Wollo University

Konbolcha institute of technology (kiot)

Mechanical department thermal engineering
ADDIS ABABA BOLE INTERNATIONAL AIRLINE

Design of solar water heater for aircraft body washing in hangar

By

GARI BEDADA
WOUR/O687/08

Performed at
Ethiopian Airlines Headquarters, MRO Division
Bole, Addis Ababa
declaration

This is to declare that I, Gari Bedada 4th year student of the Thermal Engineering Department at Wollo University, have been
working as an intern in Ethiopian Airlines, Planning and Engineering Department from March 7 – June 28, 2011 as required in the
curriculum. And have prepared this report from what I have observed and practiced during my stay. This report has been written
by me and has not received any previous academic credit at this or any other institution.

Gari Bedada
Thermal Engineering
Wollo University (kiOT)
 Acknowledgement
I would like to express my deep gratitude to who helping me and being with me throughout my endeavor. Then, I
would like to express my sincere gratitude to the Ethiopian Airlines officers notably the Customer Aircraft
Maintenance Aircraft Structure section officers: my supervisor and boss Mr. Habraham and Mr. Dereje. W, the fellow
engineers Mr. Eyuel Molalgn, Mr. Kasiha Abriha, Mr. Fitsum, Mr. Dawit, for all the assistance and work environment
conducive they have introduced me to. I would also like to thank my mentor and instructor at Wollo University, Mr.
Muluken. for the guidance and follow up

Executive Summary
 Ethiopian Airlines (Ethiopian) is a public enterprise that provides domestic and international air transport services,
general aviation services and related services. When customer aircrafts are handled along with Ethiopian aircrafts,
usually priority is given to Ethiopian aircrafts. This sometimes causes delay of plans on customer aircrafts or any
Ethiopian aircraft that has not been given priority.

The main reason for this problem despite unanticipated problems is due to the existing manpower schedule and
allocation, from among other reasons. For example, Gabon Airlines’ aircraft was to begin maintenance on the March
16 and end on April 9, 2011. But the same reason caused its flowchart or workflow to be altered repeatedly. This by
itself has its own negative effects. So by the objective of coming up with a better manpower schedule and optimum
allocation, two mathematical methods were used to solve these problems.

The first one is by using the Staff Scheduling Linear Programming method and the second by using the Job
Sequencing Johnson’s Algorithm. From the first method, an optimum number of workers were scheduled to start each
day within a week to optimize the total number of workers. From the second, the jobs performed on the aircrafts were
sequenced to give the possible minimum cycle time, at the same time allocating enough manpower and hangars to the
aircrafts to reduce/eliminate lost (idle) time.

As a result, this can increase the foreign revenue by receiving more customers and enhance the relationship and
alliance, while meeting the maintenance schedule of our aircrafts.

CHAPTER ONE

1.1. Company History

INTRODUCTION

E
hiopian Airlines (Ethiopian), one of the longest established, largest and fastest growing 100% African owned
airlines, is the flag carrier of Ethiopia. During the past sixty plus years, Ethiopian has become one of the
continent’s leading carriers, unrivalled in Africa for efficiency and operational success, turning profits for
almost all the years of its existence. Ethiopian Airlines was founded on Dec. 21, 1945 and made its maiden
flight to Cairo on April 8, 1946, with a weekly service between Addis Ababa and Cairo with five Douglas DC-3
propeller-driven aircrafts. With the recent addition of flight services to Maputo and Bangui, Ethiopian provides
dependable services to 39 cities in Africa and a total of over 60 international destinations so far, spanning throughout
four continents. Ethiopian also serves 17 domestic destinations. Operating at the forefront of technology, it has also
become one of Ethiopia’s major industries and a veritable institution in Africa. Ethiopian’s unique quality lies in its
extensive African network and the direct connections that it offers. It commands a lion’s share of the pan African
network including the only daily east-west flight across the continent. In addition to the exciting plans for fleet
expansion, the state-of-the-art cargo terminal, maintenance hangar and the modern Bole International Airport have
opened doors for more growth opportunities. Furthermore, it is working diligently to make the Ethiopian Aviation
Academy the leading aviation academy in Africa

1.2 Company Profile

Ethiopian Airline’s hub is Bole International Airport, from which the airline serves 61 international destinations and
17 domestic with 157 weekly international departures from Addis Ababa and a total of 410 weekly international
departures worldwide. The company flies to more destinations in Africa than any other airline. Likewise, it is one of
the few Sub-Saharan profitable airlines, as well as one the fastest growing airlines in the industry.

Ethiopian Airlines has code share agreements with: South African Airways, Lufthansa, Gulf Air, Air One, Brussels
Airlines, British Midland (BMI), Rwanda Air,

Awards

Ethiopian was the winner of the ‘2008 Best Airline in Africa Award’ at the African Travel Award ceremony in Lagos,
Nigeria, for its excellent network and convenient connections in Africa.

In August, 2008, Ethiopian won “The 2008 Corporate Achievement Award” of Aviation & Allied Business for setting
the pace towards the development and growth of the African aviation industry.

Ethiopian is also the first African carrier to win the 2008 Brussels Airport Company Award in recognition of its
distinguished long haul operations witnessed through the introduction of new routes, new products, and close
cooperation with Brussels Airport in marketing activities.

Ethiopian won the NEPAD Transport Infrastructure Excellence Awards 2009 on November 25, 2009 and “Airline of
the Year Award” from the African Airlines Association (AFRAA) on November 24, 2009, bringing the total Awards
honored since January 2009 to five and Saudi Arabian Airways.

Vision, Mission and Values

Vision 2025:

Ethiopian will be the most competitive and leading aviation group in Africa by providing safe, market driven
and customer focused passenger and cargo transport, aviation training, flight catering, MRO and ground
services by 2025.

Mission Statement:

 To become the leading Aviation group in Africa by providing safe and reliable passenger and cargo transport,
aviation training, flight catering, MRO and ground services whose quality and price “value proposition” is
always better than its competitors
 To ensure being an airline of choice to its customers, employer of choice to its employees and an investment
of choice to its owner
 To contribute positively to socio economic development of Ethiopia in particular rand the countries it
operates in general by undertaking its corporate social responsibilities and providing vital global air
connectivity

Value Statement:

 As an airline, safety is their first priority

 ET is a high performance and learning organization
 We are an equal opportunity employer
 We treat internal and external customers the way we would want to be treated
 Services and Customers

Ethiopian is one of the airlines in the world operating the newest and youngest fleets. It owns currently 112
aircrafts operating and 57 ordered bringing the number to aircrafts.

Ethiopian airline takes service internal and external trading type. The external is above 65 destinations in Africa.
And also 120 international destinations the internal service including above 22 domestic destinations.

 Humera
 Aksum
 Mikelle
 Gander
 Bahirdar
 Lalibella
 Dessie
 Diredawa
 Jijiga
 Asosa
 Dembi dollo
 Gambella
 Jimma
 Hawasa
 Bale
 Kebri dahar
 Gode
 Arba minch
 Jink

From those 4 are international airport mekelle (Alula Abanega), dire dawa and Bahir Dar ginbot 20 international
airport.

And most African as well as Europa and American fly taking service. Ethiopian airline also takes aviation
services.

1 Aviation

Established in 1967, Ethiopian Aircraft Maintenance Technicians School has specialized in aviation maintenance
trainings for nearly 50 years; consistently offering the highest industry standard maintenance technicians training.
Ethiopian Aviation Academy (EAA) is the largest and the most modern aviation academy in Africa recognized
as ICAO regional Training Center of Excellence. To train aviation professionals from classrooms to simulator
training, EAA offers industry standard training for pilots, aircraft technicians, cabin attendants and ground
services staff both for initial and recurrent students. The Leadership & Career Development Center is training
thousands in Management and Leadership Skills.

In aviation there are many type of professional skill is teaching by this company

 Pilot training school

 Full flight simulator training
 Cabin crew training school
 Commercial training school
 Maintenance training school
 Leadership training school
 Ticket, Airport,
 cargo service and operation training
  Ethiopian airline also takes MRO survives The scale of the MRO operation at Ethiopian is breathtaking. It is
the largest MRO service in Africa and serves Africa and the Middle East. The facility is fully equipped with
Hangars, Engine and Component Maintenance workshops with all equipment needed to repair/ overhaul
aircraft, engines and components. The MRO service was established in 1957 and it currently employs over
2,800 employees. Ethiopian MRO provides Line Maintenance services at stations where Ethiopian flies and
extends the services to other operators at some of the stations. The facility is fully certified by the ETCAA,
FAA and EASA. Ethiopian MRO offers world-class services to its customers and helps make Ethiopian one of
the most dependable and safest airlines in the world.
 Ethiopian cargo carries above 650 tons in different countries
 Ethiopian catering produce thousands of meals
 Ethiopian skylight hotel having 373 rooms,4 restaurants, big chines Restaurant swimming pools, gift shops,
pastries, accommodate 2000 guest at one time, 5 small size meeting rooms, gym, health center, ticket office,
etc. The Hotel is an edifice presented to the fast-growing African capital offering hospitality in par with the
international standard.

Ramp Services

Aircraft Loading and Unloading

Managing Ground Support Equipment’s (GPU.ACU, ASU)

Aircraft Towing and Push Back

Line Maintenance Assistance

The overall organization of the enterprise

To make easy the work of flow, the enterprise has different sections like;

Strategic planning team; which is organized under the umbrella of strategic planning and finance directorate.
The team carries out activities of preparation and implementation of the enterprise long and medium term strategic
plan. The major activities of strategic planning team are like preparation of long and medium term strategic plan,
preparation of the enterprises annual plan and performance evaluation report and conducting impact assessment
and different researches which will have vital role for the successful implementation of the strategic plan.

The safety management office; which is established as a core process responsible to the chief executive officer.
Its major objective is to change the traditional days of safety management activities to standard and organized
system supported by standard safety manuals by doing major activities like making safety audits of each airport,
general assessment of each airport with regard to facility and trained operation personnel, preparing standard
safety manuals and certify airports and preparing standard safety management system manuals.

Human resource development and management directorate; which has a mission to establish an efficient,
effective and transparent human resource development and management practice which support the enterprise in
order to achieve its strategic goal by managing staff grievance, ensuring industrial peace, administer terminal
activities and administer personal records.

The information and IT management directorate; which is one of the vital sections of EAE under the new
structure which was proposed after the recent business process reengineering scheme. It has major activities like
enhancing the development of IT within the enterprise, providing support and advice to EAEs work units and
providing effective service mechanisms for back office users.

Airport infrastructure development directorate; which is one of the economic sectors. At present the
directorate is coordinating the construction of the major projects.
 Airport facilities management and maintenance directorate; which are used for the purpose of achieving
success in all airports service provision. The directorate has the major duties like developing appropriate facilities
usage and operational procedure or manual, developing and implementing appropriate and standard maintenance
management system and analyzing facilities performance efficiency and developing professional or sound
recommendation to enable EAE to make an informed decision

Figure 2.3 Overall organization of the company

Organizational Structure

Ethiopian Airlines (Ethiopian) is a public enterprise established by the Council of

Ministers Regulation No. 216/1995, to provide domestic and international air transport services, general aviation
services and related services.

Its corporate structure consists of the following:

a) Supervising Authority: The supervising authority is the Ministry of Transport &

Communication.

b) Board of Management: Ethiopian has a management board which consists of chairman and representatives from
the supervising authority and employees.

The board also has a secretary.

c) Chief Executive Officer: The Chief Executive Officer (CEO) is responsible for

the management and operation of Ethiopia.

The activities and functions of Ethiopian are grouped into the following Senior Executive Management positions
reporting directly to the Chief Executive Officer:

The Ethiopian MRO is subdivided to 11 different departments as shown in fig. 2 below.

Figure 1.3 Organizational Breakdown Structure of MRO

Since this report focuses on the areas related to the internship, it is irrelevant to discuss each function other than the
Operational and subsidiaries.

Under the Chief Operating Officer, there are two major divisions: Flight Operation and the MRO (Maintenance Repair
and Overhaul).

The Flight Operation deals with all matters related to commercial flights, personnel training, crew, etc. whereas, the
MRO, which is a broader division, provides services to the Enterprise through the development and implementation
of objectives, plans and policies covering the activities of the Maintenance, Repair and Overhaul and related Quality
control services, Procurement & Supply Chain Management, Capacity Development & MRO HR planning, MRO
Sales & Marketing, and Technical Planning &Engineering.

Objectives and Goals of This Study

Since the beginning of the MRO, Ethiopian has been able to maintain both its own and customer’s aircrafts parallel.
But due to the limit of manpower and related factors, both have been taking turns to carry out the required operation.
And because Ethiopian is the flag carrier of the nation – which remains to be the most important fact – priority is
given to its aircrafts’ maintenance. This on the other hand has sometimes caused customers’ aircrafts to spend more
time on the ground than planned. Accepting customer aircrafts more frequently is for our profit but suspending our
scheduled aircrafts is an unacceptable loss. So how can we handle both sides optimally? Or is there any way we can
schedule the work to meet its original plan? This report reviews the package evaluation and a work flow (flow chart)
of two different customer aircrafts focusing on the later and briefly discussing the problems identified and their
possible solutions.

It is not the intention of the author that the suggestions and recommendations forwarded be taken as the right and only
solutions but be considered.

Services and Product

It operates scheduled international passenger and freight services to over 65 destinations worldwide, as well as
domestic services to destinations and passenger and cargo charter flights. Ethiopian Airlines operates the Youngest
Fleet in Africa. The following are the major categories of owned and leased aircrafts (112 aircraft

Aircraft passenger comment

Airbus A350-900 348
Boeing 737-700 118
Boeing 737-800 154
Boeing 737 Max 8 160
Boeing 767-300ER 245
Boeing 777-200LR 321
Boeing 777-300ER 399
Boeing 787-8 270
Boeing 787-9 315
Bombardier Dash 8 Q400 78
Total 112
Table 2.1 service of Ethiopian airlines

Ethiopian maintenance and Repair Overhaul(MRO) Ethiopian MRO Services is a division of Ethiopian and is
established in 1957 to provide MRO services for aircraft, engines and components of Ethiopian and third party
customers. The primary base of Ethiopian is at Bole International Airport, Addis Ababa, Ethiopia.

At present Ethiopian MRO has work force of over 1800 fully qualified technical staff and a facility certified by
competent regulatory bodies like ETCAA, FAA and EASA.

Ethiopian MRO has four main hangars used for airframe maintenance. A closed-door hangar to accommodate one
B767/787/777, a closed door hangar to accommodate two B767/787s or four B737 size airplanes at the same time.
The third hangar is open-door and can accommodate three B737 size airplanes and the fourth is an open door hangar
that accommodates two Q400s.

The maintenance base is certified by the US- Federal Aviation Administration (FAA).

 MCC production engineering

 Engine maintenance
  Base/line maintenance
 Component maintenance
 Equipment and facility maintenance
 Calibration service
 Engineering service
 Structural &composite maintenance

Figure 1.4 Aircraft at hangar

There are two warehouses for over 100,000 line items. The first is dedicated for aircraft parts whereas the second is
used for commercial and bulk items.

Administration (FAA).
Figure 1.1 engine moving to shop

Ethiopian is self-sufficient in all aviation training systems. The Ethiopian Aviation Academy offers training for
Pilots, Aircraft Technicians, Cabin Crew (Service Trainee), Marketing & Sales as well as Management and Finance
staff.

 Ethiopian MRO is utilizing “Maintenix”, a state of the art MRO

management IT system also Selected by Boeing for Gold-care program.

The values of Ethiopian MRO focus on the following four exceptional customer satisfaction.

1. Top quality

2. Short turnaround time

3. Highly competitive Price

4. Excellent customer service

Figure 1.2 Base maintenance

Ethiopian MRO has the capability to perform full airframe checks, including Heavy Maintenance on Boeing and
Bombardier model of airplanes at its base station.

Boeing 787,777,767, 757,737NG,737classic & MD-11

Bombardier Q-100/200/300/400
The base airframe maintenance comprises various dedicated shops. These include Structures shop, Interior Shops,
Non-Destructive–Testing (NDT) shop, Machine Shop etc.

2 engine maintenance
The Engine shop has over 55 years of experience in engine maintenance and it has been working with many airlines,
engine lessors and other customers. Placed on 12,000 Sq. m, the shop is equipped with state of art machines and
tools to deliver services to our customers from all over the world.

 We have highly qualified professionals, with wide range of experience

 We are certified by ECAA, FAA and EASA
 We are working to include wide range of services with more expansion plans to meet the needs of our
customers

Mechanical component shop

c) Water and waste components overhaul shop

 Ethiopian MRO has extensive maintenance capability on water and waste components.
Drain valves (lavatory drain, sump drain), Vacuum Toilet Assembly, Faucet assembly, Portable water tank, spigot
assembly, are among the components maintained in water and waste system components overhaul shop.
5 Engineering service

Aircraft Maintenance program & Task Card Engineering

1. Development of Maintenance Programs for aircraft, engines and components

2. Development of Minimum Equipment List (MEL) to regulate dispatch of an aircraft
3. Preparation of Job Cards for Maintenance, Overhaul, and Inspection requirements with task Procedures,
Tools and Materials requirements

Aircraft System Engineering

1. Performing Engine Monitoring & Diagnostics

2. Handling engine Fleet Management
3. AD/SB monitoring, accomplishment and reports preparation
4. Modifications
5. Reliability Analysis
6. DFDR data analysis
7. Incident/Accident Investigation / Assessment
8. AC Configuration Management

6 structure & composite maintenance

Structural repair shops perform maintenance repair and modification on aircraft structural parts.
 Also performs detailed works such as:

 Replacement of fuselage panels

 Winglet Modification
 Engine strut replacement

Composite services

Composite shop performs maintenance repair, on Thrust reverser, rudder, elevator and spoiler components including
composite materials.
Aircraft stripping & painting
 Application of aircraft color schemes undertaken by highly qualified operators using the best materials and
equipment. Complete aircraft exterior preparation including stripping to bare metal or heavy sanding, resealing of
all production joints, corrosion removal and treatment and complete aircraft repainting.
shop has over 55 years’ experience and routinely refinishes aircraft in its paint facility.

Chapter two
Overall experience during internship
How I get the company
I would have got the Ethiopian airline chance to enter by the kiot. that means the mechanical engineering head ask
us our interest to enter this company. Even if it I have interest to enter the Ethiopian airline this is my wishes that
is the reason that I would got dajene aviation before that. I compare the two and I select Ethiopian airline depend
on my interest I got this chance.
As I enter the company I would see different part as I would enter the Ethiopian airlines MRO which is the heart
of Ethiopian airline by doing maintain the aircraft body structure, engine and all its body components so Ethiopian
MRO have many classes among of this classes we would participated in the Technician support classes which is
Aircraft Structure Engineering office. Which is the engineering communicating with manufacturer and making
taxes to support technician to maintain aircraft for continuous fling in Africa.
Experience I obtain during internship program
Air craft are complex products comprised of many sub systems which must meet demanding customer and
operational life cycle value requirements. Aircraft system engineering is the most concerned on the area which
supports for reliability and modification improvement. The system engineering has four main groups those are
1. Avionics system engineering
2. Inflight Entertainment /IFE or cabin system engineering
3. Power plant systems engineering
4. Air frame systems engineering.
Avionics parts are the navigation, instrumentation, communication system and installation

Aircraft maintenance program

The main purpose of an airline maintenance program is to ensure continuous airworthiness of the aircraft operated by
it. The maintenance program is a document that contains all inspection, maintenance and overhaul requirements.
Organizational structure of a/c engineering and planning

Figure 2 structure of a/c engineering and planning

Basic Function The basic function of the aircraft maintenance program it develops for cost effective maintenance
programs and job cards with maintenance, overhaul, inspection requirements, procedures, tools, materials and
frequencies for all type of aircraft, engine and components in use. Maintenance program also analyses and conducts
studies on the maintenance techniques, task card improvement and check intervals with the intention of reducing cost,
improve reliability and efficiency

Task card a complete task card is a maintenance tool or working document that identifies a task to be accomplished
on an aircraft to assure a continued airworthiness of the aircraft and considered as part of maintenance or historical
record until it is replaced by superseding task card. Task card are used to summarize instruction from an applicable
maintenance program, service bulletins, airworthiness directives experience and engine components.
1 Maintenance planning The basic functions of maintenance planning are:
1. Guides the planning
2. Scheduling
3. Coordinating and
4. Controlling the inspection
5. Repair
 The maintenance planning ensures the maintenance on aircraft is made per the maintenance program, establishes
standard operating procedures for aircraft and component maintenance planning and production control sections.
Maintenance planning ensures the development s of short term, mid-term, and long term maintenance forecasts based
on level of operations planned by corporate planning and planning their requirements in terms of manpower, material
and tool. The maintenance planning has a good relationship between the internal customers as well as external
customers. The relationship between internal customers the maintenance planning mostly focusses on the following
points:
 Coordinate and consults with concerned supervisory personnel regarding maintenance and operational
activities in various aircraft maintenance sections.
 Coordinate with purchasing, supplies, maintenance division and engineering department in the acquisition of
parts and tools for engineering orders and accomplishment it
 The outside relationship establishes and develops contact with the manufacturer
Record Controller The record control is the history of the aircraft. There are conditions that a record applies
those conditions are listed below:
 When the Ethiopian airline bought a new aircraft the plane comes with a full of document or the story
of the plane at this time the document is recorded in the record control room
 When the Ethiopian airline was sold an aircraft to the other country the document or story of the aircraft
was recorded and travels with the aircraft
 When Ethiopian airline have a lease aircraft the document of the aircraft also recorded
 When the maintenance engineer maintained any part of the aircraft the process as well as
 the component that changed also recorded and controlled. Let’s for example the aircraft structural
engineer was maintained damage on the fuselage of the aircraft after investigating and repairing the
whole process was seated as a document on the record control.
As soon as I enter the company I would got chance to see different part of Ethiopian airlines (MRO) including all its
shop and function details. the place I focus The 1st week of my internship program, I focused very much in touring
the company. The departments listed above were explained briefly and they told us how things are handled, managed,
function and how the work flow inside each department.
Power plant section is responsible for the engines of all aircrafts. Structure section is responsible for the outer and
inner structure of the aircrafts. System is responsible for different types of system found in the aircraft.
 Pneumatic shop,
 wheel shop,
 brake shop,
 fuel shop,
 landing gear shop are under this department.
aircraft maintenance process
The hangar maintenance has the scheduled maintenance process. The general processes are listed below:
 First there was a scheduled maintenance A/B/C/D checks
 MP D/P. Ads/SBs/EO/ER issued by methods/planning/engineering
 Planning checks manpower/parts and ground time
 Planning issues task card to production controller
 A project managerial Forman check is the task ok? If it is ok
 place task cards on pigeon holes per specialty by production controllers then
 task cards distribute to technician by lead/Forman in to opens up or operational functional checks
 technician performs the job by the correct maintenance document then
 inspect, check the task card
 task cards distribute to inspection if the task was done by the correct maintenance, document and
 procedures and checked by inspectors and there was no any finding
 Close up and finally checks task completely by inspection and technician.
 Task controller release inspectors and prepared by project manager/Forman finally
 Aircraft position for flight
turbo prop hangar aircraft The narrow body hangar used to maintain for light aircrafts that mostly applicable for
local flight. The light aircrafts are Fokker; Q400. these aircrafts are mostly applicable for local and also neighbor
country like Kenya, Sudan, Djibouti etc…the maintenance activities like dispatch easy faults are arranged on short
period of time and make them dispatch. When the equipment comes to the hangar first they check the certificate and
then operational check. they are self-equipped department. They participate on the avionics, aircraft, and power plant.
This department was well certified from EASA and Ethiopian civil aviation.
Non-destructive test /NDT The non-destructive tests machines are helped as to know easily any crack, dent, and
gouge exist on the materials. The non-destructive test was used to know the health of the material without damaged
of the material or without direct contact of the material. There are five test steps nondestructive test method mostly
used
 X-ray or radiography method
 Gamma ray method
 Eddy current method
 Ultrasonic method
 Magnetic Patrick field method
Those all methods are applicable according the necessity and condition of the materials. Let say for example petition
it is a chemically used for ferrous and they have removers and finally dried by developer chemicals. Those methods
have their own advantage and disadvantage. the x-ray has disadvantage like hazards.

Structure and Component

Structural shop The structural shop has metal and nonmetal shops. The metal shop mostly used to repair aircrafts
related with metal parts but the nonmetal shop used for aircrafts like Boeing 787 most pars made up of composite
materials. Aircraft structural repair shop also has tool rooms.
1. High speed grinder
2. Angle drill gun 2EA
3. Vice grip 3EA
4. Cherry max rivet puller
5. Electrical power gun
6. Roller
7. Power brake
8. Sheer machine
9. Power shear
10. Dial gauge
11. Grinder
12. Curved roller
13. Air hose
14. Different kits like rivet, bolt, punches
15. Drill machine etc…
Component shop Composites contain two or more different constituents that are combined together and will be
identifiable on either a macro or microscopic scale. When a force is applied to the composite, the constituents will act
together. We produce composites to obtain structural properties that each of the individual constituents do not have
alone. The constituents of a composite do not dissolve or merge completely into each other. There is a large range of
composite applications that are in use today.
Applications on airplanes include:
 Fairings
 Flight control surfaces
 Landing gear doors
 Leading and trailing edge panels on the wing and
 stabilizers
 Interior components
 Empennage and floor beams (777).
 Wing, fuselage and empennage (787
Composite versus Metals Because of the differences between the fibers and resin matrices, the composite will
be very strong and stiff in the direction of the fibers. Composites provide weight savings in airplane structure
since they have high strength to weight ratios. Weight reduction is the greatest advantage of composite material
and is one of the key factors used in decisions regarding its selection. Significant weight reductions can occur
because of the material’s high strength and the ability to orient the fibers to efficiently react the applied loads.

Structural shop internal customers are

Hangar wide body
Hangar narrow body
Turboprop hangar
Engine shop
Fuel shop
Engine maintenance inspection
Stores
Flight catering
Engineering
Dispatch line maintenance
Interior shop and hangar
Aircraft Interior shop the aircraft interior shop generally has four main sub sections shops and each sub section have
their own function
1. Aircraft emergency equipment shop
 2. Tailor shop
3. Refurbishment shop
4. paint shop
To repair the equipment there have stages and insertion sheet tells each step how to do
Stage1 the component comes to the shop and seat on the unserviceable list table
Stage2 the component goes to the work on progress
Stage3 in the capability list gives to the component part number
Stage4 the component becomes new serviceable life vest
Stage5 before certified the component tested on the testoroch to know how the lateral guide of
the component can control the external force.
Stage6 finally after completed these all process successfully the component become certified and back to its services.
Wheel and Brake shop
The activities done on the brake shop are:
Overhaul the brake
Repairs
Inspection
materials used for the repair are classified in to two
1. steel brake
2. carbon brake
The most activities done on the brake shop are the disassembled and assembled the brake components. The operational
wise power sources are the electrical and hydraulic system. The electrical power source is for the dream liner Boeing
787 and hydraulic system used aircrafts like Boeing 737,757,767 etc...
the carbon brake for Boeing 787 is due to less weight than steel brake and more computerized and electric power
source other are repaired manually
 On the wheel shop have sequences of jobs after the damaged wheel come to this shop. The sequences of the jobs are
Unserviceable part the place the equipment received and seated with a received tag that define the damage of the
wheel. The specifically component tag has the serial number of the component, manufacturer number, and the aircraft
position.
Test: the technician starts to check the problem listed according to the written tag explained before. After the damage
was specified the inspector decide the capability of the damage, they decide is that possible to repair on this shop,
Disassemble: -at this stage all components are separated. There are machines like bed brake machine that help to
disassemble the wheel from the bid
Cleaning: -After disassemble the component goes to the cleaning area and the components cleaned with the manual
as well as automatic cleaning machines. The automatic cleaning machine has water and chemical mixture with a
normal temperature used to clean the wheel. The manual cleaning room washes by hand. The piece part cleaning room
cleans washer, bearing, bolt and nut.
Test machine area: -at this area the employee watch and check the cycle of the wheel. If the cycle has 10cycle the
wheel needs overhaul but the cycle less than 9 cycle the wheel repaired. There was a temperature sensor indication on
the wheel that used to test the non-destructive test (NDT).
Penetrate inspection room: -they inspect the wheel cycle and the typical service deterioration of aircraft wheel
bearing:
Spall, roller end scoring, dented cage, grooving, roller end polishing, brushing or nicks, pitting
corrosion
Assemble area: -after the inspection pass well the component wheel was assembled and at the assemble area there
was assemble machine like torque machine that display the serial number and torque value of the assembled
components. Pan platter machine which carries the equipment to assemble and to test on the torque machine because
the wheels are huge in weight
Tire inflation cage: -used to pressurize the tire according the manual. There was a machine that displays the amount
of pressure input on the tire.
Serviceable: -finally the wheel shop technician prepares the serviceable paper and has approval by EASA, FAA and
has capability list on EASA. After service tag there was final inspection then after pass the inspection the component
returns to the store
Release: -generally after the line technicians found the damage they send the wheel to the wheel shop with the
unserviceable tag. The wheel shop technician found the wheel from the store then after finished the repaired process
the wheel returns to the store with the serviceable tag then finally assemble to the aircraft.
in the wheel shop has different rooms found:
 1. Repair shop room: - there was oven to heat the wheel
2. Paint room: - the wheel was painted on this area
3. Penetrate inspection room: - a chemical that inspects the wheel after lose the color then goes to paint
room
4. Blast room: - at this room they give high power for the wheel and it was a solid cleaning of the
wheel
Engine maintenance shop
The second part I was got chance to see the engine maintenance shop which is a huge maintenance shop that has 583
and 584 shops
The 584D engine shop has maintenance on the type of aircrafts, Fokker engine, eshet engine, Q400 bombardier air,
CFM127, APU 767, Boeing CFC 777, external Boeing 787, engine Boeing 737, CFM-56, MD11, GNX, GN9, fan
bleed etc…
The second engine shop 583 maintained on the aircrafts mostly related with PW2000 engines, CFM MD11, RR
767, CFC6, APU, PW4000
The maintenance shop overhauls the 737-CFM.
The overall work flow of the engine maintenance was listed below:
 first the Engine comes to the shop
 As the second step was receiving the engine that means first they check by baroscopic to now the health of
the engine
 QC serialization which checks how and with what type of equipment the engine received
 preservation it preserves until one year and also they check the oil at this stage
 input meeting which guides them to disassemble parts and to now and to discuss did they have the capacity
to maintain for that engine
 disassemble the engine
 cleaning the engine
 Inspection at this stage they try to service; they send for foreign repair or unserviceable activities.
 Marshal at this stage they distribute equipment’s then
 Assembled the engine
 Test the engine then
 Receiving inspection of the engine
 After receiving the inspection QCE then
 The document was closed
 Finally release certificate at this the inspection gives the release certificate.
Pneumatic shop
Mr. Befikadu Gudeta brief us the general function of the pneumatic shop. The shop does on the pneumatic components
that repair and over haul. The shop has patch tester machine and then according the manual they taste the components
to give the airworthiness directives (ADs) certificate for the component. On the shop there was a sequences of
procedures that to maintain the damaged component.
 The damaged component first put unserviceable box with unserviceable tag then the technicians assigned to
check and to record or to judge the exactly damaged part and then to decide the skill and the number of employee
to participate on this component. When the damage of the equipment was more than of the skill or impossible
to repair on this they send to foreign repair (FR) or condemn process, condiments tag, engineer, shop Forman
and inspectors are assigned to condemn on the condemn tag then finally the component removed. The shop
measures the tolerance of the component according the manual then the component goes to tester.
 The component disassembled the bleed system component Boeing 757.Calibration tester for the components the
reading on the tester gauge on the calibration. There were tester manual procedures like tester bench machine,
flow meters and can change the gauges of pressure, Pressure differential tester. The pressure differential tester
used to test the aircraft moves on the different pressure condition and to assume the conditions of aircraft on
different pressure  The cleaning area which cleans with chemicals and the then finally assembled the
component.
 Serviceable area which put the components on the serviceable box from this to the store or to the customer.
 The pneumatic shop mostly Have power plant customer.

CHAPTER TWO
2 Internship Experience
 CHAPTER THREE
3 INTERSHIP PROJECT DESIGN

A
3.1 problem statement
aircraft hangar washing systems can be designed or applied for a variety of applications. A hanger
washing system is designed to meet the specifics of the aircraft and the mission. The common
denominators in all cases are to minimize out of service time and maximize decontamination
performance. The primary objectives for aircraft use are operational availability or mission
accomplishment. Time spent in the hanger for aircraft service certainly detracts from these objectives.
Washing an aircraft by hand 20 times per year provides a good example of the savings possible when using a high-
pressure hot water system. The hand wash process can use up to 10,000 gallons of water per wash and require about
36 man-hours per aircraft. Alternately, a hanger wash/rinse system can greatly reduce the manpower, water,
wastewater and detergent used to wash aircraft.
But in Ethiopian airlines they did not use the hot water system; rather they use tap water from the water reservoir
tanker. So this leads to Corrosion. The project deals with the hot water system in order to reduce corrosion which can
be found in using solar flat panel water heater methods.
As a whole there are many different problems we observe in Ethiopian airline such as
  when the engine of the aircraft is start in the case of APU there is huge amount of sound which is danger for
human being So its need some modification which resist and absorb such huge amount of sound in order to
comfortable in all ways.
 there is a big problem between engineering who support technician and technician themselves to solve
problem especially in communication lack of full knowledge, fear and etc so this also need one research
 the main problem of Ethiopian airline is also when maintain aircraft lack of raw material expensiveness of
material this makes Ethiopian airline non profitable as much as we expect it.
 in Ethiopian airline when maintain the tire in wheel shop there is no hot water to washes disassembly part of
tire such as nut, ring, bolts, relief valves, bearing, washer, and all other rest of wheel tire part. To wash those
part hot water is very mandatory one to
 easily washing
 to save time by easily cleaning
 accurate cleaning ways
 increase reliability of maintenance this is also as one problem of Ethiopian airlines

3.2 Internship Project Work Selected

The project I have selected to work as my internship project work is titled as “Design of Solar water heater for Aircraft
Hanger (B777) and wheel of aircraft body washing”. among of this problem I focus on b/c this one is very needed and
important area to accelerate the Ethiopian airline safety as well as reliability
The reasons why I choose the project are:
 It is a critical issue to the company to solve the problem
 It is also interesting especially from renewable energy perspective way
 From cost perspective way it is vital to the company.
Solar energy comes from the light of the sun, which means it is a renewable source of energy. We can use the sun
light to create pollution free electricity.
The energy produced and radiated by the sun, more especially the term solar energy refers to the suns energy that
reaches the earth. Solar energy, received in the form of radiation can be converted directly or indirectly into other
forms of energy, such as heat and electricity.
Objective of solar water Heater
The Main Objective
The main objective is to design solar water heater to wash body of Aircraft in hangar as well as washing part of
disassembly tire and for shower in order to reduce the cost of solar water heater systems.
Specific Objective
The specific objective of solar water heater of washing aircraft body is
1. To design water storage tanks with 12,840 liters’ storage capacity
2. To design water connecting pipe
3. To select a pump delivering ⁄ of water to the system
4. To select temperature sensors
5. To select absorber and insulator
6. To select valves
7. To design supporting frame links and poles
Significance of the project
The need of this project is on studying the problem of hot water supply for Ethiopian MRO to washing the wheel tire
with hot water and gains the following advantages:
 It will improve human power induced
 It will save energy
 It will reduce effort
 It will minimize cost
 It will save time
 It will increase service quality
 It will supply distilled water
 It will heat water at optimum temperature
  It will create safer environment
 To decrease stress on the workers

Methodology
my project is being done theoretical and analytical method in addition with the help of the following method
 direct observation
 Asking the information who may concern
 Referring online google to analysis and interpreting the result compiled and compared with the
results obtained using a mathematical model to check the validity of the result.
The Scope and Limitation of the Project
The scope of this project work is to design, analysis and test the efficiency of the solar water heater for aircraft body
in Ethiopian Airlines.
Limitations: The amount of sun energy that could be collected. And produce heater water has some limitation
 the energy conversion efficiency has a theoretical limit
 weather dependent,
 solar energy Expensive and
 use a lot of space,
 The radiation of sun is nearly fixed
 the place that can be used to pave solar panels are limited
we cannot exploit all of sunlight to electricity because biosphere needs it
CHAPTER five
5.1 Literature review
Definition of solar Heating
Solar water heating (SWH) is the conversion of sun light in to renewable energy for water heating using a solar thermal
collector. Solar water heating system comprises varies technologies that are used worldwide increasingly. [12].
Every location on Earth receives sunlight at least part of the year. The amount of solar radiation that reaches any one
spot on the Earth's surface varies according to:
Geographic location
Time of day
Season
Local landscape
Local weather

Figure 3 category of solar thermal energy

The solar collector selected to our prototype on the solar water heater is the flat plate type. This is due to the following
reasons.
0
The temperature required is below or about 100 c
i. It is simple to manufacture
ii. The flat plate collectors are convenient for water heating
iii. They have the advantage of using both beam and diffuse solar radiation
iv. They do not require much tracking unlike that of concentrating collectors
v. They require little maintenance
Working principle of flat plate
A flat plate collector, as shown in the image to the right, consists of the following components: An absorber plate,
treated with a selective surface coating to increase the fraction of incoming radiation absorbed
 A transparent cover, or glazing, which limits the radiation and convection heat losses
 A layer of insulation, which reduces conduction losses
 An enclosure to contain the different elements
 Flow tubes through which the heat transfer fluid circulates

Flat Plate Collector is a heat exchanger that converts the radiant solar energy from the sun into heat energy using the
well-known greenhouse effect. It collects, or captures solar energy and uses that energy to heat water in the home for
bathing, washing and heating, and can even be used to heat outdoor swimming pools and hot tubs. For most residential
and small commercial hot water applications, the solar flat plate collector tends to be more cost effective due to their
simple design, low cost, and relatively easier installation compared to other forms of hot water heating systems. Also,
solar flat plate collectors are more than capable of delivering the necessary quantity of hot water at the required
temperature. Flat plate collector Solar Flat Plate Collector on Roof.
A solar flat plate collector typically consists of a large heat absorbing plate, usually a large sheet of copper or aluminum
as they are both good conductors of heat, which is painted and chemically etched black to absorb as much solar
radiation as possible for maximum efficiency. This blackened heat absorbing surface has several parallel copper pipes
or tubes called risers, running length ways across the plate which contains the heat transfer fluid, typically water.
These copper pipes are bonded, soldered or brazed directly to the absorber plate to ensure maximum surface contact
and heat transfer. Sunlight heats the absorbing surface which increases in temperature. As the plate gets hotter this
heat is conducted through the risers and absorbed by the fluid flowing inside the copper pipes which is then used by
the household.
The pipes and absorber plate are enclosed in an insulated metal or wooden box with a sheet of glazing material, either
glass or plastic on the front to protect the enclosed absorber plate and create an insulating air space. This glazing
material does not absorb the suns thermal energy to any significant extent and therefore most of the incoming radiation
is received by the blackened absorber.
The air gap between the plate and glazing material traps this heat preventing it from escaping back into the atmosphere.
As the absorber plate warms up, it transfers heat to the fluid within the collector but it also loses heat to its
surroundings. To minimize this loss of heat, the bottom and sides of a flat plate collector are insulated with high
temperature rigid foam or aluminum foil insulation as shown.

Figure 4 flat plate collector

Flat plate collectors can heat the fluid inside using either direct or indirect sunlight from a wide range of different
angles. They also function in diffused light, which is dominant on cloudy days as it is the surrounding heat that is
being absorbed and not the light, unlike photovoltaic cells. How hot the circulating water gets will depend mostly on
the time of the year, how clear the skies are and how slowly the water flows through the collector’s pipes.

Direct and Indirect Hot Water Systems

In order to heat your water successfully and use it during both the day and the night, you will need to have both a
solar collector to capture the heat and transfer it to the water and also a hot water tank to store this hot water for use
as needed.

Direct Hot Water System: Also known as an active open-loop system uses a pump to circulate the water around the
system. The cooler water is pumped directly from the home to a central water storage or immersion tank and passes
through the solar collector for heating. The hot water leaves the flat plate collector and returns back to the tank flowing
in a continuous loop. From there, the water is pumped back into the house as hot usable water. A low voltage 12-volt
pump can be used which can be powered by a small photovoltaic cell or electronic controller making the system
greener. Direct systems are usually used in warmer climates with few cold days or are drained in winter to stop the
water in the pipes from freezing. Chemicals cannot be added to the water for protection as the same water that
circulates through the flat plate collector is used in the home.

In a passive direct hot water system, the system does not use pumps or control mechanisms to transfer the heat created
to the storage tank. Instead, passive systems are what are called “open-loop systems” which use the natural force of
gravity to help circulate the water around the system. This type of system uses a solar flat plate collector combined
with a horizontally mounted storage tank of some kind located immediately above the collector. The water heated by
the sun rises naturally using convection through the solar collectors pipes and enters the storage tank situated above.
As the heated water enters the storage tank above, the cooler water is forced out and flows down to the bottom of the
collectors aided by gravity as cold water is denser than hot water. This cycle of hot water rising and cooler water
falling is known as a “thermosiphon flow” and continuously repeats unaided while the sun is shining.
Figure 5 Thermosiphon Hot Water System

Indirect Hot Water System. also known as closed-loop systems, differ from the previous system in that it uses a heat
exchanger that is separate from the solar flat plate collector to heat the water in the storage tank. Indirect hot water
systems are active systems and require pumps to circulate the heat transfer liquid around the closed-loop system from
the collector to the heat exchanger in the tank. The system contains an antifreeze solution, typically a 50%
Glycol/water mixture, in the primary closed-loop instead of just water which is heated and is kept separate from the
main domestic hot water supply.

The heat exchanger transfers the heat from the collector’s antifreeze solution to the water located in the water storage
tank. The heat exchanger can either be a copper coil inside the lower part of the storage tank or a flat plate exchanger
outside the storage tank One of the main advantages to this closed loop indirect heating system is that the antifreeze
solution gives all year round operation
in areas where the temperature falls
below the freezing point.

The main advantage of a forced

circulation indirect hot water system is
that an existing domestic water heating
system can easily be converted to solar
heating of the water just by adding a
flat plate collector and a single pump.

The system is also likely to be more

efficient, and the hot water storage
tank can be placed anywhere in the
home because it does not need to be
higher than the collectors as in the
previous passive or thermosiphon
system. One disadvantage, however, is
that the closed-loop system is
dependent on electricity for the
circulating pump which may be
expensive or unreliable. Some designs use a small low voltage pump and photovoltaic panel alongside the collector
making the system more efficient and greener. For larger installations and in cooler climates the hot-water tanks are
included below the roof within buildings, so forced circulation indirect solar water heating is the norm.

Sizing a Solar Hot Water System: - Sizing a Solar Flat Plate Collector for use in a solar hot water or heating system
depends upon the hot water demand. If the homes hot water consumption or maximum water temperature is reduced,
hot water demands may be supplied by a smaller solar array that is easy to install on the roof. Also, smaller thermal
systems are cheaper to install and will pay for themselves sooner through energy savings.

Flat plate collectors are mostly used for low temperature applications because of its simple design and construction.
In Flat plate collectors, the heat loss by convection is more important in the determination of its performance. The
convective heat loss may be decreased by using double glazing, but the radiation reaching the absorber is reduced due
to double reflection. So at low temperature, the use of single glazing gives a better efficiency than the double one. The
flat plate collectors are available in various designs according to their area of applications

In natural circulation type flat plate collector air is circulated in the system by natural phenomenon of heated air
flows upward and cold air flows downward. These types of collectors do not require any type of external work.

In forced circulation type solar flat plate thermal collector, fluid is allowed to pass through a blower which
increases the velocity of fluid particles as shown in figure. Thus, more heated fluid could be transported. These types
are installed where solar radiations are available in very large extant and heated fluid is required in greater amount.
Forced circulation type solar flat plate thermal collector is shown in Figure

Flat Plate Collector and its Performance

Generally, Flat Plate Collector are made up of metals, some common used metals are aluminum, copper, brass, GI etc.
To enhance the absorbing properties these metal collectors are painted with dull black. One of the major advantage of
using flat plate collectors is that these could use both components i.e. beam and diffuse components of solar radiations
for collection. These are used in low thermal applications and maximum temperature of about 100-150 could be
achieved by the use of these collectors. Flat plate solar collector could be used for both water heating and air heating
applications.

Factors Affecting Solar Water Heating (SWH) Performance

1 Ambient Conditions
The amount of incident radiation determines the absorbed solar radiation by the collector while the ambient
temperature determines the thermal losses from the collector. Cloudy conditions limit the beam insulation levels and
thus the radiation absorbed by the collector especially the concentrating collectors2 Collector Orientation and Tilt
Geographic orientation and collector tilt can affect the amount of solar radiation received by system.
3 Transport Fluid Flow Rate
𝑚3
Low collector fluid flow rates of about (0.005-0.02 ) increases the thermal performance of the collector by
𝑚𝑖𝑛
increasing the degree of storage tank thermal stratification. In a stratified tank, the temperature of fluid at the bottom
of the storage tank is lower than at the top. Collector inlet temperature is reduced because the collector inlet fluid is
fed from the bottom portion of the tank that reduces thermal losses and increased useful energy gain [1, 5].
4 Collector Array Arrangements The performance of the collector array depends on how the collector modules are
connected. In parallel connection, module inlet and outlet ports are fed to the common respective headers. Unlike
parallel connection; in series connection, the performance of the second and subsequent modules will not be the same
as the first because its inlet temperature is the outlet temperature of the first [1, 5].
5 Collector Characteristics Collector area, its absorber plate absorbents property and its glass cover optical properties
affect the amount of the incident solar irradiation that can be absorbed while collector insulation thickness and its
thermal conductivity affect the overall heat loss coefficient and thus the thermal losses [1, 5].
Hot water Demand in Ethiopian Airline MRO
Ethiopian airline and MRO buildings are having high energy demands for both mechanical power and heat. Heat is
required for water heating system is one of the most energy extensive process. Demand for Hot water consumption in
MRO is very high That’s why the needs in hot water must be determined with accuracy, since they differ from one
MRO to another, in order to avoid unnecessary energy consumption for water heating. To reduce energy use and
greenhouse gas emissions by MRO facilities, in the Ethiopian Airline solar water heater is energy efficient solutions
operating at the lowest cost and free from environment pollution gas emission.
The performance of a flat plate collector could be evaluated by an energy balance that indicates the distribution of
incident solar energy into useful energy gain and various losses (Rajput, 2014). Under steady conditions performance
of flat plate collector is
Flat plate solar collector geometrical analysis
Design of Solar Collector
The solar collector selected to our prototype on the solar water heater is the flat plate type. This is due to the following
reasons.
 The temperature required is below or about 100°c
 It is simple to manufacture
 The flat plate collectors are convenient for water heating
 They have the advantage of using both beam and diffuse solar radiation
 They do not require much tracking unlike that of concentrating collectors
 They require little maintenance
Components of solar water heater
The components of the flat plate collector type of the solar water heater are:
 Glass = One or more sheets of glass (radiation-transmitting) material
 Pipe=To conduct or direct the heat transfer fluid from the inlet to the outlet
 Absorber=Flat, corrugated, or grooved plates, integral with the tubes.
 Storage tank= To admit and discharge the fluid and store water
 Insulation =To minimize the heat loss from the back and sides of the collector.
 Pump=pushing water to flow or circulate through system
 Temperature sensor= determine and indicate out temperatures
Data from Ethiopian Airline in MRO assumption and estimation are made based on the standard hot water delivery
system for Airline. Data gathered methods are inspection (the MRO building) and interview (the workers of the MRO
worker.
Material selection for flat plate solar water heater
Collector material selection is made based on collector efficiency, strength of material and cost of material. For this
collector design; absorber plate, riser and header tube, glass cover and insulation materials are selected.
2 Absorber Material
An absorber may be made from a wide range of materials. Collector heat losses can be substantially reduced by the
use of selective coatings, which have a high absorbance greater than 0.95 for solar radiation, but a low emissivity of
around 0.1 for thermal radiation. Collectors with selective coating have high efficiency either in increased operating
temperature of the collector in this study, Black chrome coated on plated copper is considered as the absorber material
because of the following reasons:
 Due to its high thermal conductivity.
 higher absorbance
 low emissivity of the material
 Has lower cost per heat energy transfer rate
 High thermal and corrosion resistance and
 High durability and strength.
Figure 6 absorber

Table 4.3 characteristic of absorber

Riser and Header Tube Material Copper tubes are the most common material used for the fluid passageways, while
mild steel or stainless steel and mild steel tubes are also in use. Tubes are bonded to an absorbing plate with high
accuracy to increase system smoothness and efficiency of collector. For riser and header tubes; selected material
should be having high heat transfer rate
For this design, copper is considered as fluid passageways tube (riser and header tube) material because of the
following reasons:
 Its higher thermal conductivity.
 High absorbance of material
 Low emissivity of material
 Suitability to high temperatures
  long life
 Higher corrosion resistant
 High durability and strength.
 Lower cost per the rate of heat energy transfer

Figure 7 riser

Glass Cover Material The most widely used transparent cover material in solar collectors is the common glass, which
has most of the required properties. From the standpoint of the utilization of solar energy, the important characteristics
are reflection (ρ), absorption (α), and transmission (τ). The first two should be as low as possible and the latter as high
as possible for maximum efficiency [8].
In this study, Low iron, tempered glass is selected for the following reasons:
 mechanical strength: (it has higher mechanical strength (lower failure rates) than the common glass)
 for safety: (tempered glass breaks into a large number of relatively harmless bits of glass and so it is safer
during its use)
 for higher collector efficiency: (It has higher transmittance to the solar energy)
 It is readily available everywhere and its cost is reasonable
Figure 8 glass cover

Insulation Material Heat losses from the back and sides of a collector are reduced by the use of insulation. It
should be resistant to the maximum stagnation temperature of the collector usually about 150°C in collectors with
matt black paint absorbers and about 200°C when selectively coated absorbers Rockwool insulation material is
selected for the following reasons:
 higher resistance to the water
 Low thermal conductivity properties
 Higher durability in the presence of moisture
 Higher thermal resistance
 Because of the risks of water penetration in solar collectors are used [9].
Figure 9 insulation

Assumption for Design

Different assumptions are made for the designing of the collector which is [5]:
Steady state system
Unit area of absorber plate
50% efficiency of the system
70°C outlet water temperature
20°C daily average water inlet temperature
100°C absorber plate temperature
Average daily solar radiation I=754.3𝑤/𝑚2 from metrology agency
Specific heating capacity of water Cp=4200J/KgK
Over all heat transfer coefficient UL=6W/𝑚2
Ambient air temperature from metrology agency Ta=23°𝑐

parameter Hangar shower

Wheel tire Wheel Hangar Other guest
worker worker
Number of 1 20 10 5
Room 4
Wheel per 10 2 4 2 5
Room
occupancy 100% 95% 100% 95% 100%

Determining Hot water demand of the Ethiopian Airline (MRO)

The hot water demand is decisive for the dimensioning of a domestic hot water solar system (DHWSS). However, this
depends on the users' habits.

Table 3.2: Standard Hot Water Demand for Ethiopian airline (MRO)

Demand Standard hot water demand for different users

Wheel tire Hangar shower
 Hot water 400L/Room 1000L/aircraft 40L/Room
temperature 70°𝑐 48°𝑐 40°𝑐
Table 4.2: Standard Hot Water Demand for Ethiopian airline
For this study; determination of Ethiopian MRO hot water demand per day; is performed by make assumptions.
Depending on Ethiopian condition it is good to assume that the daily hot water requirement for wheel tire washer,
shower, will be determined by multiplying the developed countries hot water requirement for shower by the ratio
(3:4). Final hot water demand for each appliance is listed in table 3.3.

Demand Wheel tire Hangar shower

Hot water/L/R/day 1600 2000 4400
Temperature 70 48 40
Energy source Electric Electric electric
Table 4.3 hot water demand for each appliance
Determination of hot water demand of the MRO for different appliance is done by considering only hot water needs
of Ethiopian Airline MRO. There are one hot water consumption systems in the MRO that is the daily hot water
consumption system, used for determination of solar thermal water heating system and to optimize storage tank and
collector area.
 Hot water demand for each appliance is given by:
HWD= (Number of Room) *(water per Appliance ) 4.6
 Hot water demand for wheel tire service is given by:
𝑝𝑒𝑟𝑠𝑜𝑛 𝑤𝑎𝑡𝑒𝑟
HWDS= (Number of room)*( )*( )*occupancy 4.7
𝑅𝑜𝑜𝑚 𝑝𝑒𝑟𝑠𝑜𝑛

 Hot water demand for Hangar used

𝑃𝑒𝑟𝑠𝑜𝑛 𝑤𝑎𝑡𝑒𝑟
HWDH= (Number of room)*( )*( )*occupancy 4.7
𝑅𝑜𝑜𝑚 𝑎𝑖𝑟𝑐𝑟𝑎𝑓𝑡

 Total daily Hot water demand for Ethiopian Airline of MRO is given by
TDHWD=HWD+HWDS+HWDH 4.8

1 Hot Water Required for wheel Tire.

Hot water required in wheel tire to wash and cleaning part of tire easily and safely we Appling the following formula;
HWDW=4*400L=1600 liter per day
2 hot water Required for hangar
For Hangar hot water required for washing body of aircraft is given by
HWDH=2*1000lt=2000 liter per day
3 hot water required for shower
The Ethiopian Airline worker especially technician is very need to use hot water for washing theirs body daily which
is given by the formula
Shower service for wheel tire worker is
HWDS1=4*20*40ltr*1=3200 liter per day
Shower for hangar worker technician and others
 HWDS2=10*2*40*0.95=760 liter per day
Shower for other guest
HWDS3=5*5*40*1=1000 liter per day
Total hot water demand for shower is
THWDS=3200lt+760lt+1000lt=4960 liter per a day
Total daily hot water demand Ethiopian Airline in MRO is determined by using above equation
TDHWD=1600 lt + 2000lt +4960lt=8560 liter per a day
Hot water demand for Ethiopian airline of MRO is

Demand service
wheel tire Hangar shower
hot water(lt/day) 1600lt/day 2000lt/day 4960lt/day

Table 4.3 hot water demand for Ethiopian airline MRO

The daily and weekly hot water consumption of the Ethiopian Airline MRO can be increase or decrease from the
calculated value, so to compensate the error created the calculated value can be multiplied by same factor 1.25. The
factor is one fourth of the total calculated daily and weekly hot water demand of the MRO.
The total hot water should be supplied (THWS) IS:
TWHS= (Daily water consumption lt/day) *1.25

Demand Services Total

wheel tire Hangar Shower 10700
Hot water demand(lt/day) 2000 2500 6200
Table 4.3 total hot water demand per service

Hot Water Storage Tank Capacity

When the daily hot water demand has been determined, the volume of the storage tank can be specified. It should be
some 0.8 to 1.2 fold the daily demand for regions with high solar radiation and 2 to 2.5 fold the daily demand for
regions with lower solar radiation respectively, so that consumption peaks can be met well and cloudy days can be
compensated [3]. The volume of the storage tank (VST) is thus calculated as follows:
VST=TWHD*1.24.5
For total daily hot water demand volume of the storage tank (Vst ) is:
Vst=10700*1.2=1,2840 liter
As the manufacturers do not offer tanks in every possible size, the choice has to be made amongthose generally
available on the market. However, it is recommended that the storage tank capacity is not less than 90% and not more
than 120% of the calculated volume [3]
Energy Capacity of a Storage Unit
The energy storage capacity of a water storage unit at uniform temperature is given by [5]:
𝑄𝑈 =𝑚𝑐𝑝 (𝑇𝑂 _𝑇𝑖 ) 4.5
Where Qu=Total heat capacity of storage tank[𝑚3 ]
𝑚̇=volume of storage tank[𝑚3 ]
𝑘𝑤ℎ
𝑐𝑝=4.2 ℎ𝑒𝑎𝑡𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
𝑚3 𝑘

𝑇𝑂 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑜𝑢𝑡 [k]

𝑇𝑖 =temperature in [k]
Total daily energy demand (Qu) is:

𝑘𝑤ℎ
Qu=12.84𝑚3 *4.2 )*(343k-293k)=2696.4kwh=2.6964Mw
𝑚3 𝑘

Summaries of Hot Water, Storage Tank and Energy Capacity

Total demand Daily Hot Water storage tank energy capacity

Consumption

Daily 12,840 lt 12.84m3 2696.4kwh

Table 4.5 Summaries of Hot Water, Storage Tank and Energy Capacity Needed

 Incident Solar Radiation: - Before the calculation of the amount of solar radiation which strikes the collector,
it is necessary to define some terms related to solar radiation
 Beam or Direct Insulation, Ib: - is the solar radiation that reaches the surface of the earth directly from the
sun without being scattered in the earth’s atmosphere
 Diffuse Insolation, Id: - is the solar radiation that reaches the earth’s surface after being scattered or diverted
from its original path in the atmosphere.
 Reflected Radiation, Ir: - is the solar radiation reflected from the ground and surroundings.
 Global Insolation: - is the sum of all solar radiation on a surface. This includes not only the beam and diffuse
insolation but also any insolation reflected from surrounding objects.
 Air Mass: - is the ratio of the distance that solar radiation travels through the earth’s atmosphere (path length),
to the distance (path length) it would travel if the sun were directly overhead.
 The solar constant (Isc): - is the total amount of electromagnetic energy that falls on a unit area normal to the
sun in unit time at the top of the earth's atmosphere when the earth is at its mean distance from the sun
 Irradiance (W/m2): - is the rate at which radiant energy is incident on a surface per unit area of surface.
 Irradiation or radiant exposure (J/m2): - is the incident energy per unit area on a surface, found by the
integration of irradiance over a specified time, usually an hour or a day.
 Insolation: - is a term applied specifically to solar energy irradiation.

The symbol H: - is used for insolation for a day and I for insolation for an hour. Both H and I can represent beam,
diffuse or total and can be on surfaces of any orientation.
The solar radiation energy incident on the collector surface which is inclined at an angle of (𝛽 ) to the horizontal
surface is defined in terms of global, diffuse, beam and reflectivity radiation. Total solar radiation incident on a surface
consists of beam, diffuse and reflected solar radiation from the ground and surrounding. Total radiation on a surface
can be evaluated by arbitrary orientation from knowledge of beam, diffuse and global radiation on horizontal surface
The total incident radiation on this surface can be written as:
5,2
The flux incident beam radiation collected by the absorber per unit time is given by:
5.2

Global Radiation (Gr)

Global solar radiation is the sum of the beam and the diffuse solar radiation on a surface (the most common
measurements of solar radiation are total radiation on a horizontal surface, often referred to as global radiation on the
surface.
1. First one is estimating the radiation data using solar energy empirically relations and
2. Second one is measuring the radiation data by using solar-meters instrument called pyrometers, that most of
available solar radiation data are obtained.
Generally, for this study, analysis of available temperature for project location to heat water uses measured global
radiation by Ethiopian metrology agency. Global radiation data gained from metrological agency is read from
automatic station within 15 minutes.
a) Average Monthly Global Radiation
The monthly average global radiation on a horizontal surface can be calculated from the meteorological data of hourly
and daily global radiation on a horizontal surface and global radiation on an inclined surface is determined multiplying
global radiation on horizontal surface by same angle (𝛽 ). Average monthly global radiation of project site gained
from metrological for 3 years (2015-2018) is given in the table
𝑤
Average Monthly Global Radiation ( 2 )
𝑚

year Months of the Year

Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
2015 613 631 628 597 556 524 465 470 611 615 632 638
2016 600 590 640 645 624 600 580 480 560 650 640 666
2017 599 620 625 632 638 640 645 648 650 655 658 660
2018 600 620 640 660 665 640 650 650 670 668 680 682

Radiation data on Ethiopian Airline location is taken from metrology agency station (bole Ethiopia). Global radiation
was evaluated in grades after every 15 minutes and then the mean value of the hourly and daily will be calculated.
b) Average Yearly Global Radiation
Average yearly global radiation (AYGR) on horizontal surface can be calculated from monthly average listed in table
4.1. Average yearly global radiation shows available solar radiation energy distribution over
different years on the given location.

𝑤
Average Yearly Global Radiation ( )
𝑚2

Year 2015 2016 2017 2018

AYGR 529 606 639 645

Average yearly global radiation listed in table 4.2 is used to understand yearly variation of global solar radiation on
the given location and help to predict or estimate the coming year global radiation on the project site.

Hourly global radiation is gain from metrology agency and hourly extraterrestrial radiation of a given area is calculated
using the location (latitude and longitude), basic sun angle and solar constant with number of days.

Beam Radiation (Ib)

The solar radiation received from the sun without having been scattered by the atmosphere. Beam radiation is often
referred to as direct solar radiation. The beam radiation incident on a surface is the deference between global radiation
and diffuse radiation is given by [5]:
 6.7

Selection and Sizing of Heaters

The design data to be used to carry out the design of solar water heater are:
I. Latitude of the location: 9.14° N of equator
II. Longitude: 38.44° E
III. Altitude/elevation: 2355m above sea level
IV. Amount of water to be heated: 12840liters
VI. Inlet cold water temperature: 20°C
VII. Outlet hot water temperature: 70°C
VIII. Inclination of collector: 45°
IX. Specific heat capacity of water: C = 4.180KJ/kg°c
X. Density of water =1000kg/m
Determination of the Monthly Average Daily Global Insolation for the Required Solar Water Heater
The collector is designed based for which =9.14° . It is to have an inclination of 45° [11]

3 Latitude (∅ ) The latitude of a location is the angle made by the radial line joining the given location to the center
of the earth with its projection on the equatorial plane. The project site of Ethiopian (MRO) located on:
Latitude∅=9.14° due to north Therefore, the latitude angle is positive.

Hour angle(𝝎) The hour angle of a point on the earth’s surface is defined as the angle through which the earth would
turn to bring the meridian of the point directly under the sun. Hour angle and solar time in hour are related as [5]

𝝎=(𝑠𝑤 − 12) ∗ 15° 4.23

Where: ST = is solar time (from1 to 24) hours.

5 Declination angle (𝜹 ) Declination angle is the angle between the earth’s equatorial plane and the line drawn between
the center of the earth and the sun. Declination angle of the sun varies daily and is calculated from the following
relation [5]:
360
𝜹=23.45Sin[ (284+N)] 4.23
365
n = representative day of May = May 15 for which n=135 as counted from January 1.
360
𝜹=23.45Sin[ (284+135)]=18.8°
365

𝜔𝑠 = cos −1 (−𝑡𝑎𝑛∅𝑡𝑎𝑛𝛿)
cos −1 (−𝑡𝑎𝑛9.14°𝑡𝑎𝑛18.8°) =96.7° for MRO Airlines

24×3600 360 𝜋
𝐻𝑜̇ =[ 𝐼𝑠𝑐 ][1+0.033cos( )]× [cos ∅ cos 𝛿 sin 𝑤𝑠 + 𝑤
𝜋 365 180 𝑠 sin 𝛿 sin ∅]
Where
𝐼𝑠𝑐 1367𝑤/𝑚2
N=for may n=135
𝛿=18.8°
∅=9.14°
𝑤𝑠 =96.7°
24×3600 360 𝜋
=[ × 1367][1+0.033cos( )]× [cos 9.14 cos 18.8 sin 96.7 + 96.7sin 18.8 sin 9.14]
𝜋 365 180

𝑯̇𝒐 =42mh/𝒎𝟐

Then it can be put in the form of power of the radiation of the sun divided by day radiation
42MJ/𝑚2 𝑑𝑎𝑦
=488w//𝑚2
86400𝑠𝑒

𝐻
Therefore 𝑘 𝑇 =
𝐻̇𝑜
19.45
𝑘𝑇 = =0.39
50
̇
𝐻𝑑
=1.403-1.672𝐾𝑇
𝐻
𝐻𝑑 =H(1.403-1.672𝐾𝑇 )
=14.6MJ/𝑚2 day
The monthly average daily beam insolation on the horizontal surface is obtained by using the equation
̅̅̅̅
𝐻𝑏 =H-𝐻𝑑 =19.45MJ/𝑚2 day-14.6MJ/𝑚2 day=4.8MJ/𝑚2 day

Radiation Factors
4.3.1 Beam radiation factor (Rb)
Beam radiation factor (Rb) is defined as the ratio of beam radiation incident on an inclined surface to that on a
horizontal surface [5].
Figure 10Data for Tampa International AP, Florid

Calculating for all the month and all for year as the example we calculate fi the may
τb = 0.47
τd = 2.029
The parameters for air mass are as follows:
b = 1.219 − 0.043τb − 0.151τd − 0.204τbτd = 0.55
d = 0.202 + 0.852τb − 0.007τd − 0.357τbτd = 0.248
The extraterrestrial solar radiation is given by

360 𝑘𝑗
𝐼𝑜 =𝐼𝑠𝑐 [1.0+0.033cos cos 𝜃𝑧 ( 2 ) 4.5
365 𝑚 ℎ
2
Where 𝐼𝑠𝑐 =1367w/𝑚
360 𝑘𝑗
𝐼𝑜 =1367 [1.0+0.033cos cos 92( 2 )
365 𝑚 ℎ
𝐼𝑜 =1365 w/𝑚2
The direct solar radiation component is
𝑏
𝐼𝐵𝑁 =𝐼𝑒 −𝜏𝑏𝑚 4.5
Where
M=
0.55
𝐼𝑜 𝑒 0.47∗
The diffuse solar radiation on a horizontal surface is

𝑑
𝐼𝑑𝑁 =𝐼𝑒 −𝜏𝑑𝑚 4.6

The instantaneous beam radiation on the surface per unit area is given by

𝐼𝐵𝑐 =𝐼𝑏 Ncos 𝜃𝑖

For this geometry, the cosine of the angle of incidence is

1 Angle of incidence(𝜽) Angle of incidence is the angle between the beam radiation on a surface and the line normal
to surface [5].

𝜃𝑖=96
𝐼𝐵𝑐 =𝐼𝑏 Ncos 𝜃𝑖
The diffuse radiation on the collector surface will b
𝛽
𝐼𝐷𝑐 =𝐼𝐷 N𝑐𝑜𝑠 2 4.14
2
The ground reflected solar radiation is
 𝛽
𝐼𝑟𝑐 =𝜌(𝐼𝑏 Nsin 𝛼 +𝐼𝑑 ℎ)𝑠𝑖𝑛2 Assuming that the solar collector is surrounded by ordinary ground or grass, then ρ≈ 0.2
2
𝛽
𝐼𝑟𝑐 =𝜌(𝐼𝑏 Nsin 𝛼 +𝐼𝑑 ℎ)𝑠𝑖𝑛2
2

Finally, the total radiation on a tilted collector surface is

𝐼𝑐 = 𝐼𝐵𝑐 +𝐼𝐷𝑐 +𝐼𝑟𝑐 4.15

Diffuse radiation factor (Rd)

Diffuse radiation factor (Rd) is the ratio of the flux of diffuse radiation falling on the tilted surface to that on the
horizontal surface

1+cos 𝛽
𝑅𝑑 = 4.6
2

1+cos 96.7
=0.44
2
Rr: - is the reflected component that comes mainly from the ground and other surrounding objects. It is given by
1−cos 𝛽
𝑅𝑟 = 4.7
2

1−cos 86.7
= =0.55
2
The monthly average daily insolation on a tilted surface is the sum of the entire beam, diffuse and reflective
𝐼𝑇̇ =𝐼𝑏 𝑅𝑏 +𝐼𝑑 𝑅𝑑 +𝜌𝑅𝑟 (𝐼𝑏 +𝐼)
Assume that 𝜌=0.22 for reflectives
𝐼𝑇 =(4.8*1.04(14.5*0.44)+(0.22*0.55[4.8+14.5]=34.2 MJ/(m2 .day)

The above results obtained are used to design the collector to be used which fits the specifications required of capacity=
12,840 liters

The flux of beam radiation incident on an incline surface is given by:

7/5

Basic Sun-Earth Angles

The position of a location on the earth’s surface is defined by the coordinates latitude and meridian or longitude
angles. Depending on the orientation of the inclined surface, the expression for (cos 𝜃 )
and ( cos 𝜃𝑧) can be obtained as:

Where: latitude (∅ ), collector tilte ( 𝛽), declination ( 𝛿) and hour (𝜔 ) angles

2 Zenith angle(𝜽𝒛 ) Zenith angle is the angle between the sun’s ray and the perpendicular line to a horizontal plane
[5]

cos 𝜃𝑧=cos ∅ cos 𝛿 cos 𝜔 + sin 𝛿 sin ∅

cos 𝜃𝑧=cos 9.14 cos 18.8 cos 96.7 + sin 18.8 sin 9.14
cos 𝜃𝑧=-0.048
=92°
Therefore, beam radiation factor (Rb) can be determined as

cos 𝜃𝑖
𝑅𝑏 = =1.04
cos 𝜃𝑧
Inclined solar insolation becomes:
486w/𝑚2 ∗ 1.04 = 505𝑤/𝑚2
The total energy output can be calculated by solar insolation and collector. Then output energy is:
𝑄0𝑢𝑡𝑝𝑢𝑡 =I𝐴𝑐 where 𝐴𝑐 =wl=4m*2m=8𝑚2
And we have two glasses 𝐴𝑐 =8𝑚2 *2=16𝑚2
𝑄0𝑢𝑡𝑝𝑢𝑡 =505𝑤/𝑚2 *16𝑚2 =8080watt
Let our aim to design solar panel having efficiency 80%
Then to determine the input energy (QI)
𝑄𝑖𝑛 8080
𝑄𝐿= 𝑄𝐿= =1010W/𝑚2
𝜂 0.8

Design of storage tan

From the tank storage we can calculate diameter of the storage
V=AL
𝜋𝑑 2
V= storage have 12.84𝑚3
4
𝜋𝑑 2
12.84𝑚3 = *L if storage have 1.5m
4
𝜋𝑑 2
12.84𝑚3 = *1.5m
4

d=3.3m
Storage cylinder have 3.3m diameter
To find the time equalize the daily radiation and
34.2mw/𝑚2 =505𝑤/𝑠𝑚2
t=63366se
𝑉
Q= where v= volume of water
𝑡

Q= Volume flow rate

t- Time in second
12.84𝑚3
Q= 0.000202𝑚3 /s
63366𝑠

The mass flow rate of the collector is computed as follow:

m=𝜌𝑄
m=1000kg/𝑚3 *0.0002020𝑚3 /s=0.202kg/s
To determine the speed of water in the pipe, volume flow rate divided by the area the pipe, then the area of pipe is
equal to the volume flow rate divided by the speed of the water in the pipe. First to calculate the speed of the water in
the pipe (Vp):
Vp=√2𝑔ℎ
=√2 ∗ 9.8 ∗ 4=8.8m/s
The area of the pipe is
𝑄 0.000202
Ap= =0.000029𝑚2
𝑉𝑃 8.8

The diameter of the pipe can be calculated as follow:

𝜋𝑑 2
Ap=
4
 𝜋𝑑 2
0.000029𝑚2 = d=0.0025m=5.4mm
4

Classification of vessel (storage tank): according to the dimension; it may be classified as thin shell or thick shell.
If the wall thickness of the shell is less than 1/10 of the diameter of the shell (d), then it is called thin shell. On the
other hand, if the wall thickness of the shell is greater than 1/10 of the diameter of the shell (d), then it is called a thick
shell. Thin shells are used in boilers, tanks and pipes, whereas thick shells are used in high pressures cylinders, gun
barrels etc. [22]
According to the end construction; the vessels according to the end construction may classify as open or close end. A
simple cylinder with a piston, such as cylinder of a press is an example of an open end vessel, whereas a tank is an
example of a closed end vessel. In case of closed ends, longitudinal and circumferential stresses are induced the fluid
pressure. [22]
To calculate hoop stress:

Figure 11 hoop stress distribution

P=internal pressure

L=length of the cylinder tank

T=thickness of the cylindrical shape

Total force acting of longitudinal section (along x-x)

F=P*D*L 4.4

=775kpas*0.0054*1.5

F=6.28kN

Power of the solar panel becomes the

P=F*V

Where; force can be calculated from the input energy divided by the speed of water in a pipe and then the speed of
water which is equal to the square root of two times gravity and height of head

v=8.8m/s

p= F*V

6.28KN*8.8m/s

55.242kw

Total Collector Area

Here, the simple and approximate way of estimating the absorber area is used. In this method, the following inputs
are used. The minimum cold water temperature is 20°C. This is estimated from table 3.1. The water heater is to deliver
1284 liters of water per day at 70°C. The collector efficiency is of the order of 0.5. This could also be confirmed by
previous experiments conducted on collector of the same type in Addis Ababa bole airport.

The mean daily available insolation on a surface inclined at about 12° to the horizontal and facing equator (South) at
MRO (latitude = 9.687°) for the average year round use is obtained above to be
𝐼𝑇 = (9.3*0.989) +(10.15*0.989) +(0.22*0.11[9.3+10.15] =34.2 MJ/ (m2. day) The mean daily energy requirement
will be Useful heat delivered by solar collector = (Energy absorbed in the metal surface Heat losses to the
surroundings)
Useful heat output of a flat plate collector is given by
Qu=Ac[S-UL{Tpm-Ta}] 4.5
Where,
Qu -Useful energy delivered by collector
AC= Collector area
S- Absorbed energy
1+cos 𝛽 1−cos 𝛽
S=𝐼𝑑 𝑅𝑏 (𝜏𝛼)𝑏 + 𝐼𝑑 (𝜏𝛼)𝑑 ( ) + 𝜌𝑔 (𝐼𝑏 + 𝐼𝑑 )(𝜏𝛼)𝑔 ( ) 4.6
2 2

1+cos 𝛽 1−cos 𝛽
S=𝐼𝑑 𝑅𝑏 (𝜏𝛼)𝑏 + 𝐼𝑑 (𝜏𝛼)𝑑 ( ) + 𝜌𝑔 (𝐼𝑏 + 𝐼𝑑 )(𝜏𝛼)𝑔 ( )
2 2

𝑈𝐿 = Over all heat loss coefficient,

𝑈𝐿 = 𝑈𝑇 + 𝑈𝑏 + 𝑈𝑒
𝑈𝑇 = Top loss coefficient
𝑈𝑏 = Bottom loss coefficient
𝑈𝑒 = Edge loss coefficient
𝑇𝑝𝑚 =Mean absorber plate temperature
𝑇𝑎 = Ambient temperature
a) Top Loss (𝑼𝑻 )
This loss occurs through the glass covers taking in to consideration the emittances of plate and glass, wind
convective heat loss. Mathematically can be expressed by
−1

N 1 σ(Tpm + Ta )(TPM 2 + Ta 2 )
UT = ( e+ ) + −1 2N+f−1+0.133ϵp
C Tpm −Ta hw (ϵp + 0.00591Nhw ) + −N
(( )) ϵg
Tpm N+f
( )

Where:
N - number of glasses
𝑓 = (1 + 0.089ℎ𝑤− 0.1166ℎ𝑤 ∈𝑝 )(1 + 0.07866𝑁)
C=520(1-.000051β2) for 0̊≤β≤70̊
𝛽 - Collector tilt angle
𝜀𝑔= Emittance of glass (0.88)
𝜀𝑝= Emittance of plate
𝑇𝑝𝑚 =Mean plate temperature
𝑇𝑎 = Ambient temperature
ℎ𝑤 =5.7× 3.8𝑣
v= wind heat transfer coefficient, with wind speed,
𝜎 =Stefan Boltzmann constant (5.67×10-8)
e =0.430(1-100/𝑇𝑝𝑚 )

To calculate the mean plate temperature, steady state heat conduction from the plate to the fluid is used, which latter
is iterated until similar result is obtained with the correct useful energy.
𝑄𝑈
⁄𝐴
𝐶
𝑇𝑝𝑚 =Tfi+ (1-FR) 4.5
𝐹𝑅∗ 𝑈𝐿
Where:
 FR- Collector heat removal factor
QU -Useful energy from collector
UL -Total heat loss coefficient
𝑇𝑓𝑖 =Inlet fluid temperature
b) Bottom loss coefficient (𝑼𝒃 )
This loss accounts the convective and conductive loss through the insulation.
Mathematically:
𝑼𝒃 =K/L
Where,
L - Thickness of insulation
K- Thermal conductivity of insulation
𝑈𝑏 -Bottom loss coefficient
a) Edge loss, (𝑼𝒆 )
This heat dissipation comes from the edge loss to the environment. It is given by

(𝑼𝑨)𝒆
𝑈𝑒 =
𝑨𝑪
Where
(𝑈𝐴 )e Edge loss coefficient-area product
AC=Collector area
Know the overall heat loss coefficient, (UL)is
UL=Ut+Ub+Ue
fin Efficiency, Fe
Fin efficiency of the collector is given by the following relation;
𝑚(𝑊−𝐷)
F= tanh [ ] /𝑚(𝑊 − 𝐷)/2
2
Where
W fin width
D outer diameter of heat pipe.
𝑈𝐿
m√
𝑘𝛿
K =thermal conductivity of fin
𝛿 = Fin thickness
F =Standard Fin efficiency
Collector Fin Efficiency Factor, F’
1
UL
F′ = 1 1 1 5.7
w[ ]+ +
UL [D+{W−D}F] Cb πDi hfi
Where,
𝑐𝑏 = 𝑏𝑜𝑛𝑑 conductance
ℎ𝑓𝑖 =local film heat transfer coefficient
=300w/m2 oc for natural circulation
Collector heat removal factor (FR)
ṁcp −AC UL F ′
FR = [1 − exp [ ]]
A c UL ṁCp

Where,
m̊ Mass flow rate of the fluid
𝐶𝑃 ) specific heat capacity for water
F’ collector Fin Efficiency Factor
Collector heat removal factor (FR)
ṁcp −AC UL F ′
FR = [1 − exp [ ]]
A c UL ṁCp

Where,
 m̊=mass flow rate of the fluid
𝐶𝑃 specific heat capacity for water
F’ collector Fin Efficiency Factor
Collector flow factor (F”)
FR mĊ p −AC UL F ′
F" = ′ = [1 − exp ( )]
F A C UL F " ṁcp

To get the useful energy

Q U = [AC (S − UL {Tpm − Ta })]

Let assume𝑇𝑝𝑚 =70+273=343k

𝑇𝑎 =20+273k=293k
N=2
F=2.82
𝑤
HW =24.7 2
𝑚 𝑘
ep= 0.27
e= 0.3
c=519.99
Therefore, coefficient of heat loss is
−1

N 1 σ(Tpm + Ta )(TPM 2 + Ta 2 )
UT = ( 0.3 + 24.) + −1 2N+f−1+0.133ϵp
519.9 343−293 (ϵp + 0.00591Nhw ) + −N
(( )) ϵg
343 2+2.82
( )
−1

2 1 σ(Tpm + Ta )(TPM 2 + Ta 2 )
UT = ( e+ ) + −1 2N+f−1+0.133ϵp
C T −T hw (ϵp + 0.00591Nhw ) + −N
(( pm a )) ϵg
Tpm N+f
( )

1 Design of absorber

Energy Balance Equation

In steady state, the performance of a flat-plate solar collector can be described by the useful gain from the collector,
Qu, which is defined as the difference between the absorbed solar radiation and the thermal loss or the useful energy
output of a collector

Where Ac=gross area of collector Ap=aperture area of collector The first term is the absorbed solar energy and the
second term represents the heat loss from the collector. The solar radiation absorbed by a collector per unit area of
absorber (S) can be calculated using the optical properties of covers and a plate. The thermal energy loss from the
collector to the surroundings can be represented as the product of a heat transfer coefficient UL times the difference
between the mean absorber plate temperature Tpm and the ambient temperature Ta
The + superscript indicates that only positive values of the terms in the square brackets are to be used. Thus, to
produce useful gain greater than zero the absorbed radiation must be greater than the thermal losses. Two collector
areas, gross collector area Ac is defined as the total area occupied by a collector and the aperture collector area
Ap is the transparent frontal area. ASHRAE Standard [1] employs the gross area as a reference collector area in the
definition of thermal efficiency of the collector. The useful gain from the collector based on the gross collector area
becomes

Where Sc is the absorbed solar radiation per unit area based on the gross collector area

Since the radiation absorption and heat loss at the absorber plate is considered based on the aperture area in this study,
it is convenient to make the aperture collector area the reference collector area of the useful gain. Then
Becomes

where U′L is the overall heat loss coefficient based on the aperture area given by

Solar Radiation Absorption

The prediction of collector performance requires knowledge of the absorbed solar energy by the collector absorber
plate. The solar energy incident on a tilted collector consists of three different distributions: beam radiation, diffuse
radiation, and ground-reflected radiation. The details of the calculation depend on which diffuse-sky model is used.
In this study the absorbed radiation on the absorber plate is calculated by isotropic sky model

where the subscripts

b, d , and g represent beam, diffuse, and ground-reflected radiation, respectively. I is intensity of radiation on a
horizontal surface, (τα) the transmittance-absorptance product that represents the effective absorptance of the cover-
plate system, and β the collector slope. Ρ g is the diffuse reflectance of ground and the geometric factor Rb
is the ratio of beam radiation on the tilted surface to that on a horizontal surface This section treats the way to calculate
the transmittance-absorptance product of beam, diffuse, ground-reflected radiation for a given collector configuration
and specified test conditions.
Reflection of Radiation
For a smooth interface the Fresnel equations evaluate the reflection of unpolarized radiation on passing from medium
1 with a refractive index n1 to medium 2 with refractive index n2 (Figure 2.3.1). The reflection of unpolarized radiation
r is given

4 Determination of air flow rate

The air flow rate was calculated using
AR = Va × Ai, where Va =Air velocity, 5m/s
Ai =Area of inlet opening. =12𝑚𝑚2

AR = 5m/s × 12𝑚𝑚2 =0.00006m/s

Determination of mass flow rate
The mass flow rate of air was calculated using
m = AR × Da, where Da== Density of air.
m = 0.0006m/s × 1.204kg/𝑠
=0.000073kgm/s
Determination of heat gained by drying air Heat gained by air in the solar tunnel dryer was calculated using).
Qg = mCa (T2 − T1),
where Ca = Specific heat of air,
T1 = Ambient temperature,
T2 = Dryer air temperature
Qg = 0.000073*1(343k− 293),
=0.00365
Heat received by the collector The heat received by the collector was calculated using
Qc = I × 0.86 × Ac [5] 4,.6
if Ac=8𝑚2
= 34.2MJ × 0.86 × 8𝑚2 =235MJ
Solar collector efficiency Solar collector efficiency was calculated using.
ηc = Qg/Qc × 100.
=0.00365/235&100

𝑄𝑙 =𝑚𝑐𝑝 ∆𝑇 4.6

Where volume of water v=12.84 m3

Specific heat capacity of water c = 4.180KJ/kg°c
Specific heat capacity of water c = 4.180KJ/kg°c

𝑄𝑢 =𝑚𝑐𝑝 ∆𝑇==𝜌𝑉𝑐𝑝 ∆𝑇

1000𝐾𝑔
𝑄𝑙 = ∗ 12.84𝑚3 ∗ 4.18(343𝑘 − 293𝑘)=642MJ/day
𝑚3
The useful insolation energy for the specified efficiency is
𝑄𝑢 =𝐻𝑇̇ × € 6.7
𝑄𝑢 =19.45 × 0.5=9.6 MJ/(m2 .day
The total collector area required is
𝑄
𝐴𝑇 = 𝐿 7.5
𝑄𝑈
209𝑀𝐽/𝑑𝑎𝑦
𝐴𝑇 = =21𝑚2
9.6
The collector is made in the size of Ac = Area of a collector [𝑚2 ] = 5mx2m = 10𝑚2 This dimension is selected so that
two persons can handle it easily and this size confirms to the size of the sheet metal available in the local market.
Thus, the total number of collector required is
𝐴 21
Collector = 𝑇 = 2 =2.1≈2 collector is used.
𝐴𝐶 10𝑚
 Cost Analysis

The main objective of cost analysis is required to know the cost of 1kwh energy produced by the solar water heater
and to compare with the cost of energy produced using 1kwh electrical energy in Ethiopia.
Specification:
Material steel sheet metal
2
Absorber size - 1900x900mm
Materials required and their costs:

No Material cost size price quantity

1 glass 4m*2m 1720 2
2 absorber 4mm*4mm 400 12
3 Water tanker 12.84 4500 1
4 supporter 200 5
5 casing 250
6 foaming 300
7 Coper pipe 4500
Total 11,870

Figure 12 table of cost analysis

Then the total cost is equal to 6,000 * 189 =1134000birr

11,870
To produce 1kwh of energy from solar energy using the solar collector the cost spend is only the depreciation cost of
the solar water heater each year, otherwise there is no other additional cost rather there may be some maintenance cost
which is negligible as compared to its cost.
0
The depreciation cost for each machine in Ethiopia is 20 0 each year The depreciation cost of the solar water heater
in 2011E.C (the time of manufacturing) is given by
100%× 𝑜𝑟𝑖𝑔𝑖𝑛𝑎𝑙 𝑐𝑜𝑠𝑡× 2
Dc=
𝑑𝑎𝑦 𝑜𝑓 𝑦𝑒𝑎𝑟

 0.2 * original cost

=0.2 *11870
=2,3740 birr/year
23740
= 65birr/day
365

But using this solar water heater the energy produced per day is
E=P*T(hr)
=554208*9hr
=489kwh/day
The cost of 1kwh energy produced by this water heater is given by:
489kwh*0.58 =289.62

1kwh = x
440kwh/day= 621.4 birr/day
X = 1.4birr for this year (2004)

The costs in the future years are calculated and written in the table below

Year (EC) Total machine cost Depreciation cost/year Cost of 1kwh

(book value) ,birr ,birr Solar energy, birr
2011 1,134,000 226800 1.4
2012 907200 181440 1.13
2013 725760 145152 0.9
2014 580608 116121.6 0.7
2015 464486.4 92897.28 0.5
2016 371589.12 74317.824 0.4
2017 297271.3 59454.3 0.3
2018 237817 47563.4 0.2
2019 190253.6 14290.2 0.1
2020 175963.4 35192.68 ≈0

As from the EELPA information the electrical cost for 1kwh in Ethiopia is 0.58 birr for institutions. When we compare
this cost with the solar energy cost over the coming 6 years,
 For the solar energy which is used for 6 years 11,00 birr only for initial cost
 When we use the electric power the cost will be
The total energy which is going to produce for the upcoming 6 years is
440*365*20
=3212000kw
And the electrical cost will be,
0.58*9,636,000
= 1862960birr
From the above step we can see that the one which use the solar energy for the amount energy saves a birr of;
1862960 – 1134000 = 728960 birr.

So the company has high advantage in terms of cost since it saves 728960 birr.
. Conclusions and Recommendations
7.1 Conclusions

Generally solar water heater is the most cost effective energy converter than that of solar electricity (photovoltaic
cells). As the system uses renewable energy from the sun it does not harm the environment unlike that of fossil fuels.
There are many types of solar collectors, but the most common type is flat plate collector with black paints and
connected (glued) with a copper pipe. The collector material used is aluminum which has high conductivity with
relatively low cost.
From the analysis we can see that it needs 189 panels to heat 7570 litter of water.
There are 756 copper pipes for the total collectors order to transfer heat from the absorber to the fluid and each of the
copper pipes has 50mm diameter. And we have to use a water pump in order to give a desired flow rate from a storage
tank. To control the exact water temperature, we have a temperature sensor thermocouple. To avoid a heat, lose that
is caused by the process of heat transfer we uses standard insulators.
Finally, I want to urge the company administrators to bring into their attention the adaptation of this technology which
can play a vital role not only in saving the company money but also in creating a world free from carbon.
6.2 Recommendations:
During installation, production and insulating of the components great care should be taken to maintain the results of
the design.
Using a single cover glass, doubles the heat loss and this in turn decrease the efficiency. So using two cover glasses
is recommended.
From the internship project design, it can be concluding that using solar water heater for air craft hanger washing body
is effective, especially from cost perspective view. Since the main aim of the company is saving expenditure cost, as
a result my design saves total of 547,888birr for the six years.
The company needs to improve its handling of intern students and their understanding about internship because today
interns can be tomorrow employs at the company.
Reference
1. G.D. Rai, 2004, ‘Energy Resources’, 4th Edition, Khanna, New Delhi.
2. JOHN A. DUFFIE & A. BECK MAN, 1980, ‘Solar engineering of thermal processes’, 2 nd edition
3. Internet
4. D.A DAVID and Associates Whitely Bay, 2006, ‘Heat pipe’ 5th edition.
ARORA.DOMKUNDWA” A course in heat and mass transfer”