ALAGAPPA CHETTIAR COLLEGE OF ENGINEERING AND

TECHNOLOGY, KARAIKUDI – 630 004

DEPARTMENT OF MECHANICAL ENGINEERING

DESIGN AND FABRICATION OF SAVONIUS PUMP

A PROJECT REPORT SUBMITTED BY

AJAY PRASANTH D 1212001

HARI PRAKASH P 1212032

GUIDED BY

Mr. T.AZHAGU GOPI GANESH, B.E.,

ABSTRACT:

In this modern world we can’t depend on non-renewable energy always. Our

aim is to use renewable energy source as a replacement for some of domestic

applications which will reduce cost and as well as consumption of draining energy.

So we are going to utilize wind power for water pump by using savonius turbine

which is vertical axis wind turbine.

INDEX

1. Objective

1.1 Reason for using wind power 1

1.2 Reason for using wind power for pump water 1

2. Wind turbine

2.1 Types of wind turbine 2

2.2 Types of rotor blade 3

2.3 Savonius wind turbine 4

2.4 Advantages of vertical axis wind turbine 4

3. Designing of vertical axis wind turbine

3.1 Design of Blade 5

3.2 Design of shaft 5

3.3 Design of bearing 5

4. Design of Reciprocating pump

4.1 Reciprocating motion 6

4.2 Direction control check valve 6

5. Specification of the wind turbine

5.1 Base dimensions 6

5.2 Blade dimensions 6

5.3 Shaft dimensions 6

6. Formula derivations

6.1 Power obtained from wind energy 7

6.2 Power required for pump 8

7. Calculations

7.1 Power obtained from wind energy 9

7.2 Power required to drive pump 10

8. Construction

8.1 Frame 11

8.2 Wind turbine and Shaft assembly 12

8.3 Pedestal bearing 12

8.4 Crank mechanism assembly 12

9. Advantages 13

10. Conclusion 13

11. Further Development 13

12. Bibliography 13

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1. OBJECTIVE

As per statistics fossil fuels the coal deposits will only give us enough energy

to take us as far as 2088. Maybe some new reserves will be found which will help

extend this deadline slightly, but these can’t last forever. New reserves of fossil fuels

are becoming harder to find, and those that are being discovered are significantly

smaller than the ones that have been found in the past.

Even though the research is going on in renewable energy, we don’t know it

will be as full replacement of fossil fuels before the deadline. So our aim is to extend

the deadline as much as we can. So that we are going to use wind energy for water

pump.

1.1 REASON FOR USING WIND POWER

India is a peninsula country and we have 7517 km of coastline. The wind

speed in India lies between 15-30 km/hr, but we generate only 1.6% of country’s

power. So we are going to utilize the wind power as possible.

1.2 REASON FOR USING WIND POWER FOR PUMP WATER

As per statistics of Census 2011 totally 171 million people living in coastal

areas. Water is mandatory for human living, Indian Human Resource development

department says an Indian needs 135 litres of water per day. So by using renewable

energy for water pump will give us profit of large amount of electrical energy.

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2. WIND TURBINES

2.1 TYPES OF WIND TURBINES

Wind turbine is a device which converts kinetic energy of fluid flow into

useful mechanical power. Normally wind turbines are used in electricity generation.

There are two types of wind turbines based on the axis of rotation.

1. Horizontal axis wind turbine (HAWT)

2. Vertical axis wind turbine (VAWT)

In Horizontal axis wind turbine fins rotate about horizontal axis and the

vertical axis wind turbine fins rotate about vertical axis.

Horizontal axis wind turbines need tower arrangements and it used only for

power production. We can’t make tower arrangements for domestic purposes and it

costs heavily. So we go for vertical axis wind turbine which will suit for domestic

applications and small in size than vertical axis wind turbine.

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2.2 TYPES OF ROTOR BLADE

Rotor blades are causes for conversion of wind power into mechanical energy.

There are two types of rotor blades based on aerodynamics,

1. Lift type

2. Drag type

In lift type rotor blades, the flow lift the blades and it causes for rotation. In

drag type the rotation is obtained from drag force created by collision of fluid flow

with blades.

Lift type blades are complicate design and not easy to manufacture and it costs

more for manufacturing. But drag type rotor blades are easy to construct and the

power obtained from drag type blades enough for domestic pump applications.

Lift type

Drag type

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2.3 SAVONIUS WIND TURBINE

Savonius turbines are one of the simplest vertical axis wind turbines (VAWT).

Aerodynamically, they are drag-type devices, consisting of two or three scoops.

Looking down on the rotor from above, a two-scoop machine would look like an "S"

shape in cross section. Because of the curvature, the scoops experience less drag

when moving against the wind than when moving with the wind. The differential

drag causes the Savonius turbine to spin. Because they are drag-type devices,

Savonius turbines extract much less of the wind's power than other similarly-sized

lift-type turbines, but this power is enough to pump water.

2.4 ADVANTAGE OF VERTICAL AXIS WIND TURBINE

There are several reasons why we would choose a vertical axis wind turbine over

a horizontal axis windmill.

1. They are mounted lower to the ground making it easy for maintenance if needed.

2. They start pumping water at speeds of only 10 kmph. And

3. Third, they may be able to be built at locations where taller structures, such as

the horizontal type, can't be.

4. Higher power utilization-- 20% higher than HAWT.

5. Lower noise level--only 27-37 DB, suitable for your living condition.

6. Safer operation--Spin at slower speeds than horizontal turbines, decreasing the

risk of injuring birds and also decreasing noise level.

7. Simpler installation and maintenance-- besides the traditional installation site, it

can be mounted directly on a rooftop, doing away with the tower and associated

guy lines.

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8. Not affected by orientation variation—no matter the wind blow from any

orientation, VAWT can work without regard to its face.

9. Economical and practical-Although one-time investment expenses are larger,

but you don’t have to pay higher tariffs forever.

3. DESIGNING OF VERTICAL AXIS WIND TURBINE

A wind mill is machine for wind energy conversion. A wind turbine converts

the kinetic energy of the wind’s motion to mechanical energy transmitted by the

shaft. A crank mechanism further converts it to pump. So it is necessary to keep in

mind, while designing the windmill’s structural part.

3.1 DESIGN OF BLADE

Wind turbine blades have on aerofoil – type cross section and a variable pitch.

While designing the size of blade it is must to know the weight and cost of blades.

In the project two blade with vertical shaft are used, it has a height & width of 48.3cm

& 47cm respectively. The angle between two blades is 600. So if one Blade moves

other blades comes in the position of first blade, so the speed is increases

3.2 DESIGN OF SHAFT

While designing the shaft of blades it should be properly fitted to the blade.

The shaft should be as possible as less in thickness & light in weight. So no problem

of slipping & fraction is created, it is made up of hollow Aluminum which is having

very light weight. Length of shaft & diameter are 24 inches & 19 mm respectively.

3.3 DESIGN OF BEARING

For the smooth operation of Shaft, bearing mechanism is used. To have very

less friction loss the two ends of shaft are pivoted into the same dimension bearing.

The Bearing has diameter of 19 mm. Bearing are generally provided for supporting

the shaft and smooth operation of shaft. We have used pedestal bearings for our

project.

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4. DESIGNING OF RECIPROCATING PUMP

4.1 RECIPROCATING MOTION

Reciprocating motion is obtained by placing a shock absorber rubber piece

of two wheeler which gives high flexibility and suits exact for our project. We fixed

it as stroke length of 7 cm.

4.2 DIRECTION CONTROL CHECK VALVE

We placed two DCV in each side for inlet and outlet which for the purpose

of resisting the returning of water flow in reverse direction.

5. SPECIFICATION OF THE WIND TURBINE

5.1 BASE DIMENSIONS

Height 24 inches

Width 24 inches

5.2 BLADE DIMENSIONS

Height 19 inches

Diameter 18.5 inches

Thickness 0.04 inches (1mm)

Angle 45 °

Angle b/w blades 60°

5.3 SHAFT DIMENSIONS

Diameter 4.826 inches (19mm)

Length 30 inches

Thickness 0.16 inches (4mm)

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6. FORMULA DERIVATIONS

6.1 POWER OBTAINED FROM WIND ENERGY

Power formula derived from kineti energy equation,

E = 1

2 mv2

Power in the wind is given by the rate of change of energy,

P = 𝑑𝐸

𝑑𝑇 =

1

2 m v2

𝑑𝑚

𝑑𝑇

As mass flow rate is given by,

𝑑𝑚

𝑑𝑇 = 𝜌𝐴

𝑑𝑥

𝑑𝑇

And the rate of change of distance is given by,

𝑑𝑥

𝑑𝑇 = v

We get,

𝑑𝑚

𝑑𝑇 = 𝜌𝐴𝑣

Hence the power equation is,

P = 1

2 𝜌𝐴𝑣3

Where,

P – Power in Watt

𝜌 – Air density in kg/m3

A – Swept area in m2

v – Velocity in m/s

By Betz limit (or) Betz Law

Maximum power efficiency of any design of wind turbine is 0.59

Cp max = 0.59

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So the extractable power from the wind is given by,

Power = 𝟏

𝟐 𝝆 𝑨 𝒗3 Cp in Watt

Angular velocity (𝝎) = 𝝀 .𝒗

𝒓

Where,

λ = Tip speed ratio

v = Velocity of wind

r = Radius of blade

6.2 POWER REQUIRED FOR PUMP

To find work done,

Weight of the fluid displaced per sec = Weight of the fluid X Discharge

= (𝜌 g) (𝐴𝐿𝑁

60) N / sec

Workdone by the pump = 𝜌 g A N L

60 X (Hs + Hd)

Power is the rate of doing work. It is equivalent to an amount of energy consumed

per unit time,

So,

Power = 𝝆 𝐠 𝐀 𝐍 𝐋 𝐇

𝟔𝟎 in Watt

Where,

P – Power in Watt N – Speed of rotor in rpm

𝜌 – Density of fluid in kg/m3 L – Stroke length in m

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H – Head distance in m A – Cross sectional area in m2

7. CALCULATIONS

7.1 POWER OBTAINED FROM WIND ENERGY

Power = 1

2 𝜌 𝐴 𝑣3 Cp

Here,

𝜌 = 1.184 kg/m3 at 250C

A = Height x Radius = 0.1134m2

Height = 0.4826m, Radius = 0.235m

v = 4.16 m/s (15km/hr)

Cp = 0.35 (Assumption)

So,

Power = 0.5 x 1.184 x 0.1134 x 4.16 x 0.35

Power obtained = 2.587 W

Angular velocity (𝜔) = 𝝀 .𝒗

𝒓

𝜔 = 0.8𝑥 4.16

0.3 = 11.09 rad/sec

Speed (N) = 𝜔 𝑥 60

2𝜋 in rpm

N = 11.09x 60 / (2 x 3.14)

Speed (N) = 105.98 rpm

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7.2 POWER REQUIRED TO DRIVE PUMP

Power = 𝜌 g A N L H

60

Here,

𝜌 = 1000 kg/m3 (Density of water)

A = Cross sectional area = 2.8637 x 10-4 m2

A = 𝜋𝐷2

4 , Diameter = 0.0191m

N = 105.98 rpm

L = 0.07m

H = 0.9 m

So,

Power = (1000 x 9.81 x2.8637x10-4 x105.98 x 0.07 x 0.9) / 60

Power required = 0.3126 Watt

Hence,

We can pump the water up to the height of 7 meter (23 feet) height with this

same prototype wind turbine.

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8. CONSTRUCTION

CAD diagram of Savonius pump

8.1 FRAME

Frame for the turbine and pump is fabricated by ASTM 106 grade B material

pipe of 1inch outer dia. The frame is welded by Arc welding method.

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8.2 WIND TUBINE AND SHAFT ASSEMBLY

This is the main component which causes for utilizing wind power. The

blades also welded with shaft at the required angle.

8.3 PEDESTAL BEARING

Pedestal type bearing is used for mounting shaft in the frame and reduces

frictional resistance.

8.4 CRANK MECHANISM ASSEMBLY

A simple crank assembly is designed and fabricated for the required stroke

length.

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9. ADVANTAGES

a) It is a renewable source of energy.

b) Wind power systems are non-polluting so it has no adverse influence on the

environment.

c) Wind energy systems avoid fuel provision and transport.

d) On a small scale up to a few kilowatt system is less costly.

e) On a large scale costs can be competitive conventional electricity and lower

costs could be achieved by mass production.

f) They are always facing the wind - no need for steering into the wind.

g) Have greater surface area for energy capture -can be many times greater.

h) Are more efficient in gusty winds – already facing the gust.

i) Can be installed in more locations - on roofs, along highways, in parking lots.

j) Can be scaled more easily - from mill watts to megawatts.

10. CONCLUSION

Our work and the results obtained so far are very encouraging and reinforce

the conviction that vertical axis wind energy conversion systems are practical and

potentially very contributive to the reduction of electricity consumption by using

wind the wind even under less than ideal sitting conditions. It is hoped that they may

be constructed used high-strength, low- weight materials for deployment in more

developed nations and settings or with very low tech local materials and local skills

in less developed countries. The Savonius pump designed is ideal to be located on

coastal area for pump water which is powered by wind. The elevated altitude gives

it an advantage for more wind opportunity.

11. FUTURE DEVELOPMENTS

1. The use of materials like Acrylic Plastic Sheets can be used to develop low

cost VWAT

2. Placing brake system and lock for stop the pump

1. BIBLIOGRAPHY

1. Eggleston, David M. Wind Turbine Engineering Design. Van Nostrand

Reinhold, 1987.

2. Fluid Mechanics by R.K.Bhansal

3. www.accuweather.com