manual - BVSDE
Contents
1. natural sands and gravels infiltration gallery aa R graded gravel os _ around pipe 3 It is always preferable to exploit ground water sources as these are naturally better protected from contamination than surface sources The pumps can only be readily used for ground water sources where the water level will not drop below 7m from the surface when pumping The static water level when pumping is not taking place will be above this The pump should be fixed a small distance from the well to help prevent contamination of the water by fuel and oil spillage and to maintain the stability of the well The strainer should be suspended just above the bottom of the well in order to avoid sucking sand The foot valve provided has an external diameter of 80mm P2 and 100mm P4H amp P4 and can be used in shallow cased tubewells just greater than these diameters 4 If no groundwater source is immediately available a good alternative is the exploitation of a surface water source by filtration through bed sediments This can be done as shown here by constructing a well in the bank of the stream and making sure that this is connected to the stream besd by a continuous sand layer This method may yield water even when there is none evident on the stream surface as much is stored in the bed sediments 5 In order to improve flows from surface and subsurface sources use may be made of an infiltration gallery A perforate2. Pumpsets Kestrel 101 Briggs and Stratton petrol lightweight pumpset kit Oxfam code PR2 ALBS approximate gross weight 52kg amp volume 0 24m8 Item Qty Part no Description 1 1 35 3 124 Seal complete 2 2 35 3 107 Body Gasket 3 1 35 3 117 Impeller Cl 275 4 2 35 3 181 Impeller locking nut 5 1 35 3 182 Spring lock 6 1 35 3 183 Locking nut joint 7 1 35 3 160 Sunk key 10 x 8 x 56 8 1 35 3 121 Ball bearing 6308 2RS1 9 1 35 3 122 Ball bearing 6307 2RS1 10 1 35 3 108 Non return valve Description KESTREL 101 2 Self priming pump of thermoplastic construction fitted with long life carbide carbon mechanical seal and BSP male steel outlet and inlet sockets flanged coupled to a Briggs amp Stratton 085432 4 HP Vanguard OHV petrol engine complete with low oil protection mounted inside a tubular steel roll over frame with anti vibration mounts 6M length of 50mm lightweight vinyl suction hose 15M length of 50mm layflat delivery hose 2 BSP female high impact polypropylene hose coupling with a 90 degrees bend 2 BSP female high impact polypropylene hose coupling straight 50mm push on thermoplastic filter footvalve 2 hose clips Briggs and Stratton Operations Manual Tool kit comprising spark plug spanner screwdriver and oil drain plug spanner 0 6 litre containers of start up engine oil each container allowing 1 complete refill Empty 5 litre plastic petrol can Spa
3. e Take particular care to exclude all dirt and debris from the fuel injection equipment while it is being serviced e Take extreme care to exclude dirt from all jointing surfaces and keep jointing compound away from all tapped holes unless otherwise specified e It is recommended that all oil seals are replaced once they have been removed from their original position Seals must be fitted square in the housing and all lip seals must be fitted with the lip facing the lubricant to be retained A service tool should be used to install seals and care must be taken to prevent damaging the new seal when it passes over shafts e Before fitting a new oil seal it is important that the recess in the seal is filled with Shell Alvania R2 Grease this is a Lithium Grease to NLG1 No 2 consistency Alternatively immerse the seal in engine lubricating oil at ambient temperature for 24 hours e When re assembling an engine it is always advisable to renew gaskets washers and nuts and bolts that have been taken from high stress locations in particular nuts and or bolts from connecting rods and cylinder heads should be renewed e All nuts bolts setscrews and studs with damaged threads must always be replaced Using a tap or die to repair damaged threads may impair the strength and closeness of fit of the threads and is not recommended Do not allow grease or oil to enter a blind threaded hole as the hydraulic action present when the bolt or stud is
4. such as flooded situation which would increase the total system pressure over the maximum limit Do not exceed the maximum speed Ensure that there are no quick closing valves in the system which could generate hydraulic shock Ensure that there are no sudden obstructions of the discharge line such as a vehicle driving over the hose Do not run the pump dry and always ensure that the pump body is filled with water before starting up the pump The lifting plates fitted to the engine are designed for lifting the engine and the fitted accessories They must not be used to lift complete pump assemblies 23 SECTION D DETAILS OF KITS AND SUPPLIERS Full list of kit contents 2 Atalanta Swallow 2100 Lister AC1 pumpset kit with hose Oxfam code P2 ALLI approx gross weight 300 kg amp volume 1 95 m8 Item Qty Description 1 1 Atalanta Swallow 2100 2 single stage centrifugal self priming pump Lister Petter AC1 single cylinder air cooled diesel engine with crank handle start 2 1 Connection accessories comprising set Suction 80mm Footvalve SOCLA 2543 3 Hose clamp 3 jubilee clip 30M x 3 R forced PVC Flexible Medium Duty hose 1 3 BSP F MI Hose coupling with Hose clamp fitted to above 1 3 M to 2 F BSP Reducer GS 10 3 Hose coupling washers Discharge 1 2 BSP F Gate Valve 1 3 M to 2 M BSP Nipple GS 1 3M x 3 Transparent PVC Medium Duty Hose 5 bar Hose ee
5. towards stop and hold in this position e Move the engine control to the RUN position e fa variable speed control is fitted move the speed control lever towards the fast position e Crank the engine really fast When sufficient speed is obtained move the decompressor lever down and continue to crank until the engine fires retaining a firm grip on the starting handle Remove the handle from the engine e Where a speed control is fitted reduce the speed as required e To stop the engine close the discharge valve and move the engine control to STOP and wait until the engine comes to rest Warning Never stop the engine by using the decompressor lever Valve damage may occur 15 Operational problems The most common problems occur on the suction side of the pump The most likely causes are lack of pump prime or blockages Lack of prime is due to air getting into the suction hose which may be caused either by leaking joints or by lack of water at the source All pipe joints should be regularly checked but beware of over tightening plastic fittings If the source is being pumped dry adjust either the pump yield or the daily pumping periods Check regularly that the foot valve is operating satisfactorily and is not being blocked open by sand and gravel Cavitation damage can be caused to the pump by running with air being sucked in Blockages may occur at the suction strainer due to sand and silt when pumping from
6. 10mm Each Oxfam pump kit contains a single pump but it is strongly recommended that there are sufficient pumps immediately available on site to ensure continuing of the water supply during periods of breakdown maintenance and repair This is essential for the emergency situations for which they are primarily designed where good maintenance facilities and the necessary skills and consumables are often unavailable There should normally be one standby pump for each three service pumps except for sites with few pumps when a standby will be required for each pump Note Persons responsible for the equipment covered in this manual must ensure that it is properly and safely installed and maintained and operated at the specified conditions Only appropriately qualified staff applying acceptable standards of engineering practice and the recommendations contained in this document must be employed in these activities Any similar instructions for the overall plant in which the equipment is to be incorporated which have an influence on the equipment and application must also be followed Statutory and local requirements concerning work practices safety and or health precautions must be observed Determining pump output Pump performance or output flow measured by litres second or m hr will be determined by e Pump performance varies from pump type PR2 P2 P4 P4H and speed of engine operation e Total pumping h
7. 3 124 Seal complete 1 35 3 107 Body gasket ENGINE CONSUMABLE SPARE SETS EACH TO COVER 2 000 HOURS OPERATION EACH SET COMPRISING Qty Part Number Description 1 657 29521 Decarb joint set 4 751 18100 Fuel filter element 8 201 55370 Lubricating oil filter 4 366 07188 Medium duty type air cleaner element Description Engine Service Manual and illustrated parts list 1 Pump Operator s Manual Parts List 1 Oxfam Pumping Pack Manual Oxfam Code PPM 1 Packing List including Oxfam s User s Notes Each to be placed in individual grip seal bags 5 litre jerry can of start up oil E Lister TS3 Engine overhaul kit with agglomerator 6000 Hours operation Oxfam code PE4H LI approx gross weight 18kg amp volume 0 05m Item Qty Part no Description 1 1 027 08221 T series workshop manual 2 6 657 29521 Decarbonising joint set 3 24 351 29760 Fuel Filter element 4 48 201 55370 Lubricating oil filter 5 12 366 07188 Medium duty dry type air cleaner element 6 6 570 31370 Big end bearing 7 12 201 80300 Con rod bolt 8 12 270 00778 Con rod nut 9 6 570 12910 Piston ring set 10 3 201 30181 Inlet valve guide 11 3 201 30171 Exhaust valve guide 12 3 201 30040 Inlet valve 13 3 201 30051 Exhaust valve 14 9 201 81395 Fuel injector nozzle 15 2 202 3054 Sump joint 4 Atalanta Condor 1001 D275 Pump major repair kit Oxfam code PS4H PS approx gross weight 3kg amp volume 0 03m 2
8. 4 hose coupling washers 10m 4 reinforced flexible medium duty suction hose Discharge 3 BSP F brass gate valve NP16 3 swing check valve NP16 4 F x 3 F BSP reducing socket 12m rolls PTFE tape 3 bolted hose clips 3 BSP M hex nipple 3 BSP F bend 3 BSP F hose coupling 3 hose coupling washers 4m x 3 of 10 bar rated rubber reinforced hose pre fitted with 2 x 3 F BSP hose couplings 3 1 set Mounting bolts 4 M10 x 100mm rag bolts nuts and washers 4 3 8 x 3 coach screw and washers 3 2 2 0 3 NAWA A Pump spares set for one year operation comprising Seal complete Inlet Gasket Clack valve Outlet Gasket Body Gasket Ring Plug Plug Washer Engine consumable spare sets each to cover 2000 hours operation comprising Decarbonising Joint Set Lister Fuel Filter Element Lubricating Oil Filter Medium Duty Dry Type Air Cleaner 6 Documentation 1 Lister Petter standard handbook and master parts book 1 Atalanta handbook operating instructions amp parts book 1 Oxfam Pumping Manual code PPM 1 Packing list and copy of Oxfam Users Notes 5 litre jerry can of start up oil O a 7 1 For 4 Atalanta Condor 1001 D275 Pump major repair kit see p 27 Lister TS2 engine overhaul kit with agglomerator 6000 hours operation Oxfam code PE4 L1 approx gross weight 15kg amp volume 0 05m Item Qty Description il 1 T S
9. Clean the fuel injector nozzles if the exhaust is dirty Renew fuel filter element if the fuel is not perfectly clean 12 Renew the fuel filter element 1000 hours 13 Decarbonise if the engine shows loss of compression or blow by past the piston do not disturb otherwise 14 Adjust the valve clearances with the engine cold 15 Clean the cylinder and cylinder head fins under dusty conditions 2000 hours 16 Decarbonise the engine 5000 hours 17 Major engine overhaul if necessary 2months 18 Dismantle pump and examine for wear The general outline given above is based on Lister Petter engines Reference should be made to manufacturers manuals supplied with each pump for details and for other manufacturers Comprehensive information concerning routine maintenance can be found either in the Operator s Handbook or Workshop Manual supplied with the pump sets Lubrication The pumps are equipped with a mechanical seal which is lubricated by the liquid being pumped always ensure body is full of liquid before starting The bearings are sealed for life which is normally 25 000 hours and require no attention but should be replaced in case of noise or premature wear 20 Routine maintenance schedule CODE PR2 ALBS Light Weight Self Priming Pump Powered by an Air Cooled Petrol Engine Always disconnect battery cables and spark plug wire from spark plug before performing any maintenance operation requiring disassembly of the pump
10. along the frame under the engine to provide additional lifting points Complete with discharge hardware support bracket supplied loose 2 1 Connection accessories set comprising SUCTION Qty Description 2 3 BSP hexagon nipple GS 1 4 BSP F hose coupling malleable iron 2 4 bolted hose clamp 4 jubilee clip 1 4 F x 3 F BSP reducing socket GS 10 4 hose coupling washers 1 10m x 4 reinforced PVC flexible medium duty low toxic suction hose pre fitted with hose coupling and 4 100mm SOCLA foot valve type 317 cat no 2546 Extra fittings provided in case water is being pumped directly from an Oxfam tank so foot valve would not be used in this case k 25 2 sets DISCHARGE Qty Description 1 3 BSP F brass swing check valve 2 3 BSP F brass gate valve with cast iron handle 4 12m rolls PTFE tape 12mm wide 3 3 bolted hose clamps 86 x 91mm 5 3 BSP hexagon nipple GS 2 3 BSP F bend GS 2 3 BSP F hose couplings malleable iron 1 3 BSP M hose coupling malleable iron 10 3 hose coupling washers 1 4m length of 3 10 bar rated rubber reinforced hose suitable for potable water pre fitted with 2 x 3 F BSP hose couplings and clamps 1 3 BSP F equal tee GS Qty Description 6 M10 x 100mm rag bolts washers and nuts 6 3 8 x 3 coach screws and washers Qty Part Number Description 1 35
11. deployment in a few hours Increasingly the nature of work which Oxfam has been called on to undertake has required equipment that can rapidly deployed then dismantled and moved to other locations This has led to the development of the so called rapid response kits since the mid 1990s This type of equipment is seen as a necessary complement to the original Oxfam equipment and is best used to provide a start up package in the absence of a detailed assessment and where affected populations are likely to be highly mobile The relatively higher equipment costs and lack of suitability for anything other than short term water supply means that the deployment of the rapid response kits should be used only where appropriate Read this manual through before starting installation Contents SECTION A EQUIPMENT USE AND DESIGN Determining pump output NN SECTION B LIST OF KITS AND INSTRUCTIONS FOR USE 7 Water pumping kits 7 Installation instructions 9 SECTION C COMMISSIONING OPERATION SAFETY amp MAINTENANCE INSTRUCTIONS 14 Commissioning 14 Operational problems 15 Maintenance 17 Safety precations 22 SECTION D DETAILS OF KITS AND SUPPLIERS 23 Full list of kit contents 23 List of suppliers 27 Final reminders recommendations and acknowledgements SECTION A EQUIPMENT USE AND SYSTEM DESIGN The Oxfam Water Pumping equipment is designed to be sufficiently versatile to provide pumps suitable for most emergency situation
12. flat and distribution mains run long distances It is recommended that either a P2 or P4 be used for this the actual selection made on the basis of pump availability and more importantly on correct sizing using the design principles outlined in Section A The connection into a 3 distribution network is made with a 32mm MDPE pressure relief bypass pipe not provided in this kit The fittings provided in the pump fittings kit Code PF can be used for this and the kit should only be ordered for this purpose or as in 10 above 12 storage tank air valve H water meter w wash out valve 13 roof to protect pump from sun rain pump Maximum pressure fluctuation above and below dynamic pressure on instantaneous valve closure or power failure Pipe pressure fall rise e g when material per metre per velocity is 2 second of m s pressure velocity in pipe change in in metres head metres head MDPE These values will be greatly reduced when using diesel engines as the inertia of the engine will slow the effective rate of closure 12 The design of any pumping main should take into consideration the following points over and above the basic system design outlined in Section A a Avoid creating peaks in pipelines which can cause air to become trapped unless air valves are fitted b You may need to include washout branches and valves where pumped water is dirty c Water meters may be
13. gives the output expected from the pump Examples Example 1 A PR2 pump will deliver 3 5 litres through 15 metres of 50mm hose with a 20 metre lift height difference filling a T11 tank in 48 minutes Example 2 A P2 pump will deliver 9 I s through 100 metres of 90m pipe with a 10 metre lift height difference filling a T45 tank in 83 minutes Example 3 A P4 pump will deliver 15 I s through 1000 metes of 110mm pipe with a 10 metre lift height difference filling a T45 tank in 50 minutes Examples 4 amp 5 A P3H pump will deliver 17 5 l s through 100 metres of 90mm pipe or 15 5 litres sec through 500 metres of 110mm pipe with a 50 metre lift height difference filling a T45 tank in 43 or 48 minutes respectively NB Pump curves shown are at 100 metres above sea level and 25 C 1 bar 10 metres head of water approx Where available pumps are inadequate due to lack of head or output two or more pumps can be connected to increase their capacity to try to match system requirements If two pumps of the same type are connected in series the pumping head is doubled where they are connected in parallel the output is doubled When starting pumps in series the pump nearest the water source should be started first The following curve illustrates the effect of placing two pumps in parallel and also shows the effect of high suction heads for this particular pump Suction losses are discussed further in the f
14. oe oo 2 3 BSP F Hose Couplings MI fitted to both ends of above 2 3 Hose clamp fitted to above 5 3 BSP Hex Nipple G S 1 2 F Swing Type Check Valve brass 3 3 BSP F 90 Degee Bend G S 2 3 BSP F Hose Coupling MI 2 3 Hose clamp fitted to above 10 3 Hose Coupling Washers 3 10m Roll PTFE Tape 12mm wide 3 1 Mounting Bolts set 4 M10x 100mm rag bolts washers and nuts 4 3 8 x 3 coach screws and washers 4 1 Pump spares for 1 year operation set comprising 1 Seal complete 1 Inlet Gasket clack valve 2 Plug Washer 1 Wear Plate 2 Prime Plug 5 2 Engine consumable spare sets each to set cover approx 2 000 hours operation s comprising 1 Decarbonising Joint Set HH OW Fuel Filter Element Oil Filter Element Air Filter Element Joint washer Documentation set Lister Petter standard handbook and master parts list Atalanta operating instructions and parts list Oxfam Pump Pack Manual code PPM Packing list and copy of Oxfam Users Notes 5 litre jerrycan with startup oil Lister AC1 engine overhaul kit Oxfam code PE2 LI approximate gross weight 8kg amp volume 0 07m Item Qty Description 1 1 Gov Shaft Bush 2 1 Flanged Bush Ss 1 Small End Bush 4 2 Nozzle 5 2 Nozzle Seal Washer 6 2 Valve Guide T 2 Valve 8 2P Collets 9 2 Valve Spring 10 2 Relief Valve Assembly 11 1 Main Bearing F W E 12 1 Main Bearing Gear End 13 1 Camshaft Bush G
15. screwed in could split or stress the housing e To check or re torque a bolt or nut it should be slackened a quarter of a turn and then re tightened to the specified value e On nuts with identification marked on one face the frictional area of that surface will be reduced therefore the nut should be fitted with the unmarked face towards the component e t is sound engineering practice to tighten bolts or nuts holding cylinder heads sumps covers and doors diagonally This will ensure the component is pulled down square resulting in less chance of oil seepage from the joint e After any maintenance work on the engine has been completed the lubricating oil and fuel levels must be checked and all safety guards replaced before starting e Warning Damage will be caused to the flywheel fan if it is used to turn the crankshaft Lubricating Oil Specification for Pump Engines Lister Petter amp Briggs and Stratton 1 These engines must be run on heavy duty lubricating oils meeting the requirements of AP1 CC MIL L 46152A B MIL L 2104B or DEF2101 D Straight mineral oils are not suitable neither are oils of less detergency than specified Generally a multi grade 15W 40 as supplied in the Pumping Pack Oil Kit Code PO will be suitable for all engines except where ambient temperatures consistently fall below freezing when a lower grade should be used 2 API CD MIL L 21 04C D or Series 3 oils can inhibit the running in process
16. with the P4 and P4H All pumps are now provided with oil as part of the kit though only limited quantities are provided for the P2 P4 and P4H pump engines and it will be necessary to order further quantities of the correct oil separately Code PO except for low temperature locations The Pump Fittings Kits Code PF provides additional fittings to allow pumps to be connected in parallel see below Tools for initial installation are provided in the Site Tool Kit Code OS Comprehensive tool kits are also available Kits OE Engineers and OM Mechanics The Pump Kits include sets of consumables and essential spares for minimum 1 year operation 2000 hours at 5 to 6 hours per day for one year and maintenance of both the engine and the pump based on operation in fairly unfavorable dusty site conditions with minimal maintenance support service This period can be extended if site conditions are more favorable The lightweight pump has spares for 500 hours Experience has shown that it is unnecessary to order a Major Repair or Overhaul Kit for every pumpset supplied On sites where a number of pumps are to be deployed it is suggested that initially one Overhaul Kit be ordered for every 5 or more pumps supplied Ultimately the appropriate quantity of overhaul or specific spares to be ordered has to be judged against the actual need and the site conditions such as competence of mechanics workshop facilities maintenance and repai
17. 1 With engine stopped check level and condition of engine oil 2 Remove chaff and debris from cylinder head fins and recoil starter finger guard 3 Check fuel supply 4 Check clack valve on pump inlet has free movement 5 Drain water from pump flush and fill with clean water NB If there is any chance of frost water should be drained immediately after use 6 Check and clean suction hose filter foot valve if fitted 7 Replace or clean sparking plug 8 Clean air cleaner elements 2 No 9 Check governor linkage spring and controls clean and lubricate as necessary 10 Drain lubricating oil refill with correct type and grade of oil Check for leaks tightening nuts and fittings as necessary 11 Change air cleaner elements 12 Carbon deposits should be removed from top of cylinder cylinder head top of piston and around valves General The Kestrel engine driven pump is of glass reinforced polycarbonate GRP construction with a semi open clog resistant impeller and a Buna N Nitrile rubber mechanical seal with carbon ceramic or carbon carbide faces designed for general purpose pumping and dewatering It is compatible with most nonflammable liquids with temperatures of 4 49 C and will handle solids in suspension up to 11mm Comprehensive information concerning Routine Maintenance can be found in the Operating Instructions and or Owner s Manual supplied with each pumpset The routine servicing and maintenan
18. BLE SPEED OPERATION 35 VARIABLE SPEED OPERATION 30 30 TOTAL HEAI w M v 8 TOFAL HEAD Bi M 0 5 10 15 20 25 30 35 40 45 50 0 5 10 15 20 25 30 35 40 45 50 FLOW Cubic Metres per Hour M3 Hr FLOW Cubic Metres per Hour M3 Hr 8 10 99 7 P4 Osprey 422 P4H Condor 1001 LISTER TS2 AIR COOLED DIESEL ENGINE LISTER TS3 AIR COOLED DIESEL ENGINE LIQUID WATER SPECIFIC GRAVITY 1 0 LIQUID WATER SPECIFIC GRAVITY 1 0 5 VARIABLE SPEED OPERATION VARIABLE SPEED OPERATION 70 240 30 60 2200 R Ph 25 50 c Ln L me z 20 20 te 4 g ORB 5 z m _ Z m ire 30 He Be fa Ls x SRA I I Z d mK 10 LE 20 Le e 2 guess 5 10 aito 99 snoa 0 20 40 60 80 100 120 140 160 180 200 0 10 20 30 40 50 60 70 80 90 100 FLOW Cubic Metres per Hour M3 Hr FLOW Cubic Metres per Hour M3 Hr Pump system curves Je Total Head metres N 0S le e O Flow litres second For direct comparison the curves for the 4 pumps have been superimposed on one graph above and also combined with system curves for particular lengths of pipe Where the pump curve crosses the system curve for the particular installation this defines the duty point and this
19. Oxfam Water Supply Scheme for Emergencies This equipment is part of several packages devised by the Oxfam Public Health Engineering Team to help provide a reliable water supply for populations affected by conflict or natural disaster The equipment is designed to be used with any or all of the following Oxfam water equipment Water Storage equipment Water Coagulation and Disinfection equipment Water Filtration equipment Water Distribution equipment Well Digging equipment and Water Testing Kit All are designed using available easily transported equipment which is simple rapidly assembled and fully self contained to provide an adequate safe water supply at moderate cost The principles used in these packages may often be useful in long term development projects The Oxfam equipment packages which consist of Oxfam tanks steel sheets rubber liners diesel water pumps 3 PVC pipes etc have been used successfully in the last two decades in often harsh environments ranging from tropical to temperate climatic areas Although this equipment is designed for emergencies if installed and protected adequately it can give many years of useful service though some up grading works will be necessary to prolong its life This equipment can be dismantled and re used elsewhere However these Oxfam equipment packages while being simple to erect over a period of days yet durable enough to last several years do not lend themselves to very rapid
20. cant and fit the clip close to the end of the hose It is important that the washer supplied is used with female hose couplers and that PTFE tape is used to seal all threaded joints All joints on the suction side of the pump must be completely airtight otherwise the pump will not operate and this is why a jubilee clip is supplied in addition to the bolted hose clamp which on its own will not provide an airtight seal 7 The delivery connection to the storage tank may be made entirely using flexible hose or by connecting to a rigid pipeline If connecting to an Oxfam storage tank the inlet may be made by using the standard 3 flange connector assembly to which the hose may be coupled directly or as shown here by passing over the rim of the tank 8 A gate valve is provided to act as a throttle if it is wished to reduce the pump yield because of insufficient inflow to the water source This valve will also aid in priming the pump if it is closed after pump operation and opened after restarting Pumping against a fully closed valve must be avoided other than for pump starting and stopping A non return valve must be included to reduce back flow through the pump especially if two pumps are working in parallel inlet pipe pipe support 11 32mm PE pipe 12 9 It is very important that the pump is securely fixed to the ground The pump may be bolted to heavy timber which is pegged to t
21. ce periods given are based on average operating conditions Under very dusty conditions air cleaners lubricating oil and fuel filters will require more frequent attention Decarbonising may be required more frequently when engines are running on light loads for long periods OXFAM PUMP RUNNING HOURS RECORD AND SERVICE SCHEDULE NAME OF OPERATOR PUMP TYPE P2 P4H P4 PR2 PUMP NUMBER LOCATION No Running Next Items Oil Fuel Notes hours total service serviced checked consumption problems running date numbers as added over period per schedule litres hr 22 Safety precautions Ensure the engine is securely mounted Ensure that there is an adequate supply of cooling and combustion air available to the engine Never operate a diesel engine or standard electric motor powered unit in an explosive atmosphere near combustible materials or where insufficient ventilation exits Ensure the engine and surrounding area is kept clean Ensure all safety guards are in position Keep clear of all moving or hot parts and secure any items of loose clothing Never allow any unprotected part of the body to come into contact with high pressure fuel oil for example when testing fuel injection equipment Thoroughly clean any lubricating or fuel oil from the skin as soon as practicable after contact Rectify all fuel and oil leaks as soon as practicable Clean fuel and oil spillage as soon as they occur Some of the mat
22. d pipe is buried in the riverbed surrounded by graded gravel and sand and connected to a collection chamber in the stream bank from which the water is pumped The yield may be increased by construction of a subsurface dam a wall across the riverbed which blocks the subsurface flow The dam would be located down stream from the infiltration gallery details of suction pipe reducing bush if required bolted hose clamp SOCLA foot valve amp strainer jutilee clip hose connector tank wall right angle male outlet female hose connector priming gate valve non return valve 3 2 reducer if needed 11 6 Pumps are supplied with foot valves and coarse strainers and 10m lengths PR2 has 6m of reinforced flexible suction hose The length should be kept as short as possible in order to increase efficiency For optimum performance the P4 and P4H pump design is based on using 4 suction pipework and this hose should be used However if the pump has to be sited more than 10m from the source then a longer length of pipe than is available with the kit will be required and 3 fittings are provided so a longer length of the more commonly used 3 pipe can be fitted However reduction in size in the suction pipework will result in significant drop in pump performance Cut hose with a hacksaw as square as possible to aid fitting to connectors Push the hose fully onto the connector using pipe grease as a lubri
23. ead consisting of static head and friction head losses in pipes e Suction lift e Engine derating to allow for operating conditions temp altitude and humidity The four sections show a number of graphs and a brief explanation is provided to help assess how much water can be pumped in a particular situation Pump performance The performance curves for each of the four pumps PR2 P2 P4 P4H are shown on page 3 and these show the variation of output with head for a range of engine speeds To find out the actual output for any particular installation i e pumps and pipes and where they are will be laid it is necessary to calculate the friction head losses within the system and measure the height to which the water will be delivered static head Head losses are calculated using the head loss diagram for uPVC and PE pipes provided in the Distribution manual The pumping curves for pumps can then be used to read off the output flow at any given head for each of the pumps and at given engine give some change in pump output Once operating speeds The engine are supplied with adjusted to give an acceptable output this a variable speed control movement of which will control should be locked to avoid tampering PR2 Kestrel 101 P2 Swallow 2100 40 40 B amp S AIR COOLED PETROL ENGINE LISTER AC1 AIR COOLED DIESEL ENGINE LIQUID WATER SPECIFIC GRAVITY 1 0 LIQUID WATER SPECIFIC GRAVITY 1 0 ae VARIA
24. ear End 14 1 Camshaft Bush Inter 15 1 Camshaft Bush F W E 16 1 Large End Bearing 17 2 Con Rod Bolt 18 2 Crank Thrust Washer 19 1 Camshaft Thrust Washer 20 1 Tabwasher F W Nut 21 1 Tabwasher F W Nut 22 1 Star Tolerance Ring 23 2 Piston Ring Set Std 24 3 Decarbonising Joint Set 25 3 Conversion Joint Set 26 12 Fuel Filter Element 27 12 Joint Washer 28 12 Air Filter Element 29 24 Lub Oil Filter Element 30 1 Lister Petter AC1 Workshop Manual 2 Atalanta Swallow 2100 pump major repair kit Oxfam code PS2 Al approx gross weight 4 4kg amp volume 0 03m 24 Item Description Seal complete Inlet gasket clack valve Plug washer Prime plug Wear plate Shim Impeller beat Gd te nang see eal S lt 1 2 3 4 5 6 7 4 Atalanta Osprey 422 pumpset kit Lister TS2 engine and hose Oxfam code P4 ALLI approx gross weight 559kg amp volume 2 57m8 Item Qty 1 1 Description Atalanta Osprey 422 diesel pumpset comprising 4 x 4 centrifugal self priming pump 4 screwed BSP M suction and discharge connections Lister Petter TS2 twin cylinder air cooled diesel engine with handle start 2 1 set Connection accessories Suction 2 4 BSP F hose coupling 4 100mm SOCLA footvalve type 317 4 bolted hose clips 4 jubilee clip 4 F x 3 F BSP reducing socket 3 BSP M hex nipple 4 BSP M hex nipple
25. eeds and leaves which could damage the pump and make treatment more difficult A perforated drum may be covered with filter fabric code FX Silt intake can be reduced by floating the intake clear of the bed of the river suspended no less than 0 3m below the surface any less and vortices may form anchored against strong currents The pump must be set above the river flood level or provision made for it to be raised lowered or slid as necessary to keep it above the river level while keeping the length of suction hose as short as possible see 6 Below 2 An alternative is to mount the pump on a pontoon This is difficult to operate but does have the advantage of uniform low suction head The pontoon must be securely anchored Fixings must be sufficiently strong to resist sudden floods and anchor ropes along enough to allow for rises and falls in level Continuous movement of the pontoon gives rise to flexing and movement of the delivery hose which can lead to connections becoming loose and damage to the hose Alternatively the pump could be mounted on a fixed platform above the water well cover to avoid contamination y static water StS rE level lowest level during pumping i trench filled i with aaa min water i L level gravel around perforated section of lining buried min 500mm below surface water _ QQ catchment well slotted or perforated pipe
26. ement of air Liquid drips where shaft enters the pump Cee a a A casing F 3 pump chamber not filled with 1 Damaged mechanical seal 2 po before start up g Pump makes an excessive noise 2 1 Cavitation in pump because suction lift is too engine not running high or restricted 2 alcolrectspecd 2 Pump not secured to firm foundation g 3 Restricted suction line UE air leaks in suction pipe 2 a joint or couplings 10 5 l fa suction hose not S 5 eS completely immersed D in water amp 2 air lock in suction pipe can increase priming time blocked filter or suction hose pumping rate reduces as total head increases Maintenance e Wear protective overalls and keep items of loose clothing clear of all hot and moving parts Use protective barrier cream when necessary e Whenever possible clean components and the surrounding area before they are removed or dismantled e Service Tools are designed to aid the dismantling and assembly procedures and their use will prevent unnecessary damage to components It is recommended that Service Tools are always used some operations cannot be safely carried out without the aid of the relevant tool e Decarbonising the engine is usually carried out at 2000 hours unless the engine shows signs of loss of compression e When re assembling an engine it is always advisable to apply a small quantity of new lubricating oil to all moving parts
27. engine before attempting to start The lead acid batteries are normally supplied fully charged but dry Before use fill cells with dilute sulphuric acid specific gravity 1 23 in tropical countries 1 28 elsewhere Fill the engine sump with clean oil of the recommended grade After completing the installation including fixing the pump securely and supporting the suction and delivery hoses ensure that the suction hose is well submersed in water Fill the suction hose with water and prime the pump by filling with water through the priming hole in the pump outlet Close the discharge valve though the pump can be started against a closed discharge valve this should only be permitted for a short time aS operating it against a closed head for more than 5 10 minutes will risks damage to the pump or a steam explosion Pump the water produced in the first few seconds to waste to flush out any debris and traces of oil rust inhibitor If the pump does not operate within five minutes from first starting the engine re check that all pipe joints on the suction side are airtight as any air in the hose will prevent satisfactory pump operation When the pump is operating adjust the yield to suit both demand and the supply available at the source Minor adjustments may be achieved by changing the engine speed but if this gives insufficient reduction use a throttle valve on the delivery side of the pump to introduce an artificial increase in head Aft
28. er making such adjustments lock the speed control and remove the hand wheel of the valve to make sure they cannot be tampered with Bury hoses and pipes wherever possible in order to reduce damage Shading is particularly important in hot climates as high temperatures reduce engine efficiency Ensure that both initial and regular maintenance of the pump and engine is carried out by a competent mechanic according to makers instructions Regular replacement of oil fuel and air filter elements is essential as is changing of engine oil Check the level of engine oil every day or more frequently if running for prolonged periods Keep the engine running at the recommended speed and ensure that fuel used is of good quality Use the filter funnel provided when filling the tank Fuel consumption should range from 1 1 litres nour for the PR2 and P2 pumps to 3 6 litres hour P4 and 4 6 litres hour P3H at 75 full load at lower altitudes The following lists the sequence of operations and checks to be made in order to start the engine Starting any diesel engine can be dangerous in the hands of an inexperienced person Before starting the operator must understand the engine controls and have been instructed in the correct starting procedures e Ensure the engine is free to turn without obstruction e Check that the fuel and lubrication oil levels are correct e Ensure the fuel system is primed e Move the decompressor lever s
29. erials used in the manufacture of filters and elements could give off toxic gases if they are burnt The materials used in the manufacture and treatment of some filters may cause irritation or discomfort if they come into contact with the eyes or mouth Used liquid filters and elements contain some of the filtered liquid and should be handled and disposed of with care After handling new or used elements the users hands should be thoroughly washed particularly before eating Some engines may be fitted with seals of O rings manufactured from VITON or a similar material When exposed to abnormally high temperatures in excess of 400 C 752 F an extremely corrosive acid is produced which cannot be removed from the skin If signs of decomposition are evident or if in doubt always wear disposable heavy duty gloves These pumps should only be used to pump clean or slightly polluted water and some mild chemicals between temperatures of 4 C and 80 C Do not pump flammable liquids such as petroleum based products Observe all safety precautions for the handling of fuel and never refuel an engine whilst it is still running The pump body must not be subjected to more than the rated internal pressure 14 bar for P4H 10 bar for P4H 5 bar for PR2 The pumps themselves cannot develop more pressure when operating at their normal speed maximum speed of 2 590 rpm 3 600 rpm for PR2 therefore Ensure that there is no high positive suction pressure
30. eries Workshop manual 2 3 Decarbonising joint set 3 12 Fuel filter element 4 24 Lubricating oil filter 5 3 Medium duty dry type air cleaner element 6 4 Big end bearing 7 8 Con rod bolt 8 8 Con rod nut 9 4 Piston ring set 10 2 Inlet valve guide 11 2 Exhaust valve guide 12 2 Inlet valve 13 2 Exhaust valve 14 6 Fuel injector nozzle 15 2 Sump joint 4 Atalanta Condor 1001 Pumpset Kit Lister TS3 engine and hose Oxfam code P4H PSLI approx gross weight 812kg amp volume 3 49m Item Qty Description ils 1 Atalanta high head diesel pumpset comprising PUMP 1 No CONDOR 1001 D275 4 x 3 centrifugal self priming pump in cast iron construction with mechanical seal Bare shaft configuration with 4 screwed BSP M suction and 3 BSP M discharge connections ENGINE 1 No Lister Petter TS3 3 cylinder air cooled diesel engine with 12 volt electric start emergency starting handle charging alternator and battery pack dry type air filter 13 5 litre fuel tank variable speed control agglomerator oil and fuel filters and exhaust silencer Pump and engine are coupled together with a FENNER HRC110 flexible coupling and mounted on a fabricated steel skid type baseplate with suitable lifting holes and drilled for 6 x M10 holding down bolts 2 No 50mm diameter holes to be drilled opposite each other through each side of the base frame approximately one third of the way
31. he ground The packing case bottom sections are designed as temporary foundations and can be used initially for a short term solution Within a few weeks more substantial foundations should be provided For the different pumps with their different weights this would require the following sizes of concrete slab P2 1 1 x 0 8 x 0 15m P4 1 5 x 1 0 x 0 2m P4H 1 8 x 1 3 x 0 25m The anchor bolts supplied with the pump should be cast into the slab using a wooden template to simulate the pump skid to ensure they are fixed at the right centres and preferably with the bolts welded to steel reinforcing bars Once the concrete has properly cured the pump can be positioned and tightened onto the slab The inlet and outlet houses should be supported close to the pump in order to prevent damage to the connections through vibration These supports should be put into place as soon as possible unless the installation is temporary 10 This arrangement allows one pump to be used as duty pump and the other as stand by It also allows doubling of flow rate when both are pumping simultaneously The fittings provided in the pump fittings kit Code PF can be used and the kit should only be ordered for this purpose or as in 11 below as the standard range of fittings included in the pump kits is sufficient for most uses illustrated in the Pumping Pack Manual 11 Where required pumps can be used for pumping directly into distribution network if the site is
32. helpful for pumped water quantity measurement d Be aware of the effects of water hammer especially for the P4 and P4H pumps see below 13 Where pump instaltions are likely to be used for more than a couple of weeks a suitable roof should be provided to protect the pump from the effects of rain and sunlight A simple shelter of plastic sheeting offers the quickest solution and may be adequate in all but snowy or very windy conditions Where the pump house is to be provided with walls adequate arrangements must be made for venting exhaust fumes outside of the building The pump house should be large enough to provide allow good access for the pump operator and strong enough to provide security where this is an issue Surge water hammer Serious changes in pressure occur when there is a sudden change of flow in a pipe This is most often observed when electric pumps stop due to power failure or sudden trips caused by level controls The approximate maximum theoretical values are shown in the table If these values are likely to cause excessive over pressure or vacuum conditions then a detailed computer analysis should be commissioned Pipes can normally sustain twice their rated working pressure for such transient conditons SECTION C COMMISSIONING OPERATION MAINTENANCE AND SAFETY INFORMATION Commissioning Follow maker s instructions shown in the engine manual enclosed with the kit for commissioning the
33. ht the following situation can develop Water gradually leaks back through the check valve and the pumps into the suction hose where it can go no further due to the footvalve Then the pressure in the suction hose which has a low pressure rating builds up until it reaches the static pressure in the system up to 60m with a P4H and the suction pipe starts to leak Closure of the discharge valve after turning the pump off will prevent this situation occurring a mechanical seal failure 6 7 Pump primes but does not deliver rated capacity Check 1 to 7 above 1 Check static height and resistance between inlet of suction line and outlet of discharge line Ensure that total system head is not greater than rated head Engine speed too low Outlet valve partially closed 16 Pump uses too much power Failure to prime pump 1 Check for debris in pump 2 Coupling out of alignment This diagram shows some of the reasons why a 3 Speed too high pump may fail 4 Impeller or bearings are binding Note If engine is operating in conditions much above 25 C and or 100m above sea level it will lose power and may become overloaded symptoms black exhaust emission and labouring To reduce load reduce speed below that indicated on rating plate and or reduce output by partially closing a valve on the pump discharge blocked discharge d hose or nozzle a Residue water in long discharge hose can restrict the displac
34. in new or reconditioned engines They are not suitable for engines running on low duty cycles but can be recommended for engines running at a high load factor particularly in conjunction with high ambient temperatures after the first oil change They must also be used if the sulphur content of the fuel exceeds 0 5 3 The Briggs and Stratton engine uses a high quality detergent oil classified for service SE SF SG specifically a SAE 30 oil Air cooled engines run hotter than automotive engines and the use of a multi vicosity grade oil will result in high oil consumption and possible engine damage If the use of multi grade oils is necessary the oil levels should be checked more regularly Storage of pumps If the pump set is to be taken out of service for a long period of time carry out the following procedures Drain all the liquid from the pump Clean and dry all components which have come in contact with liquid Spray the internal parts of the body especially around the impeller with light penetration oil such as WD40 or if this is not available flush body with diesel oil Grease the thread of the suction and discharge ports openings and tape off to keep dirt out of the pump body Store in a clean dry location away from vibration Turn the pump once every 30 days to prevent binding of the bearings and seal face sticking All of these pumps are designed for reuse and thus can be disma
35. is necessary to re order individual items please describe as specified in the above list and quote name and code of the kit in which the item occurs and specify part no and engine number for engine parts List of suppliers used by Oxfam based in the United Kingdom The Oxfam pump kits codes PR2 P2 P4H The oil kit kit codes PO and tool kits are P4 PS2 PE2 PS4H PE4H PS4 PE4 are Supplied by supplied by Kennedy International Ltd PO Box 14 Wigston PumpSets Ltd PO Box 1615 Andover Works Victoria Street Wigston Leicester Hampshire SP10 5NP LE8 1AJ Tel 01264 333737 Fax 01264 333108 Tel 01533 881616 Fax 01533 81239 The pump fitting kit codes PF is supplied by Evenproducts Ltd Oxtalls Farm Evesham Worcestershire WR11 4TS Tel 01386 41212 Fax 01386 765404
36. is should be avoided for all but shallow excavations as the exhaust fumes which collect in such confined spaces are very dangerous The engine exhaust pipe should extend to the open air at all times The following figures based upon use of Socla footvalves and curves may be relevant in calculating the final performance Flow rate in Dynamic Dynamic 10m of 3 suction head suction head pipework lossin 10mof lossin 10m of l s 3 pipework 4 pipework m m 10 1 0 0 5 15 1 6 0 8 20 2 5 1 1 25 1 4 Where the pump cannot be located less then 7m above the lowest water level then an alternative shaft driven electrically powered submersible or compressed air powered pump will be required with all the increased complications that such installations entail Oxfam stocks some of these pumps for such situations BPC progressive cavity borehole pump kit This is a progressive cavity fixed installation pump often used for deep boreholes BSP8 12 or 16 submersible pump kits driven by the electric motor in BSPE Submersible Borehole Pump Electric kit This electric submersible pump kit is intended primarily for use in deep boreholes though can be used in open wells where a shroud is used WPC Dewatering kit mobile air pump and compressor The well dewatering pump is specifically for use in well digging operations for water removal during digging WSDP Submersible Electrical Dewatering desludging Pump Ki
37. it 2 Pump Sets Kestrel 101 Briggs and Stratton Petrol Lightweight Pumpset Kit Pumping Pack Fittings for pumps in parallel or pumping into distribution Pumping Pack Oil Engineers Tool Kit mason carpenter building Mechanics Tool Kit for vehicle and engine maintenance Site Tool Kit for initial installation requirements The range of Oxfam pump kits PR2 kit P2 kit P4 kit P4H kit Installation instructions Pumping from a water source to storage pump set above outlet pipe river flood level i 7m max above river level floating alternative trench to prevent seepage of oil into river pipe support anchorage block primary screen pontoon preferably attached to both banks of river access for operation and maintenance enough slack on anchors to allow for rise in river level during floods 1 At the start of an emergency response there may be no alternative other than to use a surface water source directly In such cases it is inevitable that the water will be contaminated and some form of treatment will be necessary either by simple chlorination alone or combined with settlement which may be followed by filtration Water may be pumped directly from rivers or lakes with the coarse strainer set on the bed provided that a primary screen is improvised for example by use of a gravel filled perforated drum to avoid inflow of sand silt w
38. ntled and packed away for further use as required However particularly with the Oxfam pumps which have numerous components and some consumable materials such as PTFE tape dismantling and re boxing will have to be conducted with care All items should be checked back into boxes and ticked off against the original packing list and items replaced as required to make up a complete kit 19 Routine maintenance schedule CODE P2 P4H and P4 pumps and engines 1 Check and adjust if necessary tappet clearances Tighten nuts bolts and unions especially the fuel system Change oil 2 Check supply of fuel oil watch for dirty exhaust overload or faulty injectors 3 With the engine stopped check level and condition of lubricating oil 4 Clean the air cleaner if being used under very dusty conditions 5 Check clack valve on pump body flush and fill with clean water NB If there is any chance of frost water should be drained immediately after use 6 Check and clean suction hose filter foot valve if fitted 7 Check for mechanical seal leaks hoses for damage excessive noise or vibration all bolts for tightness and security of couplings 8 Clean or change the air cleaner element if being used under moderately dusty conditions 9 Check for fuel and lubrication oil leaks tightening nuts and fittings as necessary 10 Drain lubricating oil Flush out system renew filter element and refill with correct type and grade of oil
39. ollowing section Note that the curves shown represent the pump performance at sea level and at the maximum engine speed Prolonged and regular use at this speed is not recommended some reduction in the performance shown is thus inevitable Pumps in Parallel and Suction Curves 40 35 30 25 N oO 2 P4 pumps in parallel Head metres Flow litres second Total pumping head This has to be taken into account by measuring the following e Elevation difference between pump intake water level and final discharge level e Head losses in pipes and fittings Example system curves are shown on the graphs on pages 3 amp 4 which give outputs for particular pumps being used in_ particular situations Suction lift Suction pumps of this type have a maximum suction lift of 7m The practical and fuel efficient optimum should be considered as no more than 3m which is usually possible when pumping from shallow wells or surface water sources Use of higher than necessary suction lifts considerably reduce output and uses more fuel The pump efficiency is reduced both by suction lift see curve on page 4 and losses in the suction hoses Pumps should be located as close above the lowest expected water level as possible but beware of mounting pumps too close to rivers which are prone to rapid flooding It is often tempting to reduce the suction lift by sinking a pump into the ground Th
40. r practices duration of project etc The optional 6 000 hour Overhaul Kits for the Lister engines are coded PE2 LI PE4 LI and PE4H LI In cases where major damages occur e g cracked casing it may be more appropriate to replace than to repair the pump The optional major repair Overhaul Kit for the pumps are now coded PS2 AL PS4 AL PS4H PS Oxfam prefers to stock and supply pumps powered with Lister engines and these should be considered as the Oxfam standard However in some instances it may be more appropriate and necessary for Oxfam to supply pumps powered with Lombardini engines For this reason pumps powered with both engine types are used though normally pumps driven by Lister engines will be provided and only these are listed below This manual explains how to install and use the following kits detailed kit lists are provided in section D P2 ALLI PE2 Ll PS2 AL P4 ALLI PE4 LI PS4 AL P4H PSLI PE4H L1 PS4H PS PR2 ALBS Lister AC1 Engine Overhaul Kit 2 Atalanta Swallow 2100 Lister AC1 Diesel Pumpset Kit with Hose 2 Atalanta Swallow 2100 Pump Major Repair Kit 4 Osprey 422 Atalanta Pumpset Kit Lister TS2 Engine and Hose Lister TS2 Engine Overhaul Kit with agglomerator 6000 hours 4 Atalanta Osprey 422 452 Pump Major Repair Kit 4 Atalanta Condor 1001 Pumpset Kit Lister TS3 Engine and Hose Lister TS3 Engine Overhaul Kit with agglomerator 6000 hours 4 Atalanta Condor 1001 Pump Major Repair K
41. res for 500 hours operation comprising 1 spark plug 1 air filter element 1 air filter cartridge 1 right angle female coupling 1 straight female coupling 2 x 2 BSPT NPT barrel nipples 3 x 2 hose clips Oxfam Instruction Manual for Water Pumping equipment Oxfam Code Item Qty 1 1 11 1 set 12 1 set PPM 27 4 Atalanta Osprey 422 452 Pump major Pump Fittings Kit for pumps in parallel and repair kit bypass for pumping into distribution Oxfam code PS4 AL 1 Oxfam code PF approx gross weight 5kg amp volume 0 02m8 approximate gross weight 12kg amp volume Item Qty Description 0 01 ms is 1 Seal complete 2 1 Inlet gasket Clack valve hem Qty Description 3 1 Outlet gasket s ile 1 3 BSP M hose coupling 4 1 Body gasket 2 3 bolted h li 5 P Plug olted hose clip F i pile Wachee 3 2 3 BSP F tee 4 2 3 M x 1 F hex reducing TE 1 Impeller bush 8 1 O ring 5 1 1 BSP F brass ball valve 9 3 Shim 5 10 1 Impeller Washer e 1 BSP WM hex nipple 7 1 BSP M x 32mm PVC 11 1 Impeller Bolt i d compression coupling 8 4 12m rolls PTFE tape Pump Oil Kit Oxfam code PO approximate gross weight 66Kg amp volume 0 20m3 Item Qty Description alts 2 SAE 15W 40 Lubricating oil in 25 litre drum 2 1 Funnel and strainer 3i 1 20 Litre steel jerry can with lockable top and 2 spare washers Re ordering If it
42. s for drawing water from surface sources to provide the raw water for a potable water supply to pump clean water from one area to another or for loading and unloading water tankering trucks The Water Pumping equipment offers a range of three heavy duty self priming centrifugal pumps close coupled to reliable and economical diesel engines P2 for lower flows P4 for high flows and P4H for high flows at higher heads A lighter petrol driven pump PR2 is also available for carrying on water trucks or other mobile uses The individual pump curves are shown on page 3 The pump system curves are shown for the maximum performance available at full engine speed ideally the pumps should be run at slightly lower speeds than this Sufficient hoses and fittings are included to enable the pumps to be used either singly or in combinations for pumping water in a wide variety of situations It is necessary to select the right number and combination of pumps for a given situation These pumps are intended for immediate use in emergency situations They are not necessarily the best solution for longer term pumping needs Although the suction pumps are intended primarily for pumping clean water they will pump relatively turbid water with no problems in the short term They are not however intended for use as trash or sludge pumps and require some degree of protection from larger particles the strainers provided protect from particles larger than
43. t with Generator This very versatile light weight pumping kit has high solids and sludge handling capability which means it can be used in a variety of situations such as cleaning open wells flooded with debris desludging pit latrines and cleaning sediment out of water treatment tanks Engine de rating Altitude has a considerable effect on the efficiency of diesel engines as do both high temperature and humidity At altitude a loss of output of approximately 6 per 500m elevation above sea level will result In addition an output loss of 0 3 should be expected for every degree Centigrade above an ambient air temperature of 25 C and for each 10 rise in humidity above zero a further loss of 0 4 1 6 will occur Thus use at 2500m at 35 C with 50 humidity would result in a 36 loss in power which represents a similar drop in pump output for example a reduction from 4 I s to approximately 2 6 I s when pumping against 20m head Use the curves on page 6 to estimate the reduced output for a given location De rating of naturally aspirated diesel and petrol engines Engine De rating at Altitude 35 30 25 20 15 de rating 10 Alititude metres above sea level Engine De rating with Temperature and Humidity Percentage humidity Percentage humidity Percentage humidity Percentage humidity Percentage humidity Percentage h
44. the bottom of a well or river Either build better screening protection around the strainer or suspend it above the bottom When pumping from a river the strainer may become blocked by vegetation This can be avoided by use of a screen combined with regular cleaning Beware of completely emptying tankers and running pumps dry This can cause serious damage to the impellers Ensure that the engine fuel tank is kept regularly topped up with clean fuel If a diesel engine runs out of fuel it will be necessary to bleed the fuel system of air The standard fuel tanks should provide enough fuel for 3 4 hours running Fault checklist Special Note Most pump problems are caused by leaks in the suction line and fittings Pump does not prime or retain prime after operating 1 Ensure pump is full of liquid 2 Check suction line for leaks air locks and collapse Check discharge line for obstruction and open valves 3 Check pump and prime mover are operating at correct speed shown on pump rating plate Ensure that maximum static lift is less than 7m and length of suction line out of the pumping liquid is less than 10m to keep suction head losses low Check for clogged or worn impeller or wear ring If all the above have been eliminated suspect Note As the non return valves have metal to metal contact they do not provide a watertight seal and where there is a high static head in the system and the pumps are turned off at nig
45. umidity Percentage humidity Percentage humidity Percentage humidity Temperature C Diesel and petrol engines have similar de rating requirements Where petrol engines are overloaded due to high altitude humidity or temperature they will simply run at lower engine speeds and deliver less water Diesel engines will struggle more to maintain a speed when under the de rating effects of altitude humidity and or temperature Symptoms black smoke heavy with particulates from the speed by adjusting governor setting until these overload symptoms disappear It is a characteristic of a centrifugal pump that the lower the speed the less power is absorbed Note these graphs apply to naturally aspirated engines Turbocharged engines which are not normally used by Oxfam have exhaust and overheating around the manifold and cylinder head THE CURE Lower engine different derating requirements 1000 1500 2500 Percentage humidity 100 90 80 Percentage humidity 0 SECTION B LIST OF KITS AND INSTRUCTIONS FOR USE Water pumping kits Each of the Pump Kits contains all the fittings and hoses necessary for installation in most situations and this is standardised to 3 for discharge pipework for the P2 P4 and P4H pumps For optimum performance the P2 pump design is based on using 2 suction delivery pipework although for simplicity 3 suction discharge pipework is used 4 suction hose is provided
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