble&Inertiapumps2Performance

Thesewereverycrudetests,measuringhowfastthe
pumpcouldfilla5galbucket.Theliftwasabout6feet
andthepumpcylinderextended12feetintothewell.
Theinertiapumpcouldoutputaround4gallonsper
minuteandthemarblepumpcouldoutput57gpm.
However,themarblepumpwasmuchmoretiringto
operateandrequiredtwohandsatthehighendofits
flowrange.

Pleasenote:Theseperformancevaluesreflectasingle
operatorandasinglewaterdepth.Theinertiaand
marblepumpsreactverydifferentlywhenthepumping
speedischanged,asitwouldifthewaterweredeeper
andrequiredmoreworktolift.Theinertiapump
greatlydecreasesinefficiencywhenitisstrokedslower.
Themarblepumpincreasesinefficiencyatslowerspeed
becausethereislessresistanceinthepistoncheckvalve.

Iftheinertiapumpwillbeusedatlargelifts,itshould
haveaverysmallgapbetweentherisingmainandthe
plungersothatthewatervelocityandresistanceto
reversingdirectionarehigh.
2

Therubbersockrippedoffofthesockpumpsometime
duringthetestsoitsresultswereinconclusive.

21

FactorsthatAffectPumpPerformance

Fluidresistanceandcavitationincheckvalves.

Checkvalvesgivealotofresistancetofluidflow.This
translatestomoreforcerequiredatthehandletomove
thewater.Furthermore,aswaterspeedsuptogo
throughthevalveorifices,itspressuredrops,eventually
reachingthevaporpressure.Atthispointitflashesto
vapor(waterboilsatambienttemperatureifthe
pressureislowenough).Whenthevaporbubbles
collapse,theysendshockwavesthroughthewater
column.Theshockwavecanburstapipe,especiallyata
Torelbow.Or,ifthevaporbubblescollapseona
surfaceinsidethepump,theysendshockwavesthrough
thatmaterialandeventuallycausepittinganderosionof
thesurface.Thisprocess,calledcavitation,isaleading
causeofdamagetopumpsandvalves.Cavitationis
moreanissueinthefootvalveofasuctionpumpthan
thepistonvalvebecausethewaterpressureisalready
lowerduetothesuctionrequiredtoliftthewater.If
cavitationisoccurringinahandpump,onesolutionis
topumpslower,reducingthevelocityofwaterthrough
thecheckvalveandthusreducingthepressuredrop.
Anothersolutionistomakethevalveorificeslarger,
achievingthesameresult.

Lengthofpiping

Thelongerthepipe,eithersuctionordischarge,the
greatertheforcesrequiredtoacceleratethewateron
eachstroke.Thediameterofthepipedoesnotaffectthe
accelerationforce3.

Pipediameter

Thesmallerthepipediameter,thefasterwatermust
flowforthesameoutput.Frictioninpipesincreases
withthesquareofvelocity4.Pipecrosssectionalarea
increaseswiththesquareofthediameter.So,halving
thediametergives1/4thecrosssectionalarea,which
givesfourtimesthevelocity,whichgives16timesthe
flowfriction.Asaruleofthumb,Isuggestthatthe
suctionpipediameterbenolessthanhalfthediameter
3Inasmallerdiameterpipe,lesswatermassisbeing
accelerated,butitbeingacceleratedtoahighervelocity.These
twoeffectscancelout.
4
Therelationshipbetweenflowvelocityandfluidfrictionis
complicatedforturbulentflow;Itisonlyaroughguesstosay
thatdoublingtheflowwillresultinfourtimesthefriction.

PVC Water Pumps

ofthepumpcylinder.Ideallyitwillbenolessthanhalf
thearea,whichrequiresadiameter0.707ofthepump
cylinder.Fora2pumpcylinder,use11/4or11/2
suctionpipe.Ifthepipeisrunningalonghorizontal
distance,itmaybedesirabletoincreaseitevenmore.

Surgechamber

Asurgechambersmoothesoutapulsatingflowina
pipeline.Inthecaseofarowerpump,thesurge
chamberispositioneddirectlybelowthefootvalve.On
theupstroke,thepistonsuckshalfofitswateroutofthe
surgechamber,withtheotherhalfcominguptheinlet
pipe.Thiscreatesavacuuminthesurgechamberthat
pullswaterbackintoitduringthedownstrokeofthe
piston.Thus,theintermittentflowofwaterinthe
cylinderistransmittedintoamoreorlessconstantflow
ofwaterintheinletpipe.Watervelocityishalfasgreat
andthereforepipefrictionis1/4thasgreat.

Surgechamberscanalsobeusedonthepressuresideof
apump.Theybecomemoreandmorenecessarythe
longerthepipelineisandthemorewatermustbe
acceleratedoneachstroke.Withsinglepistonpumps,
theyallowuseofsignificantlysmallerdiameterpiping.
Withtreadlepumps,duetotheirtwocylinders
deliveringwatercontinually,theycannotreducepipe
diameterbutstillwillreducepressureshockstothe
pumpifconnectedtoalongpipeline.

Asaruleofthumb,asurgechambershouldhavea
volume2xthecylindervolume.Thelargerthevolume,
thesmallerthepressurevariationinthechamberand
themoresteadytheflowuptheinletpipe.Theperfect
chamberwouldmaintainaconstantpressureregardless
oftheirregularityofthepiston.

Surgechamberonarowerpump:4Sch40PVC,18long

22
Pistonsealmaterial

Aleathercupsealispressedagainstthecylinderwallby
thepressureabovethepiston.Thiscreatesaverygood
seal,butalsosignificantfrictionifthecylinderwallis
notsmooth.PVCcylindersareeasilyscoredand
roughenedbygritthatgetstrappedbetweenthecup
sealandthecylinderwall.

Therubberdiscpistonsealdeflectsintothegaparound
thePVCsupportdiscwithincreasingpressure.This
allowssmallamountsofwatertoleakpast,increasingas
thepressureincreases.Theselossesareinsignificant
comparedtothepumpoutput,buteliminatecontact
betweentherubberandthecylinder,eliminating
mechanicalfriction.Sandinthewaterisnotaproblem
becausetherubberdiscsfoldawayfromthecylinderon
everydownstroke,flushingoutanysandthatmayhave
becometrapped.OnepumpatECHOwasusedtobail
waterfromaholeandstillfunctionedevenwithafoot
ofsandaccumulatedontopofthepiston.

DesigningaPump:Tradeoffs

Pipecost

Suctionanddischargepipewilloftenbeamuchgreater
costthanthepump.Smallerdiameterpipeischeaper,
butyouwillgetlesswaterbecausemoreenergywillbe
losttofluidfriction.Investinlargerpipe!Humanlabor
isnotcheap!Weonlyputout1/10ofahorsepower
averageoveradaysworkandwewanttomakethe
mostofit.

Pistonrodmaterial

Metalisstrongerandcanbebentbackifdamaged.
StainlesssteelandPVCaresmoothandwillnotrust.
PVCisweakbuteasytoreplace,andifabuseditwill
breakinsteadoftransferringloadstothepumpand
breakingotherparts.PVCflexesmore,allowinga
persontopullcrookedlyonthehandlewithoutcausing
alotoffrictionintherodbushing.

Checkvalves

Sideflapcheckvalveshavemuchlowerflowresistance,
buttheyareeasiertoripoffortobecomeaskewsothe
flapdoesnotfullycoverthehole.Theyalsoopen

PVC Water Pumps

furtherandsowhentheyclosemorewaterslipsback
throughandthevalveslamsharder.Sockvalvescanrip
offmoreeasilythanflapvalves.Largerholesinradial
patterncheckvalvesgivelessresistancebutweakenthe
valvedisc.

OverallCost

Itisageneralrulethatthecheapestpumpswillhave
lowerflowratesandusethebodylessergonomically.
Moreexpensivepumpsarebuiltstrongenoughtouse
strongermusclesandaremorecomplexinordertouse
musclesinthemostcomfortableposition.So,themarble
pumpisverycheapandeasytobuild,butawkwardto
operateandgivesasmallflowrate.Thetreadlepump
ontheotherhandismostexpensivebutproducesfar
morewaterbyusingthelegmuscles.

AlternativeDesignsforComponents

FootValve

Variationsontheradialholearray:
Therearemanypossiblepatternsofholesforavalve
witharubberflapboltedinthecenterofthevalvedisc.
Layoutapatternofholesappropriateforthediameter
ofthepump.Consideringthefollowing:

Thevalvemustnotcatchonthecylinderwallwhen
itopens.
Therubbermustoverlaptheholesbyatleast1/16
ortheedgewillbesuckedintotheholeandbreak
theseal.
Distancebetweenholesshouldbe1/2thehole
diametertomaintainstrengthofthedisc.Ifthedisc
isthickerthan1/10ofitsdiameter,thismaybe
reduced.Usegoodjudgment.
Maximizethetotalareaoftheholes
Forthesametotalarea,fewerlargerholesgiveless
flowresistancethanmore,smallerholes.
Holesneartheperimeterwillgivelessresistance
thanholesnearthecenterbecausewatercanpush
therubberflapfurtheroutoftheway.

Sideflappervalve:
Thesideflappervalveismadebyflaringand
compressingpiecesofpipetobuilduptheendofa1.5
inletpipeuntiltheendisthickenoughtoscrewavalve
flapto.The2pumpcylinderisthenflaredoverthis

23
assembly.Valveflapscanbemadefromtiresidewallor
frominnertubewithabackingdisctogiveitrigidity.

Sideflapperfootvalve

Piston

Leathercupseal:
TheleathercupissandwichedbetweentwoPVCdiscs
witharadialholepatterncoveredbyarubbervalve
flap.Thecenteroftheleatheriscutout,leavingalip
about1/8wideforthePVCdiscstogrip.Cuttheinner
PVCdisctofittheleathercup,butsoaktheleatherfirst
forafewdayssoyouwillknowitstruedimensions.
CutthelowerPVCdisctofitlooselyinsidethepump
cylinder.TapthePVCdiscstoreducehardware.When
assembling,lineuptheholesinbothdiscs.

Leathercuppistonseal

RubberdiscsealwithsolidPVC:
Therubberdiscpistonsealcanbeusedwithoutdrilling
holesinthePVCdisc.MakethePVCdiscsmaller,1.75
diameterfora2cylinder,andtherewillbesufficient
waterpassagearoundthedisc.Usemorerubberdiscsto
bridgethegap.(ThesquarepieceisanutcutfromPVC
sheetandtapped.)

PVC Water Pumps

24

Alternativehoseclamp

TestingMethodologyandData

Rubberdiscpistonseal

Handle

PVCpistonrod:
Shapeawoodhandleandboreaholethroughthe
center,slightlysmallerthanthePVCpipe.Heattheend
ofthepipeandinsertintothehole.Whencool,drill
throughthewoodandinsertascreworpintosecurethe
rod.ThiswilllikelybestrongerthanthePVCTee
handle.

WoodhandleforPVCpistonrod

Metalpistonrod:
Drillandtapaholethroughthewoodhandle.

Woodhandleformetalpistonrod

HoseClamp

Drillaholeinbothendsofametalstrap,bendintoa
hoopwithearsstickingout,andputaboltthroughthe
holes.Thisprobablyhasatightergripthanahose
clampandismoreeasilypaintedforcorrosion
protection.

MeasuredQuantities
Handleforce(lb):mechanicaldialforcegaugebuilt
intopumphandle
Volumeoutput(gal):57galplasticbarrel
Time(s)
Numberofstrokes:countedbypersonpumping
Strokelength(ft)

CalculatedQuantities
Flowrate,gallonsperminute=volume(gal)/time
(s)*60(s/min)
Workinput,horsepower(hp)=strokelength(ft)*
strokecount*handleforce(lb)/time(s)/550(ftlb/s
perhp)
Dynamicforce:subtractstaticforcefromtotalforce.

Equipment
2rowerpumpwithheadsealandradialstylefoot
valve
borehole28feetdeep,watertableat7feet
platformtomountpump
supportsforsuctionpipeonhorizontalruntest
55galplasticbarrelwithflappervalvedrainin
bottom(holds57galtobrim)
outletpipetobarrel
handleforcegauge
timepiece

Procedure
ForeachtestItimedhowlongittooktofillthe57gal
barrel.Eyeingtheforcegaugeinthehandle,Iwasable
tomaintainaconstantaverageforceonthehandle,
withinafewpounds.

PVC Water Pumps

25
1suctionpipewithsurgechamber
Force(lb)
40
30
20

time(s)
178
211
315

strokecount
178
181
179

1suctionpipenosurgechamber
Force(lb)
50
40
30

time(s)
259
283
369

strokecount
138
159
169

1.25suctionpipenosurgechamber

force(lb) time(s) strokecount

50
189
142
40
226
149
30
323
161
Testsofsuctionpipeoptions

Rowerpumpwith27suctionpipeinborehole

Rowerpumpwith60horizontalrunfromborehole

Handleforcegauge(060lb)

RawData

volume
57gal
strokelength
2ft
lift,vertical
7ft
inletpipe,vertical
27ft
forcepistonreturn
14lb
Fixedquantitiesforalltests

FlapperValve,1.25suctionpipe
force(lb) time(s) strokecount
50
154
128
40
182
130
30
242
132
Testusingpumpwithsideflappervalveinsteadofradialvalve

norun
HandleForce
Timetopump
(lb)
57gal(s)
50
196
40
252
30
299
20
480
42
225
55
189
30
297
20run
HandleForce
(lb)
40
30
45
50
40
30
45
35

Timetopump
56gal(s)
260
374
223
200
257
351
204
296

PVC Water Pumps

26
40run

HandleForce
(lb)
50
40
30
45
35

Timetopump
56gal(s)
224
309
366
230
301

60run
HandleForce
Timetopump
(lb)
56gal(s)
50
282
40
337
30
430
45
301
35
393
Testsofhorizontalrun

Examples
Convert10gallonsperminute(gpm)tolitersperhour
(lph)

10 gal 60 min 3.79liters 2,274l

min hour gal hr

Convert6metersofwaterintopoundspersquareinch
(psi)

6m 14.7 psi 8.6 psi

Imperialtometricconversions

Conversionfactors
1inch=25.4mm
1gallon=3.79Liters
1atmosphere=14.7psi=34feetofwater=10.3metersof
water5
1ft^3water=62.4lb
1horsepower=~550footpoundspersecond=746watts

Calculations
Writeeachconversionfactorasaratio(fraction).
Multiplyfactorstogetheruntilyougetthedesired
dimensions.Unitscanceloutwhentheyaredividedby
themselves:gal/gal=1,justlike4/4=1.

Pressure is defined as a force per unit area, e.g. pounds per

square inch: 1 atmosphere is the pressure at sea level exerted
by the weight of the earths atmosphere. Pressure can also be
defined in terms of the weight of a column of water: A 6
meter high column of water exerts a force of 8.6 pounds per
square inch. The volume of water has no effect on the
pressure, i.e. a 2000 gallon tank and a two inch PVC pipe will
have the same pressure at the base if they are the same height.

Acknowledgments

Appendix

10.3m

Theideafortherubberdiscpistonsealandcheckvalve
originatedwithMattKiehlatMessiahCollegein
2003.IlatersawasimilardesigninWayneNiles
PVCpumpdesignedinHaiti.
Theideafortherubberdischeadsealoriginatedwith
MessiahCollegestudentsworkingontheWestAfrica
PumpProjectin2001.
Therowerpumpinthisdocumentisinspiredbythe
MCCWestAfricaRowerPump,althoughallofthe
componentsaredifferent.

Bibliography

MCCRowerPumpconstructionmanual
WayneNilespictorialmanualforconstructinga
PVChandpump(ECHOelectronicfiles)
WorldVisionAustraliabrochureforconstructing
theRusPump(EHCOpaperfiles)
TerryWaller,SketchesofaPVChandpump(ECHO
paperfiles)
DocumentsdescribingtheCanzeePump(online)
MessiahCollegeSeniorEngineeringProjectreport,
2001:IntegratedPumpDesign

Contact

JosephLongeneckerformoreinformation:
jblongen@gmail.com
RevisionHistory:Lastmodified25Oct.2010JBL