CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION Now a day the need of non renewable energy is increases day by day. But non renewable energy is exhaustible and it could be regenerated. Hence scientists and research scholars are involved a huge work to find the alternative way to compensate the need. At last they found that the improvement of renewable energy in the solution. Our project also based on renewable energy which comes under wind power. Our topic is WIND TURBINE COUPLED WATER PUMP. It is very much useful for agricultural purpose. The maximum efficiency we obtain from the wind power is nearly 64%. 1.2 SUMMARY & OBJECT OF THE INVENTION The present invention reduces the costs of converting wind energy into electricity by directly coupling windmills with water pumps that lift water from lower elevation to higher elevation where it is stored as potential energy. A primary application of this invention is at hydropower plants and dams. Winddriven pumps lift water from downstream, or tail water, to upstream, or headwater. An adjustable weir constructed downstream the water pump holds the water discharged from the turbine and creates a pool or lake from which water can be pumped. The weir can be lowered or rose using a computer. This way, the water flow can be managed to suit the wind and the hydropower plant operation. Any type of windmill can be utilized, although the vertical- axis type is preferred to the horizontal- axis type. This is because the former requires less connecting components and its tower is much smaller than that of the horizontal
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axis type. On the other hand, the horizontal- axis type can be built in larger units and can be more efficient. The object of the invention is to harness wind energy in an economical way and to improve the productivity and cost effectiveness of hydropower plants. Utilizing wind energy to directly rotate water pumps instead of generating electricity is advantageous in several respects: (1) Water pumps are far less expensive than the equipment that generates electricity. (2) Wind blows at a variable speed, sometimes gusting. While the electric generators powered by the windmills must rotate at a constant frequency, otherwise, electric appliances getting power from the windmills will burn. 1.3 FIELD OF THE INVENTION This invention describes a method and apparatus for economically converting wind energy into water potential energy by utilizing windmills coupled directly with water pumps to lift water from downstream to upstream of hydropower plant. This way, water can be used more than once to generate electricity. It is like recycling water. A major problem of existing hydropower plants is lack of water. In general, hydropower plants operate at only 35% capacity due to lack of water. In some years, the rainfall may be so scarce that the plant sits idly by most of the time. This is because the water used to generate electricity is discharged from the turbine where it flows away. Coupling windmills directly to water pumps is advantageous to using windmills to generate electricity in that water pumps are much cheaper than the equipment used to convert wind energy into electricity.

1.4 WIND ENERGY Energy is blowing in the wind. Wind power is actually another form of solar energy. A apparatus for converting the kinetic energy available in the wind to mechanical energy that can be used to power machinery (grain mills, water pumps, etc) and/or to operate an electrical generator. See also wind energy. Thanks to extensive R&D efforts during the past 30 years, wind energy conversion has become a reliable and competitive means for electric power generation. The life span of modern wind turbines is now 20-25 years, which is comparable to many other conventional power generation technologies. The average availability of commercial wind power plants is now around 98%. The cost of wind power has continued to decline through technological development, increased production level, and the use of larger turbines. The major components of a typical wind energy conversion system include a wind turbine, a generator, interconnection apparatus, and control systems. At the present time and for the near future, generators for wind turbines will be synchronous generators, permanent magnet synchronous generators, and induction generators, including the squirrel-cage type and wound rotor type. For small to medium power wind turbines, permanent magnet generators and squirrel-cage induction generators are often used because of their reliability and cost advantages. Induction generators, permanent magnet synchronous generators, and wound field synchronous generators are currently used in various high power wind turbines. Interconnection apparatuses are devices to achieve power control, soft start, and interconnection functions. Very often, power electronic converters are used as such devices. Most modern turbine inverters are forced commutated PWM inverters to provide a fixed voltage and fixed frequency output with a high power

quality. Both voltage source voltage controlled inverters and voltage source current controlled inverters have been applied in wind turbines. Water pumping systems were perfected in 1854, beginning with the Halladay, and continuing with the Dempster Design wind mills. By the end of the 19th Century, the first use of a windmill to generate electricity was a system built in Cleveland, Ohio, in 1888 by Charles F. Brush. In 1891, Dane Poul La Cour developed the first electrical output wind machine to incorporate aerodynamic design principles. In the century to follow, the integration of composite materials allowed for increased efficiencies and performance. Starting in the early 1990s increasing electricity costs spawned wind farms all over the world. The first windmills in Europe were developed in 1270 A.D. and were of the horizontal axis type. By 1390 A.D, the Dutch set out to refine the tower mill design and after 500 years of incremental developments the wind sails had all the major features recognized by modern designers. Wind mills were the electric motors of preindustrial Europe. A generator, whose function is to convert the shaft torque into electricity, This clearly illustrates that converting wind energy directly into electricity is elaborate and requires high initial costs. 1.5 WIND POWER The kinetic energy in the wind can be converted into different useful energy forms, such as mechanical energy or electricity. This is called wind power. It is a renewable energy resource that is under steady development worldwide. It is also said to be an absolutely clean source of energy, since there are no emissions or direct influences on the environment, except for the aesthetical. It can also produce disturbing noise while running. Wind power technology has come forward since the 12th century when the first windmills were built in Europe for grinding grains into flour. In 19th century
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America, windmills were used for pumping water at farms. Todays wind power stations are very advanced and use complex technology, but the old-fashioned type of windmill is still being built and used. It is common all over the world, especially in developing countries, but also among famers in America and Australia. One disadvantage with wind power is that it is unreliable, as the wind cannot be controlled. Hills and trees can reduce wind speed and cause the wind to change direction. With a suitable location and with good wind conditions, wind power is a good energy source. Wind power is the conversion of wind energy into a useful form of energy, such as using wind turbines to make electricity, windmills for mechanical power, wind pumps for water pumping or drainage, or sails to propel ships. A large wind farm may consist of several hundred individual wind turbines which are connected to the electric power transmission network. Offshore wind farms can harness more frequent and powerful winds than are available to land-based installations and have less aesthetic impact on the landscape but construction costs are considerably higher. Small onshore wind facilities are used to provide electricity to isolated locations and utility companies increasingly buy back surplus electricity produced by small domestic wind turbines. As the proportion increases problems arise such as increased costs, a need to use storage such as pumpedstorage hydroelectricity, a need to upgrade the grid, or a lowered ability to supplant conventional production Power management techniques such as excess capacity, storage, dispatchable backing supply.

CHAPTER 2

LITERATURE REVIEW
2.1WIND TURBINE A wind turbine is a device that converts kinetic energy from the wind into mechanical energy. If the mechanical energy is used to produce electricity, the device may be called a wind generator or wind charger. If the mechanical energy is used to drive machinery, such as for grinding grain or pumping water, the device is called a windmill or wind pump. Developed for over a millennium, today's wind turbines are manufactured in a range of vertical and horizontal axis types. The smallest turbines are used for applications such as battery charging or auxiliary power on sailing boats; while large grid-connected arrays of turbines are becoming an increasingly large source of commercial electric power. 2.1.1 SETTING UP A WIND TURBINE A site where average wind speed is 20 miles/hr might generate twice as much power as a site where average wind speed is only 15 miles/hr. Once you have decided that you are going to set up a wind turbine on your property, the following factors may also require your attention. Always remember that higher is better: ideally, your turbine should be thirty feet above any obstacles, with at least 300 feet of clear area around it. Wind consistency: An ideal wind turbine site has stable high speeds. Instability can put extra stress on the tower and other turbine elements.
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 Noise: There is some remaining prejudice against wind power regarding the noise of turbines. Innovations over the last few years made wind turbines far less noisy than those built in the early days of wind power. 2.2 WIND PUMP A wind pump is a windmill used for pumping water, either as a source of fresh water from wells, or for draining low- lying areas of land. Once a common fixture on farms in semi- arid areas, wind pumps are still used today where electric power is not available or too expensive. Windmills were used to pump water since at least the 9th century in what is now Afghanistan, Iran and Pakistan. The use of windmills became widespread across the Muslim world and later spread to China and India as well. Windmills were later used extensively in Europe, particularly in the Netherlands and the East Anglia area of Great Britain, from the late Middle Ages onwards, to drain land for agricultural or building purposes. Early immigrants to the New World brought with them the technology of windmills from Europe. 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. The multi-bladed wind turbine atop a lattice tower made of wood or steel hence became, for many years, a fixture of the landscape throughout rural America. These mills, made by a variety of manufacturers, featured a large number of blades so that they would turn slowly with considerable torque in low winds and be self regulating in high winds. A tower-top gearbox and crankshaft converted the rotary motion into reciprocating strokes carried downward through a rod to the pump cylinder below.

2.3 TYPES OF WATER PUMP

Fig 2.3.1 (multi- bladed wind pumps) "American", multi-bladed wind pumps, can be found worldwide and are manufactured in the United States, Argentina, China, New Zealand, and South Africa. A 16 ft (4.8 m) diameter wind pump can lift up to 1600 US gallons (about 6.4 metric tons) of water per hour an elevation of 100 ft with a 15 to 20 mph wind (2432 km/h) according to a modern manufacturer. A properly designed Wind pump begins working in a 3-4 mph (5 to 6.5 km/h) wind. Wind pumps require little maintenance, only a change of gear box oil annually an estimated 60,000 wind pumps are still in use in the United States. 2.3.2 ROTARY VANE PUMP

Fig 2.3.2(rotary vane pump)

A rotary vane pump is a positive-displacement pump that consists of vanes mounted to a rotor that rotates inside of a cavity. In some cases these vanes can be variable length and/or tensioned to maintain contact with the walls as the pump rotates. It was invented by Charles C. Barnes of Sackville who patented it on June 16, 1874. The simplest vane pump is a circular rotor rotating inside of a larger circular cavity. The centers of these two circles are offset, causing eccentricity. Vanes are allowed to slide into and out of the rotor and seal on all edges, creating vane chambers that do the pumping work. On the intake side of the pump, the vane chambers are increasing in volume. These increasing volume vane chambers are filled with fluid forced in by the inlet pressure. Inlet pressure is actually the pressure from the system being pumped, often just the atmosphere. On the discharge side of the pump, the vane chambers are decreasing in volume, forcing fluid out of the pump. The action of the vane drives out the same volume of fluid with each rotation. Multistage rotary vane vacuum pumps can attain pressures as low as 103 mbar. 2.3.3 VARIABLE DISPLACEMENT VANE PUMP

Fig 2.3.3(variable displacement vane pump) One of the major advantages of the vane pump is that the design readily lends itself to become a variable displacement pump, rather than a fixed displacement pump such as a spur-gear or a gerotor pump. The centerline distance
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from the rotor to the eccentric ring is used to determine the pump's displacement. By allowing the eccentric ring to pivot or translate relative to the rotor, the displacement can be varied. It is even possible for a vane pump to pump in reverse if the eccentric ring moves far enough. However, performance cannot be optimized to pump in both directions. This can make for a very interesting hydraulic control oil pump. 2.3.4 POSITIVE DISPLACEMENT PUMPS A positive displacement pump causes a fluid to move by trapping a fixed amount of it and then forcing that trapped volume into the discharge pipe. Some positive displacement pumps work using an expanding cavity on the suction side and a decreasing cavity on the discharge side. Liquid flows into the pump as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapses. The volume is constant given each cycle of operation. A positive displacement pump can be further classified according to the mechanism used to move the fluid. The positive displacement principle applies in the following types of pumps:

rotary lobe pump Progressive cavity pump rotary gear pump piston pump diaphragm pump screw pump gear pump Hydraulic pump vane pump
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2.3.5 ROTARY TYPE Rotary- type, internal gear, screw, shuttle block, flexible vane or sliding vane, helical twisted roots or liquid ring vacuum pumps. Positive displacement rotary pumps are pumps that move fluid using the principles of rotation. The vacuum created by the rotation of the pump captures and draws in the liquid. Rotary pumps are very efficient because they naturally remove air from the lines, eliminating the need to bleed the air from the lines manually. Positive displacement rotary pumps also have their weaknesses. Because of the nature of the pump, the clearance between the rotating pump and the outer edge must be very close, requiring that the pumps rotate at a slow, steady speed. If rotary pumps are operated at high speeds, the fluids will cause erosion, much as ocean waves polish stones or erode rock into sand. Rotary pumps that experience such erosion eventually show signs of enlarged clearances, which allow liquid to slip through and detract from the efficiency of the pump. 2.3.6 SCREW PUMPS

Fig 2.3.6(screw pumps)

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A screw pump is a positive displacement pump that use one or several screws to move fluids or solids along the screw(s) axis. In its simplest form, a single screw rotates in a cylindrical cavity, thereby moving the material along the screw's spindle. This ancient construction is still used in many low-tech applications, such as irrigation systems and in agricultural machinery for transporting grain and other solids. Development of the screw pump has led to a variety of multi-axis technologies where carefully crafted screws rotate in opposite directions or remains stationary within a cavity. The cavity can be profiled, thereby creating cavities where the pumped material is "trapped". Liquids flow into the pumps as the cavity on the suction side expands and the liquid flows out of the discharge as the cavity collapse. 2.3.7 GEAR PUMP

Fig 2.3.7 (gear pump)

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A gear pump uses the meshing of gears to pump fluid by displacement. They are one of the most common types of pumps for hydraulic fluid power applications. Gear pumps are also widely used in chemical installations to pump fluid with a certain viscosity. There are two main variations; external gear pumps which use two external spur gears, and internal gear pumps which use an external and an internal spur gear. Gear pumps are positive displacement , meaning they pump a constant amount of fluid for each revolution. Some gear pumps are designed to function as either a motor or a pump. 2.3.8 ROOTS- TYPE PUMPS

Fig 2.3.8 (roots- type pump) The low pulsation rate and gentle performance of this Roots-type positive displacement pump is achieved due to a combination of its two 90 helical twisted rotors, and a triangular shaped sealing line configuration, both at the point of suction and at the point of discharge. This design produces a continuous and nonvorticuless flow with equal volume. High capacity industrial "air compressors" have been designed to employ this principle as well as most "superchargers" used on internal combustion engines.
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2.3.9 PERISTALTIC PUMP

Fig 2.3.9 (peristaltic pump) A peristaltic pump is a type of positive displacement pump used for pumping a variety of fluids. The fluid is contained within a flexible tube fitted inside a circular pump casing (though linear peristaltic pumps have been made). A rotor with a number of "rollers", "shoes" or "wipers" attached to the external circumference compresses the flexible tube. As the rotor turns, the part of the tube under compression closes (or "occludes") thus forcing the fluid to be pumped to move through the tube. 2.3.10 RECIPROCATING- TYPE PUMPS

Fig 2.3.10(reciprocating- type pumps)

Reciprocating pumps are those which cause the fluid to move using one or more oscillating pistons, plungers or membranes (diaphragms). Reciprocating-type pumps require a system of suction and discharge valves to ensure that the fluid moves in a positive direction. Pumps in this category range from having "simplex" one cylinder; to in some cases "quad" four cylinders or more. Most reciprocating-type pumps are "duplex" (two) or "triplex" (three) cylinder. Furthermore, they can be either "single acting" independent suction and discharge strokes or "double acting" suction and discharge in both directions. The pumps can be powered by air, steam or through a belt drive from an engine or motor. This type of pump was used extensively in the early days of steam propulsion as boiler feed water pumps. Reciprocating pumps are now typically used for pumping highly viscous fluids including concrete and heavy oils, and special applications demanding low flow rates against high resistance. 2.3.11 IMPULSE PUMPS Hydraulic ram pumps A hydraulic ram is a water pump powered by hydropower. It functions as a hydraulic transformer that takes in water at one "hydraulic head" and flow-rate, and outputs water at a higher hydraulic-head and lower flow-rate. The device uses the water hammer effect to develop pressure that allows a portion of the input water that powers the pump to be lifted to a point higher than where the water originally started. The hydraulic ram is sometimes used in remote areas, where there is both a source of low-head hydropower, and a need for pumping water to a destination higher in elevation than the source.

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Velocity pumps Rotodynamic pumps are a type of velocity pump in which kinetic energy is added to the fluid by increasing the flow velocity. This increase in energy is converted to a gain in potential energy (pressure) when the velocity is reduced prior to or as the flow exits the pump into the discharge pipe. This conversion of kinetic energy to pressure can be explained by the First law of thermodynamics or more specifically by Bernoulli's principle. These types of pumps have a number of characteristics: 1. Continuous energy
2.

Conversion of added energy to increase in kinetic energy.

3. Conversion of increased velocity to an increase in pressure head. One practical difference between dynamic and positive displacement pumps is their ability to operate under closed valve conditions. Positive displacement pumps physically displace the fluid;hence closing a valve downstream of a positive displacement pump will result in a continual build up in pressure resulting in mechanical failure of either pipeline or pump. 2.3.12 CENTRIFUGAL PUMP

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Fig 2.3.12(centrifugal pump) A centrifugal pump is a rotodynamic pump that uses a rotating impeller to increase the pressure and flow rate of a fluid. Centrifugal pumps are the most common type of pump 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 or axially into a diffuser or volute chamber, from where it exits into the downstream piping system. Centrifugal pumps are typically used for large discharge through smaller heads. Centrifugal pumps are most often associated with the radial flow type. However, the term "centrifugal pump" can be used to describe all impeller type rotodynamic pumps including the radial, axial and mixed flow variations. Radial flow pumps It is simply referred to as centrifugal pumps. The fluid enters along the axial plane, is accelerated by the impeller and exits at right angles to the shaft (radially). Radial flow pumps operate at higher pressures and lower flow rates than axial and mixed flow pumps. Axial flow pumps Axial flow pumps differ from radial flow in that the fluid enters and exits along the same direction parallel to the rotating shaft. The fluid is not accelerated but instead "lifted" by the action of the impeller. They may be likened to a propeller spinning in a length of tube. Axial flow pumps operate at much lower pressures and higher flow rates than radial flow pumps. Mixed flow pumps Mixed flow pumps, as the name suggests, function as a compromise between radial and axial flow pumps, the fluid experiences both radial acceleration
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and lift and exits the impeller somewhere between 090 degrees from the axial direction. As a consequence mixed flow pumps operate at higher pressures than axial flow pumps while delivering higher discharges than radial flow pumps. The exit angle of the flow dictates the pressure head-discharge characteristic in relation to radial and mixed flow. 2.4 CHAIN DRIVE A chain is a power transmission element made as a series of pin-connected links. The design provides for flexibility while enabling the chain to transmit large tensile forces. When transmitting power between rotating shafts, the chain engages mating toothed wheels, called sprockets. Basic chain drive geometry

Fig 2.4 (chain drive) The most common type of chain is the roller chain, in which the roller on each pin provides exceptionally low friction between the chain and the sprockets. Other types include a variety of extended link designs used mostly in conveyor applications.

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2.4.1 ROLLER CHAIN Roller chain styles

Fig 2.4.1 (roller chain) Roller chain is classified by its pitch, the distance between corresponding parts of adjacent links. The pitch is usually illustrated as the distance between the centers of adjacent pins. Standard roller chain carries a size designation from 40 to 240. The digits indicate the pitch of the chain in eighths of an inch. For example, the no. 100 chain has a pitch of 10/8 or in. A variety of attachments are available to facilitate the application of roller chain to conveying or other material handling uses. Usually in the form of extended plates or tabs with holes provided, the chain attachments make it easy to connect rods, buckets, parts pushers, part support devices, or conveyor slats to the chain. The rating of chain for its power transmission capacity considers three modes of failure: 1. Fatigue of the link plates due to the repeated application of the tension in the tight side of the chain 2. Impact of the rollers as they engage the sprocket teeth 3. Galling between the pins of each link and the bushings on the pins.

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The ratings are based on empirical data with a smooth driver and a smooth load (service factor = 1.0) and with a rated life of approximately 15,000 h. The important variables are the pitch of the chain and the size and rotational speed of the smaller sprocket. Lubrication is critical to the satisfactory operation of a chain drive. Manufacturers recommend the type of lubrication method for given combinations of chain size, sprocket size, and speed. The standard sizes of chain are: no. 25 (1/4 in) no. 35 (0.375 in) no. 40 (1/2 in) no. 41 (1/2 in) no. 50 (0.625 in) no. 60 (3/4 in) no. 80 (1.00 in) no. 100 (1.25 in) no. 120 (1.5 in) no. 140 (1.75 in) no. 160 (2 in) no. 180 (2.25 in) no. 200 (2.5 in) no. 240 (3 in) These are typical of the types of data available for all chain sizes in manufacturers' catalogs. Notice these features of the data:
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2.5 SPROCKET

Fig 2.5 (sprocket) A sprocket is a profiled wheel with teeth, cogs, or even sprockets that mesh with a chain, track or other perforated or indented material. The name 'sprocket' applies generally to any wheel upon which are radial projections that engage a chain passing over it. It is distinguished from a gear in that sprockets are never meshed together directly, and differs from a pulley in that sprockets have teeth and pulleys are smooth. 2.6 BEARING A bearing is a device to allow constrained relative motion between two or more parts to only the desired type of motion. This is typically to allow and promote free rotation around a fixed axis or free linear movement; it may also be to prevent any motion, such as by controlling the vectors of normal forces. Bearings may be classified broadly according to the motions they allow and according to their principle of operation, as well as by the directions of applied loads they can handle. 2.6.1 PRINCIPLES OF OPERATION There are at least six common principles of operation: Plain bearing, also known by the specific styles: bushings, journal bearings, sleeve bearings, rifle bearings.
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 Rolling-element bearings such as ball bearings and roller bearings. Jewel bearings, in which the load is carried by rolling the axle slightly off-center. Fluid bearings, in which the load is carried by a gas or liquid. Magnetic bearings, in which the load is carried by a magnetic field. Flexure bearings, in which the motion is supported by a load element which bends. 2.6.2 MOTIONS Common motions permitted by bearings are:

Axial rotation e.g. shaft rotation. Linear motion e.g. drawer. Spherical rotation e.g. ball and socket joint. Hinge motion e.g. door, elbow, and knee.

2.6.3 TYPES OF BEARING a) Plain bearing A plain bearing, also known as a plane bearing or a friction bearing is the simplest type of bearing, comprising just a bearing surface and no rolling elements. Therefore the journal slides over the bearing surface. The simplest example of a plain bearing is a shaft rotating in a hole. A simple linear bearing can be a pair of flat surfaces designed to allow motion; e.g., a drawer and the slides it rests on or the ways on the bed of a lathe. Plain bearings, in general, are the least expensive type of bearing. They are also compact and lightweight, and they have a high load-carrying capacity.
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b) Rolling element bearing A rolling-element bearing, also known as a rolling bearing, is a bearing which carries a load by placing round elements between the two pieces. The relative motion of the pieces causes the round elements to roll with very little rolling resistance and with little sliding. One of the earliest and best-known rolling-element bearings are sets of logs laid on the ground with a large stone block on top. As the stone is pulled, the logs roll along the ground with little sliding friction. As each log comes out the back, it is moved to the front where the block then rolls on to it. It is possible to imitate such a bearing by placing several pens or pencils on a table and placing an item on top of them. c) Jewel bearing

Fig 2.6.3c (jewel bearing) A jewel bearing is a plain bearing in which a metal spindle turns in a jewellined pivot hole. The hole is typically shaped like a torus and is slightly larger than the shaft diameter. The jewel material is usually some form of synthetic sapphire, such as ruby. Jewel bearings are used in precision instruments, but their largest use is in mechanical watches. Historically, jewel pivots were made by grinding using diamond abrasive. Modern jewel pivots are often made using high-powered lasers, chemical etching, and ultrasonic milling.
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d) Fluid bearing

Fig 2.6.3d (fluid bearing) Fluid bearings are bearings which support the bearing's loads solely on a thin layer of liquid or gas. Hydrostatic bearings are externally pressurized fluid bearings, where the fluid is usually oil, water or air, and the pressurization is done by a pump. Hydrodynamic bearings rely on the high speed of the journal selfpressurizing the fluid in a wedge between the faces. Fluid bearings are frequently used in high load, high speed or high precision applications where ordinary ball bearings have short life or high noise and vibration. They are also used increasingly to reduce cost. For example, hard disk drive motor fluid bearings are both quieter and cheaper than the ball bearings they replace. Hydrodynamic bearings rely on bearing motion to suck fluid into the bearing and may have high friction and short life at speeds lower than design or during starts and stops. An external pump or secondary bearing may be used for startup and shutdown to prevent damage to the hydrodynamic bearing.

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e) Magnetic bearings

Fig 2.6.3e (magnetic bearings) A magnetic bearing is a bearing which supports a load using magnetic levitation. Magnetic bearings support moving machinery without physical contact; for example, they can levitate a rotating shaft and permit relative motion with very low friction and no mechanical wear. Magnetic bearings are in service in such industrial applications as electric power generation, petroleum refining, machine tool operation, and natural gas pipelines. They are also used in the Zippe-type centrifuge used for uranium enrichment. Magnetic bearings are used in turbo molecular pumps, where oil-lubricated bearings would be a source of contamination. Magnetic bearings support the highest speeds of any kind of bearing; they have no known maximum relative speed.
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f) Plummer block bearing housing

Fig 2.6.3f (Plummer block bearing housing) Solid Plummer block housings are housing that hold rolling element (ball) bearings. Their design elements include: Cast iron, cast steel, machined steel or rolled steel housing. Permits moderate initial misalignment. Simple, versatile and economic housing/bearing combination. Typical applications include: conveyor rolls, press rolls, conveyor deck etc.

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CHAPTER 3

DESIGN

3.1 DESIGN OF WIND TURBINE Wind turbines are designed to exploit the wind energy that exists at a location. Aerodynamic modelling is used to determine the optimum tower height, control systems, number of blades and blade shape.On most horizontal windturbine farms, a spacing of about 6-10 times the rotor diameter is often upheld. However, for large wind farms distances of about 15 rotor diameters should be more economically optimal, taking into account typical wind turbine and land costs. This conclusion has been reached by research conducted by Charles Meneveau of the Johns Hopkins University and Johan Meyers of Leuven University in Belgium, based on computer simulations that take into account the detailed interactions among wind turbines (wakes) as well as with the entire turbulent atmospheric boundary layer. Moreover, recent research by John Dabiri of Caltech suggests that vertical wind turbines may be placed much more closely together so long as an alternating pattern of rotation is created allowing blades of neighboring turbines to move in the same direction as they approach one another. 3.1.1 WIND TURBINE SIZING Two factors will contribute to the size of wind turbine: The amount of energy needed. The amount of wind energy available.
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In most areas, it is unlikely that a wind energy system will provide all your energy. Most residences will require. a turbine capacity between 1 and 5 kW. Farms or businesses will require at least 10 kW and perhaps as much as 50 kW, depending on the size and types of machines you have on site.

3.1.2 BLADE DESIGN The ratio between the speed of the blade tips and the speed of the wind is called tip speed ratio. High efficiency 3- blade turbines have tip speed/ wind speed ratios of 6 to 7. Modern wind turbines are designed to spin at varying speeds. Use of aluminium and composite in their blades has contributed to low rotational inertia, which means that newer wind turbines can accelerate quickly if the winds pick up, keeping the tip speed ratio more nearly constant. Operating closer to their optimal tip speed ratio during energetic gusts of wind allows wind turbines to improve energy capture from sudden gusts that are typical in urban settings. In contrast, older style wind turbines were designed with heavier steel blades, which have higher inertia and rotated at speeds governed by the AC frequency of the power lines. The high inertia buffered the changes in rotation speed and thus made power output more stable. The speed and torque at which a wind turbine rotates must be controlled for several reasons: To optimize the aerodynamic efficiency of the rotor in light winds. To keep the generator within its speed and torque limits. To keep the rotor and hub within their centripetal force limits. The centripetal force from the spinning rotors increases as the square of the rotation speed, which makes this structure sensitive to over speed.

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 To keep the rotor and tower within their strength limits. Because the power of the wind increases as the cube of the wind speed, turbines have to be built to survive much higher wind loads than those from which they can practically generate power. Since the blades generate more downwind force when they are producing torque, most wind turbines have ways of reducing torque in high winds. To enable maintenance; because it is dangerous to have people working on a wind turbine while it is active, it is sometimes necessary to bring a turbine to a full stop. 3.1.3 BLADE COUNT The determination of number of blades involves design considerations of aerodynamic efficiency, component costs, system reliability, and aesthetics. Noise emissions are affected by the location of the blades upwind or downwind of the tower and the speed of the rotor. Given that the noise emissions vary by the 7th power of blade speed, a small increase in speed can make a big difference. Wind turbines developed over the last 50 years have almost universally used either two or three blades. Aerodynamic efficiency increases with number of blades but with diminishing return. Increasing the number of blades from one to two yields a six percent increase in aerodynamic efficiency, whereas increasing the blade count from two to three yields only an additional three percent in efficiency. Further increasing the blade count yields minimal improvements in aerodynamic efficiency and sacrifices too much in blade stiffness as the blades become thinner. Component costs that are affected by blade count are primarily for materials and manufacturing of the turbine rotor and drive train. Generally, the fewer the number of blades, the lower the material and manufacturing costs will be. In
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addition, the fewer the number of blades, the higher the rotational speed will be. This is because blade stiffness requirements to avoid interference with the tower limit how thin the blades can be. Fewer blades with higher rotational speeds reduce peak torques in the drive train, resulting in lower gearbox and generator costs. System reliability is affected by blade count primarily through the dynamic loading of the rotor into the drive train and tower systems. While aligning the wind turbine to changes in wind direction, each blade experiences a cyclic load at its root end depending on blade position. 3.1.4 BLADE MATERIALS New generation wind turbine designs are pushing power generation from the single megawatt range to upwards of 10 megawatts. The common trend of these larger capacity designs are larger and larger turbine blades. Covering a larger area effectively increases the tip-speed ratio of a turbine at a given wind speed, thus increasing the energy extraction capability of a turbine system. Current production wind turbine blades are manufactured as large as 80 meters in diameter with prototypes in the range of 100 to 120 meters. In 2001, an estimated 50 million kilograms of fiberglass laminate were used in wind turbine blades. New materials and manufacturing methods provide the opportunity to improve wind turbine efficiency by allowing for larger, stronger blades. One of the most important goals when designing larger blade systems is to keep blade weight under control. Since gravity scales as the cube of the turbine radius, loading due to gravity becomes a constraining design factor for systems with larger blades. Current manufacturing methods for blades in the 40 to 50 meter range involve various proven fiberglass composite fabrication techniques. Manufactures such as Nordex and GE Wind use a hand lay-up, open-mold, wet process for blade manufactures. Other manufacturers use variations on this technique, some
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including carbon and wood with fiberglass in an epoxy matrix. Options also include prepreg fiberglass and vacuum-assisted resin transfer molding. Essentially each of these options is variations on the same theme: a glassfiber reinforced polymer composite constructed through various means with differing complexity. Perhaps the largest issue with more simplistic, open-mold, wet systems are the emissions associated with the volatile organics released into the atmosphere. Preimpregnated materials and resin infusion techniques avoid the release of volatiles by containing all reaction gases. However, these contained processes have their own challenges, namely the production of thick laminates necessary for structural components becomes more difficult. As the perform resin permeability dictates the maximum laminate thickness, bleeding is required to eliminate voids and insure proper resin distribution. A unique solution to resin distribution is the use of a partially preimpregnated fiberglass. During evacuation, the dry fabric provides a path for airflow and, once heat and pressure are applied, resin may flow into the dry region resulting in a thoroughly impregnated laminate structure. 3.1.5 TOWER HEIGHT The wind blows faster at higher altitudes because of the drag of the surface and the viscosity of the air. The variation in velocity with altitude, called wind shear, is most dramatic near the surface. Typically, in daytime the variation follows the Wind profile power law, which predicts that wind speed rises proportionally to the seventh root of altitude. Doubling the altitude of a turbine, then, increases the expected wind speeds by 10% and the expected power by 34%. To avoid buckling, doubling the tower height generally requires doubling the diameter of the tower as well, increasing the amount of material by a factor of eight.

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At night time, or when the atmosphere becomes stable, wind speed close to the ground usually subsides whereas at turbine hub altitude it does not decrease that much or may even increase. As a result the wind speed is higher and a turbine will produce more power than expected from the 1/7th power law: doubling the altitude may increase wind speed by 20% to 60%. A stable atmosphere is caused by radiative cooling of the surface and is common in a temperate climate: it usually occurs when there is a (partly) clear sky at night. When the (high altitude) wind is strong wind speed higher than approximately 6 to 7 m/s the stable atmosphere is disrupted because of friction turbulence and the atmosphere will turn neutral. A daytime atmosphere is either neutral or unstable.

3.2 SELECTION OF PUMP A number of parameters must be considered in designing the pumping systems irrespective of the type of pump. These parameters include head, capacity, and nature of liquid handled, piping, drives and economics. So, in general, discussion on these parameters applies equally well to centrifugal, rotary, or reciprocating pumps. Sometimes, the important concept of design economies, which originate with the project and continue through its useful life, is neglected during system planning. For example, careful study of head conditions and pump location may produce worthwhile power savings over a long period without a major increase in the first cost of the project. Wise choice of pipe sizes, based on predictable or estimated future loads, is another example of how careful design planning can be made to pay off in terms of operating economies. Piping for pumps can be conveniently classified into three
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broad categories suction, discharge, and auxiliary lines. The head to be developed in many installations is principally a function of the piping resistance, and so an extreme care is to be taken in choosing pipe size and arrangement. The success or failure of any pumping system is usually a direct function of the degree of suitability of its piping. 3.2.1 METHODS OF SELECTION Pumps are usually selected by any of the following three methods: (1) the prospective purchaser supplies one or more manufacturers with complete details of the pumping conditions and requests a recommendation and bid on the units which appear best suited for the conditions, (2) the purchaser makes a complete calculation of the pumping system and then chooses a suitable unit from current catalogs and rating charts .The essential data required by any pump manufacturer before a recommendation and bid can be prepared are: 1. Number of units required 2. Nature of the liquid to be pumped 3. Capacity 4. Suction conditions 5. Discharge conditions 6. Total Head 7. Location of installation 3.3 DESIGN OF CHAIN DRIVE For a given speed, the power capacity increases with the number of teeth on the chain sprocket. Of course, the larger the number of teeth, the larger the

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diameter of the sprocket. Note that the use of a chain with a small pitch on a large sprocket produces the quieter drive. The manufacturers ratings are for a single strand of chain. Although multiple strands do increase the power capacity, they do not provide a direct multiple of the single-strand capacity. The capacity for 2, 3, and 4 strand systems are 1.7, 2.5 and 3.3 respectively. The manufacturers ratings are for a service factor of 1.0. The designer must specify a service factor for a given application based on the type of driver and load for that system. The following are general recommendations for designing chain drives: The minimum number of teeth in a sprocket should be 17 unless the drive is operating at a very low speed, under 100 rpm. The maximum speed ratio should be 7.0, although higher ratios are feasible. Two or more stages of reduction can be used to achieve higher ratios. The center distance between the sprocket axes should be approximately 30 to 50 pitches. The arc of contact of the chain on the smaller sprocket should be no smaller than 120. The larger sprocket should normally have no more than 120 teeth. The preferred arrangement for a chain drive is with the centerline of the sprockets horizontal and with the tight side on top. The chain length must be an integral multiple of the pitch, and an even number of pitches is recommended.

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The center distance should be made adjustable to accommodate the chain length and to take up for tolerances and wear. Excessive sag on the slack side should be avoided, especially on drives that are not horizontal. A convenient relation between center distance (C), chain length (L), number of teeth in the small sprocket (N1), and number of teeth in the large sprocket (N2), expressed in pitches, is

The exact theoretical center distance for a given chain length, again in pitches, is

The theoretical center distance assumes no sag in either the tight or the slack side of the chain, and thus it is a maximum. Negative tolerances or adjustment must be provided.

3.4 SELECTION OF BEARING The most important factor to consider in bearing selection is a bearing that will enable the machine or part in which it is installed to satisfactorily perform as expected. When selecting a bearing, having an accurate and comprehensive knowledge of which part of the machine or equipment it is to be installed in and the operating requirements and environment in which it will function, is the basis
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for selecting just the right bearing for the job. In the selection process, the following data is needed. (1) The equipments function and construction. (2) Bearing mounting location (point). (3) Bearing load (direction and magnitude). (4) Bearing speed. (5) Vibration and shock load. (6) Bearing temperature (ambient and friction generated). (7) Environment (corrosion, lubrication, cleanliness of the environment, etc.).

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CHAPTER 4

FABRICATION

4.1 TURBINE BLADE 4.1.1 OVERALL DESIGN Once an operational speed has been chosen, the next step then is to establish the overall size. Depending on the operation range of the static pressure, medium to high, the hub diameter can vary from 30 to 80% of the blade outside diameter. 4.1.2 NUMBER OF BLADES The most important thing to take into consideration when talking about windmill blades is their number. The old ones normally had 4 very heavy blades. Majority of them were use in grain grinding. After that three blades became the most popular. More blades seemed to raise noise and slow down the rotation of the turbines propeller formation. After more research was done the perception of using more than three blades was no longer a factor. Currently, the most recent windmills are equipped with two or three blades. 4.1.3 BLADE WIDTH The width of the blades is measured along the intersection of a cylindrical surface with the blades. At the hub, the blades must be non- overlapping in order not to choke the airflow. Then, will be the blade width at the hub. In some designs, the blade width is constant all the way from the hub to the tip, but often it varies. 4.1.4 ALIGNMENT OF CHAIN DRIVE To obtain maximum service-life and efficiency from a chain drive, it is necessary that certain precautions in installation be taken. Chain drive installation
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is relatively simple and good results may be obtained when the following conditions are met:

1. The roller chain, sprockets, and other components are in good condition. 2. The sprockets are properly aligned. 3. Provision is made for adequate lubrication. 4. The chain is correctly tensioned. a) Condition of Components Shafting, bearings, and foundations should be supported rigidly to maintain the initial alignment. Roller chain should be free of grit and dirt. Wash chain in kerosene when required. b) Drive Alignment Misalignment results in uneven loading across the width of the chain and may cause roller link plate and sprocket tooth wear. Drive alignment involves two things: parallel shaft alignment and axial sprocket alignment. Shafts should be parallel and level. This condition may be readily checked by the use of a feeler bar, and a machinist's level. It there is axial movement of the shaft, lock the shaft in the normal running position before aligning the sprockets.

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Fig 4.1.1b1 (aligning shafts)

Sprocket axial alignment can be checked with a straight edge which will extend across the finished sides of the two sprockets. Normally, it is good practice to align the sprockets as close to the shaft bearing as possible. For long center distances, use a taut cord, or wire long enough to extend beyond each of the sprockets.

Fig 4.1.1b2 (aligning sprockets) c) Installing the Chain

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Recheck all preceding adjustments for alignment and make certain all setscrews, bolts and nuts are tight. Fit chain around both sprockets and bring the free ends together on one sprocket for connection, the sprocket teeth will locate the chain end links. Install the connecting link, and connecting link cover plate, and the spring clip or coffer pins. On larger pitch chains or heavy multiple strand, it may be necessary to lock the sprockets for this operation. After more research was done the perception of using more than three blades was no longer a factor. Currently, the most recent windmills are equipped with two or three blades. When press fit cover plates are used, be careful not to drive the plate on so far as to grip the roller links. Stiff joints can result if this is done. On drives with long spans, it may be necessary to support the chain with a plank or bar as the connection is made.

d) Chain Tension Check chain tension to be certain the slack span has 4-6% mid-span movement in horizontal drives and 2-3% in vertical drives.

Fig 4.1.1c (Chain tension) AC = Total Possible Mid-Span Movement Depth of Free Sag = .866 AB, approximately.
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4.3 ALIGNMENT OF PUMP In the pump business, alignment means that the centerline of the pump is aligned with the centerline of the driver. Although this alignment was always a consideration with packed pumps, it is critical with sealed pumps especially if you are using rotating seal designs where the springs or bellows rotates with the shaft. Misalignment will cause many problems: It can cause rotating mechanical seals to move back and forth axially two times per revolution. The more the seals move the more opportunity for the lapped faces to open. Packing could support a misaligned shaft. A mechanical seal cannot. Misalignment will cause severe shaft or sleeve fretting if you use spring loaded Teflon as a secondary seal in your mechanical seal design. The pump bearings can become overloaded. The wear rings can contact. The misalignment could be severe enough to cause contact between stationary and rotating seal components. The shaft can contact the restriction bushing often found at the end of the stuffing box. The impeller could contact the volute or back plate. The shaft or sleeve can contact the stationery face of the mechanical seal.

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Regardless of the alignment method you select, you must start with a pump and driver in good repair. A perfectly aligned piece of junk is still a piece of junk. You should also check the following: A straight shaft that has been dynamically balanced. Good wear rings with the proper clearance. The correct impeller to volute, or back plate clearance. The elimination of "soft foot". Eliminate all pipe strain. Good bearings installed on a shaft with the proper finish and tolerances. A good mechanical seal set at the proper face load. The closer the seal is to the pump bearings the better off you are going to be. All pumps to driver alignments consist of four parts: You must level the pump and driver. If the pump is aligned without being level, the oil level will be incorrect and you will develop bearing problems. You then take a series of radial and axial measurements to see where the pump is located in respect to its driver You make calculations to see how far the driver must be moved to align the centerline of the pump to the centerline of the driver. These calculations must consider that the pump and driver operating temperature will probably be very different than the ambient temperature when you are taking the readings.

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 Most pump manufacturers should be able to supply you with the proper readings for a hot alignment. They are the only people that know how their unit expands and contracts with a change in temperature. You must now shim and move the driver to get the alignment. Most of the small pump designs are not equipped with "jack bolts" so this will be the most difficult part of the alignment procedure. You cannot move the pump because it is connected to the piping. I see lots of pumps that have never been aligned properly. When you talk to the people that should be concerned, you get the following comments: Alignment is not important. I've been working with pumps for years and we never do it at this facility. There is no time to do an alignment. Production wants the unit back on line, and they will not allow me the time to do it properly. We purchase good couplings. The coupling manufacturer states that their coupling can take a reasonable amount of misalignment. 4.3.1 REVERSE INDICATOR METHOD

Fig 4.3.1 (reverse dial indicator)

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 Very accurate especially for small diameter flanges. Not affected by axial float. Can be used with a flexible coupling in place. You have to rotate both shafts. 4.3.2 LASER ALIGNING METHOD

Fig 4.3.2 (laser aligning method) The laser is the latest method. It is also the most popular. There are lots of people that can teach you to use the equipment, once you have made the purchase. 4.3.3 SHAFT TO COUPLING SPOOL METHOD

The best method when there are big distances between the shaft ends. A simple method to use. Most people rotate both shafts.

4.3.4 FACE AND RIM METHOD

Use this method if one of the shafts cannot be rotated. An excellent method for large shaft diameters (8 inches or 200mm or greater) or if the diameters are equal to, or greater than the span from the bracket location to the face and rim location where the readings are to be taken.
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Not too good methods if there is axial float from sleeve or journal bearings.

4.4 FRAME A frame is a structural system that supports other components of a physical construction, the frame which consists of several mild steel plates. All the plates are welded together. 4.5 WORKING When the air strikes on the turbine blade, the blade tends to rotate. Thus the shaft with sprocket also gets rotated, as the chain engages with the sprocket, the chain will slides over the sprocket. The pinion which is mounted to the pump shaft will rotates. Now the impellers provided inside the pump relates and it create a vacuum. Due to the vacuum water enters into the pump and get increases the pressure and flow through outlet, thus the water gets pumped out. 4.6 ADVANTAGES The following are the advantages of wind pump. Simple in design. Low cost is sufficient. Less maintenance. Low wear and tear. Pollution free method.

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CHAPTER 5

CONCLUSION
We successfully completed the prototype model of the WIND TURBINE COUPLED WATER PUMP for our design and fabrication project work. Through this project we came to know How to face a new project work. How to design and assemble. Know about the various components wind turbine and pumps.

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CHAPTER 6

REFERENCE

1) http://en.wikipedia.org/wiki/Wind_turbine 2) http://en.wikipedia.org/wiki/Windpump 3) http://en.wikipedia.org/wiki/Pump 4) http://www.brighthub.com/environment/renewableenergy/articles/7728.aspx 5) http://en.wikipedia.org/wiki/Wind_turbine_design 6) http://en.wikipedia.org/wiki/Bearing_(mechanical) 7) http://en.wikipedia.org/wiki/Chain_drive

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