GOVERNMENT COLLEGE OF ENGINEERING,

DHARMAPURI
DESIGN AND FABRICATION OF THERMAL WATER
HEATER BY USING COPPER PIPE
PROJECT WORK SUBMITTED BY:
NAME REG.NUMBER
1.G.Akash 613414114002
2.C.Balaji 613514114005
3.G.Pasupathi 613514114030
4.S.Tamilkumar 613514114041
YEAR/SEM:3rd Year/6th sem.
GUIDE BY,
Mr.T.Mathiyalagan,M.E,
Assistant professor,
Department of mechanical engineering.
 ABSTRACT

The main objective of this paper is water can be heated by

using copper pipe within sunlight energy itself and without
electrical and other fuel energy . The copper tube has high
thermal conductivity, it absorbs heat very easily. so, the copper
tube has made to spiral shape in a certain angle. The setup is
arranged in a flat plate collector . water gets heated easily
inside the spiral copper tube. So, the output result in the water
is more heater than inlet atmospheric temperature of water.
 INTRODUCTION

Sunlight is mainly used in Thermal and photovoltaic forms water

heating, but the real scope of using hot water system is in the domestic
section .
solar water applicable for use of the solar radiation falling on the Flat
plate Collector is transformed into the heat energy, which is used to
heat water in the range of 60C to 75C
This system saves the costly consumption of electrical energy .
The major problems for the existing solar water heating system is its
initial cost is very high and also required some maintenance, so for
these low cost solar water heating system with a heat storage is
of great utility , which is the result of some rectification in the
material used for making existing solar water heating system.
Sun light energy not polluted our environment and it is a renewable
energy source.
 TYPE OF COPPER PIPE

Soft Copper
Soft (or ductile) copper tubing can be bent easily to travel
around obstacles in the path of the tubing. While the work
hardening of the drawing process used to size the tubing makes
the copper hard or rigid, it is carefully to make it soft again; it is
therefore more expensive to produce than non-annealed, rigid
copper tubing. It can be joined by any of the three methods used
for rigid copper, and it is the only type of copper tubing suitable
for flare connections. Soft copper is the most popular choice for
refrigerant lines in split-system air conditioners and heat pumps.
 LITERATURE REVIEW
Soteris A. Kalogirou, 2004 presents a survey of the various
types of solar thermal collectors and Applications. All the solar
systems which utilize the Solar energy and its application
depends upon the solar Collector such as flat-plate, compound
parabolic, Evacuated tube, parabolic trough, Fresnel lens,
Parabolic dish and heliostat field collectors which are Used in
these system. The solar collectors are used for Domestic,
commercial and industrial purposes. These Include solar water
heating, which comprise thermo syphon, integrated collector
storage, direct and Indirect systems and air systems, space
heating and Cooling, which comprise, space heating and
service hot Water, air and water systems and heat pumps,
Refrigeration, industrial process heat, which comprise Air and
water systems and steam generation systems, Desalination,
thermal power systems, which comprise The parabolic trough,
power tower and dish systems, Solar furnaces, and chemistry
applications.
 Kishanpatel, pranyapatel, Jatin Patel This project work
provides basic information on the components and types of
solar water heaters currently available and the economic and
environmental benefits of owning a system. Solar water heaters,
sometimes called solar domestic hot water systems, are cost
competitive in many applications when you account for the
total energy costs over the life of the system. Although the
initial cost of solar water heaters is higher than that of
conventional water heaters, the fuel (sunshine) is free. Plus,
they are environmentally friendly.
 DESIGN

1.Cold water tank 2. control valve

3. Plywood and glass arrangement 4. copper pipe
5.Hot water tank
 WORKING
Initially toughened glass is absorbed the sun light radiation and it is
passed through the copper pipe.
Then the copper pipe is absorbed the heat energy from the glass.
Next the cooling water is passed through the copper pipe.
The control valve is to control the flow rate of cold water
Finally cold water is absorbed the heat energy from the copper pipe ,
then it is converted to hot water.
 DESIGN CALCULATION
Known parameters:
Diameter of the tube, D = 0.00635m
Length of the tube, L= 15m
Inlet temperature of the water ,Tmi = 30c
Outlet temperature of the water,Tmo = 75c
Velocity , U= 0.03m/s
Wall temperature, Tw = 75c
To calculate the heat transfer rate (Q):
1. Bulk mean temperature, Tm = (Tmi+Tmo)/2
= (30+75)/2
Tm = 52.5c
water properties at 50c,(Assume) [from hmt data book p.g no 22]
= 990 kg/m , v = 0.567510^-6 m/s , pr = 3.68 ,k = 0.63965 W/mk
 To determine the type of flow:

Reynolds number Re = UD/ v

= (0.030.00635)/(0.567 10^-6)
Re = 335.97
Re < 2300, the flow is laminar.
For laminar flow ,
Nu = 3.66 [hmt data book p.g no 124]
we know that,
Nu = (hD)/k
3.66 = (h0.00635)/(0.63965)
h = 368.68 W/mk

Heat transfer rate Q = hA [Tw-Tm]

= 368.680.299[75-50]
Q = 2756.66w
 MATERIAL PROPERTIES

1. copper tube dimensions and properties:

1.Tube diameter -1/4 inch.

2.Tube length -50 feet.
3.Thermal conductivity -401W/(m-K).
4.Boiling point -2835K (2562C,4643F).
5. It is used to absorb the sun light energy from toughened glass and it
is transfer to the water.
2. water tank
1.Capacity of water tank- 5 liters.
2. It is used to store the cold and hot water.
 3. plywood dimension
1.For copper tube arrangement- (2020 inches)
2.For glass arrangement - (2222 inches)
3. It is used to fixed the copper tube arrangement and toughened.
4.control valve
1.To control the inlet water passed through the copper tube.
 5.Toughened glass properties

Toughened or tempered glass is glass that has undergone processes of

controlled thermal treatment to increase its strength.
Toughened glass is made from annealed glass that has been heated to
approximately 650c and then rapidly cooled.

Properties
1.Dimension - 2020 inches.
2.Thermal shock resistance up to 250C
3.Mechanical strength four to five times stronger than annealed glass
4. It is used to transfer the sun light energy to the copper tube.
METHODOLOGY
 DISCUSSION

Thermal Efficiency
The Solar Sensitivity in the thermal radiation from the
sun, inside the copper tube is increases. We comparing the
atmospheric temperature in the time hours. It will be performing
in the design of casing in outlet temperature .atmospheric
temperature water in the 30c
Time Outlet temperature
9 43
10 48
11 50
12 62
13 69
14 63
15 58
16 50
17 46
 COMPARISION

S. No Normal Water Heater Copper Water Heater

1. initial cost is high initial Cost is low
2. Non renewable source Renewable source
3. Life time is low Life time is high
4. Ex: electrical water Ex: copper water heater
heater
 COST ESTIMATION

SERIAL
MATERIAL QUANTITY COST
N0

1. Copper tube 1 960

2. Toughened glass 1 800
3. Ply wood 2 100
4. Water tank 2 300
5. Other material - 100
6. Travelling charge - 600
TOTAL 2860
 RESULT AND CONCLUSION

Today, Hundreds of thousands modern solar water heater are

in use throughout the world. While the initial purchase and
installation cost of solar water heater is higher than an
equivalent conventional water heater. This extra cost can be
recovered over a period of time through lower energy bills.
Solar energy can reduce the national demand for conventional
fuels, reduce the damage to the environment, as it is a non-
polluting free energy, and reduce the need to build new power
station which require huge investment.
 REFERENCE

P.Shivkumar,W.christ Raj, N.Jaya Malathi, S. Balakrishnan

,Performance Analysis Of Flat Plate Solar Water Heater By
Changing The Heat Pipe Material, Advance material Research
vol.768(2013).
K. Sukhatme, Suhas P. Sukhatme, Solar Energy: Principles of
Thermal Collection and Storage, Second Edition, Tata
McGraw-Hill Education, 1996.
Joel Swisher, Measured Performance Results: Low-Cost Solar
Water Heating Systems in the San Luis Valley, SERI/TR- 254-
1727 UC Category: 59a, (1983).