HYDRAM TECHNOLOGY

&
FREE ENERGY RAM PUMP

A Thesis Submitted
In Partial Fulfillment of the Requirements
for the Degree of

BACHELOR OF TECHNOLOGY
In
MECHANICAL ENGINEERING
By

AKASH KOHAR ASHUTOSH

(1600240003) (1600240009)

DHEERAJ SARASWAT LAKSHITA SHARMA

(1600240016) (1700240906)

Under the Supervision of

Er. ANAND KUMAR
RAJPUT

FET AGRA COLLEGE, AGRA

To the
DEPARTMENT OF MECHANICAL ENGINEERING

DR. APJ ABDUL KALAM TECHNICAL UNIVERSITY

(Formerly Uttar Pradesh Technical University)
LUCKNOW

August, 8 2020
 DECLARATION

We hereby declare that the work presented in this report entitled “HYDRAM
TECHNOLOGY", was carried out by us. We have not submitted the matter
embodied in this report for the award of any other degree or diploma of any other
University or Institute. We have given due credit to the original authors/sources for
all the words, ideas, diagrams, graphics, experiments, and results that are not our
original contribution. We have used quotation marks to identify verbatim sentences
and given credit to the original authors/sources. We affirm that no portion of our
work is plagiarized and the experiments and results reported in the report are not
manipulated. In the event of a complaint of plagiarism and the manipulation of the
experiments and results, we shall be fully responsible and answerable.

Names:
AKASH KOHAR ASHUTOSH
(1600240003) (1600240009)

DHEERAJ SARASWAT LAKSHITA SHARMA

(1600240016) (1700240906)

Branch:

MECHANICAL ENGINEERING

(Candidate Signature)
 CERTIFICATE

Certified that AKASH KOHAR (1600240003), ASHUTOSH (1600240009)

DHEERAJ SARASWAT (1600240016), LAKSHITA SHARMA (1700240906)
Has carried out the research work presented in this thesis entitled “HYDRAM
TECHNOLOGY" from Dr. APJ Abdul Kalam Technical University, Lucknow under
my/our supervision. The thesis embodies results of original work, and studies are
carried out by the students and the contents of the thesis do not form the basis for the
award of any other degree to the candidates or to anybody else from this or any other
University/Institution.

Signature

Er. ANAND KUMAR RAJPUT

F.E.T AGRA COLLEGE,

AGRA
 ABSTRACT

This project report is about designing a hydraulic ram pump to transfer water from
a river into a water tank with given dimensions and conditions. The hydraulic ram
pump designed is believed to be the most suitable and efficient for the given
conditions based on the calculations performed.
For the first step of designing, all the related problems are listed and understand.

Then, the specifications, criteria and evaluation of the solutions are developed. This
including choosing the most suitable operational working principals for the hydraulic
ram pump (hydram), outline of the theoretical background behind the operation and its
details calculations, which are being referred to the concept and theory entitles to Fluid
Mechanics.
 ACKNOWLEDGEMENT

We take this opportunity to express our sincere gratitude to all those who helped us in
various capacities in undertaking this project and devising the report.

We are privileged to express our sense of gratitude to our respected teacher whose
unparalleled knowledge, moral fiber and judgment along with his know-how, was an
immense support in completing the project.

We are also grateful to Er. Dhirendra Singh our Head of Department, Mechanical
Engineering, for the brainwave and encouragement given.

We take this opportunity to thank our comrades for their co-operation and
compliance.
 TABLE OF CONTENTS

Declaration ii
Certificate iii
Abstract iv
Acknowledgement v

CHAPTER 1: GENERAL 1-21

LITERATURE REVIEW
1.1 OBJECTIVE 4
1.2 INTRODUCTION TO HYDRAM PUMP 4
1.3 FEATURES 5
1.4 THEORY 7
1.4 a. ENERGY
1.4 b. WATER HUMMER EFFECT

1.5 WORKING PRINCIPLE 10

1.6 OPERATIONAL EXPLANATION 12
1.6 a. MODE OF OPERATIONS
1.6 b. PROBLEMES
1.7 EFFICIENCY 26

CHAPTER 2: DESCRIPTION 29-27

2.1 STARTING OPERATION 30

2.1. a. COMPONENTS & FUCTIONS 35
A. HEADER TANK
B. DRIVE PUMP
C. PUMP BASEMENT
D. DELIVERY PIPE
2.2 DESIGN METHODOLOGY 41
2.3 CALCULATIONS 48
2.4 MANUFACTURING ASSEMBLY 49
2.5 APPLICATIONS ON SITE 66
2.6 LOCAL MANUFACTURING 70
2.7 MAINTENANCE 84
2.8 GENERAL CONSIDERATIONS 85
2.9 ADVANTAGES & DISADVANTAGES 87
2.9.A COMMON PROBLEM AND MAINTAINANCE 94

CHAPTER 3: FUTURE SCOPE 95

CHAPTER 4: CONCLUSION 97

REFERENCES 98
 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

 GENERAL
LITERATURE REVIEW

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
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: 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: Antique Hydrams

1.1 OBJECTIVE

To design a Hydraulic Ram Pump which is able to fill a water tank at some
height from river flow.

1.2 INTRODUCTION

A hydraulic ram pump (also called hydram) is a pump that uses energy from a
falling quantity of water to pump some of it to an elevation much higher than
the original level at the source. No other energy is required and as long as there
is a continuous flow of falling water, the pump will work continuously and
automatically. Provision of adequate domestic water supply for scattered rural
populations is a major problem in many developing countries. Fuel and
maintenance costs to operate conventional pumping systems are becoming
prohibitive. The hydraulic ram pump (hydram) is an alternative pumping
device that is relatively simple technology that uses renewable energy, and is
durable. The hydram has only two moving parts; these are impulse valve and
delivery valve which can be easily maintained.

Ram Pumps have been used for over two centuries in many parts of the world.
Their simplicity and reliability made them commercially successful,
particularly in Europe, in the days before electrical power and the internal
combustion engine become widely available. As technology advanced and
become increasingly reliant on sources of power derived from fossil fuels, the
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 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 ram pumps. In hilly areas with springs and streams,
the potential for a simple and reliable pumping device is large. Although there
are some examples of successful ram pump installation in developing
countries, their use to date has merely scratched at the surface of their
potential.

1.3 FEATURES

The main reason for this being, lack of wide spread local knowledge in the
design and manufacture of ram pumps. Hence, the wide spread use of ram
pumps will only occur if there is a local manufacturer to deliver quickly; give
assistance in system design, installation, and provide an after-sales service.

Ram pumps have been around for many decades and are popular for two main
reasons:

1. They need no external source of power, the force of moving water gives them
the power they need.

2. They are extremely simple with just two moving parts.

The basic idea behind a ram pump is simple. The pump uses the momentum
of a relatively large amount of moving water to pump a relatively small
amount of water uphill.

To use a ram pump, you must have a source of water situated above the
pump.
 For example, you must have a pond on a hillside so that you can locate the
pump below the pond. You run a pipe from the pond to the pump. The pump
has a valve that allows water to flow through this pipe and build up speed. Once
the water reaches its maximum speed, this valve slams shut.

• As it slams shut, the flowing water develops a great deal of pressure in the
pump because of its inertia.

• The pressure forces open a second valve.

• High-pressure water flows through the second valve to the delivery pipe
(which usually has an air chamber to allow the delivery pipe to capture as
much high-pressure water as possible during the impulse).

• The pressure in the pump falls. The first valve re-opens to allow water to flow
and build up momentum again. The second valve closes and the cycle repeats.

The delivery pipe can rise some distance above both the pump and the source of
the water. For example, if the pump is 10 feet below the pond, the delivery pipe
might be up to 100 feet above the pump.
1.4 THEORY ON HYDRAULIC RAMP (HYDRAM) PUMP

Energy Cars, airplanes, light bulb, water pumps, computers, and the human body
have all something in common: they need energy to work. This energy can come
from many sources such as electricity, fuel, manpower, food. Different
technologies are used to transform one source of energy to another. For example,
car engines transform the chemical energy of the fuel into mechanical energy
allowing wheels to rotate. Another example related to water supply projects is
electric pumps: they use electricity to transform electrical energy into potential
energy of the lifted water. The potential energy is the energy of every object due
to its altitude. The object needs another source of energy to be lifted and will
lose its potential energy if it falls. Hydrams are designed to lift water (i.e. give
potential energy to the water) from a low cost source of energy. Avoiding using
fuel and electricity, the water hammer effect has shown to be efficient and is the
principle of hydrams.

 No Velocity

 Very High Pressure

 Energy

 Water Hammer Effect

The water hammer effect is a phenomenon that increases the pressure of a water
pipe in a short period of time.
1.4 a. ENERGY

Cars, airplanes, light bulb, water pumps, computers, the human body have all
something in common they need energy to work. This energy can come from many
sources such as electricity, fuel, manpower, food.
Different technologies are used to transform one source of energy to another. For
example, car engines transform the chemical energy of the fuel into mechanical
energy allowing wheels to rotate. Another example related to water supply projects
is electric pumps: they use electricity to transform electrical energy into potential
energy of the lifted water.
The potential energy is the energy of every object due to its altitude. The object
needs another source of energy to be lifted and will lose its potential energy if it
falls.

Hydrams are designed to lift water (i.e. give potential energy to the
water) from a low cost source of energy. Avoiding using fuel and
electricity, the water hammer effect has shown to be efficient and
is the principle of Hydrams.

1.4 b. WATER HAMMER EFFECT

The water hammer effect is a phenomenon that increases the pressure of

water in a pipe over a short period of time.
 (FIG: Water hammer effect)

If the velocity of the water in a pipe is high enough, a fast closure of the pipe will
cause a water hammer effect as shown in figure. The water flowing will be
compressed to the valve which has been closed suddenly. As a comparison, if a
hundred people run very fast in a corridor and suddenly, they face a closed door,
the space between them will be reduced, everybody will touch each other. In the
same way, with velocity, water has kinetic energy. By closing quickly the pipe,
this kinetic energy will be transformed into pressure.
This effect is characterized by a loud noise that is similar to a hammer banging a
metal component.
1.5 WORKING PRINCIPLE OF HYDRAULIC RAM PUMP

Although hydraulic ram pumps come in a variety of shapes and sizes, they all
have the same basic components as shown in Fig. 2. The main parts of a ram pump
are hydra body, waste valve, delivery valve, snifter valve, air chamber and relief
valve. Ram Pumps have a cyclic pumping action that produces their characteristic
beat during operation. The cycle can be divided into three phases; Acceleration,
Delivery, and Recoil.

[Fig.-Showing the flow of water in the hydram body.]

Acceleration - When the waste valve is open as shown in figure, water accelerates
down the drive pipe and discharges through the open valve. As the flow increases
it reaches a speed where the drag force is sufficient to start closing the valve. Once
it has begun to move, the valve closes very quickly.
Delivery- As the waste valve slams shut as shown in figure, it stops the flow of
water through it. The water that has been flowing in the drive pipe has
considerable momentum which has to be dissipated. For a fraction of a second,
the water in the body of the pump is compressed causing large surge in pressure.

This type of pressure rise is known as water hammer. As the pressure rises higher
than that in the air chamber, it forces water through the delivery valve (a non-
return valve).The delivery valve stays open until the water in the drive pipe has
almost completely slowed and the pressure in the pump body drops below the
delivery pressure. The delivery valve then closes, stopping any back flow from
the air vessel into the pump and drive pipe.

Recoil- The remaining flow in the drive pipe recoils against the closed delivery
valve - rather like a ball bouncing back. This causes the pressure in the body of
the pump to drop low enough for the waste valve to reopen. The recoil also
sucks a small amount of air in through the snifter valve. The air sits under the
delivery valve until the next cycle when it is pumped with the delivery water
into the air vessel. This ensures that the air vessel stays full of air. When the
recoil energy is finished, water begins to accelerate down the drive pipe and out
through the open waste valve, starting the cycle again. Throughout the cycle the
pressure in the air vessel steadily forces water up the delivery pipe. The air
vessel smoothest the pulsing in flow through the delivery valve into an even
outflow up the delivery pipe. The pumping cycle happens very quickly, typically
40 to 120 times per minute. During each pumping cycle only a very small
amount of water is pumped. However, with cycle after cycle continuing over 24
hours, a significant amount of water can be lifted. While the ram pump is
operating, the water flowing out the waste valve splashes onto the floor or the
pump house and is considered' waste' water.
 [Figure: Flow of water when waste valve is closed.]

1.6 OPERATIONAL FIGUERE EXPLANATION

1) Water (blue arrows) starts flowing through the drive pipe and out of
the "waste" valve (#4 on the diagram), which is open initially. Water flows
faster and faster through the pipe and out of the valve.

2) At some point, water is moving so quickly through the brass swing

check "waste" valve (#4) that it grabs the swing check's flapper, pulling it up
and slamming it shut. The water in the pipe is moving quickly and doesn't
want to stop.

All that water weight and momentum is stopped, though, by the valve
slamming shut. That makes a high pressure spike (red arrows) at the closed
valve. The high pressure spike forces some water (blue arrows) through the
spring check valve (#5 on the diagram) and into the pressure chamber. This
increases the pressure in that chamber slightly. The pressure "spike" the pipe
has nowhere else to go, so it begins moving away from the waste valve and
back up the pipe (red arrows). It actually generates a very small velocity
*backward* in the pipe.
3) As the pressure wave or spike (red arrows) moves back up the pipe,
it creates a lower pressure situation (green arrows) at the waste valve. The
spring-loaded check valve (#5) closes as the pressure drops, retaining the
pressure in the pressure chamber.
4) At some point this pressure (green arrows) becomes low enough that the
flapper in the waste valve (#4) falls back down, opening the waste valve again.

5) Most of the water hammer high pressure shock wave (red arrows) will
release at the drive pipe inlet, which is open to the source water body. Some
small portion may travel back down the drive pipe, but in any case after the
 shock wave has released, pressure begins to build again at the waste valve (#4)
simply due to the elevation of the source water above the ram, and water
begins to flow toward the hydraulic ram again.

6) Water begins to flow out of the waste valve (#4), and the process starts over
once again.

Steps 1 through 6 describe in layman's terms a complete cycle of a hydraulic ram

pump. Pressure wave theory will explain the technical details of why a hydraulic ram
pump works, but we only need to know it works. The ram pump will usually go
through this cycle about once a second, perhaps somewhat more quickly or more
slowly depending on the installation. Each "pulse" or cycle pushes a little more
pressure into the pressure chamber. If the outlet valve is left shut, the ram will build
up to some maximum pressure (called shut off head on pumps) and stop working.
 MODE OF OPERATION AND PERFORMANCE EVALUATION

 Operation Principle

The energy required to form a Ram lift water to a better elevation comes from
water falling downhill thanks to gravity. As altogether other water powered
devices, but unlike a water wheel or turbine, the ram uses the inertia of moving
part instead of water pressure and operates during a cycle supported the
subsequent sequences.

 Sequence I

Water from the source flow through the drive pipe (A) into the ram pump body, fills it
and begins to exit through the waste or “impulse” valve (B). The check valve (C)
remains in its normal closed positions by both the attached spring and water pressure
within the tank (D) and therefore the delivery pipe (E) (no water within the tank before
start up). At this start line there's no pressure in tank (D) and no water is being delivered
through exit pipe (E) to the holding tank destination. See Figure 1.
  Sequence II

Water entering the pump through the drive pipe (A) has its velocity and pressure
being directed out of waste valve (B) as illustrated in Figure 2.

 Sequence III

Water has stopped flowing through the drive pipe (A) as a “shock wave”
created by the “water hammer” travels copy the drive pipe to the settling tank.
The waste valve (B) is closed. Air volume within the pressure tank (D)
continues expanding to equalize pressure, pushing alittle amount of water out
of the delivery pipe (E). See the illustration in Figure 3.
  Sequence IV

The blast wave reaches the holding tank causing a “gasp” for water within the
drive pipe (A). The waste valve (B) opens and therefore the water within the
drive pipe (A) flows into the pump and out of the waste valve (B). The check
valve (C) remains closed until the air volume within the pressure tank (D) has
stabilized and water has stopped flowing out of the delivery pipe (E). At now
sequence 1 begins everywhere again.
  Installation

The installation of a hydram pump (see figure 5) is such the cycle of its operation
depends upon the length of the drive pipe. it's recommended that the pump should
complete a cycle every 1.5 to 2 seconds. If a cycle is either too fast or too slow the
output performance will suffer. Too fast of a cycle may be a symptom of either a drive
pipe being too short or the waste valve needing more weight. Too long of a cycle is
caused by an excessively long drive pipe approximately much weight on the waste
valve that the column of water takes a extended time to beat , causing it to shut
suddenly. This creates a momentary high “Water hammer” that successively force the
check valve (C) to open allowing a high “pulse” of water to enter the pressure tank
(D). The air volume within the pressure tank is compressed causing water to start
flowing out of the delivery pipe (E) and at an equivalent time closing the check valve
(C) so on prevent reverse flow. because the air volume in pressure tank (D) continues
to expand, water is forced out of the delivery pipe (E) to the holding tank.
 Figure 5. A Typical Hydraulic Ram Installation

Common operational problems:

Failure to deliver sufficient water could also be thanks to improper adjustment of the
waste valve, having insufficient air within the pressure vessel, or just attempting to
boost the water above the extent of which the ram is capable. The ram could also be
damaged by freezing in winter, or loss of air within the pressure vessel resulting in
excess stress on the ram parts. These failures would require welding or other repair
methods and maybe parts replacement. it's not uncommon for an operating ram to need
occasional restarts. The cycling may stop thanks to poor adjustment of the waste valve,
or insufficient water flow at the source. Air can enter if the availability water level
isn't a minimum of a couple of inches above the input end of the availability pipe.
Other problems are blockage of the valves with debris, or improper installation, like
employing a supply pipe of non- uniform diameter or material, having sharp bends or
a rough interior, or one that's too long or short for the drop, or is formed of an
insufficiently rigid material. A PVC supply pipe will add some installations but isn't
as optimal as steel.
  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.

Piping and Plumbing Fitting:

A fitting is employed in pipe systems to attach straight pipe or tubing sections, adapt
to different sizes or shapes and for other purposes, like regulating (or measuring) fluid
flow. "Plumbing" is usually wont to describe the conveyance of water, gas, or liquid
waste in domestic or commercial environments; "piping" is usually wont to describe
the high- performance (high-pressure, high-flow, high-temperature or hazardous-
material) conveyance of fluids in specialized applications. "Tubing" is usually 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 put
in , and are a crucial a 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 EngineersA112.19.1 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: gas
Association
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 usually the idea
for selecting a pipe. Materials used for manufacturing pipes
include:
Carbon (CS) and galvanized steel Impact-tested steel (ITCS) Low-
temperature steel (LTCS) chrome steel (SS)
Malleable iron
Non-ferrous metals (includes copper, Inconel, incoloy and
cupronickel)
Non-metallic (includes acrylonitrile butadiene styrene (ABS),
fiber-reinforced plastic (FRP), PVC (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 frequently an
equivalent base material because the pipe or tubing connected:
copper, steel, PVC, chlorinated PVC (CPVC) or ABS. Any
material permitted by the plumbing, health, or code (as applicable)
could also be used, but it must be compatible with the opposite
materials within the system, the fluids being transported and
therefore the temperature and pressure inside (and outside) the
system. Brass or bronze fittings are common in copper piping and
plumbing systems.

 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)
1.7 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 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.

Let

 W = weight of water flowing per second into the chamber,

 w = weight of water raised per second,
 h = height of water in supply tank above the chamber,
 H = height of water raised from the chamber.
The energy supplied by the supply tank to the ram

= weight of water supplied * Height from which the water is supplied.

= W * h.

Energy delivered by the ram

= Weight of water raised * height through which water is raised.

= w * H.

Thus efficiency = energy delivered by the ram/ energy supplied to the ram

η = w * H/ W * h.

The efficiency η, specified above is called as D’ Au Buisson’s efficiency.

Rankine gave another form of efficiency as he considered that the weight of water
raised is not H, but it is (H-h).

Thus Rankine efficiency

η = w * (H-h)/ (W-w)* h.
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. 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 maybe
indicated. PVC pipe and any necessary valves are not a problem.
 DESCRIPTION

A Hydraulic Ram Pump Systems (RPS) is used within a Gravity Fed System (GFS).
The water entering in the storage tank of a GFS comes from the RPS.

A RPS has 7 main components as shown in Figure:

1. A spring or stream catchment;

2. A feed pipe;
3. A header tank;
4. One or multiple drive pipes;
5. A pump basement;
6. One or multiple Hydrams;
7. One or multiple delivery pipes; and
8. A storage tank.

The water comes from a stream or a spring. If the source of water is a stream, the
water quality is most likely unable to reach ACF standards for drinking purposes.
.

2.1 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.

GENERAL CONSIDERATION WHILE STARTING THE HYDRAULIC

RAM PUMP SYSTEM

 Before starting the Hydraulic Ram Pump

Make sure that:

  Bolts are tight (air vessel, pump body);

 The feed pipe flow is constant, header tank is clean and full and
overflow is operating;

 The pump basement is clear; and

 the impulse valve is removed.

To remove all undesired material inside the drive pipe:

 Open the ball valve at the drive pipe gently from closed to full;

 Close the drive pipe.

Finally:
 Clean the snifter valve;

 put back the impulse valve.

 Starting the Hydraulic Ram Pump

 Open the ball valve at the drive pipe until all the air is out and flow is
constant; and

 Prime the Hydram;

 Look for problems (i.e. leakages, moving parts, bolts and nuts, pipe
connections).

 Priming the Hydraulic Ram Pump

Why priming?

Before running the Hydram, there is no water in the delivery pipe: above the
delivery valve in the air vessel, there is only air.
Figure: when starting the Hydram, the water flows not only through the
impulse valve but also through the delivery valve. This is because the
delivery valve stays open: there is not any pressure above the valve to close
it. As a consequence, not enough water flows through the impulse valve to
create a strong hammer effect.
Without a strong hammer effect, the depression that allows the impulse
valve to open is not possible. It is why priming is needed to help the
impulse valve going down.

Figure: After that the water in the delivery pipe reaches the same height as
the header tank, the situation changes and the pump can work
automatically. The pressure above the delivery valve is greater than below
when the water is accelerating and flows only through the impulse valve.
It creates a strong hammer effect that increases the pressure to open the
delivery valve, let the water flow in the delivery pipe, and allows a
depression. This depression makes the impulse valve open and the cycles
of the Hydram can run automatically.
a. Priming is needed b. The Hydraulic Ram Pump works automatically

Figure: Priming the Hydraulic Ram Pump

Only by pushing down the plug of the impulse valve with a foot, the technician is
able to open the impulse valve to start a new cycle. After that the water reaches a
high enough point in the delivery pipe, the plug will go down automatically and the
technician can stop and focus on checking for problems and leakages.

Adjusting the stroke

Trials and tests need to be carried out to look for the best balance between delivery
flow and waste flow.
The locking nut is designed to increase or decrease the length stroke of the
plug in the impulse valve.
The longer the stroke the stronger the water hammer effect is. When the
plug is down, more waste water is able to flow out increasing the velocity
of the drive water. As a consequence, this high velocity is causing a strong
water hammer effect.
However, this relation is not linear: the velocity reaches even if the stroke
is at its maximum. It is causing a waste of water much greater than the
increase of the delivery flow: the efficiency reduces.
On the opposite, a too small stroke cannot create a water hammer effect
strong enough to have the required delivery flow, or even not strong
enough to make the Hydram work automatically.
The DTU gives well explained recommendations on tuning the Hydram
for different purposes. “Peak output
When there is plenty of drive water available (e.g. wet season) the pump
should be tuned for peak output (i.e. the delivery of as much water as
possible). This usually coincides with a long impulse valve stroke allowing
the velocity of water in the drive pipe to build up, increasing the energy
available for pumping. It should be remembered, however, that tuning for
peak output also raises those forces in the pump that accelerate failure. For
this reason, never exceed the recommended maximum stroke.

Peak efficiency

When there is a limited amount of drive water available (e.g. dry season),
it is important that the pumps installed are tuned down to use most of the
drive water to be lifted and delivered. This corresponds to a small length
stroke.”

COMMON PROBLEMS AND MAINTENANCE

The main problems of the RPS are the leakages and the blockages of the pipes:
 Leakages will come mainly from the pipe connections; and

 Blockages from a poor protection of the catchment or the header tank.

2.1. a THE MAIN COMPONENT AND THEIR FUNCTION OF THE SYSTEM

A. HEADER TANK

 Objectives

The header tank has five objectives:

 To prevent solid elements and air to enter in the Hydram;

 To allow a continuous flow in the Hydram;

 To allow the water to enter with a high velocity in the Hydram; and

 To resist to external aggressions;

 To allow the self-maintenance of the RPS.

 Description

In order to fulfill the uses of the header tank, the design of the
header tank depends on the characteristics of the water that flows in:
 Quality: impurities, sand, leaves, mud; and

 Quantity: flow available by the source of the water.

 Size

A Hydram cannot work automatically if air enters inside the Hydram body. It
means that the entrance of the drive pipe must be always under water. As a
consequence, the size of a header tank is decided according to the flow available
by the source of water. Then, if the quality of the water is poor (e.g. from a
stream), it is important for the sediments to have time in the header tank to settle
down in the bottom of the tank.
  Two compartments can be constructed.

The volume of the header tank for a RPS can be calculated like the header tank
for a GFS; refer to Module 2 Principles and sizing for further details.
It is easier to construct a square tank (i.e. for the construction of the molds for
concrete). The side in which the drive pipes are casted must allow at least 10
centimeters of space between two pipes.
The height of the tank must allow the water to be at least 30 centimeters above the
drive pipes.

 Connections

The inlet of the header tank is the feed pipe.

The outlets of the header tank are:
 The drive pipes;

 The wash out pipe on each

compartment;
 The overflow pipe


The maintenance of the header tank is allowed by a manhole located on

the top;
if two compartments exist, the trap must allow cleaning both.
The drive pipes cannot only be casted in the wall of the tank; the wall
thickness is not enough to hold the shocks of the water hammer
effects. It is recommended to add concrete around the entrance of the
drive pipe.
For maintenance purposes, it is recommended to install ball valve to
allow an easy opening of the drive pipes. Ball valve are recommended
over gate valve: gate valve close automatically under the effect of the
water hammer effect when the pump is running
  Example

The header tank for the RPS differs from the one from the GFS only by adding the
drive pipe as straight as possible toward the pump basement. It is recommended to
reinforce the wall where the drive pipes are: this solution allows the header tank to
sustain against the water hammer effects.

B. DRIVE PIPE

 Objectives

A drive pipe has two objectives:

 To allow the water entering in the pump body from the header tank with
high velocity; and

 To resist to the shocks of the water hammer effect.

 Description

A drive pipe is linked to only one pump. It cannot be made out of plastic because it
cannot sustain the pressure. It is highly recommended to use first quality galvanized
iron (G.I.) pipes. Poor quality of G.I. pipes will lead to difficult maintenance soon
after the installation such as repairing leakage.
The efficiency of the pump increases if the components of the system
do not absorbs the shocks of the water hammer effect. For the drive
pipe, it means that it must be very rigid and tightly hold with clamps on
supports casted into concrete.
 Finally, the shock wave that goes along the drive pipe at each water
hammer effect leads to a fatigue of the weakest part of the pipe: the
threads at each end. This is a main cause of leakage. It is highly
recommended to weld flanges all along the pipe and to insert a rubber
seal between them. AID Foundation experience has proven that it
increases the longevity of the drive pipe.

C. PUMP BASEMENT

 Functions

The functions of the pump basement are:

 To hold the Hydram against the shocks of the water hammer effect; and

 To collect the waste water and to direct it to a targeted location to avoid

having a muddy area around the pump and cavitation’s.

 Description

The pump basement must be made out from the most solid concrete. Four
screws are casted in the basement: the Hydram is to be located thanks to these
screws.
The only critical part of constructing a pump basement is the alignment
with the pump basement so that the drive pipe is perfectly straight. How
to do this task properly is explained in the part Application on site.
D. DELIVERY PIPE

 Description

The delivery pipe for a RPS is designed as a delivery pipe for a GFS; refer to
Module 2 for further details:
 It needs to be buried to avoid external aggression;

 The delivery height minimizes the internal diameter of the pipe (i.e. the
small diameter creates more head losses);

 The delivery height also designs the pressure that the pipe can hold and as
a consequence, the material of the pipe; and

 The route of the pipe must avoid going alternatively up and down and
should stay straight as much as possible.

2.1 b Main delivery pipe and multiple delivery pipes

In most of the sites where the Hydram can be implemented, more than one
pump will be installed for two reasons:
 The water available allows to use two or more Hydrams;

 Even if the volume of water is not enough, it is advised to install two pumps
and run only one: the water will still be supplied during the maintenance.

There are now two choices:

 To connect each outlet of the Hydrams together after 50 meters to a main
delivery pipe. This option has shown good results.
  To connect each outlet of the Hydrams to a delivery pipe (i.e. if there are 3
pumps, there will be 3 delivery pipes). AID Foundation believes after their
experience that this method allows a greater overall delivery flow in the
storage tank. The main disadvantage of this solution is its cost. This solution
is certainly more efficient; however, no study has been implemented on site
to evaluate the improvement of efficiency.

2.1c Minimizing head losses

The use of elbows, tees, and reducers must be minimized in order to reduce
head losses.
Especially at the exit of the pump, elbows and tees are creating head
losses that reduce a lot the flow of water in the storage tank. Indeed, at
the exit of the pumps, the flow is not yet constant: the water travels by
waves that flow at high velocity. The head loss at high velocity is greater
than at low velocity. This is why is advised to avoid elbows and tees at
the beginning of the delivery pipes.
2.2 DESIGN METHODOLOGY FOR HYDRAM PUMP

Considerations in hydraulic ram pump system design.

The following factors need to be considered in hydraulic Ram pump system
design.

 Area suitability (head and flow rate)

 Flow rate and head requirement

 Intake design

 Drive system

 Pump house location

 Delivery pipes routing

Distribution system

2.3 DESIGN

1. When we design a water system using ram pumps, we like to know before

we build it, how much water it will deliver to how much head and with
what efficiency manually manipulating these parameters using design
methodology for different input parameters. After that, we then design
the hydram using SOLIDWORKS software which a CAD (computer
aided design) software as
[Figure 1: Isometric view of the hydraulic ram ]

[Figure 2: Cross-sectional view of the hydraulic ram pump]

 [Figure 3: sectional view of the hydraulic ram pump]

[Figure 1.0: Sectional view of delivery valve]

[Figure 1.1: Outer view of delivery valve]

[Figure 1.2: Cross-sectional view of waste valve]

 [Figure 1 (a): Sectional view of waste valve]

[Figure 1 (b): Sectional view of waste valve]

 [ Figure 1(c): Outer view of waste valve]

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 minimize head losses. The configuration of the drive pipe shown in figure, 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: Hydram Schematic Layout Diagram]

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.
2.3 CALCULATION OF THE DELIVERY FLOW

The calculation of the flow that may be supplied to the community (i.e.
delivery flow) use the following inputs:

 The drive flow in liter per second (Q);

 The drive height in meter (H);

 The delivery height (h);

 The efficiency of the pump in percentage (μ).

The formula is:

H∗Q∗μ
q=
h

:
 2.4 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 Female Threaded Adapter ½ inch 1 pc.
16 Circular Saw Blade 1 pc.
17 Black Pipe 4 inch 300mm
18 Water Tank 200 liter 1 pc.
19 Bucket 1 pc.
20 Plastic Pipe ½ inch 5ft
21 Solvent Cement 100ml
Table : List of bought out items

 Product Description:

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

Figure: uPVC Pipes

  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: 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
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.

 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: Socket
  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
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: Nipple

 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
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: 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.
Other types of quarter-turn valves include the butterfly valve and plug valve and
freeze proof ball valve.

 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 and Torx heads; hexagonal or splined
sockets. These modern designs span a large range of sizes and can carry a
considerable torque.

Figure: Bolt
  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 lock wire in
conjunction with castellated nuts, nylon inserts (nylon 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: Nut

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.

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 Check, 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: Check Valve

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.

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: Tee

 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
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: Water Tank

 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, and 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.

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.

2.5 APPLICATION ON SITE

This part is essentially based on the very useful book Hydraulic Hydrams
from the DTU.

Project management of a Hydraulic Ram Pump project

 Time management

From the idea of installing a RPS to the exciting time of watching water
flowing in the storage tank, it takes time. As the project can only be
successful if the community is involved, trained and monitored, it takes
even more time.
The time with the community is more than important: it is necessary for
the success of the project. The transport and the time consuming
maintenance are two factors which cannot allow a company, an NGO or
the government to ensure a frequent and adapted maintenance of the RPS.
The users are adapted to this task: it is why they need to be part of the
project from the beginning.
A RPS project should include the following steps:
 The socialization with the targeted community and planning of the participation;

 The field survey of the area;

 The design;
  The supply of material on site;

 The construction;

 The tests and first maintenance;

 The training of the water committee;

 The handover of the RPS;

 The evaluation.

All these phases need to be implemented with constant cooperation and

communication with the community. Many of these phases have been
described in the previous modules (i.e. socialization with the community
and training with the community in Module 5, surveying in Module 3, part
of design in Module 2, part of construction in Module 3).
This module focuses on the survey of the area for the RPS, the design and
construction of the header tank, the drive pipe, the pump basement, the
Hydram and the delivery pipe, and the tests.

The time taken for each phase depends on:

 The distance that separates the targeted community from the office of the
organization;

 The season (i.e. during the wet season, construction takes twice as much time as
the dry season);

 The human resources available (both from the community and from the
organization);
 The complexity of the topography and the system (i.e. number of pumps, number
of route and of storage tank)  Agricultural and cultural calendar.

The duration of a project varies from one site to another: they last between 2 to 3
months long.
  Human resources management

For a RPS project as for a GFS project, the team should include:
 1 water technician trained in RPS for the design, the planning, and the
management of the teams;

 1 logistician for the supplies to the sites, the follow-up of materials; vehicles,
and accommodation of workers on site;

 1 foreman overseeing plumbing and brickwork teams;

 1 mason foreman;

 2 assistant masons preparing mould and concrete work;

 1 plumber foreman installing and connecting pipes;

 2 assistant plumbers laying and connecting pipes

 Daily labor for trench digging, transporting material (i.e. it is better if the
workers are from the community).

 Cost management

The range of the cost of a RPS varies from USD 2,000 to 6,000. The
figures below are an example from AID Foundation that gives a good
estimation of the amount spent on each component:
 Spring catchment tank USD 80
  Drive tank USD 59

 Hydram foundation USD 62

 Hydram and accessories USD 322

 Diversion pipe USD 834

 Drive pipe USD 201

 Delivery pipe USD 468

 Distribution line & 3 tap stands USD 148

 Management and Training USD 1,044

 Community cost (in kind) USD 307

2.6 LOCAL MANUFACTURE OF HYDRAULIC RAM PUMP

Starting a local manufacture

Skilled technician

The manufacture of the Hydram designed by ACF needs skills available in

NTT and in most part of the world. The technician has to know how to:
 Weld for waterproof connections and with different material;

 Drill;

 Cut iron plate;

 Use a lathe machine;

 Read technical drawing.

A mechanic that has worked for repairing car or motorbikes is adapted to this job.
 Supply of material

The technician needs:

 4” GI pipes, elbows and tees of first quality;

 2” GI pipes;

 3/4” pipes for gas;

 A crow bars;

 6 mm and a 10 mm stainless steel plates (mild iron plate is stronger and can
corrode, use anti-corrosion paint under a layer of color paint to improve a little
the longevity);

 3/4” stainless steel bolts and nuts;

 3 mm rubber surfaces (inside tube of truck can be used if still of good quality:
no visible damage); and  90˚ profiles 5 x 5 cm.

Equipment and tools

The workshop needs to be equipped with:

 A lathe machine;

 A welding plant and welding rod;

 A drilling machine and drilling bits;

 A cutting machine and cutting disc;

 A cutting torch and oxygen bottle;

 A grinder;

 Diameter measurer, ruler, carpenter measurer, marker, paint, a level, spanners,

keys, etc.;
 Safety goggles, safety gloves, ear plug, mask to protect from metallic dust; and
 -

Figure : Tools and equipment

Steps to follow for local manufacture

Flanges, reducer, top of the air chamber and plates

The technician cuts the 10 mm stainless steel plate to produce the flanges with
the cutting torch. After grinding, the flange (i.e. or reducer…) is taken to the
lathe machine to for surfacing and making the PCD
.

Figure : Cutting the iron plate

The PCD are concentric circles on the surfaces that will be in contact to
the rubber seal. It helps the rubber seal to anchor and resist to the high
pressure given by the water hammer effect. If not, the rubber moves and
leakages appear.
Finally, drill the holes for the bolt and flanges are ready for being welded to the
pump body.
This step is the same for the flanges for the drive pipe and for reducing on
end of the tee for connecting the drive pipe. A pipe used for the drive pipe
(i.e. 2”) is welded on

Figure: Flanges, plates, reducer, and top of air chamber manufacture

 Pump body

The first step is to weld the GI tee and the GI elbow together with a strong waterproof
weld. Then, the reducer, and finally the support are welded.

Figure : Welding the pump body

Two 90˚ profiles are cut and holes are drilled in them to create the support of the
pump. The position of the holes needs to match the position of the screws on the
Figure : Supports on pump body
 Snifter valve

The snifter valve is a 2 mm hole in the pump body 2 cm below the delivery
valve. The technician needs to weld a point on the pump body to add
material and then, drill inside. If the hole is too big while the pump is
running (i.e. too much leakage of water), a nail can be placed inside the
hole to reduce it.

Figure: Snifter valve manufacture

 Delivery valve

The delivery valve manufacture starts like the flanges except it has no large
hole at its center like the flanges or the plate for the impulse valve. It has
small holes drilled

Figure : Delivery valve manufacture

Impulse valve

 The impulse valve is the most complicated component to manufacture in

the Hydram.
The plate

Starting with a plate like the flanges, do not make the hole in the center in the
beginning: this step will be at last. Then, produce the support for the guide with
 .

Figure : Manufacture of the support for the impulse valve guide

The iron plate is cut to produce rectangles that will support the guide. After,
all steps are done on the lathe machine.
First, the top is manufactured: the top side faces the cutting tools:
 Surface the top;

 Position and weld the support for the guide;

 Drill a hole to put the guide inside the top rectangle;

 Weld the guide;

 Finish

Figure : Manufacture of the top of the impulse valve plate

On a second time, the bottom side of the stop bar faces the cutting tools:
 Cut the center hole in the plate;

 Cut the 45˚ angle edge;

 Drill inside the guide (i.e. the technician is sure that the edge and the inside of
the guide are aligned: this is important for the movement of the plug).

 Make the PCD;

 Finish.

Figure: Manufacture of the bottom of the impulse valve plate

The plug

The manufacture of the plug is done in three times. First, the technician
has to prepare the plate and the stem respectively from the 10 mm iron
plate and from the crow bar.
For the stem:
 Cut a 170 mm long piece; and
  With the lathe machine, cut off one end to 12- mm diameter on 20 mm.

For the plate:

 Cut a disc of 100 mm diameter;

 Drill a 12+ mm hole at its center;

 Position the stem inside and weld the stem to the plug on the lathe machine;

 Surface the crow bar until a diameter of 18 mm;

 Turn the assembly on the other side on the lathe machine (i.e. the bottom of the
plug facing the cutting tools, the lathe machine attaching the stem);

 Weld the stem to the plug on the lathe machine;

 Cut of the weld with the lathe machine so that the lathe machine can hold the
plug from the bottom;

 Turn the assembly so that the stem is facing the cutting tools of the lathe
machine;

 Now, in one position, the technician can surface the edge of the disc with a
45˚ degree angle, surface the stem for a good translation in the guide and make
the threads for the locking nut.
 Figure: Manufacture of the stem of the impulse valve

Air chamber

In order to manufacture the air chamber:

 Cut a 1.2 m long piece of the 4” pipe.

 Position and weld the flange on the 4” pipe on one side;

 Position and weld the top of the air chamber on the other side; and
  With the welding machine, make a 1 ¼” hole inside the 4” pipe 200 mm above
the flange.

 With a 1 ¼” pipe, cut a 200 mm long piece and make threads to connect with a
union to make the outlet; and

 Weld the outlet in the air chamber.

Figure: Manufacture of the air vessel

Finishing

To finish, it is important to protect the all parts except from the stem and the
bolts from corrosion:
 Paint a layer of anticorrosion paint, then a layer of color paint.
2.7 APPLICATIONS AND LIMITATIONS OF HYDRAULIC RAM PUMPS

For any particular site, there are usually a number of potential water lifting options.
Choosing between them involves consideration of many different factors. Ram
pumps in certain conditions have many advantages over other forms of water-
lifting, but in others, it can be completely inappropriate. The main advantages of
ram pumps are:

 Use of a renewable energy source ensuring low running cost.

 Pumping only a small proportion of the available flow has little environmental
impact.

 Simplicity and reliability give a low maintenance requirement

 Automatic, continuous operation requires no supervision or human input.

2.7 a The main limitations are:

 They are limited in hilly areas with a year-round water sources

 They pump only a small fraction of the available flow and therefore require source
flows larger than actual water delivered

 Can have a high capital cost in relation to other technologies

 Are limited to small-scale applications, usually up to 1KW, but this requires

economical and other considerations.
Specific situations in which other technologies may prove more appropriate are:

 In terrain where streams are falling very rapidly, it may be possible to extract water
at a point above the village or irrigation site and feed it under gravity. If the water
requirement is large and there is a large source of falling water (head and flow rate)
nearby, turbine-pump sets can provide the best solution. Many ram pumps could
be used in parallel to give the required output but at powers over 2KW, turbine-
pump systems are normally cheaper.

 In small-scale domestic water supply, the choice can often be between using a
ram pump on a stream and using cleaner groundwater. Surface water will often
need to be filtered or treated for human consumption, increasing the cost of a
system and requiring regular filter maintenance. Under these conditions, to select
a hydram pump, economic considerations compared to other technologies must
be look
2.7 ADVANTAGES & DISADVANTAGES

Advantages:

 No moving parts,
 No power requirements,
 Inexpensive,
 Quiet pumping continuously over a long period,
 Pollution free or “Green” pump,
 Simple construction and easy to install, and
 Only initial cost and very low or negligible maintenance cost.

Disadvantages:

 It can pump only one tenth of the received water volume remaining being wasted
through waste valve.
 It must have a continuous source of supply at a minimum height of not less than 3
feet or 91 cm.
 It cannot pump viscous fluids to a greater height. Usually used for pumping
drinking water or potable water.
2.8 MAINTENANCE AND SERVICE LIFE CONSIDERATIONS

The critical parts that require frequent maintenance are bolts, studs and nuts.
Therefore, it is usually preferable to have stainless steel bolts, studs and nuts, even
though they are costly and difficult to source.

2.9 GENERAL CONSIDERATIONS

 Shape of hydram has little effect on performance.

 Valve design considerations. The correct design of valves is a critical factor in the
overall performance of ram pumps. Hence, this needs special consideration.

 Strength considerations. This determines thickness of hydram body and air

chamber.
2.9A COMMON PROBLEM AND MAINTENANCE FROM DTU
Future Scope

The ram pump is a 'mature' technology. Over the last two centuries pump designs have
stabilized and many variations to the basic configuration (of drive pipe, pump, and
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 neighboring 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 sterilization
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 out the delivery hose and starts the
pump. With electric powered pumping using mains, photo-voltaic 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.
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.

From the results obtained, we have found out that –

2. There is broad prospect of utilizing the country's abundant surface water run
off potential for various purposes or requirements using locally designed and
manufactured hydraulic ram pumps and other similar appropriate
technologies.

3. To disseminate hydrams at potential sites throughout the country, there is a

need to create awareness through training and seek integrated work with rural
community, government institutions like water, energy and mines bureau of
local regions and non-governmental organizations.

4. Hydraulic Ram pumps made by casting have many advantages, but they
could be expensive. In addition, considering the cost of civil work and pipe
installation, the initial investment could be very high. To reduce cost of
hydrams made by casting, there is a need for standardization. Standardizing
hydram pump size will also have an advantage to reduce cost of spare parts
and facilitate their easy access when they are needed.

5. The use of appropriate means of treating river water should be looked at in

conjunction with any development project of domestic water supply using
hydrams.
 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
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[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.

[10] Fluid mechanics book [R.K.BANSAL]

[11] Krol J., Automatic hydraulic Pump, PROC.I. MECH.E 1951,

[12] Calvert N. G., Hydraulic Ram, THE ENGINEER, 1967.