INDIA MARK II

Installation and Maintenance Manual for

Hand Pump Technicians and Borehole

Caretakers

Action Against Hunger (ACF ) - Uganda Mission

ACF - WASH September 2010

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About this Manual This Manual is prepared by the Water, Sanitation and Hygiene (WASH) department of Action Against Hunger (ACF) to facilitate boreholes sustainability. This manual is not a standalone document but can be used with other operation and maintenance related documents.

Who is this manual for? This manual is prepared as an elementary guide for Hand Pump Technicians that are in-volved in the major and minor repairs of hand pumps in a community. It is also a useful guide for care takers who are from time to time required to carry out preventative mainte-nance work on the borehole/water point. Action Contre la Faim - International Network (ACF-IN) is a professional Non-Governmental organization (NGO) involved in the fight against hunger. It operates in four technical areas: nutrition and health, food security, water, sanitation and hygiene (WASH) and advo-cacy in order to help the most vulnerable populations regain their food autonomy as means to life without dependence on external help. In the Uganda Mission, there are programmes being implemented in Acholi and Lango Regions (Food Security, Nutrition & Health, WASH), and Karamoja region (Food security, Nutrition & Health and recently WASH). Across Northern Uganda where ACF operates, deep borehole wells are the most reliable and secure source of clean water for people. These simple and inexpensive technologies have revolutionized the way people in developing countries access water. Borehole wells allow people to tap into groundwater that is not accessible from the surface, as well as minimize the contamination of the water by surface pollutants by keeping it in a closed system until it reaches the spout. Borehole hand pumps use human power and mechanical means to move water in a one-way direction using a system of suction and discharge valves. The most common model of pump used in the region is the India Mark II hand pump originally manufactured in India by Apex Press.

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The Role of the Pump Mechanic

They are expected to render technical assistance to the community in maintaining their hand pumps

Regularly inspect boreholes functionality status at least once or twice every month

He/she should discuss with the WSSC issues pertaining BH status

During every inspection, necessary servicing (preventive maintenance) should be done

Ensures that the pump spares selected can give lasting solution to the existing problems

Maintain tools and a stock of spares to enable him/her to have a capacity to carry out repairs during routine maintenance visits and when called for hand pump repairers

The India Mark II Pump—Major Components The Handle Assembly – This is a long lever, which is connected to a piston in the pump (Pump Cylinder) that draws water up to the tap (spout). A longer hand lever can more effi-ciently draw water from a deeper well with fewer strokes. The Pedestal – This is the outside main body of the borehole, protection the parts inside. The Water Tank Assembly – This is the part where water from the pipes collects before it goes out through the spout. It is where the rising main is connected using thread in the riser pipe holder. The Pump Head Assembly – This houses many of the mechanical components of the bore-hole handle, including the pump-lever, chain, upper connecting rods, and the pivot. Connecting Rods and Rising Mains – These pieces usually come in 10 feet lengths and are threaded with male and female sockets to allow for connection for variable well depths. Con-necting rods are attached to the pump cylinder. This drives the pistons which draws water from the well. Riser pipes are usually 11/2-inch (40mm) diameter pipes that carry water up to the spout. Pump Cylinder – This is the main pump, which is set in the aquifer deep underground. In-cludes the plunger rod, upper and lower valves, rubber seating and sealing rubbers, brass liner, reducer caps and cylinder body. The depth that a pump is set is based on the desired yield rates. A minimum yield of 1-2 cubic meters per hour is usually targeted. One cubic me-ter is equal to 264 gallons.

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The Hand Pump Detailed Assembly

The below ground details are not included here but will be illustrated next page, in Figure 2.

Figure 1: Above ground parts of the India Mark II borehole assembly.

Riser Pipe

Connecting Rod

PVC Casing Pipe

Leg

Platform

Pedestal

Bolt, nut, washer & check nut

Water Tank Assembly

Head Assembly

Handle Assembly

Bearing

Axle washer, nut & check

Connecting Rod Check Nut

Riser pipe holder

Guide Bush

Chain Coupling

Maintenance Cover

Chain

Chain bolt & nut

Cover bolt washer

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This is the pump cylinder, which is set in the aquifer deep underground. The depth that a pump is set is based on the desired yield rates (flow rates). A minimum yield of 0.8-2.0 cubic meters per hour is usually targeted. One cubic meter is equal to 1000 liters.

Figure 2: Pump cylinder for the

India Mark II.

Below Ground Pump Cylinder

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How Boreholes Hand Pumps Break Down Hand pumps, like all mechanical assemblies tend to break down if not properly used, ne-

glected, or if overused. Long-term maintenance of rural water boreholes therefore has be-

come the most challenging task for governments and humanitarian aid organizations. In re-

sponse to this, ACF will work with beneficiaries to educate communities on proper mainte-

nance schedules for community boreholes.

Common mechanical borehole problems include:

Worn out handle assembly that is no longer properly connected to the chain and con-necting rods

Worn out bearings and bolts components in pump head assembly

Worn out pipes and leakage of the pipes.

Worn out sealing and rubber sealing rings

Riser pipes become corroded and disconnected.

Broken pedestal which can create unsanitary conditions inside the well

How boreholes can be maintained:

Ideally, a well is regularly checked and maintained by a trained pump mechanic whose du-

ties are to make sure major breakdowns do not occur, which could severely interrupt ser-

vice. This includes preventative maintenance to ensure a long life for the borehole.

A typical schedule of maintenance could involve the following:

Daily

Monitor pump operation and grease pump parts where necessary

Check for all loose nuts and tighten them when necessary

Avoid banging the borehole with the handle when pumping water

Fix any broken fencing (to keep animals out) and ensure that water point is clean

Weekly

Lubricate all joints and moving parts of the borehole

Check and tighten all nuts and bolts

Check security of pump on pedestal

Monthly

Check output rate

Check for condition of concrete apron

Yearly

Remove the pump cylinder and pipes from the well, inspect, replace any worn out parts.

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The tool set for maintaining the India Mark II Pump (Refer to the U2 and U3 installation manuals)

Tool Use Picture

Pipe/rising mains lifting spanner

For lifting or lowering the rising mains

Pipe vice, self locking clamp

For holding the pipes firm when tightening or loosening pipes, and when cutting the threads of the rising mains

Fixed/open ended spanner 17 x 19 (mm)

For connecting rod couplings, tightening and loosening bolts and nuts

Crank (axel rod) spanner 17 x 19(mm)

For tightening and loosening the chain, bolts and nuts

Connecting rod vice For holding the connecting rods

Pipe Die For cutting threads in the galvanized pipes

Connecting Rod Die For cutting threads in the connecting rods

Bearing pressing tool For fixing bearing

Hack saw For cutting pipes and rods

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The tool set for maintaining the India Mark II Pump (Refer to the U2 and U3 installation manuals)

Tool Use Picture

Rod lifter For lifting and lowering the rods

File For filing the top of connect-ing rods after cutting

Hammer ball point For driving out/in the handle axle bolt.

Pipe wrenches (600mm)or (450mm)

For tightening/enlightening of the rising mains during installation or dismantling of the pump.

Handle axle punch. Used to drive out the handle

axle bolt without damage to the threads.

A center punch Used to remove the broken

ball bearing from the bearing housing.

Oil can ¼ litre For cooling during cutting of treads.

Steel brush Used for brushing/ cleaning

the threads cut.

Coupling spanner Used for holding firm the

Nuts/ bolts when tightening or loosening

Chain supporting tool Provides support to the

chain

Screw driver For screwing the bolts for

the button dice.

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Repair and Rehabilitation Procedures For installing or dismantling a borehole, at least two trained people are required to oversee and guide the unskilled labour force. The technicians should ensure that they have a com-plete tool box with all the required tools for installing / dismantling including an extension rod of about 30-50cm length.

Various steps and tools are used for each step as illustrated in the U2-installation manual, which is expected to be in the training package (and beyond the scope of this training).

The Roles of the Water User Committee in ensuring the functionality of the Water Point

Mobilize community members to participate in water source protection e.g . Building

the fence, and regular cleaning of the surrounding.

Keep an updated list of the water users in the community.

Collect and keep contributions towards the construction cost and the O&M funds

Regularly visit and monitor the condition and performance of the water point

Verification of the purchase of materials needed for the repair or maintenance of the

water source.

Pay for any repairs carried out by a mason or hand pump mechanic.

Supervise and provide support to the water source caretakers.

The Roles of the Caretakers

Show people how to use the water point properly

Carry out regular maintenance of the water point e.g. sweeping and slashing around

the borehole.

Keeping record of all the maintenance work carried out on the source either directly

by the caretaker or by a (HPM) Hand Pump Mechanic, plumber or mason.

Mobilize community members to participate in maintenance activities e.g regular

cleaning of the surrounding of the water source, advice the community on regular

cleaning of containers both for storage and collection.

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The Standard Tools Required By a Community Hand Pump Mechanic 1. Button die to suit M12 x 1.75 threads 1 No.

2. Die set for 32/40mm N.B pipe 1 set.

3. 450 mm pipe wrench 2 No.

4. M17 x M19 double ended spanners (10mm x 12mm) 1 No.

5. 600 mm pipe wrench 2 No.

6. Screw Driver 300mm long 2 No.

7. 10 lb (ball Point Hammer) 1 No.

8. Hack saw frame and blade (300mm) 1 No.

9. Pressure type oil can (½ pint of oil) 1No.

10. Wire brush 1 No.

11.250mm half round file with handle 1 No.

12. 250mm flat file with handle 1 No.

13. Graphite and Lithium Grease 1 can

14. Adjustable spanner 1 No.

15. Nylon Rope (4 strung) 75 metres

General Maintenance Guidelines

The India Mark II deep well hand pumps are to be properly maintained to ensure safe pota-

ble drinking water to the community, without break down. Proper and regular maintenance

will prevent breakdowns as seen earlier in the booklet. The moving parts in the India Mark II

hand pump above and below the ground level are few and therefore simplifying the mainte-

nance of the hand pump.

The following schedule of maintenance has been drawn at fixed intervals and has been ex-

plained more elaborately.

1) Once in 30 days:

(i) Tighten the handle axle nut and lock nut

(ii). Look for loose or missing flange bolts and nuts

(iii). Open the front of the head cover and clean inside the pump.

(iv) Check the chain anchor bolt for proper fitment. Tighten if necessary.

(v). Clean the chain assembly. Apply graphite grease.

(vi). Look for rusty patches and clean them.

(vii). Check whether the hand pump base is lose in the foundation. In case it is loose

an arrangement should be made to redo the foundation.

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2) After 365 days (1 year)

(a) Examine the pump carefully and check whether:

(i) Discharge is satisfactory

(ii) Handle shaky and not firm

(iii) Guide bush has excessively worn out

(iv) All bolts, nuts and washers are in position

(v) Chain has worn out

(vi) Roller chain guide is excessively worn out

(b) Overhaul the pump and follow the instructions:

(i) If chain, bearing spacer are damaged, replace them

(ii) If roller chain is badly worn out, replace the handle assembly

(iii) If there are any damaged pipes have them replaced

(iv) Open out the cylinder assembly and replace cup washers, sealing rings and

other components found to be faulty

(v) Check the condition of the water tank riser holder. If the threads are worn

out, replace water chamber

(vi) Check for any other seam line failures or cracks

(vii) Re-install the pump as in the training

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No. Item Unit Price (UgX)

1 Pump Head Complete 150,000

2 Pump Handle 90,000

3 Chain 15,000

4 Ball Bearing 25,000

5 Water Tank 90,000

6 Cylinder Complete 250,000

7 Head Bolts 1,000

8 Head Nuts 1,000

9 Sealing Rings 2,000

10 Upper Valves Complete 20,000

11 Pump Buckets 3,000

12 Pipes 50,000

13 Connecting Rods 20,000

14 Lower Valves 20,000

15 Axle Bolts 7,000

16 Axle Nuts 1,000

17 Bearing Spacer 1,000

18 Washer 1,000

19 Chain Bolts 1,000

20 Chain Nut 1,000

21 Pedestal 150,000

22 Reducer Cap 3000

23 Plunger Rod 20,000

24 Rubber Seal (lower) 1,500

25 Rubber Sela l (upper) 1,500

26 Sockets 2,000

PRICES OF SOME OF THE MAJOR BOREHOLE SPARES PARTS

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S/

N

SIGN/DEFECT/INDICATION POSSIBLE CAUSE(S) REMEDY

1 Draws rusty water Pipes and the rods corrosions

Chemistry of water problems

Free the pipes and rod from corrsion

by developing/flushing the well.

2 Pumped out water containing

worms

Damaged casing

Improper sanitary seal

Poor well design

Chlorinate the well

Improve on the BH design.

3

Pump weightless and no water

Then at instant of breakdown

splash sound hardly.

Pipes/rods disconnected and

dropped.

Check for the pipes if the pipes are

dropped then Fishing out is re-

quired.

4 Pump weight is usual but no water

comes

Reducer cap disconnected and the

lower valve assembly dropped.

Complete cylinder dropped.

Cylinder yoke body disconnected

Dismantle and replace the lower

valve and the reducer cap.

Replace the whole cylinder.

Dismantle and reconnect it.

5 Pump is very light but no water

comes completely

Disconnection of rods at the joint Re-connect the disconnected rod.

6 Water takes very long to come even

after a brief stop over.

Worn out sealing rings or pump

buckets

Cracks on the rising mains

Replace the sealing rings and the

pump buckets.

Replace the damaged rising mains

7 Water only comes well during rapid

pumping

Pipe leakages

Worn out sealing and rubber sealing

rings

Replace leaking pipes or tighten the

pipes at the sockets.

Replace sealing rings

8 Unusual noise when pumping Lack of lubrication

Bearing crushing

Some Bolts and nuts are missing or

loosen

Top connecting rods is bent

Greasing

Replace bearing

Tighten the nuts or replace the miss-

ing nuts.

Remove and straighten the rod or

replace the rod.

9 Muddy or silt water pumps out Cylinder is too close to the well bot-

tom

Insufficient filtration of inflow water

by the gravel packs.

Reduce the cylinder depth –

depending on the yield of the well,

cylinders shouldn’t be installed at

least 6m from the bottom of the

well. Develop the well.

THE TROUBLE SHOOTING TABLE FOR COMMON PROBLEMS