Professional Documents
Culture Documents
ISBN: 3-908156-02-5
Drilling Boreholes for Handpumps
Foreword
HTN, the global Network for Cost-effective Technologies in Water Supply, aims to facilitate the
provision of safe water to the poor and unserved through the promotion of affordable technologies.
HTN’s scope includes the sustainable exploitation of groundwater resources, with a specific focus
on the following topics:
• Handpumps,
• Supply chains of goods and services that support system sustainability, and
• Development of efficient drilling operations.
Especially in African countries, the provision of underground water supplies has suffered for many
years from a mismatch between the water source (the borehole) and the pumping device (the
handpump). This uneven correlation has often led to the construction of costly and unsustainable
systems based on imported technology. In Africa, drilling costs are 5-10 times higher than they are
in Asia.
Optimisation of the processes for producing boreholes can reduce well drilling costs and thus help
to accelerate production. Well costs can be diminished by optimising methods employed during the
following stages of construction:
• Finding groundwater,
• Borehole design,
• Drilling techniques, and
• Well development and construction
Drilling equipment that is light and easy-to-maintain can be used for drilling boreholes. Its
successful application requires rather sound procedures and skilful operations than high
investments. This allows making use of the resources that lay in the local private sector.
This booklet seeks to suggest ways in which funds can be better used for making safe water
available to the poor by illustrating how drilling costs can be reduced without compromising water
quality, water quantity, or the productive life of the borehole. These arguments are directed
towards the rural water supply sector as a whole. Those directly addressed are primarily decision
makers, government civil servants, planners and implementers of water projects who are not
experts in drilling, as well as technical people, project leaders, technical aid personnel etc. This
publication is neither a detailed drilling manual nor a methodology of drilling methods.
The author draws on his extensive experience as a member of the UNICEF Water and
Environmental Sanitation community. He hopes that his views and proposals will be a catalyst for
change, and that this contribution will stimulate interest in experimenting with ideas on low cost
drilling of boreholes for handpumps.
This publication was made possible thanks to support and contributions made by UNICEF NYHQ
and the Water and Infrastructure Section of SDC. Although both organisations are committed to
the provision of safe water, the interesting and valid views expressed in this booklet are primarily
intended to stimulate discussion and do not necessarily reflect the official policies of either UNICEF
or SDC.
Drilling Boreholes for Handpumps
Acknowledgements:
I would like to record my gratitude to my former colleagues and good friends in UNICEF
Mozambique (1991-95) whose input has been invaluable in arriving at the conclusions reached in
this booklet. The ideas mooted were jointly developed over several years of discussion, analysis
and field trips, I thank Edward Karczewski, a skilful, hands-on driller with a M.Sc. in hydrogeology
(an unusual combination), who played a pivotal role phasing in the low cost drilling fleet in
Mozambique. To the Water and Environmental Sanitation section in UNICEF New York who
funded this work, and particularly Gourisankar Ghosh who recognised that a ‘drilling revolution’ is
overdue, my grateful thanks. I also acknowledge The Swiss Centre for Development Cooperation
in Technology and Management (SKAT), and especially Erich Baumann who provided the
hospitality of his home, wise counsel and, additionally, took the risk of allowing me to carry several
SKAT library books around the world. A word of thanks to two friends and UNICEF stalwarts,
Rupert Talbot and Ken Gray who (mostly) cheerfully put up with an endless stream of requests,
questions and argument. In Zimbabwe, Zambia, Lesotho and Mozambique I spoke to many of the
local experts, all of whom gave generously of their time and to whom I am most grateful. Finally I
thank my wife, Pauline for her enthusiastic interest in this somewhat dry topic, her critical review
and her special talent for transforming my words and thoughts into language that is grammatically
correct.
Drilling Boreholes for Handpumps
TABLE OF CONTENTS:
Low Cost Drilling Methods ............................................................................................................ 3
Matching depth of borehole to required yield ................................................................................ 4
Borehole Diameter........................................................................................................................ 4
Casing and Screens ..................................................................................................................... 4
Borehole development .................................................................................................................. 4
Artificial gravelpacks ..................................................................................................................... 4
Borehole Pump Testing ................................................................................................................ 5
Borehole Siting - Can the ‘experienced eye’ and science see eye to eye?................................... 5
Data Collection, Record Keeping and the Low Yield Water Source .............................................. 5
Environmental aspects.................................................................................................................. 5
Lessons from India ....................................................................................................................... 5
Rural Water Supply and Drilling Case Histories from Africa.......................................................... 5
1 INTRODUCTION....................................................................................................................... 6
2 A brief history of drilling ............................................................................................................. 8
3 The occurrence and disposition of underground water .............................................................. 9
3.1 Water level fluctuations........................................................................................................ 14
3.2 Groundwater and the environment....................................................................................... 15
3.3 Geology/hydrogeology of the African continent.................................................................... 16
3.3.1 Groundwater in Africa - the Resource of the Future...................................................... 17
4 Drilling methods-a brief description. ........................................................................................ 18
4.1 Overview.............................................................................................................................. 18
Manually constructed Wells ........................................................................................................ 18
4.2.1 Dug wells. ..................................................................................................................... 18
4.2.2 Hand drilled boreholes .................................................................................................. 19
4.2.3 The hand dug-well versus the hand-drilled borehole..................................................... 19
4.3 Machine drilled boreholes .................................................................................................... 20
4.3.1 Cable Tool/Percussion Method ..................................................................................... 20
4.3.2 Rotary Rigs................................................................................................................... 22
4.3.3 Rotary-percussion or Down-the-Hole Hammer method................................................. 23
4.4 Dug well versus hand bored (drilled) borehole versus machine drilled borehole .................. 23
4.5 Pollution and Shallow Groundwater ..................................................................................... 25
5 The low cost borehole-design and costing .............................................................................. 26
5.1 Overview.............................................................................................................................. 26
5.2 Borehole Diameter............................................................................................................... 26
5.3 Matching depth of the borehole to required yield ................................................................. 26
5.4 Borehole development. ........................................................................................................ 27
5.5 The use of PVC casing and screening................................................................................. 29
5.6 Artificial gravelpack - when and where needed? .................................................................. 31
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Drilling Boreholes for Handpumps
Terminology. The terms ‘borehole’ and ‘well’ are used interchangeably, in contradistinction to
‘hand dug well’ or ‘hand/manually-drilled well’. A full glossary of terms is found in Appendix 1.
2
Drilling Boreholes for Handpumps
FAST TRACK
Jump on the fast track for a quick preview of specific boreholes can be simplified, without
the book and see the framework of the cost compromising quality, by relaxing their
saving ideas expanded in the text. We hope design criteria. Even so, there is much scope
that it whets your appetite to investigate in and need for experimentation and innovation.
more detail the new drilling philosophy.
“The Handpump Option” was one of the most
Low Cost Drilling Methods
notable developments of the International
Drinking Water Supply and Sanitation Dug well vs. hand bored (drilled) borehole
Decade, which recognised the ‘triad’ of clean vs. machine drilled borehole
water together with sanitation and health,
If the water table is shallow and the rock is
and hygiene education as fundamental to
soft then manual techniques should be
improved health in rural communities. The
favoured. Both hand dug and hand drilled
Village Level Operation and Maintenance
methods are least cost solutions in shallow
concept (VLOM) applied to the handpump
water table areas (generally up to 15 or 20
underlined the desirability of design
metres). If, however, speed is important then
standardisation within countries and regions
machine drilling in such an area is justified.
and saw handpump costs plummet. The The hydrogeology and relative cost aspects
costs of construction of the water source, of dug wells and hand-drilled boreholes are
however, have remained several times dealt with in the main text on pages 18
more expensive than the handpump, through 25.
sanitation facilities and health education
costs combined. The impetus now must What is the best drill type? Horses for
be to reduce the costs of construction Courses! For the small yield borehole
and development of the water source. select the small drill! Drilling methods using
machine-mounted rigs are essentially of two
Since the absolute maximum yield of a types, the cable tool method (percussion) or
handpump is 1m3/hr, savings can be made one of several rotary methods. Both have
by tailoring depth and other parameters to particular advantages and disadvantages
this, in groundwater terms, small yield, which are discussed in the main text (pages
through the application of low cost drilling 19 through 23) but the message is: modern,
methods and design criteria adapted light manoeuvrable rotary/down the hole rigs
specifically to handpump mounted boreholes. (DHT) should be used if and only if trained
In many circumstances and crews and a supportive infrastructure-
hydrogeological settings, borehole- logistics are available. If not, simple old-
drilling costs can be reduced by a factor fashioned percussion rigs are more
of 2 - 3 in Africa. appropriate. They are simple, rugged (many
Cost savings can be made without in Africa are over 50 years old), easy to
jeopardising quality in design areas maintain and admirably suited to low cost
including: depth and diameter of the drilling. Simplicity of design means easy
borehole, both of which can be limited for servicing and relatively short training periods
handpump yields, casing and screens, for crews. The payment of drilling bonuses
borehole development, gravel packs, has been shown to have benefits way
borehole sitting and pumping tests. beyond their costs.
The recommendations below are not The cost defining decision for handpump
inviolate and may not be appropriate in all equipped borehole design is to aim for a
geological settings since nature, and limited yield of 1 - 2m3/hr, the most that
particularly geology and groundwater the handpump can deliver. The modified
hydrology, are infinitely variable. design guidelines are discussed below:
Nevertheless, the rural water supply
personnel should be cognisant that drilling
procedures and techniques for handpump
3
Drilling Boreholes for Handpumps
Matching depth of borehole to screens is not critical for low yields in normal
required yield conditions, although it can be critical in fine-
grained aquifers. Primitive machine sawn
See 5.3 p. 26 of main text slots with a total opening of 5% (slot size 0.5-
Historically boreholes have been drilled on 1mm) are appropriate. PVC casing and
the precept of “the greater the depth, up to a screens can be joined by either the bell and
critical level, the greater the yield”. If we take socket (male/female) joint with solvent
1.5m3/hr. as being the upper limit of the cement, or threaded joints.
handpump’s delivery ability (a generous
figure) then drilling should stop 10m or so Borehole development
beyond the depth at which the required yield See 5.4 p. 27 of main text
is obtained. This provides a reserve column
The development of the borehole (pumping
that will allow for seasonal variations and
and surging) results in the finer fractions of
excessive drawdown.
material being drawn from the
Once the required yield of 1.5m3/hr. is unconsolidated aquifer (and from fissures in
attained, drill a further 10m to allow for consolidated and semi-consolidated aquifers)
seasonal water level fluctuations and leaving behind a stable envelope of the
drawdown levels. The yield can be coarser, and therefore more permeable,
established with a simple bailer test (if material of the aquifer. This natural
percussion drilling is used) as drilling gravelpack is not to be confused with an
proceeds in integrals of 2 or 3m after water is artificial gravelpack.
first struck,
Development of a borehole is a crucial
Areas where seasonal water level adjunct to a properly completed hole,
fluctuations exceed 10m are relatively rare,
For low yield boreholes pumping, or better
but if the area is hydrogeologically ‘known’ to
still over-pumping, is the best method of
have large fluctuations then clearly a reserve
development. Rule of thumb pumping
column of 15 - 20m will be necessary. In sub-
periods vary from 2-24 hours or until the
artesian conditions, the borehole can be
pumped water is clear, often within an hour
considerably deeper than the norm for
or two,
handpumps of the 50-60m, because the
water level will rise. It should be noted that The bailer (standard equipment on the
the shallower the water table the greater the percussion rig) can be effectively employed
danger of groundwater pollution, hence for development in the process of surging,
properly constructed well aprons are and even for pumping if a submersible pump
mandatory. is not available,
4
Drilling Boreholes for Handpumps
See 5.7 p. 32 of main text A brief chapter (Chap. 7, page 54) is devoted
to a comparison of drilling costs in India and
Pump tests are a fundamental procedure to Africa. Clearly, the economies of scale in
assess both borehole and aquifer India can never be achieved in Africa but
performance. there are many lessons to be learned.
In low yielding limited depth boreholes
Rural Water Supply and Drilling Case
classical extended pump tests are frequently
meaningless and certainly unnecessary on a Histories from Africa.
routine basis. (Chapter 6, p. 41) is devoted to drilling case
A simple test using either a bailer or small histories from several African countries.
submersible pump to determine the yield The different drilling approaches are
over a 2-3 hour pumping period is all that is highlighted and areas of possible cost
needed. Timed water level depth reduction are discussed. Examples of low
measurements should be taken if possible. cost drilling programmes (possibly the best
method of convincing sceptics!) are cited, as
Borehole Siting - Can the are conditions where the low cost approach
‘experienced eye’ and science see eye is somewhat limited.
to eye?
The ‘handpump option’ of the 1980’s
See 5.8 p. 33 main text revolutionised rural water supply and
The author considers that the use and cost- sanitation programmes worldwide. By
effectiveness of geophysics in low cost water implementing at least some of the cost
supply is debatable since, in most cases, low saving drilling and development ideas
yield boreholes do not justify relatively suggested in this document more rural areas
expensive geophysical investigation. Most would be able to benefit from the provision of
current drilling programmes support this view potable water together with sanitation
(India is the most important example). programmes and health and hygiene
However, there is an important role for education.
geophysics in geologically difficult areas and
also in virgin groundwater regions.
Data Collection, Record Keeping and
the Low Yield Water Source
It is vital for accurate records to be kept on
every borehole drilled and well dug. Some
degree of monitoring should subsequently
take place so that a rigorous and complete
database and groundwater inventory is
maintained and/or built up. But there has to
be a compromise between the extent of data
collection and record keeping of limited
depth, low yielding boreholes and the time,
money and effort expended in obtaining such
information.
5
Drilling Boreholes for Handpumps
1 INTRODUCTION
One of the most significant developments of necessary to obtain the maximum possible
the International Drinking Water Supply and yield from the water source, regardless of
Sanitation Decade (IDWSSD) was the whether the water-lifting device (in most
recognition within the rural water supply cases the handpump) can take advantage of
sector of the critical importance of what has that yield.
become known as 'THE TRIAD' of (a) Water,
(b) Sanitation and (c) Health and Hygiene The impetus now must be to correct the
education. Classical studies by Feacham and
mismatch between the water lifting
others showed that whilst the provision of
device and the water source.
clean water within rural areas improved the
quality of life of the beneficiaries, it did not,
on its own, make a real impact on child
morbidity and mortality. Only when clean Savings can be made by tailoring depth,
water was combined with sanitation and diameter and other parameters to yield,
health and hygiene education - ‘THE TRIAD’, through the application of low cost drilling
did health significantly improve. methods and design criteria adapted to
handpump mounted boreholes. In many
The pioneering work of Arlosoroff et al circumstances and hydrogeological settings,
(1987), which focused initially on the borehole drilling-costs can be reduced by a
mechanical aspects of the 'the handpump factor of 2 - 3 in Africa.
option', led to improved handpump designs
compatible with the evolving Village Level This publication will attempt to define how
Operation and Management of maintenance drilling costs can be reduced without
concept (VLOM) and underlined the compromising water quality, water quantity,
desirability of design standardisation within or the productive life of the borehole. To free
countries and regions. A new philosophy of funds not only for more boreholes but also
community driven Community Water Supply for the other two essential elements of the
(CWS) was emerging: a demand based Community Water Supply ‘triad’. It is
approach, which emphasised the importance addressed to the Rural Water Supply sector
of ‘the triad’ as a unit. as a whole, primarily decision makers,
government civil servants, planners and
The cost of handpumps has plummeted over implementers of water projects who are not
the past decade but machine-drilling costs, experts in drilling, as well as technical
although decreasing in some countries, people, project leaders, technical aid
remain, in general, inappropriately and personnel etc. It is neither a detailed drilling
unnecessarily high. The ratio can be manual nor a methodology of drilling
highlighted on an example from methods (although a brief resume is given).
Mozambique; for a village of 210 people the Hopefully, the views and proposals outlined
cost of the handpump is USD 870, (including will be a catalyst for change, and will arouse
installation, sanitation facilities and health interest in experimenting with some of the
education costs). Yet, the cost of ideas about drilling of boreholes for
construction of the water source (in particular handpumps.
the machine drilled borehole) is USD 5,000-
6,000, several times more expensive than The fundamental premise of this booklet is
the handpump. Published data indicate that that groundwater, particularly in Africa, is and
in Africa drilling costs range from USD 3,000 will continue to be the primary source of
-USD 15,000. It is now time for a concerted water for the rural areas. Further, that
focus on the water source; an area where handpumps will be the water lifting
large savings could be generated in a sector technology of choice. In 'Community Water
notoriously strapped for global funds and Supply: the Handpump Option’ by Arlosoroff
where low cost does not imply low quality. et al (1987) the authors foresaw that
evaluation of drilling methods and
Drilling for water in Africa is still largely management would be an important
tradition bound: drilling deeper than component of future research, requiring the
6
Drilling Boreholes for Handpumps
same concentrated attention on this major etc., and indeed there may be circumstances
cost element as had already been focused where local geology may not allow the
on handpump development. adoption of all the low cost solutions
In the last years progress has been made suggested. More experimentation, field
towards lowering drilling costs, with several testing, research and, possibly, modification
African countries reporting significant are required in these situations.
reductions; but these results have been The focus in this text is on low cost solutions
insufficiently studied and the progress made using machine-drilled boreholes, in marginal
so far has not perhaps received the groundwater areas other low cost
recognition it deserves. Hopefully some of technologies such hand drilled or hand dug
the suggestions to be found in this work may wells can be more cost-effective. The maxim
spur the ‘drilling revolution’ on to the heights 'if you can dig, don't drill' is not inviolate and
and intensity achieved in ‘the handpump calls for judgement on the part of the
revolution’. decision-maker. In shallow water table areas,
Hand dug wells and hand drilled boreholes, hand drilled boreholes are cheaper and
for which several excellent texts are faster to construct and can be more cost
available, will be dealt with only briefly. effective and efficient than dug wells.
Instead we will focus on the details of design However, where low soil permeability results
optimisation of machine drilled boreholes to in excessively low yields, the hand dug well is
avoid over-design and wasteful expenditure the only appropriate technology. In such
when drilling for a small yield. cases, the well acts as a reservoir into which
water can leak slowly but continuously in
order to fulfil a peak demand much greater
The absolute maximum yield than the instantaneous yield of the aquifer. In
other words, the inherent yield can be as low
of a handpump is 1m3/hr! 3
as 0.25 m /hr but water accumulated during
the night will be sufficient for extraction of
3
3 1m /hr during several daylight hours.
A handpump can pump 1m /hr (in classical
groundwater hydrology/hydraulics this is an While the benefits of optimising borehole
3
extremely small yield) yet; traditionally design to a small yield of 1-2m /hr can be
boreholes for handpumps have been over- demonstrated, there is a drawback. If the
designed. design is optimised on such a limited yield, it
will not be possible, in the future, to easily
increase the level of service to include
If the borehole design is optimised to motorised pumps in areas that perhaps could
the small yield cost savings can be have yielded supplies larger than the 1m /hr
3
made without jeopardising quality or initially sought. The response to this valid
productive life. Areas where cost argument is that ten years after the end of
savings can be made include: depth the IWASSD, and despite ongoing intense
and diameter of the borehole, both of advocacy for ‘the handpump option’; the
which can be limited for handpump sector is currently unable to keep pace with
yields, casing and screens, borehole population growth in Africa. The number of
development, gravel packs, borehole people worldwide who lack access to potable
siting, the extensiveness of pumping water is still in the order of 1.2 billion. Thus,
tests, water level monitoring and the in the author’s opinion, the primary sector
need to keep records. focus at this time should be to minimise
costs and at the same time increase the rate
of production of completed boreholes, so as
Drilling costs are obviously critically to reach the greatest number of people,
dependent on the topography, geology, albeit at a low level of service.
rainfall frequency and intensity, soil profile,
7
Drilling Boreholes for Handpumps
8
Drilling Boreholes for Handpumps
A brief resume for the non-technical reader. underground (from a fraction of a metre to
hundreds of metres per year) until it returns
Central to an understanding of groundwater to the surface, sometimes several tens of
hydrology is the global water circulatory thousands of years later, by way of natural
system known as the hydrological cycle; flow (springs) and human enterprise (wells
depicted in Figure 2 below. and boreholes).
At this point a few terms need to be defined
(a full glossary of terms will be found in
Appendix 1:
Permeability: the ability of a rock or
formation to transmit water. Gravel, an
unconsolidated rock, has a high permeability,
whereas granite, a consolidated rock, has a
low permeability and generally, unless
fractured, equally low porosity.
Porosity: those portions of a rock or soil not
occupied by mineral matter that can be
occupied by groundwater. These spaces are
known as voids, interstices, pores and pore
space. Sand and gravel have a high porosity
and a high permeability, decomposed rock
FIGURE 2. The Global water cycle or Hydrological has a high porosity and a reasonable
cycle permeability. Surprisingly clay has a very
high porosity (the reason being that clay is
made up of minuscule grains where the pore
Precipitation falling on the land surface space is 40-50%) but a very low permeability.
represents the source of fresh water for all
Aquifer: a formation that contains sufficient
living things. A part of the precipitation runs
saturated permeable material to yield
off the surface into streams that discharge
significant quantities of water for wells,
into larger streams that finally discharge
boreholes and springs. The term ‘aquifer’
back into the oceans. Part of the precipitation
implies an ability to store and transmit water.
enters or soaks into the soil. Much of the
Unconsolidated rocks, sands and gravel
water that enters the soil is detained in the
making the best aquifers.
plant root zone and eventually is drawn back
into the atmosphere by plants Aquiclude: an impermeable formation, of
(evapotranspiration) or direct evaporation which clay is the best example.
from the soil abetted by soil capillarity. Some aquifers, called confined or artesian
However, part of the water that soaks into aquifers, are overlain by a confining layer of
the soil passes through the soil root zone rock. Water in the aquifer under the confining
and, under the influence of gravity, continues layer is under pressure; the potentiometric
moving downward until it enters the surface for a confined aquifer is the surface
groundwater reservoir. representative (height) of the level to which
The quantity of water entering the water will rise in a borehole drilled into the
groundwater reservoir, known as recharge, aquifer.
depends on the soil type, rainfall amount and
rainfall intensity. Water-bearing formations of
the earth crust act as conduits for
transmission and as reservoirs for the
storage of water. Water enters these
formations as recharge and travels slowly
9
Drilling Boreholes for Handpumps
Figure 3. Examples of rock interstices and the relation of rock texture to porosity.
a) Well-sorted sedimentary rock having high porosity,
b) Poorly-sorted sedimentary rock having low porosity,
c) Well-sorted sedimentary deposits consisting of pebbles that are themselves porous so that the deposit as a whole
has a very high porosity,
d) Well-sorted sedimentary deposit where porosity has been diminished by the deposition of mineral in the interstices,
e) Rock rendered porous by solution,
f) Rock rendered porous by fracturing.
(after Meinzer)
10
Drilling Boreholes for Handpumps
Figure 6 shows how water occurs in non-weathered crystalline rock. It reveals different groundwater
dispositions in non-weathered crystalline rock. The intensity of fracturing, fracture size and the degree of fracture
interconnection govern the yield of the borehole (after Davies & DeWiest). (For an understanding of the term ‘drawdown’
see Figure 8).
a) Borehole drawing water from small fractures near the surface. A safe pumping rate for this hole is less than 1.4m
3
/hr, but still enough for a handpump.
b) Extensive small fractures connect this borehole with a nearby source of recharge. A safe pumping rate is more than
3
1m /hr.
c) This borehole is a failure except as a source for very small amounts of water. The drawdown curve reflects
dewatering of the hole and a large isolated fracture intercepted by the hole.
3
d) Large fractures that drain the porous weathered rock maintain a moderate yield of about 1m /hr in this hole. (after
DeWiest)
11
Drilling Boreholes for Handpumps
Figure 7. Vertical profile through regolith showing variation of weathering, storage capacity and permeability (after
Acworth 1987 quoted by Barker et al in Wright and Burgess 1992)
12
Drilling Boreholes for Handpumps
Unconsolidated Rock - Examples are gravel and alluvial sands and these form the best aquifers.
(See figure 8, well type 7)
Figure 8.
In an attempt to summarise geology and expected borehole yield this figure shows the relationship between geological
features and expected yield in a hypothetical region. (after Davies & De Wiest)
Type of Use Depth (m) Source of water
well
1. Drilled Farm 70 Lower part of weathered granite and fault zone. Small amount from
joints.
2. Drilled None 70 Very small amount from joints
3. Drilled Stock 10 Small amount from joints. Water is artesian.
4. Drilled Observation 40 Lower part of alluvium and fractures and joints near dyke
5. Drilled Domestic 35 Lower part of colluvium and schist
6. Drilled Domestic 45 Cavernous zone in small body of marble
7. Dug Stock 7 Alluvium
8. Drilled Industry 55 Lower part of alluvium and same fault as in borehole no. 1.
9. Dug None 5 Small amount from joints. Well dry during droughts
10. Dug Stock 8 Weathered granite
GEOLOGIC UNITS
A Residual soil on C Granite E Alluvium G Colluvium. I Dyke
granite.
B Fault. D Joints in granite F Contact between H Schist. J Marble
granite and schist
13
Drilling Boreholes for Handpumps
14
Drilling Boreholes for Handpumps
15
Drilling Boreholes for Handpumps
16
Drilling Boreholes for Handpumps
17
Drilling Boreholes for Handpumps
The advantages:
• The level of community involvement is
very high,
• Skilled labour (unless blasting takes
place) is not required,
• Until recently, it was considered the most
inexpensive technology available,
although data from some African
countries reveal this is not universally the
case,
• Most of the construction materials are
available locally,
• The rejuvenation of an old hand dug well
is frequently the first step towards a safe
water supply for the community,
• Water can continue to be drawn from a
18
Drilling Boreholes for Handpumps
19
Drilling Boreholes for Handpumps
community, hand-drilled holes now also • In very fine grained, well-sorted sands or
involve them. Only in a particular region or silt, even a gravelpack and small slot
area where well digging is an accepted, screen may not be able to stop abrasive
competently practised and well-understood sand ingress harming the pump, although
technique, is it perhaps better not to this is unusual.
encourage change. In a new area, however,
• Decision-makers should be well versed in
where the rock permeability is not
the advantages and benefits of each
excessively low and a shallow water table
technology in specific environments and
exists, there is merit in encouraging the
able to discuss them thoroughly with the
hand-drilled borehole technique.
community at the planning stage.
Where the reservoir capacity of the hand-dug
Key Points of hand-dug and hand-drilled
well is not needed, i.e., areas with a shallow
water table and a reasonably high boreholes
permeability, the relatively low cost of the • Hand-dug wells have been known since
manually drilled borehole (see below), the biblical times and are ubiquitous in Africa,
potential for substantial community
• The old rule in rural water supply "dig
involvement, low maintenance, faster
before you drill", is still true where digging
penetration and better inherent protection
is a well-established method. In low
against surface pollution makes the hand-
permeability areas the storage capacity
drilled borehole a more attractive proposition
of a dug well is critical,
than the hand-dug well.
• Compelling evidence of the advantage of
In Tanzania, for example, it takes 2-7 weeks
the hand-drilled borehole in Africa is well
to dig a well depending on depth and soil
documented,
conditions, whereas a hand-drilled borehole
is normally constructed in 3-5 days • Hand drilling a borehole is easier than
(Blankwaardt, 1984). The portability of hand digging a 1 metre diameter well as the
drills has improved markedly and for small equipment is more portable, the cost is
distances they can be carried by hand, significantly less and it provides an
whereas pre-cast concrete lining rings for inherently better seal against the danger
wells need a truck. of polluted surface water entering the
Data from Tanzania clearly shows that groundwater reservoir.
investment costs for hand-drilled boreholes
are less than dug wells and the differential
increases with depth. 4.3 Machine drilled boreholes
Advantages of the manually drilled well: Drilling methods using machine-mounted rigs
are essentially of two types, the cable tool
• More cost effective than the hand-dug method (percussion) or one of several rotary
well, methods. Both methods have particular
• Far speedier completion, advantages, but here the drill type and
drilling approach suitable for low yielding
• High potential for community holes will be emphasised.
involvement,
• Lower capital costs,
4.3.1 Cable Tool/Percussion Method
• Can usually go somewhat deeper than
hand-dug wells The cable tool or percussion method is one
of the oldest and still one of the most popular
Disadvantages drilling techniques. In Africa, there are
• Unlike the hand-dug well, pump failure hundreds of percussion rigs, some still
renders the manually drilled well operating effectively after 50 years.
unserviceable, The essential parts of a cable tool rig are
• In extremely low permeability terrain shown in figure 13.
handpump yields may not be sufficient,
20
Drilling Boreholes for Handpumps
21
Drilling Boreholes for Handpumps
22
Drilling Boreholes for Handpumps
23
Drilling Boreholes for Handpumps
Table 1.
WELL CONSTRUCTION TECHNOLOGIES
Hand Hand Cable-tool rig Small air Multipurpose
digging drilling flush rotary rotary
Approx. capital cost range USD 1000 USD1000- USD20,000- USD100,000- USD200,000-
5000 100,000 250,000 500,000
Running cost very low low low medium very high
Training needs for operation very low low low-medium medium very high
Repair skills very low low low-medium medium very high
Back-up support very low low low-medium medium very high
Approx. range of penetration 0.1-2.0 1-15 1-15 20-100 20-100
rates in metres/ 8-hr day
200mm holes to 15m in - fast fast impossible very fast
unconsolidated formations
200mm holes to 50m in - slow and fairly fast impossible very fast
unconsolidated formations difficult
200mm holes to 15/50m in semi - Impossible fairly fast impossible very fast
consolidated formation
100mm holes to 15/50m in - Impossible very slow very fast very fast
consolidated (hard) formation
(not gravel packed)
Another valuable and more recent cost study by The Swiss Centre for Development Cooperation in
Technology and Management (SKAT) attempts costing the various technologies in Table 2.
Table 2.
3
Type of Technology Targeted Investment Cost/ Running Cost/m Running
3
persons costs cost costs/m
capita (USD)
per
(USD) (USD) (USD)
source (USD)
Dug well 150 1,650 11 50 0.35 0.06
Dug well with direct action 200 2,700 14 125 0.49 0.11
pump
Borehole with handpump 300 13,500 45 224 1.29 0.14
Borehole with electric 2,400 84,000 35 1,960 0.63 0.11
pump
Borehole with diesel pump 2,400 68,000 28 3,900 0.79 0.22
Borehole with solar pump 2,400 72,000 30 1,435 0.76 0.10
Quite unexpected is the cost/capita ranking, solutions in shallow water table areas. If,
the handpump mounted borehole having the however, speed is the main factor then
highest cost/capita. Clearly the water source machine drilling in such an area is justified.
here is costed at a high figure, which is All variables must be considered but the
typical for West Africa. general statement can be made; in shallow
water table areas manual digging or drilling is
If the water table is shallow and the rock is the most appropriate technique. The
soft then manual techniques should be definition of shallow water table will vary, but
favoured. Deciding which method is the most a reasonable figure is up to 15 or 20 metres.
appropriate can be difficult. Both hand-dug
and hand-drilled methods are least cost
24
Drilling Boreholes for Handpumps
25
Drilling Boreholes for Handpumps
26
Drilling Boreholes for Handpumps
where seasonal water level fluctuations attained, drill a further 10m to allow for
exceed 10m are rare, but if the area is seasonal water level fluctuations and
hydrogeologically 'known' to have large drawdown levels,
fluctuations then clearly a reserve column of
• The yield should be established with a
15 - 20m will be necessary.
simple bailer test as drilling proceeds in
In practical terms the drill crew (only if a integrals of 2 or 3 m after water is first
percussion rig is used), once they have struck,
struck water, should carry out a rapid bailer
• In sub-artesian conditions the borehole
test (an eminently appropriate methodology
water first struck can be considerably
in this type of work) to establish the yield.
deeper than the norm for handpumps of
The bailer test saves time and money and
50-60m, but it may rise to these levels.
gives a good indication of what can be
expected from the borehole. 5.4 Borehole development.
3
If the test shows a yield less than 1m /hr, In percussion drilling in unconsolidated rock
drilling should continue with testing in depth the inherent permeability is reduced;
integrals of, for example, 2 metres. When the permeability is lost through vibration and
required yield is attained drilling must compaction, but the loss is minimal. This is in
continue for a further 10m and then stop, contradistinction to boreholes drilled by the
although in Zambia the drilling is stopped 5m rotary method, where mud or bentonite is
3
after a yield of 0.8m /hr is obtained. A used, resulting in a dramatic fall in
drawdown of more than 10m with handpump permeability. In a fissured aquifer the mud
yields is uncommon but, if the aquifer has may be forced into the fissures cutting them
low permeability, then the borehole must be off from the borehole. To produce high yields
deeper. Experienced drillers can at times in a potentially high yield aquifer, borehole
‘gauge’ or ‘feel’ the permeability of the development is required to eliminate the
aquifer. 'skin' effect or 'cake' from the wall or extract
In 90% of cases, groundwater yields suitable the 'mud' from blocked fissures. In essence,
for handpumps exist within 50m of the therefore, the action of drilling will lead to
surface. In any event handpumps have a some damage to the aquifer immediately
maximum practical lifting capability of 60m adjacent to the hole and a reduction of
(new developments currently being borehole performance. By developing the
researched may increase this figure to 80m) borehole, damage is reduced and long-term
so generally drilling should stop at 70m. In performance improved. Thorough
some regions, however, first water may be development also ensures the accelerated
penetrated only at a relatively deep level, i.e. egress of sand and fine material from the
80-100m. Because there is a possibility that aquifer. If a borehole is not developed, and
it may be sub-artesian (and therefore under the handpump is mounted, then the pumped
pressure and able to rise to a level which can water may contain sand and/or silt which can
be pumped by the handpump), it is worth damage handpump seals and valves.
drilling to such depths in areas where sub- Development procedures are varied and
artesian conditions are known to occur, e.g. include pumping, surging, use of
in the so-called ‘basins of decomposition’ in compressed air, hydraulic jetting, the addition
granite areas. of chemicals (an important advance in rotary
In some areas in Zimbabwe there are drilling is the use of a biodegradable mud
instances where local politics overtake instead of bentonite or clay), hydraulic
technological acumen. In the mid-eighties a fracturing and the use of explosives. These
cycle of droughts hit Zimbabwe and many are specialised techniques and details can
boreholes dried up. There is now the be found in specialised drilling texts.
perception in these areas that only For small yields the 'cake' effect is not so
exceptionally deep boreholes will not be critical and, in any event, development by the
subject to drought. various methods available (excluding
Key Points: pumping and surging) all have a minimal
effect with screens that have a small
•
3
Once the required yield of 1.5 m /hr is
27
Drilling Boreholes for Handpumps
percentage opening appropriate for small Figure 17. Natural gravelpack development, (after
yields. In large yielding boreholes, screen Clarke 1988)
openings of 30-50% are common and with The grain size distribution of an
such a large percentage of open area the unconsolidated aquifer dictates how
various development methods are relatively efficiently development creates a natural
efficient. Low yielding boreholes with screen gravelpack. The D number, or more
openings of 1-5% (sufficient for handpump importantly the sorting or uniformity
yields) render the more sophisticated coefficient expresses the grain size
development techniques grossly ineffective. distribution. The D number is related to the
The most economical method of developing grain size; for example D40 relates to the
the low yield borehole is to use a bailer to sieve mesh diameter through which 40% of
pump or over-pump the hole until ingress of the aquifer material will pass (how sediment
fine material stops. In the low yield borehole, sieving is carried out is explained in several
an effective method of development, apart texts marked in the list of references). An ill-
from pumping and over-pumping, is the use sorted aquifer has a sorting or uniformity
of the same simple bailer to surge the coefficient (D60/D40) of more than 2.5. The
borehole. Surging is a process that attempts grain size and sorting of sediments are
to set up a washing action by forcing the illustrated by grain size distribution curves,
water backwards and forwards through the which are used for the design of screen slot
material to be cleaned, i.e. the screen, the size and artificial gravelpacks. This
gravelpack (if there is one) and the aquifer discussion will not be taken further in
matrix. The simplest way of surging a technical terms, suffice to note that if large
borehole is to use a bailer, taking it up and yields are required in unconsolidated
down rapidly. The bailer acts as a piston in aquifers the design of screen slot size and
the screen to pull loose material into the gravelpack are critical to the long life of the
borehole for subsequent pumping out. borehole.
The development of a borehole (pumping There are instances where, even following
and surging) results in the finer fractions of pumping and surging, pumped water may
material being drawn from the take weeks to clear up completely. If sand
unconsolidated aquifer (and from fissures in and silt continue to ingress after such a
semi-consolidated aquifers) leaving behind a period, a possibility in very fine-grained
stable envelope of the coarser, and therefore aquifer material, an artificial gravelpack is
more permeable, material of the aquifer. This mandatory. Even in fine-grained material,
natural gravelpack is not to be confused with however, an artificial pack is often
an artificial gravelpack. unnecessary. For example, in the Tharpakar
Desert in Pakistan with a drilling programme
that did not include gravel packing despite
fine-grained material, sand ingress several
weeks after drilling was reported in only 1
borehole out of 75. This one-off case did not
warrant a change in design strategy, i.e., to
gravelpack all boreholes; the particular hole
was simply abandoned.
Key Points:
• Development of a borehole is a crucial
adjunct to a properly completed
installation,
• For low yield boreholes pumping, or
better still over-pumping, is the best
method of development. Rule of thumb
pumping periods vary from 2-24 hours or
until the water pumped is clear, which is
frequently within an hour or two,
28
Drilling Boreholes for Handpumps
• The bailer (standard equipment on the will not be considered here; it is only
percussion rig) can be effectively important when large yields are pumped.
employed for development in the process Inflowing sand or silt after development can
of surging, and even for pumping if a occur and the only way to stop it is to slow
submersible pump is not available, down the water flowing into the borehole.
• Pumping and surging will create a natural This can be achieved by means of a high
gravelpack around a borehole drilled in screen open area and a natural or artificial
unconsolidated sediment which is critical gravelpack, which creates a high
to the long productive life of the borehole, permeability zone around the borehole. The
3
small handpump yield of 1 m /hr translates to
• The brief technical discussion above a very low entrance velocity, well below the
relating to distribution curves and sorting critical velocity concept in borehole design,
coefficient is not essential reading but above which sand/silt may be carried into the
illustrates the complexity of borehole borehole. High percentage opening, small
design for large yields, slot size screens (which are expensive) are
• Despite the fact that, in hydraulic terms, a not required; they are only needed when
gravelpack is not required nearly as yields are high and inflow velocities are
frequently as it is used, the widespread consequently large.
practice in some countries of routinely Screens are manufactured from a variety of
placing an artificial gravelpack should be materials, PVC, mild steel, stainless steel
allowed to continue given its low cost and and various alloys. Slot designs are many
‘anchoring’ action. and varied, stainless steel screens and spiral
5.5 The use of PVC casing and wound wire being extremely expensive,
although allowing an open area of 40-50%.
screening
For handpump supplies, low cost (locally
In boreholes designed for large flows manufactured) PVC casing and screening
screens have the effect of: can be utilised. The slot size of the screens
• Stabilising the sides of the hole, is not critical for low yields in normal
conditions, although it can be critical in fine-
• Preventing sand movement into the well,
grained aquifers. In aquifers requiring
• Allowing a maximum amount of water to screens, primitive machine sawn slots with a
enter the hole with minimum hydraulic total opening of 5% (slot size 0.5-1 mm) are
resistance. appropriate. Casing and screens can be of
The choice of a particular screen type will low cost PVC. PVC casing and screens can
depend on a combination of factors including be joined by two methods, either bell and
strength and corrosion resistance as well as socket (male/female) joint with solvent
slot size and design and open area (which is cement, or threaded joints. In most areas,
the proportion of a screen face made up of and certainly in the developed world,
open slots). threaded joints are significantly more
expensive than the bell/socket. Recent
An important design criterion relating to the developments in Southern Africa, however,
open area of a screen is the entrance show that local manufacturers are charging
velocity, which is the discharge of the little more for threaded flush joints than the
borehole divided by the effective open area bell/socket joints. For a price differential of
of the screen. It is widely accepted that the USD 1-3 per joint, threaded flush joints are
entrance velocity should be kept below the probably a better choice than the bell and
critical value of 0.3m/min. If the entrance socket joint. In those regions, however,
velocity is higher than the critical value where the use of threaded joints would
(assuming for the purposes of this discussion significantly increase costs in low capacity
an unconsolidated aquifer, typical porous boreholes, bell and socket joints should be
media), sand and silt or even finer material used. It could be argued that while the casing
will enter the borehole and turbulent flow will is being inserted the solvent cement joint
cause a loss of head. The loss of head with could come apart. As a safeguard against
the onset of turbulent flow into the borehole this unlikely event, two small self-tapping
29
Drilling Boreholes for Handpumps
screws inserted at every joint guarantee that work carried out in the United Kingdom on
there will be no problems. Interestingly, the solvent cements has resulted in the
drilling industry in much of Africa has long availability of improved products on the
been suspicious of solvent cement joints, market.
however in Asia there is considerable It has taken time for drillers to ‘adapt’ to the
experience of effective use of this type of use of PVC casing and screening. In the
casing. In South Africa, irrespective of the past, steel casing and screens were the
small cost differential between the two types norm and, while much more expensive, the
of joints, most commercial drillers now use toughness of steel meant that less care was
the bell and socket joints routinely and required in its handling.
successfully. In addition, recent research
Table 3. Cost of different casing and screens and effect on total cost of borehole. (Based on 5m of screen and 45 m of
casing in a 50m hole).
Cost/m Cost of Screen /Casing
in a 50m borehole
(USD) (USD)
Steel screen with flame cut slots used in Zambia, pre 1995 50
Steel casing used in Zambia, pre-1995 40 2050
PVC screens (bell socket joint) manufactured and used in
Zimbabwe 7.3
PVC casing (bell and socket joint) manufactured and used
in Zimbabwe 5.3 280
Steel screen used in Zimbabwe, low percentage opening, 20
large slots
Steel casing used in Zimbabwe 15 775
PVC screen used in Mozambique, imported from Holland 28
PVC casing used in Mozambique, imported from Holland 18 1040
PVC screen manufactured and used in Pakistan 6,50
PVC casing manufactured and used in Pakistan 5.50 280
PVC screen manufactured in South Africa used in Zambia 10
PVC casing manufactured in South Africa used in Zambia 8 390
The table reveals how dramatically costs can be reduced with locally manufactured PVC screens
and casing; imported PVC is expensive.
The collapse resistant rating is an important holes such as a surge block, which exerts
figure for screens and casing as it considerable pressure on the screens, are
determines the permissible installation depth inappropriate for low yield holes.
and likelihood of failure. Usually the highest Generally casing and screens are not
external pressure load occurs during required in hard rock and seldom in semi-
development and gravel packing. For decomposed rock, (except the top few
boreholes with handpumps development is metres of overburden) yet many countries
normally carried out by pumping and/or by (e.g. Mozambique) use them despite the fact
the bailer acting as a surging tool. Light, low that there is no reason to do so. The
cost screens are safe but care must be taken explanation is sometimes proffered that
in raising and lowering the bailer. The heavy casing protects the rising main in a hard rock
development tools used in large yielding
30
Drilling Boreholes for Handpumps
borehole from rubbing on the wall of the • PVC casing and screens are low cost
borehole. It is an unsatisfactory explanation and can be easily transported and
since the problem can be overcome easily handled,
and cheaply by using PVC piping cut in half
• The smallest slot size of about 0.5mm is
lengthways as stabilisers or centralisers.
generally acceptable. For low yields, an
There are, however, exceptions. In hard rock open screen area of 5% is sufficient,
terrain in Zambia the drills sometimes cut
through a soft, loose decomposed layer at • Boreholes drilled in either hard or
depth, only to go through hard rock again decomposed rock generally do not
after a few metres. Previously such holes require screens and casing; the use of
were left uncased but it was discovered that, stabilisers or centralisers is effective and
in time, 10-30% of such holes collapsed. low cost but further experimentation is
Consequently, hard rock holes in Zambia are desirable. Note the Zambian experience
now routinely cased. Research work is (see 6.3.1).
planned on the thin decomposed layers lying 5.6 Artificial gravelpack - when and
within fresh rock so that clear guidelines may where needed?
be established as to when and when not to
case. At a typical discharge rate of a handpump of
750 l/h, a 3-metre screen with only a 5
In the decomposed mantle in Malawi where
percent opening, and no gravelpack, is
Chilton and Grey did their early work,
theoretically “safe” in terms of sand ingress.
screens, some casing and gravel packing
The average velocity of the water passing
were routinely used. Conversely, in
through the screen is at least a factor 3
Zimbabwe, under very much the same
below the critical velocity where turbulent
conditions, the policy was to case off the
flow may be generated and 0.5mm sand
overburden, usually the top 10-15m, drill into
grains begin to move. In large capacity
the decomposed zone and the fresh rock
boreholes sited in aquifer material that is
and leave it open. Screens and gravel
fine-grained and well sorted, an artificial
packing were seldom used. No harmful
gravelpack is mandatory. The advantage of a
effects such as silting or decreasing yield
gravelpack is that, because the pack material
were experienced. The few screens used
is coarser than the formation, screens with
were made of mild steel with torch cut slots
larger slot sizes can be used and, by
(at least 3mm wide) resulting in an open area
surrounding the screen with highly
of only 1-2%. Although it must be said that
permeable material, inflow velocities are
Chilton and Grey suggested tapping the
reduced.
overburden.
In terms of hydraulic theory, it is clear that for
Key Points:
small yields an artificial gravelpack is not
• Two important design criteria are essential. Yet, in practice, even when
discussed in relation to screens. boreholes have gravelpacks, movement of
Entrance velocity and critical velocity. It sand into boreholes can still occur. Although
becomes apparent that the low infrequent, the fact that it happens at all
handpump yield means a low entrance illustrates how the theoretical aspects of
velocity well below the critical velocity; groundwater hydraulics can and do diverge
again emphasising the significant from field reality. Such sand may actually find
difference that yield makes in borehole its way into handpump plungers and
design requirements, accelerate the wear of seals and washers.
• PVC screens and casing are appropriate This rare, but inconvenient ingress of sand
for low yields, into low capacity boreholes dictates that
some of the possible causes should be
• In some countries and regions there is a
examined before adopting a blanket policy of
significant cost differential between the
‘no gravelpack use’. Possible explanations
jointing mechanism for PVC screens and
for the presence of sand in handpump
casing. Threaded joints are preferable
plungers include physical and hydraulic
but, if the cost differential is significant,
factors. The physical factors relate to the
bell and socket joints should be used.
31
Drilling Boreholes for Handpumps
grain size of the sand and, more importantly, • In hard rock boreholes neither a
the grain size distribution; the finer the gravelpack nor a screen and casing are
sand/silt and the greater the uniformity needed but several countries routinely
coefficient the more sand migration is likely. use them, primarily for mechanical
The hydraulic aspects are that theory purposes such as the protection of the
assumes a completely porous media with handpump rising main. Stabilisers or
water flowing through all pores at the same centralisers would do the same job for
velocity. In practice, however, porosity varies less cost.
and so do flow velocities. Additionally, flow
• There is compelling evidence that the
caused by ‘handpumping’ is not constant but
gravelpack can be eliminated but its low
pulsing, which will also increase flow
cost, mechanical, and at times even
velocities over short spans of time. In fact, a
hydraulic advantage, coupled with
faulty footvalve may even cause a small
widespread practice, probably means
scale jetting action within the screen if the
that its use should not be discontinued in
handpump plunger is inserted.
countries that routinely place a
The author believes that the above gravelpack.
discussion demonstrates that in most
situations low yield boreholes (meaning
entrance velocity well below the critical 5.7 Borehole Pump Testing
velocity) do not require an artificial
gravelpack on hydraulic grounds. In There are two main reasons usually cited for
Zimbabwe, there are well over 25,000 pump testing a borehole:
documented boreholes in a variety of terrain a) To measure the well performance and
and rock types with no gravelpack and no efficiency with a varying discharge,
screens. Some boreholes have primitive
b) To measure the aquifer characteristics
screens with ‘wide’ flame cut slots and an
of storativity and permeability (for the
open area of 1-2%. From a purist’s design
aquifer as a whole it is called
viewpoint nothing could be worse, yet many
transmissibility).
of these bores are 40-50 years old and show
no sign of deterioration. Pump tests are fundamental in groundwater
hydrology. Boreholes are pumped for
Nevertheless, in several countries a
extended periods and the drawdown is
gravelpack is frequently installed in the belief
measured over time, thus enabling
that it is needed, even in hard rock boreholes
assessment of well performance and aquifer
where it definitely is not. In such
characteristics. Pump tests normally vary
circumstances the gravelpack has a
from 6-72 hours and at times are even
mechanical effect; it helps to anchor the
longer. The tests are conducted with a
screen and casing in the borehole, but,
varying discharge and/or constant discharge.
perversely, this too is unnecessary in a hard
The flow equations describing water flow into
rock borehole!
a borehole are complex and analysis of the
Geotextile is a new material now being depth/time data to obtain the required
experimentally used instead of an artificial functions used to be intricate. Now, with the
gravelpack, and sometimes in addition to advent of the computer, analysis is much
such a pack. Unlike the gravelpack, which simpler. Notwithstanding, for low yielding
reduces water velocity, geotextile acts as a holes of limited depth it is needless to carry
filter, letting water in but excluding sand/silt out a ‘sophisticated’ test. In these holes
and other fines. Data on its long-term neither theoretical well performance nor
efficacy is still lacking. aquifer characteristics can easily be
Key Points: obtained. All that needs to be established is
whether the borehole has a yield of 1-2
• From a hydraulic viewpoint, it is 3
m /hr. Pumping for 2-3 hours at 1-2m3/hr
concluded that an artificial gravelpack is can do this. If, at the same time water depth
seldom required in low yielding measurements are taken, all the better; a
boreholes, and screen open areas can be first order approximation of the
low (5%), transmissibility is now available for future
32
Drilling Boreholes for Handpumps
33
Drilling Boreholes for Handpumps
The approach above is sensibly systematic geophysics in low cost water supply is
but perhaps it should also include a zero debatable since in most cases low yield
level that allows ‘the experienced eye’ to site boreholes do not justify relatively expensive
the borehole since groundwater in small geophysical investigation. In his view casting
quantities is ubiquitous. the ‘experienced eye’ and ‘throwing of the
The ‘experienced eye’ refers to the hat’, or bones (more appropriate in Africa) on
hydrogeologist who draws upon his scientific to the spot to be drilled is the method of
training and experience to assess the natural choice in many (but clearly not all)
clues for siting a borehole: the type of hydrogeological situations.
vegetation, rock outcrops, soil colour,
topography, valleys and drainage areas,
5.8.1 Costs of Finding Groundwater
existing nearby wells or boreholes and
springs. Negative indicators such as high The 1994 UNDP World Bank study has
ground, areas of mudstone or basalt attempted to evaluate costs of groundwater
overburden etc., etc. are also considered. assessment studies and borehole location in
For low yields and shallow depth, this is a Africa. These costs show tremendous
powerful location method. variation as can be seen below:
The author (a geophysicist) has felt for many
years that the use and cost-effectiveness of
Table 4.
Average well Average cost of
Category/region construction cost investigation per site
(USD) (USD)
The variation in construction costs per absolute terms though these figures are very
borehole between the regions of West, East low in East and Southern Africa. With such
and Southern Africa is extraordinary. In low figures, geophysics is certainly
several East African projects the inclusion of worthwhile but once construction costs go
sanitation and health and hygiene education, down the issue is more debatable.
etc., obviously raises costs. In West Africa The Case Study I, (Mozambique, see 6.1.1)
costs are very high because of deeper shows geophysical siting cost of USD 250-
drilling and the use of more expatriate staff. 500 (in 1994) is 17%-30% of total drilling
Note too the far higher siting costs in West costs. The critical question is; would the
Africa. In Southern Africa a highly money saved by omitting scientific borehole
competitive commercial drilling industry siting have made up for the loss involved in
keeps costs lean. Nonetheless there are drilling 11 dry boreholes? The Mozambique
many unanswered questions and such Case Study shows that it did, even assuming
regional differences deserve closer scrutiny. an unlikely 100% success rate had
Interestingly, the percentage cost of siting in geophysics been used. The summing up of
relation to construction for low yield Farr et al. is applicable here; ‘Groundwater
boreholes in West Africa is significantly search techniques are only justified if they
greater (8%), than in East Africa (3.5%). In increase the chances of subsequent
34
Drilling Boreholes for Handpumps
Table 5.
Rock type Number of Success Mean Mean Drilling cost per
boreholes rate depth yield productive well
3
% (m) (m /d) (USD)
Existing boreholes.
Tertiary volcanic 38 44 126 140 17,700
Nyanzian volcanic 19 68 116 95 10,600
Granites 7 43 70 48 10,200
Programme
boreholes
Tertiary volcanic 60 78 66 340 5,400
Nyanzian volcanic 11 91 54 94 3,700
Granites 10 60 61 140 6,350
In areas of high rainfall and unconsolidated 50 years, until a decade ago when
sediments, groundwater is usually shallow competing methods were introduced,
and in such cases the UNDP/World Bank geophysical methods in Africa centred
study agrees that no investigation is around an electrical resistivity depth profile
necessary for determining precise well sites used after the geophysicist had selected the
and that the community can select the site based on his experience. For 40 years
digging/drilling sites. The UNDP/World Bank borehole sites were thus located in
study also allows that in areas where ‘... Zimbabwe. No cost figures for such surveys
groundwater is known to be present at are available and an estimate would not be
shallow depth, such as in many alluvial meaningful. The author has long been
aquifers or areas with significant recharge sceptical of the ‘confirmatory sounding’, and
from rainfall or surface water resources, the has found ‘the experienced eye’ alone to
limited abstraction needs of handpumps only suffice. Witness the following success rate
require a very basic hydrological from a recent low yield borehole-drilling
investigation...’ programme in Mozambique. Out of a total
number of 145 boreholes, 129 were
However, over the vast crystalline rock areas successful, (10 were dry and 6 saline) - a
of Africa where groundwater occurs in the success rate of 89%. The most striking fact
weathered mantle, the study suggests that is that only 60 (40%) of these were sited by
geophysical techniques are useful, ‘... an experienced hydrogeologist (using his
especially where the subsurface conditions experienced eye and throwing his hat), the
are simple...’. Subsurface conditions, rest were sited by newly trained medium
however, are seldom simple, and for some level technicians with little experience of
35
Drilling Boreholes for Handpumps
36
Drilling Boreholes for Handpumps
5.9 Drill type - which is best? 10 of these rigs in 1993 (for the price of 2
large rotary rigs) and an analysis of their field
The answer is that there is no ideal all- performance will be found in one of the case
purpose rig! The maxim ‘horses for courses’ studies from that country. The rigs proved
applies to the choice of rig. Therefore, for the cost effective and reliable, cost/m was 60%
small yield borehole select the small drill rig. less than the normal drilling costs at the time.
Table 1 summarises several aspects of the Drilling covered a wide spectrum of rock
different drill types. As noted, this table has types, from unconsolidated to hard rock, but
not been updated and costs are currently drilling rates were slow.
greater than the table suggests, although the The rotary/pneumatic drill is a speedy
relative costs remain approximately the alternative in all types of terrain with rates of
same. 100m/day not uncommon. In hard, dense
Several factors are recognised by Talbot, rock the DTH can achieve a similar figure.
1992, as fundamental to the success of a Here too, designers and manufacturers have
drilling rig design. These include: recognised the need for compact, less
• Access to the drilling site and complex units and several well known
manoeuvrability over rough terrain - manufacturers produce high quality
generally smaller rigs are more equipment that is manoeuvrable and mobile
manoeuvrable, and which, while still expensive, costs less
than the ‘monsters’ of a decade ago.
• Reliability,
In Africa logistical support is extraordinarily
• Maintainability - with limited or virtually no expensive, making sophisticated machines
access to a workshop, design must allow inappropriate. Logistics are crucial with even
maximum field maintenance, the less sophisticated models tending to
• Cost effectiveness-’the right drill for the have long down times awaiting spares and/or
job’. servicing. The pneumatic rig requires a
compressor, useful for development (and
pump testing of the hole!) but difficult to
5.9.1 Rotary versus percussion? maintain, with high capital costs. The
attendant disadvantages of this type of
The choice is between differing models of technical complexity warrant serious
each type; but at least there can be no consideration before purchase, although the
argument about size, for handpump mounted days of fleets of large, sophisticated drilling
boreholes drilling equipment must be small, rigs lying idle and broken down over much of
mobile and compact. Africa have largely disappeared.
Percussion rigs are simple, rugged (many in Several African countries, notably the Sudan,
Africa are over 50 years old), easy to Ethiopia, Zambia and Nigeria, have achieved
maintain and admirably suited to low cost substantial reductions in drilling costs with
drilling. Simplicity of design means easy rotary rigs. Appropriately managed to ensure
servicing (most have the ubiquitous Lister maximum utilisation, with technically
engine) and relatively short training periods competent and experienced crews and good
for crews because the equipment is so logistics, the unit costs of rotary rigs compare
straightforward to operate. (Nevertheless favourably with percussion rigs. This is
only long experience makes a proficient especially so if the operation is commercially
driller). Recent design advances, in which run in a competitive environment as in
UNICEF has played a significant role, have Zambia in the past two years (see case
focused upon size. Compact cable rigs are history, 6.3).
now available with specifications that allow
drilling to depths of 90m (150mm diameter) At first sight the choice of a drilling rig for a
and 55m (400mm diameter). The drill is new CWS project manager may appear
highly manoeuvrable, vital in countries with confusing, although at least size is no longer
few roads and possibly a 5-month rainy a variable. If logistical support and technical
season. competence is available there is little doubt
that the small rotary/DTH is the most cost-
The Government of Mozambique purchased effective rig. But the simplicity and
37
Drilling Boreholes for Handpumps
ruggedness of the cable tool, especially the drilling costs with the use of hydraulic rotary
newer and more compact models, make it and pneumatic rigs, but an objective analysis
still the best and most cost-effective of the costing reveals that, while relative
alternative in developing Africa where there costs have fallen, absolute values are still
is little logistical support. As has been noted high.
above, several countries have reduced
Some of the quoted figures for borehole construction in Africa are reported by Skinner and
Franceys (1993):
Nigeria USD 3,700- 28,000
Sudan USD 2,800
Zimbabwe USD 6,000
Angola USD 7,500
Senegal USD 18,000
Namibia USD 8,250
South Africa USD 6,000
Togo USD 9,700
Zambia USD 2,700
Burkina Faso USD 16,150 (including USD 4,400 administration costs!)
Mozambique USD 4,000
38
Drilling Boreholes for Handpumps
utilising a fleet of small percussion rigs is or by the drill crew themselves. Details such
seen to be lower than most of those as depth at which water is first struck,
reported from the rest of Africa. In penetration rate of drilling, depth of borehole,
Zambia small DTH rigs demonstrated low yield at various depths, static water level etc.,
cost, rapid and cost effective drilling etc. are noted. This information would
capability. normally be entered into a database and thus
be available for the Ministry, for the major aid
• While the type and size of drilling
agencies and University research
equipment is a vital factor affecting cost,
departments. Equally important is the
(apart from the invariable of geology and
collection by the crew of drilling samples
topography), the importance of human
taken at pre-determined depth increments.
resources cannot be overstated. Training
As a rule, if the geology is new, sample every
and experience are prerequisites, along
1m, if not, every 5m is sufficient. The
with commitment, and, as has been
description of the samples is best done in the
shown in the Sudan and Mozambique
field, if possible by the supervisor/
among other countries, the payment of
hydrogeologist. A geological depth profile is
production related bonuses could reap
crucial to determine if screens are required,
production benefits way beyond their
as proper placement of the screens requires
cost.
analysis of the rock samples taken during
drilling. There are also times when it is
necessary to do a simple sieve analysis in
5.10 Data Collection, Record Keeping the field to decide whether a gravelpack is
and the Low Yield Water Source. needed. After analysis the samples should
It is vital to keep accurate records on every be bagged and kept by the Groundwater
borehole and well dug to ensure for some Section in the Ministry, where more detailed
degree of subsequent monitoring. The descriptions may be done in the future if
degree to which this should be done, and at required.
what stage it ceases to be cost effective, are Data collection from low yield boreholes need
moot points. Most Ministries of Water not be exhaustive but it should be accurate,
Development have a section charged with thorough and uniform. The same records
recording the details of the nation’s MUST be collected for every hole drilled.
groundwater in order to better understand There is seldom justification for logging the
the occurrence and disposition of the borehole with sophisticated geophysical
resource. Data collection from each borehole equipment, as the cost does not justify the
and record keeping of selected parameters data captured from a limited depth borehole.
allows the creation of a database for
groundwater research and study in a Two parameters should be monitored over
particular region or country. From the time. Firstly the yield, although strictly
theoretical hydrogeologist’s viewpoint speaking this does not need monitoring since
exhaustive data collection is obligatory. This it is being continuously ‘self monitored’ by the
may explain the routine (but flawed) simple act of pumping. A progressive
procedure in Mozambique whereby an decrease in yield is soon evident. The
extended pump test is done in every low second parameter that should be monitored
yield borehole (from which a meaningful is water level fluctuation, both seasonal and
analysis of aquifer parameters is seldom drawdown. Both are important, the former for
achieved). There has to be a compromise regional groundwater studies, the latter for
between the extent of data collection and the localised setting. For example, if a
record keeping and the time and effort handpump stops pumping water and the
expended for obtaining such information in drawdown is known, it is simple to diagnose
limited depth low yield holes. whether the fault is in the handpump or
borehole.
A comprehensive record of drilling progress
and hole details is important. Most countries Water level measurements are important for
have a protocol in the form of a borehole several reasons. Natural water level
completion record, in which drilling data is fluctuations are a response to either
recorded, preferably by the drilling supervisor recharge or evapotranspiration or pumping.
39
Drilling Boreholes for Handpumps
Serial measurements over a number of years cost elements but which are NOT moving
(statistics of natural events) are critical and parts), can be made of low cost PVC, as
can be obtained by the establishment of there is little wear and tear.
regional monitoring networks. Water level Correct methodology and procedures will
measurements are particularly important in ensure the construction of quality low cost
large yielding boreholes but are also of value boreholes. The borehole must be drilled
in low yielding holes. From such data it is straight. Screens and gravelpacks, if needed,
possible to compute approximate figures for should be accurately positioned. The apron
water in storage and aquifer yield, to must be properly designed and constructed
establish whether an aquifer is being over- to prevent pollution. ‘Quality’ here is a
pumped or recharged, etc. In large yielding function of how carefully and diligently a drill
aquifers, measurements are taken on a crew works, which in turn is related to the
weekly or monthly basis in what are known thoroughness of training and the
as ‘open boreholes’ that are used solely for commitment and enthusiasm of the crew. A
measuring purposes. high level of quality can only be maintained
with an adequate supervision of work and
effective quality control.
5.11 Quality versus costs - low yield,
hence low cost, is NOT low Despite all that has been said, there will be
those sceptics who will continue with steel
quality.
casing, expensive screens, deep holes,
The assumption that low cost equals poor extensive pump tests, mandatory
quality tends to colour perceptions with geophysics, gravelpacks in hard rock holes,
regard to the projected productive life of low etc. etc., in the belief that this is at least tried
cost boreholes. Low cost is in fact a relative and tested methodology. The shortage of
term used to compare the cost of boreholes both TIME (even The Decade did not catch
3
yielding several hundred m /hr with those up with population growth in providing rural
required to produce but a fraction of such a water supplies) and FUNDS, however,
yield (in the order of less than 0.5% of that suggests that, at the very least, project
figure). Low cost must not be correlated with managers and decision-makers in water
low quality but rather low yield. Low cost in supply programmes should experiment with
this text is related to design features and not some of the ideas discussed, so that drilling
inferior materials. High quality, long lived but rates may be increased and costs reduced. A
low cost boreholes are eminently possible. trial sub-programme with close monitoring of
Casing and screens, the major hardware the medium term (1 - 5 years?) performance
component of a borehole (which are large could be considered.
40
Drilling Boreholes for Handpumps
6.1 Case Studies from Mozambique ii. Transport difficulties during the
Mozambique civil war.
6.1.1 CASE STUDY 1 –
A small rig could easily be packed
Government of Mozambique/UNICEF into an Antonov cargo aircraft, often
drilling programme the only means of travelling around
the country during the war.
Objective of programme - To drill low yielding
handpump mounted boreholes using new iii. Logistics.
small percussion rigs. The decision to select a Lister engine
Drill type: 10 small light and manoeuvrable power plant for the Dando 3000 was
percussion rigs were selected, the purchase based on the availability of spares.
being based on 4 factors, iv. Ease of training.
i. Suitability and cost effectiveness. The simplicity of the drill allowed for
Because the yield sought was only 1- relatively easy training of newly
3
2m /hr and the depth would therefore recruited crews who readily accepted
be limited, many borehole design the concept that only low yielding
parameters could be relaxed and boreholes were to be drilled. Older,
small, simple and relatively low cost more experienced crews tended to
drills could be used. think in terms of larger yields.
The accompanying map and table (Figure is suitable. Nevertheless, several boreholes
18) reveal that the 10 drills operated in 7 were drilled in hard, siliceous sandstone. The
provinces over a wide geographical small percussion rig can drill in hard rock but
distribution, essentially in the unconsolidated progress is slow, primarily because the small
sediments of the coastal belt, extending in mast height of 5.2 metres means that jars
some areas as far inland as 150km. In Tete cannot be used to loosen a stuck drill bit, a
and Manica Province drilling took place in not unusual occurrence in jointed fresh rock.
Quaternary alluvial sediments and Additionally, the lack of a spudding arm
Cretaceous sandstone and conglomerates. makes drilling in hard rock difficult and slow.
b) Competent field management;
Two major aspects determined drilling rates:
a) Geology; Only one experienced hydrogeologist
supervised the drilling operation of 10 rigs,
90% of all boreholes were drilled in the (compare this with Lesotho where 1
unconsolidated to semi-consolidated hydrogeologist normally supervises 2 drills
sediments for which the small percussion drill albeit that they are both rotary drills). To
41
Drilling Boreholes for Handpumps
42
Drilling Boreholes for Handpumps
3
artificial gravelpack was installed in each 3.7m /hr with a range of 0-25. This is a
borehole. relatively high yield and, with experience, the
The cost per borehole of USD 37/m is based drilling crews will learn to stop drilling earlier,
on 2 boreholes drilled per month to an although with an average depth of only 30m
average depth of 35m. This was 30% of the a few metres more will make little cost
usual drilling costs in Mozambique in 1995. If difference.
a 50% production bonus were paid to the
drilling crew, a production rate of 4 boreholes Conclusions:
a month would be realistic which in turn
reduces the cost per borehole by 22%. • Small, simple, relatively low cost,
Moving costs for a small percussion drill manoeuvrable percussion rigs proved
were low, USD 2/km as opposed to the USD successful in Mozambique in a variety of
11/km charged by the government drilling rock types, essentially soft or
company for a large drill. unconsolidated rock, semi-decomposed
and hard,
• Costs were reasonably low, at USD 37/m
The Human Aspect
per borehole, based on drilling 2
It takes many years of experience to become boreholes/month. This is 10% of the
a proficient driller and the crews working with prevailing drilling rate in Africa (figure
the Dando 3000s were all new to the drill. based on UNDP-WB Geophysics
Despite initial enthusiasm, low pay and lack document) and 35% of prevailing costs in
of incentive bonuses tended to sap Mozambique,
commitment, as shown by an experimental
attempt to increase output by paying a • With a 50% production bonus the crew
production bonus, which resulted in a rise in increased their production two-fold to an
productivity of 100%! average 4 boreholes per month. This
reduces the cost per borehole by 22%.
Because of the high esteem in which drillers
are held in most African village communities • Success was critically dependent on
they should be widely used to train villagers competent field management and
in handpump maintenance, in promoting the supervision,
VLOM concept and even in health/hygiene • Costs can be further reduced and drilling
education. By so doing the drillers could rates increased if the drills work in
augment their salaries (which in any case are ‘packs’, leap-froging each other and as
unacceptably low) whilst providing valuable crews gain more experience and as more
benefits to the communities. of the guidelines suggested in this text
are adopted by the decision makers in
the country,
Drilling Success Rate
• The Government of Mozambique new
Out of 145 holes, 10 were dry and 6 were drilling tender document reveals
saline. The success rate was 89%. The drills enlightened thinking that recognises the
were scattered countrywide and the need to drill specifically for low yield
hydrogeology in many areas was simple. boreholes.
Nonetheless the high success rate is
compelling evidence of what can be achieved
by experience and minimal investigations
without the use of geophysics. An
experienced hydrogeologist sited 60 of the
holes, the rest being sited by medium level
technicians with minimal experience.
Community siting preferences were
considered (where the hydrogeology
permitted) and local knowledge of the area
drawn upon.
The mean yield of the boreholes was
43
Drilling Boreholes for Handpumps
44
Drilling Boreholes for Handpumps
were successful (59% success rate). The Overall costs, which included training of
contractor costs averaged USD 5,200 per health education workers, community
attempt, or USD 7,926 per successful handpump maintenance training, geophysics
borehole. Average depth was 60m at USD etc., brought the cost per borehole to USD
87/m. Drill type was a Schram DTH. 10,500.
Geophysical costs are not included.
The pump test and development were
6.1.4 Lessons Learned from the 3
combined. A submersible pump was used in
case histories in Mozambique
which the yield of the pump was greater than
that of the borehole, so for an hour or so the a) Case history 1 reveals that a fleet of
borehole was over-pumped. The pump was small percussion rigs performed
then stopped and the water level recovered. exceptionally well at a cost of 35% of
The sequence was repeated several times, current drilling rates, although progress
an excellent development procedure. was slow.
Following development the pump yield was b) Case history 2 shows the high costs
reduced so that the rate of drawdown could associated with the State Drilling
be measured over 1 hour. After 1 hour the Company, which has large drills and
pump was stopped and water recovery crews still imbued with the ‘large yield
readings were taken. syndrome’. Progress rates were little
Geophysical work was carried out on all faster than using a small percussion fleet.
boreholes drilled in 13 villages. This included c) A new government tender document that
investigations up to level three including 69 specifies low yield drilling for handpump
electrical resistivity depth soundings and 28 mounted boreholes is an enlightened
fixed depth profiles. The total cost for this attempt to reduce drilling costs.
work was USD 23,000. The cost/site was
USD 500. The success rate was low, (59%) d) Above all, the 3 case histories show that,
but the area is known to be difficult. while an improved mechanical approach
to drilling can reduce costs dramatically,
Community responsibilities included clearing the non-technical, human aspect is
access roads for the drilling rig, forming a crucial if costs are to be lowered.
maintenance group to receive training in Competent supervision and management
handpump maintenance and repair and of individual drills as well as the drilling
accepting responsibility for the full cost of fleet itself together with forward planning
purchasing spares and hiring a local of the drilling programme are essential.
mechanic to effect repairs. Training and more training is imperative.
Drilling was carried out in accordance with
the new (1996) Government of Mozambique
tender document. This document specifies 6.2 Case histories from Zimbabwe
several of the ideas discussed in this booklet;
namely drilling to continue until a yield of 1- 6.2.1 Manual drilling in Zimbabwe
3
1.5m /hr is obtained and then an extra 10m One of the new types of hand drill, which has
be drilled, PVC screen and casing to be performed successfully in several African
used, only a rudimentary pump test to be countries, the Wonder Rig, costing USD 600,
carried out, and strict and thorough was invented and produced in Zimbabwe.
supervision of drilling and sample collection Ironically, it has found more favour and
to take place. success outside Zimbabwe than within.
Observations It was first manufactured in Zimbabwe in
Despite a new and sensible Government 1982 and the Government, particularly the
tender document, costs were relatively high. Ministry of Health, bought several units.
Drilling and transportation difficulties, the Several hundred holes were drilled in the
high drill mobilisation costs, the broad range early eighties in soft, decomposed granite
of the project, which included long training with exceptionally shallow water levels, ideal
times for the community on handpump conditions for the drill. Drilling was usually
maintenance, all contributed to outlay. stopped 1m after striking water, average
45
Drilling Boreholes for Handpumps
46
Drilling Boreholes for Handpumps
from steel casing by flame cutting 2-3mm c) Private sector drilling operations.
wide vertical slots. The resulting screens are The private drilling industry in Zimbabwe is
primitive, with a low percentage opening (1- vigorous, innovative and successful,
2%). In terms of hydraulic design they are illustrating perhaps more clearly than
futile. PVC casing and screens manufactured anywhere else in Africa, the benefits of
in Zimbabwe cost USD 7/m and USD 8/m competition.
respectively, a relatively low cost. The
antipathy of the Zimbabwe drilling industry
(surprisingly not only Government drillers but
In Zimbabwe, perhaps more than
also the private drillers) towards PVC is
anywhere else in Africa, the benefits of
difficult to rationalise.
a competitive environment are most
clearly illustrated.
The antipathy of the Zimbabwe drilling
industry towards PVC is difficult to
rationalize Typical costing from a private driller in
Zimbabwe is as follows (March 1998):
Geophysics is routine, although mostly it
comprises only a desk study, some aerial Drilling (0-100m) USD 13/m
photo interpretation and examination of the Casing, steel USD 20/m
records of previously drilled boreholes in the
area, all appropriate and sensible minimal Screen (steel with flame slots) USD 24/m
cost measures. Mobilisation USD 60
b). Countrywide groundwater data base- Pump test (cable tool) USD 65
record keeping.
GOZ has recognised the advantages of Thus, for a 50m hole, in hard rock (open hole
meticulous and rigorous efforts to collect and with overburden casing) the cost is
collate data from all boreholes drilled in the approximately USD 800-900. The current
country. By law every borehole drilled must practice, as with Government drills, is that all
have a borehole completion form in which holes are now commenced at 200mm
data such as location, rock type, depth, yield, through the regolith reducing to 150mm after
water first struck, static water level etc. are a few metres.
recorded and the form is sent to the Ministry
of Water Development, Groundwater Geophysics is not routine, the ‘experienced
Section; giving the government a record of eye’ often does the job, although in areas
every borehole drilled in the country. The where the rainfall is less than 600mm/annum
data from the completion form is transferred some drilling contractors consider scientific
into the standard groundwater data base siting essential. They use electrical-
programme providing invaluable information electromagnetic- geomagnetic-techniques.
about the occurrence and disposition of The siting is not systematic; readings are
groundwater in all areas of Zimbabwe. This taken on sites that ‘look promising’ for the
is a powerful tool for planning future contractor. Such soundings are looked upon
groundwater development in specific areas. as ‘essentially confirmatory in nature’ - an
It also plays an important role in the ever- eminently debatable point!
present ‘battle’ in Zimbabwe between political During drought years in Zimbabwe, the
influences and technological wisdom based competition becomes even more acute with
on rigorous long-term data. an influx of South African drilling teams - an
influx understandably resented by the local
industry.
The private drilling companies the author
The groundwater data base built up over interviewed confirmed the strong political
two decades in Zimbabwe is crucial to a involvement in technical aspects of drilling for
better understanding of the occurrence water. More experience with optimal depth of
and disposition of underground water in
all areas of Zimbabwe.
47
Drilling Boreholes for Handpumps
drilling in drought prone areas and careful Geophysics carried out on an ad-hoc basis,
measurements of regional water levels will, principally electrical resistivity, cost USD
hopefully in the not too distant future, 300/site. DWA staff was mostly responsible
weaken the hold of the political catchphrase - for surveying. In hard rock areas the policy
’drill as deep as possible...’! was to leave the hole uncased except for the
In post independence Zimbabwe there is upper few metres.
considerable sophistication, knowledge and
much data available to the drilling industry;
good use has been made of the available
resources thus far - but there is still much to
learn. Borehole prices are relatively low, but
optimal drilling depths, diameters, design,
failure rates, optimal rigs, etc., require further
study and experimentation.
48
Drilling Boreholes for Handpumps
49
Drilling Boreholes for Handpumps
Table 6.
Relative use of geophysics and water divining for site location.
Driller Water points Number of sites selected using:
Nos. Geophysics Divining
Coratom 80 0 80
Foradex 20 0 20
Zarus 70 70 0
Aquanova 145 145 0
Desons 15 15 0
Total 330 230 100
(70%) (30%)
(Data: From UNICEF assisted programme in 10 districts in Southern and Eastern Provinces).
It is interesting to note that 30% of all the mounted boreholes.
sites were divined by traditional methods, e) the philosophy of drilling specifically for
now commonly used by drillers in Zambia. low yielding boreholes rather than a
The success rate for either technique is not potential future upgraded level of
known. Although, in hard rock areas where service is accepted in Zambia. The fact
the decomposed mantle is thin, geophysics that, globally, only about 0.1% of
is generally considered important. handpump mounted boreholes are
Drilling quality is internally controlled by eventually converted to motorised
interaction between the client (e.g. aid higher yield pumping holes underlines
agency), the community and the contractor. the appropriateness of this precept.
Frequent meetings are necessary and the f) Geophysics success rates are poor.
importance of careful and thorough work is Traditional divining (which probably has
stressed. The community, too, has a a high component of the ‘experienced
‘supervisory’ role, whereby they keep an eye eye and throw the hat’ has proved
on depth of drilling, type of casing inserted successful.
and so on in a long-term participatory
g) Most important of all; the cost per
process that they themselves evaluate.
borehole has decreased by almost a
The Results: The results of the low cost factor 2, from USD 5,000 in 1994 to
drilling endeavour appear promising; the data USD 2,800 in December 1997. (See
from the recently drilled 330 boreholes figure 20). These figures apply to the
indicate: GOZ/UNICEF assisted programme.
a) Average depth of drilling has
decreased from 60m to 44 m, and
average casing used is 33 m and 25 m
of screen.
3
b) Mean yield is 1m /hr,
c) the number of boreholes now being
drilled has increased dramatically to
400/year, 330 in 1997 by UNICEF
alone.
d) The drilling tender document which
evolved as a result of the UNICEF
WASHE program is now the standard
document for drilling handpump
Figure 20. Cost reduction of borehole drilling in
50
Drilling Boreholes for Handpumps
Zambia.
51
Drilling Boreholes for Handpumps
Table 7.
APPROXIMATE COST ESTIMATES FOR VARIOUS PUMPING SYSTEMS
Table 8:
High Capacity Borehole (<3m3/hr) Quantity Unit Unit Price USD Amount USD
Drilling (average depth 70m) 70 metres 23.00 1,610.00
Additional cost of failure (success rate 966.00
40%)
Casing 150mm ID/SABS 62, supplied 70 metres 23.00 1,610.00
installed
Cleaning & development 1 per BH 580.00 580.00
Base plates and cover plates 1 each 114.00 114.00
Pump testing (48 hours) 48 Hours 33.00 1,584.00
contingencies @ 15% 1,020.00
TOTAL COST FOR DRILLING ACTIVITIES 7,484.00
52
Drilling Boreholes for Handpumps
The geology of Lesotho is essentially hard experienced eye’) over another. Methodical
rock and therefore the cost per borehole is data collection of success related to location
not unreasonable in the context of Africa (for technique over a period of years could
the handpump borehole approx. USD 3,000, provide a comparison.
April 1998). The most significant saving to be
sought is in lowering the failure rate of
Relatively deep water levels and
drilling. But significant savings could be
3 handpump unreliability at such depths
considered for the 1m /hr borehole - if hard
are the factors behind the Lesotho
rock, reduce diameter; the pump test of 6
Government’s change of strategy.
hours is too long, and development and
cleaning costs appear very high. A possible
cost reduction of 50% is not unreasonable.
For the high capacity holes the extensive The dramatic new approach taken by the
pump test and development costs are Government of Lesotho in the rural water
justified. sector will provide an important observation
opportunity for the sector in other countries.
The statistical data on borehole success Rigorous records should be kept of costs in
rates was essentially anecdotal and the all aspects of the programme, rates of
author saw no actual data during his visit. progress, consistency and reliability of water
The main question is to reduce the drilling supply etc. If there are lessons to be learned
failure rate. Thus far it has not been possible from the non-handpump, high yield approach
to demonstrate in Lesotho the superiority of the sector will have ample data that can be
any one of the location techniques used in other areas where water levels are
(geophysics, traditional divining or ‘the too deep for today’s handpumps.
53
Drilling Boreholes for Handpumps
Drilling costs in India are much lower than in general terms, the rocks in India, mostly
Africa. In this text the UNDP/ World Bank basalt, are harder than those in Africa,
study is taken as the definitive costing for which are mostly granite/gneiss.
African boreholes. The large regional 2. Drilling contractors in a sovereign region
differences in costs are averaged out and an as large as India are not constrained by
approximate figure for drilling in Africa is borders and customs regulations. To
accepted as USD 100/m. An approximate illustrate the difficulties involved with
figure for India ranges between USD 4-6/m cross border and customs regulations
(although according to UNICEF there are consider here the attempt by
examples in India where drillers are drilling Mozambique (1994) to establish an
for USD 3/m). These figures apply to hard experimental regional co-operation
rock holes, which are left open (no casing or structure in order to reduce handpump
screens except a few metres of casing manufacturing costs. Focusing on the
holding the overburden). So, using the strengths of each country (a steel factory
figures above we have a factor 20 differential in Mozambique, rubber in Malawi, PVC in
in costs. There are, however, pitfalls in Zimbabwe) to the mutual advantage of
approximating drilling costs and making the countries involved should have been
comparisons based on such figures. Clearly economically advantageous for regional
such an attempt cannot be more than a handpump manufacturing. Unfortunately
rough comparison given the differences in such was not the case. Political
geology and hence rock hardness, depth, jealousies and customs bureaucracy
diameter, use of casing, etc., but torpedoed the attempt and handpump
nevertheless the significant cost differential costs continue to be relatively high. This
between holes drilled in Africa and those in same lack of mutual co-operation affects
India requires analysis and discussion. drilling costs in Africa. In India drillers can
Some of the factors that help to explain the traverse the length and breadth of the
drilling cost differential are as follows: country ‘without let or hindrance’.
Conversely, in Africa the large number of
1. India has a well established, borders within the continent means that
competitiveness private drilling industry commercial drillers willing to drill in other
and most importantly, economies of African countries have to pay large sums
scale. There are several million in taxes and customs guarantees, thus
boreholes in India and such large limiting competition.
numbers foster lower costs. Productivity
is high, for example, a drill rig with an 3. The long established road and rail
output of 150 boreholes of 60m mean infrastructure in heavily populated India is
borehole depth per annum drilled over a superior to that in Africa. Where still large
period of 10 years (many of the rigs in areas are sparsely populated.
India are still drilling efficiently after 15 4. The industrial infrastructure in India is
years) 90,000 metres. The amortised MUCH larger and better developed than
capital investment costs are very low per that in Africa. India has the capacity to
metre. manufacture drilling rigs and this
To further emphasise the competitive capability has allowed the Government,
nature of drilling in India; in the summer it working together with UNICEF, to evolve
is not unusual for drilling to take place over the past several decades the ‘ideal’
overnight so that in a 24 hour period 2-3 drill design. Because large numbers are
boreholes can be drilled with a DTH rig. produced costs are relatively low. In
Africa all drills are imported with
In addition, a rather surprising aspect of concomitant high capital costs, with the
the low drilling costs in India is that, in exception of South Africa where a
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Drilling Boreholes for Handpumps
fledging drill manufacturing industry does lined) enables dramatic cost reductions to
exist. be made. Although some countries in
The immense scale of the rural water Africa have local manufacturing capacity
supply programme in India has forged a (viz. South Africa and Zimbabwe), even
close relationship between the Indian so prices are higher than in India. In
government and UNICEF during the past future, however, the relatively large
3 decades. They were jointly responsible industrial and manufacturing capacity of
for the considerable experimentation and South Africa, if utilised by other African
innovation with types and sizes of drilling countries, may lower prices.
rigs, which has led to the development of 8. Unlike Africa, India has numerous
the near ideal rig for India. This evolution practical, hands on, training institutions -
of the ‘ideal’ drill in India means that an invaluable asset.
since the mid-eighties there has been a So, what are the lessons for Africa from the
balance reached between drill capital and brief Africa/India comparison above? Clearly
running cost and performance; the drill the economy of scale factor in India is
rigs are neither too fragile nor of unlikely to be duplicated in Africa. The issue
excessively large capacity. of competition is, however, something
The impact on costs of the important already being swiftly assimilated in Africa.
aspect of drill reliability deserves Additionally in Africa there is a general move
discussion. Because, in general, the drill to scale down the size of drilling rigs and, in
rigs in India have now the ideal the case of South Africa, there is even an
specifications, new rigs enjoy high attempt to manufacture drills in-country.
reliability. But even with very old and less Customs and cross-border bureaucracy will
reliable drill rigs, low cost drilling in India hopefully improve in an era of greater
is still possible. A contractor in Karnataka regional co-operation. Better transport
is presently drilling with old equipment for infrastructure is not only dependent upon a
USD 3/metre. Whilst reliability is low, greater allocation of resources but also on
such is the infrastructure in India that the co-operation between countries.
contractor can get the required spares in Standardisation of rail gauges would facilitate
the local market and with frequent rapid transport from country to country and take
repairs can still make a profit, albeit a pressure off roads, but peace and stability in
slim one! the region are paramount if these
5. Paragraphs 3 and 4 indicate that improvements are to take place. Training is
logistical support in India is much further an area where Africa can learn a lot from
advanced than in Africa. India and more hands-on training facilities for
6. As a result, sophisticated rigs drillers are an urgent requirement. It is
(rotary/DHT) can operate cost effectively critical, too, that such institutions fully
and are routinely used, resulting in rapid recognise the importance of cost reduction
drilling rates (especially in hard rock), and increased drilling rates and that some of
which in turn translate into lower drilling the other elements discussed in this text
costs. form part of the training courses. The formal
drilling curricula seen by the author in an
7. Casing and screens are imported in Australian drilling school focus on large yield
Africa (often from Europe) and are holes only and are patently unsuitable for the
therefore expensive. Local manufacture ubiquitous low yield handpump mounted
in India plus large volume local borehole found in Africa.
production of casing and screens (even
though most boreholes are only minimally
55
Drilling Boreholes for Handpumps
Appendix 1 Glossary/terminology
Terminology is not standardised globally, and some confusion exists as a result of differing
nomenclature in British and American texts.
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Drilling Boreholes for Handpumps
REFERENCES
Arlosoroff S., Tschannerl G., Grey D., Journey W., Karp A., Langenegger O., and Roche R.,
(1987), Community Water Supply - The Handpump Option, The World Bank, Washington, D.C.,
USA
Considered the ‘bible’ of the sector, bristles with original ideas, well illustrated and succinctly
written.
Beale, G., Water Management Consultants (1990), Development of the Drilling Industry in Nigeria
- An Overview, (unpublished), quoted by de Rooy (1992)
Blankwaardt, Bob (1984), Hand Drilled Wells - A Manual on Siting, Design, Construction and
Maintenance, Rwegarulila Water Resources Institute, Dar es Salaam, Tanzania (contact TOOL
Foundation, Amsterdam)
A detailed hands-on text on this topic, full of outstanding diagrams and photographs.
Chauvin J., Plopper S. and Malina A., (1992), Final Evaluation of the Benin Rural Water Supply
and Sanitation Project, WASH Field Report No. 349, Water and Sanitation for Health Project
(WASH), USAID, Washington, D.C., USA.
Chilton P.J. and Smith-Carrington A.K. (1984) Characteristics of the Weathered Basement Aquifer
in Malawi in Relation to Rural Water Supply. In Challenges in African Hydrology and Water
Resources, Ed. Walling D.E et al. IAHS Publ. 144. U.K. An admirable discussion on low cost
boreholes in Malawi.
Clark L. (1988) The Field Guide to Water Wells and Boreholes. Open University Press. UK. A
concise, excellent text, some technical knowledge assumed.
DHV (1985), Low Cost Water Supply - For Human consumption, cattle watering, mall scale
irrigation, Part 1: Survey and Construction of Wells, DHV Consulting Engineers, Amersfoort, The
Netherlands.
Feachem, Richard, et al. (1978). Water, Health and Development. Tri-Med Books Ltd. London.
The first interdisciplinary evaluation in the sector; historically important.
Foster S.S.D (1984). African Groundwater Development-The Challenges for Hydrogeological
Science. In Challenges in African Hydrology and Water Resources, Ed. Walling D.E et al. IAHS
Publ. 144. U.K.
Franceys R.W.A. (1987), Handpumps - Technical brief No. 13, Waterlines, Vol. 6, No. 1
Intermediate Technology Publications, London, UK., pages 15 - 18, (also in ITP (1991).
Lefort L, and Marchal J (?), Les Forages a Faibles Couts.- Research Technology Group, Paris.
The non-French speaker will not be disadvantaged because the text is in French because the
diagrams are so outstanding, numerous and easily understood that the text is of secondary import.
Laver, Sue, (1987), Well Sinking - a step by step guide to the construction of wells using the
blasting method, UNICEF, Harare, Zimbabwe. The illustrations are remarkably easy to understand.
Lewis, Clark, (1988), The Field Guide to Water Wells and Boreholes. Open University Press, UK.
A comprehensive but succinct text addressed to practicing geologists and engineers responsible
for designing and implementing drilling projects.
Meinzer, Oscar, (1946) Hydrology. U.S. Geological Survey, USA.
An early classic-good on the history of hydrology and water suplies.
Morgan, Peter, (1989), Upgraded Well Manual for Field Workers, Blair Research Laboratory and
Ministry of Health, Zimbabwe.
Morgan, Peter, (1990), Rural Water Supplies and Sanitation, Macmillan, London, UK. A classic, by
one of the pre-eminent workers in the sector.
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Drilling Boreholes for Handpumps
58