DESIGN AND ANALYSIS OF SIMULATION FOR HYRAULIC RAM

PUMP/FABRICATION

MOHD DARUS BIN MANSOOR RAHMAN

Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP), 26000 Pekan, Pahang,
Malaysia, Phone: +60174354786

Email: matdarus96@yahoo.com

MOHAMAD HADZIM BIN KAMALUDIN

Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP), 26000 Pekan, Pahang,
Malaysia, Phone: +60148422607

Email: hadzim96@gmail.com

ABSTRACT

This paper discusses the design and analysis of simulation for hydraulic ram pump. The objective of
this project is to design a new hydraulic ram pump and analyse the flow inside the ram pump using
solidworks flow simulation. In this study, it is focus on the history of hydraulic ram pump, the working
principle of hydraulic ram pump, specification and limitation of ram pump. The first step of designing,
all the related problems are developed. This include the most suitable operational working principle for
the hydraulic ram pump, outline the theoretical background behind the operation. The detail drawing of
the hydraulic ram pump by using solidworks software is shown. Computational fluid dynamics (CFD)
is one of the ways to virtually design and run a simulation experiment without the need to physically
build a model[4]. This process can be carried out using commercial software and is much cheaper
compared to physical model building. Furthermore, the maximum pressure and velocity at the outlet
pipe is analysed. Fabrication process of the hydraulic ram pump is shown and explained clearly. The
result conclude that increases in mass flowrate will increase pressure and velocity at outlet. The pressure
acting inside air chamber and on waste valve increases as mass flowrate increase. Therefore, making
the parts of air chamber with strong materials such as galvanized steel (GI) will make the parts durable
and can withstand high pressure. An improvement and recommendation of the designed model is
provided for further implication.

Keywords: GI galvanized steel; Computational Fluid Dynamics.

INTRODUCTION

Hydraulic ram pump is a device that pumps water which is powered by falling water. This pump works
using the energy of large amount of water falling from a small height to lift a small amount of that water
to a much greater height. In this way, water from spring or stream in valley can be easily pumped to a
village or irrigation scheme on the hillside. Whenever a fall of water can be obtained, the ram pump
can used as a comparatively cheap, simple and reliable means of raising water to considerable height.
Computational fluid dynamics (CFD) is one of the ways to virtually design and run a simulation
experiment without the need to physically build a model. This process can be carried out using
commercial software and is much cheaper compared to physical model building. CFD has been
successful in carrying out simulations of many engineering problem
 DESIGN AND EXPERIMENTAL

This chapter will briefly describe the flow of designing and simulating the hydraulic ram pump. This
methodology process is conducted in 6 stage as shown in the flow chart below. The literature review
has been carried out to establish the specification of the history development of ram pump, the working
principle of ram pump, limitation and specification of hydraulic ram pump. The design concept of the
hydraulic ram pump has been started with simple sketches with different specification. The parameter
that are has been taken care is type of pipe, size of air chamber, type valve and the design. The diameter
of pipe also effect the water pressure as it has thicker wall. Then, the concept generation and concept
selection are performed to select the best design. In this section also shows material selection and the
process that has been conducted to design the ramp pump. Then, improve the design. Try to come with
several concepts. Then compare the criteria from each design which are the best. If no improvement is
needed go to next step. Produce the drawing together with dimension of the product and choose type
materials needed. After completing the previous task, analysing the water flow using Solidworks flow
simulation software. The software is leaned and when the software is fully mastered then it goes to next
step which is analysis of simulation. The boundary conditions were set up and the software is being
used to get results. After that, the design has been fabricated and tested for better results. The result had
been recorded and continued by writing the report. Beside, how to achieve objective and solve problem
statement of the project will be discuss in this chapter.

SOLIWORKS DESIGNING

Figure 3.4: Front and Isometric view of hydraulic ram pump

RESULT AND DISCUSSION

SIMULATION RESULT

Relationship of maximum pressure inside air chamber with various type of mass flowrate.

Table 1.7: Maximum pressure inside air chamber

Mass flowrate (kg/s) Maximum pressure inside air chamber (pa)

0.005 101325.0349

0.090 101326.837

0.5 101366.6292
 Inlet Mass Flowrate vs Maximum Pressure Inside
Air Chamber
Maximum Pressure Inside Air Chamber (pa)

101370
101360
101350
101340
101330
101320
101310
101300
0.005 0.09 0.5
Inlet Mass Flowate (kg/s)

Figure 5.5: Graph of inlet flowrate vs maximum pressure inside air chamber

Relationship of maximum pressure acting on waste valve with various type of mass flowrate.

Table 1.8: Maximum pressure acting on waste valve

Mass flowrate (kg/s) Maximum Pressure acting on waste valve (Pa)

0.005 101325.0686

0.090 101328.8277

0.5 101410.4597

Inlet Mass Flowrate vs Maximum Pressure Acting

Maximum Pressure acting On Waste Valve

On Waste Valve
101420
101400
101380
(pa)

101360
101340
101320
101300
101280
0.005 0.09 0.5
Inlet Mass Flowate (kg/s)

Figure 5.6: Graph of inlet mass flowrate vs maximum pressure acting on the waste valve
Relationship of maximum outlet velocity with various type of mass flowrate.

Table 1.9: Maximum outlet velocity

Mass flowrate (kg/s) Maximum Outlet Velocity (m/s)

0.005 0.009349865

0.090 0.11935123

0.5 0.607012125

Inlet Mass Flowrate vs Maximum Oulet

Velocity
0.7
Maximum Outlet Velocity (m/s)

0.6
0.5
0.4
0.3
0.2
0.1
0
0.005 0.09 0.5
Inlet Mass Flowate (kg/s)

Figure 5.7: Graph of inlet mass flowrate vs maximum outlet velocity

Relationship of maximum outlet pressure with various type of mass flowrate.

Table 2.0: Maximum outlet pressure

Mass flowrate (kg/s) Maximum outlet pressure (pa)

0.005 101325.0439

0.090 101332.1189

0.5 101508.836
 Inlet Mass Flowrate vs Maximum Outlet Pressure
101550

101500
Maximum Outlet Pressure (pa)

101450

101400

101350

101300

101250

101200
0.005 0.09 0.5
Inlet Mass Flowate (kg/s)

Figure 5.8: The graph of inlet mass flowrate vs maximum outlet pressure.

CALCULATION RESULTS

Assumptions

1. The water is pumping up through the pipe and flowing out.

2. The flow is steady and incompressible.
3. The entrance effect and exit effect are negligible, thus the flow is fully developed.
4. The flow is turbulent (Re ≥ 4000)
5. The reservoir is large and open to atmosphere.
6. Uniform cross section of diameter1 𝑖𝑛 = 0.0254 𝑚.
7. Estimated vertical distance between 𝑧1 and 𝑧2 equals 6 m.
8. The effects of the waste valve are neglected. The delivery of the system can be predicted
through calculations between 𝑧1 and 𝑧2 .

Properties

1. Water at 20oC:
a. Density, 𝜌 = 998 𝑘𝑔/𝑚3
𝜇
b. Kinematic viscosity, 𝑣 = = 1.004 × 10−6 𝑚2 /𝑠
𝜌
2. The roughness if PVC pipe, 𝜀 = 0.0015 𝑚𝑚 = 0.0000015 𝑚
3. The total loss coefficient between 𝑧1 and 𝑧2 , ∑ 𝐾𝐿 = 2 for a fully opened gate valve.

Experimental Result

1. Inlet flow rate from experiment,

𝑄𝑖𝑛 = 7.4 × 10−4 𝑚3 /𝑠
𝑄𝑖𝑛 7.4 × 10−4
𝑉𝑖𝑛 = = = 1.46 𝑚/𝑠
𝐴 5.067 × 10−4
2. Outlet flow rate from experiment,
𝑄𝑜𝑢𝑡 = 6.5 × 10−5 𝑚3 /𝑠
 𝑄𝑜𝑢𝑡
𝑉𝑜𝑢𝑡 = = 0.128 𝑚/𝑠
𝐴

3. Reynold’s number,
𝑉𝑖𝑛 𝐷 (1.46)(0.0254)
𝑅𝑒 = = = 36936.25
𝑣 (1.004 x 10−6 )
» Since Re > 4000, the flow is turbulent.

4. Friction factor
𝜀 0.0000015
= = 5.9055 x 10−5
𝐷 0.0254
Using Haaland’s equation,
1 6.9 𝜀⁄ 1.11
= −1.8𝑙𝑜𝑔 [ + ( 𝐷) ]
√𝑓 𝑅𝑒 3.7
1.11
6.9 5.9055 x 10−5
= −1.8𝑙𝑜𝑔 [ +( ) ]
36936.25 3.7
= 6.692
1 2
𝑓=( ) = 0.0223
6.692
5. Total head loss,
𝑉1 2 𝑓𝐿
ℎ𝐿,𝑡𝑜𝑡𝑎𝑙 = ℎ𝐿,𝑚𝑎𝑗𝑜𝑟 + ℎ𝐿,𝑚𝑖𝑛𝑜𝑟 = ( + ∑ 𝐾𝐿 )
2𝑔 𝐷
(0.128)2 (0.0223)(6)
= [ + 2]
2(9.81) 0.0254
= 6.07x10−3 𝑚

Determination of delivery head, Hd

Applying Bernoulli equation and referring to Figure 4.1,

𝑃1 𝑉12 𝑃2 𝑉22
+ + 𝑍1 + ℎ𝑝𝑢𝑚𝑝 = + + 𝑍2 + ℎ𝑡𝑢𝑟𝑏𝑖𝑛𝑒 + ℎ𝐿,1−2
𝜌𝑔 2𝑔 𝜌𝑔 2𝑔

Since𝑉1 = 𝑉2 , the second terms on both sides cancel out,

100000 𝑉2 2 𝑓𝐿
+ 0.3 + 0 = 0 + 𝑍2 + 0 + ( + ∑ 𝐾𝐿 )
998(9.81) 2𝑔 𝐷

(0.128)2 (0.0223)(6)
10.21 = 𝑍2 + [ + 2]
2(9.81) 0.0254

𝑍2 = 10.20393098 𝑚

∴ 𝐻𝑑 = 10.20393098 − 0.3 = 9.90393098 𝑚

4.2.1 Approximation of Delivery Flow for different Check Valve Sizes

The approximation is based on 1 bar of water pressure at 𝑧1 .

In general, the maximum delivery head increases as the valve diameter increases.
 Table 4.1 : Delivery Flow for Different Check Valves

Diameter Initial Friction Outlet Velocity Total Head Delivery Head

(in) Velocity (m/s) Factor (m/s) Loss (m) (m)
0.75 2.596 0.0210 0.2280 0.022869724 9.887130276
1.00 1.460 0.0223 0.1280 0.006069025 9.903930980
1.50 0.650 0.0245 0.0570 0.000970176 9.909029892
2.00 0.364 0.0260 0.0320 0.000264657 9.909735343

Graf of Delivery Head vs Diameter

9.915

9.91
Delivery Head, Hd

9.905

9.9

9.895

9.89

9.885
0 0.5 1 1.5 2 2.5
Diameter, In

RELATIONSHIP BETWEEN DELIVERY FLOW, DELIVERY HEAD AND FLOW WATER

PRESSURE

4.3.1 Relationship between Delivery Flow and Delivery Head

Table 4.2 : Delivery Flow and Delivery Head

Delivery flow (x 10-6

Delivery head (m) m3/s)
5 4.7
6 3.6
7 2.8
 Graph of Delivery Flow vs Delivery Head
5.0
4.5
Delivery Flow (x 10 -6m3/s)

4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
4 5 6 7 8
Delivery Head (m)

Relationship between Delivery Head and Water Pressure

Table 4.3 : Delivery Head and Water Pressure

Water Pressure (bar) Delivery head (m)

0.50 5.1
0.75 7.7
1.00 9.9

Graf of Delivery Head vs Water Pressure

12

10
Delivery Head, Hd

0
0 0.2 0.4 0.6 0.8 1 1.2
Water Pressure, bar
4.4 PERFORMANCE CHARACTERISTICS

Fixed Variable: hs,

Controlling Variable: Hd,

Responding Variable: Delivery per day

Calculation:

(a) Head Ratio, Hd/ hs = 5m / 1.35m = 3.79

Delivery per day = (7.8 x 10-2 l/s) x (24 x 60 x 60)s = 6739.2 litres / day

(b) Head Ratio, Hd/ hs = 6m / 1.35m = 4.44

Delivery per day = (6.5 x 10-2 l/s) x (24 x 60 x 60)s = 5616 litres / day

(c) Head Ratio, Hd/ hs = 7m / 1.35m = 5.18

Delivery per day = (5.57 x 10-2 l/s) x (24 x 60 x 60)s = 4812.48 litres / day

Performance table:

Table 4.4 : Performance Characteristic

Characteristics Size of Swing Check Valve and pipe = 1 inches (0.0254m)

Delivery head, Hd (m) 5 6 7

Supply head, hs (m) 1.35 1.35 1.35

Head Ratio, Hd/ hs 3.79 4.44 5.18

Delivery Flow, (m3/s) 7.8 x 10-5 6.5 x 10-5 5.57 x 10-5

Delivery per day (Litres / day ) 6739.2 5616 4812.48

 Delivery Per Day (Litres/Day)
8000
7000
6000
Litres Per Day, i

5000
4000
3000
2000
1000
0
3.79 4.44 5.18
Head Ratio, Hd/Hs (m)

CONCLUSION

The hydraulic ram pump is successfully designed and fabricated. The designed was also analysed using
Solidworks flow simulation software. From the simulation analysis we can conclude that when inlet
mass flowrate of pipe for the ram pump is increase the outlet velocity and pressure will also increases.
The flow simulation software is a very effective software to visualise the flow of fluid inside a pipe or
any other container. From the simulation it can be said that material used in certain place where the
pressure is high should be given more attention. Finally, the objectives of the project has been achieved
in this project. For the analysis, the delivery flow will increases as the check valve diameter increases.
Using the mathematical analysis, the delivery water can be determined with different of delivery head.
From the discussion, what can be conclude is the delivery per day will increase when the head ratio
increase. The final conclusion is all the objectives have achieved and this project are done very well.

REFERENCE

1. Dnadhar, M.M and Sharma, K.N, 1979, Water Power Engineering, Vikas Publishing House
Pvt. Ltd. India

2. David, J.P. and Edward, H.W., 1985, Schaum's Outline of Theory and Problems of Fluid
Mechanics and Hydraulics, SI (Metric) Edition, McGraw-Hill Book Company, Singapore

3. Teferi Taye, "Hydraulic Ram Pump", Journal of the Ethiopian Society of Mechanical
Engineers, Vol. II, No. l, July 1998.

4. Jeffery, T. D., "Hydraulic Ram Pumps - A Guide to Ram Pumps Water Supply System",
Intermediate Technology Publications, 1992.