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Design, manufacture and test a hydraulic ram

Thesis · May 2017

DOI: 10.13140/RG.2.2.11626.72641

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 Report on:

Design, Manufacture and Test a

Hydraulic Ram
A report submitted for the partial fulfilment of the subject ‘Project’ for the course of Bachelor of Technology in
Mechanical Engineering

19th May, 2017

Submitted to:

Department of Mechanical Engineering

Heritage Institute of Technology
Prepared by:

Sudipto Shekhor Mondol

College Roll number: 1357024
Department of Mechanical Engineering
Heritage Institute of Technology
University Roll Number- 12600713052
Registration Number- 131260110613 of 2013-2014

Under the Guidance of

Dr. Siddhartha Ray

Professor, Heritage Institute of Technology
 Declaration of Originality and
Compliance of Academic Ethics
I hereby declare that this report contains original research work by the
undersigned student.
All the information in this document have been obtained and presented in
accordance with academic rules and ethical conduct.
I also declare that, as required by these rules and conduct, I have fully cited and
referred all material ad results that are not original to this work.

Sudipto Shekhor Mondol

Department of Mechanical Engineering
Heritage Institute of Technology
 Acknowledgment
I am indebted to a number of people, who helped and motivated me to bring out
this project. I would like to thank Dr. Siddhartha Ray who always guided me in
my endeavours and it has been an honour working under his guidance. I also want
to thank other members of the department of mechanical engineering of Heritage
Institute of Technology especially Professor Dr. Sukanta Sarkar and Technical
Assistant Mr. Anupam Biswas for their kind support and aid. I am grateful to Mr.
Samir Ghosh and Mr. Ramesh Naskar of Modern Engineering Works for
manufacturing and donating the waste valve. Lastly, I want to thank Mr. Jagadish
Ghosh, Project Engineer, Heritage Institute of Technology for helping me setup
the layout of the pump.

Sudipto Shekhor Mondol

Department of Mechanical Engineering
Heritage Institute of Technology
 Supervision Certificate
This is to certify that Mr. Sudipto Shekhor Mondol (University Roll Number-
12600713052 & Registration Number- 131260110613 of 2013-2014) has
completed his Bachelor of Technology final year project (ME-781) titled
“Design, Manufacture and Test a Hydraulic Ram” under our supervision. He has
meticulously carried out all the work and recorded the findings carefully. The
results presented in this work are solely the results of his theoretical/ experimental
findings and to the best of my knowledge it has not been published anywhere
else. I recommend this project to the committee for proper evaluation.

Dr. Siddhartha Ray

Professor, Heritage Institute of Technology

Countersigned by:

Signature of Head of the Department, Mechanical Engineering,

Heritage Institute of Technology
 List of Figures
Figure Description Page
Number Number
1 Montgolfier’s Hydraulic Ram Pump 3
2 Antique Hydrams 3
3 Basic components of a hydraulic ram 4
4 Hydram Modern Design 5
5 A Ram Pump Made From Standard Pipe Fittings 8
6 Hydram Schematic Layout Diagram 12
7 Waste Valve Top View and Side View 13
8 uPVC Pipes 17
9 Elbow 17
10 Socket 18
11 Nipple 19
12 Ball Valve 20
13 Bolt 21
14 Nut 22
15 Check Valve 23
16 Tee 24
17 Black Pipe 25
18 Water Tank 26
19 Waste Valve 28
20 Hydraulic Ram Pump 30
 List of Tables
Table Description Page
Number Number
1 List of bought out items 15
 Nomenclature

PVC Polyvinyl chloride

ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
SS Stainless Steel
MS Mild Steel
ABS Acrylonitrile Butadiene Styrene
ρ Density of Water
g Acceleration due to Gravity
Kg Kilogram
N Newton
uPVC Unplasticized Polyvinyl Chloride
BSP British Standard Pipe
MMAW Manual Metal Arc Welding
MTA Male Threaded Adapters
FTA Female Threaded Adapters
 Contents
Description Page Number

Abstract 1

Introduction 1

Literature Review 2

Design Procedure 12

Mathematical Description 14

Manufacturing and Assembly 15

Future Scope 31

Conclusion 32

References 33
 Abstract
A hydraulic ram is a pump in which the momentum of a driving stream of water
undergoing a small head drop is used to pump a small portion of the stream to a
head considerably greater than that of the supply. In the current study, a hydraulic
ram was designed, manufactured and tested.

1. Introduction
The hydraulic Ram pump[1] or hydram is a complete automatic device that uses
the energy of the flowing water such as spring, stream or river to pump part of
the water to a height above that of the source. With a continuous flow of water, a
hydram operates continuously with no external energy source.
A hydram is a structurally simple unit consisting of two moving parts. These are
the impulse valve (or waste valve) and the delivery (check) valve. The unit also
includes an air chamber and an air valve. The operation of a hydram is
intermittent due to the cyclic opening and closing of the waste and delivery
values. The closure of the waste valve creates a high pressure rise in the drive
pipe. An air chamber is required to transform the high intermittent pumped flows
into a continuous stream of flow. The air valves allow air into the hydram to
replace the air absorbed by the water due to the high pressure and mixing in the
air chamber.
Recognising that the hydraulic ram pump can be a viable and appropriate
renewable energy water pumping technology in developing countries, it has been
used for over two centuries in many parts of the world due to their simplicity and
reliability made them commercially successful, in the days before electrical
power and the internal combustion engine become widely available. As
technology advanced and become increasingly reliant on sources of energy
derived from fossil fuels, the hydraulic ram pump was neglected. It was felt to
have no relevance in an age of national electricity grids and large-scale water
supplies. Big had become beautiful and small-scale Hydraulic Ram Pump
technology was unfashionable.
In recent years an increased interest in renewable energy devices and an
awareness of the technological needs of a particular market in developing
countries have prompted a reappraisal of hydraulic ram pump. In hilly areas with
springs and reliable pumping device is large. Although there are some examples
of successful ram pumps installation in developing countries, their use to date has
merely scratched the surface of their potential. The main reason for this being,

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lack of widespread local knowledge in the design and manufacture of hydram.
Hence, the widespread use of hydram will only occur if there is a local
manufacturer to deliver quickly; give assistance in system design, installation and
provide an after-sales service.

2. Literature Review
2.1 History: The Hydraulic Ram Pump has been around for quite some time now,
the first device in the modern era is reported to have been devised by an
Englishman John Whitehurst in 1775. His design was not automatic and was
controlled by opening and closing a stopcock. Easier than carrying water by hand
but sure sounds like it was still a lot of work and very time consuming. The first
reported fully automatic hydraulic ram was developed by Joseph and Etienne
Montgolfier (of hot air balloon fame) in the late 1700’s (1793-1797). The original
design performed well on first start-up but suffered from a design flaw which
caused a loss or “dissolving” of air in its pressure chamber. This in turn caused
an intensive banging in the entire mechanism. It was his son Pierce Montgolfier
that solved the problem by developing and designing-in the air or “snifter” valve
to reintroduce air into the chamber. (Most home built designs try to either
simplify or work around the complexity of a snifter valve). Skip forward to the
present and not very much has changed design wise in the last couple of hundred
years. The UK based company Green & Carter now holds the original patents of
both John Whitehurst and Joseph Montgolfier and are in business today
manufacturing and installing their Vulcan Ram’s the world over.
In the original Montgolfier design (diagram shown on the next page), a water
supply or delivery pipe feeds into a larger bored pipe that is turned up at the end
and also necked down creating both a pinch point and a venturi effect causing the
water to increase in speed and pressure at the exit. The iron ball, which was most
probably a cannon ball that happened to be handy would fit comfortably into the
larger bored pipe but was larger enough that it could not escape out the venturi at
the end of the pipe. The force of the water flowing into the larger bore pipe would
push the “cannon” ball down the bore and into the venturi suddenly stopping the
flow of water. This sudden blockage of the delivery pipe would cause a dramatic
increase in the water pressure behind the ball commonly referred to as “water
hammer:” which in turn forced a small amount of water through a one-way valve
and into the air chamber and delivery pipe. The pressure would then dissipate and
release the iron ball, it would roll back into the larger bore area and the cycle
would begin all over again. In operation the water would have been delivered in
short pulses under high pressure into the air chamber which would act as a buffer,
smoothing out the supply of water heading into the delivery pipe and on its way
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to the intended destination. The addition later of the snifter valve allowed a small
amount of air to enter the air chamber keeping the system operational for much
longer periods of time between normal inspections and servicing. Some of these
designs ended up being quite large with drive pipes exceeding 8 inches in
diameter. That must have been quite a site to see them operate.

Figure 1: Montgolfier’s Hydraulic Ram Pump

Modern hydraulic rams all work on the same principle although the “cannon” ball
inside a necked down iron pipe idea has been replaced with modern steel, brass,
bronze, PVC and stainless fittings that can easily be obtained from your local
hardware store. For well over 100 years from the 1800’s through the early 1900’s
rams were very popular in the United States until the general availability of
publicly managed water mains and electric pumps became the mainstay of
twenty-first century life. Original ram pumps can still be occasionally found in
antique stores the back of barns and other odd places. They are a subject of the
search for enthusiasts to collect and restore as well as put back into use today.
Rams can be used to supply all the water you would ever need to a summer
cottage, mountain cabin or modern homestead. Some of these systems are
reported to have been in continual use supplying water for home and livestock
with very little maintenance for the past 100 years or more.

Figure 2: Antique Hydrams

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2.2 Working Principle: A simplified hydraulic ram is shown in Figure 3.
Initially, the waste valve [2] is open, and the delivery valve [3] is closed. The
water in the inlet pipe [4] starts to flow under the force of gravity and picks up
speed and kinetic energy until the increasing drag force closes the waste valve.
The momentum of the water flow in the inlet pipe against the now closed waste
valve causes a water hammer that raises the pressure in the pump, opens the
delivery valve [3], and forces some water to flow into the delivery pipe. Because
this water is being forced uphill through the delivery pipe farther than it is
falling downhill from the source, the flow slows; when the flow reverses, the
delivery check valve closes. Meanwhile, the water hammer from the closing of
the waste valve also produces a pressure pulse which propagates back up the
inlet pipe to the source where it converts to a suction pulse that propagates back
down the inlet pipe. This suction pulse, with the weight or spring on the valve,
pulls the waste valve back open and allows the process to begin again.

Figure 3: Basic components of a hydraulic ram:

1. Inlet – drive pipe
2. Free flow at waste valve
3. Outlet – delivery pipe
4. Waste valve
5. Delivery check valve
6. Pressure vessel
A pressure vessel [5] containing air cushions the hydraulic pressure shock when
the waste valve closes, and it also improves the pumping efficiency by allowing

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a more constant flow through the delivery pipe. Although the pump could in
theory work without it, the efficiency would drop drastically and the pump
would be subject to extraordinary stresses that could shorten its life
considerably. One problem is that the pressurized air will gradually dissolve
into the water until none remains. One solution to this problem is to have the air
separated from the water by an elastic diaphragm (similar to an expansion tank);
however, this solution can be problematic in developing countries where
replacements are difficult to procure. Another solution is to have a mechanism
such as a snifting valve that automatically inserts a small bubble of air when the
suction pulse mentioned above reaches the pump.[6] Another solution is to insert
an inner tube of a car or bicycle tire into the pressure vessel with some air in it
and the valve closed. This tube is in effect the same as the diaphragm, but it is
implemented with more widely available materials. The air in the tube cushions
the shock of the water the same as the air in other configurations does.

Figure 4: Hydram Modern Design

2.3 Efficiency: A typical energy efficiency is 60%, but up to 80% is possible.
This should not be confused with the volumetric efficiency, which relates the
volume of water delivered to total water taken from the source. The portion of
water available at the delivery pipe will be reduced by the ratio of the delivery
head to the supply head. Thus if the source is 2 meters above the ram and the
water is lifted to 10 meters above the ram, only 20% of the supplied water can be
available, the other 80% being spilled via the waste valve. These ratios assume
100% energy efficiency. Actual water delivered will be further reduced by the

5|Page
energy efficiency factor. In the above example, if the energy efficiency is 70%,
the water delivered will be 70% of 20%, i.e. 14%. Assuming a 2-to-1 supply head
to delivery head ratio and 70% efficiency, the delivered water would be 70% of
50%, i.e. 35%. Very high ratios of delivery to supply head usually result in
lowered energy efficiency. Suppliers of rams often provide tables giving expected
volume ratios based on actual tests.
2.4 Drive and delivery pipe design: Since both efficiency and reliable cycling
depend on water hammer effects, the drive pipe design is important. It should be
between 3 and 7 times longer than the vertical distance between the source and
the ram. Commercial rams may have an input fitting designed to accommodate
this optimum slope.[7] The diameter of the supply pipe would normally match the
diameter of the input fitting on the ram, which in turn is based on its pumping
capacity. The drive pipe should be of constant diameter and material, and should
be as straight as possible. Where bends are necessary, they should be smooth,
large diameter curves. Even a large spiral is allowed, but elbows are to be
avoided. PVC will work in some installations, but steel pipe is preferred, although
much more expensive. If valves are used they should be a free flow type such as
a ball valve or gate valve.
The delivery pipe is much less critical since the pressure vessel prevents water
hammer effects from traveling up it. Its overall design would be determined by
the allowable pressure drop based on the expected flow. Typically the pipe size
will be about half that of the supply pipe, but for very long runs a larger size may
be indicated. PVC pipe and any necessary valves are not a problem.
2.5 Starting operation: A ram newly placed into operation or which has stopped
cycling must be started as follows. If the waste valve is in the raised (closed)
position, which is most common, it must be pushed down manually into the open
position and released. If the flow is sufficient, it will then cycle at least once. If it
does not continue to cycle, it must be pushed down repeatedly until it cycles
continuously on its own, usually after three or four manual cycles. If the ram stops
with the waste valve in the down (open) position, it must be lifted manually and
kept up for as long as necessary for the supply pipe to fill with water and for any
air bubbles to travel up the pipe to the source. This may take a minute or more.
Then it can be started manually by pushing it down a few times as described
above. Having a valve on the delivery pipe at the ram makes starting easier. Close
the valve until the ram starts cycling, then gradually open it to fill the delivery
pipe. If opened too quickly it will stop the cycling. Once the delivery pipe is full
the valve can be left open.

6|Page
2.6 Design considerations: Hydrams are mostly intended for water supply
duties, in hilly or mountainous areas, requiring small flow rates delivered to high
heads. They are less commonly used for irrigation purposes, where the higher
flow rates required will usually demand the use of larger sizes of hydram having
6-inch or 4-inch drive pipes .[8]. Manufacturers usually describe the size of a
hydram by the supply and delivery pipe diameters (generally given in inches even
in metric countries because of the common use of inch sizes for pipe diameters).
For example, a 6 x 3 hydram has a 6-inch diameter drive pipe and a 3-inch
diameter delivery pipe.
Traditional hydram designs, developed a century ago in Europe, are extremely
robust. They tend to be made from heavy castings and have been known to
function reliably for 50 years or more. However, although a number of such
designs are still manufactured in Europe and the USA in small numbers, they are
relatively expensive, although generally speaking the drive-pipe, delivery pipe
and civil workings will be significantly more expensive than even the heaviest
types of hydram.
Lighter designs, fabricated using a welded sheet steel construction, were
developed first in Japan and are now in production in other parts of SE Asia
including Taiwan and Thailand. These are cheaper, but only likely to last a decade
or so as they are made from thinner material which will eventually corrode.
Nevertheless they offer good value for money and are likely to perform reliably.
Some simple designs that can be improvised from pipe fittings have also been
developed by aid agencies (Figure 5), and some interesting versions have also
been quite crudely improvised using scrap materials, such as a unit which is being
produced in some numbers in southern Laos from materials salvaged from
bombed bridges and using old propane cylinders for the air chamber. Needless to
say, such devices are very low in cost but the pipes in the end cost considerably
more than the hydram. They are not always as reliable as traditional designs, but
are usually acceptably reliable with failures separated by many months rather than
days, and are easy to repair when they fail.

7|Page
 Figure 5: A Ram Pump Made From Standard Pipe Fittings
2.7 Common operational problems: Failure to deliver sufficient water may be
due to improper adjustment of the waste valve, having too little air in the pressure
vessel, or simply attempting to raise the water higher than the level of which the
ram is capable.
The ram may be damaged by freezing in winter, or loss of air in the pressure
vessel leading to excess stress on the ram parts. These failures will require
welding or other repair methods and perhaps parts replacement.
It is not uncommon for an operating ram to require occasional restarts. The
cycling may stop due to poor adjustment of the waste valve, or insufficient water
flow at the source. Air can enter if the supply water level is not at least a few
inches above the input end of the supply pipe. Other problems are blockage of the
valves with debris, or improper installation, such as using a supply pipe of non-
uniform diameter or material, having sharp bends or a rough interior, or one that
is too long or short for the drop, or is made of an insufficiently rigid material. A
PVC supply pipe will work in some installations but is not as optimal as steel.
2.8 Maintenance: Rams Pumps are known for continuously running while
having minimal maintenance. This is largely because there are only a few
moving parts. The available materials and proximity of a technician should be
taken into account when selecting the type of pump. If there is a local person
who has the ability to make repair and check the functionality frequently it may
be best to build a ram pump using cheap local materials. If there is limited

8|Page
availability of a technician, a commercial pump may be preferable. If clean
water is used maintenance is only required after several years.[8]
2.9 Piping and Plumbing Fitting: A fitting is used in pipe systems to connect
straight pipe or tubing sections, adapt to different sizes or shapes and for other
purposes, such as regulating (or measuring) fluid flow. "Plumbing" is generally
used to describe the conveyance of water, gas, or liquid waste in domestic or
commercial environments; "piping" is often used to describe the high-
performance (high-pressure, high-flow, high-temperature or hazardous-
material) conveyance of fluids in specialized applications. "Tubing" is
sometimes used for lighter-weight piping, especially that flexible enough to be
supplied in coiled form.
Fittings (especially uncommon types) require money, time, materials and tools
to install, and are an important part of piping and plumbing systems. Valves are
technically fittings, but are usually discussed separately.
Standard codes are followed when designing (or manufacturing) a piping
system. Organizations which promulgate piping standards include:
ASME: American Society of Mechanical Engineers
A112.19.1 Enameled cast-iron and steel plumbing fixtures standards
A112.19.2 Ceramic plumbing fixtures standard
ASTM International: American Society for Testing and Materials
API: American Petroleum Institute
AWS: American Welding Society
AWWA: American Water Works Association
MSS: Manufacturers Standardization Society
ANSI: American National Standards Institute
NFPA: National Fire Protection Association
EJMA: Expansion Joint Manufacturers Association
CGA: Compressed Gas Association

9|Page
Pipes must conform to the dimensional requirements of:
ASME B36.10M: Welded and seamless wrought-steel pipe
ASME B36.19M: Stainless-steel pipe
ASME B31.3 2008: Process piping
ASME B31.4 XXXX: Power piping
The B31.3 and B31.4 codes have requirements for piping found in petroleum
refineries; chemical, pharmaceutical, textile, paper, semiconductor, and
cryogenic plants, and related processing plants and terminals. These codes
specify requirements for materials and components, design, fabrication,
assembly, erection, examination, inspection and testing of piping. The codes are
applicable to piping for all fluids, including raw, intermediate and finished
chemicals; petroleum products; gas, steam, air and water; fluidized solids;
refrigerants, and cryogenic fluids.
The material with which a pipe is manufactured is often the basis for choosing a
pipe. Materials used for manufacturing pipes include:
Carbon (CS) and galvanized steel
Impact-tested carbon steel (ITCS)
Low-temperature carbon steel (LTCS)
Stainless steel (SS)
Malleable iron
Non-ferrous metals (includes copper, inconel, incoloy and cupronickel)
Non-metallic (includes acrylonitrile butadiene styrene (ABS), fibre-reinforced
plastic (FRP), polyvinyl chloride (PVC), high-density polyethylene (HDPE) and
toughened glass)
Chrome-molybdenum (alloy) steel — Generally used for high-temperature
service
The bodies of fittings for pipe and tubing are most often the same base material
as the pipe or tubing connected: copper, steel, PVC, chlorinated polyvinyl
chloride (CPVC) or ABS. Any material permitted by the plumbing, health, or
building code (as applicable) may be used, but it must be compatible with the
other materials in the system, the fluids being transported and the temperature
and pressure inside (and outside) the system. Brass or bronze fittings are
common in copper piping and plumbing systems.

10 | P a g e
Gaskets: Gaskets are mechanical seals, usually ring-shaped, which seal flange
joints. Gaskets vary by construction, materials and features. Commonly used
gaskets are non-metallic (ASME B 16.21), spiral-wound (ASME B 16.20) and
ring-joint (ASME B 16.20). Non-metallic gaskets are used with flat- or raised-
face flanges. Spiral-wound gaskets are used with raised-face flanges, and ring-
joint gaskets are used with ring-type joint (RTJ) flanges. Stress develops
between an RTJ gasket and the flange groove when the gasket is bolted to a
flange, leading to plastic deformation of the gasket.
Gender: Piping or tubing is usually inserted into fittings to make connections.
Connectors are assigned a gender, abbreviated M or F. An example of this is a
"3/4-inch female adapter NPT", which would have a corresponding male
connection of the same size and thread standard (in this case, NPT).
Valves: Valves stop (or regulate) the flow of liquids or gases. They are
categorized by application, such as isolation, throttling, and non-return.
Isolation valves are used to temporarily disconnect part of a piping system, to
allow maintenance or repair, for example. Isolation valves are typically left in
either a fully open or fully closed position. A given isolation valve may be in
place for many years without being operated, but must be designed to be readily
operable whenever needed, including emergency use.
Throttling valves are used to control the amount or pressure of a fluid allowed
to pass through, and are designed to withstand the stress and wear caused by
this type of operation. Because they may wear out in this usage, they are often
installed alongside isolation valves which can temporarily disconnect a failing
throttling valve from the rest of the system, so it can be refurbished or replaced.
Non-return or check valves allow free flow of a fluid in one direction, but
prevent its flow in a reverse direction. They are often seen in drainage or
sewage systems, but may also be used in pressurized systems.
Valves are available in a number of types, based on design and purpose:
Gate, plug, or ball valves – Isolation
Globe valve – Throttling
Needle valve – Throttling, usually with high precision but low flow
Butterfly or diaphragm valves – Isolation and throttling
Check valve – Preventing reverse flow (non-return)

11 | P a g e
 3. Design Procedure
The aim of the hydram is to pump water from water tank at a height of 4ft to a
bucket at an elevation of 8ft. The design had the minimum number of pipe elbows
to minimise head losses. The configuration of the drive pipe shown in figure 4
was avoided as it included complex inclination angle calculations. The design
should be such that a large volume of water is available at the drive pipe. The
following layout of the hydram encompasses all the above considerations:

Figure 6: Hydram Schematic Layout Diagram

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A 200 litre water tank was used as the reservoir. A stop valve is installed in the
inlet pipe to stop the hydram at the will of the operator. The waste valve was
anchored on a rigid platform. The foot valve stops backflow of water. The
delivery pipe transports the water to a bucket with a pipe attached to its bottom
that directs the water back to the reservoir when the stop valve is opened.

Figure 7: Waste Valve Top View and Side View

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 4. Mathematical Description
The design should be such that the area of the annular region between the valve
and the four inch pipe should be more or less close to the area of all the one inch
holes on the top of the valve.
Annular Area= (π/4 x 101.62) – (π/4 x 802)
= π/4 x (101.62 - 802)
= 3080.8 mm2
Area of one hole = π/4 x 25.42
=506.71 mm2
Area of 6 holes = 506.71 mm2 x 6
= 3040.24 mm2
Thus, the areas are comparable and the design is valid.
The weight of the valve should be less than the total thrust applied by the column
of water. Otherwise, the valve would not close and the pump will not work.
Height of water in pipe + Height of water in tank – Height of waste valve =
5ft (approx).
Total Pressure, P = h ρ g
Where ρ is the density of water
And g is the acceleration due to gravity
Therefore, P= 1.53 x 1000 x 9.81
= 15009.3 pa
Area of the mild steel disk, A = π/4 x (0.082)
= 5.027 x 10-3 m2
Force = P x A
= 15009.3 x 5.027 x 10-3
= 75.452 N
Weight = Force/9.81
= 75.452 /9.81 = 7.69 Kg

14 | P a g e
Volume of stainless steel rod = 3.14 x 10-5 m3
Volume of mild steel disk = 3.02 x 10-4 m3
Total volume = 3.334 x 10-4
Mass = Density x Volume
=2.6 Kg
(Density of Steel = 7800 kg/ m3)
Thus, we can conclude that additional weights will be needed to balance the
forces. These weights will be screwed to the threaded part of the top of the
impulse valve plug.

5. Manufacturing and Assembly

Six holes each of 25.4mm were drilled on the top of the waste valve. A rubber
gasket was laid in between the metallic parts to make them leak proof. The pipe
was connected to the waste valve via a short piece – socket assembly. This makes
the design more flexible and easy to dismantle. Black ERW pipes were used to
manufacture the waste valve. Internal threads were cut at the centre of the MS
plate. The rod was made of stainless steel. The two ends of the rod was threaded.
The top thread will be used to augment additional weights and the bottom thread
was fastened to the mild steel plate. The guide is made of MS.
The list of items that were procured from the market:
Sl. Item Specification Quantity
No.
1 UPVC Pipe 1.5 inch 10ft
2 UPVC Pipe 1/2inch 15ft
3 Elbow 1.5 inch 2 pc.
4 Elbow 1/2inch 3 pc.
5 Socket 1.5 inch 1 pc.
6 Tank Nipple 1.5 inch 1 pc.
7 Ball Valve 1.5 inch 1 pc.
8 Socket ½ inch 3 pc.
9 Bolt and Nut 8M x 1 ½ 6 pc.
10 Nut 10M x 2 1 pc.
11 Check Valve ½ inch 1 pc.
12 Tee 1.5 inch 1 pc.
13 Male Threaded Adapter ½ inch 2 pc.
14 Female Threaded Adapter 1.5 inch 1 pc.

15 | P a g e
 15 Female Threaded Adapter ½ inch 1 pc.
16 Circular Saw Blade 1 pc.
17 Black Pipe 4 inch 300mm
18 Water Tank 200 litre 1 pc.
19 Bucket 1 pc.
20 Plastic Pipe ½ inch 5ft
21 Solvent Cement 100ml
Table 1: List of bought out items
5.1 Product Description:
5.1.1 UPVC: UPVC has high chemical resistance across its operating
temperature range, with a broad band of operating pressures. Due to its long-term
strength characteristics, high stiffness and cost effectiveness, UPVC systems
account for a large proportion of plastic piping installations.
Polyvinyl chloride or uPVC Pipes are not allowed for inside water supply lines
in the USA for homes from 2006 to present date. Code IRC P2904.5 uPVC Not
listed. Studies show toxic chemicals leach out from the uPVC into the water
supply. uPVC is allowed for waste lines in homes.
uPVC is a thermoplastic material derived from common salt and fossil fuels. The
pipe material has the longest track record of all plastic materials. The first uPVC
pipes were made in the 1930s. During the 1950s, they were used to replace
corroded metal pipes and thus bring fresh drinking water to a growing urban
population.
Further pressure and non-pressure applications in the field of sewers, soil and
waste, gas (low pressure) and cable protection soon followed. The material's
contribution to public health, hygiene and well-being has therefore been
significant.
Based on the standard polyvinyl chloride material, three other variants are in use.
Another variant called OPVC represents an important landmark in the history of
plastic pipe technology. This molecular-oriented bi-axial high performance
version combines high strength with extra impact resistance.
A ductile variant is the MPVC, polyvinyl chloride modified with acrylics or
chlorinated PE. This ductile material with high fracture resistance is used in high
demanding applications where resistance against cracking and stress corrosion is
important. In several studies the long track record of uPVC pipes has been
investigated. Recent investigations at the German KRV and the Dutch TNO have

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confirmed that uPVC water pressure pipes, when installed correctly have a useful
life span of over 100 years.

Figure 8: uPVC Pipes

5.1.2 Elbow: An elbow is installed between two lengths of pipe (or tubing) to
allow a change of direction, usually a 90° or 45° angle; 22.5° elbows are also
available. The ends may be machined for butt welding, threaded (usually female),
or socketed. When the ends differ in size, it is known as a reducing (or reducer)
elbow.

Figure 9: Elbow
A 90º elbow, also known as a "90 bend", "90 ell" or "quarter bend", attaches
readily to plastic, copper, cast iron, steel, and lead, and is attached to rubber with
stainless-steel clamps. Other available materials include silicone, rubber
compounds, galvanized steel, and nylon. It is primarily used to connect hoses to
valves, water pumps and deck drains. A 45º elbow, also known as a "45 bend" or
"45 ell", is commonly used in water-supply facilities, food, chemical and
electronic industrial pipeline networks, air-conditioning pipelines, agriculture
and garden production, and solar-energy facility piping.
Elbows are also categorized by length. The radius of curvature of a long-radius
(LR) elbow is 1.5 times the pipe diameter, but a short-radius (SR) elbow has a
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radius equal to the pipe diameter. Short elbows, widely available, are typically
used in pressurized systems, and in physically tight locations.
Long elbows are used in low-pressure gravity-fed systems and other applications
where low turbulence and minimum deposition of entrained solids are of concern.
They are available in acrylonitrile butadiene styrene (ABS plastic), polyvinyl
chloride (PVC), chlorinated polyvinyl chloride (CPVC), and copper, and are used
in DWV systems, sewage, and central vacuum systems.
5.1.3 Sockets: Sockets are small sections of copper tube (or UPVC tube) with a
slightly larger diameter to join the two pipes together.
It is thought by some that forming a socket by the expansion of pipes does not
provide the same standard result as a socket itself.
Though the soldering process is the same for both, the socket former is less
commonly used because the expansion process can cause the pipes to become
weaker. In the present study, UPVC sockets were joined using solvent cement.

Figure 10: Socket

5.1.4 Nipple: In plumbing and piping, a nipple is a fitting, consisting of a short
piece of pipe, usually provided with a male pipe thread at each end, for connecting
two other fittings.
The length of the nipple is usually specified by the overall length with threads. It
may have a hexagonal section in the center for wrench to grasp (sometimes

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referred to as a "hex nipple"), or it may simply be made from a short piece of pipe
(sometimes referred to as a "barrel nipple" or "pipe nipple"). A "close nipple" has
no unthreaded area; when screwed tightly between two female fittings, very little
of the nipple remains exposed. A close nipple can only be unscrewed by gripping
one threaded end with a pipe wrench which will damage the threads and
necessitate replacing the nipple, or by using a specialty tool known as a nipple
wrench (or known as an internal pipe wrench) which grips the inside of the pipe,
leaving the threads undamaged. When the ends are of two different sizes it is
called a reducer or unequal nipple.
Threads used on nipples are BSP, BSPT, NPT, NPSM and Metric.

Figure 11: Nipple

5.1.5 Ball Valve: A ball valve is a form of quarter-turn valve which uses a hollow,
perforated and pivoting ball to control flow through it. It is open when the ball's
hole is in line with the flow and closed when it is pivoted 90-degrees by the valve
handle. The handle lies flat in alignment with the flow when open, and is

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perpendicular to it when closed, making for easy visual confirmation of the
valve's status.
Ball valves are durable, performing well after many cycles, and reliable, closing
securely even after long periods of disuse. These qualities make them an excellent
choice for shutoff and control applications, where they are often preferred to gates
and globe valves, but they lack their fine control in throttling applications.
The ball valve's ease of operation, repair, and versatility lend it to extensive
industrial use, supporting pressures up to 1000 bar and temperatures up to 752 °F
(400 °C), depending on design and materials used. Sizes typically range from 0.2
to 48 inches (0.5 cm to 121 cm). Valve bodies are made of metal, plastic, or metal
with a ceramic; floating balls are often chrome plated for durability. One
disadvantage of a ball valve is that they trap water in the center cavity while in
the closed position. In the event of a freeze, the sides can crack due to expansion
of ice forming. Some means of insulation or heat tape in this situation will usually
prevent damage. Another option for cold climates is the "freeze tolerant ball
valve". This style of ball valve incorporates a freeze plug in the side so in the
event of a freeze up, the freeze plug ruptures (acts as a sacrificial disk), thus
making for an easy repair. Now instead of replacing the whole valve, just screw
in a new freeze plug.
In the case that a ball valve is used for cryogenics or product that may expand
inside of the ball, there is a vent drilled into the upstream side of the valve. This
is referred to as a vented ball. Safety is the number one concern when engineers
specify a vented ball.

Figure 12: Ball Valve

A ball valve should not be confused with a "ball-check valve", a type of check
valve that uses a solid ball to prevent undesired backflow.

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Other types of quarter-turn valves include the butterfly valve and plug valve and
freeze proof ball valve.
5.1.6 Bolt: A bolt is a form of threaded fastener with an external male thread.
Bolts are thus closely related to, and often confused with, screws.
The first bolts had square heads, formed by forging. These are still found,
although much more common today is the hexagonal head. These are held and
turned by a spanner or wrench, of which there are many forms. Most are held
from the side, some from in-line with the bolt. Other bolts have T-heads and
slotted heads.
Many screws use a screwdriver head fitting, rather than an external wrench.
Screwdrivers are applied in-line with the fastener, rather than from the side. These
are smaller than most wrench heads and cannot usually apply the same amount
of torque. It is sometimes assumed that screwdriver heads imply a screw and
wrenches imply a bolt, although this is incorrect. Coach screws are large square-
headed screws with a tapered wood screw thread, used for attaching ironwork to
timber.
Head designs that overlap both are the Allen or Torx heads; hexagonal or splined
sockets. These modern designs span a large range of sizes and can carry a
considerable torque.

Figure 13: Bolt

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5.1.7 Nut: A nut is a type of fastener with a threaded hole. Nuts are almost always
used in conjunction with a mating bolt to fasten multiple parts together. The two
partners are kept together by a combination of their threads' friction (with slight
elastic deformation), a slight stretching of the bolt, and compression of the parts
to be held together.
In applications where vibration or rotation may work a nut loose, various locking
mechanisms may be employed: lock washers, jam nuts, specialist adhesive
thread-locking fluid such as Loctite, safety pins (split pins) or lockwire in
conjunction with castellated nuts, nylon inserts (nyloc nut), or slightly oval-
shaped threads.
Square nuts, as well as bolt heads, were the first shape made and used to be the
most common largely because they were much easier to manufacture, especially
by hand. While rare today due to the reasons stated below for the preference of
hexagonal nuts, they are occasionally used in some situations when a maximum
amount of torque and grip is needed for a given size: the greater length of each
side allows a spanner to be applied with a larger surface area and more leverage
at the nut.
The most common shape today is hexagonal, for similar reasons as the bolt head:
six sides give a good granularity of angles for a tool to approach from (good in
tight spots), but more (and smaller) corners would be vulnerable to being rounded
off. It takes only one sixth of a rotation to obtain the next side of the hexagon and
grip is optimal. However, polygons with more than six sides do not give the
requisite grip and polygons with fewer than six sides take more time to be given
a complete rotation. Other specialized shapes exist for certain needs, such as
wingnuts for finger adjustment and captive nuts (e.g. cage nuts) for inaccessible
areas.

Figure 14: Nut

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A wide variety of nuts exists, from household hardware versions to specialized
industry-specific designs that are engineered to meet various technical standards.
Fasteners used in automotive, engineering, and industrial applications usually
need to be tightened to a specific torque setting, using a torque wrench. Nuts are
graded with strength ratings compatible with their respective bolts; for example,
an ISO property class 10 nut will be able to support the bolt proof strength load
of an ISO property class 10.9 bolt without stripping. Likewise, an SAE class 5
nut can support the proof load of an SAE class 5 bolt, and so on.
5.1.8 Check Valve: A check valve, clack valve, non-return valve or one-way
valve is a valve that normally allows fluid (liquid or gas) to flow through it in
only one direction.
Check valves are two-port valves, meaning they have two openings in the body,
one for fluid to enter and the other for fluid to leave. There are various types of
check valves used in a wide variety of applications. Check valves are often part
of common household items. Although they are available in a wide range of sizes
and costs, check valves generally are very small, simple, or inexpensive. Check
valves work automatically and most are not controlled by a person or any external
control; accordingly, most do not have any valve handle or stem. The bodies
(external shells) of most check valves are made of plastic or metal.

Figure 15: Check Valve

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An important concept in check valves is the cracking pressure which is the
minimum upstream pressure at which the valve will operate. Typically the check
valve is designed for and can therefore be specified for a specific cracking
pressure.
Heart valves are essentially inlet and outlet check valves for the heart ventricles,
since the ventricles act as pumps.
5.1.9 Tee: A tee, the most common pipe fitting, is used to combine (or divide)
fluid flow. It is available with female thread sockets, solvent-weld sockets or
opposed solvent-weld sockets and a female-threaded side outlet. Tees can connect
pipes of different diameters or change the direction of a pipe run, or both.
Available in a variety of materials, sizes and finishes, they may also be used to
transport two-fluid mixtures. Tees may be equal or unequal in size of their three
connections, with equal tees the most common.

Figure 16: Tee

5.1.10 Black Pipe: Steel pipe (or black iron pipe) was once the most popular
choice for supply of water and flammable gases. Steel pipe is still used in many
homes and businesses to convey natural gas or propane fuel, and is a popular
choice in fire sprinkler systems due to its high heat resistance. In commercial
buildings, steel pipe is used to convey heating or cooling water to heat
exchangers, air handlers, variable air volume (VAV) devices, or other HVAC
equipment.
Steel pipe is sometimes joined using threaded connections, where tapered threads
(see National Pipe Thread) are cut into the end of the tubing segment, sealant is
applied in the form of thread sealing compound or thread seal tape (also known
as PTFE or Teflon tape), and it is then threaded into a corresponding threaded

24 | P a g e
fitting using two pipe wrenches. Beyond domestic or light commercial settings,
steel pipe is often joined by welding, or by use of mechanical couplings made by
companies such as Victaulic or Anvil International (formerly Grinnell) that hold
the pipe joint together via a groove pressed or cut (a rarely used older practice),
into the ends of the pipes.
Other variations of steel pipe include various stainless steel and chrome alloys.
In high-pressure situations these are usually joined by TIG welding.
In Canada, with respect to natural gas (NG) and propane (LP gas), black iron pipe
(BIP) is commonly used to connect an appliance to the supply. It must however
be marked (either painted yellow or yellow banding attached at certain intervals)
and certain restrictions apply to which nominal pipe size (NPS) can be put
through walls and buildings. With propane in particular, BIP can be run from an
exterior tank (or cylinder) provided it is well protected from the weather, and an
anode-type of protection from corrosion is in place when the pipe is to be installed
underground.

Figure 17: Black Pipe

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5.1.11 Water Tank: A water tank is a container for storing water. Water tanks
are used to provide storage of water for use in many applications, drinking water,
irrigation agriculture, fire suppression, agricultural farming, both for plants and
livestock, chemical manufacturing, food preparation as well as many other uses.
Water tank parameters include the general design of the tank, and choice of
construction materials, linings. Various materials are used for making a water
tank: plastics (polyethylene, polypropylene), fiberglass, concrete, stone, steel
(welded or bolted, carbon, or stainless). Earthen pots also function as water
storages. Water tanks are an efficient way to help developing countries to store
clean water.

Figure 18: Water Tank

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5.2 Waste Valve Construction: The following manufacturing processes were
undertaken in the construction of the waste valve:
 300mm length 4” pipe was cut from a longer pipe via the lathe machine.
 The lower flange was given a skin-cut and welded to the 4” pipe such that
it had an interference fit with the pipe.
 The guide was welded to the top flange.
 The pitch circle was marked using a scriber while the flange was held on
the chuck of the lathe.
 10.2mm diameter holes were drilled using a drill chuck attachment on the
tail stock of the lathe machine.
 6 holes of diameter 8mm were drilled for bolting the top flange to the lower
flange.
 A 10mm diameter hole was drilled for the impulse plug to reciprocate and
was given a tolerance of H7g6.
 Threads were cut on both sided of the 10mm stainless steel rod.
 Internal thread in the MS plate was cut using a die.
 MMAW was used to weld the pipe to the MS platform under pressure.
 A 1 ½ ’’ inch hole and a ½’’ inch hole was drilled on opposite sides of the
4’’ pipe.
 Grooves were made using a grinder to weld the short pieces to the 4” pipe.
 Four 10mm holes were drilled on the platform so that it can be bolted to
the foundation.
 A flange was welded to the impulse valve plug for providing support to
additional weights.
 The rubber gasket was cut out and 8mm holes were drilled.

27 | P a g e
 Figure 8: Waste Valve

5.3 Layout Setup: The following steps were carried out for the installation of the
hydraulic ram:
 A stand was made out of iron brackets and wood to form a platform for the
200L tank.
 A hole was drilled at the top of the tank and a plastic pipe connected the
tank to the water supply.
 The plastic pipe was enlarged using a heater and fitted with the tap (water
supply).
 A tank nipple was connected to a Tee.
 The tee connected the tank, the drive pipe and the vent pipe together. The
vent allows gas to escape from the system.
 A cemented platform was raised to lay the waste valve.

28 | P a g e
  Foundation bolts were laid in the platform. The nuts were tightened using
a wrench after placing the waste valve in its position.
 Walls were constructed such that all the water from the waste valve goes
to the drain.
 The rubber gasket was placed between the flanges of the waste valve and
bolted using a wrench. It must be tightly fitted so that no water leaks out
from between the flanges.
 The ball valve was installed in the drive pipe where it is easily accessible.
 UPVC pipes were cut using a hacksaw and joined using solvent cement. In
solvent welding, a solvent is applied which can temporarily dissolve the
polymer at room temperature. When this occurs, the polymer chains are
free to move in the liquid and can mingle with other similarly dissolved
chains in the other component. Given sufficient time, the solvent will
permeate through the polymer and out into the environment, so that the
chains lose their mobility. This leaves a solid mass of entangled polymer
chains which constitutes a solvent weld. This technique is commonly used
for connecting PVC and ABS pipe, as in household plumbing. The "gluing"
together of plastic (polycarbonate, polystyrene or ABS) models is also a
solvent welding process. Dichloromethane (methylene chloride), which is
obtainable in paint stripper, can solvent weld polycarbonate and
polymethylmethacrylate. Dichloromethane chemically welds certain
plastics; for example, it is used to seal the casing of electric meters. It is
also a component – along with tetrahydrofuran – of the solvent used to
weld plumbing.
 Male Threaded Adapters and Female Threaded Adapters were used to join
the uPVC drive pipe and delivery pipe with the steel waste valve.
 Additional supports were given to the delivery pipe by tying steel wires
around it.
 A plastic bucket was hung using steel wires and another pipe connected at
the bottom of the bucket drained the water to the 200L tank through the
vent pipe.
 A small gap was kept between the 1/2’’ pipe and the bucket so that the
water flashing out of the delivery pipe can be realised visually.
 The bucket was also equipped with a tap so that the water that is collected
from the delivery pipe is not momentarily drained.

29 | P a g e
 Figure 10: Hydraulic Ram Pump

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 6. Future Scope
The ram pump is a 'mature' technology. Over the last two centuries pump designs
have stabilised and many variations to the basic configuration (of drive pipe,
pump, pump house and delivery pipe) have been tried. One might think that no
further significant change was likely in the ram pump itself or in the system in
which it is used. However, there are changes occurring in both pumping needs
and in materials. Before the invention of petrol engines or the arrival of electricity
on farms, the ram pump was in many locations the only feasible way of lifting
water from streams or springs to neighbouring hillsides. In consequence a high
cost was tolerated; strong but expensive pumps made from cast steel, gunmetal
and brass were used. Today there are more alternatives, so that ram pumping can
only hold its 'market share' in water supply for humans and for cattle by becoming
cheaper and simpler. All over the world water is getting scarcer and dirtier. In
consequence ideal sites for ram pumping - where a large flow of clean water drops
steeply - are becoming fewer. Quite often the water requires cleaning if it is to be
used for domestic purposes. There are various possible responses to this problem
of polluted drive flow. One is to filter the delivery flow. A second is to use an
indirect ram pump that permits falling dirty water to power the raising of clean
water from a nearby source. A third is to concentrate on applications like cattle
watering and irrigation where water quality is less important. Filtering and
disinfection are well understood, and the technical options for applying them are
increasing in number. The availability of only one or two watts of electricity, say
from a small photovoltaic panel, now enables chemical or ultra-violet sterilisation
to be performed at a household or village scale. Adding such processes to a ram
pumping system may require other design adjustments, for example those to
permit delivery flow only in day light hours.
Indirect pumping is a technique known for a hundred years or more. Indirect
pumps are still manufactured but they are complex and hence costly. They have
more wearing parts than normal ram pumps and they require a source of clean
water close to the dirtier flow that drives them. One might argue that to require
such elaboration in system installation and maintenance is to head in the wrong
direction. Field experience suggests that the use of ram pump technology is
already severely limited by people thinking it is 'too complicated'. The design
rules seem complex and they fear making any mistake that might cause a system
to fail. Yet systems do occasionally fail - through wear and corrosion, insufficient
drive flow or flood damage, siltation or blockage, theft or malicious damage. It is
not possible to build a perfect system. With petrol-engine pumping at its simplest,
the user carries the pump to site, drops a suction hose into the water source, rolls

31 | P a g e
out the delivery hose and starts the pump. With electric powered pumping using
mains, photo-voltaics or transported batteries, the procedure is a little more
complex. Ram pumping is more complex again. There has therefore been a
growing interest in simplifying the technology, especially in order to serve
irrigation operated by peasant farmers.

7. Conclusion
The hydraulic ram pump worked perfectly. It was observed that if the water in
the tank decreased the time taken between strokes increased and the pump ceased
to work. Shortening the stroke increased the frequency of strokes. Thus, a certain
amount of water has to be maintained in order to pump water via the ram pump
satisfactorily.

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 References
[1] Shuaibu Ndache MOHAMMED, “Design and Construction of a Hydraulic
Ram Pump”, Leonardo Electronic Journal of Practices and Technologies, Issue
11, July-December 2007, p. 59-70.
[2] "New Patents: Pierre François Montgolfier," The Annals of Philosophy, 7
(41) : 405 (May 1816).
[3] de Montgolfier, J.M. (1803). "Note sur le bélier hydraulique, et sur la
manière d'en calculer les effets”. Journal des Mines, 13 (73) (in French), p. 42–
51.
[4] Whitehurst, John (1775). "Account of a Machine for Raising Water,
executed at Oulton, in Cheshire, in 1772". Philosophical Transactions of the
Royal Society. London: Royal Society. 65: 277–279.
doi:10.1098/rstl.1775.0026
[5] Executive Documents of the House of Representatives at the Second Session
of the Twenty-first Congress … , vol. 2 (Washington, D.C.: Duff Green, 1831),
pages 328 and 332.
[6] “Hydraulic Ram Pumps”, Practical Action, United Kingdom, 2010.
[7] “Hydraulic Ram Pumps”, John Perkin, Green and Carter LTD.
[8] Green. Carter. (2002). Hydraulic ram leaflet. Retrieved from
http://www.greenandcarter.com/main/rampumpleaflet.htm
[9] “NEW DEVELOPMENTS IN HYDRAULIC RAM PUMPING”, Hydraulic
Ram Pump Research Programme, Development Technology Unit School of
Engineering, University of Warwick, Technical Release 13, 1996.

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