industrial swhs

7/28/2019 Industrial SWHS

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Solar Water Heating Systems

for Industrial Applications.

A Tata BP Solar Initiative.

Tata BP Solar India Ltd

Plot 78, Electronic City

Off Hosur RoadBangalore 560100Ph: 080 56601300

Email: [email protected]: www.tatabpsolar.com

YZ


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Tata BP Solars SWHS systems across India.

A picture says a thousand words We at Tata BP Solar let our body of work installed andcommissioned under a variety of circumstances speak for itself.


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Introduction to Solar Water Heating Systems:

Hot water and steam form an integral part of various industrial and commercial

applications and with rising oil prices, there has never been a better time to look at

heating water by harnessing energy from the Sun.

Typical Solar Water Heating System (SWHS) components.

Solar Water Heating Systems (SWHS):

The main components of a typical Solar Water Heating System are:

Solar Collectors: functions as the primary heating source. Insulated SS 304 hot water tank: for storing hot water. Insulated piping: regulate flow of water between components. Air vent: to release trapped air from hot water tank.

Special features from Tata BP Solar:

Based on our experience of over a decade designing & installing large capacity

systems, Tata BP has developed numerous features that enable us to custom design

our system to suit specific site/customer requirements:

Heat Exchanger Model: where water quality is poor (>300ppm) it may causethe system to clog greatly reducing efficiency and increasing maintenance

cost. A heat exchanger of HHC model ensures that water to be heated does

not pass through our solar collectors ensuring a highly robust solution.

Auxiliary tank: helps regulate and maintain the temperature of water in hotwater pipes for a ring main system to minimize losses.

Solar Collectors

Insulated SSHW tank.

Insulated Piping

Air Vent


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Solar Thermal Technology:

The Solar Collector Principle of Thermo-siphon Action

Solar Collector:

A collector consists 9 copper tubes (C) with copper fins (B) encased in analuminium box (usually powder coated in yellow) with a glass top (A).

The quality of copper used by Tata BP Solar is 99.9% pure electrolytic copperwith selective coating using Black chrome technology.

A reflective surface at the bottom (D) and rock-wool ensures that any energythat passes between the fins gets reflected back onto the copper fins to ensure

optimum performance in any condition.

The collectors measure approximately 2m x 1m and are fixed at an angle(w.r.t to the horizontal equal to the latitude of the site) facing the South sky in

a shadow free flat surface area.

Principle of Heating Water thro Solar:

The technology to heat water using solar energy is based on two simple principles:

Thermo-siphon action: Is based on a simple principle that hot water is lessdense and hence tends to rise above colder water.

Black body absorption: It is a well known fact that a black body absorbs heatwhich can be used to heat water.

The Suns rays heats the black powder coated copper fins (larger surface area)which in turn heats the cold water in the copper tubes. The heated water

slowly rises in the copper pipes thro thermo-siphon action and eventually

gets stored in the hot water storage tank.

This principle ensures that no electricity is used in the entire system.


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Applications for SWHS:

Large scale hot water usage for bathing & laundry applications in hotels,hospitals, hostels and even hi-rise apartment buildings.

Pre-feed for boilers for steam generation for various industrial applications. Milk dairies for applications such as pasteurization, condensation & cleaning. Leather processing industry for drying and tanning. Metal finishing industry for degreasing and phosphating. Resin emulsification in polymer industry. Drying & related processes in pharmaceutical industry. Solar drying thro air-heating is an area of growing interest. Swimming pool heating is a popular concept in India and abroad.

Thumb Rules:

Surface area of each collector: 2m x 1m Flat / roof area required per collector: 3.5 sqm

Table to calculate no. of collectors (No. of collectors per 1000 liters):

Cold climates & N. India Rest of India

For 60 C 10 8

For 70 C 12 10

For 80 C 15 12

TOTAL FLAT/ROOF AREA required for installing SWHS (in sqm):Total volume of Hot Water required (in litres per day)

----------------------------------------------------------------- x No. of collectors x 3.5sqm

1000 from table above.

Notes:

3.5 sqm assumes area required per collector, interconnecting insulated pipingbetween collectors & hot water storage tank fixed vertically.

1 sqm ~ 10.75 sq ft or 3.5 sqm ~ 37.5 sqft.

Pollution facts:

India currently is currently the 5th largest polluter(at 3.5% of the world). Tata BP Solar last year manufactured over 52,500 solar collectors. Globally SWHS saves equivalent of 80,000+ MWof energy! For every Unit saved, we prevent 1kg of CO2 from being released.


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Tax benefits & Financing:

All investments made for Solar technologies by a profit making organization can

claim 80% tax depreciation on year 1.

Banks offer low interest loans to popularize SWHS across India: 2% for individuals. 3% for institutional users like colleges and hostels. 5% for commercial & industrial users (including Small and Medium Enterprises).

Energy Savings:

For every 1000 liters of water heated from room temperature (25C) to 80C,

approximate equivalent energy savings per day are as follows:

Electricity: 45 Units Gas: 5.5 kgs

Diesel: 5.3 lts Firewood: 31 kgs

Pay-back Calculation:

Total price of system as quoted: Rs _______________(say Rs 100) Effective price after depreciation: Rs 100 x 0.8 x 0.32 = Rs ___________ Total energy savings year: 300 days x Unit cost of fuel (say Rs 35/lt for diesel) x

Total volume of fuel currently consumed = Rs _________ /year.

ROI in years: Effective price / Total energy savings: _________ years.

Details: (Basic details required to help us provide you with most optimum solution).

Location of proposed system: (complete address with nearest town/city) Nature of application: (bathing, boiler pre-feed etc) Total hot water requirement assumed: (ask TBP representative if in doubt) Temperature of hot water required: Existing method of heating water: (if applicable) Location of SWHS if needs to be integrated into existing system (if known) Total shadow free flat/roof area available: (drawings if available would help) Quality of water: (soft/hard, if hard what is the ppm) Usage pattern: (ex. Hours per day, days per week) Budget earmarked if available: Any energy rating system the clients wish to pursue: (ex. MOEF, LEED TERI).


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READY RECKONER: (Assumed at 10 collectors per 1000 lpd to heat water to 80 C)

Capacity

lpd

Total no. of

collectors

Area - 80C

Sqm

Elec Savings

(Units/day)

Savings/Yr

(@Rs5/Unit)

Savings/Yr

(Diesel)*

1000 10 35 45 67,500 52,500

2000 20 70 90 135,000 105,0003000 30 105 135 202,500 157,500

4000 40 140 180 270,000 210,000

5000 50 175 225 337,500 262,500

6000 60 210 270 405,000 315,000

7000 70 245 315 472,500 367,500

8000 80 280 360 540,000 420,000

9000 90 315 405 607,500 472,500

10000 100 350 450 675,000 525,000

15000 150 525 675 1,012,500 787,500

20000 200 700 900 1,350,000 1,050,000

25000 250 875 1125 1,687,500 1,312,500

30000 300 1050 1350 2,025,000 1,575,000

Note:

No. of collectors is calculated @ 100 lpd per collector. Actual no. of collectors will vary basedon exact location & requirements of the clients.

Area shown is at 3.5 sqm per collector which includes area required for hot water tank, pipingand space between collectors. Actual area will be lesser.

Electricity savings is assumed at 4.5 Units per 100 lpd. Savings per year is calculated at 300 days per year at Rs 5 Unit.

Savings from diesel are assumed at Rs 35/lt of diesel. Note, that diesel prices have beensteadily increasing and the prices does not assume maintenance, downtime and cost of parts.

Tata BP Solar India Ltd:

A joint venture between Tata Power & BP Solar is a 100% Solar Company with 15

years of varied experience & USD 100 mn turnover. The company has been involved

in providing holistic clean and green energy solutions and is fully equipped to be

your one-stop solar solution provider, help achieve greater energy efficiency and

collectively do our bit for the environment. Visit www.tatabpsolar.com for details.


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Success Stories by Tata BP Solar: (few selected examples)

SWHS in Institutions:

96,000 lpd Manipal Academy of Higher Education, Mahe 2003

29,000 lpd BITS Pillani, Rajasthan 2003-04

4,000 lpd Girls Hostel, Nagpur University 2005

4,000 lpd Institute of Management Technology, Nagpur 2004

6,000 lpd Army Institute of Management, Noida 2004

4000 lpd XIME Hostels, Bangalore 2004

5,000 lpd IIM Hostels, Bangalore 2003

6,000 lpd IIT Hostels, Kanpur 2002

SWHS in Hotels, Hospitals, Govt Institutions & Others:

12,000 lpd Holiday Inn, Khajurao 2006

10,000 lpd Chola Sherton, ITC, Chennai 2005

10,000 lpd Taj West End, Bangalore 1996

10,000 lpd Escort Heart Institute, Jaipur 2003

8,000 lpd Indian Spinal Injury Center 2003

10,000 lpd K G Hospital, Coimbatore 1996

5,000 lpd CPWD Central Electric Division, Hyderabad 2005

10,000 lpd Karnataka Police Housing Corporation 2005

140,000 lpd ITC, Gurgaon 2005

200,000 lpd Infosys Hostels 2003-04

900,000 lpd Rashtrapati Bhawan, New Delhi 2003

Ask for details of applications such as pool heating, air heating, pre-heat for boilers & more

SWHS in Hi-Rise Apartments:

10,000 lpd RBI Colony, Mumbai 1998

3,000 lpd Apartment in Bangalore 2004

5,000 lpd Apartment for Members of Darliament, Delhi 2005

8400 lpd Housing complex in Hyderabad 2006

For the latest updated list on specific application, please contact us on [email protected]


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BILL OF MATERIAL for a typical 5000 lpd system @ 60C.Description Qty Unit

Solar collector, tatasol, tbp 24m1 40 Pce

Tank, ss 304, hot water tank, 5000 ltrs. 1 Pce

Tank insulation 100mm 24 Sq mtrPump 1 hp, single phase 1 Pce

Control panel,dtc, 1 hp, 1 phase 1 Set

Meter, temperature gauge, 12" stem, 4" dial. 1 Pce

Float chamber 1 " 1 Pce

Sacrificial anode 1" 1 Pce

Strainer 11/4" cast iron 1 Pce

Valve - angle wheel valve " 8 Pce

Valve gate valve 1" 6 Pce

Valve gate valve 1 1/4" 2 Pce

Cable, armoured, for pump wiring 15 Rmt

Wiring assembly for sensor 40 Rmt

Collector clamp, 35 x 25 x 115mm x 3mm thk.,ms, painted. 80 Pce

Flange, pipe connecting flange 16 Pce

Piping, cold water piping, 1 1/4" 8 Rmt

Piping, hot water piping, insulated 1" 60 Rmt

Structure, projects 1 Set

Label, tata bp solar, gi, screen printed 1 Pce

M6x25, hex head nut bolt set, ss. 384 Set

Screw, pan head, phillip slot, self tapping,No. 6 x 19, ss 304 320 Pce

Gasket, rubber 63 dia 80 Pce

Gasket, rubber dummy - 63 dia 16 Pce

Flange dummy dia 63 16 Pce

Meter, water meter 1" 1 Pce

Flange insulation 80 Pce

Cover for pump 2 Pce

Civil work 0.6 Cu.Mtr

Valve, non return valve, 1" 2 Pce

Manual, user instruction manual for forced industrialsystems 1 Pce

Health, safety & environmental manual for solar waterheating systems 1 Pce

Meter, pressure gauge 1 Pce

Packing box, common 1 Pce


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System specification - 5000 lpd @ 60 c. - forced circulation:

SYSTEM BASICS

System Capacity 5000 LPD

System output Temperature. 60 deg.C.

No. of Collectors 40 Nos.

Tank Capacity 5000 ltrs.Circulation Forced

Pump1 no, 1.0 HP, Single Phase,Monoblock

Working pressure Atomospheric

Load on the terrace

1) Collector 25 kgs per sq.m.

2) Tank 2830 Kgs per sq.m.

COLLECTOR SPECIFICATION CONFORMING TO IS 12933:

Type : Cu-Cu

Size : 2080 mm x 1070 mm x100 mm.

Absorber area : 2 m2 .

Weight : 46 Kgs (Dry)

Absorber coating: Selective NALSUN withultrasonic welding for Fins

Absorbtivity : >0.95

Emissivity :


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INSTRUMENT & CONTROLS :

Strainer

Type : Y Type

Material : Cast iron

Purpose : Filtration of suspended material.

Temperature Gauge

Type : Mercury filled in SS tube

Range : 0 to 150 Deg. C.

Gate valve

Type : Screwed Ends

Material : Gun metal

Water meter

Type : On line type

Material : Brass

End connection : Screwed ends

Vane type : Metallic form designed

Purpose : Water usage management.Control Panel indoor type

Type : DTC-Differential temperature controller.

Pump

Operating Voltage : 1.0 HP,1 Phase, 220 V, 50 Hz

Sensors

Type : RTD PT 100

Stem : SS 304, 12"

Thread : 1/2" BSP.

Angle Wheel Valve

Type : L Type connection with 1/2" BSP 3/8" Bush.

Material : Gun MetalNon Return Valve

Type : Horizontal

Material : Gun Metal

STRUCTURES :

Material : M.S.angles, Black enamel painted.


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