DESIGN AND AUTOMATION OF AUTOMATIC BORE WELL

PIPE LIFTING SYSTEM

PROJECT REPORT 2013-2014

SUBMITTED BY
S.GOWTHAM
V.GUGAN PRABHU
V.HARIHARAN
N.JAGADESH KUMAR
JAISON.C.GEORGE
G.JAYA CHANDHRU
GUIDED BY
MR.F.ROBERT BELLARMIN B.E.,
Submitted in partial fulfillment of the requirement for the award of in diploma
in MECHANICAL ENGINEERING by the state board of technical education
government of tamilnadu Chennai.
CHRIST THE KING POLYTECHNIC COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING
COIMBATORE-641 032.


CHRIST THE KING POLYTECHNIC COLLEGE
DEPARTMENT OF MECHANICAL ENGINEERING
COIMBATORE-641 032.
PROJECT REPORT 2013-2014.

This report is certified to be the bonafide work done by selvan_________________
Reg.no _____________ of VI semester class of this college.

Project Guide Head of the department
______________ ___________________







Submitted for the practical examinations, state board of technical education,
Chennai, tamilnadu on ___________ held at the Christ the king polytechnic
college, Coimbatore.


INTERNAL EXAMNIER EXTERNAL EXAMINER












DEDICATED TO
BELEVOED OUR PARENTS AND
STAFF MEMBERS









CONTENTS

SL.NO

NAME OF THE TOPIC

PAGE.NO
1. Acknowledgement 7
2. Synopsis 8
3. Abstract 10
4. Introduction 12
5. Description of equipments
6. (i)Speed reduction gear box 14
7. (ii)Motor 18
8. (iii)Chain block 22
9. (iv)Pulley 25
10. (v)Belt 29
11. Details of drawing 32
12. Construction 35
13. Working principle 37
14. Maintenance 39
15. Advantages 43
16. Disadvantages 45
17. Applications 47
18. List of materials 49
19. Cost estimation 51
20. Conclusion 53
21. Bibliography 55
22. Photographs 57











DRAWING CONTENTS

SL.NO

NAME OF THE DRAWING

FIG.NO

PAGE.NO

1.

Speed reduction gear box

5.1.1

14

2.

Motor

5.2.1

5.2.2

19

20


3.

Chain block

5.3.1

22

4.

Pulley

5.4.1

25

5.

6.



Belt

Details of drawing

5.5.1

6.1.1

6.1.2

29

32

33






















ACKNOWLEDGEMENT








ACKNOWLEDGEMENT
At this pleasing of having successfully completed our project, we wish to
convey our sincere thanks and gratitude to the management of our college and our
beloved chairman THE MOST REV. DR. L. THOMAS AQUINAS, MA, D.D.,
D.C.L., VERY REV. FR. R. KULANDAIRAJ, MA, and our correspondent who
provided all the facilities to us.
We this like to express our sincere thanks to our principal THIRU A.
ANTONY FERNANDEZ, ME., MISTE., for forwarding us to do our project and
offering adequate duration in completing our project.
We also grateful to the head of the department Prof Mr. E. ANTONY
RAJAN B.E., MISTE, for his constructive suggestions and encouragement during
our project.
With deep sense of gratitude, we extend our earnest and sincere thanks to our
guide Mr. F. ROBERT BELLARMIN, B.E., department of mechanical engineering
for his kind guidance and encouragement during this project we also express our
indebt thanks to our teaching staff of Mechanical engineering department, CHRIST
THE KING POLYTECHNIC COLLEGE.









































3. ABSTRACT














9



ABSTRACT
The aim of this project is the bore well pipes lifted automatically without
human effort. This system is consists of speed reduction gear unit, motor, pulley,
belt, and etc., there are two gears are used to speed reduction. One is smaller gear
and another is bigger gear these gears are connected in to two individual shafts. To
reduce the friction while shaft rotation the bearing block with bush (gunmetal) is
used. And motor is fitted in another end. Motor pulley and smaller gear shaft
pulley connected with V-belt to transmission the power. When we start the motor
the power is transmitted to smaller gear and mesh with bigger gear and also rotate
anti-clockwise. The chain block is connected to bigger gear shaft using chain
pulley and automatically lift the bore well pipes. The system easily to lift heavy
weight load bore well pipes.











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4. INTRODUCTION











11


INTRODUCTION
Bore well machine is used to drill bore for lifting the water from underground to
the ground level. So the lifting of the shaft is done manually. In this project, it is
planned to lift the pipe automatically without human effort. To lift the shaft
automatically the gears are to be used. Gears are used to increase the torque level
which in turn helps to lift the shaft from underground to ground surface. Designing
involves the identification of various types, their position and geometry in the
project. Gears with various specifications such as gear ratio, pitch circle diameter,
etc., need to be used. Automation is effected by the motorized operation and by the
incorporation of gears. Thus, the design and automation of the bore lifting system
is the project proposed to be done.












12











DESCRIPTION OF EQUIPMENTS
6. (I) SPEED REDUCTION GEAR BOX











13


SPEED REDUCTION GEAR BOX


FIG 5.1.1
A reduction gear is an arrangement by which an input speed can be
lowered for a requirement of slower output speed, with same or more output
torque. Reduction gear assembly consists of a set of rotating gears connected to
a wheel work. The high speed incoming motion from the wheel work is
transmitted to the set of rotating gears, where the motion or torque is changed.
The number of gears used in the reduction gear assembly depends on the output
speed.
First off, let me explain that gear reduction in the context of this help
section refers to speed reduction in general whether it is by traditional gear,
chain and sprocket or belts. The goal of this section is to give anyone a basic
understanding of what gear reduction is and how it can be used to help give an
idea on how to implement it in a robot. Because there are different areas in a
robot that could

14


Benefit from gear Reduction we will focus on the most important one, the
driven train. And, we will take only about DC electric motors but the
fundamental can be applied to other motor as well.
The reason that we need to know about gear reduction is because the output
speed of a motor is usually too fast for normal use. Most DC motor at normal
operating voltages spins at well over 1,000 rpm (revolutions per minute) and
some even as high to 5,000 rpm for brushless DC motors. If we had a motor
than spun at say 3,000 rpm, and we attached a 6 inch wheel to it than the wheel
would theoretically be able to move the bot at almost 54 moles per hour!
That is way too fast to control in an arena due to other considerations that
wouldnt happen but we`ll get into that later. So we need to reduce the rate at
which the wheel spins so that we get a robot that we can at least control. Hint,
the quickly way of determining the speed of a wheel is to multiply the diameter
(in inches) of the wheel by the rpm and divide the result by 336.
Quite simply, gear reduction involves using gears/sprockets/pulleys of two
different sizes to work together. Because they are of differing sizes they will
have different circumferences (distance around the outer edge) and we can use
this to our advantage. Let's take a look at what this circumference thing really
means. To the left is a representation of a 4 inch diameter wheel. Click on the
wheel to watch it as it moves through one complete revolution. You will see
that the distance covered in one revolution is equal to the circumference of the
wheel.


15


Now, let's take a look at a wheel that is twice the size. Click on the 8 inch
wheel to watch it as it goes through one complete revolution. What you will
notice that not only does the wheel have twice the diameter but it travels twice
the distance in one revolution. Therefore the circumference is twice that of the 4
inch wheel. So, if the 4 inch wheel were to cover the same distance as the 8 inch
wheel then it has to complete 2 full revolutions.











16









7. (II) MOTOR







17


MOTOR
Principle and Working of Electric Motor
An electric motor is a device which converts electrical energy into
mechanical energy. A common motor works on direct current. So, it is also
called DC motor.
Principle

When a rectangular carrying current is placed in a magnetic field, a
torque acts on the coil which rotates it continuously when the Coil rotates to it
also rotates and thus It is able to do mechanical work.
Construction
Brushes
Brushes are made of carbon and rest on the commentator. The brushes
carry current from the commentator to the external stationary load. The
brushes are put inside the brush holders are kept pressed against the
commentator by as spring.
Armature
A D.C.Motor consists of a rectangular coil made of insulated copper wire
wound on a soft iron core. This coil wound on the soft iron core forms the
armature coil is mounted on an axle is placed between the cylindrical concave
poles of a magnet.

18




FIG 5.2.1


Commutator
The EMF induced in the armature is AC in nature. Commutator coverts
this AC to DC. The commutator is made of A copper segment insulated from
each other by mica sheets and is mounted on the shaft of the machine. The
armature conductors are soldered to the commutator segments in a suitable
manner to give rise to the armature winding.





19



FIG 5.2.2
Working of a D.C.Motor
When the coil is powered, a magnetic field is generated around the
armature. The left side of the armature is pushed away from the left magnet
and drawn towards the right, causing rotation. When the coil turns through 90
degrees, the
brushes lose contact with the commutator and the current stops flowing
through the coil. However the coil keeps turning because of its own
momentum. Now when the coil turns through 180 degrees, the sides get
interchanged. As a result the commutator ring C1 is now contact with brush B2
and commutator or ring C2 is in contact with brush B1. Therefore, the current
continues to flow in the same direction.




20



















8. (III) CHAIN BLOCK









21


CHAIN BLOCK

FIG 5.3.1
The safe working load is that load indicated on the hoist unit capacity
plate. This is the maximum load that May safety be lifted with the hoist under
no circumstances should a load greater than the soul be suspended from the
hoist.


22


1. As with all lifting appliance care is necessary in the
Use of the hoist and propene and safe working
Routine should always be observed.
2. Careless or rough handling or failure to maintain in the hoist
may result in dangerous failure of the unit.
3. Always examine the hoist carefully before we use it life may be at
stake look for cracks or damages particular with hooks and load
chain. Check that the hooks are not directed.
4. This chain block used to lifting the underground Bore well pipes.
5. Chain block are connected to the speed reduction gear shaft
directly.












23











9. (IV) PULLEY









24


PULLEY



FIG 5.4.1

A pulley is a wheel on an axle that is designed to support movement of a cable
or belt along its circumference. Pulleys are used in a variety of ways to lift
loads, apply forces, and to transmit power.
A pulley is also called a sheave or drums and may have
a groove between two flanges around its circumference. The drive element of a
pulley system can be a rope, cable, belt or chain that runs over the pulley inside
the groove.
Hero of Alexandria identified the pulley as one of six simple
machines used to lift weights. Pulleys are assembled to form a block and
tackle in order to provide mechanical advantage to apply large forces. Pulleys
are also assembled as

25


Part of belt and chain drives in order to transmit power from one rotating shaft
to another. A set of pulleys assembled so that they rotate independently on the
same axle form a block. Two blocks with a rope attached to one of the blocks
and threaded through the two sets of pulleys form a block and tackle.
A block and tackle is assembled so one block is attached to fixed mounting
point and the other is attached to the moving load. The mechanical advantage of
the block and tackle is equal to the number of parts of the rope that support the
moving block.
A hoist using the compound pulley system yielding an advantage of 4. The
single fixed pulley is installed on the hoist Device. The two movable pulleys
(joined together) are attached to the hook. One end of the rope is attached to the
crane frame, another to the winch.
A rope and pulley system that is, a block and tackle is characterized by the use
of a single continuous rope to transmit a tension force around one or more
pulleys to lift or move a load and the rope may be a light line or a strong cable.
This system is included in the list of simple machine identified by Renaissance
scientists.
If the rope and pulley system does not dissipate or store energy, then
its mechanical advantage is the number of parts of the rope that act on the load.
This can be shown as follows.
Consider the set of pulleys that form the moving block and the parts of the rope
that support this block. If there is p of these parts of the rope supporting the
load W, then a force balance on the moving block shows that the tension in each
of the parts of the rope must be W/p. This means the input force on the rope is
T=W/p.

26


The simplest theory of operation for a pulley system assumes that the pulleys
and lines are weightless, and that there is no energy loss due to friction. It is also
assumed that the lines do not stretch.
In equilibrium, the forces on the moving block must sum to zero. In addition the
tension in the rope must be the same for each of its parts. This means that the
two parts of the rope supporting the moving block must each support half the
load.
These are different types of pulley systems:
Fixed: A fixed pulley has an axle mounted in
bearings attached to a supporting structure. A fixed
pulley changes the direction of the force on a rope or
belt that moves along its circumference. Mechanical
advantage is gained by combining a fixed pulley with
a movable pulley or another fixed pulley of a
different diameter.
Movable: A movable pulley has an axle in a movable
block. A single movable pulley is supported by two
parts of the same rope and has a mechanical
advantage of two.
Compound: A combination of fixed and movable
pulleys forms a block and tackle. A block and
tackle can have several pulleys mounted on the fixed
and moving axles, further increasing the mechanical
advantage.


27










10. (V) BELT










28


BELT


FIG 5.5.1

Power transmission
Belts are the cheapest utility for power transmission between shafts that
may not be axially aligned. Power transmission is achieved by specially
designed belts and pulleys. The demands on a belt drive transmission system are
large and this has led to many variations on the theme. They run smoothly and
with little noise, and cushion motor and bearings against load changes, albeit
with less strength than gears or chains. However, improvements in belt
engineering allow use of belts in systems that only formerly allowed chains or
gears.
Power transmitted between a belt and a pulley is expressed as the
product of difference of tension and belt velocity.


29


Vee belt history
Trade journal coverage of V-belts in automobiles from 1916 mentioned
leather as the belt material, and mentioned that the V angle was not yet well
standardized. The endless rubber V-belt was developed in 1917 by John Gates
of the Gates Rubber Company. Multiple-V-belt drive was first arranged a few
years later by Walter Geist of the Allis-Chalmers corporation, who was inspired
to replace the single rope of multi-groove-sheave rope drives with multiple V-
belts running parallel. Geist filed for a patent in 1925 and Allis-Chalmers began
marketing the drive under the "Texrope" brand; the patent was granted in 1928
(U.S. Patent 1,662,511). The "Texrope" brand still exists, although it has
changed ownership and no longer refers to multiple-V-belt drive alone.










30










11. DETAILS OF DRAWING









31




















32




















33










12. CONSTRUCTION









34



CONSTRUCTION
The base constructed with C-Channel. The motor is fitted to the one end of
the C-Channel. There are 2 shafts are used. One shaft is connected to the smaller
gear. And another shaft is connected to the big gear. The shaft supported by using
the L-angle. The bearing block is located on the top of the L-angle to rotate the
shaft. To reduce friction a bush is used in bearing block. The bush is made of
gunmetal. To transmit power from motor to the smaller gear shaft we using V-belt
on the pulley. The chain block is connected with the bigger gear shaft by using
chain pulley.












35










13. WORKING PRINCIPLE










36


WORKING PRINCIPLE
In first we have one motor. While the motor gets started, the small gear
shafts which get links on the motor also rotated. When the small gear gets rotated
the bigger gear which is engaged on the smaller gear. Also rotated. By rotating the
bigger gear the transmission speed is reduced while compare to smaller gear. The
rotating motion of the big gear shaft is converted into linear movement by using
chain pulley. By this mechanism the chain block will lift the bore well pipes
automatically. So this project used for bore well pipes lifted automatically. Without
human effort.












37











14. MAINTENANCE









38


MAINTENANCE
After the implementation of short message service-based public toilet
maintenance system, the Coimbatore Corporation mulls a proposal to
plug loopholes in bore well maintenance.
According to sources in the Coimbatore Corporation, of late it has
come to the notice of the senior officials that contractors in-charge of
maintaining bore wells could be charging the civic body for bore wells
that are dysfunctional.
The civic body has sunk 1,986 bore wells across the 100 wards to
supply groundwater to residents to help them meet their non-drinking
water needs. It has handed over the maintenance of the bore wells to
100 contractors a contractor a ward by paying them Rs. 1,584 a
month.
The money the Corporation spends on maintenance works out to Rs.
31.45 lakh a month. And this in addition to the money the civic body
spends on power, which comes to around Rs. 1.29 crore every two
months.
The sources say that there are a few bore wells that do not function at
all. There are bore wells with motors that do not run for days together
in a month. And then there are bore wells, the water from which could
be diverted for private use.


39


To identify bore wells that function well and those that do not, the
Corporation has no choice but to rely solely on the electricity
consumption readings attached to the motors.
But then the meters do not provide accurate data because the meters
could themselves be out of use. Even if the meters work well, it will
be difficult to find Out if the water is used for public good.
To overcome the problem, the Corporation plans to develop software,
which, with the help of a subscriber identity module (SIM) card will
be able to collect data about bore wells on a day-to-day basis.
The sources say that the Corporation plans to attach a device to each
of the 1,986 bore wells to study how many hours a day each bore well
functions. And for how many days in a month. If the reading is nil, the
Corporation will not pay the contractor in-charge of maintenance.
If the bore well is functional only for a few days in a month, the
Corporation will pay not the entire maintenance charges but only the
proportionate amount. And if the motors run for longer than the usual
duration, the Corporation will check the misuse as well.
To ensure that the above mentioned system works well, the
Corporation will do a study of all the bore wells in the city to collect
details like their location, the capacity of motors attached there, how
many residents each of the bore wells feed, the average by monthly
power consumption taking

40


Into account the summer and winter variations, etc.
The sources say that the Corporation will implement the scheme with
urgency because there are demands to increase the bore well
maintenance from Rs. 1,584 a month to around Rs. 2,100 a month.
Only if the Corporation plugs the loopholes, will the hike in
maintenance charge having meaning, they add.














41











15. ADVANTAGES










42



ADVANTAGES
Manpower is reduced.
Unskilled labour is enough.
Its used for lifting heavy load pipes.
Time is saved.
All types of bore well pipes can be lift.
Low space is enough.
It is easy to design
It is long life process.












43











16. DISADVANTAGES










44



DISADVANTAGES
Initial cost is high.
Maintenance cost is high.
The system will be lifted if there is no support.
Accidents may be occurring.















45












17. APPLICATION







46


APPLICATION
Tube wells generally fails due to problems like corrosion and encrustation
associated with conventional materials Due to corrosion the strainer screens
get damaged and the sand particles come out along with the water.
Due to encrustation, pipe diameter as well as effective area of screen get
reduces and hence tube well becomes unserviceable within few years.
These problems associated with conventional materials are totally eliminated
in Supreme casing pipes made from high quality PVC resin.
Supreme casing pipes offer superior performance at a lower cost and become
the v prime choice of the customer.
Supreme offers varieties of pipes for bore well applications to cater to every
need of bore well sector which includes Casing pipes as per IS 12818, ribbed
screen casing pipes for tube wells.
SDR casing pipe series for shallow depth applications as per company
standard, Plain pipes as well as screen (slotted) pipes are available in every
category of casing pipes. (Slotted pipes can also be used for rainwater
harvesting).
Submersible column pipes for submersible pumps are also offered to lift the
water from the wells. The advantages of Supreme UPVC water well casing,
and screen pipes are given below.







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18. LIST OF MATERIALS









48



LIST OF MATERIALS
Sl.no Name of the material Requirement Feet
1 Gears 2
2 Motor 1, 3HP DC
3 Shaft (50mm) 2 7 Feet
4 V-Belt 2
5 V-Pulley 2
6 Chain pulley 1
7 Motor pulley 1
8 C-Channel 4 11 Feet
9 L-Angle 4 20 Feet
10 Bearing block 4
11 Chain block 1
12 Square rod (60mm) 4
13 Bolt 1 3/8, Nut, Washer 10
14 Motor bolt 4






49










19. COST ESTIMATION










50


COST ESTIMATION
1. LABOUR COST
Lathe, milling, drilling, welding, gas cutting, power hacksaw.

2. OVERHEAD CHARGES
The overhead charges are arrived by Manufacturing cost
Manufacturing cost = material cost + labour cost
= 10250 + 4000
= 14250

3. TOTAL COST
Total cost = material cost+ labour cost+ overhead cost
=
Total cost for this project =







51










20. CONCLUSION











52


CONCLUSION
This project is made with preplanning, that it provides flexibility in
bore well pipe lifting operation.
This innovation has made the more desirable and economical. This
project DESIGN AND AUTOMATION OF AUTOMATIC BORE WELL
PIPE LIFTING SYSTEMis designed with the hope that it is very much
economical and helpful to bore well pipe lifting system.
This project helped us to know the periodic steps in connecting a project work.
Thus completed the project successfully.











53









21. BIBLIOGRAPHY









54


BIBLIOGRAPHY
Driscoll, F. (1986). Groundwater and Wells. St. Paul: Johnson
Filtration Systems. ISBN 978-0-9616456-0-1.

Raymond Rowles (1995). Drilling for Water (2nd ed.). Avebury,
Cranfield University. ISBN 1-85628-984-2.
















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22. PHOTOGRAPHY










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57






























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