Authors: Sarah Drumm, Margot Hughan, Claire Nauman
Acknowledgements The Project Leads and Mentor Team acknowledge that: (Please initial each line item to acknowledge that each line item has been completed.)
The chapter reviewed the accompanying 525 – PreImplementation Report Instructions for accurate completion of this report. The PMEL lead has reviewed the 901B – Program Impact and Monitoring Report Template and is prepared to update the report during the upcoming trip. The chapter acknowledges that the completed 901B is required with the eventual submittal of the 526 – PostImplementation Report. The PMEL lead acknowledges that the 905 – Program Logic Framework is required as an appendix to the 901 and 901B reports. The project monitoring indicators were selected at the postassessment phase and documented in the 522 – PostAssessment Report. The PMEL lead is prepared to gather updated results for the monitoring indicators on this trip and those results will be included in the 526 – PostImplementation Report. The team has included the Draft 903 – Implementation Agreement as an appendix to this report. The 600 – Health and Safety Plan Part I and Part II are submitted as separate documents with this report. The most current contact information is updated in this report and all other reports included with this submittal. Any new or additional member to the Mentor Team has included their resume, 404 – Mentor Statement of Intent, and 408 – Application to become a Professional Mentor for an EWBUSA Project.
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
We, the project team leadership confirm that the above information and tasks have been completed and that this report presents a complete design which meets the normal engineering standard of care for this type of facility.
Claire Nauman 6/19/16 _________________________________________________________________________________________________________________________________________ Project Lead Printed Name Project Lead Signature Date
Rod Beadle 6/19/16_________________________________________________________________________________________________________________________________________ Mentor Printed Name Mentor Signature Date Or _________________________________________________________________________________________________________________________________________ Faculty Advisor Printed Name Faculty Advisor Signature Date I have reviewed the subject project. I am qualified by education and experience to design this type of project. In my best engineering judgement, this report does its best to develop a complete and comprehensive design. The design presented within this report meets my standard of quality and is ready for review by the Technical Advisory Committee.
Rod Beadle 6/19/16 _________________________________________________________________________________________________________________________________________ REIC Printed Name REIC Signature Date
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
Table of Contents
Part I –Administrative Information 1.0 Contact Information 2.0 Budget 3.0 Project Discipline(s) 4.0 Number of People Impacted 5.0 Professional Mentor Resume(s)
Part II – PreAssessment Report 1.0 Executive Summary 2.0 Facility Design
2.1 Description of the Proposed Facility 2.2 _ Description of Design and Calculations 2.3 Drawings 2.4 524 – Draft Design Report Comments
3.0 Project Ownership 4.0 Construction Plan 5.0 Materials List and Cost Estimate 6.0 Operation and Maintenance 7.0 Sustainability
7.1 Background 7.2 _ Organizational Capacity of the Community 7.3 Financial Capacity of the Community 7.4 Technical Capacity of the Community 7.5 Education
8.0 Site Assessment Activities Appendices
Appendix A – Draft 903 Implementation Agreement (English and French) Appendix B – Water Testing Results Appendix C – Drawings Appendix D – Documentation of Land Ownership Appendix E – Letter from the Community Appendix F – Maps Appendix G – Maintenance Card Appendix H – Maintenance Manual
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
2.0 Budget Insert the 508 EWBUSA Trip Budget Worksheet into this section of the report only including financials pertaining to this trip. Please provide explanation if required below. If it is desired to include further budget details for this trip please include in an appendix to this report.
In-Country Logistical Support $0Local Skilled labor $255
Sub-Total* $255EWB-USA HQ (this section is auto-calculated based on trip type)
Program Quality Assurance/Quality Control + Infrastructure* $2,000Less EWB-USA HQ Subsidy* $1,395
Owed by Chapter Sub-Total* $605Project Materials + Equipment (itemized, as appropriate)
Specimen Collection and Physical-Chemical Analysis $75Hand Digging 1190
Cement 285Gravel (10 mm) 510Gravel (20 mm) 1020
Cinderblocks (20 cm Standard) 49Sand 102
No. 10 Rebar 251No. 8 Rebar 291
Wire Mesh 163Binding Wire 6.8
Transport 340Steel Sheet 26
Chain Link Fence (200 cm height) 129India Mark II Handpump and Accessories 6460
Salary of Professional Mason to Oversee Contractor 510Sub-Total* $11,408
Misc. (details required)
Sub-Total* $0TOTAL DIRECT COST* $23,508
IN-KIND CONTRIBUTIONSCommunity In-Kind Contributions to Project Costs
Labor $0Materials $0
Logistics $0Sub-Total* $0
TOTAL IN-KIND CONTRIBUTIONS*FUNDS RAISED Funds Raised for Project + Grants Received
Cash from community (EWB-USA requires a minimum 5% contribution) $800Total $ in Project Fund at EWB-USA HQ $0
Total $ in Project Fund at University $0Total* $0
Funds Raised for Chapter Total $ in Chapter General Fund at EWB-USA HQ $5,120
Total $ in Chapter General Fund at University $16,000Total* $21,120
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
3.0 Project Discipline(s) Check the specific project discipline(s) addressed in this report. Check all that apply.
Water Supply (Project Type) X__ Source Development (Project Discipline) ____ Water Storage ____ Water Distribution ____ Water Treatment X__ Water Pump Sanitation ____ Latrine ____ Gray Water System ____ Black Water System ____ Solid Waste Management Structures ____ Bridge ____ Building ____ Retaining Wall
Civil Works ____ Roads ____ Drainage ____ Dams Energy ____ Fuel ____ Electricity Agriculture ____ Irrigation Pump ____ Irrigation Line ____ Water Storage ____ Soil Improvement ____ Fish Farm ____ Crop Processing Equipment
4.0 Number of People Impacted
Number of People Directly Affected: 273 (The population that experiences the typical, inevitable and predictable outcomes of our work.) Number of People Indirectly Affected: 1500 (The population that experiences the reasonable and probable outcomes of our work.)
• Over 30 years as a registered, professional Civil Engineer with extensive experience in the design, implementation, monitoring, and management of domestic and international WASH and infrastructure improvement projects.
• Specialized experience in disaster response aid and recovery operations including strong knowledge of WASH, water testing and treatment, and waterborne diseases.
• Specialized experience in the construction and operation of healthcare facilities to treat infectious diseases including cholera treatment centers (CTCs), cholera treatment units (CTUs), Ebola community care centers (CCCs), and Ebola treatment units (ETUs)
• Strong management and mentoring skills through 25 years of experience as the founder and President of a 30 person, engineering consulting firm.
• Strong writing and communication skills. • Expertise and training in research methods and development of practical, sustainable monitoring
and evaluation programs. EDUCATION DePaul University, Chicago, Illinois Masters of Science, International Public Service 2014 University of Wisconsin, Milwaukee Bachelor of Science, Civil Engineering 1984 PROFESSIONAL REGISTRATIONS Registered Professional Engineer, State of Illinois 062-045076 Registered Professional Engineer, State of Wisconsin E25883 Certified Floodplain Manger, ASFPM IL-06-00228 PROFESSIONAL EXPERIENCE Engineers in Action, Tulsa, Oklahoma 2015 to Present Executive Director – Management of operations for a
nongovernmental organization supporting development of community-based water and infrastructure projects in Bolivia and other Latin American countries.
Engineering Resource Associates, Inc., Warrenville, Illinois Founder/President – Managed the steady growth of a 30 person
civil engineering, structural engineering, environmental science and surveying firm.
1990 to 2015
RJN Environmental Associates, Inc., Wheaton, Illinois 1987 to 1990 Project Manager – Directed nationwide transportation and water
resource engineering services.
Rodney A. Beadle, PE, CFM 6561 Winding Way, DeForest, WI 53532
US Army Corps of Engineers, Peoria and Chicago, Illinois 1984 to 1987 Project Engineer – General design and construction oversight for
sanitary treatment plants and water resource projects.
INTERNATIONAL DEVELOPMENT AND DISASTER RESPONSE EXPERIENCE Engineering Ministries International Member, Board of Directors 2014 to Present Disaster Response –Engineering advisor and WASH specialist providing service to
nongovernmental organizations to establish clean water, sanitation and hygiene facilities. • Refugee Transit Camps – WASH Support working with
Samaritan’s Purse, support WASH activities for two camps
• Ebola Emergency Response – WASH, working directly for Samaritan’s Purse, managed construction of a pilot community care center (CCC) Zorzor, Liberia
• Cholera Response – WASH, Living Water International, Sierra Leone
September, 2012
• Horn of Africa Famine/Drought - WASH, Christian Reformed World Relief Committee, Turkana/Pokot, Kenya
August/September, 2011
• Cholera Response - WASH, Samaritan’s Purse, Port au Prince and Cabaret, Haiti
December, 2010
• Indus River Flooding - WASH, Food for the Hungry, KPK and Punjab Provinces, Pakistan
August/September, 2010
• Post Earthquake Response - WASH, Samaritan’s Purse, Leogane, Haiti
February/March, 2010
International Development – Civil engineer for projects serving ministries throughout the developing world.
• Life is Hope Orphanage and Guesthouse, Port au Prince, Haiti • Haiti Arise School and Church, Grand Goave, Haiti
June, 2013 June, 2011
• El Shaddai Baptist Church and School, Port au Prince, Haiti June, 2010 • Hope for Children Clinic, Church and Orphanage, Malakal,
Sudan May, 2009
• Centre for Peace and Reconciliation, Kigali, Rwanda February, 2008 • Tien Shan International School, Almaty, Kazakhstan June, 2007 • Youth Camp and Ministry Center, Lubango, Angola March, 2007 • Royal Poultry Microenterprise, Ndola, Zambia October, 2006 Engineers Without Borders, Chicagoland Professional Chapter Project Lead and Mentor for developing world projects involving
flood relief and clean water projects
• Chairperson, Chapter Board of Directors • Professional mentor and advisor to university chapters at
Purdue University, University of Notre Dame and Illinois
2012-2014 2009-Present
Rodney A. Beadle, PE, CFM 6561 Winding Way, DeForest, WI 53532
Institute of Technology • Sanitary Sewer Feasibility Study, Ein Sultan Refugee
Camp, UNRWA, Jericho, Palestine 2014
• Water Source Development, Sangmalima, Cameroon 2012-Present • Flood Relief Channel and Clinic Well, Las Cruces,
Guatemala 2009-2014
• Water Source Development, Papachacra, Bolivia 2009-2013 ACADEMIC RESEARCH PAPERS AND PRESENTATIONS • Building a better world: Evaluating student perceptions of
programmatic inputs and outcomes on Engineers Without Borders-USA projects
• Seminars on water testing in the developing world: Presented at Illinois Institute of Technology, Notre Dame, Wheaton College
• Global Disease and Poverty: A Geospatial and Temporal Perspective
• Bacteria without borders: King cholera comes to Haiti • Closing the rift: Examining pastoral conflicts in northwest
Kenya from a human security perspective
• United Nations agency review: Office for the Coordination of Humanitarian Affairs
• Assessing the sustainability of WOTR’s school-based water, sanitation and hygiene education programs in rural India
• The emerging roles of INGOs and CSOs in fighting corruption MEMBERSHIPS Engineers Without Borders National Society of Professional Engineers American Society of Civil Engineers Association of State Floodplain Managers American Public Works Association Illinois Society of Professional Engineers Association of Christian Design Professionals American Council of Engineering Companies Illinois Association for Floodplain and Stormwater Management Central States Water Environment Association LANGUAGES Native Language: English Basic/Intermediate Proficiency: Spanish
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
Part II – PreAssessment Report (Please provide pertinent figures, tables, and photographs with figure numbers, table numbers and photograph numbers in the section where discussed. Full drawing sets, complete lab reports, and any information larger than 2 pages should be included at the end of the report as an appendix.)
1.0 Executive Summary
1.1 Project Details This Design Report was prepared by the University of Notre Dame Chapter of Engineers Without Borders (EWBND) for the Sangmelima, Cameroon, program (project number: 10711). The problem being addressed is the lack of easily accessible potable water for the residents of the village. EWBND’s solution, as detailed within this report, will provide a solution in the form of a handdug well and a hand pump.
1.2 Request for TAC Approval The chapter is asking the TAC for approval for a hand dug well, an India Mark II Handpump, a concrete pad, and a soakage pit.
1.3 Goal and Scope The purpose of this project is to work with the Alfred and Sarah Bilingual Academy in Sangmelima, Cameroon to develop a clean, reliable water source at an academy that will serve the population of the school directly and the surrounding village indirectly. The school has a population of 273 students and faculty and is located about 7 km from downtown Sangmelima in a village called Etonolinga, which has a population of about 1,500. Currently, this village relies on drinking water from springs and handdug wells, which the team found to be contaminated with harmful bacteria that can lead to the spread of waterborne disease. Dealing with water related illnesses or the alternative of traveling miles to obtain clean water from neighboring villages have also generally hindered the ability of the students to engage in academics and pursue careers. A few of the existing water sources available to the community are detailed below in Table 0.
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Salty Well 300 meters 220 0 Privately owned, not for sale
Ma’s Well 150 meters 800 0 Free
Ma’s Drinking Water
6 kilometers 2200 120 Unknown, not free
Orphanage Well 2 kilometers 0 0 10 francs/L
As seen above, the existing water sources are not sufficient to meet the needs of the community. The majority of the water sources tested are contaminated beyond potability. The only publicly available source which EWBND was able to find was the Orphanage Well. Although this well is relatively close to the school and safe to drink, it is expensive and often rationed due to the high demand of the village. Access to a local clean water source would allow the students to commit more fully to their studies as they will not be prevented from attending school because of sickness and will not have to travel to the local spring to collect water. Additionally, the chapter will provide materials and training for testing the water that will not only ensure the safety of the well, but also provide scientific experience for the local students. Furthermore, access to clean water will help to break the cycle of poverty within the greater community, as it will enable its members to have the health and means to start new businesses and improve their lives and environment.
1.4 Community and NGO
The Alfred and Sarah Bilingual Academy is located in Etonolinga, a village situated 7 km from Sangmelima in central Cameroon. Etonolinga is home to an estimated 1500 people who currently rely on surface water sources to obtain water or privately owned, unsealed, handdug wells. Central Cameroon experiences two wet seasons and two dry seasons. The wet seasons occur from March to May (avg. 12.5 cm/month) and September to November (avg. 14.6 cm/month), and the first dry season from December to February (avg. 4.0 cm/month) while the second dry season occurs from June to August (avg. 5.6 cm/month). Total rainfall per year averages between 150cm200cm typically. The Rural Women Development Association (RUWADA) headed by Minlo Hanna NMokake (Ma Hannah) has mobilized the community and reached out to the district officials and local nobles to gain support for the project. They have established a water committee to track use, collect dues, and ensure periodic maintenance of the well and testing of the water. During both of the team’s assessment trips, Ma arranged for their lodging and the RUWADA provided meals for the team during their stay. The community has committed to aiding in the construction of the water source through providing labor. Additionally, the community will contribute 5% of the construction cost to signify their commitment to the project. The team also trained students and faculty at the school on how to perform E. Coli/Coliform detection (Coliscan Easygel) tests
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through the use of Coliscan Easygel to test the water for biological contaminants so that they can ensure that the water remains safe. EWBND is partnering with the nongovernmental organization (NGO) Plant A Seed and working closely with its founder, Ruth Akumu, who was born and raised in Cameroon. Plant A Seed was founded in 2001 as “Seek Ye Multipurpose Group” with the mission of providing financial, educational and material support of women, particularly single mothers and uneducated/undereducated children, increasing exposure to subjects such as clean water and AIDS, and sponsoring sporting events for young people in communities and schools. In 2010 the group grew to become the Plant A Seed Foundation, with offices in Southern California that serve communities throughout Cameroon. Two representatives from Plant A Seed, Ruth Akumbu and Catherine Achu Lamfu accompanied the chapter members on the assessment trips and have played a major role in the success of the project so far. The Implementation Agreement has been signed by Ma Hannah, Ruth from Plant a Seed, and the University of Notre Dame EWB chapter.
1.5 Background Information With the help of Plant A Seed, RUWADA submitted an application for a clean water source in the Fall of 2012. EWBND adopted this project in early July of 2013 and committed to working with the Alfred and Sarah Bilingual Academy and Plant A Seed to establish this water source for the school’s population and potentially the surrounding community. Prior to the first assessment trip, the team kept in close contact with Ruth Akumbu from Plant A Seed and Ma Hannah from RUWADA to understand the needs of the community and plan for the success of the assessment trip. From December 29, 2013 to January 8, 2014, EWBND conducted its initial assessment trip. A team of four students, a faculty advisor, and a professional mentor traveled to Sangmelima to meet with the community and assess their needs. While there, the team met with the Senior District Officer and Deputy Major of Sangmelima along with the local chief and nobles to ensure local support and ownership. Additionally, the team performed biological and chemical tests on the current water sources, including a spring box, existing handdug wells, lakes, and spigots. Through multiple Coliscan Easygel tests, the team found that all but one of the samples contained biological contaminants. The existing uncontaminated source was a drilled well located at an orphanage in the neighboring village. From March 5th to 13th, 2016 EWB conducted its second assessment trip. The team met with two additional contractors and gathered information on the specifics of their designs. Additionally, they mapped the location of the well, retested existing water sources, tested soil absorption rate through a handdug percolation pit, and conducted a hygiene promotion program with the students at the school. The chapter has since kept in contact with Ma Hannah and Ruth Akumbu to work towards
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finalizing the design for the project, raising the funds to realize it, and completing the necessary steps to prepare the school for implementation.
1.6 Calculations To ensure the effectiveness of EWBND’s well design, calculations were done concerning the soakage pit which will collect water runoff from the well’s concrete pad. The pit was concluded to necessitate roughly 2m by 2m by 2m of area. Calculations were also done regarding the concrete pad which EWBND will be mixing and installing on the implementation trip. Additionally, as shown in the drawings included in the Appendix, steel reinforcements were included in all concrete structures to ensure stability. The volume of materials required for the mixing of concrete were also calculated using a 1:2:3 ratio (cement: sand: coarse aggregate).
1.7 Drawings
The appendix includes the following drawings: Concrete Pad Cover, Culvert, Handdug Well, Manhole Cover, and Well Cover. The chosen contractor, Ets Groupe Manbo, will be constructing the culverts, the manhole cover, the well cover, and the handdug well. EWBND will be constructing the concrete apron, the drainage channel, and the wall.
1.8 Construction Plan From EWBND’s meeting with the chosen contractor during the second assessment trip, the team developed a plan for implementation. Because the contractor requires between 1 and 2 months to construct the culverts and dig the well, the contractor will begin work in midOctober. EWBND will hire a qualified mason/overseer with a technical background in construction of similar facilities to observe and inspect the contractor’s work, take pictures, and complete daily reports. EWBND will arrive in midDecember after the well has been dug, the culverts are in place, and the India Mark II pump is in place. The EWBND team will construct the cement pad and gate surrounding the well. Additionally, the team will provide educational materials, including a physical demonstration and written documentation for long term maintenance and operation. They will also conduct tests on the chemical and biological properties of the water using Coliscan Easygel, multimeters, and test strips, and train more students and members of the community on how to perform these tests as well.
1.9 Sustainability
The main issues that the chapter foresees as threats to the sustainability of the well are over tapping the aquifer, inadequate funds or expertise to maintain the well, and disagreement over the ownership of and responsibility for the well once it has been built. To address these concerns, the chapter has worked with the surrounding community to establish a water committee to track usage and plans to train members of this board on proper usage and maintenance of the well. EWBND has done extensive checking on its past two assessment trips to ensure the sustainability of this project. The current location has been soil tested and the
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contractor will get permits ensuring no latrine will be placed within 15 meters of our site. The water committee will also be responsible for long term maintenance, security, and proper usage, treatment, and maintenance of the well. The community’s capacity was assessed organizationally, financially, and technically and found to be adequate for this type of program. Finally, EWBND has conducted water testing with members of the community and will continue to educate in any way which could be seen as helpful. The contractor will provide a 24 month warranty during which all repairs will be free of charge. This time will give the water committee the opportunity to accumulate enough funds for continued operation and maintenance. This will be done by charging a set rate per liter of water drawn. The current estimate for this number is 5 Francs for 1 liter of water. After the first 24 months, additional repairs would cost 50,000 Francs plus the cost of parts.
2.0 Facility Design
2.1 Description of the Proposed Facility EWBND is working with the Alfred and Sarah Bilingual Academy, surrounding community, and local NGO PlantASeed to establish a potable water source for the school and surrounding community. This source will include an India Mark II hand pump in a handdug well with a concrete pad, drainage channel, cinderblock wall, and soakage pit. The team met with three contractors and decided on one that would dig the well, assemble and place the culverts, and install the hand pump. The EWBND team will build and place the concrete pad and apron, the well cover, the drainage channel, the cinderblock wall and the soak pit.
Based on the contractor’s drawings and history of past projects, the team is confident that he will be able to complete the project successfully. However, the team has also identified a representative that will oversee construction before the team arrives. The representative will inspect and observe the work, take pictures and fill out daily reports of the contractor’s work. The well will have an inner diameter of 1.2 meters and a depth of about 25 meters based off of the dimensions of other similarly constructed wells in the surrounding area. The hand pump and all replacement parts can be purchased in Douala and Yaounde. All other tools and materials such as cement, rebar, and gravel can be sourced locally in Sangmelima.
2.2 Description of Design and Calculations
Signature of Rodney Beadle, PE: The different parts of a water well system include a hand dug hole, reinforced concrete culvert sections, sand and gravel packs, a concrete pad with drainage channels, a cinderblock wall, and a handpump. The parameters of these components will be the bases for the design of the well. The primary concerns of the well design will consist of the diameter and depth of the hole. The hole depth will be determined by the depth of the aquifer but will be limited to the maximum depth of the contractor, which he quoted to be around 35 meters. From wells that were
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observed in the area the predicted depth needed for the hole is expected to be between 15 and 20 meters.
Table 1: Technical Data (SKAT – RWSN, 2016). Depth Up to 50 meters
Cylinder Diameter 63.5 mm
Minimum Casing Diameter 100 mm
Maximum Stroke 125 mm
Approximate Discharge (at about 75 watt input m3/h)
10 m Head 1.8
15 m Head 1.3
20 m Head 1.0
30 m Head 0.8
Pumping Lift 1050 meters
Max Population Served 300 persons
Households 30
Water consumption (lpcd) 1520
The hand pump that will be used will be the India Mark II as it is the most prevalent hand pump in the Sangmelima region according to contractors and as seen by team during the assessment trips, as shown from one of the wells that was documented on EWBND’s assessment trip in Figures 2 and 3. As the priority of our project is to serve the immediate community of 273 people, this pump will produce an adequate yield. The India Mark II hand pump is less susceptible to corrosion and easy to install. Additionally, maintenance for the India Mark II hand pump is known to be manageable for rural communities. As it is commonly found in the region, the community has an understanding and acceptance of such a technology and has experience to repair it as well as easy access to replacement parts should components need to be replaced. A diagram of the India Mark II pump is provided in Figure 1.
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Figure 1. India Mark II Handpump (UNICEF SKAT 200710)
The India Mark II Pump is a conventional leveraction hand pump. The configuration includes an “open top” cylinder. The piston can be removed from the cylinder without dismantling the rising main. The foot valve is retractable with a fishing tool. (SKAT – RWSN, 2007). The specifications of the India Mark II hand pump are included in the Appendix with detailed drawings of the components. There are multiple options for the pump head type, pump stand type, rising main arrangement, cylinder arrangement, and pump rod arrangement. Based on the available materials, EWBND has determined that the options included in Table 2 are optimal for the well. Based on the chosen specification, the materials required for these components are also included in Table 2.
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Table 2: Desired Options of the India Mark II Handpump Material
Pump Head Type A Galvanized Steel
Pump Stand Type A Galvanized Steel
Rising Main Arrangement A Galvanized GI Pipe
Cylinder Arrangement B Cylinder of cast iron with brass liner (Ø 150 mm) Brass plunger and foot valve
Pump Rod Arrangement B Stainless Steel
The concrete pad that surrounds the well is important for protecting the wellhead and for draining moving water away from the pump area. Included in Figure 2 below is a picture taken by EWBND on their assessment trip of a concrete pad similar to the one that EWBND plans to build. However, it is clear from the figure that this pad in insufficient as it does not drain well and has no protecting wall. EWBND plans to improve upon this design through including a slight incline, using cement and including a small protective wall. The incline will be more similar in build to the one seen in Figure 3 below that shows a well in the region.
Figure 2: Flat Concrete Pad and Well in the Sangmelima Region.
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Figure 3: Inclined Concrete Pad and Well in the Sangmelima Region.
EWBND will be responsible for the actual construction of the concrete pad. As shown in the detailed drawings included in the Appendix, the outer diameter of the concrete pad will be 4 m. It will be surrounded by a cinder block wall with a height of 40 cm and will contain a drainage channel at a 2% slope of at a minimum of 6m in length. The drainage channel will lead to a soak pit. Discharge Rate When EWBND observed the operation of a hand dug India Mark II hand pump (aforementioned orphanage well) by local members of the community, the discharge was approximated to be 15 liters in one minute. According to the RWSN India Mark II manual (Appendix I), when operated correctly the well should produce no less than 16 liters in one minute from 40 continuous strokes. Soakage Pit The size of the soakage pit was determined using a percolation test pit. The prep work consisted of digging a hole approximately 0.5m deep and filling it with water periodically so that the soil remained saturated with water for 24 hours. After that, the team filled the pit with water once more and recorded the drop in the water level every 10 minutes for about 2 hours. Using this data, we concluded that the water level drops 25 mm every 50 minutes. Resources provided by our professional mentor, Rod Beadle, indicated that soil with a soakage rate of 25mm in 50min absorbs 29 liters of water per day per square meter of surface area. It is projected that the well will provide around 6280 L of water to the community per day. Assuming that 10% of this becomes runoff water (628 L), the soakage pit must have a surface area of 22
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meters squared. This translates to a soakage pit of dimensions 2m x 2m x 2.25m, or roughly 2m x 2m x 2m. Disinfection Calculations The well will be treated with a mixture of 300 grams of calcium hypochlorite powder with 15 liters of water for disinfection. According to WHO and Water Engineering Development Centre recommendations, every 2 cubic meters of water present in the well calls for one bucket of the aforementioned solution.
0.2 mV = 4πD h2 = 4
π1.8 42 = 1 3 Immediately following well construction, the volume of the well will call for 5 buckets of solution. Following this, the team will test the water against WHO recommendations to ensure its potability. The chapter performed similar tests during the assessment trip utilizing test strips and Coliscan Easygel, and will continue to train members of the community to perform similar tests. Precautions will be made to notify the community that the water will not be confirmed safe to drink until testing is completed. The community will be trained to do disinfection and water quality testing themselves, and will also be made aware of accounting for the increased water level during the rainy season. Concrete Mix The concrete will be made out of local cement and aggregate with a maximum allowed slump of 4” per American Concrete Institute 211.1 and accounting for probable consolidation by hand methods. Aggregate size will also be kept in respect to American Concrete Institute standards. Reinforcement in the form of steel wire will be used to prevent cracking of the cement pad as well. All pouring of the concrete will wait until the soil surrounding the borehole is settled after construction of the well. Based on the drawings included in the following section, the total volume for concrete needed to construct the pad around the well will be roughly 4.02 m3. And the well cover will be 0.60 m3. Using the arbitrary volume method according to Materials for Civil and Construction Engineers Third Edition, due the fact that the specific gravity and density of the aggregates in Cameroon is unknown, it is assumed that the ratio of materials to be used is 1:2:3 (cement: sand: coarse aggregate). This breaks down to 0.77 m3 of cement, 1.54 m3 of sand, and 2.31 m3 of coarse aggregate. We will then follow ACI 211.2 and ACI 318 standards for maximum allowable water to cement ratio and in Table 3 below the water to cement ratio for three allowable coarse aggregate sizes can be seen.
Table 3: Aggregate Size and Max Allowable Amount of Mixing Water
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Soil Bearing Capacity To determine the ability of the soil to support this structure, the BS (British Standard Building Code) 8004 was consulted. According to soil type observed on the earlier assessment trip through ribbon testing, the soil bearing capacity is estimated to be 150 KN/m2. Thus, assuming an average density of concrete being 2,400 kg/m3 and a volume of the concrete pad and cinder block wall of 4.97 m3, the gravitational force of the the pad is 117 kN. With an area of the foundation of 10.05 m2, the resulting pressure is 11.65 KN/m2 which is substantially less than the allowable 150 KN/m2. These calculations can be confirmed by the stability of the inner walls of several wells in the area which were hand dug. The other wells inspected on assessment trips showed no evidence of problems with settling of the well head or sloughing from the sides. Steel Reinforcements for the Concrete Pad Using the equation below from Concrete Floors on Ground with the values in Table 4 below,
1
the recommended spacing of 10 gauge wire mesh is 26.6 cm. To have a factor of safety of 1.33, EWBND has designed the spacing of 10 gauge wire mesh to be 20 cm.
As = 2f sFLw
Table 4: Spacing of 10 Gauge Wire Mesh for Concrete Pad
Description Variable Value Unit
Coefficient of subgrade friction F 1.5
Coefficient of subgrade friction
Slab Length between free ends L 400 cm
Slab Length between free ends L 13.12336 feet
Floor thickness (cm) 15 cm
Floor thickness (in) 5.905515 in.
Weight of slab per square foot w 73.8189375 pounds/ft^2
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stress of reinforcement
CrossSectional area of steel/foot A_s 0.01614587486 in^2/linear foot
Diameter of 10 Gauge Wire 0.134 In.
CrossSectional Area of 10 Gauge Wire 0.01409546 In.^2
Spacing of 10 Gauge Wire 0.8730068901 ft.
Spacing of 10 Gauge Wire 26.60925001 cm. Steel Reinforcements for the Culverts Based on the _____ recommendation for the percentage of steel required per area of the concrete it reinforces, the transverse spacing of 8 gauge rebar and the number of longitudinal rods of 10 gauge rebar per culvert were calculated. It was found that 10 cm spacing of 8 gauge rebar would be sufficient and yield a 0.25%. Additionally, 18 rods, spaced at roughly 8 cm longitudinally would suffice and yield a 0.16%.
% = AcAs = th
Πrs2
Table 5: Transverse Spacing of 8 Gauge Rebar for Culverts
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% = AcAs = Πrs2
(Πr −Πr )/N2o i
2
Table 6: Longitudinal Spacing of 10 Gauge Rebar for Culverts
Description Variable Value Unit
Area Steel (No. 10 Metric)
A_s 78.5 mm^2
Outer Radius of Culvert
r_o 160 cm
Inner Radius of Culvert
r_i 120 cm
Area of concrete A_c 8792 cm^2
Number of Steel Rods
N 18 rods
Total Steel Area A_s 1413 mm^2
Spacing of Rods 8.88 cm
Percent Steel 0.1607 %
Steel Reinforcements for the Well Lid Based on the maximum moment found from the moment diagram, the bending stress of the concrete was calculated using the equations below where the compression of the concrete, C, is equal to the tension in the steel, T.
f = IMc bhC = f
As = Tfy
Table 7: Rebar Reinforcement Calculations for the Well Lid.
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Thickness of slab h 20 cm
Diameter of the slab b 180 cm
Bending stress f 759.33 kPa
Tension T 273.35 kN
Yield strength of steel f_y 250000 kPa
Area of Steel A_s 1093.43 mm^2
Spacing of No. 10 Rebar
12.92 cm
Water Demand WHO has established recommendations for the liters per capita per day of potable drinking water. They have broken these recommendations into sedentary and active lifestyles and male and female. For the purpose of this project, EWBND used the average of these to determine the goal lpcd for the school and surrounding community.
Table 8: WHO Requirements for Liters Per Capita Per Day of Drinking Water.
Lpcd (Sedentary) Lpcd (Active) Average
Adult Female 2.2 4.5 3.35
Adult Male 2.9 4.5 3.7
Average 2.55 4.5 3.525
Based on these recommendations, the demand for drinking water per day was calculated in Table 9. The project will serve the school population of 263 and roughly 200 household with an average of 6 people per household, as estimated by the representatives we met with on the assessment trip. Based on the average liters per capita per day recommended by WHO, the required volume of potable drinking water per day for the school and total community is included in Table 9.
Table 9: Water Demand for Population of the School and Community.
Households Served
Average People per Household Total Volume of Water Per Day Average (L)
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Students 263 927.075
Community 200 6 1200 5157.1
Total 1463 6084.15
Additionally, based on the discharge rate of the pump and the hours of operation of the pump, the liters of water per day supplied by the pump was calculated. It was found that the pump would be able to supply the population of the school and community based on the average WHO recommendations for potable drinking water.
Table 10: India Mark II Volume of Water per Day
Pump Discharge Rate (L/Hour)
Hours of Operation (Hours)
Liters of Water Per Day (L)
900 7 6300
Material Calculations Below are the calculations for the materials required for the construction of the well, including the materials for both the contractor and EWBND team. THe total material calculations have a factor of safety of 1.2.
Part Material Quantity
Unit
Concrete Pad Concrete 4.025 m^3
Well Cover Concrete 0.601 m^3
Concrete Pad + Well Cover Concrete 4.625 m^3
Concrete Pad + Well Cover Cement 0.771 m^3
Concrete Pad + Well Cover Cement 6.167 # ⅛ m^3 bags
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Appendix C includes the drawing set. The contractor will be constructing the culvert section, the manhole cover, the well cover, and the handdug well. EWBND will be constructing the concrete pad cover, the drainage channel, and the wall.
2.4 524 – Draft Design Report Comments
1. Drawings: 524 5/2016
1. All sheets must be signed and dated by Mentor/Technical Lead Engineer: to be provided
2. Map: Detailed map which includes: water sources, taps, pipelines, tanks, contamination sources (farms, grazing or latrines): to be provided.
3. Units, used by locals: provided. 4. Map and Site Plan Arrow and scale bar: provided 5. Site Plan: provided, to be put at beginning of drawing set.
6. Profile: provided
7. Well Diameter, depth to water (expected), rocks, consolidated (expected?): to be provided
8. Detailed drawings: provided, to be refined.
9. Soak a way pit detail: to be provided 10. Apron detail: to be provided 11. Chapter to ensure that all pertinent information be included on drawings, especially notes for
proper construction: to be provided. 12. Electrical: 3line diagram: N/A 13. Formwork for all cast concrete: to be provided.
See Drawing Set in the Appendix.
Chapter Response to PM Hold Comment: 1. Sheets signed and dated in the Drawing Set in the Appendix 2. Detailed maps provided in the Drawing Set in the Appendix 3. 4. 5. Site plan included in the Drawing Set in the Appendix 6. Profile provided. 7. Well diameter, expected depth to water, and soil profile include in the Drawing Set in the Appendix. 8. Refinements included in the Drawing Set in the Appendix 9. Soakaway pit detail provided in the Drawing Set in the Appendix 10. Apron detail provided in the Drawing Set in the Appendix 11. Drawing Set is construction ready. 12. 13. Formwork discussed in Section 4.1.
2. Calculations: Professional quality for all aspects.
1. All calculations must be signed and dated by Mentor/Technical Lead Engineer: to be provided 2. Demand: completed 3. Supply: completed (wells about 25 miles away, some good, some bad, chapter wants 40,000 lpd) 4. Hydraulic Analysis: addressed 5. Pipe size and material: to be completed 6. Water Hammer and Thrust Block Calculations: N/A 7. Slope stability: N/A
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8. Pump: System Head Curve: provided 9. Wet well: Sized so pump doesn’t start > 10x/ hour: n/a 10. Clear well: Sized so >= 6 inches of clear space on all sides of the pump: N/A 11. Treatment/Disinfection Calculations: to be completed 12. Tap stand discharge rate: to be documented 13. Soakage Pit dimensions (Assume 10% loss of supply): completed
Concrete:
1. Mixing proportions for concrete: Provided 2. The concrete mixture should be approximately 1:2:2 (or 1:2:3) in terms of cement: sand: aggregate. 3. Watertoconcrete ratio should be no greater than 0.45: Weight or Volume basis: to be clarified 4. More work to get to higher psi (Set cement/sand/gravel ratioDone, water: concrete ratioDone,
1. Gravity load: completed 2. Live Load includes roof workers: N/A 3. Soil bearing Capacity: completed 4. Wind Loads: n/a 5. Seismic force calculations: to be completed 6. Slab strength calculations: to be completed 7. Wall strength calculations: N/A 8. Roof strength calculations: N/A 9. Total Material Calculations with x??? Safety Factor: to be completed 10. Conservative construction timeline calculations: completed
See Section 2.2. Chapter Response to PM Hold Comment:
1. Calculations signed and dated by Rodney Beadle, PE at the top of Section 2.2 2. 3. 4. 5. Pipe size and material: hand dug well, does not have pipe. culvert sections used instead, dimensions
included in drawing set. 6. 7. 8. 9. 10. 11. Calculations on disinfection can be found in the Disinfection Calculations section of Section 2.2. 12. Tap stand discharge rate included in Section 2.2 13.
Concrete:
1. 2. 3. 4. Reinforcement calculations included in Section 2.2 and rebar included in the Drawing Set in the
Appendix. Notes for contractor included in the Drawing Set in the Appendix.
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1. 2. 3. 4. 5. Seismic force calculations not relevant for the area. 6. Slab strength and reinforcement calculations included in Section 2.2 7. 8. 9. Material Calculations included in Section 2.2 with a safety factor of 1.2. 10.
3. Operations, Maintenance and Small Repair (O&M)Manual: This can’t be just part of report, but must
be its own standalone document, and not just copies of equipment specs, but actual manual that is written
for community to operate, maintain and repair all equipment coming from project.
1. O&M Plan, in English: to be provided. 2. O&M Plan, in Local Tongue, pictoral: to be provided. 3. O&M Maintenance Log: to be provided.
See Section XX. Chapter Response to PM Hold Comment:
1. O&M Plan, in English provided. 2. O&M Plan, in Local Tongue, pictoral: to be provided. 3. O&M Maintenance Log provided.
2. Codes used: to be documented 3. Pipe Strength Reference: to be provided
Pump:
4. Total Dynamic Head: Completed 5. System Head Curve: provided 6. Pump wall spacing: to be provided: ANSI 98 code? 7. Sedimentation: The Water for the World: Designing a Small Community Sedimentation Basin technical
notes: n/a 8. Motor: Pump and phase available: n/a
9. Building: per ASCE 710 (Minimum design loads for buildings and other structures) 10. Wind pressure: provided, based on ASCE 710 11. Drainage: Completed: Rational Method/ 2% slope
12. Electrical: 2008 National Electric Code 13. Design Checklist for Solar PV Projects 14. Building: per ASCE 710 (Minimum design loads for buildings and other structures) 15. Masonry wall: designed using either the MSJC Code or ACI 530
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16. Permits: to be provided 17. Standards used, summarized at top of calculations section: documented, to be refined. 18. Assumed strength of concrete, rebar, etc.: to be provided at top of calculations section. 19. Soil: maximum soil load bearing capacity of 1000 lb. per square foot; ability of the soil to withstand the
construction of this structure the BS (British Standard Building Code) 8004 20. Ground: Provided: 21. Concrete: Density: 2,400 kg/m3 22. Concrete: Volume: Materials for Civil and Construction Engineers Third Edition 23. Concrete: Provided: 1500 psi, maximum allowed slump of 4” per American Concrete Institute 211.1 24. Concrete Water: ACI 211.2 and ACI 318 standards for maximum allowable water to cement ratio and in
Table 3 below the water to cement ratio for three allowable coarse aggregate sizes can be seen. 25. Table: Aggregate Size and Max Allowable Amount of Mixing Water 26. Aggregate Size (mm): 9.5 12.5 19 27. Mixing Water (kg/m3) 228 216 205
See Section XX. Chapter Response to PM Hold Comment:
1.
2. Codes used included in Section 2.2. 3. Hand dug well, does not have a pipe. Will be using concrete culvert sections. Strength of concrete and
rebar included in Section 2.2. Pump:
4. 5. 6. Culverts have an inner diameter of 120 cm. 7. 8.
9. 10. 11.
12. 13. 14. 15.
16. The contractor has requested a permit and agreed to file the permit prior to digging. The permit will
ensure that no latrines or other contamination sources can be put in place within at least 15 m of the will site.
17. Standards used, summarized at top of calculations section: documented, to be refined. 18. Assumed strength of relevant materials included in the tables at the top of each calculation section in
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25. 26. 27.
5. Community Agreement with Chosen Alternative Documentation: Documentation (Letter, Email, Phone Log) that community fully supports chosen alternative: provided. See Section XX. Chapter Response to PM Hold Comment: 6. Scope – Chapter not being present for well drilling is unprecedented. This is most important part of
trip. 1. Justification for not using Water4 or similar for 612” well: to be provided. 2. Culvert sections look extremely dangerous. Safety precautions: to be documented.
See Section XX. Chapter Response to PM Hold Comment:
1. Justification for not using Water4 or similar for 612” well: to be provided. EWBND put a lot of thought into this final design for the well. Ultimately, a hand dug India Mark II well was chosen due to its popularity in the area. All of the contractors interviewed for this project suggested similar designs, and all of the wells found in the area were hand dug. Instead of imposing a Water4 type system, or bringing in outside drilling equipment which locals don't know how to safely use, EWBND decided to support the local practice.
2. Safety precautions included in the Drawing Set, HASP, and Section 4.1.
3.0 Project Ownership RUWADA, headed by Ma Hannah, has mobilized the community and reached out to the district officials and local nobles to gain support for the project. They have established a water committee to track use, collect dues, and ensure periodic maintenance of the well and testing of the water. The water committee consists of Ma Hannah, the school principal, as well as seven other elected representatives from the school and the larger community. A specific bank account will be created by the RUWADA to provide for the periodic maintenance of the well and annual chlorine treatment. Although the well will be located on the property of the Alfred and Sarah Bilingual Academy, the well will be managed by the water committee, not solely the faculty and staff of the school. This water committee will be responsible for the maintenance and treatment of the well. While on the assessment trip, EWBND taught potential members of the water committee how to test the water using test strips and Coliscan Easygel and plans to meet with the board while on the implementation trip to go over the structure of the well and basic maintenance. Additionally, members of the board will appoint a monitor to oversee use of the well and to collect fees from individuals who draw water based on the volume they draw. The monitor will be present at the well when it is open to the public from 5:30 am to 8:30 am and again from 4 pm to 7 pm. School teachers on the water board have agreed to oversee the student’s usage during the school day.
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We hope to be able to charge 5 Francs per liter of water ($0.00835) to ensure upkeep of the well. We predict that this well will be used semiregularly by 200 households, each containing an average of 6 individuals. At 5 Francs per liter, in a year the water committee will have accumulated the funds to have the contractor come back for repairs, as well as an additional 388,000 Francs for parts, in one year. This price would be considered extremely reasonable to the community, as the local orphanage currently charges 10 Francs per liter of water.
4.0 Construction Plan
4.1 Well Construction Due to rainy seasons in Cameroon, the season in which well construction takes place is of vital importance. Construction would be very difficult during heavy rains, as transportation through dirt roads would be challenging. Furthermore, the lowest water table depth throughout the year occurs during the dry season. As a result, any water produced during the dry season would show that a source is feasible yearround. Lastly, the roads need to be able to accommodate material delivery and/or a drilling rig if necessary. During the assessment trip, the members of the community stated their willingness to do everything within their means to remedy such problems if they were to arise. EWBND has surveyed the community for names of experienced and qualified well construction contractors, and interviewed three. Ets Groupe Mambo was selected for the project due to their technical knowledge, previous good work, and willingness to accommodate our financial and time restrictions. Because the construction company has extensive experience with wells, having constructed many hand dug wells in the area, EWBND decided to proceed with the prevailing construction process in the region with only slight modifications to further ensure the safety of the workers. Ets Groupe Mambo’s will use a series of harnesses to lower a member of the team into the well while he digs, allowing for quick removal if necessary. This manual digging continues until groundwater is hit, after which a temporary generator driven pump is placed in hole. At that point, the worker is removed from the hole and the culverts are lowered into the hole, on on top of the others. This enables the laborer to continue digging to about 4 meters below the groundwater level with the culverts providing trench protection. No excavation work occurs below the groundwater level without the protection of the culverts. Furthermore, we will require that the contractor must designate a safety officer whose responsibilities will include checking on the harness equipment and keeping an eye out for any potential safety concerns. Additional soil testing was done to ensure the site is suitable for manual digging. Last assessment trip, the contractor conducted a soil test which was submitted to the Ministry of Health to ensure the location selected is acceptable for a well. The team also did their own testing and calculations which can be seen in the Soil Bearing Capacity section of the Calculations within this report. The site was observed to contain stable, stiff clay soils which should be able to support the well structure. Other hand dug wells in the area were inspected and seen to be stable, despite less structural support on the inner walls of the wells than
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EWBND is using for this well. The contractor also aggreed that he trusts his team will be able to operate safely given the soil of the area. The construction company is expected to provide the construction knowledge and materials needed for the implementation of the well and handpump, such as culvert sections, reinforcement bars, gravel packs, etc. Additionally, Ets Groupe Mambo is responsible for the provision of the pump to remove water while digging, and the digging will be considered successful once the regional groundwater table has been penetrated and surpassed up to 4 meters. The formwork for the culverts will be similar to the example pictured below. The formwork for the culverts will be supplied by ETS Groupe Mambo and the culvert sections will be constructed prior to EWBND arrival. A professional mason will oversee the work of the contractor as he constructs the culverts to ensure that the correct amount of rebar and ratio of concrete will be used.
4.2 Concrete Pad, Wall, Drainage Channel and Soak Pit Construction
The EWBND team will be responsible for the construction of the concrete pad, the cinderblock wall, the drainage channel, and the soak pit. As an additional precaution to prevent theft and contamination, a cinderblock fence will be placed along the perimeter of the concrete pad to prevent animals from contaminating the area and well. Additionally, the fence would be used to regulate who could use the well and at what times of the day. Precautions will be taken to notify the community that the water will not be confirmed safe to drink until testing is completed. The team will also dig a soak pit and construct a drainage channel to the soak pit to prevent water from pooling within the fenced area of the well. EWBND’s faculty advisor has offered to
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let the EWBND team practice constructing a concrete pad in his backyard to understand all of the steps involved and what issues can arise. The well will be treated with a mixture of 300 grams of bleaching powder with 15 liters of water for disinfection. Following this, the team will test the water against WHO recommendations to ensure its potability. The chapter performed similar tests during the assessment trip utilizing test strips and Coliscan Easygel, and will continue to train members of the community to perform similar tests. Precautions will be made to notify the community that the water will not be confirmed safe to drink until testing is completed.
5.3 Construction Schedule The schedule of events during the trip is crucial for a successful implementation. Because problems and delays will inevitably develop onsite, a guideline schedule has been developed which lists the major tasks that will occur during EWBND’s implementation trip from December 28th to January 15th in the winter of 20162017. Figure 4 below displays the major tasks and the approximate dates at which they will occur.
Figure 4: Planning Level Construction Schedule
From EWBND’s meeting with the chosen contractor over the second assessment trip, the team developed a plan for implementation. Because the contractor requires between 1 and 2 months to construct the culverts and dig the well, the contractor will begin work in midOctober. EWBND will hire an overseer with a technical background in construction to inspect and observe the contractor’s work, take pictures, and complete daily reports. George Mokake has
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agreed to take on this position, having had construction experience in the region. George has a team which he works with who will be able to complete the daily report for him if ever necessary.
EWBND will arrive midDecember once the well is dug, the culverts are in place, and the India Mark II hand pump is in place. George Mokake and his team has agreed to purchase the materials for EWBND in advance so everything will be ready for construction upon arrival.
The EWBND team will construct the reinforced concrete pad and the cinderblock gate surrounding the well. Additionally, the team will provide educational materials, including a physical demonstration and written documentation for long term maintenance and operation. They will also conduct tests on the chemical, physical and biological properties of the water and train more students and members of the community on how to perform these tests as well.
5.0 Materials List and Cost Estimate Table 11 below includes the materials list calculated in Section 2.2. Additionally, EWBND met with a professional mason in Sangmelima for quotes on each of the materials. The last four rows above the total cost are the cost of labor and transportation and miscellaneous items as quoted by ETS Groupe Mambo. These prices are comparable with the quotes of the other two contractors that the team met with.
Table 11: Materials List and Cost Estimate Item Quantity
(FOS 1.2) Unit Price Number
of Units Total Price (Francs)
Total Price (USD)
Steel Sheet (10 mm thickness) 0.59 m^2
15000 per sheet (1m^3) 1 15000 25.5
Cement 29. 9 bags 5,600 per bag
(8 bags per m^3) 30 bags 168000 285.6 Gravel (10 mm) 11.2 m^3 300,000 per 15 m^3 1 300,000 510 Cinderblocks 36 blocks 800 each 36 28800 48.96 Sand 7.5 m^3 120,000 per 15 m^3 0.5 60,000 102 No. 10 Rebar 393.6 m 5000 per 12 m 32.8 147600 250.92 No. 8 Rebar 685.8 m 3000 per 12 m 57.15 171,444 291.4548 Wire Mesh 19.2 m^2 5,000 per 1 m^2 19.2 96000 163.2 Binding Wire 1.2 rolls 2,000 per roll 2 4,000 6.8 Gravel (20 mm) 12.3 m^3 300,000 per 15 m^3 1 300000 510 Chain Link Fence (200 cm high) 37.7 m 2,000 per meter 38 76000 129.2 India Mark II Handpump and Accessories
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Labor 150000 255
Transport 200000 340 Professional Mason to Oversee Contractor
2 months 150,000 per month 2 300,000 510
Total 6516844 11078.63
6.0 Operation and Maintenance Once the hand pump is installed and operational, the school and surrounding community will be responsible for upkeep of the system and any additional repairs needed in the future. These tasks include taking on financial responsibility for repairs. Since the community will pay 5% of overall cost, they are considered owners of the project, hence their need to be financially responsible for future upkeeps. The contractor has agreed to take care of any repairs within 24 months of construction free of charge. The labor and the parts for these repairs would be free with the exception of a case in which the pump broke completely, in which case the water committee would have to supply those funds. After the first 24 months, additional repairs would cost 50,000 Francs plus the cost of parts. A list of the prices in both CFA Franc and USD of the major replacement parts is included in Table 12 below.
Table 12: Prices of Replacement Parts Qty. Item CFA Franc USD
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11 Pump Buckets 576.6228 1.08
12 Pipes 9610.38 18
13 Connecting Rods 3844.152 7.2
14 Lower Valves 3844.152 7.2
15 Axle Bolts 1345.4532 2.52
16 Axle Nuts 192.2076 0.36
17 Bearing Spacer 192.2076 0.36
18 Washer 192.2076 0.36
19 Chain Bolts 192.2076 0.36
20 Chain Nut 192.2076 0.36
21 Pedestal 28831.14 54
22 Reducer Cap 576.6228 1.08
23 Plunger Rod 3844.152 7.2
24 Rubber Seal (lower) 288.3114 0.54
25 Rubber Seal (upper) 288.3114 0.54
26 Sockets 384.4152 0.72
Total 178176.4452 333.72
Plans are also being made to ensure that the community is as selfsufficient as possible so the well is high quality for as long as possible. EWBND will help train people in the community to be able to perform the simpler tasks. EWBND will communicate with the contractor who built the well in order to make an instruction manual that the community can follow after all the workers are done implementing the pump and are gone from the community. A detailed Operation and Maintenance manual as prepared by the Swiss Resource Centre and Consultancies for Development for the India Mark II hand pump is included Part 2 of the document included in the Appendix. It includes instructions for monthly checks, three monthly checks, and yearly replacements. Additionally, it includes a process for diagnosis and treating problems with the pump through a “Troubleshooting Chart.” It includes detailed diagrams for
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dismantling and cleaning both the aboveground and belowground parts of the well. There are also instructions on how to maintain the area surrounding the pump to ensure cleanliness. In addition to the Troubleshooting chart, there is a list of the components that require frequent replacement, a maintenance card to track failures and cost, and a monitoring checklist. EWBND will be returning to Sangmelima on another trip after the implementation trip which will allow for tests on the system to be performed to ensure proper functionality. This will test to see if the pump has any initial problems that occur very soon after the building. Our hope is that the community will be able to handle these repairs on their own, and with the help of the contractor when necessary, and be able to finance repairs with the money collected by the water committee. The water committee, which was formed prior to submitting the application to EWBUSA, has agreed to manage any new water systems that are implemented. The committee already has a plan in place to collect fees for the water. The feasibility of the community to provide for the operation and maintenance of the well is discussed in further detail in 8.3 – Financial Capacity of the Community.
7.0 Sustainability
7.1 Background The main issues that the chapter foresees as threats to the sustainability of the well are over tapping the aquifer, inadequate funds or expertise to maintain the well, and disagreement over the ownership of and responsibility for the well once it has been built. To address these concerns, the chapter has worked with the surrounding community to establish a water committee to track usage and plans to train members of this board on proper usage and maintenance of the well. Last assessment trip, the contractor conducted a soil test which was submitted to the Ministry of Health to ensure the location selected is acceptable for a well. The contractor will also get the permits required from the local government which ensures that no latrine will be placed within 15 meters of our site. To allow for regulation of the well and proper practice, the well would be open for 7 hours during the day. Assuming a pumping rate of 15 liters per minute, this would produce roughly 6,300 liters per day, which would provide 24 lpcd for the school or 4.3 lpcd for the greater community which meets WHO’s recommendations. Lpd will therefore not be a concern during Phase 1 with the handpump. However, if the project were to proceed to a second phase to serve the greater community and employ an electric pump, this would become an important consideration. To ensure the longterm success of the project, proper maintenance will be required. The team plans to prepare a stepbystep guide for regular maintenance in additional to a detailed diagram of the well with information regarding where to purchase parts if they were to fail. The team plans to work with the contractor to use as many locally sourced materials as possible to
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make it easier for the water committee to access replacement materials. EWBND plans to hold a training during the implementation trip with members of the water committee and students at the school on proper usage, treatment, and maintenance to inform as many people as possible on how to care for the well. While there, the team will identify one to three people that will be primarily responsible for the technical aspects of the well who will be especially familiar with the internal components of the well and will meet with the team and the contractor following construction to ensure a thorough understanding of the assembly of the well. The chapter will also ensure that the water committee will take responsibility for regular chlorine treatment of the well.
7.2 Organizational Capacity of the Community Before the chapter even became involved, RUWADA had already made steps to assemble a water committee to properly manage and maintain the well once constructed. This board consists of publically elected representatives from the community and school and nobles from the village. RUWADA has also already set up an independent bank account to provide for the maintenance, treatment, and security of the well. While on the assessment trip, the team and Ma Hannah met with the President’s representative in Sangmelima and various other government officials to ensure their support of the project. Additionally, while on the assessment trip the team was presented with a formal agreement from the water committee to ensure proper use and maintenance of the well and to accept ownership. This document, signed by 21 members of the community including the chief of the village, five notables, and various other assistants and members is included in the Appendix.
7.3 Financial Capacity of the Community As stated above, RUWADA will create a separate bank account to provide for the maintenance of the well. While on the implementation trip, the team will meet with the representatives from the water committee responsible for the collecting and reporting of dues from the households that use the well. The board has determined a fee of 5 Francs per liter to provide for the operation and maintenance of the well. While on the assessment trip, the team conducted a community survey and polled various households on whether or not they would be able to afford this fee and whether or not they thought that access to the well would be worth this amount. The team received an overwhelmingly positive response as many of the households now pay carriers to collect clean water from neighboring villages or pay a similar fee to an orphanage in the neighboring village to obtain clean water. Table 13 below contains the results of this survey. From this table it is clear that the fee of 5 Francs per liter would be manageable for the members of the community.
Table 13: Current practices of the community for potable water.
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
Household Liters Per Day
People Per Household
Liters per Person Per Day Notes
1 7 6 1.17
Travels 10 km every three days to obtain potable water which costs more than 500 Francs ($0.96) per trip.
2 10 12 0.83 Drives 7 km for drinking water.
3 20 20 1 Travels 5 km for drinking water.
4 15 20 0.75 Pays a biker 300 Francs ($0.58).
5 20 14 1.43 Use a handdug well.
6 10 20 0.5 Pays a driver 200 Francs ($0.38).
7 ? 10 ? Use a handdug well on their property.
The water committee has agreed to have a member stationed at the well during operational hours to keep track of which households use the well and to collect monthly dues.
7.4 Technical Capacity of the Community Although none of the community members are technically trained in well construction or maintenance, they are eager to learn and willing to participate in trainings. Because the chosen contractor has plenty of construction experience, they will be able to provide assistance and advice to the water committee on proper maintenance and where to acquire replacement materials. EWBND does, however, recognize that extensive trainings will be required to get the board to an adequate level of understanding of the parts and assembly of the well and is willing to work with the chosen contractor and the partnering NGO to accept this responsibility.
7.5 Education Because the well is located at the Alfred and Sarah Bilingual Academy, EWBND has an opportunity to not only train the board on proper maintenance and treatment, but also provide an opportunity to the students of the school to test the water and learn about the biological and physical properties of the water. While on the assessment trip, the chapter conducted many E. Coli/Coliform detection tests using Coliscan Easygel to test for biological contaminants. Ma Hannah cleared out a room at the academy as a lab for the team for these test and invited students, staff, and faculty at the school to observe the tests and participate. As pictured below in Figure 5, these members of the community were eager to learn how the tests were conducted
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
and what the results meant. The team plans to conduct similar trainings during the implementation trip on how to perform these biological tests using Coliscan Easygel and tests on the chemical properties of the water using test strips.
Figure 5: Kendra Harding and students of the Alfred and Sarah Bilingual Academy
conducting E. Coli/Coliform detection tests using Easygel. As stated previously, in addition to these trainings on how to test the quality of the water, the team will also work the contractor and NGO to provide trainings on the components of the well and proper usage and maintenance of the well to ensure its longevity.
8.0 Site Assessment Activities There are several options for additional implementation plans near the Alfred and Sarah Bilingual Academy that our travel team will investigate during our upcoming implementation trip. Our team will explore the feasibility of installing rainwater catchment systems around the school as well as the possible construction of a water tank, water lines, and an electric pump to accompany the well. EWBND intends to conduct site assessments within the community to collect data to assess these different options. The main goals of the site assessment are to:
∙ Listen to community values and goals for possible future implementations ∙ Gather data on water quality and hand pump functionality ∙ Determine most suitable locations for potential rainwater catchment systems if desired
by the community ∙ Evaluate the need for new and better latrines to serve the school and surrounding
community The equipment needed for the site assessment will consist of a Coliscan Easygel testing set to test the water’s quality and GPS technology. In the assessment trip, EWBND tested the water using the same Coliscan Easygel set to assess its quality. Holding the equipment constant, the travel team for the implementation trip will test the water in the same manner as before, under
525 – PreImplementation Report Revised 11/2015 University of Notre Dame Cameroon, Sangmelima, 10711
the guidance of our professional mentor Rod Beadle. Several water samples will be drawn from the hand pump by the travel team and tested following the instructions of the system. The GPS will be used to record further data on the community area and elevation. This data could prove valuable should our chapter move forward on future projects involving the newly constructed well. The results of the site assessment should be compiled and presented to the community at the conclusion of the trip to inform the community members of the efficiency of the constructed hand pump and to discuss feasibility of future projects. Future projects could include, as mentioned above, a rainwater catchment system as well as a water tank, water lines, an electric pump and new latrines. The rainwater catchment system would make use of the tin roofs on the school buildings to gather water for the school’s general use and education for the students. The assessment for this project would involve technical measurements of the roofs themselves as well as interviews with locals concerning rainfall and with the teachers concerning how they think the catchment system would be used and kept up. The water tank would be part of a larger project which would include a second pump in the current well, this one being electrical, as well as a distribution line. This project is being considered due to its ability to provide more water taps to the community. The assessment for this project would include a bit of electrical work. Contact would be made with the local electrical company, SONEL, regarding the logistics of getting power to the pump. Further discussion would also be done with the contractor for his technical opinion as well as with the students concerning their opinions and predicted usage of handwashing stations.
Document 903 IMPLEMENTATION AGREEMENT EWB-USA projects are most successful when there is a three-way partnership between each of the entities listed below. Each partner has specific skills and expertise, which together, contribute to a more sustainable project over the long-term.
• Sangmelima: The Water Board, The Alfred and Sarah Bilingual Academy, and The Rural Women Development Association (RUWADA)
• Plant a Seed • The EWB-USA University of Notre Dame chapter (EWB-ND)
This contract is between EWB-USA University of Notre Dame chapter (EWB-ND), Sangmelima, and Plant a Seed for the purpose of setting guidelines for Sangmelima, Cameroon- Water Supply (School). The specific conditions listed below must be included in the standard EWB-USA Implementation Agreement. Additional roles and responsibilities identified by any party to the agreement may be added at the discretion of all parties to the agreement. This document must be signed by all parties in order to begin construction of Sangmelima, Cameroon - Water Supply (School). The roles and responsibilities agreed to in the previously-signed Project Agreement remain in effect in addition to the commitments outlined below. PRE-CONSTRUCTION PHASE Sangmelima responsibilities:
• Provide 5 % (430,000 CFA Francs/ $800) of the capital construction cost in cash before construction begins.
• Provide written confirmation that the land required for the project implementation is owned by the community before construction begins. Alternatively, in lieu of ownership,
the community can provide written confirmation that it has a permanent easement to use the property.
• Provide written confirmation that it has the legal right to use the water supply that is being developed in this project.
• Commit 5 workers for 4 hours per day for 7 days to the construction site. • Minlo Hanna N-Mokake will be responsible for organizing the in-kind labor. • If necessary, provide a qualified member of the community to be present dur.ing
construction for observation or oversight.
Plant a Seed responsibilities: • Provide 10 % (860,000 CFA Francs/ $1600) of the capital construction cost in cash
before construction begins. • Provide an open line of communication between EWB-ND and the community. • Inform EWB-ND about changes to security/safety situation
University of Notre Dame chapter of EWB-USA responsibilities:
• Provide 85% ($13,600) of the capital construction cost in cash before construction begins.
• Provide qualified representatives of the design team during construction for observation or oversight or arrange for a qualified member of the community to be present.
• Communicate the requirements of site preparation prior to the chapter arriving for construction. This will be communicated to the community and the local partner two months prior to construction, or earlier as determined by the project needs.
POST-CONSTRUCTION/OPERATIONS AND MAINTENANCE PHASE Sangmelima responsibilities:
• Pay for 100% of the costs to operate and maintain the project, Sangmelima, Cameroon - Water Supply (School). This cost is estimated to be 88,000 Francs ($165) per year.
• Collect monetary resources from the community for operations and repairs monthly. • The amount collected per the schedule above will be: 200 Francs ($0.04) per household. • The position/committee responsible for identifying maintenance needs is: Minlo Hanna
N-Mokake from The Rural Women Development Association (RUWADA)and faculty of the Alfred and Sarah Bilingual Academy.
• This position/committee has been elected. • This position/committee will serve in this role for 10 years. • The position/committee responsible for performing maintenance is The Water Board or a
hired technicial depending on complexity. • This position/committee has been elected.
• Each representative of this committee will serve in this role for a minimum of 5 years, with replacement representatives elected when openings occur.
Plant a Seed responsibilities:
• Provide ongoing support to Sangmelima for a minimum of 5 years after construction is complete, as needed.
• Assist with additional monitoring activities as identified by University of Notre Dame chapter of EWB-USA as long as the program is active for the EWB-USA chapter.
University of Notre Dame chapter of EWB-USA responsibilities:
• Develop a detailed operation and maintenance manual for the community (including applicable photos and local language, as appropriate). The manual will include a maintenance schedule and anticipated costs.
• Provide monitoring and evaluation of the project, Sangmelima, Cameroon - Water Supply (School) for a period of not less than one year post-construction and as long as the program is active.
• Perform repairs to the project that are the result of errors in the design until they are corrected.
In addition to the responsibilities listed above, the responsible party for each of the following is:
• Coordination of transportation for travel team members of University of Notre Dame chapter of EWB-USA will be provided by Sangmelima.
• Coordination of translation services for travel team members of University of Notre Dame chapter of EWB-USA will be provided by Sangmelima.
• Scheduling of community-provided labor will be provided by Sangmelima. This includes 5 community workers for 4 hours per day for 7 days at the construction site.
• Procurement of construction materials before University of Notre Dame chapter of EWB-USA arrives for construction will be provided by Sangmelima.
• Transportation of materials will be funded by EWB-ND.
On behalf of, and acting with the authority of the residents of Sangmelima, the NGO/local municipal partner Plant a Seed and University of Notre Dame chapter of EWB-USA, the under-signed agree to abide by the above conditions.
Signature Date Printed Name Position in (chapter name) chapter of EWB-USA Signature Date Printed Name Position in Community-Based Organization Signature Date Printed Name Position in Local Partner Organization
Projets EWB-USA sont les plus efficaces quand il se agit d'un partenariat tripartite entre chacune des entités énumérées ci-dessous. Chaque partenaire a des compétences et de l'expertise spécifiques , qui, ensemble , contribuent à un projet plus durable sur le long terme .
• Sangmelima: The Water Board, The Alfred and Sarah Bilingual Academy, and The Rural Women Development Association (RUWADA)
• Plant a Seed • The EWB-USA University of Notre Dame chapter (EWB-ND)
Ce contrat est conclu entre EWB-USA University of Notre Dame chapter (EWB-ND), Sangmelima , et Plant a Seed dans le but de directives fixant pour Sangmelima , Approvisionnement en eau Cameroun- ( école ) . Les conditions spécifiques énumérées ci-dessous doivent être inclus dans l'accord de mise en œuvre EWB-USA standard. Rôles et responsabilités supplémentaires identifiés par l'une des parties à l'accord peuvent être ajoutés à la discrétion de toutes les parties à l'accord . Ce document doit être signé par toutes les parties en vue de commencer la construction de Sangmelima , Cameroun - Approvisionnement en eau (école) . Les rôles et les responsabilités convenues dans l'Accord de projet précédemment signé demeurent en vigueur , en plus des engagements décrits ci-dessous. PRE - PHASE DE CONSTRUCTION Responsabilités Sangmélima:
• Fournir 5 % (430,000 CFA Francs/ $800) du coût de construction de capital en numéraire avant le début de la construction ( $$$) .
• Fournir une confirmation écrite que les terrains nécessaires à la mise en œuvre du projet est possédée par la communauté avant le début de la construction . Alternativement , au
lieu de la propriété , la communauté peut fournir une confirmation écrite qu'il a une servitude permanente d'utiliser la propriété .
• Fournir une confirmation écrite qu'il a le droit légal d'utiliser l'alimentation en eau qui est en cours d'élaboration dans ce projet .Commit 5 workers for 4 hours per day for 7 days to the construction site.
• Minlo Hanna N-Mokake sera responsable de l'organisation du travail en nature . • Si nécessaire, fournir un membre qualifié de la communauté d'être présent la construction
de dur.ing pour l'observation ou de surveillance .
Responsabilités Plant a Seed: • Fournir 10 % (860,000 CFA Francs/ $1600) du coût de construction de capital en
numéraire avant le début de la construction . • Fournir une ligne de communication ouverte entre EWB-ND et la communauté
.Informer ISF -ND des changements de la situation de sécurité / sûreté.
Responsabilités University of Notre Dame chapter of EWB-USA:
• Fournir 85 % ($13,600) du coût de construction de capital en numéraire avant le début de la construction .
• Fournir des représentants qualifiés de l'équipe de conception lors de la construction pour l'observation ou de surveillance ou d'organiser un membre qualifié de la communauté d'être présent .
• Communiquer les exigences de préparation du site avant le chapitre arrivant pour la construction . Ce sera communiquée à la communauté et le partenaire local deux mois avant la construction , ou plus tôt , tel que déterminé par les besoins du projet.
POST - CONSTRUCTION / EXPLOITATION ET ENTRETIEN PHASE Responsabilités Sangmelima:
• Payer pour 100 % des coûts d' exploitation et la maintenance du projet , Sangmelima , Cameroun - Approvisionnement en eau ( école ) . Ce coût est estimé à 88 000 francs ($165) par an .
• Collecter des ressources monétaires de la communauté pour les opérations et les réparations mensuelle.
• Le montant perçu par le calendrier ci-dessus sera : 200 francs ($ 0.04) par ménage. • La position / comité chargé de l'identification des besoins de maintenance est : Minlo
Hanna N - Mokake de l'Association des femmes rurales de développement (RUWADA) et le corps professoral de l' Alfred et Sarah bilingue Académie .
• This position/committee has been elected. • Cette position / comité servir dans ce rôle pendant 10 ans.
• La position / comité chargé de procéder à l'entretien est L'Office des eaux ou d'un technicien engagé en fonction de la complexité .
• Cette position / comité a été élu . • Chaque représentant de ce comité servira dans ce rôle pour un minimum de cinq années ,
avec des représentants élus de remplacement lorsque des ouvertures se produisent . Responsabilités Plant a Seed:
• Fournir un soutien continu à Sangmelima pour un minimum de cinq années après la construction est terminée , selon les besoins .
• Participer aux activités de surveillance supplémentaires identifiés par l'Université du chapitre Notre-Dame d'ISF - Unis tant que le programme est actif pour la section d'ISF -USA .
Responsabilités University of Notre Dame chapter of EWB-USA:
• Développer une opération détaillé et manuel de maintenance pour la communauté ( y compris des photos et applicables langue locale , le cas échéant ) . Le manuel comprendra un calendrier d'entretien et les coûts prévus .
• Assurer le suivi et l'évaluation du projet , Sangmelima , Cameroun - Approvisionnement en eau ( école ) pour une période de pas moins d'un an après la construction et aussi longtemps que le programme est actif .
• effectuer des réparations sur le projet qui sont le résultat d'erreurs dans la conception jusqu'à ce qu'elles soient corrigées .
En plus des responsabilités énumérées ci-dessus, la partie responsable de chacun des éléments suivants est :
• Coordination de transport pour les membres de l'équipe de Voyage de l'Université du chapitre Notre-Dame d'ISF - Unis sera assurée par Sangmelima .
• Coordination des services de traduction pour les membres de l'équipe de Voyage de l'Université du chapitre Notre-Dame d'ISF - Unis sera assurée par Sangmelima .
• Planification du travail fourni par la communauté sera fourni par Sangmelima . Cela comprend cinq travailleurs communautaires pour quatre heures par jour pendant 7 jours sur le site de construction .
• Acquisition de matériaux avant l'Université du chapitre Notre-Dame d'EWB-USA construction arrive pour la construction seront fournis par Sangmelima .
• Transport des matériaux sera financé par EWB-ND .
On behalf of, and acting with the authority of the residents of Sangmelima, the NGO/local municipal partner Plant a Seed and University of Notre Dame chapter of EWB-USA, the under-signed agree to abide by the above conditions.
Signature Date Printed Name Position in (chapter name) chapter of EWB-USA Signature Date Printed Name Position in Community-Based Organization Signature Date Printed Name Position in Local Partner Organization
Cinderblocks 36Chain Link Fence (200 cm Height) 38 mNo. 10 Rebar (Metric) 394 mNo. 8 Rebar (Metric) 686 mNo. 10 Wire Mesh (20 cm spacing) 20 m2
Binding Wire 2 rolls
General Notes -A member of the contractor's team must be experienced with welding and bring welding equipment for the manhole cover lid. Safety Precautions-ETS Groupe Mambo will use a series of harnesses to lower a member of the team into the well.-A temporary generator driven pump will be placed in the hole once groundwater is hit.-The worker will not be in the hole while the culverts are being lowered.-No excavation work occurs below the groundwater level without the protection of culverts.-ETS Groupe Mambo must designate a safety officer with responsibilities such as checkig the harness equipment and watching for safety concerns. Material Properties-Yeild Strength of Steel Reinforcement: 45000 psi
-Density of Concrete: 2400 kg/m3
-Ratio for Concrete: 1:2:3 (cement:sand:coarse aggregate)
-Density of Cement: 3.14 g/cm3
-Coarse Aggregate Diameter: 10 mm-Gravel Diameter: 20 mm-Assumed Weight of Person: 62 kg-Weight of pump head: 720 kg-Coefficient of subgrade friction: 1.5-Percent Steel in Culverts (Transverse): 0.25%-Percent Steel in Culverts (Longitudinal): 0.16%
Date Signed: 6/19/2016Signature:Date Drawn: Jun-03-16 Site PlanTitle:0.000Scale
160 cm well dug by ETS Groupe MamboPrior to EWB-ND arrivalWell Depth projected to be 15-20mSoil profile: silty clay10 m Diameter Chain Link Fence surrounding the Well
For security and prtection from animals
Cinderblock WallConstructed by EWB-ND
Overseen by professional mason
Concrete ApronConstructed by EWB-ND
Overseen by professional mason
GroundSoil Profile: Silty Clay
India Mark II HandpumpInstalled by ETS Groupe Mambo
CulvertsConstructed by ETS Groupe Mambo
Prior to EWB-ND arrival
Well CoverConstructed by ETS Groupe MamboWhile EWB-ND present
Drainage Channel, 2% SlopeConstructed by EWB-NDOverseen by professional mason
20 mm Washed Gravel
40
400
1015
40
45
25
20
10
8042.5
140
Date Signed: 6/19/2016Signature:Date Drawn: Jun-03-16 CONCRETE_PAD_COVER Title:0.050Scale
Maintenance Card for India Mark II Handpump1. Monthly Checks
Check all flange bolts and nuts for tightness (8 off), Check that handle axle nuts and chain bolt and “Nyloc” nut are tight, Grease the chain, Repair holes and cracks on pump platform, Clean drainage and repair cracks, Clean the pump surroundings and repair the fence.Check that no fasteners are missing (if any are, replace them)
Make a Leakage Test: Operate pump handle until water is flowing from the spout. Stop operating the pump handle for approximately 30 minutes. Then operate the handle and count exactly how many strokes are required until the water is starting to flow again. If more than 5 handle strokes are required to make the water flow again, there must be a leakage in the rising main or the footvalve. Report to a pump mechanic!
Make a Discharge Test: Operate pump handle until a constant water flow is achieved. (pump ratio approximately 40 full handle strokes per minute). Place a bucket in the continuous water flow for exactly one minute. Take the bucket off the water flow and check the amount of water. If the discharge is less than 15 litres, there might be a problem with the bobbins or the cup seal. Report to a pump mechanic!
2. Yearly Checks (to be done by contractor)
Dismantle “above ground” and “below ground components”.Replace rubber seatings (upper valve & lower valve), cup seals (3 off) and sealing rings (3 off)Replace ball bearings.
Please Note: If one of the replaced components is still in good shape, spare it for emergency replacement (in case a new spare part is not immediately available).
Steps of Maintenance a) understand the cause for a
problem and determine the remedy needed,
b) dismantle the pump as necessary,
c) assemble the pump after replacing defective components,
d) record details in the “Maintenance card”.
Tools Required for Maintenance2 spanners for M10 hexagonal bolts & nuts (C1137) and 2 new Standard spanners (C1xxx), 2 spanners for M12 hexagonal bolts & nuts (C1005) and 2 new Standard spanners (C1xxx), One 20 litre bucket for discharge test and leaking test.
These tools are required by the pump users for preventive maintenance and are therefore left with the caretaker. All other tools used for maintenance and repair (the same as used for the pump installation) are with the area mechanic
Materials Required for MaintenanceThe basic materials required for handpump maintenance and repair are the same as listed for the pump installation.
Besides that are required: A small amount of cement, sand and gravel for platform repair, Local material to maintain and repair the fence, Heavy duty grease for lubricating the chain assembly.
1. Les contrôles mensuels
Cocher tous bride boulons et les écrous de serrage (8 off), vérifier que les écrous de l’axe et boulon de chaîne et "Nyloc" écrou sont serrés, graisser la chaîne, de réparation de trous et de fissures sur la plate-forme de la pompe, drainage de nettoyer et réparer les fissures, nettoyer les environs de pompe et réparer la clôture. Vérifiez qu’aucun. éléments de fixation sont manquants (s’ils, les remplacer)
Faites un test d’étanchéité:Actionner le bras de la pompe jusqu’à ce que l’eau sorte du tube de sortie. Arrêter d’actionner le bras de la pompe pendant environ 30 minutes. Alors, actionner le bras et comptez exactement combien de mouvements sont nécessaires avant que l’eau ne jaillisse de la pompe. Si plus de 5 mouvements sont nécessaires avant que l’eau ne jaillisse de la pompe, il doit y avoir une fuite au niveau du tube d’exhaure ou du clapet de pied. Se référer à l’artisan réparateur de pompe!
Faites un test de débit:Activer le bras de la pompe jusqu’à ce qu’un débit constant d’eau soitatteint (cadence d’environ 40 mouvements complets par minute). Placer un seau sous le tube de sortie pendant exactement une minute. Soustraire le seau de l’écoulement et contrôler la quantité d’eau recueillie. Si la quantité d’eau recueillie est inférieure à 15 litres, il peut y avoir un problème avec les joints de clapet de pied ou de piston. Se référer à l’artisan réparateur de pompe!
Carte de Maintenance pour le Pompe Manuel India Mark II
2. Les Contrôles Annuels (réalisé par l’entrepreneur)
Démanteler "hors sol" et "ci-dessous les éléments terrestres".Remplacer les sièges de caoutchouc (valve supérieure & robinet inférieur), coupelles d’étanchéité (3 off) et étanchéité anneaux (3 off) remplacement roulements à billes.
Veuillez noter : Si un des composants remplacés est encore en bonne forme, l’épargner pour le remplacement d’urgence (dans le cas où une nouvelle pièce de rechange n’est pas immédiatement disponible).
Steps of Maintenance a) understand the cause for a
problem and determine the remedy needed,
b) dismantle the pump as necessary,
c) assemble the pump after replacing defective components,
d) record details in the “Maintenance card”.
Outils Pour L’entretien2 clés pour vis à tête hexagonale M10 & noix (C1137) et 2 nouveaux Standard clés (C1xxx), 2 clés pour vis à tête hexagonale M12 & noix (C1005) 2 nouveau Standard clés (C1xxx), un 20 litres seau pour essai de décharge et de test de fuite.
Ces outils sont requis par les utilisateurs de pompe pour la maintenance préventive et restent donc avec le gardien. Tous les autres outils utilisés pour l’entretien et de réparation (le même que pour l’installation de la pompe) sont avec la mécanique de la zone
Matériaux Pour L’entretienLes matériaux de base nécessaires à la réparation et l’entretien de la pompe à main sont les mêmes que ceux indiqués pour l’installation de la pompe.
En outre qui sont exigés:Réparer une petite quantité de ciment, de sable et de gravier pour la plate-forme, des matériaux locaux pour entretenir et réparer la clôture, pesante graisse pour lubrifier l’ensemble de la chaîne.
Troubleshooting for India Mark II Handpump
Trouble Possible Causes Remedy Who
Pump works easily, but no flow of water
Worn cup-seals Pull out rising main, open cylinder and replace all worn cup-seals
Pump mechanic
Water level dropped below cylinder
Add more riser pipes and pumprods Pump mechanic
Broken chain Replace chain Pump users
Check valve jammed (not closing)
Pull out rising main, open cylinder, check function of check valve and make needed replacements
Pump mechanic
Pumprod disconnected Pull out rising main and join disconnected pumprod
Pump mechanic
Delayed flow or little flow of water
Check valve leaking Pull out rising main, open cylinder, check leaking of check valve and make replacements if required
Pump mechanic
Worn sealing rings Pull out rising main, check sealing rings and make replacements if needed
Pump mechanic
Worn cup-seals Pull out rising main, open cylinder and replace all worn cup-seals
Pump mechanic
Damaged rising main (leaking pipe threads or severe pipe corrosion)
Pull out rising main, check all riser pipes and make replacements if required
Pump mechanic
Folding of chain during down-stroke
Plunger jammed inside cylinder
Pull out rising main, open cylinder, check size of plunger and cylinder and replace wrong or defective components
Pump mechanic
Top rod too long, plunger is sitting on top of the check valve
Take off pump head, check correct length of pumprod assembly and trace top rod if needed
Pump mechanic
Noise during pump operation
Lack of grease on chain Grease chain Pump userWorn ball bearings Replace ball bearings Pump
mechanicShaky foundation Check foundation and make necessary
Installation & Maintenance Manualfor the India Mark II Handpump
skat Resource Centre and
Consultancy for Development
RWSN Rural WaterSupply Network
1
Installation and Maintenance Manual for the India Mark II Handpump
Edition 2008 The Installation and Maintenance Manual for the India Mark II Handpump is intended to assist all users of this handpump, especially to give a guideline for the installation procedures as also for maintaining the pump including the pump platform. This document results from several years of work carried out by UNICEF Eritrea in partnership with SKAT – RWSN. Special thanks are given to the staff of the Debub region of Eritrea, especially Mr. Giorghis Tecle; and Mr. Eric Toft and Yodit Hiruy of UNICEF Eritrea. Suggestions for improvement on the manual are welcomed for future updates and can be sent to SKAT – RWSN at the address given below. Drawings: SKAT – RWSN, Photographs: Meera & Ceiko Pumps Ptv. Ltd., Hyderabad, India, UNICEF Delhi, India and SKAT –
Background Information The “India Mark II Handpump” was developed in India more than 30 years ago and it is designed for lifting water from deep wells up to 50 m. Strict maintenance of deep-well pumps is very important to keep them operational. Therefore the pump users must be trained and willing to make regular maintenance in a disciplined manner. Spare parts that require regular replacements must be easily available and stored in a sufficient number nearby the pump users. Good quality is another important factor, which can increase the lifetime of a pump considerably. Therefore all pump components needs to be checked strictly prior to installation. This manual is specially designed for installation personnel and includes therefore additional information in connection with the India Mark II Handpump. For the pump users, a Maintenance Card should be developed, which contains pictures to shows all maintenance interventions in a simple way. To keep this Maintenance Card in good shape for many years, it can be plastic-laminated before given to the pump users. Pump Features On Pages 4 and 5: drawings of India Mark II Handpumps installed on boreholes and dug-wells are shown with all technical names of pump details used in this manual. On Page 5: a section drawing of a pump cylinder is showing the arrangement of the different components. Supporting Documents
a) India Mark Handpump Specification, Revision 2-2007
b) Moulding Guidelines for the Production of Rubber Components, Revision 1-1999
4
Drawing of an India Mark II Pump installed in a Borehole
5
Drawing of an India Mark II Pump installed on a Dug-well
6
Drawing of the India Mark II Pump Cylinder
7
Part 1 Installation of the India Mark II Pump General Comments
Sustained safe drinking water supply and sanitation facilities are essential to improve the living conditions of the rural population. The provision of safe water helps to combat water borne diseases and improves community health in general. Benefits of a safe water supply can reach far beyond considerations of public health and have a positive influence on the general well being, economic status and quality of life in a community.
Protection of Water Source
If a well site is chosen and the well drilled (or dug) into the ground at a site which is elevated and away from water logged areas during the rainy season, the water which percolates from an underground aquifer into the well should be pure enough to drink. However, a water point obviously attracts a great deal of human contact. This is a potential source of contamination and should be protected against. The safety measures are as follows:
Well Siting
a) The well should be in an elevated place, so that during the rainy season the water will run away from it, rather than into it,
b) It should be at least 40 meters away from a latrine and uphill of the latrine, c) It should be at least 30 meters away from a cattle kraal, and uphill of the kraal, c) It should be well away from any depressed area in the ground, such as hollows used for
rubbish dumping, hollows used for brick making or any other areas where water might collect. Hygiene Education and Water Supply
Throughout the water supply process, it is vital to bear in mind the important linkages between health, hygiene education and water. An awareness of the intimate relationships between these factors should be made clear to all water users. Before the arrival of a new or improved water supply system, the water users of a village should receive hygiene training with regard to the collection, storage and use of water. For example, the transmission of diseases through contaminated water may not be understood in the community.
8
Cleanliness in the area of the water point is an important factor in the overall impact of the introduction of a new or improved facility. If the surrounding area is not kept clean and free of animals, debris, waste and stagnant water, the water point could become a hub for the transmission of many infectious diseases. In this respect, the ability of the community to manage the system and ensure regular cleaning of the water point is vital.
Suggested Platform Design
If the area around a well is allowed to become dirty, and waste and stagnant water is allowed to accumulate, it will become a source of infection for the users. Standing in bare feet in stagnant water or mud is a serious health risk in the tropics since the open water provides an ideal breeding ground for many types of parasite and/or disease carrier. Awareness of the direct links between hygiene and water must start at the collection point, otherwise the possible benefits from an improved water supply will be lost. The construction of a platform (or slab) at the wellhead is an important contribution to the general hygiene in a community. In addition to discouraging the accumulation of stagnant water at the surface, the slab will help to prevent the contamination of the well through the infiltration of dirty water back into the aquifer.
The following points are important: a) The slab surrounding the water point should
be made as wide as possible from properly made reinforced concrete of good quality. The water outlet (spout) should be placed in the centre of the slab, so that spill water gets collected and can run away thorough the drainage channel.
b) All surfaces should slope towards the drainage channel and the edges of the slab should be raised.
c) The slab should be well reinforced with steel wire, to prevent cracking. Dirty water can pass through cracks in a poorly constructed slab and contaminate the well beneath.
The shape of the slab is not as important as its capacity to drain water away from the well as quickly as possible and to ensure wastewater dispersal in a hygienic manner. Where possible, the drain can lead to an area of vegetation, such as banana plants or a vegetable garden. If this is not an option, a soak-pit can be built or a trough for watering livestock can be provided. It is important that construction of the slab does not commence until the soil around the well, which was disturbed by the construction activities, has had an opportunity to settle properly.
Selection of Platform Type
Consultation with the community is a must before a decision is taken on the platform layout. In the following page you will find the typical platform design used for handpumps installed on boreholes. This is an indicative layout that can be modified to suit communities’ needs, which may include the following:
• Facilities for washing clothes, • Facility for bathing, • Trough for cattle watering, • Collection of water for small-scale irrigation etc.
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Fencing the Water Source
In addition to constructing a slab, it is important to erect a good fence around the water point. This can be done immediately after the construction of the well is finished, and should give enough space to operate the handpump. The advantages of fencing a water point is that it serves to define quite clearly, for the whole community, the area of the well and it keeps also animals away from the wellhead. In some cases, it may be necessary to have a gateway to keep out smaller animals such as dogs and goats.
The fencing can be made of suitable local materials like wood or stones. Problems of replacement and repair can be avoided altogether, by using a living hedge as fencing. Whatever type of fencing is used, it is important that access by the well users is guaranteed.
Disinfecting the Well
As soon as the curing time is over and the platform is ready for installation of the handpump, the well needs to be disinfected with chlorine.
Many of the diseases that are common in the communal lands are carried by water, especially from unprotected wells, water holes, rivers and dams. Dysentery, diarrhoea and typhoid can arise as a result of drinking water that is infected. The disease carrying organisms found in the water can be effectively killed by disinfecting the water with chlorine.
Therefore it is recommended to disinfect the well shortly before the installation of the handpump takes place. Proceed as follows: • Mix 300 grams of bleaching powder
thoroughly in 15 litres of water in a bucket and pour the solution into the borehole.
• The required dosage of bleaching powder is depending of the amount of water stored in the well.
• It is recommended to use between 150 to 200 grams of bleaching powder per cubic meter water for safe disinfection.
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Preparation for Handpump Installation Correct Cylinder Setting Static Water Level (SWL)
One of the important factors for the cylinder setting is the surface of the water in a well, which is called “Static Water Level” (SWL). The SWL can vary due to seasonal conditions (dry or wet seasons) and therefore should be checked and recorded over a period of several years. Such records would be important for the decision at what depth the cylinder should be placed.
Dynamic Water Level (DWL)
Apart from seasonal fluctuations, there are also fluctuations in the well itself because of pumping water from the well. In order to check the drop in the water level (draw down) and to find the DWL, test pumping on a new borehole should be done by the drilling crew. For handpumps, the test pump should be set for 1000 litres per hour (maximum) in order to see where the DWL is reaching. These tests should be continued for approximately 2 hours, in order to ensure the correct DWL. This figure is another important factor for deciding on the best setting depth of the handpump cylinder. (On marginal holes, pumping rate might be reduced to 800 litres/hour.)
Other important factors
• Any pump intake in a borehole must be set above the well screen in fully screened well or above any rock fissures providing water in an unlined well. A pump intake above the well screen or rock fissures is minimizing the turbulent flow of water and therefore reduces the pumping of fines and silts.
• Pumping water with a too high content of fines or silt is wearing the surface of the pump cylinder and the plunger seals in an unacceptable rate.
• If a pump cylinder is placed to close to the bottom of a borehole, silt and sand could build-up and trap the pump in the hole.
Cylinder setting in Boreholes
• Check the depth of the DWL and the depth where the well screen starts (information must be available from the drilling crew). The start of the well screen should be considerably lower than the DWL. If there were a large difference, it would be ideal to place the cylinder approximately 1 meter above the well screen.
• Check the SWL regularly, especially during the dry season, in order to avoid that the newly installed pump is running dry. Should the cylinder setting depth be critical during the dry season, add one length of riser pipe and one pumprod.
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Tools and Materials required for Installation Tools and Equipment
a) Tripod for installing and retrieving the rising main with cylinder, b) Chain block for installing and retrieving the rising main with cylinder,
(or pulley with rope) c) Treading stand with vice for cutting and threading of GI riser pipes, d) Ratchet pipe threader 1 ¼ “ for threading GI riser pipes, e) Die set for M12 thread for threading top rod, f) Water dipper (measure tape) for measuring the depth of the borehole and water level, g) Hacksaw (with spare blades) for cutting top rod or riser pipes, h) Flat file for metal for deburring sharp edges and chamfering prior to threading, i) Pipe wrenches (2 off) for fastening or opening GI riser pipe threads, j) Hammer (300 grams) for fitting or replacing ball bearings, k) Pipe vice A2515 for fixation of riser pipes during installation and retrieval, l) Lifting spanner (2off) for lifting riser pipes during installation and retrieval, m) Pumprod vice A2443 for fixation of pumprods during installation and retrieval, n) Connecting tool B2420 for secure installation and retrieval of pumprods, o) Pipe clamp A2470 for connecting riser pipes during installation and retrieval, p) Bearing mounting A2478 for preparing pump head with ball bearings, q) Chain support C2476 for lifting rising main for attachment of chain to pump handle, r) Axle punch C2477 for dismantling pump head (dismantling handle axle), s) Spanner 17* mm (2 off) for fastening or opening M10 bolts and nuts, t) Spanner 19* mm (2 off) for fastening or opening M12 bolts and nuts, u) Wire brush for cleaning threads from sand and dust, * Please add 2 spanners each for the new standard of hexagonal bolt sizes (16 mm for M10 and 18 mm for M12)
Material
a) Cutting oil for threading of GI riser pipes and top rod, b) Heavy duty grease for greasing the chain, c) Hemp fibre with grease for sealing GI Riser pipe threads and cylinder cap threads,
(or sealing fluid with brush) d) Emery cloth (sand paper) for cleaning cylinder parts from residue or paint, e) Clean cloth for cleaning threaded parts from cutting oil, f) Bleaching powder for disinfecting the well, g) Bucket with clean water for leakage testing of pump cylinder (and cleaning purposes),
Preparation Work prior to Installation
Preparation of “Below Ground Components” Riser pipes and Pumprods
Step 1 Check all pipe threads with socket for good engagement,
Step 2 Check all pumprod threads with couplers for good engagement,
Step 3 Apply hemp fibre with grease or sealing liquid to one threaded end of all pipes and attach one socket,
Step 4 Place a number of logs or a pipe stand near the installation place,
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Step 5 Place all prepared pipes neatly
on top of the logs or pipe stand (above the ground) so that all threads remain clean,
Step 6 Introduce one pumprod to each of the riser pipes and make sure that the long hexagonal couplers are on the same side as the riser pipe sockets.
Pump Cylinder
Step 1 Assemble all components of the plunger
Place Rubber seating to the Upper valve Attach a Cup seal to the lower part of the Spacer
Attach another Cup seal Introduce the Follower ..place the Upper valve at the top of the Spacer into the Spacer and on top of the assembly
Attach Plunger body and tighten securely Take Plunger rod and tighten it to the Plunger assembly
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Step 2 Assemble all components of the check valve body.
Assemble Check valve with Check valve seat Place Rubber seating and secure with Seat retainer
Step 3 Assemble the Pump Cylinder Prior to assembling check cleanliness of cylinder liner and clean all threads and prepare them with sealing fluid or hemp fibre with grease (cylinder pipe and Reducer caps).
Place first Sealing ring Introduce Check valve and Attach the cylinder with into a Reducer cap place second Sealing ring liner to the Reducer cap
Introduce Plunger assy. Place third Sealing ring Tighten both Reducer into the Cylinder pipe and attach Reducer cap caps with pipe wrenches
Step 4 Leakage Test Proceed as follows: • Immerse suction part of cylinder
into a bucket with clean water, • Operate the plunger by pulling
and pushing the plunger rod, • As soon as the cylinder is filled,
place it in a vertical position and check for any leaks,
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Be aware that a small amount of water is dripping from the outer surface of the cylinder. Wait therefore for some minutes until the cylinder surface is dry, not to assume any dripping water automatically as leakage. If there is any leakage, try to tighten both reducer caps, before dismantling the cylinder for finding the reason of the leakage. Once the cylinder is water tight, the installation of the “down hole components” can start.
Preparation of “Above Ground Components” Step 1 Assembling of Pump handle
Place first Ball bearing Introduce Mounting tool Insert Spacer into to Bearing mounting tool into Bearing housing Bearing housing
Place second Ball bearing Introduce Pressure plate on Bearing mounting tool on Bearing mounting tool Add the hexagonal nut
Take two spanners (19 mm) and tighten the nut of the Bearing mounting tool, so that both Ball bearings are pushed into their end position.
If Ball bearings are mounted, remove Bearing mounting tool.
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Step 2 Assembling of Pump head
Introduce the pre-assembled Pump handle into the Pump head assembly and place the Ball bearings near the Axle bushes at the sides of the Pump head.
Knock the handle axle gently into the end position (use a plastic hammer if available).
Introduce Axle washer and If the pump handle is moving smoothly (up- & down), take fasten one nut by hand second nut as a check nut to secure the correct position.
Step 1 Take the first riser pipe with pumprod from the logs. Place it horizontally on the pump platform and connect the pumprod to the plunger rod of the cylinder.
Step 2 If the pumprod is tight, apply hemp fibres with grease, sealing liquid or Teflon tape to the pipe thread and screw the riser pipe into the reducer cap of the cylinder.
Step 3 Tighten riser pipe with reducer cap of the
cylinder with two pipe wrenches.
Step 4 Lower the first riser pipe with cylinder into the pump stand (by hand) until the riser pipe protrudes the top face of the pump stand by approx. 50 cm.
Step 5 Introduce the pipe vice and fasten the riser pipe in this position (ideal working height).
Step 6 Take the second riser pipe with pumprod from the logs, connect the pumprods first and then the riser pipe after hemp fibres with grease, sealing liquid or Teflon tape has been applied.
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Step 7 With the help of the two lifting spanners, the rising main can be lowered after the pipe vice has been opened and removed.
Step 8 Proceed in the same manner until the last pumprod and riser pipe is connected.
Please note: As soon as the rising main is too heavy for being handled with the lifting spanners (5 to 10 pipe lengths), attach the pipe clamp and connect it with the hook of the chain block. Lower the rising main with the help of the chain block on the tripod until the height required (50 cm) for the next connection is reached!
Step 9 At the end of the last riser pipe located in the pipe vice, the water tank will be attached. Therefore take off the last socket of the last riser pipe and re-apply hemp fibres with grease or sealing liquid to the pipe thread.
Step 10 Then the water tank is screwed onto the last pipe end and tighten by hand.
Step 11a (For shallow installations, when rising main is not heavy). With the help of a short piece of riser pipe attached to the socket in the water tank, the entire rising main can be held in place with the help of 2 or 3 lifting spanners. As soon as the pipe vice has been removed, the riser pipe assembly with water tank can be lowered slowly to the pump stand flange.
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Step 11b (For deep installations with heavy rising main assemblies). With a short piece of rope attached to the hook of the chain block, the water tank can be held securely in position, so that the pipe vice can be removed from the pump stand. Then the water tank with rising main attached can be slowly lowered to the pump stand flange.
Step 12 Turn the water tank so that the spout is pointing into the required direction and tighten it properly to the pump stand with 4 x M12 bolts and nuts. Now the installation of the “above ground components” can start.
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Installation of “Above Ground Components” Step 1 The protruding last pumprod needs to be
cut to the exact length, so that the plunger connected is not knocking the check valve or the cylinder cap during pump operation.
Step 2 Use a hacksaw for marking the exact
length of the last pumprod (at the top face of the water tank flange).
Step 3 Lift marked pumprod for easy cutting and
fasten with connecting rod vice on the top flange of the water tank. Take a clean piece of cloth and wrap it around the marked rod, in order to prevent metal shavings or oil from falling into the well (contamination).
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Step 4 Cut last pumprod at the mark.
Step 5 Remove sharp edges and make a nice chamfer prior to threading.
Step 6 Use little oil for cutting the M12 tread (40 mm long). As soon as thread is finished, remove cloth carefully and clean pumprod, vice and pump stand from remaining oil and shavings. Prevent shavings from falling into well.
Step 7 Insert middle flange.
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Step 8 Allow middle flange to rest on
top of connecting rod vice and fix the check nut on the newly threaded top rod.
Step 9 Screw the chain coupler on the connecting rod threads by hand.
Step 10 Tighten check nut of connecting rod with the chain coupler.
Step 11 Insert chain coupler supporting
tool below the chain coupler. Hold middle flange and remove connecting rod vice.
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Step 12 Carefully lower the middle flange to
the top of water tank and ensure that all four corners coincide.
Step 13 Hold head assembly in position and insert chain through the hole in the bottom/flange. Lower head on top of middle flange ensuring all four corners to coincide.
Step 14 Tighten head, middle flange and water tank with bolts and nuts.
Step 15 Lift handle up and attach free end of
the chain with high tensile bolt, washer and “Nyloc” nut.
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Step 16 Tighten “Nyloc” nut.
Step 17 Lower the handle and remove chain coupler supporting tool.
Step 18 Lift handle up and apply grease on the chain.
Step 19 Make sure: • that the connecting rod moves up
and down freely. If it does not, the rod has been bent. Check the rod,
• that the chain coupler is fully engaged on the connecting rod and that the lock nut is tight,
• that the axle nut and lock nut on the handle are tight,
• that the handle axle is firm in place,
• that the “Nyloc” nut has been tightened securely with the chain anchor bolt,
• that all 8 flange bolts and nuts are tight,
• that nothing has been left inside the pump head (tools, cloth etc.).
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Step 20 Fit inspection cover.
Step 21 Tighten the cover bolt. Step 22 Now the handpump must be operated for first filling of the rising main pipe. Depending on the depth of the cylinder setting, the pump handle has to be operated for many strokes (as an example: an 40 m cylinder setting requires approx. 100 full handle strokes for filling the entire rising main). Step 23 As soon as the water is flowing from the spout, operate the pump for another 100 full strokes. Check whether the water is clean (no oil or dirt). If the water is not clean, the pump operation needs to be continued until the water is acceptable. Step 24 If the water quality is acceptable (optically), the leakage test and the discharge test
must be made (see Page 27). Step 25 If the India Mark II Pump is working as expected, the users must be instructed in “Operation and Maintenance” (O&M) of their pump. Step 26 Don’t forget to fill the “Installation Card” (please see Annex 3).
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Performance Testing Leakage Test
Testing shall start after a continuous flow of water through the spout has been obtained. The water shall then be collected in a container or bucket for 40 continuous full strokes of the plunger in one minute. Measure the quantity of water collected. Then allow the pump to rest for 30 minutes. Repeat the test and measure the discharge. The difference between the first and the second reading of discharge indicates leakage. If the difference is more than 2 litres, there is an un-acceptable leak and the cause should be investigated.
Another method is to count the number of strokes required before water comes out of the spout after stopping operation for 30 minutes. If the number exceeds 5 strokes until water is flowing, it is an indication that there is an un-acceptable leak and the cause should be investigated.
Leakage mostly occurs because of worn rubber components in the cylinder, leaking rising main joints or severely corroded riser pipes.
Discharge Test
Testing shall start after a continuous flow of water through the spout has been obtained. The water shall then be collected in a container or bucket for 40 continuous full strokes of the plunger in approximately one minute. The water collected should be generally not less than 16 litres. If the discharge is less then 10 litres for 40 strokes, the area mechanic needs to be called for pulling out the rising main pipe and dismantling the cylinder for detecting the reason of the leakage. Another cause for a low discharge could be a perforated or cracked riser pipe due to severe corrosion or a non-tight riser pipe joint.
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Part 2 Maintenance and Repair Preventive Maintenance
Every pump owner, caretaker or user committee is responsible for preventive maintenance of the water point (handpump including surrounding) and therefore is entitled to receive regular training from the supplier of the handpump. However, the India Mark II Pump is not a VLOM handpump (VLOM = Village Level Operation & Maintenance) and therefore most interventions need to be done with the help of an Pump Mechanic.
Preventive maintenance means regular check-up of the handpump at a fixed time interval and changing of spare parts before they are fully worn. As an example; if the estimated lifetime of a cup seal is one year, the cup seal will be changed after a period of one year even if it is still functional. If during a preventive maintenance check a check valve leakage is noticed, the caretaker must contact the area mechanic. He should carry out repairs in the check valve even though the pump has not broken down. Such interventions help in preventing the sudden failure of the pump.
Time Intervals of Preventive Maintenance Interventions Monthly Checks
(made by the Pump Users) • Check all flange bolts and nuts for tightness (8 off), • Check that handle axle nuts and chain bolt and “Nyloc” nut are tight, • Grease the chain, • Repair holes and cracks on pump platform, • Clean drainage and repair cracks, • Clean the pump surroundings and repair the fence.
Tree monthly Checks
(made by the Pump Users with assistance of a Pump Mechanic) • Check if any fasteners of the pump are missing - if so, add the missing parts. • If any unusual noise is noticed, check reason for the same (worn ball bearings or scratching of
bent pumprods). • Check if the pump stand is shaky during operation. If yes, the stand is loose in the foundation
and contamination of the well can take place. Take corrective measures to improve the foundation.
• Check if there is leakage in the pump. If more than 10 strokes are required before water flows from the spout, it means the pump is leaking beyond an acceptable limit. This needs to be attended to. It may be necessary to replace a rubber seating, a sealing ring or attend to a leaking joint in the rising main. For attending to a defect of all “down hole components” you need the help of a pump mechanic with his special equipment. However, a special leakage test can be conducted by the pump users themselves, prior to the notification to the pump mechanic.
• Carry out a “Leakage- and Discharge Test” (see Page 22). Yearly Replacements
• Dismantle “above ground” and “below ground components”. • Replace rubber seatings (upper valve & lower valve), cup seals (3 off) and sealing rings (3 off). • Replace ball bearings.
Please Note: If one of the replaced components is still in good shape, spare it for emergency replacement (in case a new spare part is not immediately available).
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Maintenance & Repair of the India Mark II Pump The handpump is like any other mechanical device that needs maintenance to keep it in good working condition. It has been observed that the maintenance in community handpumps is very often “Breakdown-based”. In the absence of preventive maintenance, sudden breakdown of handpumps and disruption in water supply do occur. The danger of abrupt breakdown of the pump can be minimized if preventive maintenance is carried out.
The steps involved in maintenance are to: a) understand the cause for a problem and determine the remedy needed, b) dismantle the pump as necessary, c) assemble the pump after replacing defective components, d) record details in the “Maintenance card” (see Annex 3).
Diagnosis of Handpump Problems To identify the cause of a problem and the remedy needed, please consult the “Trouble Shooting Chart (Annex 1). This chart lists general operational problems, their causes and remedies. Tools required for Handpump Maintenance and Repair The basic tools required for handpump maintenance and repair are:
a) 2 spanners for M10 hexagonal bolts & nuts (C1137) and 2 new Standard spanners (C1xxx), b) 2 spanners for M12 hexagonal bolts & nuts (C1005) and 2 new Standard spanners (C1xxx), c) One 20 litre bucket for discharge test and leaking test.
These tools are required by the pump users for preventive maintenance and are therefore left with the caretaker. All other tools used for maintenance and repair (the same as used for the pump installation) are with the area mechanic (see also Page 13). Materials required for Handpump Maintenance and Repair
The basic materials required for handpump maintenance and repair are the same as listed for the pump installation (see also Page 13). Besides that are required:
a) A small amount of cement, sand and gravel for platform repair, b) Local material to maintain and repair the fence, c) Heavy duty grease for lubricating the chain assembly.
Spare Parts required for Handpump Maintenance and Repair
A list of “Fast moving Spare Parts for the India Mark II” is given in Annex 2. A complete list of all India Mark II Pump Spare Parts (including drawing number for ordering) can be found in Annex 4.
Safety Precautions Safety Precautions during Handpump Maintenance and Repair • Never put fingers in moving parts of the pump (between pump head and handle) as this likely to
seriously harm your fingers. • Always use the right tools for the job to avoid accidents and damage of your tools and spares. • Ensure that you communicate with the people you are working with, to ensure that everyone is aware
of what to do. This avoids accidents during repair. • Rising pipes must be held firmly by hand or with rod lifters and clamped securely with the pipe clamp,
ensuring that pipes do not slip down and cause an accident (i.e. squashing of fingers).
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Dismantling Procedure Sequences
Dismantling the “Above Ground Components” Step 1 Loosen pump head cover bolt. Step 2 Remove pump head cover.
Step 3 Lower pump handle. Put chain Step 4 Lift up the pump handle to top
supporting support below the position. Use two open-ended chain assembly. spanners to loosen “Nyloc” nut.
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Step 5 Remove the “Nyloc” nut anchor bolt Step 6 Loosen and remove bolts and nuts and pull out chain from the handle. connecting head and water tank. Step 7 Lift and remove head assembly. Step 8 Turn flange 90º. Lift connecting rod
The chain will go through hole by holding middle flange and insert in the bottom flange. connecting rod vice.
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Step 9 Place rods vice on water tank
tank top flange and tighten it. Leave the middle flange resting on the rod vice. Take off the chain support and loosen and remove the chain assembly from top rod.
Step 10 Unscrew check nut and
remove middle flange.
Step 11 Attach the rod lifter (in clockwise direction). Hold the rod lifter firmly, open the vice and remove it
Step 12 Gently lower the pumprod assembly
until it sits on top of the check valve. Unscrew the rod lifter.
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Step 13 Remove all bolts between water
tank and pump stand. Step 14 Lift the water tank upwards Step 15 Unscrew water tank by turning the
(about 50 cm) and introduce spout by hand. and fasten pipe vice.
Lifting below ground components and water tank with Lifting spanners (see short riser pipe attached to the water tank).
Additional fixation of the riser pipe is required with the help of a pipe wrench.
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Dismantling the “Below Ground Components” The below ground components of the India Mark II Pump can be dismantled (and re-installed) with two Lifting spanners different systems:
a) For pump installations between 10 to 30 m, the rising main pipe with pumprods and the cylinder can be lifted with 2 or 3 specially designed Lifting spanners. Therefore a short piece of a threaded riser pipe can be connected to the thread of the water tank, so that the Lifting spanners can be applied.
b) For pump installations between 30 to 50 m, Tripod with Chain block the weight of the below ground components is increasing and therefore a Tripod with a Chain block (or pulley wheel with rope) can be used for lifting the rising main pipe with pumprods and cylinder. For getting a secure grip on the rising main, a Pipe clamp needs to be attached and a piece of rope is used to attach the pipe with pipe clamp to the hook of the lifting device (chain block). Pipe clamp Pipe vice After lifting the below ground components for a complete pipe length (3 m), a Pipe vice is used to fix the riser pipe in position when the retrieved riser pipe and the pumprod are getting unscrewed.
The following description is for dismantling the below ground components with a tripod & chain block:
Step 1 Attach pipe clamp and connect it with a piece of rope to the hook of the chain block.
Step 2 Operate chain block until the chain is tight and then open the pipe vice slowly and remove it.
Step 3 Lift rising main pipe / pumprods and cylinder until the next pipe socket is about 0.5 m above Riser pipe with pipe clamp & attached hook the top flange of pump stand.
Step 4 Introduce the pipe vice and clamp the rising main securely.
Step 5 Remove the pipe clamp and open the protruding riser pipe with two pipe wrenches.
Step 6 Lift the unscrewed riser pipe by hand, so that the pumprod connection is visible.
Step 7 Unscrew the pumprod connection and place the rods and pipes separately on a clean place.
Step 8 Attach pipe clamp to the remaining rising main pipe (close to the pipe vice).
Step 9 Connect pipe clamp to the hook of the chain block and tighten the chain.
Step 10 Continue with Step 1 to Step 9 until the whole Pumprod opening while holding riser pipe rising main, pumprods and cylinder are retrieved.
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Please note: For shallow installations where the total weight of the rising main, pumprods and cylinder is not so heavy, dismantling (and also re-installation) of the below ground components can be done easily with the Lifting spanners.
Lifting spanner in operation
Step 11 The last riser pipe can then be removed from the cylinder.
Removing last riser pipe from the cylinder
Step 12 Then the last pumprod gets disconnected from the plunger rod.
Disconnecting pumprod from plunger rod Step 13 From the cylinders, both caps can be opened and the plunger & check valve removed. Step 14 The plunger and the check valve can also be dismantled to check or replace worn parts
(cup seals and rubber seatings).
Cylinder parts of the India Mark II Pump
Step 15 Once the defective pump components have been replaced and the pump is re-assembled again, explanations needs to be given to the pump users, about what the problem was and why the break down might has happened.
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Maintenance of Pump Surrounding Handpumps with platforms offer a good protection, because they seal off the well from external sources of contamination. However, even when handpumps are fitted, contaminations can still pollute the well through:
a) Cracked platforms and drainage channels, b) Stagnant water near the well, c) Animals (and human) excrements too close to the well (no fence), d) Waste and other sources of contamination too close to the well.
It is the important task of the Handpump Caretaker to: a) Check the platform for cracks and do the necessary repair, b) Eliminate stagnant water by filling the dents and holes with earth, c) Maintain the fence around the water point, so that no animals have access, d) Keep the surroundings clean and tidy at all times, e) Instruct the pump users how to use the pump and how to keep the pump
surroundings clean.
(See also chapter Well Siting and Hygiene Education and Water Supply on Page 7.) Platform Maintenance Tools
The following tools are recommended for regular maintenance of platforms: a) Hammer and chisel for opening cracks and for taking off weathered and bad quality cement, b) Bucket - for measuring cement, sand (gravel) and water, c) Shovel - for mixing the concrete, d) Trowel - for applying the concrete mix.
Instructions for mixing Concrete for Platform Repair
Mixing of Concrete (for large repair work) As measurement can be used a bucket, shovel or trowel, depending on how much concrete is needed.
1. Fill 2 measurements of sand and pour it on a hard smooth surface preferably on the platform, 2. Fill 1 measurement of cement and pour it on to the sand, 3. Mix the cement and sand until the mixture has an uniform colour, 4. Fill 3 measurement of gravel and pour it onto the sand/cement mixture (gravel can be made by
crushing rock with a hammer), 5. Turn the mixture over three times, 6. Form a crater in the middle of the dry mixture add water in the crater, being careful not to add too much
water. If you need water you can always add some more later, 7. Carefully turn the concrete on the side of the crater into the water. Don't let the water spill over or it will
wash away the cement, 8. Turn the pile over until it is moist and uniformly mixed with the water; the concrete should be dense and
just moist, 9. If the concrete is too dry, make another crater in the middle of the mixture and add a little more water, 10. If the concrete mix is too wet, add more cement, sand and gravel, do not add only cement or sand. 11. Remember that the Curing time for the concrete is seven (7) days, therefore the platform has to be
protected for seven days and the new concrete has to be kept wet throughout the seven days in order to receive the required strength.
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Part 3 Recording of Interventions It is advisable to collect and record any data of a well, starting from digging or drilling, platform construction, installation of a handpump including all maintenance and repair interventions during the lifetime of the handpump and the well (like a “log-book” on a ship).
Besides Installation and Monitoring details, make the necessary entries of Maintenance and Repair in the documents of each pump. The information to be recorded will include date of breakdown, date of repair, nature of complaint, parts replaced and kind of repair or any other important observations. (see also the Installation Card, the Maintenance Card and the Monitoring Card in Annex 3).
Mixing of Mortar (for small repair work) As measurement can be used a bucket, shovel or trowel, depending on how much concrete is needed.
1. Fill 2 measurements of sand and pour it on a hard smooth surface preferably on the platform,
2. Fill 1 measurement of cement and pour it on to the sand, 3. Mix the cement and sand until the mixture has an uniform colour, 4. Form a crater in the middle of the dry mixture add water into the crater, being careful not to add too
much. If you need more water you can always add some more later, 5. Carefully turn the mortar on the side of the crater into the water. Don't let the water spill over or it
will wash away the cement, 6. Turn the pile over until it is moist and uniformly mixed with the water; the mortar should be dense
and just moist, 7. If the mortar is too dry, make another crater in the middle of the mixture and add a little more
water, 8. If the mortar mix is too wet, add more cement and sand. 9. Remember that the Curing time for the masonry work is seven (7) days, therefore the platform
has to be protected for seven days and the new masonry work has to be kept wet throughout the seven days in order to receive the required strength.
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Annexes Annex 1
Trouble Shooting
Trouble Possible Causes Remedy Who Worn cup-seals Pull out rising main, open cylinder
Annex 2 List of Fast Moving Spare Parts Below are the fast moving spare parts for the India Mark II Handpump. Preferred number of parts available is indicated. As soon as one part is used, the process of obtaining a new replacement should be initiated. For regular maintenance • Grease Multi purpose – for greasing chain assembly 1 can • Grease (and hemp fibres) or sealing compound for riser pipe connections 1 can For head assembly • Hexagonal bolt for pump head and water tank - M12 x 40 mm 8 off • Hexagonal nut for pump head, water tank and handle axle - M12 18 off • Hexagonal bolt for inspection cover - M12 x 20 mm 1 off • Washer for inspection cover - to suit M12 bolt 1 off For handle assembly • Hexagonal bolt for chain assembly – M10 x 40 mm 1 off • Hexagonal lock nut for chain assembly – M10 (“Nyloc”) 1 off • Washer for handle axle - drawing C2334 1 off • Spacer for handle axle – drawing C2332 1 off • Ball bearing – drawing C1035 2 off For cylinder parts • Cup seal for plunger assembly – drawing C2359 2 off • Rubber seating – drawing C2360 1 off • Rubber seating – drawing C2364 1 off • Sealing ring – drawing C2354 3 off Please note: A complete list of all spare parts of the India Mark II Handpump can be found in Annex 4.
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Annex 3
41
42
43
Annex 4
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Please note: Due to a new Standard for threaded bolts, the hexagonal head sizes require different spanner sizes:
a) C1152 Spanner size for M10 bolts are 16 mm, b) C1153 Spanner size for M12 bolts are 18 mm.
Therefore, pump manufacturers are requested to supply the new spanner sizes in addition to the existing spanners in order to avoid mixing of different sizes during the transitional period (10 years).
