1. WATER HEATING SYSTEM PROJECT
A VISION TO NUTURE LIVES USING SIMPLE TECHNOLOGY
FINAL PRESENTATION

2. CLIENT
World Vision is a humanitarian aid, development,
and advocacy organization.
It is active in more than 90 countries.
Their motto is to serve without reason and help without
return.

3. COMPANY
 DESIGN & MANUFACTURING COMPANY
 BOUTIQUE WORK
 HAMILTON, NEW ZEALAND
 ESTABLISHED IN 1990
 IPENZ ACCREDITED MEMBERS

4. PROJECT TEAM
JACK WILLIAMSON – DESIGN ENGINEER
HUZAIFA MOHSINALLY – PROJECT MANAGER
ETHAN LITCHFIELD – MECHANICAL ENGINEER
ADEN TE KIRI – PRODUCT DEVELOPMENT ENGINEER

5. PROJECT BRIEF
Design a small, energy efficient and low carbon footprint water
heating system for use in a developing region
SOLAR ENERGY 50-100L WATER
NO ELECTRICAL
MAINS
TECHNICALLY
UNSOPHISTICATED
AVAILABILITY OF
PARTS
LOW COST
PRE-MADE PARTS
EASY TO PACK &
SHIP
NO SPECIALISED
TOOLS

6. DESIGN CONSIDERATIONS
MECHANICAL
CONSTRUCTION
ELECTRICAL
CONTROL
THERMAL
EFFICIENCY
ENVIRONMENTAL
IMPACT
SERVICE
REQUIREMENTS

7. PROCESS OUTLINE
1 • COMPLIANCE WITH THE IPENZ CODE OF ETHICS
2 • 3 DESIGN POSSIBILITIES
3 • EVALUATION PROCESS
4 • IMPROVE CHOSEN DESIGN
5 • SOLIDWORKS DRAWING
6 • 3-D PROTOTYPE
7 • FINAL REPORT & PRESENTATION

8. LOCATION
AFRICA

9. 3 DESIGN POSSIBILITIES
SOLAR
ELECTRIC
HEATING
SYSTEM
FIREBOX /
SOLID FUEL
HEATING
SYSTEM
SOLAR
EVACUATED
TUBE
HEATING
SYSTEM

10. CHOSEN DESIGN
SOLAR EVACUATED TUBE COLLECTOR HEATING SYSTEM

11. INITIAL CONCEPT & SCHEMATIC

12. WHAT IS A THERMOSTATIC MIXING VALVE?

13. SYSTEM CONNECTIONS DRAWING
Solar Evacuated Tube
Collector - Manifold

14. SOLIDWORKS DRAWINGS

15. FINAL ASSEMBLY WITH BILL OF MATERIALS

16. 3-D PROTOTYPING
INTERFACE
CONNECTION
BETWEEN SOLAR
EVACUATED TUBE &
MANIFOLD SOCKET

17. CALCULATIONS
AIM: TO FIND REQUIRED ENERGY
Q=m.c.ΔT
Q=heat required(J)
m=mass of water(kg) = 50L :: 50kg
Cwater=4200J/kgK
ΔT=change in temperature(K) = (55-25)°C

18. CALCULATIONS
From Q = m.c.ΔT, Q = 6.3 x 106 J
1 tube maximum heat absorption = 60W
12 tubes maximum heat absorption = 720W
Average time in optimum conditions = 6 hours
Minimum average heat absorption rate = 291.67W
Minimum absorption efficiency of system = 40%
Minimum time in optimum conditions = 2hr 25min 48s
1 tube effective absorption area = 0.105m2
12 tubes effective absorption area = 1.26m2
Maximum heat available in optimum conditions = 1726.2W

19. CALCULATIONS
KEY POINTS:
 LOCATION: KENYA, AFRICA
 Solar radiation from the sun in Kenya with no
distortion or obstructions = 1370W/m2
 It would operate at maximum conditions as long as
41% of the sunlight is absorbed.
 It would operate at minimum conditions as long as
16% of the sunlight is absorbed.

20. PACKAGING
Packaging Material Price
Poly bubble 1300mm Wide $1.80 per metre
Poly bubble 650mm Wide $0.92 per metre
Corrugated Cardboard
1200mm Wide
$1.68 per metre
Corrugated Cardboard 600mm
Wide
$1.03 per metre
Cord Strap 25mm $1.26 per metre
Steel Strap 19mm $0.54 per metre
Clear Packaging Tape 48mm x
100m
$5.12 per roll
FULLY
ENCLOSED
WOODEN
PLY CRATE

21. SHIPPING
• Dry cargo
• 40 Foot
• Ships to Kenya
• $6500 NZD
• Bulk shipping
• 208 kits

22. SHIPPING ROUTES
CHINA PORT
END USER’S HOME
AUCKLAND PORT
AUCKLAND PORT
WORLD VISION
DISTRIBUTION CENTRE
JHEA ENGINEERING
HAMILTON WAREHOUSE
KENYA
PORT

23. FINAL PRODUCT KIT
• Solar Evacuated tube collector
– Installation instructions
– 20 x 60W evacuated tube
– 30L Manifold
– Pressure relief valve
– Frame with all parts
• Thermostatic mixing valve
• Three-way water fitting
• 2 x Red Hose
• 2 x Blue Hose
• 2 x 15L Solar bag
• Outlet tap
• Operating & assembly instructions
All enclosed
in a ply crate
with poly
bubble wrap

24. AFTER REACHING END USER’S HOME
WOODEN PLY CRATES
STORAGE
PURPOSES BY
END USER
GIVEN BACK TO
WORLD VISION
DISTRIBUTION
CENTRE
POST
INSTALLATION
INSPECTION
INFORM WORLD VISION
REPRESENTATIVE
REPLACEMENT
DISPATCHED WITHIN A
FEW DAYS

25. COSTING
COMPONENT QUANTITY COST TOTAL COST
SOLAR
EVACUATED TUBE
COLLECTOR KIT
1 $600 $600
THERMOSTATIC
MIXING VALVE
1 $30 $30
RED HOSE 2 $5 $10
BLUE HOSE 2 $5 $10
SOLAR BAG 2 $20 $40
OUTLET TAP 1 $10 $10
TOTAL $700
SHIPPING & PACKAGING SERVICE TOTAL COST
SHIPPING CHARGE FROM AUCKLAND TO HAMILTON $20
LABOUR CHARGE FOR REPACKING KITS $50
PACKAGING CHARGE FOR PRODUCT KITS $210
SHIPPING CHARGE FROM HAMILTON TO AUCKLAND $20
SHIPPING CHARGE FROM AUCKLAND TO KENYA $40
FREIGHT CHARGE FROM KENYA TO WORLD
DISTRIBUTION CENTRE
$10
QUALITY CONTROL & ON-SITE COSTS $50
TOTAL $400
RESOURCE COST GRAND TOTAL
SYSTEM COMPONENTS $700
$1100SHIPPING & PACKAGING
SERVICES $400

26. PROJECT TIMELINE

27. PRODUCT DESIGN: SELLING POINTS
CHEAP RENEWABLE
ENERGY
NO WASTE
UNIVERSAL
APPEAL
NO
MAINTENANCE
EASY TO
ASSEMBLE & USE
HELPS POOR
COMMUNITIES
PARTS EASILY
AVAILABLE
HIGHLY
EFFICIENT

28. REFERENCES
http://mfat.govt.nz/Foreign-
Relations/Africa/index.php
http://www.teara.govt.nz/en/map/35
899/new-zealands-trade-with-africa

29. THANK YOU
ANY QUESTIONS?