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CHAPTER I
The Problem and Its Background 1.1 Background of the Study Since the dawn of time, the use of windmills has been one of the most reliable methods of converting wind energy to mechanical energy. Due to the enormous amount of wind energy around the globe, people have developed different methods on how to utilize this kind of energy that is seen on wind turbines and wind pumps. In the Southeast Asian region specifically the Philippines, the first windmill park was built in the windy seashores of Bangui Bay, Ilocos Norte. Thus, it officially started the advent of renewable energy sources. With this technology, Filipinos have taken full advantage of the abundant wind energy provided by the Asia-Pacific monsoon and have built different kinds of windmills around the archipelago. One of the most widely used types of windmill in the Philippines is the wind pump. Windmill driven pumps are usually used to sustain the need of water when there is shortage of supply in certain areas. It has mainly benefited famers in providing water for their animals and crops. The Caleruega Retreat House, an escape from the bustling metro district of Manila, is a spiritual retreat house of the Dominicans located at Nasugbu, Batangas just after Tagaytay City. It has almost the same elevation with

Tagaytay City which is 2,100 ft. (640m) above sea level.

Thus, installing a

wind pump in the area will be useful in transporting rain water from a reservoir to a water tank which they use to water their plants. The rain water will be collected from a man-made pond and will be pumped to a water tank located at a higher elevation. 1.2 Conceptual Framework Gathering related topics and other information needed is the initial procedure in conducting the study of this project. During the data gathering, the most important step is to survey the location and collect all necessary information in windmill construction. Also, actual background studies with the windmill fabricators are essential in this study. Computation and analysis of gathered data is required to come up with a design and forecast possible remedies in different situation that the windmill may experience. Lastly, designing the structure and looking for errors so that researchers could come up with improvements and recommendations.

1.3 Theoretical Framework The theoretical properties of this research study are based on the following principles;
1. The available materials for the construction of the wind pump and

the multi bladed vertical windmill are found and bought locally.
2. The research study done applied wind driven pumps method and

can be associated to the standard mechanical water pump method.


3. The researchers have adequate information about wind energy,

fluid mechanics, machine design and strength of materials.

1.4 Research Paradigm

1.5 Paradigm

1.6 Statement of the Problem The main problem of this study is to design a wind pump that will utilize the wind at Caleruega Retreat House, Nasugbu, Batangas. The wind pump design should be able to produce a certain shaft speed that will meet the required power of the centrifugal pump to transport rainwater from a reservoir to an existing tank at the area. This study should be able to answer the following questions:
1. What would be the optimum pump capacity and power requirement

for the given application?


2. Is the nature of the wind (power and speed) enough to run a

centrifugal pump based on the design?

1.7 Scope and Delimitation of the study The objective of the study is to design a wind pump that will utilize the abundant wind energy at Caleruega Retreat House, Nasugbu, Batangas. The researchers will focus on determining the amount of power that can be transmitted by the rotor to the centrifugal pump. With the calculated amount of power transmitted by the rotor, the researchers will then determine if the power supplied is sufficient enough to operate a centrifugal pump that will supply water to the existing water tank at Caleruega Retreat House, Nasugbu, Batangas. The researchers will limit their study on designing that wind pump alone. By designing a wind pump, the researchers will consider

the materials needed to construct the wind pump to come up with the desired power that will operate the system. Thus, fabrication and installation of the designed wind pump will not be the concern of the researchers.

1.8 Significance of the study The design of the wind pump for Calaruega, Nasugbu, Batangas is very significant for the people who reside there and for the students who come there for their retreat. This is to show that the Dominican Community is supporting the use of renewable energy. Once fabricated, it can be a good example for the other communities so that they will also follow suit in using renewable energy sources.

Definition of Terms Blade. The part of a wind generator rotor that catches the wind. Braking System. A device to slow a wind turbines shaft speed down to safe levels electrically or mechanically. Check Valve. A valve allowing flow in one direction only. Power. The rate of energy output. Pump. A machine, usually with rotary action or reciprocal action of a piston, for raising or moving liquids, compressing gases, inflating types etc. Pump Efficiency. Ratio of power out and power in of a pump. Reciprocating Pump. Reciprocating type pumps use a piston and cylinder arrangement with suction and discharge valves

integrated in the pump. Rotor. The blade and hub assembly of a wind generator.

Shaft. The rotating part in the centre of a wind generator or motor that transfers power. Static Head. It is the maximum height that can be delivered in a pump. Total Head. It is the measure of the energy increase per pound imparted to the liquid by the pump and is therefore the algebraic difference between the total discharge head and the total suction lift exists. Torque. The moment of a system of forces tending to cause rotation. Tower. A structure that supports a wind generator, usually high in the air. Wind. Air moving from a area of high pressure to an area of low pressure. Windmill. A device converting wind power to mechanical rotation with a low velocity turbine designed for compressible fluids. Wind Velocity. It is referred to as the rate of motion of wind.

CHAPTER II
Review of Related Literature 2.1 History of Windmill According to Wailes (1954), a windmill is a machine that is powered by the energy of the wind. It is designed to convert the energy of the wind into more useful forms using rotating blades or sails. Windmill also refers to the structure it is commonly built on. Windmills served originally to grind grain (hence the "mill" derivation), though later applications included pumping water and, more recently, generation of electricity. Recent electricitygenerating versions are referred to as wind turbines. Most windmills have a wheel of blades or sails that is turned by the wind. In most cases, the wheel is set on a horizontal shaft. The shaft is mounted on a tower, mast, or other tall structure. The shaft is turned by the movement of

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the wheel, and it transmits power, through a series of gears, to a vertical shaft. The vertical shaft then carries power to a water pump, electric generator or other device (World Book, 1995) The majority of windmills had four sails. An increase in the number of sails meant that an increase in power could be obtained, at the expense of an increase in the weight of the sail assembly. The earliest record of a multisailed mill in the United Kingdom was the five sail Flint Mill, Leeds, mentioned in a report by John Smeaton in 1774. Multi-sailed windmills were said to run smoother than four sail windmills. In Lincolnshire, more multisailed windmills were found than anywhere else in the United Kingdom. There were five, six and eight sail windmills.

Fig 1. An example of eight sailed windmill, Wailes 1954

If a four sail windmill suffers a damaged sail, the one opposite can be removed and the mill will work with two sails, generating about 60% of the power that it would with all four sails. A six sail mill can run with two, three,

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four or six sails. An eight sail mill can run with two, four, six or eight sails, thus allowing a number of options if an accident occurs. A five sail mill can only run with all five sails. If one is damaged then the mill is stopped until it is replaced (Wailes, 1954). One type of a windmill is the wind pumpa type of windmill used for pumping water from a well or draining land. Wind pumps are used extensively in Southern Africa and Australia and on farms and ranches in the central plains of the United States. In South Africa and Namibia thousands of wind pumps are still operating. These are mostly used to provide water for human use as well as drinking water for large sheep stocks.

Fig. 2(a) Fig.2(b) Figure 2(a) and (b). Examples of wind pumps

Kenya has also benefited from the African development of wind pump technologies. At the end of Eventually steel blades and steel towers replaced wooden construction, and at their peak in 1930, an estimated 600,000 units

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were in use, with capacity equivalent to 150 megawatts (Wiley and Sons, 1995) Eldridge (1980) explains that early wind pumps directly operated the pump shaft from a crank attached to the rotor of the windmill; the installation of back gearing between wind rotor and pump crank allowed the pump to function at lower wind speeds. Today water is primarily raised by electric pumps, and only a few wind pumps survive as unused relics of an environmentally sustainable technology. This type of wind pump can be found worldwide and is still manufactured in the United States, Argentina, New Zealand, and South Africa. A six-foot diameter wind pump rotor can lift up to 180 gallons per hour of water with a 15 to 20 mile per hour wind, according to a modern manufacturer (about 700 litres/hour by a 1.8 metre rotor in 2432 km/hour wind). Wind pumps require little maintenance, only requiring gear oil changes about once per year. An estimated 60,000 wind pumps are still in use in the United States. They are particularly economical in remote sites distant from electric power distribution. 2.2 Wind Machines and Rotors Also, Eldridge (1980) enumerates the classification of machines using rotor as wind energy collectors in terms of the orientation of their axis of rotation, relative to the wind stream:

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1. Horizontal axis rotors the axis of rotation is parallel to the direction of the wind stream; typical of conventional windmills. 2. Crosswind Horizontal axis rotors the axis of rotation is both horizontal to the surface of the earth and perpendicular to the direction of the wind stream; somewhat like a mater wheel. 3. Vertical axis rotors the axis of rotation is perpendicular to the surface of the earth and the wind stream. The blade of the windmill is to be computed by following the Blade Element Theory. The Blade Element Theory is a mathematical process which is originally founded by William Froude, David W. Taylor, and Stefan Drzewiecki to be able to determine the concept of propellers. The process is done by breaking a single blade down to several small partitions and then finding the forces in each of these small blade elements. The forces are within integration along the entire blade over one rotor revolution to be able to obtain the forces and the moments that is produced by the entire propeller blades. The hard part lies within modelling the induced velocity on the rotor disk. As a solution to this, the Blade Element Theory is often combined with the Momentum Theory to further provide additional

relationships necessary to describe the induced velocity on the rotor disk. 2.3 Wind Pump and the Blade of a Windmill During the 1970s, the UK NGO Intermediate Technology Development Group provided engineering support to the Kenyan company Bobs Harries

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Engineering Ltd for the development of the Kijito wind pumps. Bobs Harries Engineering Ltd is still manufacturing the Kijito wind pumps, and more than 300 Kijito wind pumps are operating in the whole of East Africa. Many wind pumps were built in The Broads, of East Anglia in the United Kingdom for the draining of land. They have since been mostly replaced by electric power, many of these wind pumps still remain, mainly in a derelict state (pictured), however some have been restored. On US farms, particularly in the Midwest, wind pumps were used to pump water from farm wells for cattle. The self-regulating farm wind pump was invented by Daniel Holladay in 1854.

Figure 3. Velocities and Forces Acting on the Blade Component Diagram

Where:

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dT = Thrust dF = Force dD = Drag UA = Axial induced speed VA = Translation speed r = Blade tip speed = Inflow angle

dL = Lift dN = Torque / radius U = Induced speed UT = Tangential induced speed nP = Pitch speed = Angle of attack

The blade of a windmill can also be computed by using the Momentum Theory. This theory describes a mathematical model of an ideal propeller. The originators of the momentum theory are W.J.M. Rankine, Alfred George Greenhill, and R.E. Froude. Under certain principles in fluid dynamics, there can be a mathematical connection between power, radius of the rotor, torque, and induced velocity. This theory is best described by the formula:

Where: T = the thrust = the density of air A = the area of the rotor disc 2.4 Betz Law

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According to Betz Law, wind turbine obtains its power input by converting the force of the wind into torque (turning force) acting on the rotor blades. The amount of energy that the wind transfers to the rotor depends on the density of the air, the rotor area, and the wind speed. The kinetic energy of a moving body is proportional to its mass (or weight). The kinetic energy in the wind thus depends on the density of the air, or its mass per unit of volume. So the "heavier" the air, the more energy is received by the turbine. Also, the air is denser when it is cold than when it is warm. At high altitudes, (in mountains) the air pressure is lower, and the air is less dense. Also, the rotor area is an important factor because it determines how much energy the wind turbine harvests from the wind (www.windpower.org). Normally, the wind turbine deflects all the wind that is coming towards it, so this means that it will never catch all the energy in the wind. This only means that it could only catch part of the wind energy as stated in Betz Law. Its because the more kinetic energy we absorb, more wind will be slowed down as it goes away from the left side of the turbine (see fig. 4). As usual one would think that extracting all the wind will make more energy but that is untrue because if this is done, no air would leave the turbine as to air would be prevented from entering the rotor. So, there must be some breaking of the wind that must be done and it is explained in Betz Law.

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Figure 4. The Stream Tube, www. windpower.dk

Betz Law is a theory stating that no turbine can capture more than 60% of the kinetic energy in the wind. This theory was developed by German physicist Albert Betz in 1919. To further understand Betz Law, we assume that the average wind velocity through the rotor area is the average of the undistributed wind speed before the wind turbine which is V1, and the after passing of the wind velocity leaving the turbine which is V2.

The mass of air flowing through thee rotor per second is equal to the formula: M = F (V1 + V2)/2

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Where: M = the mass per second = the density of air F = the swept rotor area (V1 + V2)/2 = the average wind velocity in the rotor zone Thus the power that is coming from the wind by the rotor is equal to the mass times the wind velocity drop squared (based on Newtons Second Law): P = (1/2) m (V12 * V22) Then we substitute the mass into this formula from the first expression we will arrive at the following expression for the power that is extracted from the wind P = /4 (V12 * V22) (V1 + V2) F Comparing the result with the total power in the undisturbed wind streaming exactly the same area F, with no rotor blocking the way of the wind. Lets call this Power Po: Po = /2 V13F So the ratio between the extracted power and the undisturbed power is:

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P/Po = (1/2)(1- {V2/V1}2)(1+{V2/V1}) Plotting their relationship in a graph, we can see that the function reaches its maximum for V2/V1 which is equal to 1/3 and the maximum value extracted from the wind is 0.59 or 16/27 of the total power of the wind (Betz, 1966).

Figure 5. Graph showing ratio of Power and Velocity of the wind

2.5 History of Pumps Many pumps were invented around the world during the old times. Among the ones that was the first to be used is the shadoof. A shadoof was originally developed in ancient Mesopotamia, which also appeared on a Sargonid Seal of c2000BC (Needham, 1965). It was used as an irrigation tool during 2000BC. The shadoof consists of an upright frame on which is suspended a long pole or branch, at a distance of about one-fifth of its length from one end. At the end of the pole lies a bucket or skin bag while on the other side carries a clay which acts as a balance. Typically this works like

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scooping up the water from a well. With an almost effortless swinging and lifting motion, the waterproof vessel is used to scoop up and carry water from one body of water (typically, a river or pond) to another. At the end of each movement, the water is emptied out into runnels that convey the water along irrigation ditches in the required direction. It is estimated that a shadoof can raise over 2,500 litres per day. Typical discharge of the well is around 2 litres per second. Maximum water depth may be up to 3 meters. They are still used up to now in some rural parts of the world.

Fig Shadoof in Egypt Figure 7. Shadoof in Romania

ure

6.

Then during the year 200BC, a Greek inventor and mathematician in Alexandria, Egypt whose name was Ctesibius invented the first reciprocating pump. Ctesibius wrote the first treatises on the science of compressed air and its uses in pumps. Also, the principle of the siphon was attributed to him. He also described one of the first force pumps for producing a jet of water, or lifting water from wells, examples of these have been found in various Roman sites such as the Silchester in Britain (Encyclopaedia Britannica).

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Also, during the 250 BC, pistons pumps were already present. They were invented by the Romans. Authors like Vitruv and Heron of Alexandria gave descriptions of pumps and other mechanisms whose function is based on cylinders and pistons.

Figure 8. An example of a Piston Pump during 250BC

In the 3rd Century BC, the invention of the water screw pump was attributed to the Greek Archimedes. So in honor of Archimedes it was named after him therefore calling it the Archimedes Screw. This machine was historically used for transferring water from a low lying body of water into irrigation ditches (Oleson, 1984).

Figure 9. Archimedes screw

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This screw consists of a screw inside a hollow pipe that is usually turned by hand or ran upon during the old times. At the bottom end, the screw scoops up water which is then brought upward by the rotating motion of the screw, after that the water when it reaches the top of the screw it pours out thus feeding the irrigation systems. In 1650, a German scientist, namely Otto von Guericke invented the vacuum pump. This vacuum pump consisted of a piston and an air gun cylinder with two way flaps designed to pull air out of whatever vessel it was connected to, and used it to investigate the properties of the vacuum in many experiments (Wikipedia). For folks with hand dug, rock or wood lined wells, a chain pump appeared on the market along about 1870. It had a series of rubber washers attached to an endless chain attached to the crank. The rubber washers fit snugly into a metal tube on the upward travel, carrying water to the top of the well, where it spilled into the spout or outlet. This was a refinement of an ancient Roman system for carrying water to the surface with rags tied to a chain and the water squeezed out at the spout by drawing the rag through a short tube (A History of Mans Progress, 1978).

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Figure 10. An example of an old chain pump

The common well or cistern pump came out about 1880 and was a refinement of a huge old English reciprocating pump of the sixteenth century. It has a cylinder and a plunger. Both the cylinder and the leather sealed plunger carry check valves that allow the water to go only one way, usually straight up. Early day reciprocating pumps had wooden pipe or casing and a glass lined cylinder down in the well. The cylinder must not be placed more than twenty-two feet above the water level, for this is the maximum height to which water can be sucked by vacuum. It can be pushed hundreds of feet, however, the weight of the water itself being the only limitation (A History of Mans Progress, 1978).

Figure 11. An example of the first common reciprocating pump, 1880

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The first centrifugal pump prototype which was characterized as a water or mud lifting machine appeared as early as 1475 in a treatise by the Italian Renaissance engineer Francesco di Giorgio Martini. True centrifugal pumps were developed during the late 1600s. This is the time when Denis Papin, who was a French physicist known for his invention of the steam digester, made one with straight vanes. Then the curved vane was introduced by British inventor John Appold at the Great Crystal Palace in 1851. 2.6 Dynamic Pumps Dynamic pumps are one category of pumps under which there are several classes, two of which are: centrifugal and axial. These pumps operate by developing a high liquid velocity and converting the velocity to pressure in a diffusing flow passage. Dynamic pumps usually have lower efficiencies than positive displacement pumps, but also have lower maintenance requirements. Dynamic pumps are also able to operate at fairly high speeds and high fluid flow rates. 2.7 Centrifugal Pumps This type of pump is a rotodynamic pump that uses a rotating impeller to increase the pressure of the fluid. They are commonly used to move liquids through a piping system. The fluid enters the pump impeller along or near to the rotating axis and is accelerated by the impeller, flowing radially outward into a diffuser or volute chamber, from where it exits into the Exhibition at the

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downstream piping system. Centrifugal pumps are used for large discharge through smaller heads. Some of the advantages of cenrtifugal pumps are, smooth flow through the pump and uniform pressure in the discharge pipe, low cost, and an operating speed that allows for direct connection to steam turbines and electric motors.The centrifugal pump accounts for not less then 80% of the worlds pump production because it is more suitable for handling large capacities of liquids than the positive-displacement pump.

Figure12. Warman Centrifugal Pump in a Coal Handling and Preparation Plant (CHHP) Application

A centrifugal pump works by the conversion of the rotational kinetic energy, typically from an electric motor or turbine, to an increased static fluid pressure. This action is described by Bernoullis principle. The rotation of the pump impeller imparts kinetic energy to the fluid as it is drawn in from the impeller eye and is forced outward through the impeller vanes and to the periphery. As the fluid exits the impeller, the fluid kinetic energy is then

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converted to static pressure due to the change in area the fluid experiences in the volute section. Typically the volute shape of the pump casing (increasing in volume), or the diffuser vanes (which serve to slow the fluid, converting to kinetic energy in to flow work) are responsible for the energy conversion. The energy conversion results in an increased pressure on the downstream side of the pump, causing flow.

Figure 13. Single Centrifugal Pump

Stage Radial Flow

Meanwhile a centrifugal pump containing two or more impellers is called a multistage centrifugal pump. The impellers may be mounted on the same shaft or on different shafts. The advantages to using a multistage centrifugal pump or a single stage pump include: o Producing a higher pressure head o Discharging a larger amount of liquid If a higher pressure head is to be developed then the impellers are mounted on the same shaft (series) while for large discharge of liquid the

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impellers are mounted on different shafts (parallel). In getting a high head, the number of impellers are connected in series. And in getting high discharge, the impellers should be connected in parallel.

Figure 14. A Multistage Centrifugal Pump

2.8 Energy Usage in Pumps The energy usage in a pumping installation is determined by the flow required, the height lifted, the length, and the characteristics of the pipeline. The power required to drive a pump (Pi) is simply defined simply using SI units by:

Where: Pi - is the input power requirement in watts is the fluid density in kg/m3 g is the gravitational constant (9.81m/s2) H is the energy Head added to the flow in meters

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Q is the flow rate in m3/s pump plant efficiency The head added by the pump is a sum of the static lift, the head loss due to friction and any losses due to valves or pipe bends all expressed in meters of water. Power is more commonly expressed as KW (103 W) or horsepower (multiply KW by 0.746). The value for the pump efficiency may be stated for the pump itself as a combined efficiency of the pump and motor system. The energy usage is determined by multiplying the power requirement by the length of time the pump is operating.

2.9 Head Developed by Pump The head developed HT, by a pump consists of the difference between the head at the discharge flange and that at the pump suction flange. The head can be solved by the formula:

P (hp) = Q (ft3/s) y (lbf/ft3) H (ft) 550 ft lbf/sec hp

Since the power requirement of any pump is a function of the capacity and total head against which pump works, the total head HT, should be

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determined accurately. In determination of the total head, the following statements should be borne in mind: 1. The datum line is the center line of the pump. All the datum line have a plus sign line have a minus

vertical distances above

and all vertical distances below the datum sign. 2.

The reference pressure is the atmospheric pressure. psi gage or 14.7 psia. All pressures above and all pressures below

At sea level, it is zero

atmospheric have a plus sign atmospheric have a minus sign. 3.

All loses of head due to friction turbulence in the minus sign and those losses of head due

suction line have a

to friction turbulence on the discharge line have a plus sign. Based on the foregoing statements, the general equation for

determining the total head, HT is: HT = Hd Hs where: Hd = total discharge head in ft., = Zd + Pd / y + Vd2 / 2g and Hs = total suction head in ft., = Zs + Ps / y + Vs2 / 2g

The total discharge head or sometimes called the dynamic discharge head consists of the static discharge head plus velocity head on discharge

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plus head lost due to friction and turbulence (which is generally included in friction head). Hd = Zd + Pd / y + Vd2 / 2g

The total suction head meanwhile, or sometimes called dynamic suction head consists of static suction head or lift and the velocity head and the friction head from source of supply to pump suction nozzle corrected to datum line condition. Hs = Zs + Ps / y + Vs2 / 2g 2.10 Centrifugal Pump Performance Curves with Different Impeller Sizes Pump manufacturers use this graph in order to show that impellers of several different diameters can be used in the same housing.
Pump Size & Type 4x13LPO-F Ring clearance 0.015in RPM 1170 Nss = 7000 Ingersoll-Rand Pumps Curve no.

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Figure 15. Actual Performance Curves for a Centrifugal Pump

Three different impeller diameter pump head curves are presented in Figure 9 along with corresponding curves of constant values of efficiency and input shaft power. BHP stands for Brake Horsepower, which is the same as input shaft power. Figure 15 provides pump head curves for impeller diameters of 5in., 5.5in., 6in., 6.5in., and 7in. Also superimposed are constant efficiency curves of 45%, 55%, 60%, 65%, and 68% and constant input power curves of 1/2 hp, hp, 1 hp, 1 hp, 2 hp, and 3hp. Pump head values range up to 190 gallons per minute (gpm). 2.11 Head versus Flow Rate Curves for Centrifugal Pumps

Figure 16. Head versus flow rate for a centrifugal pump for water and for a more viscous liquid.

Figure 16 shows pump head versus flow rates curves for a centrifugal pump. The maximum head produced by a centrifugal pump is called pump

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shutoff head because an external system is closed and there is no flow. We can see in Figure 16 that as the external system resistance decreases (which occurs when a system valve is opened more fully), the flow rate increases at the expense of reduced pump head. Because of this the outflow rates change significantly with external system resistance, centrifugal pumps are rarely used in fluid power systems. Zero pump head exists if the pump discharge port were reopened to the atmosphere such as when filling a nearby open tank with water.

2.12 Performance Characteristic Curve for Centrifugal Pumps When centrifugal pump manufacturers test their pumps, they typically produce (for given geometry and speed) performance curves of head. Overall efficiency, and input shaft power versus flow rate of the specified fluid. Figure 17 shows these three curves plotted on the same graph. Not that as the flow rates increases from zero, the efficiency increases from zero until it reaches a maximum, and then it decreases as the maximum flow rate is approached. The point where the maximum efficiency occurs is the best efficiency point (BEP), and the corresponding flow rate is the design flow rate. When selecting a pump for a given application, it is usually desirable to use a pump that will operate near its best efficiency point. Maximum efficiency values for centrifugal pumps typically range from 60% to 80%.

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Figure 17. Typical Performance Characteristic for Centrifugal Pumps

CHAPTER III
Research Methodology 3.1 Research Design This study focuses on a design of a wind pump for the community of UST Dominican Fathers at Caleruega, Nasugbu Batangas. Such study will determine the conditions in the area that will be very important in designing the components of the wind pump. There were a number of factors that were considered in the design such as the atmospheric conditions of the area and the location of the wind pump. Some existing wind pumps were also analyzed by the researchers in order to gain more knowledge in designing.

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3.2 Research Instrument Design of existing windmill both local and foreign was evaluated based on available research materials. This was done to determine the general design of a windmill and applying to it the local conditions in the area and the functional requirement. The group used research materials such as books, encyclopedias, existing studies, and the internet to be able to get useful information. The group also conducted inspection trips to Caleruega in order to make ocular assessments of the area. The group used their knowledge in the subjects of Machine Design and Fluid Machinery to be able to solve the power done by the windmill and the total dynamic head.

CHAPTER IV
Presentation, Analysis and Interpretation of Data

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Figure 18. Windmill and Pump Nomenclature

Figure 18 shows the researchers design of the wind pumps mechanism. The rotor, which is a standard design of an American multibladed windmill, is the prime mover of the whole system. It is composed of 18 blades (A) and has a diameter of 16 feet. The power that it can extract from the wind will be transmitted through shaft 1 (N) which connects the rotor and bevel gear 1 (B). Bevel gear 1 which is meshed with bevel gear 2 (C) will then transmit the shaft power from shaft 1 to shaft 2. Shaft 2, which links bevel gears 2 and 3, supplies power to shaft 3 through bevel gears 3

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and 4. Sheave 1, which is connected to bevel gear 4, is belted to sheave 2 to create a high speed rotation needed by the centrifugal pump to attain the required power and head that will transport the rain water to the elevated storage tank. To prove that this mechanism design is efficient in operating a centrifugal pump, the researchers made certain calculations and

assumptions based on mathematical theories and existing studies about windmills and wind energy. The pump power requirement to deliver the rain water from a manmade pond to the elevated storage tank was first considered. The formula used for calculating the pump power is shown below: Parameters:

Volume of existing storage tank is 1335ft3 Assuming that the minimum wind pump operation per day with maximum wind speed of 8m/s would be 3 hours only.

Since only 50% of the tank volume is used for irrigation per day; therefore, water flow rate is: Q = (Virrigation)(hours of operation) operation)(1 hr/60 min) = 0.5 (1335ft3)(1 day/3 hrs of

Q = 3.71 ft3/min

Output power of the pump

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(1)

Pout = water HT Q

where:

Pout is the output power needed by the centrifugal pump water is the specific weight of water, 62.4 lb/ft3 HT is the total dynamic head Q is the water flow rate of the existing storage tank, 3.71 ft3/min

To compute for the total dynamic head: (2) HT = Hdischarge Hsuction

where:

Hdischarge is the total discharge head


o

Hdischarge = Zd + Pd/ + Vd2/2g + Hfd


Zd is the static discharge head, 32ft Pressure head (Pd/ ) and velocity (Vd2/2g ) head are negligible

Hfd is the head loss due to friction turbulence at the discharge line

Hsuction is the total suction head

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Hsuction = Zs + Ps/ + Vs2/2g + Hfs


Zs is the static suction lift at low water level, -4ft Pressure head (Ps/ ) and velocity (Vs2/2g ) head are negligible

Hfs is the head loss due to friction turbulence at the suction line

To get the total discharge head and total suction head, the head losses on discharge and suction lines are estimated using the Darcy-Weisbach Equation: (3) Hfs = f Ls V2/Ds 2g where:

f is called the friction factor (a dimensionless parameter) Ls is the estimated length of suction straight pipe, 50ft Ds is the actual inside diameter of pipe
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Since the nominal pipe size is designed to be 1.5 in GI pipe schedule 40, the actual inside diameter is 1.610in.

Vs is the average fluid velocity at suction pipe g is the acceleration due to gravity, 32.2ft/s2

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Computing the average fluid velocity in the suction pipe: (4) Vs = Q/As

where:

As is the cross-section area of the suction pipe


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As = (/4) (Ds2)

Solving eq. (4) Vs = (3.71ft3/min)(1min/60s)/( /4)(1.610in)2(1ft/12in)2 Vs = 4.37 ft/s To compute for the friction factor, the type of fluid flow is determined through the Reynolds Number, NR: (5) NR = VsDs/vwater

where:

vwater is the kinematic viscosity of water at based on surrounding temperature, 0.926x10-5 ft2/s

Solving eq. (5) NR = (4.37ft/s)(1.610in)(1ft/12in)/( 0.926x10-5 ft2/s) NR = 63,316

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Since 63,316 > 4000, then the flow is classified as turbulent. Relative Roughness = GI pipe/Ds = 0.0005ft/(1.610in)(1ft/12in) = 0.00373 Therefore, plotting the intersection of the Relative Roughness and Reynolds Number on the Moody Diagram: f = 0.0295 Solving eq. (3) Hfs = (0.0295)(50ft)(4.37ft/s)2/(1.610in)(1ft/12in)(2)(32.2ft/s2) = 3.26ft (6) Hfd = f Ld V2/Dd 2g where:

f is called the friction factor (a dimensionless parameter) Ld is the estimated length of discharge straight pipe, 180ft Dd is the actual inside diameter of pipe
o

Since the nominal pipe size is designed to be 1 in GI pipe schedule 40, the actual inside diameter is 1.049in.

Vd is the average fluid velocity at discharge pipe g is the acceleration due to gravity, 32.2ft/s2

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Computing the average fluid velocity in the discharge pipe: (7) Vd = Q/Ad

where:

Ad is the cross-section area of the discharge pipe


o

Ad = (/4) (Ds2)

Solving eq. (7) Vd = (3.71ft3/min)(1min/60s)/( /4)(1.049in)2(1ft/12in)2 Vd = 10.30 ft/s To compute for the friction factor, the type of fluid flow is determined through the Reynolds Number, NR: (8) NR = VdDd/vwater

where:

vwater is the kinematic viscosity of water at based on surrounding temperature, 0.926x10-5 ft2/s

Solving eq. (8) NR = (10.30ft/s)(1.049in)(1ft/12in)/( 0.926x10-5 ft2/s)

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NR = 97,234 Since 97,234 > 4000, then the flow is classified as turbulent. Relative Roughness = GI pipe/Dd = 0.0005ft/(1.049in)(1ft/12in) = 0.00572 Therefore, plotting the intersection of the Relative Roughness and Reynolds Number on the Moody Diagram: f = 0.0325 Solving eq. (6) Hfd = (0.0325)(180ft)(10.30ft/s)2/(1.049in)(1ft/12in)(2)(32.2ft/s2) = 110.24ft Solving eq. (2) Since: Hsuction = Zs + (-Hfs) = -4ft 3.26ft = -7.26ft Hdischarge = Zd + Hfd = 32ft + 110.24ft

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= 142.24ft Therefore: HT = 142.24ft (-7.26ft) HT = 149.5ft Solving eq. (1) Pout = [(62.4lb/ft3)(149.5ft)(3.71ft3/min)]/[33,000 ftlb/min HP] Pout = 1.05 HP Input power needed by the pump Considering a conservative pump efficiency of 70%: pump = Pout/Pin Pin = 1.05 HP/.70 Pin = 1.5 HP

Since the power input needed by the pump is 1.62 HP, the power to be produced by the rotor less all the losses in the mechanism should be greater than or equal to the needed power input by the pump. Also, a certain driver speed will be considered to reach the desired head. Therefore, to determine

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the power and shaft speed that the rotor can produce such calculations should be done: To harness the power from the wind (9) Pwind = Arotor Vwind3

where:

Pwind is the wind power is the air density based on 26C temperature and 2100ft elevation at Caleruega, 0.0679lb/ft3

Arotor is the swept rotor area


o o

Arotor = (/4) Drotor2 Drotor = diameter of rotor =16ft

Vwind is the average wind speed at Caleruega based on wind map, 8m/s

Solving eq. (9) Pwind = (0.0679lb/ft3)(1kg/2.2lb)(3.28ft/1m)3(/4) (16ft)2(1m/3.28ft)2(8m/s)3 = 5210.64 kgm2/s3 = 5210.64 (Ns2/m)(m2/s3) = (5210.64 W)(1HP/746W) Pwind = 6.98 hp since: kg = Ns2/m since: Nm/s = J/s = W

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Although the computation above showed the power in the wind, the actual power that can be extracted from the wind is significantly less than what that figure suggests. The actual power will depend on several factors, such as the type of machine and rotor used, the sophistication of blade design, friction losses, the losses in the pump or other equipment connected to the wind machine, and there are also physical limits to the amount of power which can be extracted realistically from the wind. Thus, according to the Betz limit theory, it is shown that any windmill can only possibly extract a maximum of 59.3% of the power from the wind. But, in reality, for a wind pump, that figure usually ranges from 25% to 40% only. The said percentage is the proportion of the power in the wind that the rotor can extract depending on the several technical parameters that are used to characterize windmill rotors. This proportionality constant is termed as the coefficient of performance (or power coefficient or efficiency; symbol Cp) and its variation as a function of tip-speed ratio is commonly used to compute the actual power that a certain type of windmill rotor can get from the wind. Hence, the following calculations thereafter have been done as proof for the presented theory on wind power extraction.

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Figure 19. Windmill rotor

Blade Specification

Thickness of GI sheet: gage 15

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Power transmitted by the rotor (10) Protor = Cp Arotor Vwind3 where:


Protor is the actual power extracted by the rotor from the wind Cp is the coefficient of performance of a windmill
o

Since the design is a typical multi-bladed rotor, Cp = 0.4

Solving eq. (10) Protor = (0.4)(0.0679lb/ft3)(1kg/2.2lb)(3.28ft/1m)3(/4) (16ft)2(1m/3.28ft)2(8m/s)3 = 2084.25 kgm2/s3 = 2084.25 (Ns2/m)(m2/s3) = (2084.25 W)(1HP/746W) Protor = 2.79 hp Since the rotor is attached to shaft1, the shaft power is equal to the rotor power. Protor = 2.79 hp = Pshaft1 since: kg = Ns2/m since: Nm/s = J/s = W

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The resulted power of the rotor from the computation is still not the actual power that will drive the centrifugal pump. Losses in the whole mechanism are still to be considered. Calculations of power losses are shown below:

Figure 20. Power transmission from shaft 1 to shaft 2

According to Kent (1976), studies say that rigidly mounted and well designed bevel gears are 98% efficient in transmitting power; therefore: Power transmission from shaft 1 to shaft 2 Pshaft2 = 0.98Pshaft1 = (0.98) (2.79 hp) Pshaft2 = 2.73 hp

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Speed of Bevel Gear 1 Vrotor = DrotorNrotor * transforming the formula to get Nrotor (11) Nrotor = Vrotor/Drotor where:

Nrotor is the speed of rotor Vrotor is the velocity of rotor

*to get the velocity of rotor, Vrotor Vrotor = (TSR) (Vwind) where:

TSR (Tip Speed Ratio) is 2 based on Cp of 0.4 Vrotor = (2) (8m/s) Vrotor = 16 m/s

Solving eq. (11) Nrotor = [16 m/s] [60s/1min] / [()(16ft)(1m/3.28ft)] Nrotor = 62.64 rpm Since the rotor and bevel gear 1 are on the same shaft, therefore:

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Nrotor = Nbg1 Nbg1 = 62.64 rpm Speed of Bevel Gear 2 Dbg2Nbg2 = Dbg1Nbg1 * transforming the formula to get Nbg2 (12) Nbg2 = (Dbg1Nbg1)/( Dbg2) where:

Nbg2 is the speed of bevel gear 2 Dbg1 is the diameter of bevel gear 1 based on the design, 12in Nbg1 is the speed of bevel gear 1, 62.64 rpm Dbg2 is the diameter of bevel gear 2 based on the design, 4in

Solving eq. (12) Nbg2 = [(12in)(62.64 rpm)]/[4in] Nbg2 = 187.92 rpm Since the bevel gear 2 and bevel gear 3 are on the same shaft, therefore: Nbg2 = Nbg3 Nbg3 = 187.92 rpm

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To prove that shaft 1 exerts enough force to drive shaft 2, the torque on both shafts should be compared. Torque available on shaft 1 Tshaft1 = Pshaft1/2Nshaft1 Nshaft1 = Nbg1 = Nrotor = 62.64 rpm Tshaft1 = [2.79 hp(33000 ft-lb/min-hp)]/[2(62.4 rpm)] Tshaft1 = 234.83 ft-lb Torque available on shaft 2 Tshaft2 = Pshaft2/2Nshaft2 Nshaft2 = Nbg2 = 187.92 rpm Tshaft2 = [2.73 hp(33000 ft-lb/min-hp)]/[2(187.92 rpm)] Tshaft2 = 76.3 ft-lb Since the torque on shaft 1 is greater than the torque on shaft 2, therefore shaft 1 is capable of driving shaft 2.

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Figure 21. Power transmission from shaft 2 to shaft 3

Considering 98% efficiency of Power transmission from shaft 2 to shaft 3 which is connected to spur gear 1: Pshaft3 = 0.98Pshaft2 = (0.98)(2.73 hp) Pshaft3 = 2.68 hp Speed of Bevel Gear 4 Dbg4Nbg4 = Dbg3Nbg3 * transforming the formula to obtain Nbg4 (13) Nbg4 = (Dbg3Nbg3)/( Dbg4)

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where:

Nbg4 is the speed of bevel gear 4 Dbg4 is the diameter of bevel gear 4 based on the design, 4in Nbg3 is the speed of bevel gear 3, 187.92 rpm Dbg3 is the diameter of bevel gear 3 based on the design, 12in

Solving eq. (13) Nbg4 = [(12in)(187.92 rpm)]/[4in] Nbg2 = 563.76 rpm Since the bevel gear 4 and sheave 1 are on the same shaft, therefore: Nbg4 = Nsheave1 Nsheave1 = 563.76 rpm To prove that shaft 2 exerts enough force to drive shaft 3, the torque on both shafts should be compared. Torque available on shaft 3 Tshaft3 = Pshaft3/2Nshaft3 Nshaft3 = Nbg4 = Nsheave1 = 563.76 rpm Tshaft3 = [2.68 hp(33000 ft-lb/min-hp)]/[2(563.76 rpm)]

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Tshaft3 = 24.97 ft-lb Torque available on shaft 2 Tshaft2 = 76.3 ft-lb Since the torque on shaft 2 is greater than the torque on shaft 3, therefore shaft 2 is capable of driving shaft 3. Torsional stress on shaft 1 St1 = 16Tshaft1/dshaft13 Where:

dshaft1 is the diameter of shaft 1 based on the design, 1.5in Su is the ultimate strength of the material used for the shaft, 122,000 psi-AISI 4340

St1 = [16(234.83 ft-lb)]/[(1.5in)/(12in/ft)]3 = 612,341.437 lb/ft2 (1ft/12in)2 St1 = 4,252.37 psi

Since: Su (122,000 psi) St1 (1,252.37 psi)

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Therefore, the diameter of shaft 1 and the material used can endure the torsional stress induced by the shaft torque. Torsional stress on shaft 2 St2 = 16Tshaft2/dshaft23 Where:

dshaft2 is the diameter of shaft 2 based on the design, 1.5in Su is the ultimate strength of the material used for the shaft, 122,000 psi-AISI 4340

St2 = [16(76.3 ft-lb)]/[(1.5in)/(12in/ft)]3 = 198,959.467 lb/ft2 (1ft/12in)2 St2 = 1,381.66 psi Since: Su (122,000 psi) St2 (1,381.66 psi) Therefore, the diameter of shaft 2 and the material used can endure the torsional stress induced by the shaft torque.

Torsional stress on shaft 3 St3 = 16Tshaft3/dshaft33

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Where:

dshaft3 is the diameter of shaft 3 based on the design, 1.5in Su is the ultimate strength of the material used for the shaft, 122,000 psi-AISI 4340

St3 = [16(24.97 ft-lb)]/[(1.5in)/(12in/ft)]3 = 65,111.637 lb/ft2 (1ft/12in)2 St3 = 452.16 psi Since: Su (122,000 psi) St3 (452.16 psi) Therefore, the diameter of shaft 3 and the material used can endure the torsional stress induced by the shaft torque.

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Figure 22. V-Belt drive

Speed of Sheave 2 Dsheave2Nsheave2 = Dsheave1Nsheave1 * transforming the formula to get Nsheave2 (14) Nsheave2 = (Dsheave1Nsheave1)/( Dsheave2) where:

Nsheave2 is the speed of sheave 2 Dsheave2 is the diameter of sheave 2 based on the design, 3in Nsheave1 is the speed of sheave 1, 563.76 rpm

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Dsheave1 is the diameter of sheave 1 based on the design, 18in

Solving eq. (14) Nsheave2 = [(18in)(563.76 rpm)]/[3in] Nsheave2 = 3,382.56 rpm Since sheave 2 is the driver of the pump, therefore: Nsheave2 = 3,382.56 rpm = Rated Speed Output of the windmill mechanism Number of belts needed: Since Design hp is 2.68 and rpm of smaller sheave is 3,382.56, section A Vbelt is to be used. (Figure 17.14 of Design of Machine Elements by Faires) (15) Vbelt = Dsheave1Nsheave1 where:

Vbelt is the belt speed

Solving eq. (15) Vbelt = (18in)(1ft/12in)(563.76 rpm) Vbelt = 2,656.66 ft/min

(16) Lbelt = 2C + (/2)(Dsheave1 + Dsheave2) + (Dsheave1 Dsheave2)2/4C

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where:

Lbelt is the length of V-belt C is the center line distance of sheave 1 and sheave 2 based on the design, 18in

Solving eq. (16) Lbelt = [2(18) + (/2)(18in + 3in) + (18in 3in)2]/ 4(18in) Lbelt = 72.095 in Therefore, standard length of belt is 76.3inA75 (Table 17.3 of Design of Machine Elements by Faires) Considering the design factors of section A V-belt on Design of Machine Elements by Faires: (17) Rated hp = [a (103/Vbelt)0.09 (c/KdDsheave2) b(Vbelt2/106)][Vbelt/103] where:

a is 2.684, b is 0.0136, c is 5.326 Kd is 1.14

Solving eq. (17) Rated hp = [2.684 (103/2,656.66)0.09 (5.326/(1.14)(3)) 0.0136(2656.662/106)][2656.66/103]

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Rated hp = 2.14 hp/strand Adjusted hp = Rated hp KKL = 2.14hp/strand(0.87)(1.02) Adjusted hp = 1.90 No. of V-belts = Design hp/Adjusted hp = (2.68 hp)/(1.90 hp/strand) No. of V-belts = 1.4 2 strands Considering the calculations made with the required pump power input to transport the rain water from the man-made pond to the elevated tank, the wind pumps mechanism can operate a centrifugal pump with a standard specification of: Pump Power Input = 1.5 hp 2 hp
Pump Speed 3,382 rpm

Maximum head of at least 150 ft

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MATERIALS AND COSTING (Gears, shafting, bars, and rods are all AISI 4340 and rods and bars are available 20 ft max

62 TOTAL COSTING: Php 108,630.00

Chapter V
Summary, Conclusions and Recommendations

5.1 Summary The researchers have gathered data and information from different references and existing studies to broaden their ideas and wind energy and how to harness it efficiently using a wind pump. Since typical windmills seldom operate a centrifugal pump, the group studied and considered numerous theories and principles to come up with a patented and feasible design of the mechanism. Also, ocular inspections were done by the researchers at Caleruega so that actual conditions of the site will be used to arrive at more accurate results. Moreover, the researchers collated formulas on aerodynamics and machine design to support their design through mathematical computations. 5.2 Conclusion To justify the design of the windmills mechanism, the pump power requirement was compared to the power that the mechanism can supply. Hence, based on the calculations made, the power transmitted by the mechanism met the power requirement of the centrifugal pump. Also, the

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mechanism produced a high shaft speed that is needed to require a centrifugal pump and attain the required total dynamic head.

5.3 Recommendation The researchers recommend a more precise and accurate data gathering in the location. Testing wind speeds must be done over a period within the location in order to get better results in computations. Also, it is important to know the time and duration when the wind velocity is at its peak. The researchers also recommend conducting experiments and tests. Since most of the formulas are based on theories, conducting experiments will further support the wind pump design. Also, the researchers recommend some additional set ups on the design when it is needed. Upgrading the design when needed may be costly but it will save money in the future. Examples of these upgrades are the overrunning clutch and the gear train mechanism.

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INDICATE REFERENCE SOURCES OF THE PICS/IMAGES IN THE REVIEW OF RELATED LIT BIBLIOGRAPHY AFTER CHAPTER V FOLLOWED BY THE APPENDICES AND CVs

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