Domestic Water Heater

Study, design And Fabrication of Water Tube Boiler Type Domestic Water Heater.
1 INTRODUCTION
Among all the nations in our universe India is one of the second largest countries in the world occurring 120 corers of population. Our nation consists of 80% people from rural area which are from middle class. In a year of twelve month, in our country, people take bath by hot water for eight month. But because of increase in financial cost for heating water, this is not offerable for common man. Now a days we have several type of water heater system such as solar water heater, electric water heater, gas water heater etc. But these methods are too costly which is not offerable for common people. Also for running this system, more consumption of energy needed such as electricity, coal, gas etc. is necessary. From all these water heating system one of the less costly and useful water heating systems is that Water Tube Boiler Type Domestic Water Heater. In this water heater, there is no need to use electricity or gas. Just in little amount of wastage material, more amount of water is heated. Material used such as wood, coal, paper, waste leaf of trees, cattle cake etc. Because of this we can save time and money. Also as it is less weight, it can be moved from one place to another place. In this water heating system only amount of fuel is needed to heat the water and water is heated maximum in five minutes.
Vikramshila Polytechnic, Darapur
Page 1
2 CLASSIFICATION OF BOILERS
2.1 According to the relative position of water and hot gases
2.1.1 Fire tube boiler In fire tube boilers, hot gases pass through tubes which are surrounded with water. There may a single or double tube as in the case of Lancashire boiler or there may be a bank of tubers as in a locomotive boiler. The Cochran, Lancashire and Locomotive are examples of this individual users, these boilers are universally used in many industries like paper, sugar and chemical industries for producing process steam. 2.1.2 Water Tube Boiler In water tube boilers, the water circulates through the tubes and hot gases around them. Steam is generated inside the tubes and collected in a cylindrical vessel known as boiler drum. The boiler drum may not be exposed to the hot gases at all. This type of construction is flexible and so is found suitable for different capacity and pressure requirements, from process steam to power generation.
2.2 According to the axis of shell

2.2.1 Vertical Shell type In vertical shell type boilers, the axis of the shell is vertical. 2.2.2 Horizontal Shell Type In horizontal shell type boiler, the axis of shell is vertical.
2.3 According to method of firing

2.3.1 Externally fired In externally fired boilers, the furnace is placed outside the boiler shell. The advantage of this type is that the fire place is simple and may be enlarged easily. Water tube boilers are always externally fired.
Page 2
2.3.2 Internally Fired In internally fired boilers, the furnace is placed inside the boiler shell. Most of the fire tube boilers are of this type.
2.4 According to the method of water circulation

2.4.1 Natural Circulation In natural circulation boilers, the water is circulated by natural convection currents which are set up due to the temperature difference. Most of the boilers of low capacity fall under this category. 2.4.2 Forced Circulation In forced circulation boilers, water is circulated with the help of pump driven by motor. Forced circulation is used only in high pressure high capacity boilers.
2.5 According to the use of boiler

2.5.1 Stationary Boiler Most of the industrial boilers and boilers use for power generation are of stationary type. 1.1.2 Movable Boiler The boilers used to run the locomotives and ships are mobile boilers as they continuously move from one place to other.
Page 3
3 WATER TUBE BOILER DETAILS

The details of the boilers are listed below:
3.1 Shell
The shell of the boilers is the main container usually of cylindrical shape, which contains water and steam.
3.2 Furnace
A furnace is another important part of the boiler. This may be a grate to burn coal or a burner to atomies and burn liquid fuel. Suitable area and volume should be provided for efficient combustion.
3.3 Water Flow Path.

Water flow path is the path followed by the water in the boiler during the process of absorption of heat from hot gases and conversion into steam. The water should be free from dissolved material in order to reduce the scaling of the heating surface.
3.4 Gas Flow Path.

The hot gas flow path either in fire tube or in water tube should be arranged in such a way that maximum heat of hot gases should be transferred to the water for steam generation. The boiler efficiency mainly depends upon the gas flow path.
3.5 Steam Path.

In most of the boilers, the steam is taken out preferably at the top of the shell to avoid water particles being carried with the steam. To reduce the water particles carried by the steam, it is generally taken out through steam separators, in the case of large boilers.
3.6 Fittings
The valves and gauges which are necessary for the safety of the boilers, are known as mountings. Water level indicator, safety valve, blow-off cock and fusible plug are some examples of the mountings.
Page 4
3.7 Accessories
Some equipment like economizer, air pre-heater and super heater is attached to the boiler to improve its overall efficiency. The economizer and air pre-heater are used to extract maximum heat from the flue gases and super heater is used to increase the temperature of steam above saturation temperature.
Page 5
4 WORKING OF WATER TUBE BOILER
Fig.4 working of water tube boiler As classified earlier, in a water tube boiler, the water is inside the tubes and hot gases flow over the tubes. A simple stationary boiler of this type is described here. The boiler with its parts is shown in Fig.1 The boiler shell known as water and steam drum is made of high quantity steel. It is connected by short tubes with the uptake header or riser and by longer tubes to the down take header. The water level in the drum is slightly above the centre. The water tubes are connected to the top and bottom header and are kept inclined at an angle of 15o to the horizontal. The headers are provided with hand holes in the front of the tubes and are covered with caps. This arrangement helps in cleaning of the tubes. The inclined position helps the flow of water.
Page 6
The furnace is arranged below the uptake header. Coal is fed to the grate through the fire door. Two firebricks baffles are arranged in such a manner that the hot gases from the grate are compelled to move in the upward and downward directions. First the hot gases rise upward and then go down and then rise up again and finally escape to the chimney through the smoke chamber. The outer surface of the water tubes and half of the bottom cylindrical surface of the drum form the heating surface through which heat is transferred from the hot gases to the water. The front portion of the water tubes comes in contact with the hot gases at higher temperature. So the water from this portion rises in the upper direction due to decreased density and passed into the drum through the uptake header. Here the steam and water are separated and the steam being lighter is collected in the upper part of the drum. From the back portion of the drum, the water enters into the water tubes through the down take header. Thus, continuous circulation water from the drum to the water tubes and water tubes to the drum is maintained. The circulation of water is maintained by convective currents and is known as natural circulation. A super heater is placed between the drum and water-tubes as shown in the figure. During the first turn of the hot gases, the gases are passed over the super heater tubes and the steam is passed through the super heater and becomes superheated steam. The steam is taken into the super heater from the steam space of the drum through a tube as shown in the figure. The super heater steam coming out through super heater is supplied through steam pipe and steam stop valve to the turbine. When the steam is being raised from cold boiler, the super heater is filled with water to the drum water level. This is essential to prevent the overheating of the working pressure. Once the rated pressure of steam is achieved in the boiler, then the water from the super heater is drained and steam is fed to it for superheating purposes. A mud box is fitted to the down header as shown in the figure. The impurities and mud particles from the water and collected in the mud box and they are blown-off from time to time by means of a blow off valve as shown in the figure. The access to the interior of the boiler is provided by the doors. This is necessary for cleaning the tubes and removing the soot from their surfaces. The draught is regulated by a damper which is provided in the back chamber as shown in the figure. The damper position is controlled with the help of chain connected to it from the pulley as shown in figure.
Vikramshila Polytechnic, Darapur Page 7
The outstanding features of the water tube boiler are listed below: The evaporative capacity of this boiler is high compared with other boilers (20,000 to 40,000 kg. /hr.) The operating pressure lies between 11.5 to 17.5 bars. The draught loss is minimum compared with other boilers. The defective tubes can replace easily. The entire boiler rests over an iron structure, independent of brick work. So that the boiler may expand or contract freely. The brick walls which form the surroundings of the boiler are only to enclose the furnace and the hot gases.
Page 8
5 DRAUGHT
In order to maintain the continuous flow of fresh air into the combustion chamber, it is necessary to exhaust the products of combustion from the combustion chamber of the boiler. A pressure difference has to be maintained to accelerate the product of combustion to their final velocity and to overcome the pressure losses in the flow of system. This pressure difference so maintained is known as Draught.
5.1 Classification of Draught

The method of producing the draught is generally classified as;
Draught
Natural Draught
Mechanical Draught
Induced Draught
Balanced Draught
Forced Draught
5.1.1 Natural Draught Natural draught is obtained by the use of chimney. A chimney is a vertical tabular structure of brick, masonry, steel or reinforced concrete or even reinforced plastic, built for the purpose of enclosing a column of hot gases, to produce draught. The effective draught is reduced in the brick chimney due the leakage loss can be eliminated by the use of concrete or steel chimney.
Steel chimney required less space, less weight and less costly but the life is small only 15 years. Lining of the steel chimney can increase the life of chimney. The concrete chimney is costlier and constructing time is more. The draught produced by the chimney is due to the density difference between the column of hot gasses inside the chimney and the cold air outside. 5.1.2 Mechanical Draught The draught required in actual power plant is high and to meet this high draught requirement, mechanical l draught system should be used. The artificial draught may be of mechanical type or of stream jet type. If the draught is produced by fan, it is known as fan (Mechanical) draught and if draught is produced by a steam jet, the draught is known as stream jet draught. Stream jet draught is use for small installation like locomotives while mechanical draught is invariably used in central power station. 5.1.3 Forced Draught In a forced draught pass system, a boiler installed near the base of the boiler and air is forced to pass through the furnace, flues, economizer, and to the stock. This draught system is known as positive draught system because the pressure of air through the system is above atmospheric pressure and it is force to flow through the system. 5.1.4 Induced Draught This draught is generally when an economizer and a preheated are incorporated in the system .the fan should be located at such a place that the temperature of the gas handle by the fan is lowest. The chimney is also used in this system and its function is similar to that in the draught but total draught produced in induced draught system is the sum of the draughts produced by the fan and chimney. 5.1.5 Balanced Draught It always preferable to use a combination of forced draught and induced draught instead of using either forced or induced draught alone. If only the forced draught is used, the furnace cannot be opened either for firing or inspection because the high pressure air inside the furnace will below out suddenly.
If only the induced draught is used, the furnace cannot be opened either for firing or inspection because the cold air will try to rush into the furnace as the pressure inside the furnace is bellow atmospheric pressure. This reduced the effective draught and dilutes the combustion gases. The air pressure bellow the grate is above atmospheric and it helps in the proper and uniform combustion. The pressure of air above the grate is bellow atmospheric and it helps to remove the exhaust gasses as quickly as possible from the combustion zone.
5.2 Advantages of Mechanical draught over Natural draught

The artificial or mechanical draught gives better control over combustion and is more economical than the natural draught. The advantages of mechanical draught over natural draught are listed below: The rate of combustion is high as the available draught is more. Better distribution and mixing of air with fuel is possible and therefore the quantity of air required for burning each kg of fuel is less. This further reduces the mass of the flue gases formed and heat carried by exhaust gases, thus increasing the efficiency. The air flow can be regulated according to the requirement by changing the draught pressure. The mechanical draught is independent of the atmospheric temperature whereas the natural draught is seriously affected by the atmospheric temperature. Low grate fuel can be used as the intensity of artificial draught is high. The nature draught is produced at the cost of thermal efficiency of the plant because it is necessary to exhaust the gases at a high temperature to produce the draught. In mechanical draught, the exhaust gases can be cooled to the lowest possible temperature before exhaust and this improves the overall thermal efficiency of the plant. The height of the chimney used can be reduced as the function of the chimney is only to exhaust the gases high in the atmosphere to provide better dispersion of the gases. It prevents the formation of smoke as complete combustion is possible even with a low percentage of excess air
Page 11
6 COMPARISION BETWEEN VARIOUS DOMESTIC WATER HEATING MEATHODS

Parameters Solar water heating method Solar energy. Near about 30 to 60 minutes. Required more space It can use only in summer and winter. More than Rs. 10,000 High maintenance cost as compared to electric & gas water heating method. No hazards problem. Electric water heating method Electric energy. Near about 10 to 15 minutes. Small in size It can be used in any session. Gas water heating method LPG, CNG etc. Near about 5 to 10 minutes. Small in size It can be used in any session.
1. Fuel used 2. Time required heating water per 10 lit. 3. Plant size
4. Using condition
5. Initial cost
In between Rs. 3000 to In between Rs. 2000 to 9000 10,000 Low maintenance cost as compared to solar water heating method. Due to the electricity there is the possibility of shock. Low maintenance cost as compared to solar & electric water heating method. There is may be leakage problem and hence possibility of firing.
6. Maintenance cost
7. Hazards problem
Table No. 5 Comparison between various water heaters
Page 12
7 DESIGN AND BRIEF IDIA ABOUT PROJECT
Fig No. 6.1 design of water heater
Page 13
7.1 Outer Shell

The out shell of the water heater is the main container usually of cylindrical shape, in which a tube of mild steel is connected to the inner area of shell. The diameter of outer shell is approx 0.22m and length is approx 0.67m. from base. The main purpose of outer shell is to resists heat transfer to the atmosphere.
7.2 Furnace
A furnace is another important part of the water heater. This is a fire grate used to burn coal or to burn fuel. Suitable area and volume is provided for efficient combustion.
7.3 Water tube

It is the long tube of mild steel wound inside the shell as like helical spring. Water flows inside the tube and absorb the heat from hot gases. The outer diameter of tube of is 1.5cm and length is approx 7m.
7.4 Ash Plate

It is in circular shape and made of mild steel. It is provide at the base of furnace. When fuel is burned inside the furnace, ash is drawn by the ash plate and due to witch more area is provided to the combustion of fuel. The diameter of ash plate is 0.21m.
7.5 Support stand.

The whole water heating system mounted on the support stand. It is used to provide sufficient height to the system from the base. This height is approx 7cm.
7.6 Handles
Two handles are provided to the water heater to hold it and put anywhere as our requirement.
Page 14
8 SELECTION OF MATERIALS
8.1 Selection of material for tube
8.1.1 Thermal Conductivity The thermal conductivity of tubing materials describes the amount of energy required to increase the temperature of the liquid inside the tubing to the same temperature on the exterior of the tubing. Simply stated, thermal conductivity is the rate at which heat is transferred through a material. Different materials contain differing thermal conductivity rates, based upon their molecular structure. The heat flow through the tubing material increases or decreases in heat by the amount of energy presents. The thermal conductivity of the selected materials and the calculated heat transfer per unit of time is presented in Table 7.1.1. The ratings provided indicate the materials ability to transfer heat. The higher the rating of the material indicates the greater the ability of the material to transfer heat. This transfer rate is influenced by the thickness of the materials. All units are presented in SI units. The SI unit W/mK indicates the amount of energy in Watts or one joule per second taking into consideration the thickness of the material in meters and the temperature in Kelvins Material Steel Copper PEX CPVC PE PVC Piping Carbon Steel Copper Cross-linked High-density Polyethylene Chlorinated Polyvinyl Chloride Polyethylene Polyvinyl Chloride Table No. 7.1.1 Thermal conductivity of material
W/mK 54 401 0.51 0.14 0.38 0.19
Fouriers law examines the heat transfer through a solid material. This transfer is relative to outside area and thickness of the walls of the tubing. This is assuming that the heat transfer is at right angle to the path of the flow of heat and the taking into consideration the differences in temperatures on the outside of the tubing and the inside of the tubing. Differing tubing materials and their varying thermal conductivity factors are affected differently throughout the fuel used.. Fourier's Law is presented as: q = k A dT / s Where: q = heat transferred per unit time (W, Btu/hr) A = heat transfer area (m2, ft2) k = thermal conductivity of the material (W/m.K or W/m oC, Btu/(hr oF ft2/ft)) dT = temperature difference across the material (K or oC, oF) s = material thickness (m, ft) The transfer and absorption of heat is an important factor in the efficiency of domestic water heater. The greater the heat transfer the greater the amount of solar heat is captured for use. The flow rate of the fluid within the tube creates a differing heat transfer for differing systems. In an open system a slower rate allows for a higher transfer. In contrast to closed system where the same fluids are re-circulated a higher flow rate will not have the same affect upon the amount of heat transfer. Numerous types of piping materials are available in todays market. This types of piping materials that are commonly used in residential structures and readily available to the consumer. These piping materials are; copper, steel. When the differing tubing materials are used in a Domestic water heater there is a variation between the thermal conductivity of the materials. The expected results will show that the metal piping materials will conduct heat better than the plastics and that the copper pipe will outperform all the materials as this is most commonly used tubing material
Page 16
8.2 Selection of material for outer shell

Different types of piping metal sheets are available in todays market. Commonly used metal sheet in residential structures are mild steel sheet, stainless steel sheet, aluminum sheet ect. which are readily available to the consumer. When the differing metal sheets are used in a Domestic water heater there is a variation in the thermal heat transfer to the surrounding. 8.2.1 Common Mild Steel Metals Sheet - Gauge & Weight Chart Mild Steel Gauge 3 4 5 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Thickness In 0.2391 0.2242 0.2092 0.2242 0.2092 0.1644 0.1495 0.1345 0.1196 0.1046 0.0897 0.0747 0.0673 0.0598 0.0538 0.0478 0.0418 0.0359 0.0329 mm 6.073 5.695 5.314 5.695 5.314 4.176 3.797 3.416 3.038 2.657 2.278 1.897 1.709 1.519 1.367 1.214 1.062 0.912 0.836 Weight Per Area lb/ft kg/m 9.754 47.624 9.146 44.656 8.534 41.668 9.146 44.656 8.534 41.668 6.707 32.745 6.099 29.777 5.487 26.79 4.879 23.822 4.267 20.834 3.659 17.866 3.047 14.879 2.746 13.405 2.44 11.911 2.195 10.716 1.95 9.521 1.705 8.326 1.465 7.151 1.342 6.553
Fig. No. 7.2.1 Mild steel Sheet Gauge & Weight chart
Page 17
8.2.2 Common Stainless Steel Metals Sheet - Gauge & Weight Chart
Stainless Steel Gauge 3 4 5 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Thickness In 0.25 0.2344 0.2187 0.2031 0.1875 0.1719 0.1562 0.1406 0.125 0.1094 0.0937 0.0781 0.0703 0.0625 0.0562 0.05 0.0437 0.0375 0.0344 0.0312 0.0281 mm 6.35 5.954 5.555 5.159 4.763 4.366 3.967 3.571 3.175 2.779 2.38 1.984 1.786 1.588 1.427 1.27 1.11 0.953 0.874 0.792 0.714 Weight Per Area lb/ft kg/m 10.404 50.797 9.755 47.627 9.101 44.437 8.452 41.267 7.803 38.098 7.154 34.928 6.5 31.738 5.851 28.568 5.202 25.398 4.553 22.229 3.899 19.039 3.25 15.869 2.926 14.284 2.601 12.699 2.339 11.419 2.081 10.159 1.819 8.879 1.561 7.62 1.432 6.99 1.298 6.339 1.169 5.71
Fig. No. 7.2.2 Stainless steel Sheet Gauge & Weight chart
Page 18
8.2.3 Common Aluminum Metals Sheet - Gauge & Weight Chart
Aluminum Gauge 3 4 5 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Thickness In 0.3249 0.2893 0.2576 0.2294 0.2043 0.1819 0.162 0.1443 0.1285 0.1144 0.1019 0.0907 0.0808 0.072 0.0641 0.0571 0.0508 0.0453 0.0403 0.0359 0.032 mm 8.252 7.348 6.543 5.827 5.189 4.62 4.115 3.665 3.264 2.906 2.588 2.304 2.052 1.829 1.628 1.45 1.29 1.151 1.024 0.912 0.813 Weight Per Area lb/ft kg/m 4.585 22.386 4.083 19.933 3.635 17.749 3.237 15.806 2.883 14.076 2.567 12.533 2.286 11.162 2.036 9.942 1.813 8.854 1.614 7.882 1.438 7.021 1.28 6.249 1.14 5.567 1.016 4.961 0.905 4.417 0.806 3.934 0.717 3.5 0.639 3.121 0.569 2.777 0.507 2.474 0.452 2.205
Fig. No. 7.2.2 Aluminum Sheet Gauge & Weight chart
Page 19
9 FABRICATION
Different types of machines are used in fabrication of domestic water heater such as Pipe bending machine, Welding machine, and Shearing machine, Spray painting.
9.1 Pipe bending

We can bend pipe and tube in one of several methods, depending on what we plan to use the bent pipe or tube. There are 6 main bending methods. Each is best suited to a particular type of pipe. Ram style bending, also called incremental bending, is usually used for putting large bends in light-gauge metal, such as electrical conduit. In this method, the pipe is held down at 2 external points and the ram pushes on the pipe at its central axis to bend it. Bends tend to deform into an oval shape at both the inside and outside of the bend. Rotary draw bending is used to bend pipe for use as handrails or ornamental iron, as well as car chassis, roll cages, and trailer frames, as well as heavier conduit. Rotary draw bending uses 2 dies: a stationary counter-bending die and a fixed radius die to form the bend. It is used when the pipe needs to have a good finish and constant diameter throughout its length. Mandrel bending is used to make stock and custom exhaust pipes, dairy tubing, and heat exchanger tubing. In addition to the dies used in rotary draw bending, mandrel bending uses a flexible support that bends with the pipe or tubing to make sure the pipe interior isn't deformed. Induction bending heats the area to be bent with an electric coil, and then the pipe or tube is bent with dies similar to those used in rotary draw bending. The metal is immediately cooled with water to temper it. It produces tighter bends than straight rotary draw bending. Roll bending, also called cold bending, is used whenever large bends are necessary in the pipe or tubing, such as in awning supports, barbecue grill frames, or drum rolls, as well as in most construction work. Roll benders use 3 rolls on individual shafts to roll the pipe through as the top roller pushes down to bend the pipe. (Because the rolls are arranged in a triangle, this method is sometimes called pyramid bending.)
Page 20
Hot bending, in contrast, is used considerably in repair work. The metal is heated at the place where it is to be bent to soften it
Fig. No. 7.1 Different pipe bending tools
9.1.1 Things we'll need Length of pipe Bending tool and dies Flat, clean floor or large table Chalk (or sheet of butcher paper and pencil if using a table) Carpenter's square Pipe cutter Assistant (for long, heavy pipe)
Page 21
9.2 Shearing of sheet metal

Different types of shearing machines are used for sheet cutting. We use a bench shear to cut the sheet. The bench shears consist out of the upper and lower shear blade. The lower blade is static and the upper blade rotates around the Rotation pin. Besides the fact, that the rotation pin is fastening and enabling rotation of the upper blade, it also serves as the support of the upper blade during the cutting.
Fig. 8.2 Bench shearing machine
9.2.1 Using sheet metal bench shears Mark the straight line on where you want to make the cut, lining it up in the blade and slowly pull the handle down with your hand, until you cut the sheet metal. Always be careful where you put your fingers, as shears cut steel easily, just think how easily it could cut off your finger! It is especially useful to have a source of light next to the bench shears, so you could perfectly see the marked cutting line. This way, cutting will be done much faster and the precision will be higher.
Page 22
Fig. 8.2.1 Principle of shearing These sheet metal bench shears have built in the back gage part, which sets and fastens easily. This feature is useful if you're planning on cutting many sheets of metal down to the same size. That way, you don't have to measure each sheet. Fasten the Back gage part on the same distance from the blade, as the length of cutting is. When cutting sheet metal, we are placing the sheet metal from the left side, and then push it until it comes to the back gage and we cut it. We put aside the cut piece and we push again sheet metal until it comes to the back gage. During the cutting, push the handle little to the left, so you would not separate the blades. Lower knife and Upper knife have to be tempered in order to harden them and besides that, these two items have to be made out of the quality high-carbon steel with high hardness. Keep shear blades sharp, well oiled, and adjusted just tight enough to work freely
Page 23
9.3 Selection of Welding process

Welding is basically a joining process. Ideally a weld should achieve a complete continuity between the parts being joined such that the joint is indistinguishable from the metal in which the joint is made. Such an ideal situation is unachievable but weld giving satisfactory service can be made in several ways. The choice of particular welding process will depend on the following factors Type of material and its metallurgical characteristics Type of joint, its location and welding position Cost of production Structure size Desired performance. Experience and abilities of man power. Joint design. Accuracy of assembling required. Welder skill Frequently several processes can be used for any particular job. The process should be such that it is most, suitable in terms of technical requirements and cost. Different types of welding processes are Gas Welding, Arc Welding, TIG and MIG Welding, Resistance Welding etc. For our project we select arc welding according to availability.
Page 24
9.4 Spray painting

Spray painting is a painting technique where a device sprays a coating (paint, ink, varnish, etc.) through the air on to a surface. The most common types employ compressed gas usually air, to atomize and direct the paint particles. Spray guns evolved from airbrushes, and the two are usually distinguished by their size and the size of the spray pattern they produce. Airbrushes are hand-held and used instead of a brush for detailed work such as photo retouching, painting nails or fine art. Air gun spraying uses equipment that is generally larger. It is typically used for covering large surfaces with an even coating of liquid. Spray guns can be either automated or hand-held and have interchangeable heads to allow for different spray patterns. There are various techniques which may be used in spray painting. These techniques will vary according to the job and the type of coating used. Each has characteristics that must be understood to undertake Work safely. We used Air gun spraying 9.4.1 Air gun spraying This process occurs when paint is applied to an object through the use of an air-pressurized spray gun. The air gun has a nozzle, paint basin, and air compressor. When the trigger is pressed the paint mixes with the compressed air stream and is released in a fine spray.
Fig. 9.1.1 Air spray gun
Page 25
Due to a wide range of nozzle shapes and sizes, the consistency of the paint can be varied. The shape of the work piece and the desired paint consistency and pattern are important factors when choosing a nozzle. The three most common nozzles are the full cone, hollow cone, and flat stream. There are two types of air-gun spraying processes. In a manual operation method the airgun sprayer is held by a skilled operator, about 6 to 10 inches (1525 cm) from the object, and moved back and forth over the surface, each stroke overlapping the previous to ensure a continuous coat. In an automatic process the gun head is attached to a mounting block and delivers the stream of paint from that position. The object being painted is usually placed on rollers or a turntable to ensure overall equal coverage of all sides.
Page 26
10 ANALYSIS AND TESTING DATA OF DOMESTIC WATER HEATER

Temperature at inlet (oC) Temperature at outlet (oC) 25 25 25 25 25 25 25 Table No. 10 Testing data 100-105 74-80 60-65 52-55 40-46 33-36 29-31
Sr. No. 1 2 3 4 5 6 7
Flow Rate (Ltr./Min.) 5 8 15 20 26 32 40
Page 27
11 ESTIMATION AND COSTING
Sr No. 1 2 3 4 5 6 7
Name of component Water Tube Outer Sell Supporting Stand Ash Plate Bucket Pipe Paint
Quantity 1 1 1 1 1 1 1
Material used Mild steel Mild steel Mild steel Mild steel Plastic Plastic
Cost 630 120 40 80 40 50 40
Total Table No. 11 Estimate and costing
1000/- only
Page 28
12 ADVANTAGES AND LIMITATION OF DOMESTIC WATER HEATER

12.1 Advantages of Domestic Water Heater
Initial cost is low. Running cost is low or negligi1ble. We can move easily from one place to another place. Light in weight. Water is heated in minimum time. Less space is required. Easy to fabricate. Any type of waste material can be used as a fuel for heating purpose.
12.2 Limitations Create Smoke and dust pollution.

Bulky Design in nature. Not suitable for urban area. Continuous monitoring is required. (manually operated) Frequency of fuel refilling is more. It required continuous regulated water supply only form storage tank. Maintenance is tedious.
Page 29
13 FUTURE SCOPE
The efficiency of existing domestic water heater can be increase by using copper tube or high thermal conductivity material instated of mild steel tube. Also we can provide fan near to the furnace to increase the efficiency of this water heater. Presently we made the outer shell by using M.S. sheet which transfer maximum heat to the surrounding. This can be reducing by using material having low thermal conductivity outside the outer shell. We can use material like wood, plastic, ceramic etc. this help us to increase the efficiency of water heater. Presently the operator has to fill the fuel manually. This can be made automatic by incorporating hopper.
Page 30
14 CONCLUSITION
In our India heating water is the main need of people because of people take bath by hot water. Now a days we have several type of water heater system such as solar water heater, electric water heater, gas water heater etc. But these methods are too costly which is not offerable for common people. Hence to save electricity or any costly fuel, this water heater is very useful and also more economical. The Water Tube Boiler Type Domestic Water Heater is a new innovative concept which works on the wastage material, due to this reason its offerable for every man.
Page 31
15 PHOTOGRAPH
15.1 Side Views of water heater
Fig. 11.1.1
Page 32
Fig. 11.1.2
Page 33
Fig. 11.1.3
Page 34
15.2 Top views of water heater
Fig. 11.2.1
Page 35
Fig. 11.2.2
Page 36
Fig. 11.2.3
Page 37
15.3 Ash plate
Fig. 11.3 Ash plate
Page 38
16 REFERANCES
http://www.metalbytheinch.com http://www.cadtekk.com http://www.qualitytool.com http://www.testronindia.com
Page 39

Domestic Water Heater

Enviado por

Dados do documento

Descrição original:

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Domestic Water Heater

Enviado por

Direitos autorais:

Formatos disponíveis

Study, design And Fabrication of Water Tube Boiler Type Domestic Water Heater.

Vikramshila Polytechnic, Darapur

2.2 According to the axis of shell

2.3 According to method of firing

Vikramshila Polytechnic, Darapur

2.4 According to the method of water circulation

2.5 According to the use of boiler

Vikramshila Polytechnic, Darapur

3 WATER TUBE BOILER DETAILS

3.3 Water Flow Path.

3.4 Gas Flow Path.

3.5 Steam Path.

Vikramshila Polytechnic, Darapur

Vikramshila Polytechnic, Darapur

4 WORKING OF WATER TUBE BOILER

Vikramshila Polytechnic, Darapur

Vikramshila Polytechnic, Darapur

5.1 Classification of Draught

5.2 Advantages of Mechanical draught over Natural draught

Vikramshila Polytechnic, Darapur

6 COMPARISION BETWEEN VARIOUS DOMESTIC WATER HEATING MEATHODS

Table No. 5 Comparison between various water heaters

Vikramshila Polytechnic, Darapur

7 DESIGN AND BRIEF IDIA ABOUT PROJECT

Fig No. 6.1 design of water heater

Vikramshila Polytechnic, Darapur

7.1 Outer Shell

7.3 Water tube

7.4 Ash Plate

7.5 Support stand.

Vikramshila Polytechnic, Darapur

W/mK 54 401 0.51 0.14 0.38 0.19

Vikramshila Polytechnic, Darapur

8.2 Selection of material for outer shell

Vikramshila Polytechnic, Darapur

Vikramshila Polytechnic, Darapur

8.2.3 Common Aluminum Metals Sheet - Gauge & Weight Chart

Fig. No. 7.2.2 Aluminum Sheet Gauge & Weight chart

Vikramshila Polytechnic, Darapur

9.1 Pipe bending

Vikramshila Polytechnic, Darapur

Fig. No. 7.1 Different pipe bending tools

Vikramshila Polytechnic, Darapur

9.2 Shearing of sheet metal

Fig. 8.2 Bench shearing machine

Vikramshila Polytechnic, Darapur

Vikramshila Polytechnic, Darapur

9.3 Selection of Welding process

Vikramshila Polytechnic, Darapur

9.4 Spray painting

Fig. 9.1.1 Air spray gun

Vikramshila Polytechnic, Darapur

Vikramshila Polytechnic, Darapur

10 ANALYSIS AND TESTING DATA OF DOMESTIC WATER HEATER

Flow Rate (Ltr./Min.) 5 8 15 20 26 32 40

Vikramshila Polytechnic, Darapur

11 ESTIMATION AND COSTING

Cost 630 120 40 80 40 50 40

Total Table No. 11 Estimate and costing

Vikramshila Polytechnic, Darapur

12 ADVANTAGES AND LIMITATION OF DOMESTIC WATER HEATER

12.2 Limitations Create Smoke and dust pollution.

Vikramshila Polytechnic, Darapur