Example system design manual section on conceptual analysis and feasibility study

Exarnvle Svstern Design Contents -Page ex -i
EXAMPLE SYSTEM DESIGN
Solar Design Manual

l2sEmxE
Page
INTRODUCTION .......................... ..................................................................... EX-1

SECTION t .CONCEPTUAL ANALYSIS ...............................................................EX-1
Owner/Architect/Engineer Conference ................................................................

EX-1
Conceptual Site Survey ........................................................................................... EX-1

Preliminary Load Estimate ...................................................................................... EX-1
Conceptual PerforrnancetCost Study ..................................................................EX-2

Conceptual Array Sizing Method .............................................................................EX-2
Preliminary System Cost Estimate .......................................................................EX-3
Evaluation of Cost Effectiveness.............................................................................EX-3
SECTION 2 .FEASIBILIN STUDY ........................................................................EX-9
Application Review ............................................................................................ EX-9

Data Gathering and Conservation Measures ....................................................... EX-9
Thermal Load Requirements................................................................................... EX-9
Sizing/Performance Analysis ...................................................................................EX-9

Computer System Simulation .................................................................................. EX-9
Construction Costs ..................................................................................................EX-12
Economic Evaluation ...............................................................................................EX-13
SECTION 3 .DETAILED DESIGN ........................................................................ EX-30
Overall System Schematic ......................................................................................

EX-30
Collector Subsystem Design ................................................................................... EX-30

Array Design............................................................................................................
EX-30
Piping Design ..........................................................................................................
EX-31
Collector Subsystem Component Requirements ....................................................EX-32
Storage Subsystem Design ...................................................................... ...............EX-50

Storage Tank Design ............................................................................................... EX-50
Piping Design .........................................................................................................
EX-50
Storage Subsystem Component Requirements .................................................... EX-51
Example System Design Contents -Page ex iii -
CONTENTS (continued)
Page
3.5 Instrumentation and Controls Subsystem Design ...................................................EX-52

3.5.1 Solar Energy System Operational Controls.............................................................EX-52
3.5.2 Solar Energy System-to-Load Interface Controls .................................................... EX-52
3.5.3 Operational instrumentation .................................................................................... EX-52
3.5.4 System Performance Monitoring Instrumentation ................................................. EX-52
3.5.5 Instrumentation and Control Component Requirements .........................................EX-52
3.9 Perforrnance/CostVerification................................................................................. EX-74

3.9.1 Verification of Thermal Performance ..................................................................... EX-74
3.9.2 Cost Estimate ..........................................................................................................
EX-76
3.9.3 Economic Evaluation ............................................................................................. EX-76
TABLES
First Economic Evaluation of Solar Energy System ................................................EX-14

Results of F-CHART Runs for Variety of Array Sizes .............................................EX-15
Results of TLCC Calculations for Various Solar fnergy System Sizes .................. EX-15
Second Economic Evaluation of Solar Energy System ...........................................EX-16
Design Cost Estimate Detail ...................................................................................
EX-77
Solar Energy System Goals ....................................................................................EX-5

Service Hot Water Data ...........................................................................................EX-6
Building Information.................................................................................................
EX-7
Collector and Storage Locations .............................................................................EX-8
Building Information..................................... .. ......................................................... EX-17

Site and Environmental Considerations ................................................................ EX-21
Energy Conservation Measures ..............................................................................EX-23
Service Hot Water Data ...........................................................................................EX-27
Construction Cost Estimate Summary .................................................................. EX-29
*Only those checklists applicable to this specific system design were used. Other designs may require use of
all checklists .
Solar Design Manual

FlGURES
Page
Building Sketches ........................................................................................ EX-4

Example System P & ID................................................................................EX-33
Typical 8-Collector Bank ............................................................................... EX-34
Location of Collector Banks on Roof ..............................................................EX-34
Collector Pipe Sizes and Flow Rates ..............................................................EX-34
Typical Collector Bank Piping ........................................................................ EX-34
CollectorlPipe Support ...................................................................................EX-35
Storage Tank ..................................................................................................EX-35
Storage Tank Details ......................................................................................EX-35
Collector Sensor Locations................................................................. EX-53
Storage Tank Sensor Locations................................................................... EX-53
PEClFlCATlON WORKSHEETS
Flat Plate liquid Collectors ....................................................................................EX-36

Heat Transfer Fluids ................................................................................................ EX-39
Pumps .................................................................................................................... EX-40
Expansion Tanks .................................................................................................. EX-42
Air Separator Valve .......................................................................................... EX-43
Flex Couplings ....................................................................................................... EX-44
Insulation ................................................................................................................ .
EX-45-
.,. ,. ...=., ..T...=..,. ....--..T ...I. ....: ..................................................EX-46
- . . .
. . . . .
Aidlent ,
- .
Check Valves .......................................................................................................... EX-47

Pressure Relief Valves ..........................................................................................EX-48
Piping .................................................................................................................... EX-49
Thermal Storage Tanks ...........................................................................................EX-54
Heat Exchangers .................................................................................................. EX-55
Pumps .....................................................................................................................EX-57
Tempering Valve ....................................................................................................EX-59
Pressure Temperature Relief Valves .................................................................... EX-60
Insulation ................................................................................................................. EX-61
Air Vent ................................................................................................................. EX-62
Check Valves ......................................................................................................... EX-63
Pressure Relief Valves ......................................................................................... EX-64
Piping ................................................................................................................ EX-65
Differential Temperature Controller ....................................................................... EX-66
Temperature Switches ......................................................... . . .............................EX-67
Temperature Sensor ............................................................................................ EX-68
Btu Meters ............................................................................................................... EX-69
Pressure/Temperature Ports .................................................................................EX-71
Pressure Gauges .................................................................................................... EX-72
Thermometers .................... .... ............................................................................. EX-73
Solar Design Manual

Example System Design Conceptual Analysis- Page EX-I
INTRODUCTION
An example solar energy system design was prepared following the guidelines of the design manual. The
example is intended to show how the equations, tables, figures, checklists, worksheets, and evaluations are
used in the solar energy system design process.
The system selected for the example application is a closed-loop antifreeze system that can be used to
supplement heating of service water for a dormitory. The example system uses flat plate collectors that are
mounted on the roof of the dormitory.
Numbers used to identify sections, headings, tables, figures, checklists, and worksheets for the example are
directly relatedto those used in the main text of the design manual.
The example solar energy system design was performed using the inch-pound (I-P) units and symbols.
SECTION 1
CONCEPTUAL ANALYSIS
1.2 Owner/Archltect/EnglneerConference
The "owner" is a college in Tucson, Arizona, that is considering a solar energy system to supplement the
service hot water load in a men's dormitory. Checklist 1-1 summarizes the owner's goals.
1.3 Conceptual Site Survey

1.3.2 Preliminary Load Estimate
Ideally, either historical records of service hot water usage or real-time data collection would be used to
estimate the service hot water load. In this example, these methods were not available for use. The load is
estimated based on the ASHRAE 1980 Systems Handbook guidelines for hot water demand (Table 6 of the
Service Water Heating section).
The dormitory contains 100 rooms, 25 per floor, and there are three students per room. The school is on the
trimester system with about h2lf the capacity during the summer trimester (Mayto August). The hot water
load, by month, is determined below using the equation from Worksheet 1-1. The average hot water demand
is 13.1 gavstudent per day.
Solar Design Manual

Example System Design Conceptual Analysis- Page EX-2
Cold Water Hot Water

Month Gallons Temperature ( O F ) Temperature (OF) Load(Btu/month)
January 122,000 48 140 93.16 x loa

February 110,000 48 140 84.0 x 10e
March 122,000 50 140 91.13 x 10e
April 118,000 52 140 86.19 x 10"
May 61,000 57 140 42.02 x 10"
June 59,000 59 140 39.66 x 106
July 61,000 63 140 38.98 x 1Og
August 61,000 75 140 32.91 x 108
September 118,000 79 140 59.74 x 108
October 122,000 69 140 71.90 x 10B
November 118,000 59 140 79.33 x 10s
December 122,000 54 140 87.08 x 108
Total 806.00 x 1Os
Load {Btu/month) = (gaVmonth)(8.3 Ib/gal)(l Bt~/lb.~F)(f,- TJ°F
1.3.3 Physical Constraints
A sketch of the dormitory building is illustrated by Figure A. Checklists 1-4 and 1-5 outline the results of the
building site survey.
1.4 Conceptual System Selection
Due to the relatively large static head, approximately 50 ft, and the freeze potential at the site, the conceptual
system selected for this site is a closed-loop antifreeze system, as illustrated by Figure 1-3 of the manual. 4
1.5 Conceptual PerforrnanceICost Study
1.5.1 Conceptual Array Sizing Method
The expected performance of the system, for both an average flat plate and an average evacuated tube
collector, can be found in Table 1-3 of the manual.
Flat plate performance - 269,000 Btu/ft&yr

Evacuated tube performance = 287,000 BtuMGyr
I
Solar Design Manual

Exam~leSvstem Design Conceptual Analysis- Page EX-3
The estimated required array, storage, and mechanical room sizes are calculated per Section 1.5.1 as
follows.
a. Array area = (806 x 1 0 % ~ x 0.80) + (269,000 Btu/ft2eyr)@ 2400 ft2 (flat plate)
b. Array area = 2250 ft2 (evacuated tube)
c. Storage size = 2250 to 2400 gallons
d. Mechanical room size = 100 to 150 ft2
15 . 2 Preliminary System Cost Estimate
The cost estimate will be based on the assumption that flat plate collectors will be used. The sytem cost
range is estimated as follows.
a. Minimum cost = $40/ft2x 2400 ft2 = $96,000
b. Maximum cost = $801ft2x 2400 ft2 = $192,000
A representative 40-ft2flat plate collector can currently be purchased for $520. This represents less than 30%
of the system cost and is acceptable.
13 . 3 Evaluation of Cost-Effectiveness
The simple payback period can be calculated following the steps in Section 1.5.3.
a. Output = 269,000 Btu/ft2*yrx 2400 ft2 = 646 x 1O6 Btu/yr
b. The cost of electricity in Tucson, Arizona, is $19,92/MMBtu
C. Therefore, the value of the annual energy saved is
646 x 1O6 Btulyr x $19.92 x 10" Btu = $12,870Jyr
d. The simple payback periods for both the minimum and maximum cost estimate are
Minimum = $96,000 + $12,870Jyr = 7.5 yr
The payback periods are within the owner's goal of 15 years. The allowable first cost can be calculated
following the steps in Section 1.5.3.
e. Value of energy saved = $12,87O/yr
f. From Table 5, using an interest rate of 12% (estimated over the life of the system, an
economic life of 20 years and a fuel price change of +2.50/dyr, the economic factor is 8.956.
Qw The allowable first cost is then $1 2,870 x 8.956 = $115,300
This is in between the minimum and maximum cost estimates of the system. The system will be cost-effec-
tive if it can be installed for this amount or less.
Basement
Entrance
Roof Plan
Floor Plan
Ground Level
Furnace
, ~ . ~ C r . ~ . c c , r r r . r r Storage
1
*r &
: Sohr ; Workspace
Existing j Equipment
Water R o o m :
i
Heater d
1 #I
Mechanical Room Plan Scale: 1 in. = 50 ft
Figure A. Building Sketches
S o b Design Manual
CHECKLIST 1-1
SOLAR ENERGY SYSTEM GOALS
Building ownerluser A college in Arizona

(name)
Address Tucson, Arizona
Desired solar application:
Hot water only -X-Space heating Space heating and hot water
Reasons for interest (rank in order):
-2-Promotion of renewable energyfwnservation of fossil fuel

-1-Save money
-3-Own a solar system
Expected solar f radon:
Hot water heating (%) -80-

Space heating (%) -NIA-
Overall expected cost benefits
Maximum initial investment allowed ($)-200,000-
Maximum years allowed to pay back investment (yr) 15
Minimum yearly fuel cost saving ($/yr)--
Solar Design Manual

CHECKLIST 1-2
SERVICE HOT WATER DATA
A. Building Hot Water Requirements
1. Daily Load 22 gal/day (maximum per student), -13.1 @/day

(average per student)
How determined? ASHRAE 1980 Systems Guidelines
2. Daily use pattern Mostly daytime, 7 days/week
3. Temperature 12OP0F
4. Load profile (list monthly hot water load estimates) (gallons): (000 omitted)
Jan -122- Feb 1 1 0 - Mar -122- Apr -1 18- May - 6 1 Jun -59-
J u l - 6 1 A u g 6 1 S e p ~ 1 1 8 O c t ~ 1 2 2 ~ N o v Dec-122-
~118~
5. Total annual load 1 ,I 96,000gallons
B. Main Heating System
1. Energy source: Gas Electric X O i l Steam
2. Hot water heaterhtorage capacity 1 0 7 0 _ _ g a l l o n s
3. Hot water circulation: Yes No x -

4. Cold water temperature 7 9 - O F (max) 4 5 - O F (min)
Solar Design Manual

CHECKLIST 1-4
BUIL1)ING 1NFORMATlON
Date July 1987
Building A college in Tucson
1. Primary building use: Dormitory
2. Number of floors: 4 Total floor area -77,350-ft2
3. Utilities available:
Natural gas Propane gas Fuel oil

Electric: -1 20/208- volt, -1/3- phase, -214- kW
4. Water quality: pH -8.5 Dissolved solids c 1 0 - pprn
Solar D e s i ~ nManual
CHECKLIST 1-5
COLLECTOR AND STORAGE LOCATIONS
1. Potential collector location: Roof -X- Ground Wail
Ifroof, type: Fiat -X- Pitched
If pitched, pitch line direction and slope
Roofing material B u i l t up with cap sheet
Area available for collectors -59.5- ft (N/S) x -325- ft (UW)

Potential shading problems e l e v a t o r equipment room
Provide sketch showing shape, overall dimensions, and location and type of any
obstructions or potential shading sources.
2; Potential storage location: Indoor -X- Outdoor
If indoor, available area 5 0 - ft x 3 0 - ft; Ceiling height -1 5-ft
Access to storage location: 2 0 x 8- door sues other
3. Potential mechanical equipment location: indoor X Outdoor
If indoor, available area 5 ft x 7 . 5 ft
4. Approximate distance collector to HX or storage 5 0 - ft (elev),2 5 - ft (horiz)
5. Approximate distance HX to storage 0 ft (elev), -1 0-ft (horiz)
Solar Design Manual

Example System Design Feasibility Study- Page EX-9
SECTION 2
FEASIBILITY STUDY
2.2 Appllcatfon Revlew
2.2.1 Data Gathering and Conservation Measures
Checklists 2-1 through 2-4 are filled out as attached. The only conservation measure is to lower the tank set
temperature to 120°F.
2.2.3 Thermal Load Requirements
The ASHRAE data for hot water usage calculated in Section 1 still applies.
2,3 Sizing/Perforrnance Analysis
2.3.1 Computer System Simulation
The example system simulation program chosen for this example feasibility study is F-CHART version 5.5.
The initial input required to run F-CHART 5.5 is determined using Appendix 2B and the F-CHART user's
manual.
Collector Parameter Set

1. Number of collector panels
As a first cut, 54 collectors are estimated. This is an area, 10% less than that calculated in
Section 1.
2. Collector pane[ area = 40 ft2
3. FRUL= 0.792; this is the value for an average flat plate collector as shown in Section 1.5.
4. F,m = 0.61 6; this is the value for an average flat plate collector as shown in Section 1.5.
5. Collector slope = 32". For this first run, this is set to the site latitude.
6. Collector azimuth = default value (0).
7. Incidence angle modifier = 8, for the program to calculate the modifier values.
8. Number of glazings = 1.
9. incidence angle modifier constant = (no input required).
10, Incidence angle modifier values = (no input required).
ai. Collector flow rate/area = 17.5 Ib/h*ft2,as recommended in Appendix 28.
Solar Design Manual

Collector fluid specific heat = 0.875 Btu/lbe°F, the value for 50/50pmpyleoe gly
Modify test values = 2, for no modification.
Test collector flow ratehrea = (no input required).
Test fluid specific heat = (no input required).
City call number = 215 for Tucson, Arizona
Water storage volume = 2140 gallons, 1 gaWt2 of array area
Building UA = 0 for DHW only
Fuel = 1 for electricity
Efficiency of fuel usage = 100%
Domestic hot water = 1
Daily hot water usage; the monthly values are input by typing "7 V"
Jan 3936 May 1968 Sept 3933

Feb 3929 June t 967 Oct 3936
Mar 3936 July 1968 Nov 3933
AP~ 3933 Aug 1968 Dec 3936
Water set temperature = 120°F
City water temperature; the monthly values are input by typing '9 Vw
Jan 60 May 65 Sept 70

Feb 60 June 75 Oct 70
Mar 65 July 75 Nov 65
AP~ 65 Aug 75 Dec 60
DHW storage tank size = 2140 gallons
UA of auxiliary storage tank = 23.8 Btu/hm°F; the auxiliary tank is 1070 gallons. 4.5
diameter, and 9 ft high. The installed insulation is 2.5 inches thick with a k = 0.031
Pipe heat loss = 2
Inlet pipe UA = (no input required)
Outlet pipe UA = (no input required)
the default value

Relative load heat exchanger size = I,
Collector storage heat exchanger = 1 ,
Solar Design Manlral

Example System Design Feasibility Study- Page E X 4
-
C
17. Tank side flow rate = 18.375 Ib/hr*ft2;calculated as 5% greater than collector side flow rate
(1.05)(17.5 Ib/hr.ft2) = 18.375 Ib/hraft2
18. Heat exchanger effectiveness = 0.60, as recommended in Appendix 28
Results are listed below.
Tucson, AZ
Design Handbook Sample Run 1
Water Storage System

Flat Plate Collector
Solar Heat DHW Aux

MMBtu* MMBtu* MMBtu* MMBtu*
Jan
Feb
Mar
AP~
May
Jun
Jul
Aug
S ~ P
Oct
Nov
Dec
Yr i J
Note: MMBtu = Btu x 106
The results show that with 54 collectors, the solar fraction will be 0.79, meeting 100% of the load during the
months of May through August.
Assuming that the example simulation program overestimates the output by 20%, the installed performance
can be estimated by:
Installed Solar Contribution -

= (DHW Aux) + 1.20
= 348.1 MMBtu
Installed Solar Fraction
Solar Design Manual

2.3.2 Construction Costs
Following the guidelines of Appendix 2C (Casts are expressed in 1985 U.S. dollars and must be adju
the year of proposed construction):
The National Average "Bare Costs" are:
1. Collector + Thermal Storage Tanks
BC = 9.13(2,160 ft2) + 21,308 = $411029

2. Mechanical Material
-
BC 7.05 (2,160 ft2) + 5,337 =-$
3. Electrical Material
BC = 0.134 (2,160 ft2) + 2,432 = $9.771
4. Mechanical Labor
BC = 2.93(2,160 ft2) + 18,662 = $24.991
5. Electrical Labor
BC = 0.026 (2,160 ft2) + 1,550 = $1.608
6. Other
BC = 0.018 (2,160f12)+743 = $782

7. -
Freight Costs $1000 assume for this example
Bare Cost at Tucson, Arizona
B C ~ ~ ~ n= 41,029 + (.989)(20,565) + (1.022)(2,721)

+ (.961)(24,991) + (.953)(1,61)6) + (.961)(782)
= su&z
Subtotal Cost at Tucson, Arizona
Subtotal Cost = 90,447 + .07(41,029 + 20,565 + 2,721)

+ (.0529 + .0715 + .01)(24,991 + 1,606)
=$98.524
Total Cost
Total Cost ~($98,524+ 1,000)(1.296) = $128.983
where: $1,000 = freight cost
Cost/ft2 ~$59.71
/ft2
Solw Design Manual

Exam~leSystem Design Feasibility Study- Page EX-13
2.3.3 Economic Evaluation
The system is evaluated economically by looking at the total life cycle costs (TLCC) of the existing system
and of the solar retrofit system. The two TLCCs are assumed to be:
where: PMT = design and installation costs

PV,,,,= present value of the annual auxiliary
fuel expenses
Pv~,~ = present value of the annual solar energy
system O&M casts
No tax credits or salvage value is included in this example, and the design cost is exduded. Also, the existing
system is assumed to last as long as the solar energy system.
To convert the annual auxiliary fuel and O&M costs to a present value, the modified uniform present worth
(MUPW) formula is utilized as follows:
(Note: Table 5 of Section 1 can be used, also.)
+ e)/(d- e)] [I
MUPW = A. [(i - ((1 + e)/(i + d)IN]
where: A, = annual cost at beginning of study period ($/yr)
e = annual energy escalation rate (decimal)
d -- annual discount rate (decimal)
N = study period, yr
For this example, the following values are assumed:
Therefore, MUPW = 8.9564 A,
The annual auxiliary fuel cost is determined from the F-CHART run.
Aux fuel cost = Aux MMBtu x $19.92/MMBtu
The annual operating costs are assumed to be 5% of the solar energy collected, or:
The annual maintenance cost is assumed to be 20h of the installed costs.
The first cut of the economic evaluation is as shown in Table I.
Solar Design Manual

-
Table 1 First Economlc Evaluation of Solar Energy System
Aux. Oper- Mainte-

Design and Aux. Energy Energy ating nance
InstallatIon Requlrernent Costs Costs Costs
System Costs ($) (MMBtutyr) ($/Yr) ($/Y J') ( $ 1 r)
~ TLCC ($1
- - - - - - -
No solar 0 531-7 10,591 0 0 94,861
With solar 128,983 183.6 3,658 347 2,580 187,961
As can be seen from Table 1, the TLCC with the solar energy system is much greater than the TLCC without
a system. Therefore, some optimization is required.
The first step in optimization is to maximize the output of the system. The second step is to reduce the array
area and, therefore, the system cost until the TLCC, with solar, is less than the TLCC without solar.
Since the maximum load exists during the winter months, the system output can be increased by increasing
the collector slope. This results in an optimum slope of 42", with the corresponding F-CHART run shown
below.
Tucson, AZ
- - - -

Flat Plate Cotlector
Solar Heat DHW Aux

MMBtu MMBtu MMBtu MMBtu
Jan
Feb
Mar
Ap r
May
Jun
Jul
Aw
S~P
Oct
Nov
Dec
Yr
Table 2 summarizes the F-CHART runs for a variety of array sizes. I.
Solar Design Manual

Examde System Design Feasibilitv Studv- Puae EX-15
-
Table 2 Results of F-CHART Runs for Varlety of Array Sizes
20% Reduction
In F-CHART Output
Number
of Panels Solar MMBtu Aux MMBtu F Aux MMBtu F
The first cut at the economic evaluation assumes that the installation cost remains $59.711ft2. Table 3
summarizes the results of the TLCCs for the various system sizes.
-
Table 3 Results of TLCC Calculations for Various Solar Energy System Sizes
Aux. Oper- MaInte-

system Design and Aux. Energy Energy sting . nance
(No. of lnstallatlon Requlrement Costs Costs Costs
panels) Costs ($) (MMBtulyr) ( $ 1 r)~ ( $ 1 r)
~ ( $ 1 r)
~ T u x ($)
As can be seen, none of the systems have a lower TLCC than the existing nonsolar water heater.
To complete this example, Table 4 summarizes a second economic evaluation with an assumed
electrical energy cost of $39.84/MMBtu.
Solar Design Manual

-
Table 4 Second Economic Evaluation of Solar Energy System
Aux. Oper- Malnte-

System Design and Aux. Energy Energy atlng nance
(No. of Installation Requirement Costs Costs Costs
panels) costs ($) (MMBtulyr) ( $ 1r)~ ($/Yr) ( $ 1r)~
'These values are based on the cost estimating procedures of Section 2 instead of the assumed cost
of $59.71 /ft2.
Using the assumed installation cost of $59.71/ft2,the installation is economical from approximately 35 panels
down to at least 20 panels. Using the installation cost estimating procedure outlined in Section 2, the TLCC
bottoms out at 40 panels and at that level is approximately $30,000 more than the TLCC without a solar
energy system. This example solar system will be designed using 40 panels.
Example System Design Feasibility Study- Page EX-1 7
CHECKLIST 2-2
BUILDING INFORMATION
(Sheet 1 of 4)
Date July 1987
Building A college in Arizona
BUILDING CONSTRUCTION CHARACTERISTICS
Primary building use: D o r m i t o r y
Provide sketchtplan with overall dimensions and orientation.
Number of floors: 4
Volume of occupied space: -61 8,800-ft3

Gross floor area: -7?,350- ft2
Window glazing: - X s i n g l e - X double
Window shading coefficient:
Windows, number and area: north windows ea. -ft2 = ft2
west -ft2 r ft2
east ft2 = ft2
south -ft2= ft2
TOTAL ft2
Door types and number:
north single vestibule revolving - -doors
west -single vestibule revolving = -doors
east -single vestibule revolving = -doors
south -single vestibule revolving = -doors
Gross wall area: north
Gross wall area: west
Gross wall area: east
Gross wall area: south it2

TOTAL ft2
*Items8 through 19 are not applicable.
Solar Design Manual

CHECKLIST 2-2
"U"Value
20.' Net wall area: north ft2 (Net E gross less window
and door area)
21. Net wall area: west ft2
22. Net wall area: east ft2
23. Net wall area: south ft2
TOTAL ft2
24. Roof construction: Support structure
Surface material
Slope Area ft2
"U"Value
25. Floor:
Over unheated space ft2
"U"Value
BUILDING USE CHARACTERISTICS
26. a. Number of occupied hours per week: -1 68- hours
b. Number of occupants: -300- occupants (for offices, employees and visitors; for stores,
employees and customers; for religious buildings, schools only count occupants)
27. Number of custodial hours per week: after dark, summer -N/A- hours
after dark, winter -N/A- hours
Saturdays -N/A- hours
Sundays -N/A- hours
*Items 20 through 25 are not applicable.
Solar ueszgn Manual

Example System Design Feasibility Study- Page EX-I 9
CHECKLIST 2-2
(Sheet 3 of 4)
28.' Temperature and relative humidity inside canditions:
Season Temperature Humidity
-
a. heated winter Occupied hours O F % RH
Unoccupied hours OF % RH
-
b. air-conditioned summer Occupied hours O F % RH
Unoccupied hours O F % RH
29. Ventilation, outside air:
a. during occupied hours -onloff: amount in total d m = ft3/min
b. cfm per person (line 29a +- line 26b) = dmfperson
c. during unoccupied hours -on/off; amaunt in total cfrn = ft3/min
30. Type and location of space heating equipment: Single unit Multiple units
Boosters
-OutsrdeJocati~
- - - - -
- - - - - - - - - - - - -
- - - - - - -
-Inside, location
Type and location of water heating equipment: X Single unit Multiple units
-Outside, location
-X- Inside, locatian -Basement
31. Utilities available
Natural gas Propane gas Fuel oil
Electric: -1 2O/208-volt, -1 13- phase
32. Water quality: pH 8 . 5 - Dissolved solids < 0I

- ppm Solids -None-
Dormitory has installed water treatment system.
*Items 28 through first part of 30 are not applicable.
Solar Design Manual

CHECKLIST 2-2
33. Collector and thermal storage locations
a. Collector location -- Roof - X Ground Wall
If roof, type - Flat X Pitched
If pitched, pitch line direction -and slope

Area available for collectors -59.5- ft (N/S)
x 3 2 5 - ft (EM)
Provide sketch showing shape and overall dimensions of collector location with
location and type of any obstructions or potential shading sources.
b. Thermal storage location - Indoor -X- Outdoor
Provide sketch/plan showing all dimensions and access.
c. Mechanicalequipmentlocation-IndoorXOutdoor
Provide sketcNplan showing all dimensions and access.
d. Approximate distance collector to HX or storage -50-ft (elev), - 2 5 ft (horiz)
e. Approximate distance HX to storage -Q-fi (elev).-1 0-ft (horiz)
Solar Design Manual

Example System Design FeasibiZiO Study- Page EX-21
CHECKLIST 2-3
SITE AND ENVIRONMENTAL CONSIDERATIONS
(Sheet 1 of 2)
Building location T u c s o n - (City), -Arizona-(State)
3 2 (Latitude), 1 1OW (Longitude)
Local population
If small city or noncity, distance city of 50,000 or more miles
Local zoning ordinances affecting solar Yes NoX-

If yes, describe
Local code requirements affecting solar system Yes NoX-

If yes, describe:
Building:
Plumbing:
Electrical:
Fire:
Other:
5. Requirement for double separation between antifreeze

solutions and water Yes No X
6. Long-term climatic condition (as available: use NWS data or SERl Atlas')
Maximum daily temperature 81.5-OF

- - - - - - - - -
Minimum daily temperature -54.1-OF
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
- - - - - - - - - - - - - - - -
Maximum monthly average temperature -86.3-OF (Aug.) '
Minimum monthly average temperature -50.9-OF (Jan.)
Heating degree days -1,751-
Maximum global insolation - Daily Btu/ft2 - Monthfy -2,730-Btu/ft2 (June)

Minimum global insolation - Daily Btulft2 - MonthJy -995-Btu/ft2 (Dec.)
Clear days per year -K, = ,679- Clearest month -May-
Cloudiest month Dee.- Daily cloud pattern: a.m. p.m.
Maximum (mean) snowfall -6- inches
Maximum wind velocity -8-mph
Direction of maximum wind N W - Direction of prevailing w i n d N W -
* "Climatic Atlas of the United States," U.S. Department of Commerce, 1977.

SERI/SP-642-1037, "Solar Radiation Energy Resource Atlas of the United States," October
1981.
SERVSP-755-789, "Insolation Data Manual," October 1980.
Solar Design Manual

CHECKLIST 2-3
SITE AND ENVIRONMENTAL CONSlDERATlONS

(Sheet 2 of 2)
Solar Design Manual

-6
CHECKLIST 2-4
ENERGY CONSERVATION MEASURES

(Sheet 1 of 4)
A. NO COSTJLOW COST
HVAC
To be
Implemented
_Yes&
Install locking thermostats

Adjust supply or heat transfer medium temperature
Install nighttime thermostat setback
Restrict heat and air conditioning in unoccupied areas
Clean radiators, air registers, filters, condenser coils
Check operation of automatic controls
Reduce heat in garages, dock, and platform areas
Balance heating system
Evaluate humidification system
Check operation of all electric heating units
Establish a regular program to inspect, clean, and tubricate
equipment
Lower (winter} or raise (summer) indoor thermostat settings
Replace filters.
VENTILATION
Shut down system in unoccupied areas

Improve operation controls (tirneclocks)
Reduce ventilation rates to code allowables
Reduce outside air intake
TnspectoutdKor air &ampem - - - -
- - - -
Balance air intake-to-occupant load

Balance intake and exhaust air rate
Improve mechanical operation (fans, motors, dampers)
lmprove filter maintenance
Maintain positive interior pressure
Inspect all central systems and unitary controls.
INFILTRATION
Repair door and window caulking

Repair door and window weatherproofing
Replace broken glass
Adjust door closer
Refit doors and windows
Install temporary storm windows.
UTlhlTY PLANT DISTRIBUTION SYSTEMS
Adjust barometric damper

Monitor boiler makeup water
Operate minimum number of boilers
Isolate off -line boilers
Check condensate return system
Repair boiler, tank, and pipe insulation
Solar Design Manual

Example System Design
--;-
CHECKLIST 2 4
- -
As

(Sheet 2 of 4)
To be
Implemented
Yes&
UTILITY PLANT DISTRIBUIIONSYSTEMS (Continued)
Check boiler efficiency and monitor combustion

Eliminatdturn off gas pilot
Reduce steam pressure
Repair faulty radiator shutoff valves
Check operation of steam traps
Repair all leaks
Clean plant and distribution system equipment
Adjust airfluel ratios.
SERVICE WATER SYSTEMS
Repair leaks (piping, pump glands, steam traps)

-
Reduce the quantity of water used add restrictors
Lower hot water temperature setting
Check efficiency of oil- or gas-fired equipment
Raise cold water temperature settings on water fountains
Repair insulation on pipes and storage tanks
Install timeclock on recirculation pump.
Reduce illuminationk v e k where appropriate

Maximize use of daylight
Use higher efficiency lamps
Reduce or eliminate evening cleaning
Ciean lamps and fixtures
Improve reflectance of surfaces
Utilize task lighting
Use lower wattage lamps
Turn off when not in use.
8. MODERATE COST/HIGH COST

HVAC
1. Shut off air handling units whenever possible -3-

2. Reduce outside air intake when air must be heated or cooled
before use; repair or replace outside air dampers if necessary -2-
3. Reduce volume of air circulated through air handling units -2-
4. Shut off or reduce speed of room fan coils -3-
5. Shut off or reduce stairwell heating -2-
6. Shut off unneeded circulating pumps -2-
7. Reduce humidificationto minimum requirements -3-
8. Cycle fans and pumps where appropriate -x -
9. Reduce pumping flow --x-
10.
11.
Use damper controts to shut off air to unoccupied areas
Raise chilled water temperature
-2-
-3-
12. Shed loads during peak electrical use periods -3-
Solar Design Manual
~ x ~ l fSystem
l e Design Fearibil* Study- Page EX-25
CHECKLIST 2-4
ENERGYCONSERVATIONMEASURES
(Sheet 3 of 4)
To be
Implemented
YssNa
HVAC (Continued)
Use outside air for free cooling whenever possible

Reduce reheating of cooled air
Recover heating or cooling with energy recovery units
Reduce chilled water circulated during light cooling Loads
install minimum sized motor to meet loads
Replace hand valves with automatic controls
lnstall variable air volume controls
Install common manifolding of chillers
Insulate ducts and piping
Eliminate simuhaneous heating and cooling
lnstall night setback controls
Install water treatment to prevent tube fouling
lnstall multispeed/variablespeed cooling tower fans.
UTlLlN PLANT DlSTRlBUTlON SYSTEMS
Reduce steam distribution pressure

Shut off steam to laundry when not in use
increase boiler efficiency
Insulate boiler and boiler piping
-
InstalFeG6noflzer - - - - - - - -
lnstall air preheater

Install blowdown controls
Modernize boiler and chiller controls
Convert gas pilot to electronic ignition.
Convert to energy efficient systems

lnstall reflector systems.
BUILDING ENVELOPE
Reduce infiltration by caulking and weatherstripping

Install storm windows or double-pane windows
Install roof insulation
Install loading dock seals
lnstall vestibules on entrances
lnstall solar shading, screening, curtains, and blinds
install insulation in walls.
PLUMBING
lnstall faucets that automatically shut off water flow

Decentralize hot water heating or install tankless heaters
Add piping insulation
Electrically trace hot water supply piping to eliminate return piping
and pumps.
Solar Design Manual

-
Example System Design

(Sheet 4 of 4)
Implemented
Yes&
LAUNDRY
lnstall heat reclamation system for laundry wash water

Install heat reclamation system on dryers
Shut off equipment and appliances whenever possible
Install makeup air supply for exhaust.
KITCHEN
Shut off range hood exhaust whenever possible and install

dampers
lnstall high-efficiency steam control valves
Shut off equipment and appliances whenever possible
lnstall makeup air supply for exhaust
Install heat reclamation system for exhaust heat
Turn off lights in coolers
lnstall nighttime automatic steam cutoff.
SERVICE WATER
lnstall local boost heater(s) for 140 to 180°F water in lieu of raising
heater set temperature.
MISCELLANEOUS
lnstall incinerator heat recovery system

lnstall computerized energy monitoring and control system
Install motion sensors
lnstall thermal storagekogenerationsystem
Replace electric hot water heater with heat pump system.
Solar Design Manual

CHECKLIST 2-5

(Sheet 1 of 2)
Building Load Requirements
Daily Load: 22galiday-student (maximum), 13.lgaVday

-
(average before conservation)-
How determined? ASHRAE 1980 Systems Guidelines
Daily load after conservation -Same BtuJday (maximum)

Same- Btulday (minimum)
Load temperature -1 20-OF
Load profile (list hot water load estimates) (Btu/month): (x 1Os)
Jan 9 3 Feb 8 4 - Mar -91- Apr 8 6 - May 4 2 - Jun 4 1 -
Jut 3 9 - Aug 3 3 - Sep 6 0 - Oct 7 2 Nov 7 9 - Dec 8 7 -
Annual load -007 x 106 Btu
Weekly use -7 days X w e e k d a y only

Daily use- Mostly days - X Mostly night Day and night
Use Patlern - Mostly steady Intermittent -X-
-
Use Rate Mostly constant
Variable (--I
(-
-
O ~ p tom - 2 O a p m )
gpm),
Typical daily load profile:
-See ASHRAE Systems p. 37.15 for sample profile
10. Usage - Lavatories , Showers - X , Food Preparation ,

Process ,Other (indicate usage by percent)
11. Distance from heater to point of use 20-ft (nearest),

- 200- ft (farthest)
Solar Design Manual

CHECKLIST 2-5

(Sheet 2 of 2)
B. Main Heating System
1. Energy source: Gas Electric -X-Oil Steam

If steam, energy source for steam
2. Hot water heaterlstorage capacity 1,07O__gallons
3. Hot water heater type - Storage tankhurner - X Tankless

In-storage HX
4. Hot water set point 120-OF
5. Hot water draw rate -1 9 a p m (maximum), nominal
6. Hot water circulation Yes No -X-
7. Number of circulation loops Total piping length ft
8. Total circulation flow rate gpm
9. HW circulation operation -Day only Night onty

Constant
10. Cold water temperature 7 9 O F (max) 48 O F (min)
11. Cold water pressure 8 0 pig
12. Hot water pressure 80 psig
13. Hot water pressure relief valve setting: -1 2S__psi
14. Hot water high-temperature relief valve setting 2 10-OF
Solar Design Manual

CHECKLIST 2-7
CONSTRUCTION COST ESTIMATE SUMMARY

(See Appendix 2C for Calculations)
System Application: -Service hot water
Collector Type (i.e., fiat plate or evacuated tube): Flat plate
Collector Area (ft2): 1 , 6 0 0 -
Collector and Storage Tank Material Costs ($): -35,916

Mechanical Material Costs ($): -16,617
Electrical Material Costs ($): -2,646
Mechanical Labor Costs ($):
Electrical Labor Costs ($):
Other Costs ($1:
Bare Cost ($):
Subtotal Cost ($): ( Including freight)
Miscellaneous Costs (includes contingency,

overhead, profit, bonds and permits,
and liability) ($):
Total Construction Costs ($1:
Solar Design Manual

Exarnde Svstem Design Detailed Design- P a ~ EX-30
e
SECTION 3
DETAILED DESIGN
3.2 Overall System Schematic
From Table 3-1, Figures 3-2 and 3-6are selected as the coltector subsystem and interface subsystem
schematics, respectively. From Table 3-10, Figure 3-31 is used to determine the controls components.
Figures 3-38, 3-39,and 3-40are used to determine the performance instrumentation components.
Figure B illustrates the Example System P&ID.
3.3 Coltector Subsystem Design

3.3.1 Array Design
Array design is determined as follows:
a. The collector type is a flat plate, single-glazed coliector with internal manifolds
b. The collector size is 40 ft2 and the estimated number of collectors required is 40 panels
c. The collector tilt and orientation are to be 42" and 0° of true south, respectively. The 42" tilt was
determined by the example simulation program, and the 0' of true south is used because the
b
building orientation is true south.
d. The collector field layout is determined as follows:
1. The collectors should be mounted to one side of the elevator equipment structure on the roof.
The available width is approximately 150 ft. Using the suggestion in the manual for using 8
collectors to a bank, the required space per bank would be as illustrated by Figure C .
At 38 ftlbank, five banks will not fit to one side of the elevator equipment structure. Therefore,
to make two symmetrical rows of collectors, the design will be modified to contain 6 banks of
7 collectors each, for a total of 42 collectors.
2. Shading Calculation
Using the shading calculation methodology in Section 3.3.1.4, the minimum spacing distance
between rows is calculated as follows:
D = (L)(cos S) + (L)(sin S)(cos f) + (tan q)

where: L = loft
S = 42"
f = azimuth = 33.2' at 10 a.m., December 21 for a 32"N latitude
q = altitude = 30.8' at 10 a.m., December 21 for a 32"N latitude
D = 16.8ft~17ft
The layout of the collectors on the roof is illustrated by Figure D.
Solar Design Manual

Exarnvle Svstem Design Detailed Design- Page E X 3 1
e. Structural analysis and design is left for a structural engineer to do. The collectors will be roof
mounted, attached to a rack recommended by the collector manufacturer. The rack will be
supported on columns, penetrating the roof membrane, attached to I-beams in the roof structure.
The rack should be a minimum of 2 ft above the finished roof membrane. The collector weight is
120 Ib/collector. The fluid weight is estimated as:
(8.4 lb/gal)(2 gaWcollector)(42 collectors) + 200 ft pipe)(nlrl)(3/12)*(ft2)(63lb/ft3)= 1,324 lb fluid
Weight of 2-in. average copper pipe is: 21 lbl20 ft x 200 ft = 210 lb of copper pipe
Therefore, the dead weight on the roof, excluding the supporl structure, is estimated to be:
(120 Iblcollector x 42) + 1,324 lb fluid + 210 Ib of pipe = 6,574 Ib
The support structure must be designed to withstand 100-mph winds and support the collectors at
a 42' slope angle.
3.3.2 Piping Design
The piping design is determined as follows:
Piping material will be copper Type L
The pipe size for the collector loop is determined based on the recommended maximum velocity
of 4 to 6 ftlsec. Using the flow data from Table 3-5, Figure E illustrates the estimated volumetric
flow rates throughout the collector loop and the pipe sizes. The collector manufacturer recorn-
mends a flow rate of 2.5 gpm per collector.
The typical collector bank piping arrangement is illustrated by Figure F. The entire array is
plumbed in reverse return as shown in Figure E.
Pipe support shall be provided by the collector rack as shown in Figure G. Pipjng inside the
building should be supported in the same manner that the existing piping is supported.
Calculation of piping head loss. The head losses for the various components are listed below.
Table 3-5 was used to find the pressure drop of 150°F 50/50 propylene glycol.
Commnent Quantitv Pressure Drao (mil
3" Type L, Cu 4.55

2" Type L, Cu 2.50
1 114" Type L, Cu 4.06
1 1/4" ball valve 0.1 3
3" ball valve 0.1 0
3" check valve 0.02
Air separator 0.04
Heat exchanger 5.00
2" tee 0.1 3
3" standard elbow 0.91
3" coupling 0.27
2" coupling 0.15
1
1 1/4" coupling 0.10
Collector w
Subtotal pressure drop 18.0 psi
Allowance for error u
Total pressure drop 21.6 psi
Solar Design Manual

Example System Design -
Detailed Design Page EX-32
To convert to feet of glycol: 21.6 psi x 2.3 Wpsi = 49.7 ft
f. The initial loop pressurization requirement is calculated as follows:
Total static head = 50 + 12 + 10 = 72 ft
Initial pressurization = 72 + 4 = 76 ft (at pump level in basement)
76 ft / (2.3 Wpsi) = 33 psi (at pump level in basement)
3.3.3 Collector Subsystem Component Requirements
The component specification sheets are attached. The calculations for the pump and expansion tank are
outlined below.
a. Pump NPSH available: Using the procedure from Section 3.3.3.4.;
1. Suction pressure = 33 psig + 14.7 psi = 47.7 psia
2. Vapor pressure for 50150 glycol at 150°F = 3 psi
3. . NPSH allowable = 47.7 - 3 - 2 = 42.7 psia = 98.21 ft (Note: The fluid velocity head is
considered negligible)
b. Pump speed specification: Using the procedure of Section 3.3.3.4.;
2. Nl sr,so mm = (1750) (105 gpm)la / (49.7 ft)" = 958 rprn
3. N, ssm rpn = (3500) (105 gpm)lR1(49.7 ft)" = 1916 rpm
Based on the requirements discussed in Section 3.3.3.4, the 3500 tpm pump speed provides the
allowable specific speed (N,) closest to 2500 rprn.
c. Expansion Tank Sizing
Using the procedure of Section 3.3.3.6,the fluid volume estimate is:
collectors: 1.75 gallon/collector x 42 collectors = 74.0 gallons

3 inch pipe: (6.81I144) ft2x 250 ft x7.48 gallon/ft3= 88.4
2 inch pipe: (3.091144) ft2 x 85 ft x 7.48 gallon/ft3= 13.6
1 114 inch pipe: (1.261144) fF x 80 ft x 7.48 gallonlft3= 52
Subtotal fluid volume: 107.2 gallons
1Ooh contingency 10.7
Total: -1 18.0 galions
Solar Design Manual

-- C1 Collector Temperalure Sensor
Collector Array Data: Freeze Temperature Switch (NC)
42 collector panels
a,
'3,
FS1, FS2 Flow switch (NO)
40 ft2 /panel (3.7 rr?tWel) FM1, FM2, FM3 8tu Meter Flobwneter
42" slope TH1, TC1 Btu Meter 1 Temperature Sensor
M 2 ,TC2 Btu Meter 2 Temperature Sensor
M3, TC3 Bhr Meter 3 Temperature Sensor
Si, s2 Storage Temperature Sensor
53 Overtemperature Switch (NC)
From
4 I Other
NOTE: Use of Bhr meters is optional
COLD WATER
--
PI Air
/
Separator H4
Fill & Drain
P2
tines
Figure 0. Example System P&ID.

Example System Design Detailed Design- Page EX-34
Note: Minimum space required is 38 feet @I bank
Figure C. Typical 8 - Collector Bank
t
North Roof Plan (Not to Scale)
Figure D. Location of Collector Banks on Roof
2"/'
52.5 gpm
) gpmq
(7.5 ~ P ~ ( T Y P ) 35 ~ P ~ C T Y P 105 I
Array
Flgure E. Collector Pipe Sizes and Flow Rates supply
Solar Design Manual

Exam~leSvstem Design Detailed Design- fage EX-35
Flexible
Coupling q
-4- Bank Supply (TYP)
Figure F. Typical Collector Bank Piping
Figure G. CollectorIPipe Support
Location of
314" Female NPT Ports
Top & Bottom (Typ)
e
+ 6b+ Male N m 6q
9'
e
b
Figure H. Storage Tank

T-
Figure I. Storage Tank Details
Examvle Svstern Desi'an Detailed Desian- P a ~ EX-36
e
SPECIFICATION WORKSHEET
Flat Plate Liquid Collectors
Designer Owner Date
Project Page 1 of 3
Item Requirement
General Data
Application: (i.e., DHW heating, space heating, etc. -DHW heating

Fluid Type: 50150 propylene glycol and water-
System Type: (i.e., draindown, recirculation, etc.) -Closed loop anti-freeze

Quantity:
Nominal Size: i-e., 4 x 8 ft, 4 x 10 ft (1219 x 2438 rnm,

1219 x 3048 mm)
Gross Area: -40 ft2
Net Area: -37.5 ft2
Filled Weight: (Max., based on structural estimates) 140 Ibs
Wind Loading Capability: 100 rnph
Design Life:
Warranty:
Absorber Plate
Material: -Copper
Flow Pattern: ( i a , series, parallel) -Parallel
Manifold: (i.e., internal or external size) -Internal
Maximum Operating Pressure: 150 psig
Coating Type: Black chrome
Absorptivity: (Min.) 0.97
Emissivity: (Max.) -0.12

Expansion Capability: (fixed or floating within frame) -Floating absorber plate
Degradation: None
Solar Design Manuat

Examvle System Design Detailed Design- Page EX37
i SPEC1FlCATlON WORKSHEET
'i
/ Designer Owner Date
Project Page 2 of 3
I
Requirement
Cover Glazing
Glazing Material: Low iron tempered glass
Glazing Fasteners: (easy field replacements) -Anodized aluminum strips

Number of Covers:
Impact Resistance:
Collector Casing
Casing Fastener: Screws
Frame Material: -Aluminum

Weep Hole Locations: -2-bottom
Finish: -Anodized brown
InleUOutlet Connection Locations: Sides
Mounting Method: (integral flange, etc.) -integral flange

Cover Gaskets and Outlet Grommets
Temperature Limits: (operation)
Temperature Limits: (installation)
insulation
Material and Type: -Polyisocyanurate

Back Thickness: -2 inch (1 inch fibergjass)
Side Thickness: -112 inch
R-Value for Back: -R-14
Solar Design Manual

/ \
f SPECIFICATION WORKSHEET
\
Designer Owner Date
Project Page 3 of 3
Item Requirement
Fluids and Flows
Fluid Type: -50/50 propylene glycol and water-

Operating Temperature Range: 0 -212 O F
Flow Rate Range: 2.5 gprn / collector
Allowable Pressure Drop at Design Flow Rate: 0.03 psi
ASHRAE Performance Test Data
F@): (Min.) 0.778
F,U,: Max.) -0.855 8tu/h*ft2*OF

Test Fluid: Water
Test Flow Rate: 2.5 gpm
Incident Angle Modifiers: -Kat =l.O -0.143 ( l / c o & - 1)
Certifications: -SRRC
SRCC Approvals: Yes
Mounting Requirements
Installation Orientation: (vertical or horizontal) -Vertical

Drainability Requirement: Yes
Maximum Collector-to-CollectorLateral Space: 4 inch
Manufacturer'sTypelModeI (or equivalent)

Example System Design Detailed Design- Page E X 3 9
Heat Transfer Fluids
) Designer Owner Date
I Project Page 1 of 1
Item Requirement
Application: -DHW heating

Type: (i.e.,glycol, water, etc.) -Propylene glycol and water
Operating Temperature Range: Maximum 2 5 0 ° F -Viscosity -0.64 cps-
Minimum - 3 0 ° F -Viscosity -1 87 cps-
Mixture Ratio: -50150

Toxicity Rating: -20.3 LD, 50
Vapor Pressure: (at rnax. temperature) -19.9psia
Maintenance Requirements: -2 yr change
Available Container Sizes: -55 gallon drum
Material Compatibility: -Copper and bronze compatibility
- -
- - - - - - - - - - - - - - - - -
- - - - - - - - -
Special Additives: - - - - - -
GuaranteeNarranty:
Manufacturer's Type/Model: (or equivalent)

,Item Requirement

Pump Type: -Single-stage, single suction, centrifugal-
Pumped Fluid: -50/50 propylene glycol and water
Pumping Temperature Range: ,
Fluid Specific Gravity @ Temperature: -I.024 @ 100°F

Fluid Viscosity @ Temperature: -3 cps @ 100°F
Design Flow: -105 gpm
Developed Head:
Shutoff:
Loop Max. Operating Pressure:
Available NPSH: -42.7 psig

Pump Speed: -3500
Pump Seals Compatibility with Fluid: -50/50 propylene glycol
Motor Impeller Connection: -Direct couple
System Connection Sizes and Types: -3 inch flanged
Mounting Orientation: -Horizontal
Pump Support Requirements: -Concrete pad
Available Electrical Service (V, I, 0, Hz) -120 v, 30 amp & 208 v, 60 amp, 3 phase-
Pump Code Requirements:
Pump Material: -Cast iron

Pump Operating Environment: -Indoor
Solar Design Manual

Exarnvle System Design Detailed Design- Page E X 4
Pumps
Designer Owner Date
I Project Page 2 of 2 I
Item Requirement
Ambient Temperature:
Motor Code Requirements: -Explosion proof

Space Requirements: -None
Drainback Operation Capability: (if applicable)
(Note: For some drainback systems,fluid must be
able b flow backward through pump.)
Manufacturer's TypelModel: (or equivaient)
Solar Design Manual

Expansion Tanks
Designer Owner Date

Project Page 1 of 1
Item Requirement
Application: DHW Heating
Type: (bladder or free surface) -Bladder

Bladder replaceableinonreplaceable: -Replaceable
Total Volume: 1 18 gallons (in collector loop)
Type of Fluid: -50/50 propylene glycal and water

Operating Temperature Range: 30 to 250 O F
Maximum Operating Pressure: -75 psig

Fluid Expansion: (over temperature range) -10 gallons
Material Compatibility: -EPDM-50/50propyiene glycol compatibility-
Overall Envelope Limits: -None
Connection Type and Size: 112 inch NPT male
Warranty: 1 Yr
Manufacturer's TypeIModel: (or equivalent)

SPEClFlCATlON WORKSHEET
Air Separator Valve
Designer Owner Date
Project Page 1 of 1
Item Requirement
Application: DHW heating
Size and Type of End Connections: 3 inch NPT, female, bronze
Material Compatibility: -50/50propylene glycol compatibility-

Minimum/Maximum Working Temperature: -30 to 250 O F
Maximum Working Pressure: -75 psig

Vent Connection Size and Type: -112 inch NPT, female
Warranty: 1 Yr
Manufacturer's TypdModel: (or equivalent)

Example System Design Detailed Design -Page EX-44
Flex Couplings
Designer Owner Date
Project Page1 of 1 I
Application: (torsion, lateral) -Lateral

Material: -Copper
Compatibility: -50/50 propylene glycol compatibility-
Connection Size and Type: -1 1/4 inch sweat
Geometry: -Bellows
Nominal Length: -1 ft
Maximum Expansion: -118 inch
Maximum Contraction: -118 inch
Minirnum/Maximum Temperature:
Insulation Requirements: Must be insulated
Cycles to Failure:
Warranty:
Manufacturer's Typehlodel (or equivalent)
Solar Design Man uaE

Exarn~leSvstem Design Detailed Design- Page EX-45
Insulation
Designer Owner Date
Project Page 1 of 1
Requirement

Type: -Rigid, closed cell
Material: Polyisocyanurate
Thermal Conductivity: -0.25 Btu inch/h ft2 O F
Ozone Resistance: -Yes

U.V. Resistance: -Yes
Odor/Outgassing: None
Flame and Smoke Characteristics: Stable to 350 O F
Code Requirements:
WeatherproofingNacketing: PVC jacket
Water Absorption: -None

Mildew Resistance: -Yes
Wall Thickness: (La., overall R-value requirement) R-8 minimum
Warranty: 1 Yr
Manufacturer's TypefModel: (or equivalent)
Solar Design Manual

Air Vent
Requirement
Type: (i.e.,automatic, float, and manual, etc.) Automatic
Minimum/Maximum Operating Pressure: 0 to 25 psig
Minimum/Maxirnum Temperature Range: -0 to 350 O F

Size and Type of End Connection: 1/2 inch NPT, male
Fluid Compatibility: -50f50 propylene glocal compatibility-

Environmental Conditions: (i.e., freezing, dirt, rain, etc.) Outdoor, freezing, rain, dirt, etc,.
Warranty:
Manufacturer's Type/Model (or equivalent)

\
/-
Check Valves
Designer Owner Date
I Project I
Requirement

Type: (La,
spring-loaded or swing check) -Swing check
End Connections: (type and size) -3 inch sweat
Material: -Copperlbronze
Pressure Rating: -150 psig
Code Requirements: ASME
Minimum/Maxirnurn Temperature: 30 to 250 O F
Minimum/Maxirnum Pressure: -0 to 75 psig

Minimum/Maximurn Pressure Differential
(i.e., across f IapperJplug): -0 to 40 psig
Fluid Compatibility: 50/50propylene glycol

Required Opening Pressure: -0.02 psig
Warranty: -1 Yr
Manufacturer's TypdModel: (or equivalent)
Solar Design Manual

cample System Design Detailed Design - Page EX-48
SPECiFICATION WORKSHEET
Pressure Relief Valves
Designer Owner Date
Project Page 1 of 1 I
\
Requirement

End Connections: -314 inch NPT, male
Material: Bronze
Set Pressure Limit: (setting) As noted below
Working Pressure: As noted below
Code Requirements:
Fluid Compatibility: 50150 propylene glycol compatiblity-
Steam Rating or Relief Capacity: -650,000 Btulh ASME steam rating

MinimumIMaximurn Working Temperature: 0 to 350 O F
Lifting Lever: Yes
Set Pressure Adjustability:
Warranty:
-
PRVs at collectors 6 each at 25 psig setting, 20 psig working pressure
-
PRVs at heat exchanger 1 each at 75 psig setting, 50 psig working pressure
Polar Design Manual

7 - -
SPEC1FlCATlQN WORKSHEET
Piping
>
Designer Owner Date
Project Page 1 of 1 ,
item Requirement

Minimum/Maximum Temperature Range: -0 to 350 OF
Fluid Compatibility: 50/50 prapylene glycol compatibility-
Fluid Velocity: (Maximum) -6 ft/s

Material: Copper
Size and Type or Schedule: See below
ASTM Specification Requirements:
Dissimilar Material Connections: -None

Manufacturer's TypelModel: (or equivalent)
-
3 inch 250 ft Type L-
-
2 inch - 85 ft Type L
-
1 1/4 inch 80 ft Type L -
Solar Design Manuc

,ample System Design Detailed Design- Page EX-50
Storage Subsystem Design
..I Storage Tank Design
e storage volume for this design, using the 1 gallon/ft2requirement, is:
42 collectors x 40 ft2/collectorx 1 gallon/ft2= 1680 gallons
lettical tank will be designed. Typically vertical tanks have a length-to-diameter ratio of 3. The dimensions
the tank can be determined as follows:
1680 gallons x 0.1 337 ft3/gallon= 225 ft3
3/4~tD3= 225 ft3

D = 4.56 ft and L = 13.7 ft
\isis taller than the space available, but a diameter of 6 ft will provide a height of 9 it, which is acceptable.
eref fore, the storage tank will be 6 ft D x 9 ft H and will have four nozzles located as illustrated by Figure H.
4.2 Piping Design
a. Piping material will be copper Type t
b. The pipe size from the heat exchanger to the tank is determined based on the recommended
maximum velocity of 4 - 6 Ws. The required volumetric flowrate from Section 3.4.2 is calculated
as follows:
),g
n
p
(,r (62.1b/ft3)(1 Btu/lb*OF)> (1.05) (105 gpm) (64.27 lblft3)(0.866 Btu/Ib*OF)
gprn = 98.97 z 100 gprn
From Table 3-2A, the pipe diameter should be 3 inches. The pipe size from the solar storage
tank to the existing storage tank is based on existing line sizes which are 2 inch copper Type L.
c. Calculation of piping head loss
The head losses for the various components in the collector/storage subsystem interface are:
Component Quantity Pressure Drop-psi
Heat exchanger 1 5.0

3 in. Type L Cu 50 ft 1.O
3 in. ball valve 4=4ft 0.07
3 in. check valve I =lft 0.02
3 in. coupling 5 = 7.5 ft 0.14
3 in. standard els 10=50ft ful
Subtotal 7.14
Calculation error - 20 5% 1.43
Total 8.57 G 9.0 psi
To convert to feet of glycol: 9 psi x 2.3 ft/psi = 21 ft
'olarDesign Manual
Example System Design Detailed Design- Page EX-5j
3.4.3 Storage Subsystem Component Requirements
The component specification sheets are attached. Additional information regarding the components is
discussed as follows:
a. Storage Tank
In addition to the specification sheets, Figure I is required to complete the tank specification.
b. ,Heat Exchanger
A plate heat exchanger will be utilized. Using the procedure outlined in Section 3.4.3.2:
1. Effectiveness = 0.7
2. Fluid properties @ 110 O F are:
Glycol
C1= 2.84 cps

Water
P= 62.0 lb/ft3
C, = 1.0 E3tu/b°F
P= 0.68 cps
5. C, = 8.021 (105 gpm) (63.96 lblft3)(0.871 Btu/lba°F) = 46,918 Btulh-F
6. Cc = 8.021 (100 gpm) (62 Ib/ft3)(1.O B t ~ l l b ~=~ 49,730

F) Btu/he°F
7. T,,, = [(201,600 Btu/h)l{(O.7)(46,918 Btu/hm°F)}] + 100 OF = 106.1 OF
, = [{(0.7) (106.1-100°F) (46,918 Btuh))/(49,730 Bt~lha'F)] + 100 O F = 104.1 O

8. T
, = 106.1°F - [0.7(106.1 -100 OF)] = 101.8 OF

T
9. Estimated fouling factor = 0.00020
The specification sheet contains the balance of the requited information.
Solar Design Manuc

xarnvle Svstem Design Detailed Design- Page EX-52
c. Pump NPSH-Available and Speed
10 ft = estimated static head (4.35 psig)

184 ft = city pressure (80 psig)
3.72 psia = vapor pressure of water at 150 O F
= 248 ft of water
2. Pumpspeed
,N = [(4000) (248 ft)34]/(100)1R

= 25,998 rpm
N,, 750) (1OO)1Y(21)Y4

= [(I = 1784 rpm
Based on the requirements discussed in Section 3.3.3.4, the1750 rpm pump

provides the allowable specific speed (Ns) closest to 2500 rpm.
3.5 Instrumentation and Controls Subsystem Design
3.5.1 Solar Energy System Operational Controls
The recommended operational controls schematic is illustrated by Figure 3-31 as determined from
Table 3-10. The collector sensor and thermal switches will be located as illustrated by Figure J.
3.5.2 Solar Energy System-to-Load Interface Controls
System-to-load interface controls are not required.
3.5.3 Operational Instrumentation
The operational monitoring instrumentationconsists of temperature gauges, pressure gauges, and pressure/
temperature ports. These are located as illustrated by the PBID, Figure B. The pressureltemperatureports
will be installed within a few feet of each temperature gauge.
3.5.4 System Performance Monitoring lnstrumentation
Performance monitoring instrumentation consists of three Btu meters located as illustrated by

Figures 3-38(top), 3-39, and 3-40(top).
3.5.5 lnstrumentation and Control Component Requirements

The component specification sheets are attached. The locations of the sensors and switches on the storage
tank are illustrated by Figure K.
Solar Design Manual

Exarnvle Svstem Desian Detailed Design- Page EX-53
I A I
South T
Array
Return
Figure J. Collector Sensor Locations
f Valve
'Array \Spare
Outlet Return Well
Left Side! Front Riaht Side
w w w
>
Spare Cold Water Drain
Well T - Gage Array
S1 Valve
WP~Y
0
' 0 \0 d o '
.
Figure K. Storage Tank Sensor Locations
Solar Design Manui

/
-
'
Thermal Storage Tanks
Designer Owner Date
Project Page 1 of 2 *
Item
Applicatiion: DHW heating
Volume: 1680 gallons
Dimensions: (refer to tank drawing) See sketch
Material: Steel
Code Requirements:
Maximum Allowable Pressure: 250 psig
Maximum Allowable Temperature: 225 O F
Mounting Orientation: Vertical
Mounting Supports: Flat bottom on concrete pad
Connection Types and Sizes: 3 inch NPT, male & 3/4 inch NPT, female
Connection Locations: See sketch
Manhole: No
Baffles: No
Lining: -Epoxy coating

Corrosion Protection: Epoxy coating
Level Gauge Requirements: Not required
Insulation Requirements: (if factory installed) N/A
Warranty:
Auxiliary Heating Type:
Manufacturer'sTypeIModel: (or equivalent)
*Second page not applicable to this system design.
Solar Design Manual

Exarnvle Svstem Design Detailed Design- Page EX-55
Heat Exchangers
Designer Owner Date
1
Project Page 1 of 2
Requirement
,pplication: (i.e., liquid-to-liquid, liquid-to-air,etc.) Liquid to liquid
ype: (i-e., shell and tube, multiplate, etc.) -Multiplate

lumber of Units:
IveraH Envelope: 4 wide x 4 long x 4 high
.imitations: -None
>odeRequirements: ASME
>onnectionSizes and Types: i.e., 2-in. (51 mm) flanged -3 inch flanged
system Interface Materiat: (i.e., copper tubing, etc.) -Copper Type L
service Life: (casing materials) -20 yr
Mounting Requirements: (i.e., floor, wall, etc.) Floor
:leaning Requirements: -Must be accessible

Number of Walls: (i.e., single wall, double wall, etc.) -Single
Venting: (for double-wail designs)
Operating Effectiveness: (nominal conditions)
Hot Side Cold Side
Fluid Type: -50/50 propylene glycol -Water

Fluid pH: -8.0 -8.0-
Dissolved Salts:
Nominal Inlet Temperature: -106.1 O F -100 O F

Nominal Outlet Temperature: -101.8 O F -104.1OF
Minimum Operating Temperature: -35 O F -35 O F
Nominal Flow Rate: -105 gpm - -1DO O F
Energy Transfer Rate: -201,600 Btulh- -201,600 Btulh-
Solar Design Manua

Example System Design Detailed Desi~n-Page EX-56
Heat Exchangers
Designer Owner Date
I Project Page 2 of2 I
Requirement
Hot Side Cold Side
Face Velocity: (for liquid-to-air systems only) -N/A -NIA

Specific Heat: -0.871 -1.O
Specific Gravity of Fluid: -1.025 -0.994
Thermal Condudivity of Fluid: -4.36 Btu*in/h*ft2*OF -2.63 Bt~*in/h*ft**~F
Viscosity of Fluid at Min. Temperature: N/A -NIA
Viscosity of Fluid at Operating Temperature: -2.84 cps @ I 1 0 OF -0.68 cps @ 110 O F
Maximum Allowable Pressure: -150 psig -250 psig
Operating Pressure: -75 psig -125 psig
Maximum Allowable Pressure Drops at Nominal Flow Rate: -5 psi -5 psi
Fouling Factor: -0.0002
Warranty: -5 Y r
Manufacturer's TypelModel: (or equivalent)
Solar Design Manual

Pumps
Designer Owner Date
Project Page 1 of 2
Requirement
Pump Type: Single stage, single suction, centrifugal-
Pumped Fluid: -Water

Pumping Temperature Range:
fluid Specific Gravity @ Temperature:
Fluid Viscosity @ Temperature: -0.68cps @ 100 O F

Design Flow: -100 gpm
Devetoped Head: 21 ft at design flow
Shutoff: -25 ft
Loop Max. Operating Pressure: -125 psig
Availabfe NPSH: 108 psia
Pump Speed: -1750 rpm

Pump Seals Compatibility with Fluid: -N/A
Motor Impeller Connection: -Direct couple
System Connection Sizes and Types: -3 inch flanged
Mounting Orientation: Horizontaf
Pump Support Requirements: -Concrete pad

Available Electrical Service (V, I,0, Hz) 120 v. 30 amp & 208 v, 3 phase, 60 amp
Pump Code Requirements:
Pump Material: All bronze
Pump Operating Environment: -Indoor
Solar Design Manua

Examnle Svstem Design Detailed Design- Page E X 4 8
Pumps
Designer Owner Date
Project Page 2 of 2
Requirement
Ambient Temperature: -80 OF
Motor Code Requirements: Explosion proof
Space Requirements: NIA
Drainback Operation Capability: (if applicable)

(Note: For some drainback systems, fluid must be
able to flow backward through pump.)
Warranty:
Manufacturer'sType/Model: (or equivalent)
Solar Design Manual

Example System Design Detailed Design- Page E X 5
-
Tempering Valve
/ Designer Owner Date
Project Page 1 of 1
Item Requirement
End Connections: 3 inch sweat
Operating Pressure: 125 p i g
Operating Temperature Range: 35 to 212 OF
Output Temperature Adjustment Range: 90 to 140 O F
Code Requirements:
Output Temperature Indicator: -Yes

Response Time: <1os
Warranty:
Solar Design Manuc

Exam vle Svstem Deskn Detailed Design- Pane E X 4 0
SPECIFICATIQNWORKSHEET
Pressure Temperature Relief Valves
t Designer Owner Date
Page 1 of 1
Project
Requirement
Application : -DHW heating

Material: -Bronze
Set Pressure: -125 psig
Working Pressure: -125 psig
Set Temperature: -210 OF
MinimumIMaximum Working Temperature: -210 O F
Code Requirements: -ASME

Fluid: -Water
Steam Rating or Relief Capacity: -650,000 Btulh, ASME pressure steam rating
Minimum Temperature Element Length: -6 inch
Lift Lever: -Yes
Test Capability: -Yes
Set Temperature and Pressure Adjustability:
Warranty:
Solar Design Mallual

E x a m ~ l eSvstem Design Detailed Design - Page EX-61
\
Insulation
Designer Owner Date
Project Page 1 of 1
Item Requirement

Type: Rigid dosed cell
Material: Polyisacyanurate
Thermal Conductivity: -0.25 Btu*in/h*ft2*OF

Operating Temperature Range:
Ozone Resistance: Yes
U.V. Resistance: -Yes

Odor/Outgassing : None E
Flame and Smoke Characteristics: -Stable to 350 O F
Code Requirements:
Weatherproofing/Jacketing: None
Water Absorption: None
Mildew Resistance: -Yes

Wall Thickness: (i.e., overall R-value requirement) Tank & Hx, R-j 6 min.; Piping, R-8 min.
Warranty: 1 Yr
Solar Design Manu4

Example System Design Detailed Design - Page EX-62
Air Vent
Designer Owner Date
I Project Page 1 of 1 I
Type: (i.e.,automatic, float, and manual, etc.) Automatic
Minimum/Maximum Operating Pressure: -0to 125 psig

Minimum/Maximum Temperature Range: 35 to 210 O F
Size and Type of End Connection: -112 inch NPT, male

Fluid Compatibility: -Water
Environmental Conditions: (i.e.,freezing, dirt, rain, etc.) -NIA
Warranty: 1 Yr
Mar Design Manual

Check Valves
Designer Owner Date
Project Page 1 of 1
ltem Requirement
Type: (i.e., spring-loaded or swing check) Swing check
End Connections: (type and size) -3 inch sweat

Material:
Pressure Rating: 125 psig
Code Requirements:
MinimumIMaxirnum Temperature:
Minimurn/Maximum Pressure: -O to 125 psig

Minimum/Maxirnum Pressure Differential
(i.e., across ffapperlplug): -0 to 40 psig
Fluid Compatibility: Water

Required Opening Pressure: -0.02 psi
Warranty:
Manufacturer'sTypeIModel: (or equivalent)
Solar Design Manu

/ \
f SPECIFICATION WORKSHEET
'i
Pressure Relief Valves
I Designer Owner Date
Project Page 1 of 1
Requirement

Material: -Bronze
Set Pressure Limit: (setting) -125 psig
Working Pressure: 80 psig
Code Requirements: -ASME

Fluid Compatibility: -Water
Steam Rating or Relief Capacity: 650,000Btulh ASME pressure rating-
Minimum/Maximum Working Temperature: 35 to 210 O F
Lifting Lever: Yes
Set Pressure Adjustability:
Warranty:
Manufacturer's TypeiModel: (or equivalent)
Solar Design Manual

Piping
Designer Owner Date
Project Page 1 of I
Item Requirement
Appiication: DWH heating
Maximum Operating Pressure: 125 psig
Minimum/Maximum Temperature Range: -Oto210 O F

Fluid Compatibility: Water
Fluid Velocity: (Maximum) 6 ft/s
Material: -Copper
Size and Type or Schedule: 3 inch Type 1
ASTM Specification Requirements:
Dissimilar Material Connections: -Dielectric unions required at tank-

Exam~leSvstem Design Detailed Design- Page EX-66
SPEClFlCATlON WORKSHEET
Differential Temperature Controller
Designer Owner Date
Project Page 1 of 1
Requirement

Number of Outputs:
On/Off ThresholdsIRange: -20A°F

Storage High Temperature Shutoff: -160 to 210 O F
Freeze Protection: Not required
Operating Environment: -Indoor

Input Power: -110 v, 20 amp
Output Relay Capacity: (Volt, amp) -1lOv,20amp
Power Backup: -Not required
Set Point Adjustability: -No
Control Accuracy: -* 2%
Display Capability: -Temperature readings
ManualfAuto Capability: Yes
Mounting Dimensions: Wall mounting
UL Requirements: -UL listed

Warranty:
Solar Design Manual

Example System Design Detailed Design- Page EX47
Temperature Switches
Designer Owner Date
Project Page 1 of 1
Requirement
Application: Freeze & overheat protection
Type: (NC, NO, DP, ST, DT) -As shown on electrical schematic-
Temperature Set Point Range: -As shown on electrical schematic-
Switch Contact Rating:
Number of Contacts: 1
Construction: -Copper
Warranty: 5 Yr
Solar Design Manuc

.-- \
SPECIFICATION WORKSHEET \
Temperature Sensor
1 Designer Owner Date

I
Project Page 1 of 1 1
Requirement
Application: Differential temperature controller-
Type: (thermister, RTD, IC) RTD
Resistance/TemperatureCharacteristics: As required for contro!ler
Accuracy: *2 O F
Leads: -As required for controller

Casing Material: Copper
Interchangeability: -Not required

Matching: Yes
Attachment: -Strap or bolt on

Response Time: As required for controller
Warranty: -5 Yr
Solar Design Manual

Btu Meters
Designer Owner Date
Project Page 1 of 2 I
Item Requlrernent
Type: Electronic
#1 #2 #3
Average Continuous Flaw:
Peak Flow:
Minimum Flow:
Maximum Operating Pressure:
Temperature Sensor Type: -RTD

Temperature Sensor Matching: -Yes
Temperature Sensor Attachment: -Thermowell
Flowmeter Type: -Nutating disk
Flowmeter Connection Sizes and Types: -3 inch sweat
Maximum Allowable Pressure Drop Across Flowmeter: -1 psi
Integrator Readout Requirements: -Btu, DT, Volume, & flowrate
Fluid: prop-glycol w a t e r water
Fluid Specific Gravity: (@ 11O°F) 1.025 0.993 0.993
Fluid Specific Heat: (Btu/lba°F @ 1 10°F) -0.871 1 1
Sensor (Temp and Flow) Mounting Requirements: Horizontal
Input Power Requirement: -110 volts, ac

Warranty:
Solar Design Manual

Example System Design Detailed Design -Page EX-70
/ --,
f SPECIFICATION WORKSHEET \I
Btu Meters 1
Designer Owner Date
Project Page 2 of 2
Item Requirement 1
Site Adjustment Capability: -Yes

Tamper Resistance: -Yes
Power Backup: -Yes - batteries
Environmental Conditions of Integration:
Manufacturer's TypeIModet: (or equivalent)

SYstem Design
Exam~h? Detailed Design- Page EX-71
PressureRemperature Ports
Designer Owner Date
Project Page 1 of 1
Item Requirement
Application: -Performance monitoring of solar system-

Material: (body and gasket) -Brass, Nordel
Connection Size and Type: -112 inch NPT, male
Minirnum/Maximum Operating Temperature: -0 to 350 O F
Test Probe Diameter Requirements: -1/8 inch diameter probe

Solar Design Manual

Exam ole Svstern Desian Detailed Design- Page EX-72
- - - - - - - - - - - -- -
Pressure Gauges
I Designer Owner Date

I
I Project Page 1 of 1
Item Requirement
Pressure Range: (max.) -250 psig
Operating Pressure Range: 0 to 250 psig
Operating Temperature Range: -0 to 212QF

Connection Type and Size: -1/2 inch NPT,male
Dial Size: -4 inch
Pressure Indication Range: -collector loop-0-100; storage loop-0-150-
Accuracy:
Indication Increment: -1 psi

Fluid Compatibility: -Collector-50f50 pro-glycol; storage-water-
Warranty:
- -
Solar Design Manual

/ \
Thermometers
Designer Owner Date
Project Page 1 of 1
Requirement
Application: 7
DHW heating
Type: -Mercury bulb

Temperature Indication Range: -0 to 225 O F
Connection Type and Size: -1 2 inch NPT, male-

Dry Well or Immersion: -Dry well
Size of Readout: 7
8 inch
Accuracy: -f 5%
Stern Length: -As required
Fluid Compatibility: -N/A
Warranty: 5 Yr
Solar Design Manual

3.9 PerformancelCostVerification
3.9.1 Verification of Thermal Performance
Ideally, a sophisticated simulation computer program would be used to determine the performance of the de-
signed system. For this example, the example simulation program used in Section 2.3.1 will be used. The
inputs for the program are fisted as foilows.
Collector Parameter Set
1 NUMBER OF COLLECTOR PANELS

2 COLLECTOR PANEL AREA
3 FRWL (TEST SLOPE)
4 FR*TAU*ALPHA (TEST INTERCEPT)
5 COLLECTOR SLOPE DEG
6 COLLECTOR AZIMUTH (SOUTH = 0) DEG
7 INCIDENCE ANGLE MOD TYPE (8-10)
8 NUMBER OF GLAZINGS
9 INC ANGLE MODIFIER CONSTANT
10 INC ANGLE MODIFIER VALUE(S)
11 COLLECTOR FLOW RATVAREA
12 COLLECTOR FLUID SPEClFtC HEAT
13 MODIFY TEST VALUES (1=Y,2=N)
14 TEST COLLECTOR FLOW RATOAREA LB/HR- IT2
15 TEST FLUID SPECIFIC HEAT BTUILB-F
Storage Parameter Set
1 CITY CALL NUMBER

2 WATER STORAGEVOLUME - - - - GALLONS
3 BUILD~NG
- - - - - - - - -
UA (0FOR DHW ONLY) BTU/HR-F

4 FUEL (I=EL, 2=NG, 3=01L, 4=OTHER)
5 EFFICIENCY OF FUEL USAGE
6 DOMESTIC HOT WATER (1=Y, 2=N)
7 DAILY HOT WATER USAGE GALLONS
8 WATER SET TEMPERATURE F
9 ENVIRONMENT TEMPERATURE F
10 DHW STORAGE TANK SlZE GALLONS
II UA OF AUX STORAGE TANK BTUtHR-F
12 PlPE HEAT LOSS (l-Y, 2-N)
13 INLET PlPE UA
14 OUTLET PlPE UA
f 5 RELATIVE LOAD HX SlZE
16 COLLECTOR-STORAGE H (1=Y, 2 4
17 TANK SIDE FLOW RATEIAREA
18 HEAT EXCHANGER EFFECTIVENESS
Solar Design Manual

Note:
*Daily hot water usage; the monthly values are input by typing "7V"
Jan 3936 May 1968 Sept 3933

Feb 3929 June 1967 Oct 3936
Mar 3936 July 1968 Nov 3933
AP~ 3933 AW 1968 Dec 3936
**Environment temperature; the monthly values are input by typing'9 V"
Jan 60 May 65 Sept 70

Feb 60 June 75 Oct 70
Mar 65 Juty 75 Nov 65
AP~ 65 Aug 75 Dec 60
"*Value indicated is based on the following:
where: L= pipe length (ft)

AT = temperature difference (OF)
r, = outside radius of insulation (ft)
ri = inside radius of insulation
k= insulation thermal conductivity (Btu/h8fte°F)
h= convective coefficient (Btu/h*ft2*OF)
0.03 1 0.214 0.13 36.9

0.03 1 0.172 0.088 9.5
0.03 1 0.141 0.057 13.5
Total 59.9 z 60.0
The results are listed as follows:
Design Handbook Sample Run 2

Ftat Plate Collector
Solar Heat DHW Aux

MMBtu MMBtu MMBtu MMBtu F
Jan
Feb
Mar
AP~
May
Jun
Jut
Aug
S ~ P
Oct
Nov
Dec
Yr
Solar Design Manual

3.9.2 Cost Estimate
The attached tables show the estimated cost for the example, expressed in 1985 U.S. dollars. The
costs must be adjusted to the year of proposed construction. The system cost is:
Material = $44,452.00
Labor = 14,861.00
Freight = 1,290.00
Work Comp (5.29%) = 776.00
Soc. Sec. (7.05%) = 1,034.00
Unempl. Tax (1%) = 147.00
Sales Tax (7%) = 3.lf2.00
Subtotal $65 ,472.00
Contingency (5%) =
G & A (I Oa/o) =
Profit (10%) =
Bonds & Permits (1%) =
Liability t nsurance (1%) =
Subtotal
Total iiu&&!u
The design cost estimate detail is listed in Table 5.
3.9.3 Economic Evaluation
The installed performance for the Detail Design run is estimated to be:
Solar contribution = (531.7 - 101.5)/1.20 = 358.5 MMBtu
Solar fraction = 358.5/531.7 = 0.67
Assuming the electrical energy cost of $39.84/MMBtu, the TLCC with solar is:
Design and Installation Costs $84,855.00

Auxiliary energy requirement (MMBtuIyr) 173.2
Auxiliary energy costs ($/yr) 6,900.00
Operating cost ($/yr) 714.00
Maintenance costs ($/yr) 1,697.00
Total Life Cycle Cost $168,248.00
When this cost is compared with the TLCC without solar of $189,723, the design is seen to be cost-
effective.
--
Solar Design Manual

-
Table 5 Design Cost Estimate Detail
Description Quantity Unit Materials Labor Total
Coltectors 42 each
Collector supports $2140
Crane 4 hours 90
Tank ( I 680 gallon) 1 each 31 6
Crane 2 hours 90
Piping
3 in., Cu L 300 feet 10.65
2 in., Cu L 115 feet 7.70
1 1/4 in., Cu L 80 feet 5.75
Ets
3 in., Cu L 20 each 29.00
2 in. ,CuI. 10 each 16.15
I 114 Cu., L 12 each 12.38
Tees
3 in., Cu L 4 each 46.00
2 in., Cu L 10 each 25.00
1 114 in., Cu L 6 each t 9.88
Couplings
3 in., Cu I. 15 each 25.00
2 in., Cu L 10 each 13.65
1 1/4 in., Cu L 10 each 10.85
Air separator 3 in I each 80 .
Check valves 3 in. 2 each 25
Ball valves 3 in. 9 each 25
Bal valves 1 114 in 12 each 11.SO
Pump P1 1 each 80
Pump P2 1 each 80
Valve V1 1 each 125
Expansion tank 1 each 75
Automatic air vent 8 each 5.55
Insulationfoam
pipe 3 in. 300 feet 1.99
pipe 2 in. 115' feet 1.87
pipe 1 If4 in. 80 feet 1.72
el 3 in. 20 each 3.99
el 2 in. 10 each 3.72
el 1 1/4 in. 12 each 3.43
tee 3 in. 4 each 5.90
tee 2 in. 10 each 5.60
tee 1 114 in. 6 each 5.17
valve 3 in. 9 each 5.90
valve 1 1/4 in 12 each 5.17
tank urethane 230 SF 0.78
Controls/instruments Est. 1750
Electrical Est. 9M,
Subtotal $14,661
Freight
Totals $14,661
Solar Design Manual

Desian Manual Index Index- Paze I N 4
ACTIVE SOLAR HEATING SYSTEMS

DESIGN MANUAL
Air collector system, 1-10, 3-110 Component specifications

Air cooled collectors, 3-110, 3-114 sample worksheets, 4-4,4-5, 4-6
Air filters, 3-13, 3-113, 3-129 Conceptual analysis, 1-1
Air handler unit, 3-116 summary, 1-29
Air separator, 3-12,3-54 Conference
Air vent owner-NE, 1-2
manual, 3-54 Conservation methods, 2-3
automatic, 3-12,3-54 Construction
Antifreeze system, 1-8, 5-4 cost, 2-8,2-27,2C-1
Array(see collector array) package, 4-2
ASHRAE specifications, 4-3, 4B-1
handbooks, 1-3,3-51 Control mode matrix, 3-77, 3-108, 3-132,3-142
standards, 2-7,3-40 Control schematic drawing, 3-77, 3-108,3-132,
3-142
Backflow preventer, 3-13,3-70 Controllers, 3-105, 5-15
Btu meter, 3-99,3-106,546 Coolant(see heat transfer fluids)
Building information, 1-33, 2-2, 2-15 Corrosion, 3-42,3-62, 5-7
Costs, 1-13
Checkout procedures, 3-98 construction, 2-8
Codes and standards, 3-28, 3-39, 3-113 estimate for installed system, 3-144
Collectors preliminary estimate, 1-28
certification, 2-6, 3-40 Cost-effectiveness, 1-28, 2-9
evacuated tube, 3-17, 3-40,3B-1 allowable first cost, I-28
flat plate life-cycle cost, 2-9
air cooled, 3-110, 3-114 simple payback, 1-28
liquid cooled, 3-17,3-39
lessons learned, 5-9 Damper
mounting location, 3-25, 3-26, 3-27 backdraft, 3-116
orientation, 2-7, 2A-2,3-19,3-110 flow balancing, 3-113
performance range, 1-13 lessons learned, 5-18
size, 3-18, 3-110 manually operated, 3-116
slope, 2-7, 2A-2,3-19,3-110 remotely operated, 3-115
Collector array Design
arrangement, 3-19,3-22,3-56, 3-111 drawings, 3-56, 3-72, 3-108, 3-117, 3-130,
design, 3-17 3-142,4-2
manifold package, 4-2
external, 3-19, 3-21 review, 3-14,3-59, 3-73, 3-109, 3-119, 3-131,
internal, 3-19, 3-20 3-143,3-145
shading, 3-19, 3-23 Detailed system design, 3-1
sizing calculations ,I-13J-27, 2-6, 2-10, 5-2, 5-3 Dielectric insulator, 3-29
spacing, 3-19,3-24, 3-111 Differential temperature controller(DTC),3-74,
support structure, 3-24,3-28,3-111 3-1O5,3-l4l
thermal expansion, 3-1 9 Drainback system, 1-6, 5-4
Collector subsystem design Ducting
air collector, 1-10, 3-110 constnrction requirements, 3-118
liquid collector, 1-5, 3-17 design, 3-112
drawings, 3-117
Solar Design Manual

Design Manual Index Index- Page IN-2

DESIGN MANUAL
W E X (Continued)
Ducting(c0ntinued) Heat exchangers(c0ntinued)
flow balancing, 3-113 shell-and-tube, 3-63
flow rate, 3-112 waterlair, 3-129
insulation, 3-113 Heat transfer fluids, 3-41
leaks, 3-1 13 corrosion control, 3-42
lessons learned, 5-18 density, 3-43
pressure drop, 3-112 double separation, 2-2,2-16,3-42
reverse return, 3-112 glycol, 3-42,5-4
routing, 3-113 heat capacity, 3-43
sealing, 3-113 potable water, 3-42
thermal conductivity, 3-44
Economics(see cost) viscosity, 3-44
Electrical drawings, 4-3 Hot water recirculation loop, 2-5, 2-6, 2-24
Energy conservation methods, 2-3,2-18
Environmental constraints, 2-2, 2-16 Insolation, 2A- 1
Evacuated collectors, 3-17, 3-40, 38-1 lnstallation checkout procedure, 3-98
Expansion compensation device, 3-34 sample, 4A-1
Installation drawings, 4-2
Fans, 3-114,s-17 Instrumentationand controls
F-CHART,2-6 air collector system, 3-132
adjustment, 2-7 liquid collector system, 3-74
guidelines for use, 2B-1 operational, 3-14, 3-74, 3-98, 3-132, 3-140, 5-15
Feasibility study, 2-1 performance monitoring, 3-99, 3-140
Filters fnsulation, 3-54, 3-71, 5-14
air, 3-13, 3-113,3-129 ducting, 3-113
Fiat plate collector materials, 3-54
air cooled, 3-110,3-114 piping, 3-55
liquid cooled, 3-17, 3-39 Interface controls
Flexible coupling, 3-56 solar/conventional, 3-89
Flow indicator, 3-98 IOM manual, 4-6
Flow switch, 3-75
Freeze protection methods, 1 4 5 - 4 Lessons learned, 5-1
Freezestat, 3-75 Btu meters, 5-16
collectors, 5-9
Glycok, 3-42, 5-4 controllers, 5-15
Goals, 1-2, 1-30, 2-2, 2-1 1 corrosion, 5-7
dampers, 5-18
Heat exchangers, 3-63 drainback system, 5-4
design requirements, 3-64 drainback tank, 5-17
double-walled, 1-9, 3-42 ducting, 5-18
drawing, 3-72 fans, 5-17
effectiveness, 3-64, 3-65, 5-12 freeze protection, 5-4
fouling factor, 3-67, 3-68,3-69 glycol system, 5-4
in-tank, 3-2, 3-63, 3A-1 heat exchanger, 5-12
insulation, 3-71 insulation, 5-14
muftiplate, 3-63 lightning, 5-8
overpressure, 5-7
Design Manual Index Index- Page IN-3

DESIGN MANUAL
JlDF&(Continued)
Lessons learned(continued) Piping(continued)

oversizing system, 5-2 drainback systems, 3-30,5-13
overtemperature, 5-6 drawing, 3-57
pebble bed, 5-19 flow balancing, 3-53
piping, 5-13 head loss, 3-36
pumps, 5-12 insulation, 3-55
recirculation system, 5-5 materials, 3-29
storage tank, 5-11 oversize return, 3-30
undersizing system, 5-3 pressure drop, 3-36
valves, 5-14 reverse return, 3-20,3-21, 3-29
Lightning protection, 3-26,3-27,5-8 size, 3-29,5-13
Liquid collector systems, 1-5,347 soldered joints, 3-35
Load, 2-4 support, 3-34
preliminary estimate, 1-3 vent, 3-32
profiles, 2-4 Piping and instrumentation diagram(P&ID), 3-2,
service water heating, 1-3, 2-5, 2-22 3-1 4, 3-15,3-16
space heating, 1-3, 2-5,2-25 Pressure drop, system, 3-36,3-123
Location, 1-3 Pressure gauge, 3-98 a,
collectors, 3-25 Pressure regulator, 3-13,3-70

storage, 3-61, 3-121 Pressure temperature port, 3-56, 3-99
Pressurization, initial, 3-36
Manning equation, 3-30 Problems(see lessons learned)
Pumps, 3-45,3-70,s-12
National Weather Service, 2-2, 2A-1 capacity, 3-45
drive motor, 3-49
Owner dual pump installation, 3-50
A/E conference, 1-2 headlflow curve, 3-46
goals, 1-2, 1-30, 2-2, 2-11 materials, 3-49
NPSH minimum, 3-47
Pebble bed, 1-11,3-121,5-19 port size, 3-49
air velocity, 3-123 selection, 3-45
configurations, 3-122,3-124, 3-126, 3-127 speed, 3-48
container design, 3-124
filling procedure, 3-128 Recirculation system, 1-9,5-5
insulation, 3-124 Reverse return, 3-20, 3-21, 3-29
pebbles, 3-125 Roof penetrations, 3-26, 3-57, 3-58
plenums, 3-123, 3-124
pressure drop, 3-123 Service water heating
sizing, 3-122 toad, 1-3, 1-31, 2-5,2-22
Performance schematics, 3-3
collectors, 2-6 with air collector system, 1-11,3-129,3-130
systems, 1-13, 2-6, 3-144 with antifreeze system, 1-8
Pete's plug, 3-56, 3-99 with drainback system, 1-6
Physical constraints, 1-3, 1-27 with recirculation system, 1-10
Piping, 3-28, 3-61 Sight gauge, 3-51,3-62
branch connections, 3-32,3-33
design, 3-28, 3-61, 5-13
Design Manual Index Index- Page IN-Q

DESIGN MANUAL
JNQFX(Continued)
Site survey, 1-2, 2-2,2-16 Thernometers, 3-98

environment, 2-2 Thermsiphoning, 1-8
physical constraints, 1-3 TRNSYS, 2-8
Solar in Federal Buildings Program, 1-3 N A
Solar radiation, 2A-1 energy design guidelines, 1-3
Solder, 3-35
Space heating Valves, 3-52,s-14
load, 1-3,2-5, 2-25 check, 3-53
schematics, 3-3 control, 3-13
with air collector system, 1-10 drain(manual), 3-54
with antifreeze system, 1-8 fill/flush, 3-13, 3-54
with drainback system, 1-6 flow setting(circuit setter), 3-12,3-30,3-53
with hydronic radiant heat system, 1-12, 3-2 flushtfreeze protection, 3-12, 3-54
with recirculation system, 1-10 isolation, 3-12,3-30,3-53
Specification pressure relief, 3-12, 3-53,3-70, 5-7
components, sample worksheet, 4-4, 4-5, 4-6 pressure/temperature relief, 3-12,3-70
construction, example, 4-3, 48-1 tempering, 3-13,3-71
Standards, ASHRAE, 2-7 vent, 3-12
Standards, HVAC, 3-112 Vent pipe, 3-32
Storage size estimation, 1-27,3-60, 3-122
Storage subsystem design Wire routing drawing, 3-108,3-142
air collector system, 3-121 Wiring diagram, 3-1O8,3-142
liquid collector system, 3-60
Structural analysis, 3-24,3-28
Supply water temperature, 1-3,1-4
System configurations, 1-5,3-2
System design description, 2-10, 2D-1
System schematic drawing, 3-2
Tanks
drainback, 3-50, 5-17
drawings, 3-51! 3-58, 3-72
expansion, 3-13, 3-51
lining, 3-5 1, 3-62
material, 3-50
preheat, 3-61
size estimating, 3-60
storage, 3-60,3-62,5-11
Temperature sensors, 3-107
limit switch, 3-75
location, 3-75,3-78
RTDs, 3-105, 3-107
thermistors, 3-105,3-107
thermometers, 3-98
Thermal expansion, 3-32
Thermal load(see load)
Thermal storage(see storage)
1
Solar Design Manual

Example system design manual section on conceptual analysis and feasibility study

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Exarnvle Svstern Design Contents -Page ex -i

EXAMPLE SYSTEM DESIGN

Solar Design Manual

INTRODUCTION .......................... ..................................................................... EX-1

Owner/Architect/Engineer Conference ................................................................

Conceptual Site Survey ........................................................................................... EX-1

Conceptual PerforrnancetCost Study ..................................................................EX-2

SECTION 2 .FEASIBILIN STUDY ........................................................................EX-9

Application Review ............................................................................................ EX-9

Sizing/Performance Analysis ...................................................................................EX-9

SECTION 3 .DETAILED DESIGN ........................................................................ EX-30

Overall System Schematic ......................................................................................

Collector Subsystem Design ................................................................................... EX-30

Storage Subsystem Design ...................................................................... ...............EX-50

EXAMPLE SYSTEM DESIGN

3.5 Instrumentation and Controls Subsystem Design ...................................................EX-52

3.9 Perforrnance/CostVerification................................................................................. EX-74

First Economic Evaluation of Solar Energy System ................................................EX-14

Solar Energy System Goals ....................................................................................EX-5

Building Information..................................... .. ......................................................... EX-17

Solar Design Manual

Building Sketches ........................................................................................ EX-4

Flat Plate liquid Collectors ....................................................................................EX-36

Check Valves .......................................................................................................... EX-47

Solar Design Manual

EXAMPLE SYSTEM DESIGN

1.3 Conceptual Site Survey

Solar Design Manual

Cold Water Hot Water

January 122,000 48 140 93.16 x loa

March 122,000 50 140 91.13 x 10e

April 118,000 52 140 86.19 x 10"

May 61,000 57 140 42.02 x 10"

June 59,000 59 140 39.66 x 106

July 61,000 63 140 38.98 x 1Og

August 61,000 75 140 32.91 x 108

September 118,000 79 140 59.74 x 108

October 122,000 69 140 71.90 x 10B

November 118,000 59 140 79.33 x 10s

December 122,000 54 140 87.08 x 108

Total 806.00 x 1Os

Load {Btu/month) = (gaVmonth)(8.3 Ib/gal)(l Bt~/lb.~F)(f,- TJ°F

1.3.3 Physical Constraints

1.4 Conceptual System Selection

1.5 Conceptual PerforrnanceICost Study

1.5.1 Conceptual Array Sizing Method

Flat plate performance - 269,000 Btu/ft&yr

Solar Design Manual

b. Array area = 2250 ft2 (evacuated tube)

c. Storage size = 2250 to 2400 gallons

d. Mechanical room size = 100 to 150 ft2

15 . 2 Preliminary System Cost Estimate

a. Minimum cost = $40/ft2x 2400 ft2 = $96,000

b. Maximum cost = $801ft2x 2400 ft2 = $192,000

a. Output = 269,000 Btu/ft2*yrx 2400 ft2 = 646 x 1O6 Btu/yr

b. The cost of electricity in Tucson, Arizona, is $19,92/MMBtu

C. Therefore, the value of the annual energy saved is

646 x 1O6 Btulyr x $19.92 x 10" Btu = $12,870Jyr

Minimum = $96,000 + $12,870Jyr = 7.5 yr

e. Value of energy saved = $12,87O/yr

Qw The allowable first cost is then $1 2,870 x 8.956 = $115,300

Mechanical Room Plan Scale: 1 in. = 50 ft