Domestic Water System (Replacement for air-conditioner) Final Report Project Members/IDs Youssef Ehab Tohamy (1001987) Youssef Ehab Nehad (1002359) Raed Talal Khaili (1002322) Project Supervisor(s) Prof. Ashraf Zaher. Eng. Tadrous Melad. Department of Electrical/Mechanical Engineering Faculty of Engineering German International University June, 15 , 2022 i Declaration We certify that this project work titled “ Domestic Water System ” is our work. The work has not been presented elsewhere for assessment. The materials that have been used from other sources have been properly acknowledged/cited. Project Members Youssef Ehab Tohamy (1001987) Youssef Ehab Nehad (1002359) Raed Talal Khaili (1002322) ii Plagiarism Certificate (Similarity Report) This project report has been checked for Plagiarism. A similarity report, endorsed by the Supervisor(s), is attached. Project Members Youssef Ehab Tohamy (1001987) Youssef Ehab Nehad (1002359) Raed Talal Khaili (1002322) Signature of Supervisor(s) iii Copyright Statement Copyright in text of this project report rests with the student authors. Copies (by any process) either in full, or of extracts, may be made only in accordance with instructions given by the authors and lodged in the Library of GIU. Details may be obtained by the Librarian. This page must form part of any such copies made. Further copies (by any process) may not be made without the permission (in writing) of the authors. The ownership of any intellectual property rights which may be described in this project report is vested in GIU ’ s Departments of Electrical & Mechanical Engineering, subject to any prior agreement to the contrary, and may not be made available for use by third parties without the written permission of the GIU ’ s Departments of Electrical & Mechanical Engineering, which will prescribe the terms and conditions of any such agreement. Further information on the conditions under which disclosures and exploitation may take place is available from the Library of GIU, Egypt. iv Acknowledgements This page can be used to acknowledge any technical or financial support and collaboration with academic, industrial or funding partners, support from supervisor, other faculty members, and/ or other fellow students. Students may also include acknowledgements of family members. Font, line spacing, and page margins must not be changed throughout this section and other sections in the report. Example texts for acknowledgements are given below. Youssef Ehab Tohamy (1001987) Youssef Ehab Nehad (1002359) Raed Talal Khaili (1002322) v “ Dedicated to our exceptional parents and adored siblings whose tremendous support and cooperation led us to this wonderful accomplishment ” vi Abstract Nowadays, the use of air-conditioners has increased tremendously leading to significant changes in the climate and high-power consumption. Based on that we decided to design a replacement system for the air-conditioner to be more eco-friendly and have less power consumption. Our system uses the heat of the sun to heat the thermal carrier, in our case the water, and another refrigeration kit, which works with electricity, not prion, to cool the water. And a control system is implemented to mix these waters based on their temperatures and the desired temperature entered by the user to get the make the water ’ s temperature the same as the desired temperature. Then water is pumped through copper pipes circulating in the system and laying on a sheet with high thermal conductivity. To allow the home temperature to be nearly the same as the room temperature. And to close the cycle the water is pumped back into the system and here comes the rule for another control system that controls the inlet of the water to the tanks to preserve a certain height. Lastly, to turn the pump off another system monitors the temperature and when it ’ s nearly the same as the desired one it turns off the pump. The heating and cooling system proved to be working properly same for the water mixing system as it managed to mix the water in a way that gets the desired temperature. However, due to the shortage in time the last system for preserving the water level in the tanks is mathematically done but not implemented on the practical model Key Words: air-conditioner, climate change, control system, eco-friendly, power consumption, water level. vii Table of Contents Declaration ...................................................................................................................... i Plagiarism Certificate (Similarity Report) ..................................................................... ii Copyright Statement ..................................................................................................... iii Acknowledgements ....................................................................................................... iv Abstract .......................................................................................................................... vi Table of Contents ......................................................................................................... vii List of Figures ............................................................................................................... ix List of Tables .................................................................................................................. x CHAPTER 1: INTRODUCTION ................................................................................. 1 1.1 Background ............................................................................................................................. 1 1.2 Problem Statement ................................................................................................................. 1 1.3 Aims and Objectives of the Project .................................................................................... 1 1.4 Significance, Scope and Definitions .................................................................................... 2 1.5 Report Outline ........................................................................................................................ 2 CHAPTER 2: LITTERATURE REVIEW .................................................................... 3 2.1 Historical Background ........................................................................................................... 3 2.2 Topic 1 ............................................................................. 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Bookmark not defined. 2.5 Summary and Implications ................................................................................................... 7 CHAPTER 3: METHODOLOGY, DESIGN AND ANALYSIS ................................. 7 3.1 Methodology ........................................................................................................................... 7 3.1.1 Heating System .................................................................................................................. 8 3.1.2 Cooling System .................................................................................................................. 9 3.1.3 Water Mixer System ........................................................................................................ 11 3.1.4 Piping System ................................................................................................................... 11 3.1.5 Tank level control system .............................................................................................. 12 3.1.6 Pump Control System ..................................................................................................... 12 viii 3.2 Research Design ................................................................................................................... 13 3.2.1 Outlet System (Water Mixer) ......................................................................................... 13 3.2.2 Inlet System ...................................................................................................................... 16 3.2.3 Design Alternative 1 ....................................................................................................... 21 3.3 Software and Hardware ....................................................................................................... 22 3.4 Analysis .................................................................................................................................. 23 CHAPTER 4: IMPLEMENTATION ......................................................................... 24 4.1 Hardware Implementation ................................................................................................. 24 4.2 Software Implementation ................................................................................................... 27 CHAPTER 5: EVALUATION .................................................................................... 32 5.1 Heating and Cooling System .............................................................................................. 32 5.2 Water Mixer System ............................................................................................................. 32 5.3 Pumping System ................................................................................................................... 32 CHAPTER 6: CONCLUSION AND FUTURE WORK ............................................ 33 6.1 Conclusion ............................................................................................................................. 33 6.2 Future Work .......................................................................................................................... 33 References ..................................................................................................................... 35 APPENDIX A ............................................................................................................... 36 ix List of Figures Figure 1 Schematic of a conventional solar water heating system ................................................ 4 Figure 2 (a) passive system (b) active system .................................................................................... 4 Figure 4 Non-pressurized solar water heater .................................................................................... 6 Figure 5 Pressurized Solar Water Heater ........................................................................................... 6 Figure 6 Low Pressure Solar Water heater ........................................................................................ 8 Figure 7 Cooling System ..................................................................................................................... 10 Figure 8 Refrigeration Kit .................................................................................................................. 10 Figure 9 Example to in roof piping .................................................................................................. 11 Figure 10 Above ground pipes .......................................................................................................... 12 Figure 11 Structure of the linear valves ........................................................................................... 13 Figure 12 Flow Characteristics of different types of valves. ........................................................ 14 Figure 13 Linear Flow Characteristics of the valves ...................................................................... 14 Figure 14 Block Diagram of the hole system .................................................................................. 15 Figure 15 Motorized Valves with Arduino ...................................................................................... 15 Figure 16 DS18B20 Temperature Sensor ........................................................................................ 16 Figure 17 Temperature Monitoring System .................................................................................... 16 Figure 18 Block Diagram of the Temperature control system .................................................... 16 Figure 19 Components of water-level control systems ................................................................. 17 Figure 20 Detailed Description of the System and the Parameters ............................................ 17 Figure 21 Water level control system. .............................................................................................. 18 Figure 22 The pipe used to measure the pressure .......................................................................... 20 Figure 23 3D Model of the house ..................................................................................................... 24 Figure 24 PVC Pipes Used for tanks ................................................................................................ 25 Figure 25 The Prototype of the system ............................................................................................ 25 Figure 26 Locally Made Motorized Valve. ...................................................................................... 26 Figure 27 The Tanks after installation ............................................................................................. 26 Figure 28 Temperature Sensors code ............................................................................................... 27 Figure 29 Direction Control of Stepper Motor .............................................................................. 27 Figure 30 Moving the Stepper for certain amount of steps ......................................................... 28 Figure 31 Second way to overcome the fluctuations in the Temp Sensors ............................... 28 Figure 32 Calculating the steps to move of the stepper motors .................................................. 29 Figure 33 Update of Previous steps .................................................................................................. 29 Figure 34 Determination of the direction of movement. ............................................................. 29 Figure 35 Initializing the previous steps from the EEPROM ..................................................... 29 Figure 36 Saving the life time of the EEPROM Memory. ........................................................... 29 Figure 37 Step one of Calibration ..................................................................................................... 30 Figure 38 Second Step in calibration ................................................................................................ 30 Figure 39 Handling Different cases of temperature failure .......................................................... 31 x List of Tables Table 1 Evacuated and Flat tubes 1 .................................................................................................... 5 1 CHAPTER 1: INTRODUCTION 1.1 Background The use of air-conditioners has aroused a lot recently due to the population growth and the extreme change in the climate. However, air-conditioners result in gaseous emissions that contributes in the global warming and it ’ s expected that by 2050, air conditioners would have contributed by 25% of global warming (Masters Heating& Cooling INC, n.d.) Second thing is the relatively high-power consumption of the air-conditioners, it varies depending on different factors. However, the average use is nearly 3000 watts per hour so, if you have it running the whole day it would be 72,000 watts (inpsire CLEAN ENERGY, n.d.) Also, in remote areas, which don ’ t have access to high power sources the power consumption will be a valuable luxury people there may not have. All, of these above causes have inspired us to design an eco-friendlier system with less power consumption to be able to replace the air-conditioner either for environmental reasons, economic reasons or availability reasons. 1.2 Problem Statement During the last decades air-conditioners have been significantly contributing in the climate change due to the emissions of gaseous due to the use of the prion. Also, there high consumption makes them economically exhausting devices and it may be challenging to have one in the remote areas away from the grid. 1.3 Aims and Objectives of the Project The aim of this project is to design a cheaper system that can handle the functionality of the air-conditioning unit which is basically heating and cooling. And in the same time the process of heating and cooling needs to be more ecofriendly than the air-conditioner, second thing is to be able to adjust the temperature in the room to an acceptable accuracy of the desired temperature. And this will help to combine the benefits of the air-conditioners which are controlling the temperature of the place causing a healthier and more comfortable indoor climate. And in the same time, it reduces its bad effects on the environment and on the power consumption. 2 1.4 Significance, Scope and Definitions The Project in hand will help to reduce the bad effects of the air-conditioners by using eco- friendly sources for heating and cooling, the two functionalities of the air-conditioner, and storing the heat on a heat carrier, in our case is water, in isolated tanks. And it will be a more economical alternative for the air-conditioner. 1.5 Report Outline Chapter2 tackles the literature review of the previous work done regarding the main idea Chapter3 tackles the procedure followed in the project to achieve the final prototype of the system and it starts with simple illustration of the systems and how to tackle the expected problems then it goes into details in the problems that faced us during the theoretical work. Also, it mentions all the hardware and the software used in this project. Chapter4 tackles the implementation steps of the system starting by designing the model going through hardware and problems that faced us while installation and finally the software which is the code the controls the system and how we managed to handle all the safety hazard cases that faced us within the system. Chapter5 tackles the evaluation of the implemented system and to see based on what we accepted the behavior of the system or rejected it. Chapter6 concludes the results of this work and mentions all the suggested future work for any upcoming investigation in this area. Then the report ends with the references used in this report and the Appendix contains the full code of the system and datasheets of the used hardware in the system. 3 CHAPTER 2: LITTERATURE REVIEW 2.1 Historical Background The literature review presented within this report didn ’ t tackle the system as a whole but it tackled the subsystems especially the heating system and how to implement it. It was meant to make an eco-friendlier system that does the same functionality of the air- conditioner which are heating and cooling. The main source of heat in planet is the sun. so, the first thing thought of was to use solar thermal energy to heat up the system. And to use the solar energy to power the system mainly. Solar water heating is one of the most popular solar thermal system and forms 80% of the solar thermal market worldwide. (Zhangyuan Wang a, 2015) Over the past four decades solar water heating systems has been widely used in many applications, however they suffer from technical problems preventing their promotions like low existing efficiency, high heat loss and poor solar energy harvesting capability. Also, a point to consider is the cost of installation in the buildings. Most solar water heaters installed in the buildings are flat-plate type or conventional heat pipes array installed on roofs. This type of installation requires long runs of pipelines to move the water from the heater into the house and this installation detracts from the aesthetics of the building. However, in recent years solar heaters have been developed to be positioned on the walls or balconies. (Hestnes, 1999) which prevented the occupation of the roof space and shortened the distance of piping and improved the building ’ s aesthetic view. 2.2 Different Types of Solar water heating systems. 2.2.1 Working Principle The components of the solar water heater as shown in the below figure are Discrete collector, which functionality is to reduce heat losses and maximize solar absorption. Solar collector can be one of two options either to be flat-plate collector which will be a flat-plate absorber painted in black, bonded to copper piping and covered with a transparent glass. Or to be evacuated-tube collector which consists of copper tubing surrounded with evacuated and selectively-coated glass tubes. When solar radiation passes the transparent glass or the evacuated tubes. A large part of the 4 energy is absorbed and then transferred to the fluid to be transported by the pipes. The heat transfer fluid is a mixture of water and antifreeze fluid. (Boyyle, 1996) Figure 1 Schematic of a conventional solar water heating system 2.2.2 Classifications 2.2.2.1 Passive and active systems This first category classifies them based on whether the system needs a pump or not. The schematic of both systems is shown in figure2. (OguekeN, 2009) Passive Systems heat is transferred from the collector, the flat books with the copper pipes in it, to a tank located above it based on the fact that hot water has less density. And this phenomenon is known as natural circulation, and it could supply water of 60C. (Naher, 2002) Active Systems Active systems depends on electric pumps and control valves to circulate the water in the system. The advantages it has over the passive system is that it ’ s 35% to 80% more efficient than the passive one (Khalifa, 1998) Also, these systems don ’ t need to be as close to the tank. But it could be complicated due to the dependent on the electricity to power the pump and control it. Figure 2 (a) passive system (b) active system 5 2.2.2.2 Direct and indirect systems In a direct system, the service water is directly circulated between the collector and the tank. While in an indirect system, the heat transfer fluid is water mixed with an antifreeze fluid, could be organic fluid, is circulated between the collector and the tank. In most situations the indirect systems perform better than the direct ones, which are less climate-selective and more suitable for regions with very cold temperature. 2.2.2.3 Low and High temperature solar collectors. Flat-plate water collector this type is the mainstay of domestic solar water heating worldwide. It could be either single or multiple glazing system. The panel has a black surface or special coating that has high optical absorption and low emission to cut heat loss. The absorber plate must have high thermal conductivity, could be a sheet of metal, to be capable of transferring the collected energy to the water with a minimum drop. Evacuated-tube collector it consists of set of modular tubes. To minimize the convective heat losses there is a virtue vacuum in the tube. The absorber plate is a metal strip in the center of each tube, the collected energy is carried out by the heat pipes to the water which circulates a long a header at the top of pipe array. There are other types of low and high temperature solar collectors however, the previous two are the most commonly used ones and the figure below shows comparison between them. Evacuated-tube collector Flat-plate collector Heat production Rapid – vacuum prevents heat losses Slow Heat losses during daytime Negligible High Influence of the incidence angle of the sun rays Maximum solar absorption throughout the day – cylindrical shape Maximum solar absorption at noon – flat shape Cold weather operation Satisfactory performance – vaporizing/condensing processes within the heat pipes Limiting effect – direct heat transfer processes, risk of freezing Maximum temperature range Above 95 ° C Up to 80 ° C Cost-effective Advanced technology at competitive price Old technology at higher price Hot water availability For a greater number of days throughout the year For a lesser number of days throughout the year Position of the collector on the roof Assembled onto the surface of the roof Preassembled flush with the roof Table 1 Evacuated and Flat tubes 1 6 2.3 Pressurized and non-pressurized solar water heating system There are also two different categories lies under flat-plate water heat collector which are pressurized and non-pressurized solar water heating systems shown in the figure below (Mishra, 1992) Figure 4 Non-pressurized solar water heater Figure 5 Pressurized Solar Water Heater As, it ’ s clear from the above two graphs the main differences between the pressurized and non- pressurized model is the arrangement of the pipes themselves as in the non-pressurized the pipes form multiple pipes that are connected in parallel which gives shorter path for the water and doesn ’ t allow for high temperature gaining on the other hand it ’ s not multiple of pipes it ’ s an one long 7 twisted pipe which causes the water to have longer path and therefore gaining more temperature, even evaporates, and this causes it to pressurize the tank it ’ s being stored into. Here is a small comparison between the low-pressurized system and the high pressurized one. Non-Pressurized System: Main advantages: Simple with no moving parts, cheaper than the other one, has a longer life due to low-pressure, lightweight so doesn ’ t need strong material to support the tank, can provide hot water without external power, external electrical heater. Disadvantages of the system: Has limited uses due to the small head of pressure, and this could be compensated if there is a pump in the system. Pressurized Water solar heaters: Main Advantages: Water pressure could be very high, make it suitable for systems with no pumps. The water tank could be far away from the heating unit and this makes it easier in terms of the support needed to carry the tank. Disadvantages: More expensive than low pressure solar heater systems. 2.4 Summary and Implications After discussing the working principles of water solar heaters and investigating different types of them. It was decided to use flat-plate solar water heater due to its easy installation anywhere and to make non-pressurized which means the heating pipes are multiple pipes connected in parallel which implies longer life time and more safety margin within the system itself also the system will be an active one, because we chose it to be non-pressurized, which means it has a pump within the system to allow for the circulation of the heat carrier, water in our case, in the system. And the same construction was the inspiration for implanting the same core idea for the cooling system but using refrigeration kit, cooling unit, instead of the heating unit and storing the cold water in a lower tank not an upper one. CHAPTER 3: METHODOLOGY, DESIGN AND ANALYSIS In this Chapter the criteria to be followed in the research will be illustrated elaboratively, the mathematical model for the system. 3.1 Methodology As illustrated before the idea of the system is to make a replacement of air-conditioner. In order to tackle this problem as an Engineering problem. Then new system has to be able, technically, to do all the tasks done by the air-conditioner not only this but it has to have some privileges over it 8 to encourage people to choose our system over the regular air-conditioner. In order to simplify the procedure, the system will be broken down into subsystems in order to be able to go through each one of them. So, the subsystems in terms of physical systems they will be divided as follows, heating system, cooling system, Piping System. In terms of software-based-on-hardware implementation. It will be the mixer system, tank level control system and Pump control system. 3.1.1 Heating System In order to get the desired temperature for the user either you will need to heat up or cool down the surrounding climate so, the system needs to supply both functionalities. Starting by heating. This system is meant to provide the heat to the system to rise the temperature of the building whenever needed. The mechanism of the system is that it would use a solar collector system to collect the heat and warm up the water, so it could be carried through the pipes which then could be used to warm up the air in the room to increase the overall temperature of the room to the desired one. There are two main types of solar collector system: Low pressure solar water heater and high-pressure solar water heater. The chosen system to be implemented is the low-pressure system due to its advantages and low hazards. As, it is Simple with no moving parts, cheaper than the other one, has a longer life due to low-pressure, lightweight so doesn ’ t need strong material to support the tank, can provide hot water without external power, external electrical heater. And the main advantage of it is the low head pressure and this could be overcome. if a pump is used in the system, which is the case in our system. Also, due to having low pressure there will not be any hazards of explosion or safety issues regarding the opening of the tank (Maramani.com, n.d.) Figure 6 Low Pressure Solar Water heater 9 The working principle of the system is that there are pipes connected to the elevated heating tank. The tank angle and elevation is based on the calculation of the angles of the sun to collect the most amount of solar energy during the needed season. However, it ’ s not the scope of this study. These pipes are made from copper due to its high thermal conductivity that it can absorb as much heat as possible from the sun. When the water is heated based on its thermal properties it becomes less dense. So, the heated water in the pipes will rise up to the tank and exchange its place with colder water and this current will continue circulating the water till all the water in the tank become of the same temperature (Macroscopic changes in liquid water volume, n.d.) The tank is made from an isolated material to isolate the water within the tank from losing temperature. 3.1.2 Cooling System Being inspired by the working principle of water circulation due to the thermal properties of water. A Design is made to make use of the fact that cold water is more dense and hot water is less dense. So, the idea is to couple two tanks using pipes made of copper. Then to use a cooling unit, which in our case is refrigeration kit, to cool down the pipes between the tanks and this will make the colder water goes to the bottom tank and hotter water goes up. And the circulation will go on and one. For sure the pipes have to be isolated from the surrounding in order not to be affected by the outside temperature.