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Solar Thermal
Training System
Experiment Manual
Includes 11 experiments with step-by-step guidance
© Insight Solar. 2013. Ecosense. info@ecosenseworld.com, customercare@ecosenseworld.com
About “Insight Solar” Solar
Thermal Training Kit
Specifications of the
System
• Water heater system
(Collector and hot water
tank)
1 • Artificial Radiation System
and Regulator
• Radiation meter
• External water tanks
Flat Plate Collector • Water pump
• Water flow meter (For force
mode of flow)
Insight Solar
Introduction 1
Insight Solar
Introduction
Solar water heater is one of the simplest Theory
and basic technologies in the solar energy
field. Collector is the heart of any solar A typical flat-plate collector consists of
water heating system. It absorbs and an absorber plate in an insulated box
converts the solar energy into heat and together with transparent cover sheet(s).
then transfers that heat to a stream of Work and properties of different
water. There are different types of solar components of a flat plate collector
energy collector. In our system we have
used a flat plate collector. yy Absorber plate:
It is a flat conducting plate to which
JDos LDON’Ts the tubes, fins, or passages are
attached. It may be a continuous
y y Valve positions yy During draining or discrete plate. The plate is usually
are critical, so from the hot water coated with a high absorptance and
ensure their tank do not open low emittance layer.
position before the exhaust valve
& after every in one go. yy Cover plate:
experiment. yy Do not touch the One or more sheet of glass or other
y y The system halogen fixture by radiation-transmitting material forms
drains very your hand the cover plate. The cover plate
high current so yy Do not run the serves two purposes, minimization of
make sure that pump in dry convective heat loss and blocking of
all connections condition. IR radiation.
are properly yy Do not open the
insulated. tap or the three yy Heat removal passages:
y y Fill cold water way valve without These are tubes, fins, or passages
tank through the taking utmost which conduct or direct the stream
pipe below the care. of water from the inlet to the outlet
three way valve. yy Do not touch the of the collector.
y y Clean the back side of the
control panel. yy Headers or manifolds:
glass before
performing any yy Do not spread These are the pipes to admit and
experiment. water over the discharge water that is meant to be
control unit. heated.
yy Insulation: yy Casing:
Insulations such as Rockwool or Glass The casing surrounds the
wool are fitted in the back and sides aforementioned components and
of the collector to prevent heat loss protects them from dust, moisture
from the collector. and any other material.
In the following figure schematic diagram of a typical flat-plate collector is shown with
different parts at their proper locations.
Overall data
Overall collector dimension mm 915x810x95
Weight of the collector Kg 13
Aperture Area m2 0.63
Glazing
Glazing type and number Type of glass Toughened Glass
Glazing thickness mm 3
Glazing transmission % 85
Glazing Emissivity % 88
Absorption plate
Absorber material Copper
Absorber plate thickness mm 8
Absorber plate dimension mm 115
Emissivity of surface % 12
Absorption of surface % 96
Risers & headers
Number of risers 6
Riser Length mm 800
Outer diameter of risers mm 12.7
Thickness of risers mm 0.56
Distance between two risers mm 115
Headers dimension mm 882
Header diameter mm 25.4
Header thickness mm 0.71
Test pressure kpa 400
Maximum working pressure kpa 250
Insulation
Insulation material Rockwool
Insulation density g/m 3
48
Insulation thickness-base mm 50
Insulation thickness-side mm 25
Conductivity W/mK 0.04
Casing
Frame type Aluminum
Frame colour Black
Casing thickness mm 1.4
Insulated tank
Tank type Non-pressurised
Tank materials SS – 304
Tank insulation PUF
Tested pressure kpa 300
Tank size 815 X370
Overall Efficiency
η % (50-70) %
Heat removal factor represents the ratio Collector time constant is required to
of the actual useful energy gain to the evaluate the transient behavior of a
useful energy gain if the entire collector collector. It is define as the time required
were at the fluid inlet temperature. It rising the outlet temperature by 0.632
depends upon the factors like inlet and of the total temperature increase from
outlet water temperature, the ambient Tfo–Ta at time zero to Tfo–Ta at time infinity
temperature, area of the collector etc. i.e. time at which the outlet temperature
The importance of heat removal factors attains a stagnant value. It can be
remains with the efficiency of the system. calculated from the curve between R and
For a highly efficient system a higher time as shown below. The time interval for
value of heat removal factor is must. which R value is 0.632, is the time constant
of the give collector.
Efficiency (η):
In terms of temperatures R is define as,
Efficiency is the most important factor
for a system. This factor determines the
system’s output. For a flat plate collector
based solar water heater system the
efficiency is defined as the ratio of the Where,
useful energy delivered to the energy
Tfo (t) : Outlet water temperature at any
incident on the collector aperture .
time t
The value of efficiency is dominated
by parameters like product of glazing’s Tfo (0) : Outlet water temperature at time
transmittance and absorbing plate’s zero
absorptance, intensity of global radiation
falling on the collector, water inlet Tfo (α) : Outlet water temperature at
temperature and ambient air temperature. infinite time (maximum temperature)
Basic Equations to calculate different loss from the back of the plate rarely
parameters: exceeds 10% of the upward loss. So if we
neglect the convective term there will not
A. Heat Loss coefficient (UL) be much effect in the final result. Thus to
calculate the bottom loss coefficients we
UL is the overall heat transfer coefficient can use the following formula
from the absorber plate to the ambient air.
It is a complicated function of the collector
construction and its operating conditions. (3)
In simple term it can be expressed as, Typical value of the back surface heat loss
coefficient ranges between 0.3 to 0.6 W/
UL= Ut + Ub + Ue (1)
m2K.
According to Klein (1975), the top loss In a similar way, the heat transfer
coefficient can be calculated by using the coefficient for the heat loss from the
flowing formula. collector edges can be obtained by using
the following formula
(4)
(2)
B. F factors of a flat plate collector (F, F’,
FR, F”)
(5)
The heat loss from the bottom of the
collector is first conducted through
the insulation and then by a combined
convection and infrared radiation transfer
to the surrounding ambient air. However
the radiation term can be neglected
as the temperature of the bottom part 2. Collector efficiency factor (F’)
of the casing is very low. Moreover the
conduction resistance of the insulation
behind the collector plate governs the
heat loss from the collector plate through
the back of the collector casing. The heat
(11)
(6)
D. Thermal Efficiency of the collector
(η)
FR= (Actual Useful energy gain)/(useful It is the ratio of the Useful heat gain to the
energy gain if the entire collector were at Total input energy
the fluid inlet temperature )
Mathematically,
3. Heat Removal Factor (FR)
(12)
Mathematically, (13)
Experimental set-up:
The system has been designed to perform experiments in both Thermosyphonic and
Forced modes of flow.
The air flow sensor is a conventional yy Heat flow through the cover is one
angled vane arms with low friction ball dimensional.
bearing while the temperature sensor is yy Temperature drop through the cover
a precision thermistor. The anemometer is negligible.
can measure the wind velocity in the
range of 0.4 to 45.0 m/s while the yy Covers are opaque to infrared
temperature range is -10 to 60°C radiation.
Fan : One AC fan is integrated with the yy Same ambient temperature exists at
system to generate the artificial wind the front and back of the collector.
speed. To set the wind speed as per yy Dust effects on the cover are
requirement a regulator is there in the negligible (if otherwise mention).
main control unit.
yy There is no shading of the absorber
Valve : Different valves are there to direct plate (if otherwise mention).
the water flow as per requirement.
Insight Solar
Experiment No. 1
Objective: 10. Switch ON the Halogen system
and set the regulator for maximum
Evaluation of UL, FR and η in radiation level
Thermosyphonic mode of flow with fixed
input parameters 11. Measure the radiation level at
Methodology: different locations on the collector
glazing by using the radiation meter.
1. Keep all valves closed To get the radiation levels at the
desire value apply the regulator. Use
2. Fill cold water tank number 1 an average value for calculation.
3. Open the valves 1 and 2 and fill cold 12. Note the values shown by different
water tank 2 by using the pump meters after every 15 minutes.
4. Once the cold water tank 2 is full, 13. To know the mass flow rate open the
open valve 3 and 4 and allows the three ways valve and note the time
water to flow into the hot water tank required to fill a desire amount of water
and the collector by gravity. in the beaker.
5. Once the hot water tank overflows and 14. Repeat the above step (13) at
water comeback to the cold water tank least five times during the whole
1 close the valves 1, 2 and 3. experiments. Use an average value
for calculation.
6. Switch ON the wind generating fan
15. Keep the halogen system ON until
7. Measure the wind speed at different the outlet water achieved a stable
locations of the collector by using temperature.
the Anemometer. Use an average
value for calculation. 16. Once the experiment is over drain
the hot water to the cold water tank
8. Similar to the wind speed measure the 1 by opening valve 5.
ambient air temperature by using the
same Anemometer at different locations For all the calculations refer to Table no. 1
around the experimental setup. Use an
average value for calculation.
Important:
Before draining the hot water to the cold
9. Connect all the meters and note all water tank 1, make sure that you have
the readings fill up the cold water tank 2 for the next
experiment.
By using the values of different entities 2. Find the value of optical efficiency of
from the Table-1 user can examine some the collector from the graph
other characteristic parameters of the
collector. The parameters are, 3. Find the slop of the curve which
gives the sense of the overall heat
a. Collector efficiency factor (F’) by loss coefficient of the collector.
using equation 8.
4. Find the gain and loss equalization
b. Collector Flow Factor (F”) by using point.
equation 9.
Insight Solar
Experiment No. 2
Objective: Observations:
Evaluation of UL, FR, η in Thermosyphonic yy Tilt angle of collector (β)______deg
mode of flow at different radiation level yy Wind speed (v):___________ m/sec
2.1 Highest Radiation Level yy Radiation level (I):__________ W/m2
User can use all the results from the sub 2.3 Low Radiation Level
part of experiment no. 1 provided inlet
water temperature is same. Methodology:
Follow all the steps as in experiment no.1 For all the calculations refer to Table no. 2.3
except setting the halogen regulator at a
medium radiation level. Observations:
yy Tilt angle of the collector (β)____deg
For all the calculations refer to Table no. 2.2
yy Wind speed (v):___________ m/sec
yy Radiation level (I):__________ W/m2
Calculations: Results:
1. Calculate UL, FR and η for all radiation Draw the efficiency graph for different
levels as in experiment no.1 radiation levels
Notes
...................................................................................................................................................................................................
Insight Solar
Experiment No. 3
Objective: 3.3 Inlet water at lower than the
atmospheric temperature
Evaluation of UL, FR, η in Thermosyphonic
mode of flow at different inlet water Methodology:
temperature.
Same as experiment no. 1 except
3.1. Inlet water at the atmospheric changing the water temperature by using
temperature the water cooler
This part of experiment is exactly same as For all the calculations refer to Table no. 3.2
the experiment no.1. So for the calculation
user can use all the results from that Observations:
experiment.
yy Tilt angle of collector (β)______deg
3.2. Inlet water higher than the
atmospheric water temperature yy Wind speed (v):___________ m/sec
Observations: Results:
yy Tilt angle of collector (β)______ deg 1. Draw the efficiency graph for
different inlet water temperature as
yy Wind speed (v):___________ m/sec well as for all inlet parameters.
Insight Solar
Experiment No. 4
Objective: Observations:
Evaluation of UL, FR, and η in yy Tilt angle of collector (β)______deg
Thermosyphonic mode of flow with
different wind speed yy Wind speed (v):___________ m/sec
For all the calculations refer to Table no. 4.1 For all the calculations refer to Table no. 4.3
Observations: Observations:
1. Set the fan regulators for a medium Draw the efficiency graph for different
wind speed. wind speed.
Insight Solar
Experiment No. 5
Experiments related to forced mode of flow
2. Close all valves except valve no. 3 13. Note all the readings after every 15
and 4. minutes.
3. Once water overflows the hot water 14. Keep the pump ON throughout the
tank close all valves except valve no.6 experiment.
and 7.
For all the calculations refer to Table no. 5
4. Switch ON the pump and set the
regulator at the lowest point. Observations:
5. See the flow rate on the flow meter yy Tilt angle of collector(β)_______deg
screen (forced mode).
yy Wind speed (v):___________ m/sec
6. To get the required flow rate first
open the valve No.8 completely and yy Radiation level (I):__________ W/m2
then adjust the valve no. 7.
Calculations:
7. Wait for some time to get a stable
flow rate reading. 1. Calculate UL, FR and η for each cases
as in experiment no. 1
8. Once flow rate is set note all the
readings. Results:
Table -5: Experimental values of different parameters in forced mode of flow with fixed
inputs
Notes
...................................................................................................................................................................................................
Insight Solar
Experiment No. 6
Objective: 9. Switch ON the wind generating fan
and set the speed at the desire level.
Evaluation of UL, FR, η and drawing of
different curves in forced mode of flow at 10. To know the wind speed and
different flow rate. ambient air temperature use same
methodology as in experiment no 1.
Note: The minimum flow rate that can be
measured by the flow meter is 0.5 LPM. So 11. Switch ON the halogen system and
user should set the flow rate above 0.5 LPM. set the radiation at the desire level.
6.1. Flow rate 0.5 LPM 12. To know the radiation level use same
methodology as in experiment No 1.
Methodology:
13. Note all the readings after every 15
1. Fill the cold water tank 2. minutes.
2. Close all valves except valve no. 3 and 4. 14. Keep the pump ON throughout the
experiment.
3. Once water overflows the hot water tank
close all valves except valve no.6 and 7. For all the calculations refer to Table no. 6.1
Observations: Observations:
yy Wind speed (v):___________ m/sec yy Tilt angle of collector (β)______deg
Methodology: Calculations:
Same as experiment no. 6.1 except setting 1. Calculate UL, FR and η for each cases
the pump regulator for a flow rate 1 LPM as in experiment no. 1.
For all the calculations refer to Table no. 6.3 2. Calculate flow factor (F”) for each
cases.
Table -6.1: Experimental values of different parameters in forced mode of flow with flow
rate 0.5 LPM
Table -6.2 Experimental values of different parameters in forced mode of flow with flow
rate 0.7 LPM
Table -6.3: Experimental values of different parameters in forced mode of flow with flow
rate 1 LPM
e. Plate temperature v/s Mass flow f. Heat loss v/s Flow factor
rate
Notes
...................................................................................................................................................................................................
Insight Solar
Experiment No. 7
Objective: 10. Note all the readings after every 15
minutes
Evaluation of UL, FR, η in forced mode of
flow at different radiation level 11. Keep the pump ON throughout the
experiment
7.1. Maximum Radiation Level
12. To know the radiation level, wind
Methodology: speed and ambient air temperature
use same methodology as in
1. Fill up the cold water tank 2 with experiment no.1
water at the desire temperature
For all the calculations refer to Table no. 7.1
2. Close all valves excepts valve No. 3
and 4 Observation:
2. Once water overflows the hot water yy Tilt angle of collector (β)______deg
tank close all valves except valve yy Wind speed (v):___________ m/sec
No.6 and 7 yy Radiation level (I):__________ W/m2
3. Switch ON the pump and set the 7.2 Medium Radiation Level
regulator
Methodology:
5. See the flow rate on the flow meter
screen (forced mode) Same as experiment no. 7.1 except
setting the halogen regulator for medium
6. To get the required flow rate adjust radiation level
the valves no. 7 and 8
For all the calculations refer to Table no. 7.2
7. Wait for some time to get a stable
flow rate reading Observation:
8. Once flow rate is set note all the yy Wind speed (v):___________ m/sec
readings yy Radiation level (I):__________ W/m2
9. Switch ON the halogen system and
set the Regulator for Radiation at the
desire level
Observation:
yy Tilt angle of collector (β)______deg
yy Wind speed (v):___________ m/sec
yy Radiation level (I):__________ W/m2
Table -7.1: Experimental values of different parameters in forced mode of flow with
maximum radiation level
Table -7.2: Experimental values of different parameters in forced mode of flow with
medium radiation level
Table -7.3: Experimental values of different parameters in forced mode of flow with low
radiation level
Notes
...................................................................................................................................................................................................
Insight Solar
Experiment No. 8
Objective: 9. Switch ON the halogen system and
set the radiation at the desire level.
Evaluation of UL, FR, η in forced mode of
flow at different inlet water temperature 10. Note all the readings after every 15
minutes.
8.1. Inlet water at the atmospheric
temperature 11. Keep the pump ON throughout the
experiment.
Methodology:
12. To know the radiation level, wind
1. Fill up the cold water tank 2 speed and ambient air temperature
with water at the atmospheric use same methodology as in
temperature. experiment no 1.
2. Close all valves except valve no. 3 For all the calculations refer to Table no. 8.1
and 4.
Observation:
3. Once water overflows the hot water
tank close all valves except valve no.6 yy Tilt angle of collector (β)______deg
and 7.
yy Wind speed (v):___________ m/sec
4. Switch ON the pump and set the
regulator at the minimum power at yy Radiation level (I):__________ W/m2
which the pump can work.
yy Water mass flow rate(m) ____ kg/sec
5. See the flow rate on the flow meter
8.2 Inlet water at 5 or 10°C higher
screen.
than the atmospheric water
6. To get the required flow rate adjust temperature.
the valve no. 7 and 8.
Methodology:
7. Wait for some time to get a stable
flow rate reading. Same as the experiment no. 8.1 except the
inlet water temperature
8. Once flow rate is set note all the For all the calculations refer to Table no. 8.2
readings.
Observation: Observation:
8.3 Inlet water temperature lower yy Water mass flow rate(m) ____ kg/sec
than the atmospheric water
temperature.
Calculations:
Calculate UL, FR and η for each case as in
Methodology: the experiment no.1
Same as the experiment no. 8.1 except
the inlet water temperature
Results:
For all the calculations refer to Table no. 8.3 Draw the efficiency graph with different
inlet water temperature and all inlet
parameters.
Table-8.1: Experimental values of different parameters in forced mode of flow with inlet
water at atmospheric temperature
Table-8.2: Experimental values of different parameters in forced mode of flow with inlet
water 5 or 10°C higher than the atmospheric water temperature
Table-8.3: Experimental values of different parameters in forced mode of flow with inlet
water at lower than the atmospheric water temperature
Notes
...................................................................................................................................................................................................
Insight Solar
Experiment No. 9
Objective: 10. Switch ON the halogen system and
set the radiation at the desire level.
Evaluation of UL, FR, η in forced mode of
flow at different wind speed 11. Note all the readings after every 15
minutes.
6.1. Low wind speed
12. Keep the pump ON throughout the
Methodology: experiment.
1. Fill up the cold water tank 2 13. To know the radiation level, wind
with water at the atmospheric speed and ambient air temperature
temperature. use same methodology as in
experiment no 1.
2. Close all valves except valve no. 3
and 4. For all the calculations refer to Table no. 9.1
6. To get the required flow rate adjust 9.2 Medium wind speed
the valve no. 7 and 8.
Methodology:
7. Wait for some time to get a stable
flow rate reading. Same as the experiment no. 9.1 except the
setting the wind speed for a medium value
8. Adjust the fan regulator to get the For all the calculations refer to Table no. 9.2
desire wind speed.
Observation: Observation:
yy Tilt angle of the collector (β)____deg yy Tilt angle of the collector (β)____deg
yy Water mass flow rate(m) ____ kg/sec yy Water mass flow rate(m) ____ kg/sec
Table -9.1: Experimental values of different parameters in forced mode of flow at low wind
speed
Table -9.2: Experimental values of different parameters in forced mode of flow at medium
wind speed
Notes
...................................................................................................................................................................................................
Insight Solar
Experiment No. 10
Experiment related to tilt angle
10.2 Medium Tilt Angle For all the calculations refer to Table no. 10.3
Methodology: Observation:
Same as the experiment no. 10.1 except yy Tilt angle of the collector (β)____deg
the setting the tilt angle for a medium
value. Check the collector angle before yy Wind speed (v):___________ m/sec
starting the experiment.
yy Radiation level (I):_________ W/m2
For all the calculations refer to Table no. 10.2
yy Water mass flow rate(m) ____ kg/sec
Observation:
Calculations:
yy Tilt angle of collector (β)______deg
Calculate UL, FR and η for each case as in
yy Wind speed (v):___________ m/sec the experiment no.1 and then calculate ηθ
by using equation 14.
yy Radiation level (I):__________ W/m2
Results:
yy Water mass flow rate(m) ____ kg/sec
Draw the efficiency graph with different
10.3. Large tilt angle tilt angle
Methodology:
Same as the experiment no. 10.1 except
setting the collector for the large tilt angle.
Check the collector angle before starting
the experiment.
Table -10.1: Experimental values of different parameters in forced mode of flow with a
small tilt angle
Table -10.2: Experimental values of different parameters in forced mode of flow with a
medium tilt angle
Table-10.3 Experimental values of different parameters in forced mode of flow with a large
tilt angle
Notes
...................................................................................................................................................................................................
Insight Solar
Experiment No. 11
Objective: Observations:
Evaluation of UL, FR, and η in yy Tilt angle of collector (β)______deg
Thermosyphonic mode of flow at
different tilt angle yy Wind speed (v):___________ m/sec
Methodology: Calculations:
Follow all the steps as in experiment Calculate UL, FR and η for each case as in
no.11.1 after changing the tilt by 10 deg experiment no. 1 and then calculate ηθ by
from the standard collector position. Make using equation 14.
the collector angle to be 50 deg. Check
the collector angle before starting the Results:
experiment.
Draw the efficiency graph for different tilt
For all the calculations refer to Table no. 11.2 angles in thermosyphonic mode
Insight Solar
Nomenclatures:
Ac : Area of the collector (m2) τ0: Transmissivity of the glass cover
hfi : Heat transfer coefficient between the ∂ : Thickness of the fin (mm)
water and the riser wall
θ : angle of incident (Deg)
It : Radiation falling on the collectors per
unit area (W/m2 ) Constant values:
Notes
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Notes
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Notes
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Notes
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About Ecosense
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renewable energy and clean environment. As a group
of engineers, researchers and designers, Ecosense has
developed cutting edge products to create skilled human
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