Foundation

Rota Sludge
&
Stone Hammer drilling


Part two
Production Manual
























A. van Herwijnen

Sept.1th, 2005


This part two describes the production of the components for the Rota sludge and
Stone-hammer manual drilling equipment as developed by PRACTICA foundation.
For the correct use of the equipment please refer to part one, the Drilling Manual.

Disclaimer

Any parts of this manual, including the illustrations, may be copied, reproduced, or
adapted to meet local needs, without permission from the author or publisher,
provided the parts reproduced are distributed free or at nominal cost, not for
profit and reference to the source is made. The author would appreciate being
sent a copy of any materials in which text or pictures have been used.
For any reproduction with commercial ends, permission must first be obtained from
the Technical Training Programme of the ETC Foundation (TTP/ETC) and/or Practica
foundation
This manual is often used in technical training courses organised for the intended
users. In case, you want to organize such training, you may contact TTP/ETC for
further information and support.
Note to those considering translation or modification: To avoid duplication of
efforts, unintended mistakes, and for suggestions about adapting the ideas and
information in this manual, please contact TTP/ETC before beginning any translation
or modification.
This publication was made possible by a financial contribution of the HPF
Foundation, through the Technical Training Programme of the ETC-Foundation.
While every care has been taken to ensure the accuracy of the information given in
this manual, neither the publisher(s) nor the author(s) can be held responsible for any
damage resulting from the application of the described methods. Any liability in this
respect is excluded.

Technical Training Programme
ETC-Foundation, The Netherlands
P.O. Box 64, 3830 AB Leusden
The Netherlands
E-mail: ttp@etcnl.nl

PRACTICA foundation
Maerten Tromp str. 31
NL-2628 RC Delft
The Netherlands
Info @practicafoundation.nl
www.practicafoundation.nl
Rota Sludge & Stone hammer production Manual page 1

Contents

Page

1. Introduction 3

2. The Rota-sludge drilling equipment 4
Required machinery for manufacture
Overview of the components
Manufacturing of the components. .
The drill bit
Weighted drill pipe
The arm
Cross bar
2 GI coupling pipe
2GI pipes of 3 metres

3. The Stone-hammer drilling equipment 13
Required machinery for manufacture
Overview of the components
Manufacturing of the components
The stuffing box packing, buffer ring and the stabilisation rings
The chamber with the floor and the drain plug
The weight with the connecting rod
The stuffing box
The drill bit






Annexures:
Drawing 1, Rota sludge bit
Drawing 2 The arm
Drawing 3, The Stone hammer
Drawing 4, The stuffing box packing, buffer ring and the stabilization ring.
Drawing 5, The Stone-hammer bit

Rota Sludge & Stone hammer production Manual page 2
Rota Sludge & Stone hammer production Manual page 3
1. Introduction

The Stone-hammer and Rota-sludge manual drilling methods were developed by
Practica in India and Nicaragua respectively. With these methods manual drilled
wells can be made, or be made easier and cheaper, than was previously possible.
The equipment is simple to use and to produce. The required materials and
workshop facilities are such that in most developing countries local production should
not be a problem.
This manual describes step by step what materials are necessary, what equipment is
required, how to make the different components and for each component the specific
attention points.
For operation the equipment (drilling) please refer to the Drilling manual.
This manual is meant to provide sufficient information for NGOs, development
agencies or local contractors to have the necessary equipment for manual drilling
locally produced.
































Disclaimer
Practica nor ETC cannot be held responsible for any accidents or damage resulting
from the production of the equipment as described in this manual.
Rota Sludge & Stone hammer production Manual page 4
2. The Rota sludge drilling equipment

Required machinery for manufacture
The Rota-sludge equipment consists of parts which can be constructed simply in a
basic workshop.
A basic workshop is considered to be one which contains the following machines:

Arc welding unit
Drilling machine
Metal cutting machine (hack saw or gas)
Angle grinder
Pipe thread cutter (up to 2inch)
Basic tools like spanners, wrenches, hammer, etc.


Overview of the components
For Rota sludge drilling, the following
parts have to be made:

Drill bit
Weighted drilling pipe
Arm
Cross bar
GI coupling pipe 1.5 metres
GI pipes of 3 metres

























NB: The text will refer to the construction drawings in appendix I.

Rota Sludge & Stone hammer production Manual page 5


Manufacturing of the components

The drill bit
(Drawing 1)

This is in fact a two step drill bit because
it consists of two drills: one for actually
drilling and one for reaming the drilling
hole to the desired diameter of 5 inches.

Material requirements:
(car)Spring steel:
Strip 8mm thick by 60mm wide,
120mm in length.
Strip 12mm thick by 70mm wide,
80mm in length.
GI Pipe 2, wall thickness
minimum 3,2mm, 250mm in
length, provided with thread on
one end
GI Pipe 3, wall thickness
minimum 3,2mm, 50mm in length


Construction
Cut the teeth into the spring steel to the
correct width, using an angle grinder

Cut the teeth into the spring steel to the
right width
7 teeth at 15 mm wide. (Strip 8mm
thick)
4 teeth at 18 mm wide. (Strip 12mm
thick) Fig. 1, drill bit

Now weld the teeth on, keeping an equal distance between them, at an angle of 70
degrees. (see drawing 1)











NB! Ensure that the teeth have a contact
surface of 50% of their total length with
the bit. Weld all around the tooth.
Use angle irons to centre the
2pipe
Rota Sludge & Stone hammer production Manual page 6

















































Rota Sludge & Stone hammer production Manual page 7
Weighted drill pipe











Cut the round bar in pieces of 1300
mm length

Keep the pipe 100mm free at both
ends and weld the bars lengthwise
around the GI pipe.

Smooth down the ends of the bars
to avoid them scraping the wall of
the bore while drilling




























Requirements:
2 inch GI pipe 1.5 metres. provided with
thread on the two ends
Round bar , 18mm in diameter, 18,2 metre in
length.
(1300mm per length, per weight +/- 14
lengths.)


NB! Extra weight may be necessary. This can be decided in
consultation with the driller.
Rota Sludge & Stone hammer production Manual page 8



Arm
(Drawing 2)

The arm consist of the handle and the clamp

























Cut the materials to size, using a hacksaw.

- : 160mm.
- 1: 2 pieces of 5mm, and one
piece of 75mm and 800mm each.
- 1: 2 pieces 5 mm, one piece of
150mm and 2 pieces of 200mm.
- 2: 60mm
- Iron rod: 4 pieces of 60mm
- Iron strip: 2 pieces of 60mm






Fig. 3, the complete arm

Requirements:

GI pipe , 160mm.
GI pipe 1, 900mm
GI pipe 1 , 580mm
GI pipe 2, 60mm
Iron strip, 5 mm thick, 30mm wide,
120mm in length
Iron rod, 6mm in diameter, 700mm
in length
Nut and bolt, diameter 10mm,60mm
in length
Steel chain, 3 links (6mm thick,
each link approximately 20mm in
Rota Sludge & Stone hammer production Manual page 9
The clamp is discussed below.
The other parts are is easy to make using drawing 2.

Saw the 60mm 2 pipe into two, creating two half pipes. These parts are
connected with a three links of a chain which functions as a hinge. The
outside links of the chain are welded onto the two pipe parts while the
middle link is free to move.
Weld the 4 6mm rods lengthwise in the half pipes. These will increase the
grip preventing the arm from slipping when turned.


The clamp









Clamp in open position


This clamp is now fitted round a 2 drilling pipe. Ensure that, by shortening
the pipes far end, the two far ends have a distance of 25 mm.

Drill two holes into the
centre of the iron strips.
(diameter 12mm)

Once again, fit the clamp
onto the 2drill pipe and weld
the strips, parallel to each
other, on to the far end.






Clamp in closed position


.


NB. The holes should be drilled
opposite each other so that the
bolt can be fitted more easily.
Attach the four far ends of the
strips to the pipe by using 6 mm
round bar. This prevents warping
whilst the bolt is being turned
Rota Sludge & Stone hammer production Manual page 10






Now weld the various components as shown in drawing 2..
Rota Sludge & Stone hammer production Manual page 11




The handle
(Drawing 2)

A short length of 1 pipe (200mm) is slid over the end of the 1 pipe, the so-called
handle. The handle is held in place by rings welded on to the arm (5mm round bar).
The handle can thus move freely and is more comfortable to operate.


Cross bar
(figure 4)






Fig.4, Cross bar


Cut the 10mm round bar in 4 pieces of 100 mm length and bend them to
rings which can be slid over the 30mm bar.

Weld the two rings at 70 mm from the two ends of the 30mm round bar and
then the next two at 10 mm.






Requirements:

Round bar, 30mm in diameter, 500mm in
length.
Round bar, 10mm in diameter, 500mm in
length.
Rota Sludge & Stone hammer production Manual page 12


2 GI Coupling pipe
(1.5 metres)

This is a 1.5 metre pipe which is
threaded at both ends. Only one is
required. On one end a socket is fitted
and welded on to the pipe.


2 GI Pipes
(3 metres)

These are 3m pipes, threaded at both
ends. The number of pipes depends
on the depth which has to be drilled.
A socket is welded onto one end of
each pipe.






























Fig. 5, 2pipes

NB! GI pipes should have a
minimal wall thickness of
3.2mm.
In some cases American
thread is used which occurs in
Central America. In contrast
to English threads, these have
are cut deeper, rendering the
pipe very weak in these
places.
A solution was found by
welding on a thicker end
piece (GI pipe with a wall
thickness of 5mm and 15cm
in length), on which the
thread can be cut without any
problems.

Rota Sludge & Stone hammer production Manual page 13

3. The Stone-hammer
(Drawing 3)

Required equipment for manufacture

It is not possible to construct the entire stone
hammer in a basic workshop as some of the
parts need to be made with a lathe.


Overview of the components and the material
requirements

For the Stone-hammer, the following parts have
to be made with a lathe:

Stuffing box housing
Buffer ring
Stabilisation rings


The following parts can be made in a basic
workshop:

The chamber (with the floor and the
drain plug
Connecting rod
The drilling bit
Pulley and the cross bar



















Fig. 6, Stone-hammer
Rota Sludge & Stone hammer production Manual page 14
Manufacturing the Stone-hammer

Stuffing box packing, buffer ring and the stabilization rings
(Drawing 4)










































Fig.7, Stuffing box parts

The stuffing box (figure 7) consists of the box and the ring. Because they have to fit
together precisely and the water tightness depends on this, they are made in a lathe.
The buffer ring and the stabilisation rings are also made in a lathe.
Material requirements:

Stuffing box packing
Buffer ring
Stabilisation rings
GI Pipe 4, wall thickness > 3,2mm, 300mm in length
GI Pipe 3, wall thickness > 3,2mm, 2740mm in length
GI Pipe1, wall thickness > 3,2mm, 1200mm in length
GI Pipe 1, wall thickness > 3,2mm, 1200mm in length
Iron rod, 8mm in diameter, 320mm in length
Solid iron rod, 70 mm in diameter,1500mm in length.(The weight)
Solid iron rod, 80 mm in diameter, 50mm in length. (The bottom)
Solid iron rod, 18 mm in diameter, 70mm in length. (Locking pin)
(car)Spring steel: Strip 12mm thick by 80mm wide, 320mm in length.
Bolt (2) diameter 8mm,30mm in length (drain plug)
Bolt,(2) diameter 8mm, 35mm in length (Stuffing box packing)
Nut and bolt, diameter 18mm,100mm in length (locking bolt)

Rota Sludge & Stone hammer production Manual page 15

The chamber with the floor and the drain plug

A 3 pipe is sawn off to a length of 140mm. A solid floor with a thickness of
5cm is welded into this pipe. The floor is welded at respectively 1 and 8cm
from the far end of the pipe.

The bore for the drain plug valve is drilled, after which the thread is tapped.

Drill the holes for the locking bolt.

Saw the 3 pipe to a length of 2600mm and drill 4 holes (12mm) round it at
25mm from one end of the pipe.









The weight with the connecting rod

The 1 inch and the 1 inch diameter pipes are slid together and welded
together at each end.

The hole is drilled for the locking pin.

The bolt for the drain plug is welded on.

The sharp edge of the weight is chamfered. This only has to be done at
one end.

When there is too much gap between the weight and the chamber,
stabilisation rings should be added. (minimum clearance 1 mm).





The buffer ring is welded on to the centre of the weight.

Connect the connecting rod to the weight and fasten the locking pin.

Now place the weight in the chamber.


NB. The floor also serves to keep the water out so it has to be welded
leak free..
NB: weld the shallow end of the floor pipe on to the part of the pipe
without holes!
NB! Ensure that a gap of 20mm is created in these rings for the water to
pass.
Rota Sludge & Stone hammer production Manual page 16
The stuffing box
(Drawing 4)

Slide the stuffing box over the connecting rod and slide them into the
chamber until they protrude 10mm above the chamber. Weld around the
box to secure it and weld the 4 holes to close them.




Slide the stuffing box ring over the connecting rod.

Finally, now make the eye for the connection with the rope and the
stabilisation ring.


The drill bit for the hammer
(Drawing 5)

The drill bit is constructed from a 4 pipe and a spring steel head as per attached
drawing nr. 5.


NB! Once again ensure that the construction is watertight.
Rota Sludge & Stone hammer production Manual page 17


















































Drill bit for Rota sludge
Drawing 1
The arm
Figure 2
Rota Sludge & Stone hammer production Manual page 18
The arm Drawing 2
















































Rota Sludge & Stone hammer production Manual page 19



















































Drawing 3

The stone hammer
A) Draw-off valve (bib-valve).
Should leakages occur, dirty
water will flow through the
system. The draw-off valve
enables the water to drained
and offers the possibly of
rinsing the system.
B) Connecting rod. This consists
of a 1 inch GI pipe which
contains a 1 inch GI pipe
which serves to strengthen
it.
C) Stuffing box ring.
D) Stuffing box. For detailed
parts see Diagram 4.
E) Stabilisation rings. These
provide vertical
stabilisation.
F) Buffer ring
G) Locking pin. Provides the
connection between the
buffer ring and the
connecting rod.
H) Weight
I) Stabilisation rings.
J) Floor
K) Draw-off valve
Rota Sludge & Stone hammer production Manual page 20


















































The stuffing box packing, buffer ring
and the stabilization ring
Drawing 4

A)
The stuffing box ring.
This compacts the
packing material creating
a watertight seal with
the outer wall of the
packing box and the
connecting rod. The ring
is screwed on by means
of 2 bolts (35 by 8mm).

B)
The stuffing box. This
also functions as buffer
stop which the weight
hammers against in
hammering the drill free.
At the same time, the
box is provided with
holes with internal screw
thread for the bolts.
For the packing material,
packing yarn is used with
a thickness of 8 mm.

C)
The buffer ring. This
ring is welded onto the
weight and hits the
stuffing box when the
drill bit is removed.

D)
Stabilisation ring.
Rota Sludge & Stone hammer production Manual page 21

Drawing 5
Stone-hammer bit