Solar Hot Water Heating Systems

Courtesy of DOE/NREL

PG&E
Pacific Energy Center, San Francisco
Energy Training Center
Center, Stockton
 Instructor

Pete Shoemaker
PG&E Pacific Energy Center
(415) 973-
973-8850
pjsy@pge.com

with assistance from

G Paul Menyharth of the American Solar Institute
G.
and
Josh Plaisted of Kineo Design and PVT Solar
Agenda

• Industry overview
• Essential physics
• Terms and concepts
p
• Collector and System types
• Site evaluation and design
 The Full Energy Picture

PG&E Portfolio Solution

1) Reduce consumption as
much as possible. Reduce
Energy
Use 2) Get the
“greenest”
power you
Partnership
3)) Offset any
y can.
remaining Education
carbon Outreach
Renewable
emissions. ClimateSmart Power
Supply
Different Types of “Solar”
Light
Li ht energy
Photovoltaic (PV)
Electricity produced directly from light

Heat energy
C
Concentrated
t t dSSolar
l Power
P (CSP)
Electricity produced by steam

Solar Pool Heating

Hot water for pools

Solar Water Heating

(SWH - Solar Thermal)
Hot water for domestic use (DHW) All courtesy of DOE/NREL
 Solar Pool Heating
Swimming pool water heating
80 - 85 degrees from May to October

Courtesy of DOE/NREL

M t
Mature industry
i d t with
ith main
i markets
k t in
i C
California
lif i andd Fl
Florida.
id
Overview

Courtesy CCSE
Overview

Courtesy CCSE
Overview

Courtesy CCSE
Overview

Courtesy CCSE
SHW Industry Overview: World

By Permission: REN21. 2008 ”Renewables

Renewables 2007 Global Status Report
Report”
(Paris:REN21) © 2008 Deutsche Gessellschaft fur Technische
Zusammenarbeit GmbH
SHW Industry Overview: U.S. History
1890 to 1930’s: Beginnings in California

1930 to 1973: Growth in Florida

1973 to 1986: Oil Embargo and Carter Tax Credits

1986 to 2003: Removal of Tax Credits and Decline

2003 – present: Revival of Incentives and Climate Action

Industry Overview: U.S.
Favorable regulatory environment
Federal Tax Credit:
• Extended through 2016
• 30% ffor b
both
th commercial
i l and
d residential
id ti l
• MACRS depreciation for commercial

Other state and local rebate programs exist or

are in the planning stages.
Industry Overview: California
State rebate program: AB1470

• Applications accepted 5/1/10 (residential) and TBD

(commercial).
• Systems installed after 7/15/09 eligible.
• Allocation is 40% residential, 60% commercial and
multi-family.
Essential Physics

Courtesy ofNASA

It all starts with the sun.

Electromagnetic Spectrum

10 -3 10 -7
heat light

Courtesy of Wikipedia

Continuum of energy
energy.
Greenhouse Effect

Ozone layer

light Short waves get through

Long waves
a es are trapped
heat
Earth
Greenhouse Effect

Glass

light Short waves get through

Heat
absorber Long waves
a es are trapped
heat

SWH
collector
Color Absorption

Dark colors absorb a lot, reflect little

Li ht colors
Light l absorb
b b little,
littl reflect
fl t a lot
l t
Metal Conductivity

Some metals transfer more heat than others.

Fluid Fluid

Pipe
p cross-section

Copper Iron
Water Behavior

Water expands both when heated and frozen.

Steam Ice

Moving
g water will NOT freeze.
Water Behavior

Warm water will rise, cold water will sink.

Water Behavior

Water contains dissolved minerals, which can

cause unwanted buildup and clogging.
gg g

• “Hard” water contains more minerals, “soft” water less.

• Most common minerals are calcium and magnesium.
• The buildup of minerals is called “calcification” or “scaling”.
Essential Physics: Summary

• Greenhouse effect
• Light
g enters but heat trapped
pp
• Color absorption
• Dark colors absorb and light colors reflect
• Metal conductivity
• Copper conducts more than others
• Water
W t behavior
b h i
• Expands when heated and frozen
• Moving water will not freeze
• Warm water rises, cold water sinks
• Water contains dissolved minerals
Which leads to …

Glass-covered collectors,
dark-colored, with copper or
aluminum piping…

Systems designed to take

advantage of the movement
of heated water …

With protection against

freezing, overheating, and
mineral buildup.
Terms and Concepts

Courtesy ofNASA
Terms and Concepts
BTU: British Thermal Unit
Unit. Amount of heat needed to raise
one lb. of water one degree F.
Watt-hour: 3.4 BTU Kilowatt-hour: 3,413
, BTU
Therm: 100,000 BTU (29.3 kWh)

Th
Thermosiphon:
i h N t l process off h
Natural hott water
t rising
i i (i
(in a ttube).
b )
Stratification: Separation of hot and cold water (in a tank).
Heatt exchanger:
H h D i th
Device thatt ttransfers
f heat
h t from
f one medium
di
to another.
Climate zones: Areas of distinct seasonal temperatures
temperatures.
Hard freeze: A freeze in which seasonal vegetation is
y
destroyed, ground is frozen solid, and heavy
g y ice is formed.
Stagnation: Condition when collectors are not used and
become overheated.
Terms and Concepts

System design: Storage is the key.

Solar Electric: Solar Thermal:

Tied to the grid. No grid--you’re on

Every kWh is used, your own.
y
no waste. Potential for waste.
Courtesy of DOE/NREL
Terms and Concepts
Solar Fraction: Percentage of building’s hot water requirements
that can be met by solar—at optimum economics (no waste).

Example:
Design to cover 100% of usage year-round, including winter.
Minimal sun in winter, so need many collectors (expensive).

But in summer sun,

sun these collectors produce far more hot water
than you use, and you can’t store it or sell it.
Wasted energy, wasted money.
Solar Fraction: Design

Cover 100% in summer.

Will result in 30 – 50% in winter.

Average year-round coverage of 60 – 70% in PG&E territory.

Will ALWAYS need a backup heating source (gas or electric).
Change in perspective

Solar Electric: Solar Thermal:

Selling / maintaining Selling / maintaining

“solar” “total hot water system”
(solar + backup)

Courtesy of DOE/NREL
Change in perspective

One overall system

solar + backup
p

One overall cost One overall maintenance

O overall
One ll efficiency
ffi i O overall
One ll lifespan
lif
Collector and System Types

Courtesy ofNASA
Standard Water Heaters

Typical gas heater:

Direct flue.
Much
M h heat
h t loss
l “up
“
the chimney”.
Low efficiency.
((50 – 70%)
%)

Courtesy PG&E
Standard Water Heaters

Improved model:

Same basic technology,

better insulation
insulation.
Efficiency around 70 –
80%.
80%

Source: Energy Star

Standard Water Heaters

More improved model:

Condensing heater.
Extended flue which
releases much of its heat
to the water before
venting.
ti
Vent gases are cool
enough to condense.
Efficiency
y around 80 –
90+%
Source: Energy Star
Standard Water Heaters

New model:

Heat pump.
Like refrigerator in
reverse.
Electric powered, no gas
burning.
Best to replace electric
water heater.

Source: Energy Star

Standard Water Heaters

Tankless

Gas or electric.
Can require special
hookup service.
Effectiveness related to
usage patterns.

Source: Energy Star

System Overview

Five main aspects of solar systems:

1. Heat collection
2 Heat transfer
2.
3. Heat storage
4 Heat backup
4.
5. Extreme temperature protection
(f
(freezing/stagnation)
i / t ti )
System Overview

Five main aspects of solar thermal systems:

1. Heat 2. Heat 3. Heat 4. Heat 5. Extreme

Collection Transfer Storage Backup Temperature
Protection

Special
valves,
pumps,
processes,
Gas or etc.
Water or electric
Solar
glycol heater
panel
p Storage
g
tank
System Overview

Two types of heat transfer systems:

1 O
1. Open Loop
L 2 Closed Loop
2.
(Direct) (Indirect)

water glycol

Uses just the water Uses heat-transfer fluid

from the main. in “closed” system.
“Open”” to
“O t outside
t id Needs heat exchanger.
elements.
Collector and System Types

Two types of heat transfer systems:

1 O
1. Open Loop
L 2 Closed Loop
2.
(Direct) (Indirect)

one fluid Heat Potable

HX
loop water
water glycol

Uses just the water Uses heat-transfer fluid

from the main. in “closed” system.
“Open”” to
“O t outside
t id Needs heat exchanger.
elements.
System Overview

Further categorized by “pumping” source:

1 P
1. Passive
i 2. Active (electric
(natural) pump)

Thermosiphon
Must have electric
process.
source.
Tankk mustt be
T b higher
hi h
Tank can be anywhere.
than collector.
Collector Types

ICS (Batch) Flat Plate Evacuated Tube

Fi
Figure courtesy NREL
ICS: Integral Collector Storage

Heat Heat
C ll i
Collection St
Storage

Solar
panel Storage
tank
ICS: Integral Collector Storage

Courtesy energybychoice.com
ICS: Integral Collector Storage

Hot water Roof

out tilt

Cold
water in
Holds 20 to 40 g
gallons of water
ICS: Integral Collector Storage

Courtesy NREL
Flat Plate Collector

Headers Risers

Figure courtesy SunEarth

Flat Plate Collector

“Fin” for heat

absorption

Souce: PG&E
Flat Plate Collector

Header
Hott water
H t
out

Rooff
R
Risers

tilt

Header

Cold
C ld
water in Holds about one gallon of fluid
Evacuated Tubes

Photo courtesy Industrial Solar Technology

Photo courtesy William Lord

Figure courtesy Edwards Hot Water

Courtesy of DOE/NREL
Evacuated Tubes

Copper rod: may be

solid or hollow.

Heat
eat moves
o es
up to bulb.

Double glass wall with

vacuum between.

Souce: PG&E
Evacuated Tubes
Figures courtesy Thermomax

6
1. Vacuum tube 7
2
2. Heat pipe
3. Cold liquid 1 8
9
2
4. Hot vapor 3
5. Absorber 4

5
6. Collector return
(hot)
7. Collector supply
(cold)
8. Heat exchanger
9. Shock absorber
Evacuated Tubes
H d
Header

Cold water in Hot water out

Roof
tilt

Holds little or no fluid

Evacuated Tubes
H d
Header

Cold water in Hot water out

Roof
tilt

Holds little or no fluid

Plumbing Different Collectors

Flat Plate Evacuated tube

Photo courtesy Industrial Solar Technology

Return
Supply Return

S
Supply
l
ICS: Integral Collector Storage
The Simplest
p Form of Solar

Benefits
• Low first cost
• No moving parts
• Inherent overheat protection
• Moderate freeze protection

Disadvantages
• Sensitive to ambient temperatures
• Weight
Figure courtesy SunEarth

Sample specifications

Figure courtesy NREL

Simple system with ICS
Courtesy of EERE
Simple system with ICS
Heated water
moves to top

Hot water is
drawn into tank

120 degree water goes

into house

Additional heating element

boosts temperature as
necessary
Water comes
in from main
System Characteristics
F typical
For t i l ICS system:
t

Passive
• No pumps, nothing requiring outside power

Open Loop
• New fluid (water) is constantly entering—system is “open”
to outside elements

Figure courtesy NREL

Flat Plate Collectors
The Industry Workhorse

Figure courtesy SunEarth

Sample specifications

Figure courtesy NREL

Thermosiphon Passive Systems

Photo courtesy NREL

Thermosiphon Passive Systems

Courtesy CCSE
Thermosiphon Passive Systems
T k
Tank—potable
t bl water
t

Heat-exchange
loop—”closed” to
outside elements

Separation between water in

tank and heat-exchange fluid

Figure courtesy SunEarth Inc

Thermosiphon Passive Systems
Additional heating element boosts
t
temperature
t as necessary

120 degree
g water goes
g
Water
W t comes in
i into house
to tank from main

Heated fluid rises

Heat is transferred to
water in tank

Cooled fluid sinks

Solar fluid circulates

through collector
Figure courtesy SunEarth Inc
System Characteristics
F typical
For t i l ttank-on-roof
k f systems:
t

Passive
• No pumps, nothing requiring outside power

Closed Loop
• Heat-exchange loop is closed to new elements

Also can be:

Open Loop
• New fluid (water) is constantly entering—system is open
to new elements

Figure courtesy NREL

Active Systems

P
Active Systems
Can be Open-
p or Closed-loop
p

Benefits
• Highest thermal performance
• Freeze protection to –60 F
• Lightweight low roof profile

Disadvantages
Figure courtesy SunEarth Inc
• Some active components
• More expense and maintenance

Courtesy of DOE/NREL
Active Systems

Courtesy University of Central Florida

Active Systems

Courtesy University of Central Florida

System Characteristics
F typical
For t i l flflatt plate
l t or evacuated
t d tube
t b systems:
t

Active
• Uses pumps and other active elements

Open Loop
• Potable water itself is heated
or
Closed Loop
• Glycol is heated and heat-exchanger
heat exchanger is used

Figure courtesy NREL

Freeze Protection

Six different methods (can be combined):

1.
1 Thermal mass (ICS)
2. Antifreeze (closed loop glycol)
3
3. Auxiliary heater (electric element)
4. Drip valves (moving water won’t freeze)
5. Forced circulation of hot water (DFC)
6. Draining (removing water from collector)

Figure courtesy NREL

Thermal Mass
20 to 40 gallons of water will only freeze under extreme conditions.

ICS systems are freeze-protected in mild (coastal) climate zones.

Antifreeze

• Closed-loop (indirect) systems

• Uses food-grade glycol, specific mixture depending
on climate zone.
• Must be serviced every 5 – 15 years.
• The hotter the glycol is run, the more it breaks down
and the sooner it needs to be replaced.
• Freeze protection up to 40 degrees below zero.
Auxiliary Heater

• Electric resistance (strip) heater on pipes, collectors.

• Like a heating pad
pad.
• Triggered at specific temperature.
• Vulnerable to power outages
outages.
Drip Valves

Membrane in valve retracts at

around 40 degrees, permitting
water to drip out onto the roof.

Courtesy University of Central Florida

Drip valves are good backup protection against mild freezes, but
are vulnerable to failure, particularly in hard-water areas.
Direct Forced Circulation (DFC)

Freeze drain valve Always combined

with drip valve(s).

Courtesy University of Central Florida

Direct Forced Circulation (DFC)

In freeze
conditions, Freeze drain valve

reverse flow
gi es up
gives p heat
to protect the
system.

Hot water

Courtesy University of Central Florida

Drain-back System (closed loop)

Collectors are
always empty
when
hen system
s stem
(pump) is not
running.

Courtesy University of Central Florida

Drain-back System (closed loop)

Start up:
Collectors are
filled and
heating cycle
begins.

Courtesy University of Central Florida

Drain-back System (closed loop)

Shut down:
Collectors
automatically
drain and
heating cycle
ends.

Courtesy University of Central Florida

Drainback System

• Closed loop
• Can use water or g glycol
y in heat-collection loop
p
• Fluid is drained from collectors whenever
system is not running
• Needs large pump to push water into collectors
• Pipes must be sloped properly for drainage

Figure courtesy NREL

Site Evaluation and System Design

Courtesy ofNASA
Site Evaluation and Design
Criteria:
• Solar resource
• A il bl space and
Available d orientation
i t ti
• Climate zone (temperature range, freezes)
• Hot water usage amount and patterns
• Economics

Courtesy of DOE/NREL
Solar Resource

Sun--hours Measured in kWh/m2/day

Peak Sun

Source: DOE National Renewable Energy Laboratory (NREL) Resource Assessment Program
http://rredc.nrel.gov/solar/old_data/nsrdb/redbook/atlas/serve.cgi
Shading

• SWH panels not as sensitive to shading as

solar electric (PV) panels
• Shade measurements and tools similar to
that of PV
• Major difference: the SWH rebate program
only
l considers
id shading
h di from
f 10 to 3.
3
Sunset Sunrise

Solar Window
“Shade-free from 10 to 3”
Tilt and Orientation
Tilt = angle
l from
f the
th horizon.
h i
Orientation = Azimuth = direction north-south in
which the panels are facing
facing.

tilt
Ex. 30º angleº
axis
From Horizon

Tilt Azimuth
Surface Orientation Factor (SOF)

San Francisco, CA
90

SOF
0.40-0.50
60
0 50 0 60
0.50-0.60
0.60-0.70 Tilt
0.70-0.80
0 80 0 90
0.80-0.90 30
0.90-1.00

0
-90 -60 -30 0 30 60 90
East West
Chart courtesy
y NREL
Azimuth
Rough Home Estimate
•D
Do you h
have 60 to 80 square ffeet off rooff ((or
ground) space that is unshaded from 10 to 3?
• Is it on a non-North facing slope (flat is OK)?

If you pass this first screening then the next step is to

solicit bids from contractors. They y can determine the
appropriate system and give a financial assessment.
 Solar Pathfinder
Used to gain a quick and approximate understanding
of solar access and objects
j on the horizon that shade a
given location.

• Latitude specific sun path diagram is

placed in the pathfinder.
• The transparent,
transparent convex plastic dome
reflects objects on the horizon, enabling
the user to see the relationship between
th
these objects
bj t and d th
the path
th off th
the sun.
• Obstructions can be traced onto
p
sunpath diagram.
g
 Solmetric SunEyeTM

• Handheld
measurement
d i that
device th t
accurately
measures solar
access and
shadingg (about
(
$1400)

Courtesy: Solmetric, Corp.

Mounting
Mounting
Usage

How much energy are you using to heat water?

Usually it’s not easy to determine, since water heating

bills can include space
p heating
g and cooking
g as well.

Three ways:
1. Direct measurement
2 Bill analysis
2. l i
3. Estimation from industry standards
Industry Standards / Surveys

Average hot water usage per home per day:

• 20
0 ga
gallons
o s for
o tthe
e first
st pe
person
so
• 15 gallons for the second
• 10 each for all others

4 person household =
20 + 15 + 10 + 10 = 60 gallons per day

These assumptions are used in the CSI Thermal

online
li calculator.
l l t
Industry Standards / Surveys
Averages for typical 4-person home in PG&E territory:

Natural Gas Water Heating

Yearly usage: 200 therms
Yearly cost: about $300 (current prices)
Typical solar fraction: 65 - 70%
Typical solar savings: about $200 per year.

Electric Water Heating

Yearly usage: 3,500 kWh
Yearlyy cost: about $700
$ ((current p
prices))
Typical solar fraction: 65 - 70%
Typical solar savings: about $500 per year.

Electric heating is 2 to 3 times as expensive as gas.

State Rebate Program: AB 1470
Modeled after the very successful solar electric program (CSI)
to lower costs and raise product and contractor quality.
Uses online entry/calculation program:

• Only allows approved systems.

• Makes sure system is sized appropriately.
• Ensures proper freeze protection for climate zone.
• Gives conservative estimate of production.
• Determines rebate.
State Rebate Program: AB 1470
In addition…
addition
All contractors or self-installers who want to participate in the
rebate program must attend a one-day
one day workshop given by the
Program Administrators.
After attending
g they
y will receive a unique
q ID number to use in
the online entry program.
The URL for the CSI Thermal site is: www.csithermal.com

For a list of registered contractors go to

http://www.gosolarcalifornia.ca.gov/solarwater/contractors.php
Rebate Program: AB 1470
Systems must be SRCC certified: www
www.solar-rating.org
solar rating org

OG 300
OG-300
System ratings

OG-100
Panel ratings
Sample Costing

Savings:
• Average yearly usage 210 therms
• Solar saves 70% of that, or 147 therms
• Average cost per therm $1.37
• Yearly savings about $200 (first year)

Cost:
• Total installed price $7000
• State rebate $1875 (147 * $12.82 up to max)
• Tax credit ((7000-1875) * .3) = $1537
• Net cost = (7000 – 1875 – 1537) = $3588
Sample Costing
Glycol:
y
• Will need to be recharged every 5 – 10 years
• Best to be professionally done
• Estimate of $250 per visit
• Total about $750

Pump(s):
• At least one replacement
• Estimate
E ti t off $500 - $1000,
$1000 use $750

Tank + heat exchanger

• At least one replacement
• Estimate $1000
Estimated total = $750 + $750 + $1000 = $2500
Sample Costing
Natural Gas:
• Typical heater costs $500
• Labor costs can be another $300 - $500
• Lifespan is 7 – 10 years
• Electric heaters may be somewhat less

Conservative total approx. $2500

Similar to solar maintenance

What’s a reasonable assessment?

Sample Costing

Solar needs to maintain both systems

(solar + backup), but backup works 70%
less.
Can we assume 70% less maintenance
costs for backup?
If so
so, backup costs with solar would be
about $2500 * .3 = $750.
Maintenance with solar (25 yrs.)
M i
Maintenance costs with
i h solar:
l
$2500 (solar) + $750 (backup) = $3250

Maintenance costs without solar: $2500

Difference: $3250 - $2500 = $750
Conclusion: solar maintenance costs are
about $750 extra than before, and this
should be added in to the overall cost of a
solar system.
Works out to about $30/year, or about
0.5% of the purchase price per year.
Sample Costing

Payback:
• First cost: $3
$3,600
600
• Maintenance adder: $750
• Total
T t l lifecycle
lif l cost:
t $4350
• Savings first year: $200
• Straight payback (no inflation factor) =
4350 / 209 = 21 years
• With inflation factor of 5.5%, payback
shortens to about 15 years.
Economics
It s recommended that you get at least three bids from
It’s
reputable contractors. The bids should all contain the
following, clearly specified:

• Full price, including tax, permit, and any additional

charges.
g
• Estimated maintenance costs and maintenance
schedule.
• Estimated production, based on the CSI Thermal
calculator output.
• Estimated first year and system lifetime savings, based
on reasonable assumptions of utility costs and inflation.
• Warranties for all products and labor, clearly written.
Solar Water Heating Benefits

• Saves money
• Lowers greenhouse gas emissions (local
and national goals)
• Qualifies for state and federal incentives
• Promotes energy independence
• Keeps money in local economy
Thank you for participating!
PG&E Pacific
P ifi Energy
E Center
C t

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