Fabrication & Performance Testing1

Fabrication Performance Testing of Household Solar Water Heater
1. INTRODUCTION
Man has needed and used energy at an increasing rate for his
substance i.e. he can use either conventional energy or unconventional energy but
most of time all over the world human beginning use unconventional energy.
Unconventional energy sources are limited so after few years man will be facing
for them to avoid this problem in some quantity used to fulfill its need
unconventional source of energy for domestic purpose. Such as solar energy is the
best and economically less for used. Solar energy used in various manners in daily
life such as water heating, cooking to produce electricity etc.
Due to rapid growth of industrialization man need more and more
energy due to this government does not supply proper electricity to human being
some problems are created such as daily load shading. To avoid this problem the
best way to heating water by solar energy.
Solar energy are freely all over the world. It utilized in various
manner but domestic water heating is the less economic an easy way to utilized
solar energy to help the environment.
Govt. Poly., Washim 1

UTILIZATION OF SOLAR ENERGY DIRECTLY INTO HEATING
WATER :-
A solar water heater commonly comprises a blackened Flat plate
metal collector with associated metal tubing. Facing the general direction of sun.
The collector is provided with transparent glass cover and a layer of thermal
insulation beneath the plate. The collector tubing is connected by a pipe to an
insulated tank that store hot water during non-sunny periods. The collector
absorbs solar radiation and by transfer of resulting heat to the water circulating
through the tubing by natural circulation (temperature different) or by gravity.
Performance of the Focusing collector depends upon the selective
coating on the absorber plate.
Solar still can produce 3 to 5 liters of distilled water per square
meter on an average sunny day. The solar distillation technology to convert
brackish water into potable water is simple and small solar stills can be fabricated
locally in rural areas.
Solar energy is very UN-exhausted source of energy. The power
from the sun intercepted by the earth is approximately 1.8 x 10” MW which is
many thousand of time longer than the present consumption rate on the earth of all
commercial energy sources. Thus in principle solar energy could supply all the
present and future energy needs of the entire world on a continuing basis. This
makes it on of the most promising of the unconventional energy sources.

In addition to its size solar energy has two other factors in its favor.
Firstly unlikely fossils fuels and nuclear power it is an environmentally clean
source of energy is secondly it is free and available in adequate quantities in all
most all part of the world where people alive. However there are many problem
associated with its use. The main problem is that it is dilute source energy even in
the hottest region of earth solar radiation fuel available rarely exceeds 1 KW/MZ
which is low value for technological utilization consequently large collecting areas
are required in many application and these results excessive cost.
A second problem associated with the use of solar energy is that its
availability various widely with time. The variation in the availability occurs daily
because of the day eight cycle also seasonally because of the earth’s orbit around
the sun in addition variation occurs at a specific location because of local weather
condition consequently the energy collected when the sun is shining must be
stored for use during periods when it is not available. The need for storage also
adds significantly to the cost of any system. Thus the real alternative is of an
economic nature. One has to strive for the development of cheaper methods of
collections and storage so that the large initial investment read at present in most
application are reduced.

SOLAR ENERGY SITUATION IN INDIA: -
The solar liquid heater was invented by H. B. source during the
second half of 17th century. Hersehel and Tellier also experimented with solar
water heater in 1837 and 1885 respectively. Even in earlier times the indigenous
people in Africa, the Arab countries the China and India used their ingenuity in
heating water by placing specially shaped copper pot filled with water in the sun
during the time in winter. Now a day it is economical to use solar water heater for
domestic application. As such they are used all over the world.
Approximate quantity of solar energy falling on India is 3000
million Kwh/year which is 3000 times energy consumed by to day and 200 times
energy required in 2000 A. D. These are between 250 to 300 days of useful
sunshine per year in most part of the country over 3000 his of bright sunshine per
year in most part of the country over Rajasthan, Gujarat, West M. P. & North
Maharashtra 2600 to 2800 hrs over rest of the country except Kerala. Asam and
J & K where there are acceptable lower.
Systematic efforts to harness solar energy where initiated in India in
year 1950 with emphasis on low grade thermal processor all the recording
instruments are now available in India.

2. WORKING PRINCIPLE OF SOLAR WATER
HEATER WITH PARABOLIC COLLECTOR.
The sun is a huge and unlimited source of heat and light energy.
Now a days we are using coal, natural gas, wood as a source of energy but this are
limited and polluted one.
Therefore for reducing pollution and taking the use of solar energy
which is available free of cost. The solar water heater is used.
The rays from the sun falls on the aluminum sheet through
transparent glass. The sheet is in parabolic shape, it absorb the maximum amount
of treat from rays to increase efficiency.
The solar rays are absorbed by the absorbing tube, which is fitted on
the concentrator. The absorber tube is painted by black paint due to black paint
maximum amount of solar rays are absorbed by absorbing tube. The reason for
giving the black paint to tube is to absorb whole rays by the black body principle.
“Black body absorb all the incident rays. Falling on it”. So to increase the
absorbivity of tube it is painted with the black paint.
The absorbing tube is cover with transparent glass, which is fitted on
parabolic collector. The function of transparent cover is to reduce the loss of
energy by convection and radiation. It helps to increase the efficiency of plant.

The tracking is also given to the collector to increases the efficiency.
In tracking the collector is fitted on MS. Angle frame structure and the tracking
unit of gear is connected to it with the help of handle the tracking is given to
collector according to sun position due to which maximum energy is gets absorb
by the absorbing tube. The solar energy of sun gets converted into heat energy.
Therefore, the temperature of the fluid passing through the tube is
get heated the fluid is water.
The circulation of water from storage tank to tube is done with the
help of thermo siphon system natural circulation of waters. In this system, the
Flow of water takes place with the help of gravity. In thermo-syphon system to
maintain the flow of hot water, storage tank has to be placed as a higher level
usually above focusing point to concentrator.
In this system cold water first enters into the tube from storage tank
through flexible pipe and gets heated in the absorbing tube due to solar energy.
Due to which density of water is decreased so water rises automatically and it is
collected at upper side into storage tank through pipe. The circulation is caused
due to density difference. The cold water pushes the hot water and takes place of
hot water in absorbing tube.
This process goes on and whole water is heated and collected in
storage tank.

3. LITERATURE REVIEW OF SOLAR ENERGY
VARIOUS APPLICATION OF SOLAR ENERGY
As we seen solar energy option is one of the most promising
alternative energy source of the future.
The solar energy can be used for two basic purposes are as,
(1) Heating
(2) Cooling
Following are the application of solar energy option in relation of
heating or cooling.
(1) Power Generation.
(2) Solar heating and cooling of the building.
(3) Photovoltaic power generation.
(4) Solar space power system
(5) Solar pump.
(6) Solar Refrigeration.
1. Solar Power Generation
The generation of electrical or mechanical power is one of the most
important applications of solar energy source. Solar energy can be converted the
thermal energy by flat plate or focusing collectors. That thermal energy can then,
in principle used drive a heat engine, thus converting solar energy into mechanical

energy, solar thermal power angles can be broadly classified as low medium and
high temperature cycles, low temperature cycle generally used flat plate collector
so that maximum temperature are limited to about 1000 C medium temperature
cycles work at maximum temperature cycles work at maximum temperature
ranging from 1500 C to 3000 C.
For the low and medium temperature ranges the thermodynamic
cycle preferred is the ranging cycle. For the high temperature range, apart from
rankine cycle the bryton and the starting cycle are also been considered.
2. Solar Heating & Cooling of the Building: -
Once of the promising thermal applications of solar energy is for the
purpose of heating and cooling the space. Space cooling and heating may be done
with the objective or providing comfortable living conditions.
Water is heated is solar collectors and started in the tank. Energy is
transferred to the circulating in the house by means of the water to air heat
exchanger. Two pumps provide forced circulation between the collectors and the
tank and between the tank and heat exchanger. The heat is stored in a tank packed
with rock, graver or pebbles, this method is called active method. Another method
is passive method in which the thermal energy flows through a living space by
means without the help of a mechanical device like a pump or shower.
The use of solar energy for cooling can be either to provide
refrigeration for food preservation or to provide comfort cooling. The two

principle methods are refrigeration evaporating cooling. The evaporate of
perspiration from the skin is on of the msm. Which our bodies use to remain cool.
Evaporate cooling occurs when water vaporized. Evaporative cooling for
buildings work heat in dry climate.
3. Photo Voltaic Power Generation
One way of utilization the energy of the sun is to generate electricity
directly from the sum sight by the photovoltaic process. The photovoltaic effect is
defined as the generation of a electromotive force as a result of absorption of
ionization radiation. Solar cells are used to convert sunlight into electricity. By
this process electricity costs of Rs. 8 to 15 Kwatt per hour. Another disadvantages
is that solar coil output is not constant and varies with the time of day and weather.
The costs can be reduced by
(1) Reducing the cost of manufacturing the solar single crystal silicon cells.
(2) Developing the high efficiency cells which can be installed at the focus of
magnifying optical system. If this goals are achieved it is estimated that
20000 MW of solar cell power will be available.
(4) Solar Distillations: -
In many small communities the natural supply of fresh water is
inadequate but brackish or saline water is available. Solar distillation can prove to
be an effective way of supplying drinking water in such communities. Solar stills
are used for distillation of water.

(5) Solar Refrigeration: -
Space cooling may be done with the objective or providing
comfortable living conditions or to keeping a food product cool. There are two
types of refrigeration.
(1) Vaporizers compression system.
(2) Vapour absorption system.
APPLICATION OF SOLAR WATER HEATER
(1) In domestic sector hot water is used for bathing water may many with season
of year and no. of finally members or an average 20 lit. of hot water also
declension is consumed by and individual. Thus for family of 5 members 100
LPD solar water heating system is sufficient.
(2) In commercial and industrial sectors where large quantity of water is required
at high tank is degcelcius the solar water heating system with flat plate collectors
having selective cooling on absorbers are used. Depending upon the requirement
either the hot water from the system could directly used.
(3) Organization like hotel, departmental stores hospitals, restaurants, hostels and
similar commercial and industrial sector can which over from using conventional
system to meet their hot requirement and saw the expenditure on energy and also
avoid pollution from fired boilers.

4. CONSTRUCTION
VARIOUS PARTS OF SOLAR WATER HEATER.
1) Parabolic concentrator: -
This is one of the main part of solar water heater, mainly it consist of
transparent glass attached to parabolic collector.
Aluminum sheet having thickness range from 0.5 mm to 1 mm and
glass having thickness 4 mm is used. For forming the collector.
This collector is covered a bottom from thermocoule sheet. It is
connected to support structure.
To give the traction to collector some suitable system is used.
2) Traction System: -
Tracking means to rotate or titling the collector through given angle.
For increasing the efficiency of concentrator. Due to tracking concentrator is
always in front of sun and so the maximum amount of ‘Sun rays’ are get collected
and hence collector work whole days.
In tracking system one gear is fixed on the shaft of concentrator,
which is fixed on the support structure by means of bearing for giving rotation.
And second parallel gear with it which is fixed on support structure handle is
provided to the shaft of this gear at end link with the help of handle and tracking is
provided to the concentrator in certain angle according to the sun position in a day.

3) Absorber tube: -
It is also an important part of the collector. The material used for the
absorber tube is aluminum because it has an absorption co-efficient 0.89 and
emission coefficient in long wave region of order 0.039 which is better than any
other material.
The weight of aluminum is also less than other material for stand
long on a structure. Coil shaped is provided to the absorber tube on concentrator
sheet so that water should remains more time in tube and gets heated at the end of
tube according to the capacity of water heater.
The absorber tube is painted with black paint, as the heat absorption
capacity of black colour is high. The absorber tube is located at upper side of
collector. The supports are provided to hold it from concentrator.
The function of tube is to receive the maximum amount of sunrays
and heat the water passing through it by converting solar energy into heat energy
by the law of conservation of energy.
4) Supporting Structure
It is made up of cast iron angles. It is used for holding and
supporting the collector and storage tank. It is also an arrangement of tracking on
collector holding structure. It is rigid enough to carry the load of collector and
component supported to it.

5) Storage tank –
The storage tank is used for storing the hot water. It is situated near
the collector assembly on a certain height. The capacity of storage tank is
approximately 35 liters. The material used for storage tank is P.V.C. The
insulation is provided around the tank is of cotton wool, thermocouple sheet, glass
and plywood.
In plant natural circulation of water is used. The natural circulation
is takes place due to gravity of density difference. For this purpose the storage
tank is provided with three holes. One for inlet of cold water from inlet tank to the
absorber tube second for hot water from absorber tube to again tank for circulation
purpose. Third for removing hot water for use. The flexible pipes are connected
between the inlet of tank to tube and between outlet of absorber tube to inlet of
tank. For circulation of hot water.
FABRICATION OF SOLAR WATER HEATER
Various parts of solar water heater are
1. Parabolic concentrator.
2. Absorber tubes.
3. Supporting stands and
4. Storage tank.

1. Parabolic concentrator -
Parabolic concentrator used for concentrating sunrays is made from
Aluminum sheet.
The size of sheet =
A sheet of this size is taken and is turn to a particular rim angle, with
the help of a bending machine.
To increase concentrating power a glass is fitted on parabolic
collector and backside of collector is made insulated with thermocol to interrupt
the flow of heat to atmosphere from backside.
2. Absorber tube
Absorber tube is used to receive sunrays from concentrator and heat
the water flowing through it.
Material used – Aluminum pipe.
Size of tube - length –
diameter –
A coil shape absorber tube of black color is fitted in concentrator.
Absorber tube of given size is bended in four loops with the help of bending
machine.

3. Supporting stands: -
In water heater assembly two stands are fabricated, one for storage
tank assembly and other for collector.
On collector assembly stand tracking arrangement to provide using
three standard plummers and pair of gears.
Material used – Mild steel bars of ‘L’ shape.
These angles of M. S. are cut and welded to give desired strength.
4. Storage tank
Storage tank is one of the important elements of this assembly; it is
specially designed to reduce heat loss.
Heat gained by water for whole day is retained for whole night with
merge heating in morning it can be used.
For this purpose, storage tank is made insulated with various
insulating materials like.
1st layer – Thermocole
2nd layer – Glass
3rd layer – Cotton wool
4th layer – Thermocole
5th layer – Plywood.
Two holes are provided for inlet and outlet of water to concentrator
also one outlet for hot water is provided specially.

5. TESTING AND ANALYSIS
Date 6/10/02 (Without insulated Tank)
Inlet Water Temperature: - 210C.
Sr. Time Rise in Atmosphere

No. Temperature 00C Temperature 0C
1. 8.80 260C 280C
2. 10.80 300C 250C
3. 12.80 400C 320C
4. 2.30 420C 320C
5. 4.30 400C 300C
Date 14/12/02 (Without insulated Tank)
Inlet Water Temperature: - 180C.


1. 9.30 320C 200C
2. 10.30 360C 240C
3. 11.80 440C 300C
4. 12.30 490C 320C
5. 1.30 420C 300C
6. 2.80 400C 300C
Date 15/2/03 (On insulated Tank)
Initial Temperature: - 260C.

1. 10.30 330C 290C
2. 11.90 360C 310C
3. 12.90 390C 320C
4. 1.30 410C 320C

5. 2.30 410C 320C
Date 16/2/03 ( On insulated Tank )
Initial Water Temperature :- 260C.

1. 9.00 310C 280C
2. 11.00 360C 340C
3. 1.00 400C 340C
4. 3.00 450C 320C
5. 5.00 450C 300C

Date 23/02/03 ( On insulated Tank )
Initial Water Temperature: - 250C.

1. 8.00 290C 230C
2. 10.00 340C 280C
3. 12.00 390C 320C
4. 2.00 430C 340C
5. 4.00 450C 330C

6. CONSTRUCTIONAL DETAILS OF INSULATED

CONTAINER
SR. MATERIAL THICKNESS THERMAL

NO. (mm) CONDUCTIVITY
1. Plastic container 4 mm 0.5 Kcal
2. Cotton wool 6 mm 0.5 Kcal
3. Thermocol 10 mm 0.27 to 0.29 Kcal
4. Glass 3 mm 0.35 to 0.43
5. Plywood 6 mm 0.5 Kcal
TO CHECK PERFORMANCE OF INSULATED TANK: -

OBSERVATION TABLE: -
DATE TIME TEMPERATURE
15/02/03 5 P.M. 440c
16/02/03 7.30 A.M. 330c
16/02/03 5 P.M. 480c
17/02/03 7.30 A.M. 370c
17/02/03 5 P.M. 460c

18/02/03 7.30 A. M. 370c
18/02/03 5 P.M. 490c
19/02/03 7.30 A.M. 380c
19/02/03 5 P.M. 490c
20/02/03 7.30 A.M. 390c
7. COST ESTIMATION
SR. PARTS NAME QTY SIZE COST

NO.
1. i) AL - Sheet 1 2.5 x 2.5 Feet. 180
ii) Transparent cover (glass) 1 67 x 37 inch 170
iii) Insulator (Thermocol) 2 20
2. Stands
i) Concentrator stand 1
ii) Storage tank stand 1
iii) Plummer block 3 Standard 255
iv) Gear 2 Standard 8.5 210
v) Nut bolts 6 mm 36
vi) Bearings 3 7.5 cm 210
Standard
3. Absorber tube
i) AL - Tube 1 11 Feet. 165
ii) Black coloc 1 50 ml. 15
iii) Colour 85
4. Storage tank 1
i) Plastic container 1 35 litres 90
ii) Insulators 3 332

(cotton wool, glass, Thermocol)

5. Flexible pipe 2 13 Feet 57
6. Shaft 1 3.5 Feet 63
7. Labor cost 180
Total Cost 2718
COMPARISION
We compare our project (Solar Water heater) with other existing
solar water heater following observation are conclude.
(1) Cost of our solar water heater is very less than other existing other solar
water heater, which is near about 5 to 6 thousand less.
(2) Other solar water heater having more cost as compare to our collector
which is not suitable for ordinary man.
(3) In our project we make insulated tank, which doesn’t losses the heat i.e.,
insulated tank keeps the temperature of water constant from evening to
next day morning.
(4) Our solar water heater is suitable for any family, which is in town, city, or
any village.
(5) Insulated tank like our tank is not available in market.

8. RESULT
In this way we take performance of household solar water heater.
Finally we can concluded that, our solar water heater is very suitable for ordinarily
family having 5 to 6 member. It does not occupy more space, stand on roof or
terres of the house also by using this water heater for heating water we save
electricity about per month for this electricity we spend electric bill near about
Rs.200 per month by using this we can help for saving national wealth. Cost of
our solar water heater is very low which is neglected in one year by using then
after we get free of cost hot water. In this heater water temperature goes up to
490C, which is suitable for sanitary purposes.
In this project we makes insulated tank which store not water for
long time and also this hot water we can use after 12 to 14 hours with very less
amount of heat loss.
Finally we says that this is very good source of unconventional
source of energy, which is need of to days world.

9. FUTURE MODIFICATION
1. Electroplating of solar collector.
2. Use of “HONEY – COMB” absorber tube.
3. Using Solar panels.
4. Using Number of transparent glass.
5. Using high standard insulator having low Thermal conductivity.

10. BIBLOGRAPHY
1. SOLAR ENERGY
S.P. SUKHATME
2. UNCONVENTIONAL SOURCES OF ENERGY.
G.D. RAI
3. SOLAR ENERGY
M. P. AGRAWAL
4. HEAT TRANSFER PRINCIPLE.
5. SOLAR POWER ENGINEERING
B. S. MAYAL

ACKNOWLEDGEMENT
The completion of our project on “FABRICATION &

PERFORMANCE TESTING OF HOUSEHOLD SOLAR
WATER HEATER” has given us immense pleasure, satisfaction and
knowledge.
Everybody is familiar with the saying that, “Ideas rule the
world”. Ideas provide us knowhow or techniques. Blind efforts and mere
mechanical toil can not deliver the goods.
Success is not merely a question of luck or genius. It depends on
hardwork, sustained toil and most important of all its guidance. Working under
the guidance of Prof. S.A. DHANKUTE, we learned to understand and
accept responsibilities. We were inspired to take reasonable work under his
guidance. We extend our deep sense of gratitude to him.
We are also thankful to our respective Prof. N. J. PANDE for his
valuable suggestion and guidance for the successful completion of this project
work.
Our foremost thanks to Principal Prof. F.A. KHAN who have
extended every facility to us for the completion of our project.
We are greatly thankful to all those who helped us directly or
indirectly in our project work..
Projectees ...
INDEX
Sr. No. Particulars Page No.

1 Introduction 1
2 Working Principle of Solar Water 5
Heater With Parabolic Collector

3 Literature Review of Solar Energy 7
4 Construction & Fabrication of Solar 11
Collector & Storage Tank

5 Testing Analysis 16
6 Constructional Details Of Insulated 21
Container
7 Cost Estimation 22
8 Result 24
9 Future Modification 25
10 Bibliography 26

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Fabrication Performance Testing of Household Solar Water Heater

life such as water heating, cooking to produce electricity etc.

Due to rapid growth of industrialization man need more and more

best way to heating water by solar energy.

solar energy to help the environment.

Govt. Poly., Washim 1

UTILIZATION OF SOLAR ENERGY DIRECTLY INTO HEATING

A solar water heater commonly comprises a blackened Flat plate

insulation beneath the plate. The collector tubing is connected by a pipe to an

through the tubing by natural circulation (temperature different) or by gravity.

Performance of the Focusing collector depends upon the selective

coating on the absorber plate.

Solar still can produce 3 to 5 liters of distilled water per square

meter on an average sunny day. The solar distillation technology to convert

locally in rural areas.

Solar energy is very UN-exhausted source of energy. The power

makes it on of the most promising of the unconventional energy sources.

Govt. Poly., Washim 2

Firstly unlikely fossils fuels and nuclear power it is an environmentally clean

source of energy is secondly it is free and available in adequate quantities in all

are required in many application and these results excessive cost.

application are reduced.

Govt. Poly., Washim 3

SOLAR ENERGY SITUATION IN INDIA: -

The solar liquid heater was invented by H. B. source during the

Approximate quantity of solar energy falling on India is 3000

J & K where there are acceptable lower.

Systematic efforts to harness solar energy where initiated in India in

instruments are now available in India.

Govt. Poly., Washim 4

2. WORKING PRINCIPLE OF SOLAR WATER

HEATER WITH PARABOLIC COLLECTOR.

limited and polluted one.

which is available free of cost. The solar water heater is used.

of treat from rays to increase efficiency.

absorbivity of tube it is painted with the black paint.

The absorbing tube is cover with transparent glass, which is fitted on

parabolic collector. The function of transparent cover is to reduce the loss of

energy by convection and radiation. It helps to increase the efficiency of plant.

Govt. Poly., Washim 5

The tracking is also given to the collector to increases the efficiency.

Therefore, the temperature of the fluid passing through the tube is

get heated the fluid is water.

usually above focusing point to concentrator.

Due to which density of water is decreased so water rises automatically and it is

hot water in absorbing tube.

This process goes on and whole water is heated and collected in

Govt. Poly., Washim 6

3. LITERATURE REVIEW OF SOLAR ENERGY

VARIOUS APPLICATION OF SOLAR ENERGY

As we seen solar energy option is one of the most promising

alternative energy source of the future.

Following are the application of solar energy option in relation of

(1) Power Generation.

(2) Solar heating and cooling of the building.

(3) Photovoltaic power generation.

(4) Solar space power system

(5) Solar pump.