Design and Development of Solar Thermal Expansion Pump

DESIGN AND DEVELOPMENT OF SOLAR THERMAL EXPANSION PUMP
1. ABSTRACT
BMIT, Solapur.
ABSTRACT:The conventional fuels sources are getting depleted due to continuous use of it. The prices of petrol increasing day by day. These fuels emit hazardous pollutants like CO2, CO. etc. Conventional energy sources are not long lasting .Nowadays energy is continuously in demand and the world is on the one hand facing problem with limited availability of conventional energy sources and on the other hand global warming because of pollutants from fossil fuels. There is need to use the alternative sources like solar, air and water. The solar energy source is nonconventional type of energy finding solution for above problem which can replace conventional fuels for number of applications. For lifting and raising liquid levels electrical motor coupled pumps can be replaced by solar thermal expansion pump which basically operates on thermal level difference of thermal expansion. The experiments are conducted to measure the performance of a solar thermal expansion pump. The results obtained are encouraging. The report includes design, construction and working of solar thermal expansion pump. Report also contains project expenditure, future modification and scope of solar thermal expansion pump.
BMIT, Solapur.
2. Literature Survey
BMIT, Solapur.
LITRATURE SURVEY:
(http://www.edwardsvacuum.com/uploadedFiles/Resource/Technical_Articles/
Recent%20Experience%20of%20Mechanical%20Vacuum%20Pumps.pdf) Name Of Paper: Recent Experience Of Mechanical Vacuum Pump Replacing Steam ejectors in vod and vd process. In the area of ladle refining recent advances in the degassing process utilizing dry mechanical vacuum systems in place of liquid based water ring and/or steam ejector systems offer clear savings in running costs, maintenance costs, and installation space, and also offer increased speed, flexibility, and overall productivity to steel degassing operations. Large Roots style vacuum booster pumps designed for high dust tolerance are the major component of such mechanical vacuum degassing systems, backed by dry mechanical pumping systems. (http://www.venturipumps.com/ejector.htm) We studied the working details of steam jet ejectors. It is based on ejector venture principle in which nozzle are provided. It provides controlled expansion of the motive steam to convert pressure in to velocity which creates a vacuum within the body chamber to draw in and entrain gases or vapours.
(http://www.venturipumps.com/siphon.htm) Steam Jet Siphons operate on the steam jet principle utilizing the energy of steam under pressure to pump, mix liquids and handle solids. In operation siphons use the kinetic energy of motive steam to entrain another liquid or slurry, completely mix the two, and then discharge the mixture against a head or counter pressure.
(http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=5363205&url=http%3
A%2F%2Fieeexplore.ieee.org%2Fstamp%2Fstamp.jsp%3Ftp%3D%26arnum ber%3D5363205) We also studied thermal expansion pump (TEP) based on a principle of liquid thermal expansion for capillary high performance liquid chromatography has been developed.
BMIT, Solapur.
3. INTRODUCTION
BMIT, Solapur.
INTRODUCTION:The fossil fuels reservoirs are getting depleted due to continuous use of it in automobile, industries and other applications. The prices of petrol and diesel, coal are increasing day by day. The following table shows the increase in prices of petrol and diesel from 1990 to 2011. Year 1990 1996 2003 2005 2010 2011 2012 Petrol (per lit.) 9.84 21.13 32.70 40.49 51.43 67.87 72.25 Diesel (per lit.) 4.08 9.04 20.73 28.45 40.10 44.60 44.80
Table 1:- Prices of petrol and diesel. (Reference:-http://in.reuters.com/article/2010/07/16/india-fuel-price idINSGE66F08P20100716, Fri Jun 25, 2010 7:17pm) There is need to use renewable energy sources like solar, air, water or combination of these to meet the requirements of transportation, industrial and all other application. So solar energy one of the best alternative source for electricity, gas etc. Existing pumps are either electrical pump or hand pump or foot pump. Electrically operated pump require electrical energy, hand or foot operated pump require human efforts. As energy crisis is problem in front of our country, so we are going to design pump which works on principle of solar thermal expansion and as compare to hand or foot pump it will reduce human effort. In the solar thermal expansion pump we use solar thermal energy for lifting the water. As solar energy is freely available its running cost is very low. The application of solar thermal expansion pump is not only in thermal industry but also it is used for the chemical industries, it may be used for domestic applications.
BMIT, Solapur. 6
Typical comparison:Sr no.

1 2 3 Water lifting pump For Initial domestic applications 0.5 hp motor 1 hp motor Solar thermal expansion pump cost Running cost
(approximate) 1900/3000/14000/-
(approximate) 150 PM 200PM 0
Table 2:- Comparison of pump on the basis of running cost.
Various pumping techniques:The following are the various pumping methods which are available for lifting the water. For the purpose of lifting the water vacuum creation is very important and it is created by following methods
1) Vacuum creation by temp difference:In this method vacuum is created by maintaining temp difference body and surrounding.
2) Vacuum creation by pressure difference:In this method vacuum is created by maintaining pressure difference .maintaining pressure difference means reducing pressure of flow with the help of nozzle. As fluid flows through the nozzle it reduces pressure due to which velocity increases which results in creation of vacuum.
BMIT, Solapur.
Fig 1:- vacuum creation by throttling effect
3) Vacuum creation by stem jet siphon:Steam Jet Siphons operate on the steam jet principle utilizing the energy of steam under pressure to pump, mix liquids and handle solids. In operation siphons use the kinetic energy of motive steam to entrain another liquid or slurry, completely mix the two, and then discharge the mixture against a head or counter pressure.
Fig 2:- steam jet siphon
BMIT, Solapur.
4) Vacuum creation by solar thermal expansion pump:In this process first steam is allow to expand then it is to be cooled. While cooling the steam get contracted which results in vacuum creation.eg:- Based on a principle of liquid thermal expansion for capillary high-performance liquid chromatography has been developed.
3.1 Primary advantages of solar thermal expansion pump over other vacuum pumps:
Low cost. No moving parts Mechanical simplicity. No vibration. As there is no moving part less wear takes place. Low running cost. Corrosion and erosion resistant. Easy to install.
3.2 Applications of solar thermal expansion pump:1. Domestic application: Normally in domestic application hydraulic pumps are used for lifting the water from lower level and store it in the tank on higher side. For completing this activity we use electricity. Instead of using this pump, solar thermal expansion pump is used to lift the water from lower level and store it on higher side. As we using solar energy so no running cost is required.
2. Industrial application:
In industry it may be used for various application of pumping. It may be also used for supplying hot water. It may be used for lifting muddy water which is difficult to lift by conventional pumps.
BMIT, Solapur. 9
4. SOLAR THERMAL EXPANSION PUMP
BMIT, Solapur.
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4.1 SOLAR THERMAL EXPANSION PUMP:The whole solar thermal expansion pump is shown in the following figure. It consists of a tank, solar panel, ball valve, breaded pipe, PVC pipe, supporting base frame, lower reservoir, reducer, elbow etc.
1. Tank:Normally in one family 5 members are living and their requirement of water in one day is nearly 150 liters i.e. each member required 30 liters of water per day. Therefore we decided to manufacture the tank of 300 liters which fulfils requirement of minimum 10 members. We selected the material for manufacturing of the tank is mild steel instead of stainless steel. As the mild steel is having poor corrosion resistance as compared to stainless steel. Therefore stainless steel is more effective material for manufacturing of the tank .But stainless steel is more expensive as compared to mild steel. Therefore we selected the mild steel because of it is cheap, easy to machine and weld and having more stiffness. Due to poor corrosion resistance some form coating also provided on the tank. Tank is having four ports contains one suction port, discharge port; & other two ports i.e. inlet & outlet ports which are connected to solar panel ports. The diameter of tank (D1) is 0.45 meter and length (L1) is 0.80 meter. The diameter of suction port and discharge port is about 1 inch nearly. The ball port fitted to the discharge port is also about 1 inch. The capacity of the tank is about 300 liters. At the suction port of the tank reducer of 1 inch is provided to fitting of the flexible pipe to the port. The height of suction port from ground is about 7 feet. The flexible pipe is placed in the bucket which is filled by the water placed on the ground. The height of the discharge port from the ground is at about 5.5 feet. The Ball port is attached to the discharge port. Other two ports i.e. one inlet port of tank is attached to the inlet port of solar panel and other outlet port is connected to the outlet port of the solar panel.
BMIT, Solapur.
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Fig 3:- Black coated tank of solar thermal expansion pump
2. Base frame:The base frame is made of mild steel material. Base frame having 4 angles. The height of the base frame from the ground is about 3 feet. On this base frame black coated tank is mounted and with respect to the base frame the solar panel is fitted. The thickness of 4 angles is about 25mm nearly. The base frame is welded from all sides. The base frame has following detail Hst: 2.04 m L2: 0 .94m L3: 0.48m W1: 1.08m W2:0.78m
BMIT, Solapur.
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Fig 4:- Base frame of solar thermal expansion pump
3. Solar panel:As capacity of our tank is 300 liters, we select the solar panel having capacity of heating 300 liters per day. We select flat plate solar collector having 9 tubes inside it. The diameter of each tube is 10mm and that tubes are made up of copper. We select the flat plate collector because it is efficient than evacuated tube type solar collector and it can produce better pumping effect even in summer season. Aluminum insulation is provided on the solar panel. We provide fins on copper tubes for increasing contacting surface area. The solar panel is placed in inclined position with respect to the ground. The angle of inclination is about 30 degree .The inlet and outlet valve of the tank is fitted with of flexible pipe.
BMIT, Solapur.
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Fig 5:- Solar panel of solar thermal expansion pump
4. 1 C PVC pipe:Solar thermal expansion consists of no of pipes for carrying either water or steam. It consists of 1 (d2) PVC pipe at the inlet for lifting the water.
Fig 6:- C PVC pipe of solar thermal expansion pump
BMIT, Solapur.
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5. Copper tube:A copper tube of diameter (d4) upto 3mm is used for producing throttling effect.
Fig 7:- Copper tube of solar thermal expansion pump
4.2 WORKING OF SOLAR THERMAL EXPANSION PUMP:The solar thermal expansion pump is a piston less or rotor less pump. This pump working on solar thermal expansion technique. First of all, some water is filled in the solar panel from the inlet valve of the panel. After filling water in the panel inlet valve is closed with the help of clips fitted on the flexible pipe. The main function of the solar panel is to heat the water with the help of sun radiation without consuming electricity. As solar thermal expansion pump is rigid in construction we keep it open to the atmosphere at that time due to solar energy solar panel covert water into wet steam. That wet steam is collected in the black coated tank .The tank is black coated and black body absorbs heat the temperature of steam get increase. When atmospheric temperature increases the steam inside the tank get expanded and when atmospheric temperature decreases at that time steam tries to contract which results in creation of vacuum. At the same time steam enters into the suction pipe. As steam enters inside the pipe its pressure decreases and velocity increases which results in creation of vacuum. As vacuum is created the water from lower reservoir gets lifted upwards.
BMIT, Solapur.
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5. DESIGN OF SOLAR THERMAL EXPANSION PUMP
BMIT, Solapur.
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5.1 SYSTEM DESIGN:Following Parameters influencing system design:-
1) System Selection Based on Physical Constraints:While selecting any Pump it must be checked whether it is going to be used in a large-scale industry or a small-scale industry. Thermal expansion pump is to be used by a small-scale industry and it may be used for domestic appliances. So space is a major constrain. The system is to be very rigid and robust construction and for its application we require solar energy so that it cannot be adjusted to corner of a room. It must be kept open to atmosphere. The mechanical design has direct norms with the system design. Hence the first job is to control the physical parameters, so that the distinctions obtained after mechanical design can be well fitted into that.
2) Arrangement of Various Components:Keeping into view the space restrictions the components should be laid such it is easy to remove or service. More over every component should be easily seen none should be hidden. arrangements. Every possible space is utilized in component
3) Components of System:As already stated the system is having rigid and robust construction so that it cannot be accommodated at a corner of a room. It does not contain any moving part. A rigid and robust system design gives a high weighted structure which is desired.
4) Man Machine Interaction:The friendliness of a machine with the operator that is operating is an important criterion of design, but in this application there is no need of controlling the system as it is automatically operated. Interaction between man and machine is for only operating delivery valve.
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5) Chances of Failure:The loss incurred by owner in case of any failure is an important criterion of design. In this system if any leakage takes place it directly affects output as losses takes place. The system should be leak proof and air tight.
6) Servicing Facility:The layout of components should be such that easy servicing is possible. Especially those components which require frequent servicing can be easily disassembled.
7) Scope of Future Improvement:Arrangement should be provided to expand the scope of work in future. Such as to make the multicycle operating pump.
8) Weight of Machine:The total weight depends upon the selection of material components as well as the dimension of components. A higher weighted machine is difficult in transportation but if we install pump once there is no need to make change in installation.
BMIT, Solapur.
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6. FABRICATION PROCESESS
BMIT, Solapur.
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FABRICATION PROCESS:6.1 Design and manufacturing of tank: First of all, we have prepared the design of tank with suitable dimensions. Then selected the material of mild steel for manufacturing the tank. Because mild steel is mostly used. Then by using the plate cutting machine, the plates of mild steel are cut with suitable sizes. After cutting the plates are rolled to the required radius with the help of plate rolling machine. Then the sides are beveled with help of proper welding by welding machine. Before doing the welding, the welding procedures are prepared and qualified these procedures and then the welding is to be carried out. Then weld lets are installed for fixing the suction, discharge, inlet and outlet ports. In our manufactured tank, the weld lets for fixing the temperature gauges, pressure gauges are not installed. After that end caps are fitted to the tank. After that we applied the weld heat treatment for the tank by using weld heat treatment machine. After these all procedures, the tank is sealed with the black coating powder with oil. However, with an oil, wax, or lacquer, it is possible to achieve excellent indoor corrosion protection (100+ hrs. in a humidity cabinet). Black oxides on steel are not suitable for severe outdoor applications or corrosive environments, but they can provide superior humidity cabinet results with proper supplementary coating. In order to determine the appropriate after-finish, first evaluated which afterfinish to use. The following factors should be considered: Length of protection required, desired finished appearance (gloss/matte), Storage conditions (humidity, vapor, temperature), final application The coating powder is selected black because black oxide coatings are clean and rinse, also for our project it is essential because it absorb the heat with maximum rate. Then fitting the ball valve, reducers, and pipes to the suction and discharge ports which are welded to the tank.
BMIT, Solapur.
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6.2 Manufacturing of base frame:

In order to manufacture a base frame following processes are followed. 1) MS angle of thickness 25.4mm is selected. 2) We have cut down the MS bar as per dimensions on hand cutting machine. We cut 2 bars of 70cm and 2 bars of 40cm. 3) By using Electric arc welding, these bars are being welded to form metallic frame of size (70cm*40cm). Then we cut the bar into 4 pieces of length 110 cm, 2 pieces of 90cm and 2 pieces of 60cm. These bars are also welded to form a frame of size (90cm*60cm) by using electric arc welding. 4) The 4 pieces of bars of length 110cm are welded to the 4 corners of smaller frame. Then keeping 20cm distance from the ground, larger frame is welded. Smaller frame is parallel to larger frame. The inclination of smaller frame to the larger frame is 10 degree. 5) The manufacturing of the base frame is completed.
Fig 1. Catia model of base frame
BMIT, Solapur.
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Model of solar thermal expansion pump:
Fig 2 Model of solar thermal expansion pump
BMIT, Solapur.
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7. Experimental Results
BMIT, Solapur.
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Experimental Results:7.1. Experimental Results With 1 C PVC pipe:Procedure: We have fitted the CPVC pipe of 1 diameter to the suction port with the help of
reducer. One end of pipe is connected to reducer and other end is kept free to atmosphere. Solar panel is connected water tank. As at noon time steam is generated it is to be stored in the tank. Steam gets expand in the tank and excess steam is released to the atmosphere through suction pipe. At evening steam tries to get condense due to which vacuum is created and water is lifted and observations are recorded.
7.2. Experimental Results with 6 mm flexible pipe:Procedure:
Instead of 1 PVC pipe we use flexible pipe of 6mm diameter at the suction port by using reducer and all procedure is repeated.
7.3. Experimental Results with 3 mm cooper tube:Procedure: For obtaining better result we reduced the diameter of suction pipe upto 3mm. now instead of 6mm flexible pipe we used copper tube of diameter 3mm and procedure is repeated.
BMIT, Solapur.
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8. Observations
BMIT, Solapur.
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OBSERVATIONS:Pumping effect is observed as follows:

1) When we use pipe of 1 diameter then 2 liter of water was lifted at the head of 7 feet. 2) When we use pipe of 6mm diameter then 4 liters of water was lifted at the head of 7 feet. 3) When we use pipe of 3mm diameter then 7 liters of water was lifted at the head of 7 feet.
BMIT, Solapur.
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9. BILL OF MATERIAL
BMIT, Solapur.
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9.1 BILL OF MATERIAL:SR NO. 1. 2. 3. 4. DESCRIPTION TANK BUSH BALL VALVE REDUCER QTY 01 01 01 MATERIAL CI BRASS CI CI
5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
END CAP REDUCER TAPELAN TAPE GASKET BOTTLE NAPPLER COUPLER NIPPLE REDUCER 6 MM BREADED PIPE SOCKET 3/4 PVC PIPE
08 02 01 01
CI -
02 01 01 10FEET 02 20
CI CI GI STD CI STD
Table No 11:- Bill of Material
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9.2 COST ESTIMATION:1. Raw Material Cost:The total raw material cost as per the individual materials and their corresponding rates is as follows, Total raw material cost = 800 /Fabricating cost = 800 /-
2. Cost of Purchased Parts:SR NO. DESCRIPTION QTY COST
1. 2. 3. 4. 5. 6.
C PVC PIPE FLEXIBLE PIPE COPPER PIPE REDEUCER 1 BALL VALVE 1 OTHER MISCELLANEOUS MATERIAL
20 FEET 10FEET 10FEET 2 1
400 280 500 100 50 500
Table 12:- cost of purchased parts The cost of purchase parts = Rs 1830/-.
3. TOTAL COST
Total Cost = Raw Material Cost (800) +Machining Cost (800) + cost of air tight tankl provided by industry(6000) + cost of Purchased Parts (1830)+ solar panel provided by industry(8000). TOTAL COST = Rs 17430/- .
BMIT, Solapur.
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10.
CONCLUSION
BMIT, Solapur.
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CONCLUSION: Small amount of water gets lifted during heating and cooling (day & night) in solar water heaters due to thermal expansions. This experimental result leads & requires further study of the thermal expansion process for purpose of pumping the liquid using solar pumps working on thermal expansion by using some accessories to lift same or different type of liquids.
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11.
FUTURE SCOPE
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FUTURE SCOPE:Certain modifications and can be carried out to expand the scope of work in future. There is huge scope for future work. We constructed this pump especially for domestic applications but in future we can utilize it for industrial applications. In future this pump may be used for lifting the muddy water. In future this pump may be utilized for pumping chemicals in chemical industry.
This pump produce pumping effect only once in day but in future we can increase
its efficiency by making multicycle.
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12.
REFERENCES
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REFERENCE:1. http://www.venturipumps.com/ejector.htm 2. http://www.venturipumps.com/syphon.htm 3. http://ieeexplore.ieee.org/xpl/login.jsp?tp=&arnumber=5363205&url=http%3A% 2F%2Fieeexplore.ieee.org%2Fstamp%2Fstamp.jsp%3Ftp%3D%26arnumber%3D 5363205 4. http://ieeexplore.ieee.org/xpl/articleDetails.jsp?arnumber=5943862&contentType =Conference+Publications Papers: 1. Author : Dr. Simon Bruce, Vic Cheetham, Graham Legge
(http://www.edwardsvacuum.com/uploadedFiles/Resource/Technical_Articles/Rece nt%20Experience%20of%20Mechanical%20Vacuum%20Pumps.pdf)
Books: 1. R.S.Khurmi, Thermal Engineering- thermosyphon system, S Chand & PVT.LTD (New Delhi - 2008) Page no.602 -603. 2. R.S.Khurmi, Thermal Engineering-steam nozzle, S Chand & PVT.LTD (New Delhi - 2008) Page no.469 -470. 3. S.K. Hajra choudhury , A.K. Hajra choudhury & Niraj Roy, Elements of workshop technology volume-1 Manufacturing Processes, Media promoters& publishers PVT.LTD (Mumbai - 2005)
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DESIGN AND DEVELOPMENT OF SOLAR THERMAL EXPANSION PUMP