Then I found out, that some of these well were drilled 60 meters deep in areas where the water table was 1 meter below the surface during the dry season. Why drill 60 meters? Well (no pun intended) that was the standard.
I don’t know about you, but I was raised in a house where the well was 30 ft (10 meters) deep and we have always had plenty of water. I still own a house were the well is 50 feet deep and the original owner drove that well himself in 1949. So, why not something like this in Zambia?
After investigating the options and prices, I bought and packed up a well point - $30, a pitcher pump - $40, some drive couplings - $6 each and a driving cap - $5. When I looked at pipe and considered the challenge of transport to Africa by suitcase, I punted and said, let me buy it there. However, in consultations I was warned that the pipe from Asia was too soft or brittle to take the driving. Point noted for the future.

So, after a small hassle from Mozambique customs agents who wanted a “tax” to take the pump and point out of the country, I arrived in Lusaka, Zambia to buy pipe. Fortunately, I had a contact who knew the businesses to buy from. We went together and bought a 20 ft piece of pipe that then needed to be cut and threaded on the newly cut ends. When in conversation with the shopkeeper where I bought the pipe, I asked him why he did not offer a cutting and threading service. He said, so he can sell more machines. As we discussed the project, he said he had never had a big enough order to run out of pipe and if he could supply me the projected number of pipe he could retire. Fat chance, I thought.
Then we went off to find another business to cut and thread the pipe. We found one in the market. Yes, the same market that sells hot food, soap, cell time, shoes, nuts and bolts, etc. So, right there between the hot sausage vendor (grill and all) and the used nuts and bolts seller, we squatted in the shade for more than an hour while two guys wrestled with my now three pieces to thread 4 ends, twice because the first cut didn’t take enough metal off to fit the couplings.
There was a steady flow of people and ambulatory vendors walking by. Cold drinks, snacks, bread and sliced watermelon wrapped in plastic in a basket carried on the head were part of the view.
After the pipes were threaded, (for about $1 each thread) I wrapped the newly cut ends in whatever plastic and paper I could find and took them to the bus station. "Mongu," I said and into the belly of the bus they went, along with the pump and point. During my 8 hour trip, I had time to reflect on the shopkeeper’s offer. Maybe I should help the local economy a little more.
After arrival in Mongu, I began the task of collecting the tools we needed to put in a well. One 10 pound sledge hammer, two large pipe wrenches, a level, one shovel, an elevated stand (previously used for spraying tall cashew trees), bleach and a camera. Wiggan (the Zambian director) found me a helper and off we went to our irrigation project site in Mawawa to install the well and pump. We had visited the previous Saturday and found people dipping water for personal use out of a 2 foot deep hole/ground well. This way we reasoned, there would be clean water for drinking, washing and mixing any spray materials. (Just don’t dump the chemicals on the ground around the pump!)

After attaching the well point to an 8 foot piece of pipe, we drove the first section easily. Some of the individual blows sent the pipe down 1 inch. When we went to attach the second piece of pipe, we took off the factory installed plastic cover and found a seriously dented pipe end. Those Asians! What to do? We decided to put on a lot of sealing tape and thread it in past the dented part and give it a try. This would be fine as long as it stayed intact, right?
After driving it down about 2 feet, I noticed a wobble coming from the coupling area. We tightened the pipe a little more. Just a few more blows and it happened again. The coupling was already below ground level in the hole. We retightened with the same loosening/heart sinking result. Something was desperately wrong down there!! Three of us pulled it up to where we could access the coupling and took the pipe off, and sure enough the pipe had broken at in the middle of the threaded area. You can’t say I wasn’t warned about cheap pipe! The only option to even consider, was return to Mongu and find someone to rethread it.
So, we found Norad a local well drilling company. They rethreaded the damaged end, and I rechecked the other factory end. It looked ok. The thread die produced a pretty flat thread, so we had to cut it pretty deep to accept our coupling. No matter, as long as we had new threads to work with, I could try again. Back to the field we went.
One end of the 8 foot pipe didn’t want to thread into the coupling at the well site. No problem, the solution would be to turn the pipe over and put the drive cap on that end. So we started driving the well again. After putting it down about 4 feet, the pipe was no longer tight below ground. I didn’t even want to risk it, so we pulled it up and sure enough the threads were damaged, plus the driving cap had slipped its threads and was now crossed threaded on the other end. There were two threads to repair now. Back to town we went.
The shop manager looked at the broken parts and said, “They did not do a good enough job last time, let me call them and have them do it over.” They did, and I made sure we had some taper this time. When I left, I promised not to trouble them again because if these threads did not hold up, I did not want to try their device again. Back to the field we went.
To spare you the details, we tried to drive both an 8 foot and 4 foot piece of pipe with the same result, broken or damaged threads on both ends of the pipes. We left the well point and 8 foot piece of pipe in the ground and retreated to fight another day. What to do now? Is there even another pipe threader in town?
That same afternoon, someone appeared in the office who has been contracted to put in some more $5,000 wells. Was this help from above? He said that he could help me and called for a pipe threading tool to be put on the truck from Lusaka. It arrived the next day, but after three hours work, they only had fixed two of the three bad threads properly. What kind of help is this? They promised, “We will bring it back in the morning after one hour.” The morning came and went with no pipe. Then I started wondering, will I be able to complete the project? We tried calling, no answer. About 12:30 there is a knock on the door and there is the guy. Wiggan asks him, "Where is Steve’s pipe?" "Oh, my guys were to bring it. Hasn’t it come yet?" It arrives in 15 minutes. Maybe it will happen yet before I leave town at 11 p.m. (He was kind enough not to charge me.)
We went back to the field at 4 p.m. and I told Wiggan, "No matter what happens, this won’t take long. Either we will be successful or we won’t." Ha. When we arrived, we collected a crowd pretty quickly. The pipe threaded in to the coupling in the ground ok, but the drive cap did not thread on well. Hmm? I did not want to take the chance of damaging the top threads again. The solution was to find a chunk of wood that we could use to replace the cap. A board was located and we bashed it up pretty bad, but it did the trick. Hurray!

Attaching the pump was a little tricky as the threaded opening seemed slightly smaller than our pipe end, but we got it done. Priming the pump was the next step. It would not pull a vacuum. Ouch! What was going on? Upon examination, it looked like the factory installed gasket was bulging on one side and even leaking water. Now for an open end wrench, which of course I did not bring. But somebody had one! Wow. We repositioned the gasket and started pumping. It drew a vacuum, but once the air bubbles stopped coming that was it. No flowing water. We had skipped one important step because I did not have the wherewithal to do it. That was surging and cleaning the screen, now twenty feet down. You are supposed to put down a plunger or a running hose to flush the system. I had neither.
I guess it is time to call Iowa for tech support. I left the pump in place with some brief instructions for the technical guy and went back to the office.

Later that night I called the WaterSource company in Iowa using Skype. Yes, they confirmed, we need to flush it. After reviewing the options, we both had some new ideas and I realized we could use the canal water and a couple of hoses to link to the big irrigation pump for our pressure water source this time. Once we get it flushed, we will have to bleach it to kill all the bacteria and then pump it awhile to flush the bleach. I left some clear instructions for the staff in Zamia to complete the task and got on the bus for Lusaka. I hope to hear someday soon.





















