Solar Water Heating Systems for Industrial Applications.

A Tata BP Solar Initiative.

Tata BP Solar India Ltd

Plot 78, Electronic City Off Hosur Road Bangalore 560100 Ph: 080 56601300 Email: tatabp@tatabp.com Web: www.tatabpsolar.com YZ

Tata BP Solars SWHS systems across India.

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

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.

Air Vent

Insulated SS HW tank.

Solar Collectors Insulated Piping

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 cause the 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 hot water pipes for a ring main system to minimize losses.

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 an aluminium 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 copper with selective coating using Black chrome technology. A reflective surface at the bottom (D) and rock-wool ensures that any energy that 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 less dense and hence tends to rise above colder water. Black body absorption: It is a well known fact that a black body absorbs heat which 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.

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 For 60 C For 70 C For 80 C 10 12 15 Rest of India 8 10 12

TOTAL FLAT/ROOF AREA required for installing SWHS (in sqm):

Total volume of Hot Water required (in litres per day)

----------------------------------------------------------------1000

x No. of collectors x 3.5sqm from table above.

Notes: 3.5 sqm assumes area required per collector, interconnecting insulated piping between 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+ MW of energy! For every Unit saved, we prevent 1kg of CO2 from being released.

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: Firewood: 5.3 lts 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).

READY RECKONER: (Assumed at 10 collectors per 1000 lpd to heat water to 80 C) Capacity lpd 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 15000 20000 25000 30000
Note:

Total no. of collectors 10 20 30 40 50 60 70 80 90 100 150 200 250 300

Area - 80C Sqm 35 70 105 140 175 210 245 280 315 350 525 700 875 1050

Elec Savings (Units/day) 45 90 135 180 225 270 315 360 405 450 675 900 1125 1350

Savings/Yr (@Rs5/Unit) 67,500 135,000 202,500 270,000 337,500 405,000 472,500 540,000 607,500 675,000 1,012,500 1,350,000 1,687,500 2,025,000

Savings/Yr (Diesel)* 52,500 105,000 157,500 210,000 262,500 315,000 367,500 420,000 472,500 525,000 787,500 1,050,000 1,312,500 1,575,000

No. of collectors is calculated @ 100 lpd per collector. Actual no. of collectors will vary based on exact location & requirements of the clients. Area shown is at 3.5 sqm per collector which includes area required for hot water tank, piping and 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 been steadily 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.

Success Stories by Tata BP Solar: (few selected examples) SWHS in Institutions: 96,000 lpd 29,000 lpd 4,000 lpd 4,000 lpd 6,000 lpd 4000 lpd 5,000 lpd 6,000 lpd Manipal Academy of Higher Education, Mahe BITS Pillani, Rajasthan Girls Hostel, Nagpur University Institute of Management Technology, Nagpur Army Institute of Management, Noida XIME Hostels, Bangalore IIM Hostels, Bangalore IIT Hostels, Kanpur 2003 2003-04 2005 2004 2004 2004 2003 2002

SWHS in Hotels, Hospitals, Govt Institutions & Others: 12,000 lpd 10,000 lpd 10,000 lpd 10,000 lpd 8,000 lpd 10,000 lpd 5,000 lpd 10,000 lpd 140,000 lpd 200,000 lpd 900,000 lpd Holiday Inn, Khajurao Chola Sherton, ITC, Chennai Taj West End, Bangalore Escort Heart Institute, Jaipur Indian Spinal Injury Center K G Hospital, Coimbatore CPWD Central Electric Division, Hyderabad Karnataka Police Housing Corporation ITC, Gurgaon Infosys Hostels Rashtrapati Bhawan, New Delhi 2006 2005 1996 2003 2003 1996 2005 2005 2005 2003-04 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 3,000 lpd 5,000 lpd 8400 lpd RBI Colony, Mumbai Apartment in Bangalore Apartment for Members of Darliament, Delhi Housing complex in Hyderabad 1998 2004 2005 2006

For the latest updated list on specific application, please contact us on tatabp@tatabp.com

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

Solar collector, tatasol, tbp 24m1 Tank, ss 304, hot water tank, 5000 ltrs. Tank insulation 100mm Pump 1 hp, single phase Control panel,dtc, 1 hp, 1 phase Meter, temperature gauge, 12" stem, 4" dial. Float chamber 1 " Sacrificial anode 1" Strainer 11/4" cast iron Valve - angle wheel valve " Valve gate valve 1" Valve gate valve 1 1/4" Cable, armoured, for pump wiring Wiring assembly for sensor Collector clamp, 35 x 25 x 115mm x 3mm thk., ms, painted. Flange, pipe connecting flange Piping, cold water piping, 1 1/4" Piping, hot water piping, insulated 1" Structure, projects Label, tata bp solar, gi, screen printed M6x25, hex head nut bolt set, ss. Screw, pan head, phillip slot, self tapping, No. 6 x 19, ss 304 Gasket, rubber 63 dia Gasket, rubber dummy - 63 dia Flange dummy dia 63 Meter, water meter 1" Flange insulation Cover for pump Civil work Valve, non return valve, 1" Manual, user instruction manual for forced industrial systems Health, safety & environmental manual for solar water heating systems Meter, pressure gauge Packing box, common

Qty
40 1 24 1 1 1 1 1 1 8 6 2 15 40 80 16 8 60 1 1 384 320 80 16 16 1 80 2 0.6 2 1 1 1 1

Unit
Pce Pce Sq mtr Pce Set Pce Pce Pce Pce Pce Pce Pce Rmt Rmt Pce Pce Rmt Rmt Set Pce Set Pce Pce Pce Pce Pce Pce Pce Cu.Mtr Pce Pce Pce Pce Pce

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

SYSTEM BASICS System Capacity System output Temperature. No. of Collectors Tank Capacity Circulation Pump Working pressure Load on the terrace 1) Collector 2) Tank 5000 LPD 60 deg.C. 40 Nos. 5000 ltrs. Forced 1 no, 1.0 HP, Single Phase, Monoblock Atomospheric 25 kgs per sq.m. 2830 Kgs per sq.m.

COLLECTOR SPECIFICATION CONFORMING TO IS 12933: Type Size Absorber area Weight Absorber coating Absorbtivity Emissivity Frame material Insulation Glazing Grommet Glass beading Hardware Finish INSULATED HOT WATER TANK : Tank type Tank dimensions - Dia x Height Material Insulation Thickness of insulation Cladding material Sacrificial anode SYSTEM INTERNAL PIPING : Material Pipe fitting Valves Insulation Thickness Cladding : 1 Class `B GI as per IS : 1239 : ISI make : Gun metal : Rubber Nitrile Elastomer : 9 mm : 28 swg Aluminum. : Cylindrical - Vertical : 1.65 m x 3.15 m : SS 304 grade : Rock Wool, 48 kg/m3 Density : 100 mm Thick : 22 Swg Aluminum : To prevent Galvanic corrosion : Cu-Cu : 2080 mm x 1070 mm x100 mm. : 2 m2 . : 46 Kgs (Dry) : Selective NALSUN with ultrasonic welding for Fins : >0.95 : <0.2 : Extruded aluminum, 16 SWG : Rock Wool : Toughened Glass : EPDM : EPDM : Stainless Steel 304 / Zinc plated : Yellow powder coated.

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INSTRUMENT & CONTROLS : Strainer Type Material Purpose Temperature Gauge Type Range Gate valve Type Material Water meter Type Material End connection Vane type Purpose Control Panel indoor type Type Pump Operating Voltage Sensors Type Stem Thread Angle Wheel Valve Type Material Non Return Valve Type Material STRUCTURES : Material : M.S.angles, Black enamel painted. : Y Type : Cast iron : Filtration of suspended material. : Mercury filled in SS tube : 0 to 150 Deg. C. : Screwed Ends : Gun metal : On line type : Brass : Screwed ends : Metallic form designed : Water usage management. : DTC-Differential temperature controller. : 1.0 HP,1 Phase, 220 V, 50 Hz : RTD PT 100 : SS 304, 12" : 1/2" BSP. : L Type connection with 1/2" BSP 3/8" Bush. : Gun Metal : Horizontal : Gun Metal

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