Tuesday, 11 June 2019

Windpump Repair and restoration

The POLDAW windpump or windmill is now over 5 years.  Of late it is giving a lot of trouble when at a time my team is gone into comfort zone. However I love my windpump.  The more I wanted that to be up and running, the more it sucks.  It is a challenge and I am prepared for fight.

My objective is to put this back in action with lot of water pumping. And perhaps showcase it for future business.  This will be for higher end customers and my own verticle axis windmill that I am designing for low end customers. That's the idea.

The windmill with one tooth missing
Recently few months hence, one by one the bolt/nut had unscrewed itself and started falling down. A large bolt from the main rotor fell down, luckily no one was there. Windpump without load is a monster and rotates faster. Recently last week it broke one of its wings on its own and that wing fell on the water tank splicing it. Luckily again no one was there.

I declared it unsafe and given clear directions to Subbu. The more it breaks, more we resolve ourselves to repair it.  Following are attempts.

a) I called on an agency (Vista telecom networks) through known contacts for help. They have trained riggers (certified tower climbers) who maintain cell phone towers. A person came from Tirunelveli by bus for inspection, Subbu picked him up.  He climed the tower and went back without quoting anything. Two days of followup with his supervisor had no results. They were just now answering phone. perhaps they were not interested in this small job. Or found it odd job to do. They obliged to come only because i took help of a common friend who is their client.

Closer examination shows, the cut is not due to
any bird strike or object impact. It is due to sheer
rotational tear apart force. Not due to rust either.
Just a high velocity object torn.
b) Crane is an option to reach the windpump quickly. To my suprise, there is a crane operator in Nanguneri,10 Kms away. It costs Rs. 5000/- for half day including crane charge, bucket fitting and transport and driver bata. However that is an option I want to use only when we are fully ready with all tools.
The broken wing


c) Our default option was to climb ourselves. Earlier I had already purchased and sent online two numbers of body harness. Subbu likes it. I feel safe if they wear it while climbing.

Subbu and one more boy Ramesh who is experienced in this. However he had a sprain and we had to wait for a month. The boy had become more mature and demanding more money. That however is working. The couple had so far applied crease, fixed the loose bolts.  But the propeller wing that is broken need to be removed for a welding shop. While the broken wing is with us, the nut from the frame is not coming easily. It is at an inaccessible distance with ordinary spanner.   I asked Subbu to purchase a cross bar wrench tool.  Subbu went to Valliyoor and the shop which generally had everything did not have this one. they ordered to Madurai for stock and one week later got it.

d) Windspeed is very high. They are waiting for it to slow down so that we can tie the windpump rotor and do the work. If load is given to windpump, it is unlikely it will break down like this. The wing had broken only due to high velocity wind and the rotating speed.  This reminds me of the danger the propeller aircrafts would have faced during world wars.

e)  One of the favourite pending requirement is making a ladder to climb the tower. The thought of climbing the tower should make Subbu weary. A ladder will make climbing cool.  As per a local garriage, a ladder of 45 feet costs 20,000/- to make.  I rejected. Asked Subbu to find cheaper alternative. After several days and months, now the bill would be around 10K.  It requies 7.5 pipes of 20 feet to make a 50 feet ladder. Same pipe for side and rungs.  I asked Subbu to purchase material in one place and make it in another workshop only paying labor charges. That seems to work.  However Subbu is yet to hit the road. perhaps with ladder in place, next time, the tower maintenance would be a pleasure.


Coconut tree

Newly planted jasmine. Around 3 months old.












Monday, 10 June 2019

Farm Update 10-Jun-2019

I am providing a farm update as a check list; Each of these items deserve a separate story by itself and am Intend to cover that as I keep writing.

a) Subbu and Supervision
b) Windpump under repair
c) Condition of Farm and my recent visit
d) Verticle windpump research:

a) Subbu and Supervision

Coordination with Farm supervisor Subbu reached frustrating levels and now a new normal.  He just doesnot respond for several calls or even days. When responds, he makes false promises. Always has some excuse or the other on hand. The half truth is, his smart phone has got screwed up. It was an "Oppo" which fails on speaker ring volume. For several days he missed business calls, then gave it for repair at authorised service centre. As usual the centre with juniors took 15 days to send phone to another city and permanently damaged the phone. I Hope he has done something about it. After long interval, he could send some snaps of windmill (under repair).

Subbu was'nt attending the farm regularly, which I sensed thorugh his never ending excuses. Later I learnt that he was helping his mother-in-law build her own house in a small town called Eruvadi, under minimum budget of 25 lacs. He seemed to be doing daily sortie on his bike to the construction site around 20 Kms one way which now he regrets. Finally his hard-work was not appreciated, mother-in-law donot like the house which was built to her specs. Anyway Subbu is back on farm.

Subbu's family has expanded. His 3 children are studying and growing. He needs more money. He has brought a second hand car for 57K which he was happy about initially. I heared he washed it, tended it daily and decorated with jasmine flowers from our farm. His joy lasted not long.  Recently he regretted he brought the car. His MIL, sister & family were driving him to crazy reducing him to a driver on waiting. He got so vexed he removed a wheel and delcared it broke-down !

In any case, I had several hard talks and inspiring talks with Subbu. He need to realise that only by systematically working for "tomorrow" that we can comeup in life. That "tomorrow" can come through agriculture or allied activities (like manufacturing windmill itself). I wanted to impress him with thought that we need to do "some business" and for that he must pay attention now.

/-

Friday, 7 June 2019

Catching up on Blog posts

The problem with blog is that unless you continuously drain your thoughts on blog, your thoughts get clogged in brain and doesnot allow even new and trivial posts to come out.

I have given huge gap by not writing anything and posting. I need to catch up.

Several times kept postponing and did not realise it is already 3 months that slipped away...

One of the reason was I was too much disturbed by the developing trend around General Elections in India.

Somewhere I have to start. I will start with ongoing thing first. Here comes the story.......

(I also just noticed that  Google+ is no more available. I am not sure how the regular readers of this blog will get information on any new post).