ODA BULTUM UNIVERSITY

INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
TITLE: DESIGN OF TURBINE DRIVEN PUMP
NAME…………………………………………….……ID. NO
1. SHELEMA DAME:…………………..…………… 1922/14
2. YADESA GEREMU:………………………. 2060/14
3. SENA NUGUSE:………...…………………..1920/14
4. MEBTI ENDALEW:………………………...0768/14
5. ABDO MUKTAR:……………………………0895/14

ADVISOR:- ABDENA Z.

Chiro Ethiopia
May 2026
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 DECLARATION
We hereby declare that the thesis project entitled “DESIGN OF TURBINE DRIVEN PUMP”
submitted for the [Link]. degree is our original work, and the thesis project has not formed the
basis for the award of any degree, association, fellowship, or any other similar titles.

Name of student ID Sign

1. SHELEMA DAME ………………….…………..1922 /14 _________
2. YADESA GEREMU:............................................ 2060/14 _________
3. SENA NUGUSE....................................................1920/14 __________

4. MEBTI ENDALEW……………………………...0768/14 __________

5. ABDO MUKTAR..................................................0895/14 __________

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 APPROVAL
I, the advisor of this thesis, at this moment, certify that I have read the revised version of the
thesis entitled “DESIGN OF TURBINE DRIVEN PUMP” prepared under my guidance
submitted in partial fulfillment of the requirements for the Bachelor degree of Science in
Mechanical Engineering. Therefore, I recommend the submission of a revised version of the
thesis to the department following the applicable procedures
Approved By: Sign Date
Abdena Z. __________ ___________
Fiqadu B. ____________ ____________

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 ACKNOWLEDGMENT
Firstly, great thanks to our GOD that give us the strength and capacity. This thesis would not
have been possible without the support of many people. We wish to express our sincere gratitude
to our advisor’s Mr. Abdena Zewude who was abundantly helpful and offered valuable
assistance, support and guidance as well. And we supporter Mr. Fiqadu Bogale and Deepest
gratitude also for staff members of the school, whose share us their knowledge and assistance
and play a great role for the success of this project. Special thank also go to our gratitude friends
for sharing ideas and literature. Not forgetting to our best friends who always been there. The
Great appreciation goes to the rest of mechanical engineering department staffs that help us from
time to time during our course of time writing the project. Finally, we wish to express our love
and gratitude to our beloved families for their understanding and constant love through the
duration of our study.

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 ABSTRACT
This project focuses on the design of a turbine driven pump intended for efficient and reliable
fluid transportation in industrial and agricultural applications. A turbine driven pump is a
mechanical system in which a turbine supplies the rotational power required to drive a pump for
moving liquid from one point to another. Such systems are important where alternative energy
sources such as steam, water, or gas are available for mechanical power generation. The main
objective of the study is to develop a suitable design for a turbine driven pump system based on
required operating conditions such as flow rate, head, power, and efficiency. The study includes
the selection and design of the major system components such as the turbine, pump, shaft,
coupling, bearings, and support structure. Engineering design calculations are carried out using
standard formulas and machine design principles to ensure that the system can safely and
effectively transmit power and deliver the required pumping performance. The project also
evaluates the expected performance of the system in terms of hydraulic power, shaft power,
torque transmission, and overall efficiency. The study is limited to theoretical design and
analytical evaluation and does not include fabrication or experimental testing. The expected
result of the project is a complete engineering design of a turbine driven pump that can be
applied in irrigation systems, water supply stations, industrial pumping operations, and power
plant services. The study contributes to the understanding of turbine powered pumping systems
and provides a basis for future fabrication and practical implementation.

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Table Of Contents

DECLARATION..............................................................................i
APPROVAL....................................................................................ii
ACKNOWLEDGMENT................................................................iii
ABSTRACT...................................................................................iv
LIST OF SYBOLS.........................................................................ix
CHAPTER ONE..............................................................................1
INTRODUCTION...........................................................................1
1.1 Background............................................................................................1
1.2 Problem Statement.................................................................................2
1.3 Objective of the study............................................................................4
1.4 Significance of the study.......................................................................4
1.5 Scope of the study..................................................................................4
1.6 Limitation of the Study..........................................................................5
1.7 General consideration in machine design..............................................5
CHAPTER TWO.............................................................................7
LITERATURE REVIEW................................................................7
2.1 Introduction............................................................................................7
2.2 Theoretical Review of Turbine Driven Pump.......................................7
2.3 Literature Review on Pump Design.......................................................7
2.4 Related Work.........................................................................................9
2.5 Research Gap.......................................................................................10
CHAPTER THREE.......................................................................12
MATERIAL AND METHOD.......................................................12
3.1 Materials Used in the Design...............................................................12
3.2 Methodology of Turbine Driven Pump Design...................................13
3.3 Design Procedure.................................................................................15
3.4 Tools and Software Used.....................................................................15
3.5 Assumptions Used in the Design.........................................................15
3.6 Limitations of the Method...................................................................16
3.7 Selecting an appropriate material........................................................16
3.8 Manufacturing construction in Design................................................16
3.9 Welded Joint........................................................................................16
CHAPTER FOUR.........................................................................18
DESIGN OF TURBINE DRIVEN PUMP....................................18
4.1. Design Of The Aerofoil Structure......................................................18

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 4.2 . V- Belt Selection................................................................................28
4.3. Design of the driving shaft.................................................................33
4. 4. Bearing selection...............................................................................36
4.5. Design Of Key....................................................................................37
4.6. Piston Pump Design............................................................................38
4.7. Design of connecting rod and crankshaft...........................................45
CHAPTER 5..................................................................................50
CONCLUSION AND RECOMMENDATIONS..........................50
5.1 Conclusion...........................................................................................50
5.2 Recommendations................................................................................51
REFERENCES..............................................................................52

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List Of Figure
Figure 1.1 river that can not use for irrigation.................................................................................3
Figure 4.1 blade turbine.................................................................................................................18
Figure 4.2 aerofoil holder bar........................................................................................................23
Figure 4.3 components (tangential and axial)................................................................................24
Figure 4.4 weld design for the foil.................................................................................................26
Figure 4.5 shows the weld area in the aerofoil..............................................................................27
Figure 4.6 V-belt pulley sectional view.........................................................................................29
Figure 4.7 belt drive pulley............................................................................................................29
Figure 4.8 bearing selected for the standard bearing.....................................................................32
Figure 4.10 input shaft which support aerofoil turbine and pulley................................................33
Figure 4.11 shows the delivery pipe line of the turbine driven pump...........................................40
Figure4. 12 shows six piston pump alignment..............................................................................44
Figure 4.13 connecting rod............................................................................................................45
Figure 4.14 design of crank pin.....................................................................................................47

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List Of Table
Table 4.1 Radious and Chord length.............................................................................................19
Table 4.2 lift coefficient................................................................................................................20
Table 4.3 lift coefficient................................................................................................................20
Table 4.4 lift coefficient................................................................................................................21
Table 4.5 drag coefficient..............................................................................................................22

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 LIST OF SYBOLS
a Axial induction factor L Lift force, angular V volume
moment
a0 Angular induction v valve
factor L length
W Relative velocity
A area m mass
w water
Av area of vane M moment
x Axial coordinate
B Number of blades .
m Mass flow Relative flow angle onto
c Aerofoil chord length blades
N Number of blade
CL Lift coefficient elements Tip speed ratio

CD Drag coefficient n number of revolution r Local Tip speed ratio

CP Power coefficient p pump piston Mechanical/flow

efficiency
CT torque coefficient P Power
Density
CX axial coefficient Q flow rate
’Local Solidity
D Drag force r local radius
Tangential coordinate
d diameter R Blade tip radius Blade rotational speed

Fx Axial force Re Reynolds number Wake rotational speed

FTangential force S stroke Aerofoil inlet angle

g gravity Sb bending stress  Shear stress

G weight St tensile stress

H lifting head T Torque

Hst static head V Absolute velocity

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 CHAPTER ONE
INTRODUCTION
1.1 Background
A turbine driven pump is a pumping system in which a turbine acts as the prime mover to drive
the pump instead of an electric motor or internal combustion engine. The turbine converts the
energy of a working fluid (such as steam, gas, or water) into mechanical rotational energy, which
then drives the pump shaft to move liquids from one location to another. This type of system is
commonly used in industries where a reliable and continuous pumping process is required.
Turbine driven pumps are widely applied in power plants, irrigation systems, oil and gas
industries, fire protection systems, and water supply systems. In many industrial plants, steam
turbines are used to operate pumps because they can function even when electrical power is
unavailable, which increases system reliability and safety. For example, in thermal power plants,
turbine driven pumps are often used for boiler feed water pumping.
The design of a turbine driven pump involves several engineering considerations such as flow
rate, pressure head, efficiency, shaft design, bearing selection, and material strength. Proper
design ensures that the pump operates efficiently, safely, and with minimal maintenance. The
integration between the turbine and pump must also be carefully designed so that the rotational
speed, torque transmission, and alignment are suitable for the pumping requirements.
In modern engineering practice, turbine driven pump systems are designed to improve energy
efficiency, operational reliability, and durability. Engineers analyze hydraulic performance,
mechanical stresses, and operating conditions to ensure that the system can withstand long-term
operation in demanding environments. Machine Design is the creation of new and better machines and
improving the existing ones. A new or better machine is one which is more economical in the overall cost of
production and operation. The process is a long and time consuming one. From the study of existing ideas, a
new idea has to be conceived.

In designing a machine component, it is necessary to have a good knowledge of many subjects such as
mathematics, Engineering Mechanics, strength of materials, Theory of Mechanics, Workshop processes and
Engineering Drawing.

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1.2 Problem Statement
A turbine driven pump system is widely used in industries such as power plants, irrigation
systems, and water supply systems to pump large quantities of water efficiently. The system uses
a turbine as the prime mover to drive a pump through a shaft and coupling mechanism.
However, designing an efficient turbine driven pump presents several engineering challenges.
The pump must operate at the required flow rate, head, and efficiency, while the turbine must
supply sufficient power and rotational speed to drive the pump. Improper design may lead to
problems such as low efficiency, excessive vibration, shaft failure, bearing wear, and high
energy consumption.
In many applications, especially in water supply and irrigation systems, there is a need to
optimize the design of the turbine, shaft, bearings, and pump components to ensure reliable
operation and long service life. The selection of suitable materials, dimensions, and operating
parameters is also critical for maintaining system performance.
Therefore, the main problem is how to design a turbine driven pump system that can deliver the
required discharge and head efficiently while ensuring mechanical reliability, safety, and
minimum maintenance cost. This project focuses on determining the appropriate turbine power,
pump capacity, shaft design, and supporting components required for an effective turbine driven
pump system.
As it is known, our country Ethiopia is highly affected by consequence drought and starvation.
But the truth is this country has a considerable amount of water resource. There are a lot of rivers
that flow through gorge all day and night through out the year. So how this country will immerse
in these complex problems of drought? The answer is simple; those rivers are not comfortable to
use them for irrigation and other purposes. Most of the rivers created due to the flow of magma
in the earth surface. The magma creates a large channel that the rivers flow within it. And due to
large deforestation in our country, a lot of soils eroded each years. That mean those rivers
become deeper and deeper each years. So almost it is impossible to use this river water for
irrigation purpose. So how is it possible to use this river water for multi purposes? The answer is
again simple, just pumping the water to some distance above the river. Pump is mechanical
equipment that able to create a pressure on the fluid and transport it to some distance in side the
tube. But the pumps need energy to pump the water. There are two main energy source called
electric energy and fuel energy. Countries like Ethiopia can never able to use fuel as energy

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source, because it is so expansive currently. Using of electric energy is also expansive and not
available in rural area of the country. In addition the pump should work 24 hours a day if it is
irrigation. That means neither electric nor fuel energy is expansive even for developed country.

Figure 1.1 river that can not use for irrigation

So the only choice that faces, are using the river flow energy for pumping the water. There are
different types of pumps that run these types of tasks. Those are hydraulic pump, reversible
pump, turbine driven pump and others. From the above three, turbine driven pump is the best
suited for irrigation purpose. It can pump a large amount of water and a good lifting height than
the other pumps. TDP (turbine driven pump) is a conjugation of different machine elements that
is turbine, shaft, power transmission unit, radial piston pump and others. It is possible to use
different turbines for this system, like pelton wheel, aerofoil turbine and others. But aerofoil
design is the best because of simplicity for manufacturing, relatively lesser vibration, produce
better power,
The aero foil design is committed using the design of wind turbine. This method can be used for
either analysis of existing machines or the design of new ones. More sophisticated treatments are
available but this method has the advantage of being simple and easy to understand.

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1.3 Objective of the study
1.3.1 General Objective
 To design an efficient and reliable turbine driven pump system for pumping water at the
required discharge and head.
1.3.2 Specific Objectives
 To design the pump shaft, bearings, and other mechanical components.
 To analyze the performance and efficiency of the turbine driven pump.
 To ensure the system operates safely and reliably under working conditions
1.4 Significance of the study
The design of a turbine driven pump is important in many engineering applications such as
irrigation systems, water supply, power plants, and industrial processes. This study helps
improve the efficiency and reliability of pumping systems by properly designing the turbine,
pump, shaft, and supporting components. The study is significant because it helps engineers
understand how to select suitable design parameters, including pump capacity, head, and turbine
power, to ensure the system operates effectively. Proper design can reduce energy consumption,
mechanical failure, and maintenance costs. In addition, the study contributes to improving water
management and irrigation systems, especially in developing regions where efficient pumping
systems are required to support agriculture and water distribution.
Finally, the study provides useful knowledge for mechanical and hydraulic engineering students
and professionals by demonstrating the practical application of engineering principles in the
design and analysis of turbine driven pump systems.
1.5 Scope of the study
The scope of this work focuses on the design and analysis of a turbine driven pump system used
for pumping water in industrial or irrigation applications. The study includes the determination
of the required flow rate (discharge), head, and power needed for the pump operation.
The work also covers the selection and design of the main components of the system, such as the
turbine, pump, shaft, coupling, and bearings. Basic design calculations are carried out to
determine the dimensions, strength, and operating conditions of these components.

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In addition, the study evaluates the efficiency and performance of the turbine driven pump
system under specified operating conditions. The project mainly focuses on the mechanical
design and theoretical calculations required for the system.
However, the scope does not include actual manufacturing, installation, or experimental testing
of the turbine driven pump. The analysis is limited to design calculations, component selection,
and theoretical performance evaluation.
1.6 Limitation of the Study
The study entitled “Design of Turbine Driven Pump” is mainly focused on the design and
analytical evaluation of the system. Although the project is intended to provide a reliable and
practical engineering design, some limitations are expected during the study.
First, the project is limited to theoretical design calculations and does not include full fabrication
and experimental testing of the turbine driven pump. As a result, the actual performance of the
system under real operating conditions may not be fully verified within the scope of this study.
Second, the study depends on standard design assumptions, engineering formulas, and handbook
data. Some operating conditions such as vibration, leakage losses, frictional losses, and wear
effects may not be analyzed in full detail.
Third, there may be limited access to industrial data, laboratory facilities, and specialized design
software, which can affect the depth of performance analysis and simulation.
Fourth, the project may be constrained by time and financial limitations, making it difficult to
perform prototype manufacturing, material testing, or advanced numerical analysis.
Finally, the study is limited to the design of the main mechanical and hydraulic components such
as the turbine, pump, shaft, coupling, and bearings. Other aspects such as control systems,
automation, and long-term maintenance performance are not covered in detail.

1.7 General consideration in machine design

Following are the general consideration in designing a machine component.

 Type of load and stresses caused by the load

 Motion of parts or kinematics of the machine
 selection of materials
 from and parts of the part size
 Frictional resistance and lubrication

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  Conventional and economical failures
 Use of standard parts
 Safety of operation
When a new machine or its elements are to be designed, no rigid rules can be specified for a design to
follow the problem can be specified for many ways. However the designer may proceed as follows:
 Make selection of the possible mechanisms which will give the designed motion or
group of motions.
 Determine the forces acting on and the energy transmitted by each element of the
machine.
 Select the material best suited for each element of the machine.
 Determine the allowable or design stress considering all the factors that affect the
strength of machine part.
 Modify the machine elements in parts to agree with the part experience and judgment
and to facilitate manufacturing.
 Make assembly and detail drawings of the machine with complete specification for
materials and the manufacturing method.
So the design of a new material or its elements may follow a tentative plan.
The design plan is not a rigid one way process but is casting feed back. After the general specification
of the machine or the machine member been set, the kinematics scheme is decided. This is followed by
a force analysis forces is made and the stage will be rather incomplete for design where dynamics is of
important, Since masses components is done because the forces are not known exactly.

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 CHAPTER TWO
LITERATURE REVIEW
2.1 Introduction
A literature review is an important part of any engineering project because it helps to understand
what previous researchers, engineers, and designers have done in relation to the selected topic. It
provides theoretical knowledge, design concepts, performance characteristics, and engineering
methods used in the design and analysis of turbine driven pump systems.
A turbine driven pump is a mechanical system in which a turbine acts as the prime mover to
drive the pump. The turbine converts energy from steam, gas, or water into rotational mechanical
energy, which is then used to operate the pump. Such systems are widely used in power plants,
irrigation systems, petroleum industries, chemical industries, and water supply systems.
This chapter reviews previous works and engineering studies related to pump design, turbine
systems, shaft design, impeller design, bearing selection, and pump performance analysis. It also
identifies the research gap that justifies the need for the present study.
A literature review provides an overview of previous studies, research findings, and engineering
concepts related to turbine driven pumps. Many researchers and engineers have studied pump
systems, turbine drives, and fluid transport technologies to improve efficiency, reliability, and
performance in industrial and irrigation applications.
2.2 Theoretical Review of Turbine Driven Pump
A turbine driven pump combines two major engineering systems: the turbine and the pump.
The pump is a hydraulic machine used to move fluids from one place to another by increasing
the pressure and velocity of the liquid. Pumps are commonly used in water supply, irrigation,
industries, and thermal systems.
The turbine is a rotary machine that converts the energy of a moving fluid into mechanical
energy. In turbine driven pump systems, the turbine supplies the rotational power required to run
the pump.
2.3 Literature Review on Pump Design
Many researchers and authors have studied pump design and performance improvement.
According to Karassik et al., pumps are among the most widely used fluid machinery in
industrial and agricultural applications. Their work explains that the performance of a pump is
highly influenced by the design of the impeller, casing, shaft, and bearings.

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According to Rajput, Studies in fluid mechanics show that the pump must be selected and
designed according to the required flow rate and pressure head. If the pump is not properly
designed, it may suffer from low efficiency, vibration, cavitation, leakage, and mechanical
failure.
According to White, 2016 most engineering literature shows that centrifugal pumps are widely
used because of their simple construction, smooth operation, and ability to handle large volumes
of fluid. However, the performance of a centrifugal pump depends strongly on the efficiency of
the driving system.
2.3.1. Study on Centrifugal and Turbine Pump Performance
Several studies explain the performance characteristics of pumps driven by turbines. Researchers
have found that turbine driven pumps are widely used in power plants, petroleum industries, and
water supply systems because they can operate without electrical power. The studies show that
the efficiency of the pump mainly depends on impeller design, flow rate, and head conditions.
Proper matching between the turbine power output and the pump power requirement is essential
to achieve efficient operation.
2.3.2. Research on Turbine Driven Pump Systems in Power Plants
In thermal and nuclear power plants, turbine driven pumps are commonly used for boiler feed
water and emergency cooling systems. Researchers report that steam turbines are often used as
the driving source because they provide high rotational speed and reliable continuous operation.
Previous studies also indicate that turbine driven pumps improve system reliability, especially
during electrical power failure.
2.3.3. Studies on Hydraulic Design of Pumps
Many researchers have focused on the hydraulic design of pumps to improve efficiency and
reduce energy loss. The design of impeller blades, casing, and flow channels plays a significant
role in pump performance. Research shows that optimizing these components can increase pump
efficiency and reduce cavitation problems. Cavitation is a major issue that can cause damage to
pump components and reduce service life.
2.3.4. Research on Mechanical Design Components
Previous engineering studies emphasize the importance of mechanical components such as
shafts, bearings, and couplings in turbine driven pump systems. Proper shaft design ensures that
the system can transmit torque from the turbine to the pump without failure. Bearings are also

8
essential for supporting the rotating shaft and reducing friction during operation. Researchers
recommend selecting bearings based on load capacity, speed, and lubrication conditions.
2.3.5. Studies on Reliability and Maintenance of Pump Systems
Several researchers have analyzed the reliability and maintenance requirements of pump
systems. Their studies indicate that regular maintenance, proper lubrication, and vibration
monitoring are necessary to ensure long service life. Failure analysis studies show that most
pump failures are caused by bearing wear, shaft misalignment, corrosion, or fatigue.
2.4 Related Work
Several researchers and engineering designers have contributed to the study and development of
pump and turbine systems. Their works provide important background for the design of turbine
driven pumps.
2.4.1 Work on Centrifugal Pump Design
Different researchers have studied the design and performance of centrifugal pumps under
various operating conditions. Their studies mainly focused on determining the relationship
between flow rate, head, efficiency, and impeller geometry. These works concluded that pump
performance can be improved by proper impeller design and correct matching of rotational speed
with discharge requirements.
2.4.2 Work on Turbine Power Transmission
Several studies have also been carried out on turbine systems used as mechanical power sources.
These studies emphasized that turbines are effective prime movers in systems requiring
continuous operation and high reliability, especially in industrial applications such as boiler feed
water systems and emergency pumping systems.
2.4.3 Work on Mechanical Component Design
Other related studies focused on the design of shaft, bearings, couplings, and support structures
in rotating machinery. These studies show that improper shaft diameter, poor bearing selection,
and misalignment can reduce system efficiency and lead to early mechanical failure.
2.4.4 Work on Energy Efficiency Improvement
Recent engineering works have also focused on reducing energy losses in pumps and turbines by
improving hydraulic design, material selection, and component alignment. Many researchers
suggest that a properly designed turbine driven pump system can achieve higher performance
and longer service life than a poorly matched system.

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2.4.5 Work on Industrial and Irrigation Applications
Previous projects and practical applications have shown that turbine driven pumps are useful in
irrigation schemes, industrial plants, and water supply systems, particularly where electrical
power is unreliable or unavailable. These works prove that turbine driven pumps have both
technical and economic importance.
2.5 Research Gap
Although many studies have been conducted on pumps, turbines, and rotating machinery, there
are still important gaps that need further attention.
2.5.1 Lack of Integrated Design Approach
Most previous studies discuss pump design and turbine design separately. Very few studies
provide a complete integrated design that combines:
 Turbine power selection
 Pump hydraulic design
 Shaft design
 Bearing selection
 Mechanical power transmission
This creates a need for a study that brings all these design elements together in one project.
2.5.2 Limited Focus on Educational Design-Based Projects
Many published works focus on industrial applications and advanced simulations, but they do
not provide a clear and simplified engineering design procedure suitable for academic project
work. There is a need for a design study that can be easily understood and applied by engineering
students.
2.5.3 Insufficient Emphasis on Mechanical Component Matching
In many cases, more attention is given to pump hydraulic performance than to the proper
matching of the shaft, bearings, and turbine output. Poor matching of these components can lead
to:
 Excessive vibration
 Low efficiency
 Overloading
 Mechanical failure
This indicates a design gap in the practical integration of turbine and pump components.

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2.5.4 Need for Reliable Alternative Drive Systems
In many developing areas and industrial environments, electrical power may be unreliable.
However, there are limited practical studies that explore turbine driven pumps as alternative
drive systems for such conditions. This study helps address that need by focusing on the design
of a turbine powered pumping system.
2.5.5 Gap in Localized and Practical Application
Most literature is based on general industrial cases, but there is limited work that applies turbine
driven pump design in a practical way for water transport, irrigation, and small industrial
systems, especially in developing-country contexts.

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 CHAPTER THREE
MATERIAL AND METHOD
3.1 Materials Used in the Design
The turbine driven pump system consists of several components. Each component must be made
from suitable materials to withstand mechanical stress, corrosion, and operational conditions.
3.1.1 Pump Casing
The pump casing is the outer housing that contains the fluid and protects internal components.
Materials used
 Cast iron
 Stainless steel
 Carbon steel
Reason for selection
 High strength
 Good corrosion resistance
 Ability to withstand high pressure
3.1.2 Impeller
The impeller is the rotating component that transfers energy to the fluid.
Materials used
 Bronze
 Stainless steel
 Cast steel
Properties
 Corrosion resistance
 High mechanical strength
 Good durability
3.1.3 Shaft
The shaft connects the turbine to the pump and transmits rotational power.
Materials used
 Alloy steel
 Carbon steel
Required properties
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  High tensile strength
 Resistance to fatigue
 Good machinability
3.1.4 Bearings
Bearings support the rotating shaft and reduce friction.
Common types used:
 Deep groove ball bearings
 Roller bearings
 Thrust bearings
Bearings must provide:
 Smooth rotation
 Low friction
 Long service life
3.1.5 Turbine
The turbine converts fluid energy into mechanical power to drive the pump.
Common types used:
 Steam turbine
 Water turbine
 Gas turbine
Material requirements:
 High temperature resistance
 High strength
 Corrosion resistance
3.2 Methodology of Turbine Driven Pump Design
The design methodology involves several stages.
3.2.1 Determination of Pump Requirements
The first step is to determine the required flow rate and pressure head.
Parameters considered include:
 Flow rate (Q)
 Total head (H)
 Fluid density

13
  Operating speed
The pump power requirement is calculated using the hydraulic power equation.
P= ρgQH
Where:
P = Power required (W)
ρ = Density of fluid (kg/m³)
g = Gravitational acceleration (9.81 m/s²)
Q = Flow rate (m³/s)
H = Total head (m)
3.2.2 Selection of Turbine Power
The turbine must produce enough power to drive the pump.
The required turbine power is determined from:
Power required by pump
 Mechanical losses
 Safety factor
This ensures the turbine provides sufficient energy for pump operation.
3.2.3 Shaft Design
The shaft is designed to transmit torque from the turbine to the pump.
The torque transmitted by the shaft is determined using:
P = Tω
Where
T = Torque
P = Power
ω = Angular velocity
The shaft diameter is calculated considering shear stress and safety factors.
3.3.4 Bearing Selection
Bearings are selected based on:
 Load acting on the shaft
 Rotational speed
 Expected life of the bearing
Proper lubrication and alignment are also considered to reduce wear and failure.

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3.2.5 Impeller Design
The impeller is designed based on fluid flow requirements.
Important parameters include:
 Impeller diameter
 Blade angle
 Number of blades
 Rotational speed
Proper design ensures efficient energy transfer to the fluid.
3.2.6 Pump Efficiency Analysis
Pump efficiency is evaluated using the efficiency equation.
High efficiency indicates better performance and reduced energy loss.
3.3 Design Procedure
The following steps were followed in the design process:
1. Determination of pump capacity requirements
2. Selection of turbine type
3. Calculation of hydraulic power
4. Design of shaft and mechanical components
5. Selection of bearings and coupling
6. Determination of pump efficiency
7. Verification of safety and performance
3.4 Tools and Software Used
The following engineering tools may be used during the design process:
 Computer-Aided Design (CAD) software
 Engineering design formulas
 Mechanical design standards
 Fluid mechanics principles
These tools help ensure accuracy and efficiency in the design.
3.5 Assumptions Used in the Design
To simplify the calculations, the following assumptions were made:
 The fluid is incompressible
 Flow is steady and uniform

15
  Mechanical losses are within acceptable limits
 Material properties remain constant during operation
These assumptions help simplify the design analysis.
3.6 Limitations of the Method
The design is based mainly on theoretical calculations and standard engineering formulas.
Experimental testing and prototype manufacturing were not included due to time and resource
limitations.
3.7 Selecting an appropriate material
The primary difficulties in selecting an appropriate material can be seen as lying in two areas:

 The gathering of information concerning suitable materials, their properties and cost.
 Developing an understanding of the service requirements.
Consideration of these two areas will allow the range of possible alternatives to be found. Then to
select from this group, the design must identify other criteria, such as the material offering the lowest cost or the
minimum weight, and explore the manufacturing implication of any particular alternative. Which material is
selected may vary largely determined the manufacturing rate and there will be implication for the detailed
design of the product form.

3.8 Manufacturing construction in Design

The purpose of standardization is to establish mandatory or obligatory norms or standards to which the different
types, grades, parameters, quality characteristics, test methods and rules of marketing, packing and storage of
finished items, raw materials and semi finished articles should confirm. Its aim is to minimize variety so that the
number of types, dimensions and sizes are limited to a definite number of models. Standardization is of great
importance in mechanical engineering in which a large variety of types and sizes of items in single quantities
exist, a wide range of material used and a great number of diverse manufacturing of required machines
comparatively quickly and economically despite this diversity.

3.9 Welded Joint

A welded joint is a permanent joint which is obtained by the fusion of the edges of the two parts to be
joined together, with or without the application of pressure and a filler material. The heat required for
the fusion of the material may be obtained by burning of gas (in case of gas welding) or by an electric
arc (in case of electric arc welding).

16
Welding is extensively used in fabrication as an alternative method for casting and forging and as a
replacement for bolted and riveted joints. It is also used as a repair medium. The welding process may
be classified into the following two groups:
 The welding process that uses heat alone, e.g. fusion welding
 Welding process that uses a combination of heat and pressure e.g. forge welding.
In case of fusion welding, the parts to be joined are held in position while the molten metal is supplied
to the joint. The molten metal may come from the parts themselves (i.e. parent metal) or filler metals
which normally have the composition of the parent metal. The joint surface becomes plastic or even
molten because of the heat from the molten metal or other sources. Thus when the molten metal
solidifies or fuses, the joint is formed. The fusion welding, cording to the method of heat generated
may be classified as Thermal welding, Gas welding and Electric arc welding.
Now, for our design of the feeder system the suitable type of welding that gives high strength and
toughness for our welding process is electric arc welding. This is because according to the thickness of
the sheet metal and the shape of the material used arc welding is preferably used than other type of
welding.
In electric arc welding, the work is prepared in the same manner as for gas welding .In this case the
filler metal is supplied by metal welding electrode. The operation, with his eyes and face protected,
strikes an arc by touching the work of base metal with the electrode. The base metal in the path of the
arc stream is melted, forming a pool of molten metal, which seems to be forced out of the pool by the
blast from the arc.
Though there are two types of arc welding depending up on the type electrode, unshielded arc welding
and shielded arc welding, we are using shielded arc welding. Shielded arc welding ,the welding rods
coated with solid material are used .The resulting projection of coating focuses a concentrated arc
stream, which protects the globules of metal from the air and prevents the absorption of large amounts
of harmful oxygen and nitrogen .
Though there are different type of welding , the two main type of welding from the subject point if
view is lap joint or fillet joint and butt joint , the main considerations involved in the selection of weld
type are
 The shape of the welded component required
 The thickness of the plate to be welded
 The direction of force applied

17
 CHAPTER FOUR
DESIGN OF TURBINE DRIVEN PUMP

4.1. Design Of The Aerofoil Structure

The solution for a given blade cannot be found directly from the equations but an iteration solution is
required. There is more than one way to carry this out, in this document a solution based on guesses for a
and a’ and subsequent iteration.

First prepare the aerofoil shape dimension. To be some what precise the foil should be divided for at least
three parts.

From the table for six blade turbine tip speed ratio ( λ ) will be 2.

Then the dimension to start the design will be

λ=2
r = 0.65 c = 0.65

dr =0.65

Here those divisions of blade have different chord length and angle.

Figure 4.2 blade turbine

18
 Divisio
n
Radius from
the center
Chord length
γ
C

1 1.3 0.25 900

2 1.09 0.29 870

3 0.9 0.3 800

4 0.65 0.3 770

Table 4.1 Radious and Chord length

Division #1

Now design for the first division

r =1.3 c =0.25 and blade number, B =6

Then,

σ=BC/2πr
σ=(0.25∗6)/(2π∗1.3)=0.184
Assume the value of a and a’ for starting the iteration

a = 0.33 and a’=0.031

Iteration a a' β γ i CL

1 0.32 0.143 70.5 87 16.5 0.75

2 0.2872 0.0606 68.162 “ 18.8 0.72

3 0.235 0.056 66.6 “ 20.4 0.7

4 0.206 0.0532 65.8 “ 21.2 0.72

5 0.198 0.0533 65.6 “ 21.4 0.73

19
 6 0.1983 0.0536 65.6 “ 21.4 0.73

7 0.1983 0.0536. 65.6 “ 21.4 0.73

Table 4.2 lift coefficient

Here the final lift coefficient is CL=0.73 and the corresponding value of the drag coefficient is Cd = 0.33

Division # 3

R3= 0.9 C3= 0.3

Then the local tip speed ratio for the given division is calculated as follows:

λ 3 /r 3 =λ /r ⇒ λ3 =r 3∗λ/r
λ 3=1 . 385

And local solidity

σ '=BC 3 /2 πr 3=6∗0. 3/(2 π∗0. 9 )

σ '=0 . 318

After than, a and a ' will be assumed:

a=0 . 31 anda '=0 . 292 for only to start the iteration:

Iteration a a' β γ i CL

1 0.31 0.292 69 80 11 1.05

2 0.378 0.104 67.8 “ 12.2 1.18

3 0.384 0.1123 68.2 “ 11.8 1.1

4 0.37 0.1070 67.66 “ 12.34 1.27

5 0.39 0.1165 68.5 “ 11.5 1.17

6 0.39 0.112 68.47 “ 11.53 1.17

7 0.39 0.112. 68.5 “ 11.5 1.17

20
 Table 4.3 lift coefficient
The final value is diverge at iteration number 7, therefore C L=1.17 and Cd=0.03

Division # 4

For this division

R4=0.65 C3=0.3 and γ=77 0

And the local tip speed ratio for the given division:

λ 4 /r 4 =λ /r ⇒ λ 4 =r 4∗λ /r
λ 4 =1

And the local solidity:

σ '=BC 4 /2 πr 4 =6∗0 . 3/(2 π∗0 . 65)

σ '=0 . 44

Before starting the iteration we should assume some value of a and a’, So

a=0 . 31 and a '=0 . 292

Iteration a a' β γ i CL

1 0.31 0.292 61.89 77 15.11 0.77

2 0.25 0.1345 56.3 “ 20.5 0.7

3 0.174 0.1152 53.5 “ 23.5 0.77

4 0.16 0.1194 53.14 “ 23.86 0.79

5 0.16 0.121 53.13 “ 23.87 0.79

6 0.16 0.121 53.13 “ 23.87 0.79

Table 4.4 lift coefficient

So now the value of CL= 0.79 and corresponding value of Cd=0.4

Let revise the whole value of the iteration in table:

21
 division λ σ' a a' β CL Cd

1 2 0.184 0.18865 0.0368 68.63 0.724 0.32

2 1.677 0.254 0.1983 0.0536 65.6 0.73 0.33

3 1.385 0.318 0.39 0.112 68.47 1.17 0.03

4 1 0.44 0.16 0.121 53.13 0.79 0.4

Table 4.5 drag coefficient

As it mentioned before, this all results iterated for the sake of calculating the power coefficient of the
given aerofoil structure.

λ
C P=(8/ λ ) ∫ λ 3∗a '(1−a)[ 1−(C d ¿ C L )*tan β ]dλr
2
r
λr

Here the value of the Cp will approximate using trapezoidal approximation rule. It says,

Here the let’s calculate the Cp

First Yo substitute the value of the fourth iteration as it needed

Y 0 =13∗0 . 121∗(1−0 .16 )[ 1−(0. 4 /0 . 79)*tan53 . 13 ]=0 . 033

And using the same substitution for each iterations

Y 1 =0 .1697
Y 2 =6 . 99∗10−4
Y n =0 . 02244

P=0. 5∗C p ρV 3 πR 2 =0 .5∗0 .114∗1000∗1. 23∗π∗1 .3 3

Then P=522 . 9≈523 watt
Again using trapezoidal rule the torque can be calculated, but it has other simplified method.
λ
dT =∫ σ ' πρ V ((1−a) /cos β )∗(C L cos β −Cd sin β )dλ r
2 2 2

λr

First calculate the angular velocity,

ω / V =λ / r ⇒ ω=λV / r=2∗1 .2 /1 . 3=1 .846 rad /sec

22
 And the torque will be

T =P/ω=523/1 . 846=282 . 87≈283 N −m

Using the torque calculated it is possible to calculate the radial force on the foil.
r
dF X =∫ σ ' πρ V 2 (1−a )2 (C L sin β +C D cos β )rdr
r0

The calculated value will be FX = 3515N

4.1.1 Design Of Aerofoil Holder Bar

First transfer the force on the point B.

For this bar, mild steel is selected; this steel type is called Fe E 770.

That means it have yield strength Y.S= 460MPa.

It is familiar for construction and support purpose.

Let take factor of safety F.S = 3

So τ max =(Y . S /2)/ F . S=(460 /2 )/3=115 MPa

The foil has to be assumed as a simple bar with a support

23
 Figure 4.3 aerofoil holder bar

So
V B =3515/2=1757 . 5 N

Then again assume the inclined parts of the bar as a cantilever beam, and calculate the maximum
principal shear stress on the body. The calculated maximum shear stress should be minimum related with
the maximum shear stress of the material.

Figure 4.4 components (tangential and axial)

As it shown in the picture the force on the bar has two components (tangential and axial). So check for
principal shear for the tangential force and buckling for axial load.

F A=F cosθ=1757 . 5 cos22 .25=1623 .72 N

F R=F sin θ=1757 . 5 sin 22. 25=665. 475 N

Check for principal shear stress

Now, first let design the bar for principal shear stress.

τ =P/ A=665. 475 /(10∗40 )=0 . 887 MPa

And bending stress will be

24
 M=P∗l=665 . 5∗594=395307 N −mm
and
σ b =M / Z Where, Z=(1/6 )bh2 =(1/6 )50∗152 =1875 mm 3

Substitute the above value of Z and M.

σ b =395307/1875=210 MPa

Check for maximum shear stress

√
τ max =0 .5 ( σ 2 + 4∗τ 2
C

τ max =0 .5 √(210 2 + 4∗0 .887 2)=105 MPa

Here shear stress of the material is115MPa, but the shear stress calculated is 105MPa. This
indicates shear occurs at 115MPa and above it, but it is always safe from shear if the calculated value is
lesser.

Check for buckling

First of all for mild steel

σ C =320 MPa
a=1/7500
A=15+50=750 mm 2
3 2
And K XX =I / A=(1/12)bh /(bh)=(1/12)h

So, Rankine buckling load formula says:

W Cr =(σ C A )/(1+a( L/ K XX )
W Cr =(320∗750)/(1+(1/7500)(594∗112. 5 )2 )=5720 N

The load can resist a force of 7520N. The applied force is so small related to the maximum
buckling load require. So the design is safe.

7520 N ⊃1623. 72 Safe,

25
 Weld design for the foil

Figure 4.5 Weld design for the foil

The side of the aerofoil is welded with the rectangular plate, which have 2mm thickness.

Again for the sack of simplicity the aerofoil shape is approximated to a rectangular shape.

After then use rectangular fillet weld

And let S – size of the weld

t – Throat thickness

Maximum shear stress for the weld material is 25MPa

The weld joint is subjected to direct shear stress and the bending stress. It is known that, the
throat area for rectangular fillet weld:

A=(2 b+2 l)∗t=0 .707 s(2∗b+2∗l)

A=0 .707∗s(2∗300+2∗80)=537 .32∗s t = 0.707s

∴ Direct shear stress will be:

τ =F / A=3672/537 . 32 s=6 . 8/s MPa

It is known that bending moment:

M =P∗e=3672∗325=1193400 N −mm

26
The rectangular section modulus is:

Z=t∗(b∗l+b 2 /3 )=0 . 707 s (300∗80+0 .3 2 /3 )=38178∗s mm3

∴ Bending stress will be,

σ b =M /Z=1193400/38178 s=31 .26 /s MPa

It is known that the maximum shear stress will be

√
τ max =0 .5 ( σ 2 + 4∗τ 2 )
b
τ max =0 .5 √((31. 26 /s )2 + 4∗(6 . 8/ s )2=34 /(2 s )
25=17/ s ⇒ s=17/25=0. 825≈1 mm

Weld design for screwing the foil supporting bar

Figure 4.6 Shows the weld area in the aerofoil

The joint is subjected to direct shear stress and bending stress. We know that the throat areas for a circular
fillet weld.

A=t∗πD=0 . 707 s∗πD

A=0 .707 s∗π 15=33 .32 s
Then shear stress will be:

τ =P/ A=3672/33 . 32 s=110 / s MPa

Then the bending moment will be:

27
 M =P∗e=7 . 5∗3672=27540 N −mm

Where as the bending stress is

σ b =M / Z

But, Z=π td 2 /4=(π∗0 . 707 s∗102 )/ 4=55 . 5 smm 3

So
σ b =M /Z=27540 /55 . 5 s=496/ s MPa

Then using the maximum shear stress theory it is possible to find the weld thickness.

√
τ max = ( σ 2 +4 τ 2 )=0 .5∗√ ( 496/ s )2 +4 ( 110 /s )2 =271/s
b

τ =140 MPa
Here the strength of weld material is: max

271/140=1. 935≈2 mm

4.2 . V- Belt Selection

In v-belt transmission the pulley is selected from standard table of pulley.

And the belt material is manufactured by with different component those are: Fabric (rubber covers),
chords and threads. This mixed material will have a density of ρ = 1100Kg/m 3 and a tensile strength of
2.1MPa. Any way this is Indian standard v- belt.

The basic requirement for selection of v-belt is the power transmitted and the factor that the speed
multiplied.

P=523 watt ω=1 .84 rad /sec

And the factor that the speed multiplied is taken as 2.5

N 2 /N 1=ω2 /ω1 =2. 5

From Indian standard table found in page 21 and 22 of this project paper,

Type C is selected for this design. Type C will have 200mm pulley diameter.

So
d 1 /d 2=N 2 / N 1 ⇒ d2 =d 1 /2. 5=80 mm

28
This 80mm diameter pulley is located in the driven, shaft that transmits the power to the pump.

Figure 4.7 V-belt pulley sectional view

Every standard dimension of the 200mm diameter v-belt transmission is tabulated as follows:

f =17 b=22
e=25 t=14 a=6
w=19 2 β=380 c=14
Then the length between each belt drive pulley is selected to be 1.2m, so

Figure 4.8 belt drive pulley

Now, let use Pythagoras theorem to find α and θ

29
sin α =0 1 M /0 1 02 =( r 2 −r 1 )/ l=( d 2−d 1 )/ 2 l
sin α =( 0. 2−0. 08 )/( 2∗1. 2)=0 .05
α =sin−1 0 .05=2 .866 0

0
And θ=180−2 α=174 . 27

The value in radian is θ=3. 04

And the mass of the belt per unit length (l=1 m )

m=area∗length∗density

Density of the belt material is: ρ=1100 Kg/m3

Area = Total area – triangles area

= (22*14) – 2*0.5(14* tan 19)

= 303.18mm2

So the mass will be:

m=a∗l∗ρ=3 . 0318∗10−4∗1100=0. 33 Kg/m

And velocity of the belt is:

V =ω∗r=0 . 1∗1 . 84=0 .184 m /sec

∴ Centrifugal tension,

T C =mV 2 =0 . 33∗0 .184 2=0. 011

So the maximum tension in the belt is:

Material strength for the belt σ =2 .1 MPa

T =σ∗a=2 .1∗303 .18

T =636 . 68 N
There for tension in the tight side of the belt,

30
 T 1=T −T C =636 . 68−0. 011=636 . 67 N

Let say T2 –tension in the slunk side of the belt,

It is known that

2 .3 log(T 1 /T 2 )=μθ csc β

Friction between the belt and pulley will be 0.28.

And

log T 1 /T 2=(0 .28∗3 . 04 )/(2 .3 *sin 19)=1. 1367

1. 1367
Then T 1 /T 2=10 =13. 7

So
T 2=T 1 /13 . 7=46 .5 N

∴ Number of belts (n ) needed to transmit the power is:

n=Pi / P , where Pi is the power in one belt

Pi =(T 1−T 2 )V =(636 . 67−46 . 5)∗0 .184

P =108. 6 watt
So i

The number of belt needed to transmit the power P=523 watt .

n=Pi / P=523 /108 . 6=4 . 8≈5 Belts are needed.

So width of the pulleys be B=(n−1 )e+2 f

Heree=25 , f =17 so

B=134 mm

Diameter of the driven pulley

Let calculate the diameter of the driven pulley shaft and let D is the diameter of the driven
shaft.

It is known that torque transmitted by the driven pulley shaft:

31
 T =( P∗60 )/(2 πN 2 )=P /ω=523/4 . 6=113. 695 N −m

Since the driven pulley is over hung and distance of the center from the nearest bearing is taken as:

S=250 mm

Then, bending moment on the shaft, due to the tension on the belts.

M=(T 1 +T 2 +T C ) S∗n
M=(636 .67+46 . 5+2(0 . 011))∗250∗7=853990 N−mm
∴ Equivalent twisting moment,

T e= √(T 2 +M 2 )= √(8539902 +(113.695∗103 )2 )

T e=861525 N −mm

Finally, the equivalent twisting moment will be:

T e=(π /16 )τ∗D3

√3 ((861525∗16 )/( π∗τ ))=D Here τ =60 MPa

D=41 .82 mm

For selection of bearing from standard and manufacturing simplicity of the shaft, it is better to take the
diameter of the shaft as:

D = 45mm

32
Figure 4.9 Bearing selected for the standard bearing

4.3. Design of the driving shaft

Before designing the shaft every loads due to weigh and torsional force should be identified.

33
 Figure 4.10 input shaft which support aerofoil turbine and pulley.
Here the load of the pulley is calculated using the area

A = πd2 = π*2002 = 0.1256m2

Width of the pulley will be 134mm. So volume V = 0.1256*0.187= 0.023m3

The material for the pulley material from Indian standard table is cast iron

So ρ = 7250Kg/m3

Therefore ρ = m/V implies m = ρ*V = 7250 * 0.023 = 170.3 Kg

F = 9.81 * 170.3 = 1671N

Using the above procedure, the rough weight of the aerofoil, the connecting bar, rotter and screw element
the total weight will be 1035N.

1035N 1671N
1.15
425 250

RAV RBV

34
 It is known that torque acting on the pulley C,

T =(T 2 −T 1 )∗R D =(505 . 5−36 . 86 )∗0 . 1=46 .86 N −m

 At the above diagram, those forces are vertical force due to the weight of the
components.

Here
R AV +R BV =2706 N

Take moment about A

R BV ∗1825=1035∗425 +1671∗1575
Then
R BV =1683 N

So
R AV +R BV =2706 N ⇒ R AV =2706−1683=1023 N

Then the bending moment at A and B is

MAV = MBV = 0

So B.M at C
⇒ R BV ∗0 . 25=420 .75 N −m

B.M at D
⇒ R AV ∗0. 425=434 .775 N −m

 Now horizontal forces on the shaft due to the torque generate.

In the V-belt pulley there are tensions which result a horizontal force on the shaft.

So (T 1 +T 2 )=R P =(636 . 67+46 . 5 )=683 .17

And the torque developed due to turbine is:

T = 282.87N-mm

So
RT =T /r =282 .87 /0 .65=435 . 18 N

35
 435.18N 683.17N

425mm 1150mm 250

RAH RBH

R AH + R BH =1071. 35

Moment about A

R BH∗1825=435 . 18∗425+683 . 17∗1575

R BH =650 N
R AH =977 . 54−RBH =10871 .35−650=421 N

The bending moment (B.M) at A and B is zero. But

B.M at C
⇒ R BH ∗0 . 25=162 .5 N−m

B.M at D
⇒ R AH∗0 . 425=178 . 925 N−m

Then resultant of bending moment at C and at D, is

√ BV 2+ M BH 2 )=√ 420 . 752+162 . 52=451 N −m

M C= ( M

M D=√ ( M 2 + M 2 )= √178 . 9252 + 434 . 7752 =470 N−m

BH AH

It is seen that the bending moment is maximum at D. So the equivalent twisting moment will be:

√
T e= ( M 2 +T
2
)=√ 470 2 +282 .87 2=551 N −m
D

Then the equivalent twisting moment will be:

36
 T e =( π /16 )∗τ∗d 3 ⇒(T e∗16 )/(π∗τ )=d 3
(551∗10 3∗16)/(π∗40 )=d 3
d=41. 2 mm

Again let’s take the diameter of the shaft as 45mm.

4. 4. Bearing selection
In the bearing there are two types of forces, axial and radial.

Radial force (WR) = 650N

Axial force (WA) = 1683N

Let take the average life of the bearing in two years at 24 hours per day, there fore life of the bearing in
hours.

In one year there is 2 month of raining so there is only 300 days of working for the bearing.

So the life time of the bearing will be:

LH = 2*300*24 = 14400hours

And the life of the bearing in revolutions:

6
L = 608*N *LH = 600*44*14400 = 38.016*10 revolution

We know that the basic equivalent radial load,

W =X∗V∗W R +Y ∗W A

In order to determine the radial load factor (X) and axial load factor (Y), W A/WR and WA/Co is
required. Since the value of basic static load capacity (Co) is not known, therefore let us take WA/WR =0.5.
Now from Indian standard table (Gupta it is found that the value of X and Y corresponding to W A/Co =
0.5 and WA/WR = 1683/650 = 2.6 (which is greater than e = 0.04) are

So X = 0.56 and Y= 1

W =X∗V∗W R +Y ∗W A =0 .56∗1∗650+1∗1683=2047 N

Assume the rotational load is uniform and steady, so the service factor (K S) for all bearing is 1. Therefore
the bearing should be selected for W = 2047N

It is known that, the basic load rating,

37
 C=W ( L/106 )1 /K
C=2047∗((38. 016∗106 )/106 )1 /3 =6 . 883 KN

The approximated value for dynamic load capacity (Co) from the Indian standard table:

So C=4.4KN

Now WA/Co=1683/4400 = 0.3825

The value 0.3825 is between 0.25 and 0.5, which are found in the table.

So the value of X and Y can be calculated by interpolation method.

0.25 --------⇒ X=1.2

0.3825-----⇒ X=?

0.5 ---------⇒ X=1

So

(0.3825 - 0.25) / (0.5 - 0.25) = (Y - 1.2) / (1 - 1.2)

Y = 1.09 and X = 0.56

Substitute these values in the equation of dynamic equivalent radial load.

W =X∗V∗W R +Y ∗W A =0 .56∗1∗650+1. 09∗1683=2198. 5 N

∴ Basic dynamic load rating,

C=2198 .5 ((38 . 016∗10 6 )/106 )1/3=7392. 34 N≈7 . 4 KN

Approximate value of 7.4KN will be 7.5KN, which is found in the Indian standard table.

Therefore the bearing number 203 is the best type of bearing for this design.

4.5. Design Of Key

For the given shaft diameter

Material for the key is taken the same as shaft.

D = 45mm, for the corresponding shaft diameter, the value of the key

W = 14 and thickness t = 9mm.

38
 The length of key is obtained by considering the key in shearing and crushing stress.

T =l∗w∗τ∗d /2=l∗14∗40∗45 /2
T =12600 l

T =( π /16 )∗τ 1∗d 3 =( π /16 )∗40∗453

But T =715 . 69 N −m

12600 l=715 . 69∗103 N −mm

So l=56 . 8 mm

Now consider the failure of the due to crushing. We know that the maximum torque transmitted
by the shaft and key (T),

T=l∗(t /2)∗σ CK ∗( d /2)=l∗(9 /2 )∗(45/2 )∗70

715. 69∗103 =7087 .5 l
(715 .69∗106 )/7087 . 5=l=100. 9=101 mm

4.6. Piston Pump Design

Most of the design procedure of piston pump is typically selection. From manufacturing point of view
and other considerations those value below are selected by the designer.

Piston diameter =80mm

Height of the piston = 90mm

Stroke S =200mm

Pump capacity design

1. flow rate calculation
Discharge capacity of reciprocating pump will be:

Consider a single acting reciprocating pump and let

L = length of the stroke of the piston

A = Cross sectional area of the piston and

N = number of revolution per minute of the crank

39
So for the given design L=200mm

A= π *402 = 5026.5mm2

N = 44 rev/min

Then the discharge of the pump will be:

Qi =LAN /60=(0. 2∗0 .005∗44 )/60=7 . 4∗10−4 m3 /sec

η =0 . 8
But volumetric efficiency should be considered, so V

Then the real flow rate will be:

Q=Q i∗η v =0 .8∗7 . 4∗10−4

Q=6∗10−4 m3 /sec

As it is know, to calculate the power developed by the pump, the total head of the pump should be
calculated.

2. Pump head calculation

Given

Q=6∗10−4 m3 /sec
Diameter of selected for suction is

D suction=40 mm

Diameter of steel pipe selected for delivery is

Dd =40 mm

Now suction head = ZS + Hfs

H fs=( fLV 2 )/( D S ∗2 g )=( 8 fLQ 2 )/( π 2 D 5∗g )

Here S

V =Q / A=(Q∗4 )/ πD 2
Where S

40
 V- Average velocity

Here DS = 40mm

L- Length of the pipe = 1m

−4
Q- Flow rate of the water = Q=6∗10 m3 /sec

Figure 4.11 shows the delivery pipe line of the turbine driven pump

There is one unknown called f (friction factor). This value can be read from Moody diagram referring
E/D (roughness constant) and Re (Reynolds number)

Here E is constant for all steel pipe = 0.046mm

−3
So E/D = 0.046/40 =1 .15∗10 =0 . 00115 , V =4 Q/ πD2 =0 . 47 m /sec

And Reynolds number (Re)

Re =VD S /ν =(0 . 47∗0 . 04 )/10−6 =1. 88∗104

−6
ν− Dynamic viscosity = 10

V- Velocity

Now from moody diagram Re is the vertical axis and E/D is the horizontal axis.

And the corresponding value of f = 0.0257

Now it is possible to calculate the friction loss in the suction pipe

41
 So the total suction head will be:

H fs=(8 fLQ 2 )/( π 2 D 5∗g )=( 8∗0 .0257∗(6∗10−4 )2 )/( π 2∗0 . 045∗9. 81 )
S
H fs=7 . 5∗10−3

−3
HS = HFS + Z =1 + 0.0075 where E-3 =10

= 1.0075m

Delivery head

As it is shown in the pipe line plot, the total delivery head will be:

The diameter of the delivery head will be

D = 40mm

The total delivery head will be

H D=Z 1 + Z 2 + H F 1 + H F 2 + H F 3 + H F 4 +nhe

Here Z1 and Z2 is static head and the other is friction losses and elbow loses.

Now let calculate each value of the losses

For the first pipe line

H f 1 =( fLV 2 ) /( Dd 1∗2 g )=( 8 fLQ )/( π 2 D 5∗g )

d Here L= 8m

Calculate Reynolds number V= 1.05m/sec

−6 4
Re =VD/υ = (0.47*0.04)/10 = 1.88*10

And roughness constant will be:

E/D = 0.046*/40 = 0.00115

Then from moody diagram f can be read referring E/D and Re.

So f =0 . 0256

42
 H f 1 =( fLV 2 )/( Dd 1∗2 g )=(8 fLQ 2 )/(π 2 D 5∗g )
d
−4 2
H f 1 =( 8∗0 . 0256∗8∗(6∗10 ) )/(π ∗(0 . 06)5∗9. 81 )
2

H f 1 =7 . 8∗10−3 m

For the second pipe

Friction loss on 15mm length horizontally align pipe is:

Again, let read f (frictional factor) from Moody diagram. But before:

E/D = 0.046/40 = 0.00115

−6
And Re =VD/υ=(0 . 47∗0 . 04 )/10 =1 .88∗10 4

Because of the delivery pipe have the same diameter and velocity through out, the Reynolds

number and roughness factor are the same for the above one. So f =0.0256

H f 2 =( fLV 2 )/( DS∗2 g )=( 8 fLQ 2 )/( π 2 D 5∗g )

S

Let calculate:
H f 2 =0 . 11m

For the third pipe

Now let calculate frictional lose in the third pipe:

H f 3 =( fLV 2 )/( Dd 3∗2 g)=( 8 fLQ) /( π 2 D 5∗g )

d3

Here the diameter and the velocity of the second pipe and the third pipe is the same. So the
friction factor reads from the Moody diagram also the same. And the friction lose in the pipe will be the
same also.

Hf3 = 0.11m

Calculate the lose for the fourth pipe

The frictional lose on the fourth pipe will be:

L4 =2 m
2 2
H f 4 =( fLV )/ ( D d 4∗2 g )=( 8 fLQ )/( π D 5∗g ) D =60 mm
d4 Here 4

43
Here the frictional lose in the pipe is the same as the above ones, because the velocity and the diameter is
the same through out the pipe.

f =0 . 0256
−4 2 2 5
Hf4 = (8*0.0256*2*(6*10 ) )/ ( π (0.04) *9.81) = 0.015m

Calculate of elbow lose

2
He = (nK e V )/2 g Ke = 30*fT

Here fT is read from the table referring the diameter of the pipe.

fT = 0.0185 for the 60mm diameter

So Ke = 30*0.0185 = 0.555

2
He = (3*0.555*(0.47) )/(2*9.81) = 0.019m
Now the total lose will be

H = Ze +Z + He + Hf

 Static head
Z = Z1 + Z2 = 8 + 2 = 10m

 Suction head
Ze = Zs + Hfs = 1+0.0016 = 1.0075m

 Pipe lose and elbow lose together

−3
He + Hf = 7.8*10 + 0.11 + 0.11 + 0.068 + 0.019

= 0.315m

Finally the total pump head will be:

H = Ze +Z + He + Hf

= 10 + 1.0075 + 0.2106

44
 = 11.3m

So the power developed in the single piston pump will be:

P= ρ∗gHQ
3 3
Here ρ water = 10 Kg/m

H = 11.3m

−4 3
Q = 6*10 m /sec

Substitute each value in the above equation,

P= ρ∗gHQ=103∗9 . 81∗11. 3∗6∗10−4

P=66. 512 watt≈66. 5 watt
If single piston pump can take 146 watt of energy then how much pistons needed to utilize the
total power:

Here
n=PT / P

PT – is the total power generated by the turbine

PT = 523 watt

n - Number of piston pump

n=PT / P=523 /66. 5=7 .8

Here 7.8 piston pumps are needed to use the total power sufficiently, but it better to minimize to
the nearest even number because of manufacturing simplicity and for the life time of the system. So six
pistons are selected. This results a good discharge of water.

45
 Figure4. 12 shows six piston pump alignment
4.7. Design of connecting rod and crankshaft
Here material selected for connecting rod design is Mild steel that has a crushing stress
σ C =320 MPa . This material has a reasonable strength and price for this design and it is also easily
available.

Figure 4.13 connecting rod

Almost all connecting rod is I- section. First of all, let us find whether the section chosen is
satisfactory or not.

If the section is said to be satisfactory

Ixx – moment of inertia of the section about X- axis

46
 Iyy – moment of inertia of the section about Y- axis

In actual practice, Ixx is kept slightly less than 4 Iyy. It is usually taken between 3-3.5

Now, let check the section.

A=2(4 t∗t )+3t∗t=11t 2

I XX =(1/12 )[4 t(5 t )3 −3 t∗(3 t )3 ]=( 419/12)t 4
I YY =2∗(1 /12 )∗t (4 t )3 +(1/12 )∗3 t∗t 3=(131/12)t 4
I XX /I YY =( 419/12)t 4∗(12/131 t 4 )=3 . 2

Therefore the section chosen is given satisfactory.

Since the connecting rod is designed by taking the horizontal maximum force on the connecting rod.

F θ=P /(ω∗r ) Here ω=4 .6 rad /sec and P=523 watt

Radius of crank web r = 110/2= 55mm

Substitute those values to the equation

F θ=P /(ω∗r )=523/(4 . 6∗0 .055 )

F θ=2067 .2 N

It is known that connecting rod is designed for buckling about X-axis. And the factor of
safety is taken as much as possible:

F.S = 6, so W=
W =Fθ∗F . S=12405

And length of the connecting rod is chosen to have L=250mm

Now according to Rankine’s formula, we know the buckling load (W B )

W B=( σ C A )/(1+a( L/ K XX ))

Here KXX is radius of gyration of the section about X-axis

K XX =I XX / A= √((419 t 4 /12)∗(1/11t 2 )=1. 78 t

And for mild steel

47
σ C =320 MPa And a=σ C / ( π 2 E )=1 /7500

Put every value to the rankine formula.

12405=(320∗11t 2 )/(1+(1/7500)(250 /1 .78 )2 )

12405=3520t 4 /(t 2 +2. 63)
t 4 −3 . 524 t2 −9 . 27=0
2 4 2
Let say u=t ⇒ t =u

Then substitute in the above equation.

u2 −3 .524 u−9 . 27=0

Using quadratic equation

u=(−b+ √ b 2−4 ac)/2 a

u=(3.524 + √(3.524 2 +4∗9 . 27))/2
u=5. 28
t 2=u ⇒ t=±√u
t=2.29≈2 .3 mm
For easy manufacturing of connecting rod, the thickness value is approximated to, t=3mm.

l=5 t=15 mm
So t=3 mm w=4 t=12

48
 Design of crank pin

Figure 4.14 Design of crank pin

Let dc- diameter of the crank pin

Lc- length of the crank pin, lc=1.3dc

2
Pbc- bearing pressure, usually taken as 10 N /mm

It is known that the load on the crank pin or big end bearing

F θ - Project area * bearing pressure

F θ=d c∗l c∗Pbc =d c∗1 . 3 d c∗P bc

F θ=1. 3 d 2∗Pbc =1 .3∗10∗d 2
c c
F θ=13 d
c2

Here, as it is determined above:

F θ=2067 .2

√(2067.2/13)=d
12 .6 mm=d

d≈13 mm
lc =1. 3d c=1. 3∗13=16 . 4 mm≈17 mm

49
 Design of bolt for securing the big end cup
Given:

d cb = core diameter of the bolts.

σ t = Allowable tensile stress for bolt material

σ all =60 N /mm 2

2
This is because yield stress of Fe 310, Y . S=180 N /mm

Factor of safety =3

And number of needed is 2 ,so nb=2

So we know that force on the bolt.

So we know that force on the bolt.

F 1=( π / 4 )( d 2∗σ t∗n b )=( π / 4 )( d 2∗60∗2 )

cb cb
F 1=94 .25 d
cb2

The bolt and the big end cap are subjected to only tensile force which corresponds to the inertia
force of the reciprocating parts at the top dead center on the pumping stroke.

We known the inertia force of the reciprocating part

F 1=m2∗w2∗r (1+r /l)

m R=m piston +[Link] =4. 88+0 . 4=5. 23 Kg

ω=4 .6rad /sec

r=55 mm
And, l=250 mm

F 1=m2∗w2∗r (1+r /l)=5. 23∗4 .6 2∗0. 055(1+(0 .055 /0 .25 ))

F 1=7 . 43 N

Then, equate the inertia force on the bolt.

50
 This much small diameter can resist the inertia force of the reciprocating part. But for the sack of
manufacturing simplicity, It is better to take core diameter of belt equal to 3mm.

d cb =3 mm

The crank web dimensions generally calculated using the crank pin diameter.

w=1 .125 d C +12 .7=1 .125∗13+12 .7=27 . 5 mm Where d =13mm

c

And t =
0 . 65 d C +6. 35=0 .65∗13+6 . 35=14 .8≈15 mm

CHAPTER 5
CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion
This design targets to improve the life of the poor farmer in Ethiopia. Even if Some farmers have
a water resource near their farm land, the can not able to insure their food security. Especially
country like Ethiopia has a lot of river that can be used for cultivation using pumps. That is why
turbine driven pump is one of the best solutions for this problem. Because it needs no energy
instead of the energy generate from the kinetic energy of the running river. In this design every
parts of the system is design properly. The pump can able to discharge 1620 barrel of water per
2
day. This amount of water can cultivate at least 500m of land through out the year. The other

51
thing, the total design is easily applicable in any area and need no skill to assemble or
disassemble the system easily. Because of the aerofoil shape creates a resultant force tangent to
the circular path of the turbine; there will be negligible vibration on the system. The bearings
selected have two years life time. In order to have a proper life time of the machine component,
in each part of the design factor of safety and other considerations is taken as maximum as
possible. And most of the river does not have the same height through out the year. It is proposed
that the power screw and other supporting mechanism must be designed in order to adjust the
system up and down. Finally, if the system is needed to have long life time, greasing the bearings
with two or three weeks interval and cleaning the piston pump in each week will be advisable.
The design and analysis of the turbine-driven pump system have been successfully completed
based on the specified operating conditions and engineering principles. The study demonstrated
how mechanical power generated by a turbine can be effectively transmitted to drive a pump for
fluid transportation. From the design calculations, the required hydraulic power, shaft power, and
turbine power were determined, ensuring that the selected components operate within safe and
efficient limits. The pump type was selected based on the required flow rate and head, while the
turbine was chosen to provide adequate power under the given efficiency conditions. The shaft
design was carried out considering torque transmission and allowable stress, ensuring structural
integrity during operation. Proper selection of bearings and coupling systems contributed to
smooth operation, reduced vibration, and increased service life of the system.
Efficiency analysis showed that system performance depends on both pump and turbine
efficiencies, as well as mechanical losses
5.2 Recommendations
Based on the findings of this study, the following recommendations are suggested:
 Improve Efficiency
High-efficiency pumps and turbines should be selected to reduce energy losses and
improve overall system performance.
 Regular Maintenance
Routine inspection and maintenance of bearings, seals, and lubrication systems should be
carried out to prevent unexpected failures.

52
 Proper Alignment
Accurate alignment between turbine and pump shafts is essential to minimize vibration
and wear.
 Use of Advanced Materials
Corrosion-resistant and high-strength materials should be used, especially when handling
aggressive or contaminated fluids.
 Monitoring Systems
Installation of sensors for temperature, vibration, and pressure is recommended for real-
time performance monitoring and fault detection.
 Future Improvement
Further research can focus on:
o Automation and smart control systems
o Hybrid energy-driven turbine systems
 Energy Management
Energy-efficient operation strategies should be adopted to reduce operational costs and
environmental impact.

REFERENCES
 Pump Handbook – Igor J. Karassik, Joseph P. Messina, Paul Cooper, and Charles C.
Heald, McGraw-Hill Education, New York, 2008.
 Fluid Mechanics and Hydraulic Machines – R. K. Rajput, S. Chand Publishing, New
Delhi, 2010.
 Hydraulic Machines: Turbines and Pumps – K. Subramanya, Tata McGraw-Hill
Education, 2013.
 Fluid Mechanics – Frank M. White, McGraw-Hill Education, 2016.
 Hydraulic Turbines – P. K. Nag, Tata McGraw-Hill Education, 2014.

53
 Introduction to Fluid Mechanics – Robert W. Fox and Alan T. McDonald, John Wiley &
Sons, 2015.
 Mechanics of Fluids – B. S. Massey, CRC Press, 2012.
 Hydraulic Machines – Jagadish Lal, Metropolitan Book Company, 2009.
 American Society of Mechanical Engineers (ASME). Standards and technical papers on
pump and turbine design.
 International Organization for Standardization (ISO). ISO standards for centrifugal
pumps and turbine performance testing.R.K. Rajput, Fluid Mechanics and Hydraulic
Machines.
 GuptaJ.K, Khurmi R.S; A text of machine design, New Delhi; 2002.
ND
 Shigely Joseph E; Mischke Charles R; Standard Hand book of machine design, 2
edition
ND
 Grigori Krivchenko; hydraulic Machines; Turbines and Pumps, USA: 1994, 2 edition.
TH
 Victor L. Streeter, E. Benjamin Wylie; fluid mechanics, Mc Grew-Hill; 1998, 9
edition
 [Link]/[Link]

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