Career as one of the most potential source of

                                                     Career Episode -3 a)   IntroductionCE 3.1MyThird career episode is based on my project ‘THE DESIGN AND INSTALLATION OF WINDMILL POWERED WATER PUMP’.The project was initiated by mewhen I was doing my B tech in Mechanical Engineering. The project duration was 3 month and carried out from March 2011 toJune 2011.

The project was carried outfor the partial fulfilment of the requirements for the award of the degree of Bachelorof Technology. The project was based in my college, Toc Hinstitute of Science and Technology Kochi, India.BackgroundCE 3.2TocH Institute of Science and Technology is one of the leading professional collegein the country affiliated to Cochin Univeristy of Science and Technology. Inhousehold electrical consumption a lion’s share of the usage goes for pumpingwater from the well to storage tanks. If this can be substituted with a windmill water pump a good amount can be saved on the monthly electric bill.

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Wind mills are a non-conventional source of producingpower and it is considered as one of the most potential source of energy. Theaim of my project was to design, fabricate and install a wind mill as a sourceof generating power for running a water pump.         CE 3.3I have performed the following tasks during the project;·        Studiedand prepared a project synopsis.·        Plannedthe project for timely completion.·        Designedthe entire system and prepared necessary mathematical calculations.  ·        Preparedthe cost estimation for fabrication and installation.·        Prepared a block diagram of the system using AUTOCAD·        Purchasedthe materials after detailed research.

·        Inspectedthe fabrication processes.·        Coordinatedwith civil department regarding the construction of foundation.·        Controlledthe installation of the system and conducted trial run.·        Conductedregular project meetings with the project guide and the team ·        Developeddetailed project report   CE 3.4Below is the hierarchy of the project with clear demonstration ofmy position;  c) Personal Engineering ActivityCE 3.

5I started theproject with a detailedstudy about wind mills and its components, water pump and other components. Adetailed study was conducted on the availability of wind and power that can betrapped by wind mills. After initial study, I prepared a synopsis indicatingthe objectives, components to be used, expected power generation and estimatedcost. This has been then submitted for the approval of Department head andproject guide along with the project planning draft. After the approval Iproceed further towards the design of the system.  CE 3.6I designed the system consists of a high solidity multi-vane windrotor, drive shaft, crank, connecting rod and a reciprocating pump. Rotarymotion of the windmill rotor is translated to reciprocating motion of theconnecting rod by the crank.

The connecting rod operates the pumps piston upand down through the cylinder during its strokes. Two check valves, bothopening upwards, are fitted on the piston and the bottom of the pump. Thesevalves allow the flow only in upward direction.

When the connecting rod drivesthe piston in the upward direction, the piston valve is closed and thus thewater column above the piston is lifted up, until it is delivered out throughthe discharge line. At the same time, suction is created below the piston,which causes the suction valve to open and thus fresh water from the well enterinto the space below. During the downward stroke, the piston valve is openedand the suction valve is closed. The water collected below the piston thusenters into the space above, through the piston valve. These cycles arerepeated resulting in pulsating sinusoidal water discharge from the system. CE 3.7The main difficulty faced during the design was thedesign of blades. Just like anaeroplane wing, wind turbine blades work by generating lift due to their shape.

The more curved side generates low air pressures while high pressure air pusheson the other side of the aerofoil. The net result is a lift force perpendicularto the direction of flow of the air. The dimensions of blades were fixed after calculatingthe power required to run the pump. The required suction head and delivery headof the pump is taken into account to calculate the power input required for thepump.

Then I calculated the required diameter of the wind mill turbine. The pumpchosen was a reciprocating pump since its efficiency is more compared tocentrifugal pump; Reciprocatingpumps utilize the principle of a moving piston, plunger, or diaphragm to drawliquid into a cavity through an inlet valve and push it out through a dischargevalve.CE 3.8Then I calculated the dimensions of the drive shaft,which is to be used to carry the power produced by wind mill to run the pump.The dimensions were calculated by taking the expected load on the shaftaccount. After the design of components, I prepared a block diagram of thesystem indicating the dimensions using AUTOCAD.

Then I formed a team forfabrication with experts from the field of welding, molding. The materialrequirement was calculated with the help of an expert team and purchasedensuring the quality. I arranged all the tools and equipment’s before thebeginning of fabrication and ensured the availability of required labor force.A planning was drafted for the fabrication and installation process and it wasaimed to complete within 45 days. CE 3.9The fabrication was started by molding the turbineblades as per the design. The location for the wind mill was already selectedas per the flow of wind.

I consulted with the civil department for theconstruction of foundation for the wind mill. Then the components of the windmill are joined together by welding. The pump was erected at a concreteplatform. The drive shaft was fabricated in a local workshops and it is thenconnected both to the wind mill and pump through slider crank mechanism. Iconsulted with senior engineer of a contracting firm for practical solutionsthroughout the installation process.    CE 3.10After installation, I performed detailed inspectionand checked the position of all the mechanical components. Then I consultedwith my project guide and department head and fixed a time for the trial run.

During the trial run, all the people worked behind the project were present. Icontrolled the trial run and ensured safety. The trial run was a success andthe system worked as desired. CE 3.

11The main difficulty faced during the installation wasto ensure the proper joining of components. I ensured it by careful inspectionand declared that the entire system is strong and safe. A team of experience ininstalling heavy equipment helped me a lot in finding practical solutions toproblems raised. I monitored the precautions to be taken care during fabricationand installation. I ensured that the workers are strictly following the safetyprinciples and using the safety equipment’s when ever required.      CE 3.12Another difficulty was to build a strong foundation for both thewind mill and pump.

This is essential since the machines are vibrating whileworking. The civil engineering department helped me on this and they designed andbuilt strong foundations.  CE 3.13This project was a challenging one and I was ableto make it a success. This is achieved as a result of detailed backgroundstudy, well coordination with other departments and above all with thededication of my team. I applied the knowledge gained from my studiesespecially from the workshops and practical sessions. My knowledge in the fieldof design of engineering components, fabrication processes, engineeringdrawing, material planning, working of different machines and practicalknowledge on installation helped me to accomplish my aim. My department headand project guide was with me every time and provide advice and suggestions.

 CE 3.14 I prepared a detailed project report after the success of myproject. I drafted the literature survey, specification and working of machinesused, overall processes, challenges faced and solutions implemented, designcalculations, drawing, cost analysis, suggestions for improvements, criticalfindings and recommendations for maintenance and photos. The purchasing ofmaterials and other expenses were through proper channels. In addition to the evolution of asuccessful design for using a non-conventional energy source, the project dayswere helpful in building me especially by enhancing my engineering knowledge.   d) SummaryCE 3.15