Industrial User Manual of SWHS
Contents
1. SECTION 5 TYPICAL SCHEMATIC DIAGRAM SECTION 4 INSTALI ION amp COMMISSIONING CHECK LI ma AT T TO BE VERIFIED BY amp C PERSONNEL AND CUSTOMER BEFORE iF HANDING OVER THE SVSTEM li 1 Completion of Collector Installation YES NO 2125 18 2 Completion of Tank installation YES NO 7 is 2 HUBS 3 Completion of Hot water Piping Only system YES NO Pat 5j fi internal piping is In TATA BP cope Cat 4 Completion of Cold water Piping Not in TATA BP YES NO 8 scope 5 Completion of Tank insulation YES NO aE 6 Completion of insulation YES NO i 7 Completion of system Hot water Piping insulation YES NO 8 Temperature Booster Cap fitted properly after YES NO 3 li wiring H i i Ph 9 C clamps provided on collector YES NO Fri i jal i i 5 aa z i EPP 10 Completion of grouting work for all Collectors amp YES NO gh irpo Tank 2 i Z kati i gt i CEN ipa 11 Check for leakages at pipe joints YES NO i Z H 8 i H E 12 Completion of Commissioning amp Testing VES NO i ki i H k g i 2655 H i 2 BFEFH i 558 B i fa peas E g2. Gaezsato g Sssssees Be
3. further it will lead to corrosion of the tank In such cases the system is not guaranteed for its performance Chlorine amp Flourine content in usage water should be less than 100 ppm ENSURE THESE a You are using the solar water heating system as per the instructions given in the manual for the best results Water hardness is less than 300 ppm a Flourine content is less than 100 ppm in the usage water Chlorine content is less than 100 ppm in the usage water The height of the Air Vent provided is more than that of the over head tank 2 5 to 3 0m geass SECTION 3 THERMOSYPHON SYSTEM 3 5 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE ACTION REMEDY No water at a Over head tank empty a Fill up overhead tank usage point ge po b Gate valves closed b Open gate Valves on hot cold and internal pipelines Only cold water a Mixing tap problem a Adjust mixing tap at ta usage proportionatelv poi b Heat loss in hot water pipe b Drain cold water until warm due to long interval between water flows usage Leakage in al a Collector a Damage in absorber a Inform TATA BP b Pipe line amp b Loose fittings of pipes and b Tighten respective flanges flanges flanges amp pipes c Tank c Damage to the tank c Report to TATA BP Water at usage a Hot water line not insulated a Insulate the usage hot Fi point with less water pipeline with hotness Rockwool amp Aluminum cladding
4. is always open 3 3 4 Clean the glass once in a week 3 3 5 For hot amp cold water lines use only Gl pipes Don ts 3 3 6 Don t cover the collectors 3 3 7 Don t erect any structures which can cast shadow on the collectors 3 3 8 Don t put the auto Air Vent provide Air Vent pipe or install Float Chamber if the Air Vent pipe exceeds 3 0m height 3 3 9 Don t draw the water during day time 3 3 10 Don t put the water on the collector glasses when it is hot SECTION 3 THERMOSYPHON SYSTEM 3 4 MAINTENANCE INSTRUCTIONS 3 4 1 Before the onset of monsoon check the pipe and tank insulation for possible leakage If damage has occurred to the cladding due to tampering ensure that the water doesn t seep into the insulation Use proper sealant like M Seal for joining the openings susceptible to water seepage 3 4 2 Once in three months drain the tank by opening the Drain Plug provided at the bottom of the tank 3 4 3 Before draining close the cold water inlet valve and after draining open the same 3 4 4 Draining should be done only after the usage of hot water 3 4 5 Once in an year check for erosion of sacrificial anode Replace it if found eroded or 80 of the material has sacrificed 3 4 6 The solar usage water hardness should be less than 300 ppm If it exceeds 300 ppm scale formation takes place within very short period resulting in choking of Collectors amp Tank and leads to drastic reduction in system efficiency amp
5. we produce such as dye lubricant metals glass plastic and the services we render such as transportation amp communication energy is inextricably woven into it all Energy can be classified into RENEWABLE and NONRENEWABLE It has become a reality that availability of Non renewable energy like fossils hydro sites and even uranium is finite Renewable energy is one which is available in abundance and can be harnessed in an unlimited way Everyday the sun showers the earth with several thousand times the energy we use In other words the entire stock of fossil fuels on earth is not worth more than few days of sunlight Solar energy can be effectively utilized in two ways either by converting light energy into heat Solar thermal OR converting light into electricity Solar photovoltaic A flat plate collector is used to convert light energy into heat 2 2 HOW A FLAT PLATE COLLECTOR WORKS The collector is made up of a set of fins Raisers and headers known as Absorber assembled inside an insulated extruded aluminum frame covered with a transparent glass When the solar radiation falls on the collector the absorber converts this radiation into heat energy the water passing through the raisers and headers absorbs this heat energy This water as it absorbs the heat becomes less dense and rises to the top of the collector and comes out at a higher temperature This hot water can be used for bathing cleaning washing and any productive
6. CONTACT INFORMATION Registered Office TATA BP SOLAR INDIA LIMITED Plot No 78 Electronics City Hosur Road BANGALORE 560 100 INDIA Tel 080 2235 8465 4119 4230 5660 1300 Fax 080 2852 0972 2852 0116 Website www tatabpsolar com Email tatabp tatabp com Toll Free Customers service Helpline 1800 425 7860 NEAREST SERVICE CENTER Doc No 2627 0096 Issue 2 INDUSTRIAL THERMAL SOLAR WATER HEATING SYSTEM TYPE THERMOSYPHON POWER OF THE SUN WORKING FOR YOU DESIGNED MANUFACTURED INSTALLED amp COMMISSIONED BY TATA BP SOLAR INDIA LIMITED PLOT NO 78 ELECTRONICS CITY HEBBAGODI HOSUR ROAD BANGALORE 560 100 INDIA s TEL 080 56601300 FAX 080 28520972 28520116 CONTENTS PAGES SECTION 1 INTRODUCTION SECTION 2 GENERAL INFORMATION SECTION 3 THERMOSYPHON SYSTEM SECTION 4 INSTALLATION amp COMMISSIONING CHECK LIST SECTION 5 TYPICAL SCHEMATIC DIAGRAM SECTION 1 INTRODUCTION TATA BP SOLAR INDIA LIMITED is the leader in Design Development Manufacture and Marketing of complete Solar Hot Water and Photovoltaic generator systems Tata BP Solar is promoted by the reputed TATA s in collaboration with world leaders BP SOLAR of UK the British Petroleum Group TATA BP SOLAR is in an unique position of being able to supply totally integrated systems comprising of major components viz Solar collectors Insulated Stainless Steel Storage Ta
7. nk Sacrificial Anode Pumps and Pump Control Panel manufactured in house or to our specifications We have evolved a philosophy embracing the TOTAL SYSTEM CONCEPT which ensures optimum reliability and life expectancy a policy borne out by the performance of collaborator systems worldwide As a member of TATA GROUP we are in position to enjoy substantial Technical Marketing and Financial support All our customers can be secured in knowledge that is carrying the TATA name We are committed to provide a totally professional and reliable service before during and after any sale TATA BP SOLAR THERMAL Systems wide spectrum of applications are Domestic Uses Hot water for Laundry Cleaning Bathing and other Chores Industrial Applications Boiler Feed Cleaning and Washing Hotels Hot water for Bathing Cleaning Washing Laundry and for swimming pool heating Educational Institutions For Bathing Cleaning and Washing e Hospitals Washing Cleaning Bathing and Sterilisation Dairies Washing cans amp cattle and for Boiler feed water SECTION GENERAL INFORMATION 2 1 ENERGY Energy is the lifeblood of our society Whatever the source oil coal hydro nuclear gas the use of energy is all pervasive Energy lights and heats our homes offices amp factories It powers the machine in industries and transportation The clothes we wear the food we eat the building we live and work in the goods
8. prevents escape of heat back to the environment Water contained in the raisers and headers absorbs the heat from the fins and raises and becomes less dense than the water in the storage tank On the principle of THERMOSYPHON it starts rising through the collector and enters the top of the hot water tank Simultaneously cold water from the tank descends to the bottom header of the collector gets heated up in the absorber and rises back to the hot water tank and the cycle repeats The movement of heated water from the collector to the storage tank Which is placed above the collectors is due to the difference of density only There are no moving parts in the system and hence the system reliability is very high The water retains its heat for long time as the hot water storage tank is insulated to prevent significant heat loss The sacrificial Anode provided in the hot water storage tank protects the system against Galvanic Corrosion The Temperature Gauge provided in the tank will indicate the water temperature in the tank SECTION 3 THERMOSYPHON SYSTEM 3 3 OPERATING INSTRUCTIONS For optimum performance of the system it is required to follow the Do s amp Don ts given below Do s 3 3 1 Ensure that the cold water tank is always full and never runs dry 3 3 2 Ensure use of hot water once in a day either in the morning or in the evening 3 3 3 Ensure that the GATE VALVE provided customer s scope in the cold water line
9. process requiring hot water 2 3 BASIC SOLAR WATER HEATING SYSTEM Each typical solar collector gives an approximate output of 125 Itrs per day at 60 degree C Such collectors are connected in parallel and series to obtain desired quantity of hot water at desired temperature The Solar water system consists of following major components A Solar Collectors B Insulated SS Tank with Sacrificial Anode C Pump and Pump Control Panel if it is forced circulation system D Indicating and Control Instruments optional at additional cost Based on the solar intensity of 5 0 kWh sq m dav for Bangalore 2 SECTION 3 THERMOSYPHON SYSTEM 3 1 HEALTH amp SAFETY 3 1 1 READ the Manual thoroughly before USING THE SYSTEM Observe the precautions detailed in the manual 3 1 2 The collector surface develops very high temperature To avoid this the collector should be shaded from the sun by opaque sheeting before making any internal piping connection 3 1 3 Do not use the hot water for direct drinking application 3 1 4 Do not touch the collector surface glazing during sunshine hours as it could lead to bum injury 3 1 5 Do not touch the tank surface or internal or external piping of the system bare handed 3 2 SYSTEM DESCRIPTION Solar radiation falling on the collectors passes through the glazing and is absorbed by the absorber consisting of fins raisers and headers A special selective coating on the absorber
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