Designing Solar Thermal

System
 Introduction

• Before we start discussing the designing of solar thermal systems we need to know
the concept of a system. My definition of a system is a combination of equipment and
devices which have been put together to perform a certain predetermined function. If
we accept this definition, a system has to have a function to perform and it has to
have equipment and devices to perform that function.
• In case of Solar Thermal Systems the function to be performed is some variant of
delivering heat for an application. The system has the input in the form of available
solar radiation and output in the form of heat.
• The basic of the solar thermal system thus consist of input device which will convert
the solar radiation to heat and a combination of other equipment or other devices to
output this heat into useful form.
• The most common input device for Solar thermal system has been Solar Flat Plate
collector and I have so far done most of design based on this device and will follow
this for the designs being discussed. The underlying principals of the design however
can be used for other devices also with adjustments according to the nature of these
devices.
• Even in flat plate collectors the collectors used to heat liquids are the most common
ones and most design aspects discussed will relate to this type of flat plate collectors.
 Application of Solar Thermal Systems

• For any system design to be taken up we have to consider the

intended heat output from the Solar system.
• The most common form of heat output has been the in the form of
hot water delivered in a temperature range suitable for various uses.
This covers all applications which deliver hot water as a final
product.
• Another form of heat output is to provide heat to maintain
temperature of some reservoirs at certain specified temperatures.
This covers all systems used for heating swimming pools or
electroplating/ metal processing baths.
• Other type of systems deliver heat to air but using liquid collectors.
The systems for drying and systems for space heating come in this
category.
 Solar Hot Water systems

• This application has been the most popular application so far and 95% of systems
installed in the country probably belong to this category. The installation of systems
for this purpose was stated long time back and I had felt that all concerned people
have understood every aspects of design of these systems.
• But recently it so happened that a company with more than 15 years of experience in
this field had come to me as they were facing problems during commissioning of the
system. I found that the most of the components of the system were mismatched.
The piping connections were not designed but arbitrarily made as per the decision
made by the supervisor at site.
• It almost became clear that the organisation has not understood the concept of
design and need for the design of such a system. This has been happening
repeatedly with most of the organisations in this field. This practice came into
existence as the engineering aspects of Solar Thermal Systems has been neglected
under the mistaken belief that these systems are too simple and do not require any
engineering effort.
• My attempt at this time will be to remove that feeling and introduce some aspects of
engineering required for these systems. Also I will give details of some of the Solar
systems for which I had provided the engineering details.
 Thermosyphon Solar Water Heating System

• In these systems arrangement of Solar collectors and Storage

Tank/Heat Exchanger and connecting pipes is such that the flow
of fluid takes place due the density differential of hot and cold fluid
and no prime mover is provided in the system for mass flow.
• These systems have been the ones most misunderstood for the
requirement of engineering inputs. Feeling in the industry and other
people concerned has been almost like asking “What do you mean
by Engineering of Thermo-syphon system” or that nothing is
required to be done in a thermo-syphon system and you have solar
collectors, a storage tank and you connect these with some piece of
pipe and the system starts working.
• I shall attempt to some how remove this feeling and try to explain
how each element of the system behaves in such a system.
• I shall start with the smallest of these system( the single collector
solar system) and also show you the larger systems which have
been engineered and successfully operating for number of years.
Single Collector Thermosyphon System
Calculation of Thermo-syphonic Head

Thermosyphonic Head Calculations

Distance Angle Height Height Height Temp Water Temp Water Differential
Header to Collector Header to Header Tank inlet collector Density Tank Density Head
Header Header Tank inlet to outlet top at Temp Bottom at Temp
Mtr Deg Mtr Mtr Mtr Deg C Kg/Cub M
1.9 43 1.296 0.15 0.33 60 983.2 20 998.2 14.44

1.9 43 1.296 0.15 0.33 50 988.1 20 998.2 9.73

1.9 43 1.296 0.15 0.33 45 990.6 20 998.2 7.32

1.9 43 1.296 0.15 0.33 40 992.1 20 998.2 5.87

1.9 43 1.296 0.15 0.33 35 994 20 998.2 4.04

1.9 43 1.296 0.15 0.33 30 995.7 20 998.2 2.41

1.9 33 1.035 0.15 0.33 60 983.2 20 998.2 12.49

1.9 33 1.035 0.15 0.33 50 988.1 20 998.2 8.41

1.9 33 1.035 0.15 0.33 45 990.6 20 998.2 6.33

1.9 33 1.035 0.15 0.33 40 992.1 20 998.2 5.08

1.9 33 1.035 0.15 0.33 35 994 20 998.2 3.50

1.9 33 1.035 0.15 0.33 30 995.7 20 998.2 2.08

1.9 25 0.803 0.15 0.33 60 983.2 20 998.2 10.75

1.9 25 0.803 0.15 0.33 50 988.1 20 998.2 7.24

1.9 25 0.803 0.15 0.33 45 990.6 20 998.2 5.45

1.9 25 0.803 0.15 0.33 40 992.1 20 998.2 4.37

1.9 25 0.803 0.15 0.33 35 994 20 998.2 3.01

1.9 25 0.803 0.15 0.33 30 995.7 20 998.2 1.79

 Pressure Loss Calculation for Flows

Pressure Drop Calculations Single Collector Configuration

Flow Rate Dia Velocity Vh Avr V Travel L Visc at40 Reynld No f Friction p Delta P
Ltre/Hr CM M/Sec mm Water M/sec M sqM/s mm Water mm Water
X 10 P(6)
Header 10 2.36 0.0064 0.0202 0.0032 2.2 0.657 228.1 0.081 0.0009 0.02
Riser 1.11 1.128 0.0031 0.0048 0.0031 1.8 0.657 53.0 0.117 0.0010 0.01
Pipe 15 10 1.6 0.0138 0.0954 0.0138 4 0.657 336.5 0.074 0.0282 0.60

Header 20 2.36 0.0127 0.0806 0.0064 2.2 0.657 456.2 0.068 0.0030 0.08
Riser 2.22 1.128 0.0062 0.0191 0.0062 1.8 0.657 106.1 0.098 0.0034 0.02
Pipe 15 20 1.6 0.0276 0.3817 0.0276 4 0.657 672.9 0.062 0.0947 2.39

Header 30 2.36 0.0191 0.1815 0.0095 2.2 0.657 684.3 0.062 0.0062 0.19
Riser 3.33 1.128 0.0093 0.0429 0.0093 1.8 0.657 159.1 0.089 0.0069 0.05
Pipe 15 30 1.6 0.0414 0.8589 0.0414 4 0.657 1009.4 0.056 0.1926 5.35

Header 40 2.36 0.0254 0.3226 0.0127 2.2 0.657 912.4 0.057 0.0102 0.33
Riser 4.44 1.128 0.0124 0.0763 0.0124 1.8 0.657 212.1 0.083 0.0114 0.09
Pipe 15 40 1.6 0.0553 1.5269 0.0553 4 0.657 1345.8 0.052 0.3187 9.48

Header 50 2.36 0.0318 0.5041 0.0159 2.2 0.657 1140.5 0.054 0.0151 0.52
Riser 5.56 1.128 0.0154 0.1192 0.0154 1.8 0.657 265.1 0.078 0.0168 0.14
Pipe 15 50 1.6 0.0691 2.3859 0.0691 4 0.657 1682.3 0.049 0.4709 14.79

Header 30 2.36 0.0191 0.1815 0.0095 2.2 0.657 684.3 0.062 0.0062 0.19
Riser 3.33 1.128 0.0093 0.0429 0.0093 1.8 0.657 159.1 0.089 0.0069 0.05
Pipe 20 30 2.16 0.0227 0.2586 0.0227 4 0.657 747.7 0.060 0.0625 1.61

Header 50 2.36 0.0318 0.5041 0.0159 2.2 0.657 1140.5 0.054 0.0151 0.52
Riser 5.56 1.128 0.0154 0.1192 0.0154 1.8 0.657 265.1 0.078 0.0168 0.14
Pipe 20 50 2.16 0.0379 0.7183 0.0379 4 0.657 1246.1 0.053 0.1528 4.46

Header 90 2.36 0.0572 1.6331 0.0286 2.2 0.657 2052.9 0.047 0.0422 1.68
Riser 10.00 1.128 0.0278 0.3863 0.0278 1.8 0.657 477.2 0.068 0.0470 0.43
Pipe 20 90 2.16 0.0682 2.3273 0.0682 4 0.657 2243.0 0.046 0.4275 14.39

Header 90 2.36 0.0572 1.6331 0.0286 2.2 0.657 2052.9 0.047 0.0422 1.68
Riser 10.00 1.128 0.0278 0.3863 0.0278 1.8 0.657 477.2 0.068 0.0470 0.43
Pipe 25 90 2.72 0.0430 0.9255 0.0430 4 0.657 1781.2 0.049 0.1801 5.73

Header 145 2.36 0.0921 4.2391 0.0460 2.2 0.657 3307.5 0.042 0.0972 4.34
Riser 16.11111 1.128 0.0448 1.0028 0.0448 1.8 0.657 768.9 0.060 0.1083 1.11
Pipe 25 145 2.72 0.0693 2.4024 0.0693 4 0.657 2869.7 0.043 0.4149 14.83
Thermo-syphon Head Calculation for 5 Collectors System

Thermosyphonic Head Calculations 5 Collector System

Distance Angle Height Height Height Temp Water Temp Water Differential
Header to Collector Header to Header Tank inlet collector Density Tank Density Head
Header Header Tank inlet to outlet top at Temp Bottom at Temp
Mtr Deg Mtr Mtr Mtr Deg C Kg/Cub M
1.9 43 1.296 0.15 0.8 60 983.2 20 998.2 17.97

1.9 43 1.296 0.15 0.8 50 988.1 20 998.2 12.10

1.9 43 1.296 0.15 0.8 45 990.6 20 998.2 9.10

1.9 43 1.296 0.15 0.8 40 992.1 20 998.2 7.31

1.9 43 1.296 0.15 0.8 35 994 20 998.2 5.03

1.9 43 1.296 0.15 0.8 30 995.7 20 998.2 2.99

1.9 33 1.035 0.15 0.8 60 983.2 20 998.2 16.01

1.9 33 1.035 0.15 0.8 50 988.1 20 998.2 10.78

1.9 33 1.035 0.15 0.8 45 990.6 20 998.2 8.11

1.9 33 1.035 0.15 0.8 40 992.1 20 998.2 6.51

1.9 33 1.035 0.15 0.8 35 994 20 998.2 4.48

1.9 33 1.035 0.15 0.8 30 995.7 20 998.2 2.67

1.9 25 0.803 0.15 0.8 60 983.2 20 998.2 14.27

1.9 25 0.803 0.15 0.8 50 988.1 20 998.2 9.61

1.9 25 0.803 0.15 0.8 45 990.6 20 998.2 7.23

1.9 25 0.803 0.15 0.8 40 992.1 20 998.2 5.80

1.9 25 0.803 0.15 0.8 35 994 20 998.2 4.00

1.9 25 0.803 0.15 0.8 30 995.7 20 998.2 2.38

Deciding Design Parameters for Thermo-syphon Solar Water Heating
System

The design parameters for thermo-syphon solar water heating systems can be decided with the following
The solar heat is be collected on as when available basis.
The use pattern will be as and when required basis.
There will be need for matching these requirements.
This can be done by using a storage device in the form of Hot Water storage Tank..
The Capacity of the Hot Water Tank is decided to balance the chronological mismatch between the supply and the
demand.
When solar heating is available and demand also exists the system must be in a position to deliver the heat.
This condition imposes a restriction that generation must be at the required or higher than the required temperature.
Supposing we are designing a system with capacity of tank equal to the demand of hot water say at a temperature 60
Deg C. Also water below 45 deg C will not be useful and we have the requirement during the day also. If a
system of 100 litre capacity is designed for flow rate of 50 litre/hr. The tank will get heated to 60 Deg C in 6 hrs of
sunny period but it will require 3 circulations for the temperature to be built up .Which means temperature at the
top of the tank will lower than required after first circulation of tank water through the collector. This means water
at useful temperature will be available only in the afternoon period after previous days heating has been used up.
However if circulation rate is to be between 20-30 litre/hr , water reaching the top of the tank is at useful
temperature in the first circulation itself and it is instantly available.
We are able to decide tank capacity and water flow rate accordingly.
 Deciding Design Parameters

After deciding the capacity of storage tank. We have to decide other design parameters of the
tank. The operating and design pressure of the storage tank and tank material. The design
pressure is the expected highest operating pressure of the system and the material of the tank is
decided by the compatibility of the material with the quality of water being used .
The seasonal variation in demand decides the optimisation of the collector tilt.
The temporary hardness level of water decides whether the system can be direct heating type or
indirect heating type with heat exchanger to be built in the circuit. Heat exchanger can also be
used to isolate collectors from the high pressures on the use side.
If heat exchanger is required it's capacity should be such that at the required flow rate can be
maintained and the heat can be transferred without raising the collector outlet temperature
significantly.
Having decided these parameters and also the routing of the collector piping we can calculate
and chose the pipe sizes which will be suitable for providing the desired flow rate.
Examples of Thermo-sysphon Solar Water Heating System Design
Examples of Thermo-sysphon Solar Water Heating System Design
Example of Thermo-syphon Solar Water Heating System
Examples of Thermo-sysphon Solar Water Heating System Design
Examples of Thermo-sysphon Solar Water Heating System Design
Heat Exchanger for 6000e system at 60 Deg C
Examples of Thermo-sysphon Solar Water Heating System Design
Heat Exchanger for a 2500 Litre capacity System at 60 Deg C
Examples of Thermo-sysphon Solar Water Heating System Design
Layout for System at IIC
Examples of Thermo-sysphon Solar Water Heating System Design
Tank with Heat Exchanger on Supply Side 10000 lpd System at IIC
Examples of Thermo-sysphon Solar Water Heating System Design
10000 lpd System at Kautlya Inndustries Gurgaon
 Designing Solar Thermal Systems with Pumps

• It has been possible to design and install large capacity thermosyphon systems.
Some of these are
• 10000 lpd system at Andhra Bhavan intalled in 1997
• 10000 lpd system at Kautlya Indutries Gurgaon
• 10000 lpd system at IIC for kitchen use
• However at times it becomes necessary to design and instal systems with prime
movers.
• In designing such systems we have to first decide the design parameters of the
system
• The design starts with determining the no of collectors and their orientation, also
determining the storage capacity required. Decision regarding the need for Heat
exchanger is to be made for the system. Based on the requirement and performance
optimisation the flow rate is determined.
• Collector Layout is decided on the place availability and orientation.
• Interconnecting piping is then decided based on flows in different collector banks.
• After this calculations for pressure drops calculations can be made and pumps can
be chosen for the primary side and secondary side
Example of Design Parameters for Solar Thermal system with pumps

SOLAR HEATING SYSTEM For ULTRA forKeeping the drums

Open Bath of Size of Size 5x1.1x1 mtr operating Temperature 55+-2Deg C
BOM and specifications
Operating 24 Hrs with covers removed only for loading and unloading
(covered during nonoperating period)
ITEM
SPECIFICATION QUANTITY
1 Solar Collectors Copper-copper 2Sq meter each selectively coated
High temperature application 80

2 Hot water Baths

Insulated 5mtr x 1.1mtr x 1mtr filled upto 0.7 mtr when without drums
upto 0.9 mtr with drums capcity 6 drums each 2 nos

3 Loading Arrangement Monorail beam with 1 ton hoist for loading and unloading 2 nos

4 Pallets for drum S S pallets of capacity 500 kg for 200 Kg drums 12 nos

5 Supports for collectors Angle iron supports properly fixed to the roof for fixing
solar collector to the roof at 43 deg to horizontal, painted
with 2 coats of primer and 2 coats of paint For 80Collectors
6 Hot Water Storage tank 6000 l[tre Capacity MS vertical insulated

7 Interconnecting Piping Piping for connecting solar collectors and Estimated qauntities
and Storage tank
litres/hr GI Medium class piping to BIS standard
All piping to be insulated with glass/rock wool of 40NB-50Mtr
48kg/cubic meter of approprate thickness and clad with 32 NB-50meters
aluminium cladding 25NB -30 Metres
8 Piping from pool to Heat Estimated qauntities
Exchanger Insulated Piping to GI Medium Class as per BIS standard 40NB- as per site
Approx-20 M
9 Pumps For flow rate of 4000 litre/hr at operating conditions
Kirloskar Make 4 nos.

10 Electric/Gas Back up 30Kw fitted in storage tank of 1000 Litres MS tank of 1 no

4 mm thickness painted with polyurethene based paint
with thermostatic controls. Heating elements to be
sutable for chlorinated water.
11 Control Panel DTC control for primary as well secondary loop and 1 Set
thermostac control for Electric Back up
12 Instruments Temperature and pressure gauges and DTC sensors 1Set
13 Bath cover Bath cover of 6Sq meter 2 nos

1Set

14 Makeup /Expansion Tank 500 litre capacity Sintex /MS tank 1 No

Example of Design Parameters of Solar Thermal System with Pumps

SOLAR HEATING SYSTEM FOR Imreial Hotel 60 Deg C

BOM and specifications

Ouput will vary from 19000litres /day to 24000 litres/day onclear sunny days in different seasons
operating Temperature60 Deg C
ITEM SPECIFICATION QUANTITY

1 Solar Collectors Copper-copper 2Sq meter each selectively coated

conforming to BIS specifications and BIS marked 200

2 Heat exchanger Tube and Tube type SS

Drawing to be provided later
For Flow rate of 4000 litres /hr

3 Supports for collectors Angle iron supports properly fixed

solar collector at 43 deg to horizontal, painted
with 2 coats of primer and 2 coats of paint For 200Collectors

4 Interconnecting Piping Intter coneecting Piping for thermosyphon Mode Estimated qauntities

25 nb-50Mtr
50NB -200Mtr
40NB-200Mtr

5 Piping from Storage Tank to Heat 50NB

Exchanger 100 Mtrs approx

6 Pumps 4000 litre/hr at 2.5KG/ sq Cm 4 nos

7 Storage Tank 25000 litres MS 6mm thick Shell and 10MM bottom 1No
and 6mm conical top Vertical tank at basement ground level

8 Control Panel DTC control for primary and themostac control 1 Set
for secondary loop
9 Instruments Temperature guage,DTC,Pressure Gauge 1Set
and Themostat
Example of Design Parameters of Solar thermal System With Pumps

SOLAR HEATING SYSTEM FOR SWIMMING POOLS at Chandigarh 24.69x16.15 mtr

BOM and specifications

Hours of Operation 12Am-4Pmfrom Dec, Jan & Feb, and 9Am-7Pm in March,Oct, Nov
Alternately 5 PM to 8 PM in Dec ,Jan, Feb
Avoid using during windy period to avoid cooling and chill
effect of wind on swimmers
Operating Temperature
25+-2 Deg C
ITEM SPECIFICATION QUANTITY

1 Solar Collectors Copper-copper 2Sq meter each selectively coated

conforming to BIS specifications and BIS marked 80

2 Heat exchanger Titanium Plateor SS Tube and tube type with flow rate of 7000 Litre /hr in
in primary and secondary loops with primary temperature
of 45 and 35 deg centigrade and seconadary temperature
of 35 and 25 deg centigrade.Capable of withstanding
pressure of 10Kg/sq cm and gaskets designed for
100deg c and chlorinated water.Pressure Drop 1
not to Exceed 1Kg/Sqcm
3 Supports for collectors Angle iron supports properly fixed
solar collector at 46 deg to horizontal, painted
with 2 coats of primer and 2 coats of paint For 80 Collectors

4 Interconnecting Piping Piping for connecting solar collectors and heat Estimated qauntities
exchanger primary Loop and pump for flow rate of 7000 Average 40NB-200M
litres/hr GI Medium class piping to BIS standard 50NB -
All piping to be insulated with glass/rock wool of 40NB
48kg/cubic meter of approprate thickness and clad with 25 NB.
aluminium cladding
5 Piping from pool to Heat Estimated qauntities
Exchanger Insulated Piping to GI Medium Class as per BIS standard 50NB-? Meters
As per Site
6 Pumps For flow rate of 7000 litre/hr at operating conditions
Kirloskar Make 4 nos.

7 Gas/Electrical Back up 60Kw fitted in storage tank of 1000 Litres MS tank of 1 no

if required 4 mm thickness painted with polyurethene based paint
with thermostatic controls. Heating elements to be
sutable for chlorinated water.
8 Control Panel DTC control for primary as well secondary loop and 1 Set
thermostac control for Electric Back up
9 Instruments Temperature and pressure gauges and DTC sensors 1Set
10 Pool cover Pool cover for pool of 400Sq meter with a trolley for
transporatation and handling of pool cover. Pool cover to
Transparent but opaque to infrared. It should be 1Set
suitable for tying at the ends to avoid being blown away by winds
11 Makeup /Expansion Tank 250-300 litre capacity Sintex /MS tank 1 No
Solar Water Heating System with Heat Exchanger and Pump
Schematic Arrangement for an Electroplating Bath Heating
Schematic Arrangement for a Swimming Pool Heating System
Heat Exchanger for a Swimming Pool
Schematic for Drying Application Using Liquid Collectors