1. SMART WATER HEATER
TI 10
TEAM TRIPLE SQUAD
HARIHARAN T
ELVIN VARGHESE
ELVIN JACOB SAJI

2. SYNOPSIS
Water heaters or geysers as its popularly called has
become an integral part of our daily life. Its essentially
a drum or tank which is filled with water that is
equipped with a heating mechanism. Due to distinctive
needs and requirements to be met for customer
satisfaction , innovation and new ideas in the field of
water heaters are in dire need.
Smart water heater; as the name itself,provides smart
solutions to overcome the problems faced by most
water heaters. These include providing higher
efficiencies, heating the water at a faster rate,
prevention of corrosion in the storage tank, and finally
meeting customer needs.
Smart water heater provides better solutions to battle
the issues faced by water heaters.

3. LIST OF CONTENTS
SL NO DESCRIPTION
1. PROBLEM STATEMENT
2. ADOPTED SOLUTION
3. FINANCIAL FEASABILITY
4. EVALUATION OF EXISTING TRENDS
5. INNOVATION AND NEW IDEAS
6. RESEARCH AND STRATEGIC INPUTS OF PLAN
7. SUMMARY
ABSTRACT
Water heaters are one of the most commonly used
day to day product. The increased use of wide variety
of water heaters is on the rise in the commercial and
industrial sectors which fuels the demand of the
product. The market is even set to rise due to the

4. Increase in hot water consumption in hospitals and in
hotels and in a variety of manufacturing sectors
including the processing of food and beverages in
chemical industries.
As more and more technological advancements in
water heaters are already available in the market,
there is an absence in providing faster heating and
energy saving water heaters. Also most of the water
heaters takes more time to heat the water, this not
only decreases the efficiency but energy loss is more.
Smart water heaters helps to provide efficient and
power saving heating of water. The usage of whirl flow
technology in storage tank helps to heat the water at
a faster rate and provides maximum efficiency, this
also helps to save a lot of time . It also includes the
usage of nichrome as the heating element which
provides higher resistance and gives more efficiency.
PROBLEM STATEMENT
Most water heaters available In the market has
technological usages like IOT software for monitoring
temperatures. But the key feature missing in most
water heaters is provide better output efficiency. Water

5. heater that are in the market focuses more on
technological features rather than providing efficient
output systems. So innovation in this area is absent.
Also the there is less innovation in the area of heating
element. Most water heaters in the market focus more
on providing heaters of less cost. This may help to
provide cheaper water heaters but quality of the
product gets compromised. Another issue with most
water heaters is the time taken to heat the water.
This is again directly related to efficiency as more
time taken to heat the water means the more usage of
electricity is needed which increases the power
consumption. The demand for water heaters are on
the rise mainly due to the distinctive customer
expectations, this brings in the need to; not only
increases the usage but increases the need to for
innovative water heaters, so as to satisfy customer
needs. So in conclusion the main issues with water
heaters are partially solved by most heaters and this
needs to be solved by providing innovations in the
particular area that not only allows the usage of the
technology but gives a better efficient water heater
that saves power.

6. ADOPTED SOLUTION
In order to save time and to get higher resistance
without compromising the higher efficiency of the
water heater, we have come up with the solution by
using nichrome wire as the heating element
The usage of nichrome as heating element provides
higher resistance compared to other materials that are
commonly used in water heaters. In addition to this,
nichrome does not oxidise and burn easily at high
temperatures. Nichrome has higher melting and boling
points than most metals.
Another issue with water heaters is the time taken to
boil the water, if more time is taken for heating then
electricity needed is more. This can reduce the
efficiency and time taken to heat the water. This
problem of saving time to increase the efficiency of
heater is achieved by the usage of whirl flow
technology.
In smart water heater , we use Whirl flow technology
which helps to avoid direct contact between hot and
cold water flow. This provides faster heating and
provides optimized energy saving. This helps us to get

7. 20% more hot water output giving longer lifespan of
the water heater and saves time.
The smart water heater battles corrosion by employing
Glass line coating in the inner tank. The storage tank in
any water heater is used to store water , so corrosion
is bound to occur. To avoid this we use glass line
coating. In glass line coating the inner surfaces of the
storage tank is coated with a layer of an anti-corrosive
materials which prevents the surface from getting
corroded, even when it is in contact with the hot
water.
The inlet and outlet pipes are coated with Liquid
Enamel Coating for preventing it from corrosion.
The temperature of the water in storage tank is
regulated using a good thermostat.

8. The interface of the heater and mobile software are
shown above.
FINANCIAL FEASABILITY
The expected costs of various components of the
water heater is as follows:
COMPONENTS EXPECTED PRICE (in RS)
NICHROME ALLOY 2870
STORAGE TANK 2000
INLET AND OUTLET PIPE 500
WHIRL FLOW TECH 1000
IOT AND SENSORS 1000

9. COST OF PRODUCTION 800
MISCELLANIOUS COST 500
The total price of the product is estimated to be
around 9000 INR inclusive of the labor and service
costs.
We are planning to sell the product at an MRP of around
10000 INR getting a margin of about 1000INR which can
increased during the bulk production phase.
MARKETING CAMPAIGN
The targeted customers would be people who prefer
less time consuming of energy and faster heating
water heaters.
So in marketing this product we would like to send
sample products to various hotels for customer

10. feedbacks and this can later used to modify the water
heater accordingly to customer needs.
Advertisements of the product can be telecasted in
various channels and social media platforms
This helps in reaching the product to the targeted
customers.
EVALUATION OF EXISTING TRENDS
Most of the water heaters available in the market are
less efficient due to the scarcity of the latest
technologies. The heating elements used in most of
the water heaters are copper , iron etc…; These
materials does not give much efficiency. The existing
water heater takes more power and it is difficult to
monitor the heater from anywhere. So we have design
the existing water heater into a new one with latest
technologies and features.
We designed with latest technology with the help of
IoT and many more features. The features included in
our water heater are
1. Timer and Alarm setting

11. 2. Holds good capacity
3. Good efficiency
4. Controlled with smartphone
5. Stores hot water for 5 to 6 hours without any
fall in temperature.
6. Faster heating and maximum energy saving.
7. Good lifespan
TIMER AND ALARM SETTING
If a person needs to set his/her required time for
heating the water, A timer system in smart water
heater helps to set the timer for the required time.
This is physically available in the heater where the
user can set the required time but the added on
feature as we can set the timer in the users mobile
phone. This is achieved by the usage of IOT software
by connecting the timer interface of the water heater
to the users mobile phone through IOT. When the set
time of the heater is reached an alarm is generated
from the water heater and also from the mobile
phone. This helps in using the heaters according to
the users need which in turn satisfies the user.

12. CAPACITY
The minimum amount of water needed in a household
is approximately 5-10 litres,
The amount of water consumed in most hotels and
restaurants are around 15-20 litres
So we can conclude that the amount of water needed
and consumed is more. Due to this we use storage
type water heaters to hold a good capacity of water.
The smart water has a good capacity of 20 litres
which is enough to satisy the needs of the users. The
inner walls of the storage tank is glass line coated and
also with good insulation . This not only helps to
prevent corrosion.
WHIRL FLOW TECHNOLOGY
The main issue with water heaters is the ability to
conserve power, that is the ability to provide the
required heat but not compromising the efficiency of
the heater. This problem is strategically solved by the
usage of Whirl flow technology. Whirl flow technology
avoid s direct contact between cold and water flow,
the advantage is that the water can now be heated at

13. a faster rate. This helps in saving a lot of energy and
which results in giving 20 % more hot water output,
thereby increasing the efficiency .
LIFE SPAN
Most water heaters loses its efficiency in a short
period of time due to the usage of cheap materials,
this is actually done to decrease the price of the
product, not bearing in mind that the quality of the
product decreases. The usage of nichrome wire as
heating element is a quality material which helps to
provide higher heating of the water and at a faster
rate. Also the usage of whirl flow technology helps to
optimize power saving of the water heater. Both of this
helps in creating an efficient water heater. When
efficiency of a product increases the life of that
product which inturn increasing the life span. This is
how smart water heater provides long lasting heater.

14. INNOVATION AND NEW IDEAS
The innovation used in smart water heater is the
usage of whirl flow technology. We use Whirl flow
technology for better efficiency. The temperature and
timer of the water heater can be controlled by a
smart phone using IOT software, which helps us to
monitor from anywhere. The heating element used here
is Nichrome which provides higher resistance than
other materials that are used for water heaters, also
usage of Nichrome makes the heater more efficient. To
protect the heating element and the inner tank we
use glass line coating. The long term problem of water
heaters is Corrosion of the inlet and outlet pipes, to
prevent this we use liquid enamel coating on the
pipes which provides good resistance and is of less
cost compared to all the other materials used in most
of the water heaters that are available in the market.

15. STRATEGIC INPUT AND OUTPUT OF THE PLAN
Water heaters with tanks can run on solar or
electricity. Mainly we have two types, inlet and outlet
pipes. The inlet pipe brings the cold water in and
outlet pipe delivers the hot water.
There are two types of water heaters: instant water
heater and storage water heater.
Instant water heaters have comparatively tiny storing.
They are called instant because of their small storage
volume and high heating rate. But if we take an
example by considering a person who washes his
clothes with an amount of 5 litres of water. Now if
another person wants to wash his clothes again, he
wants to turn on the heater again so this takes more
power at each and everytime. This makes it inefficient
by consuming more energy.
So we have decided to take storage water heater.
Here we don’t always to heat the water each and
everytime. It stores the hot water for many hours, so
we don’t want to turn on the heater again and again.
This makes it efficient and saves more power as
compared to the instant water heater.

16. As the new technologies and materials are used
in water heaters , we have come up with smart
storage water heater.
EXISTING PRODUCT
Water heaters existing in our day to day life comes
up with many technologies. But some of the
technologies have many features but coming to the
customers needs, they are not much interested. They
want to have the water to get fastly heated and
conserve the energy.
If the customer’s old parents wants hot water they
don’t know how to control or operate the heater. So
it is very difficult for them to use. Customer’s may be
workers so they will be not at home so they could
not help them.
Also the heating elements used does not give much
efficiency. Sometimes it may get overheated. It takes
more time to get the water to be heated. These are
some of the main problems faced by the customers.

17. WORKING PRINCIPLE
The main simplest working principle of water heater is
by converting the electric energy into heat through the
heating element to raise the temperature of the water.
Heating elements like incoloy, copper or stainless are
used in many water heaters.
We have taken nichrome as heating element. It is an
alloy of mixture of nickel and chromium which has
high resistance and gives maximum efficiency. This does
not melt even when a large amount of heat is
produced. It does not undergo oxidation easily even at
high temperature.
HOW DOES THE WATER HEATER WORKS?
Our water heater works with one of the latest
technology which is known as whirl flow technology.
Whirl flow technology avoids direct contact between
cold and hot water flow for faster heating and
optimized energy saving resulting in 20% more
efficiency. The cold water enters through the inlet pipe
and reaches the storage tank. The heater consists of

18. two heating elements which heats the top and bottom
of the water entered using whirl flow technology .
When the water is heated to the required
temperature, the sensor of alarm makes beep sound
which informs the user. Similarly it also notifices the
user with help of a smartphone using IoT. A green
light indicator is used for identifying whether the water
heater starts heating . The user can also control the
heater from anywhere with the help of a smartphone.
The water heater gets automatically turned off when
the water is heated to the required temperature that
is the cut off system.
So we have come up with a 20% of increase in
efficiency. In case of any service or maintenance the
warning signal gets turned on.
CUSTOMER ATTRACTION
Coming to our solution, we have come up with
several features and increasing the efficiency of the
water heater. Customers may be workers so they could
not help their old parents. So for them we have come
up with the help of IoT in which the water heater can
be controlled. It can be operated from anywhere. We
designed this water heater with one of the latest

19. technology called the whirl flow technology. With this
technology, the water gets fastly heated. So we are
saving time and getting more efficiency. The heating
elements used here is nichrome which is an alloy of
nichrome and chromium. This element has high
resistance and high melting point. We have designed
in a shape of a rectangle which looks elegant and
aesthetic.
Also a stylish display with temperature module and a
timer is provided and also a warning indicator is given
for any service or maintenance. The cost also makes it
consumer friendly. This makes our product more
feasible and efficient.
RESEARCH WORK
Usage of Nichrome Wire
Nichrome is the oldest air-stable resistance-heating
alloy. Nichrome wire is made of a non-metallic alloy
that is generally composed of elements namely
Nickel, Manganese, Chromium as well as Iron.

20. The properties of Nichrome helps us to understand
the benefits of using this material. Some properties
of Nichrome are :
 Ductility
Even after long usage, the ductility of Nichrome
remains.
 Higher hot and creep strength
Nichrome alloys have a higher hot and creep
strength when compared to other air-stable
resistance alloys.
 Higher emissivity
Nichrome alloys have a higher emissivity
compared to other air-stable resistance alloys,
when it is fully oxidised. So, at the same surface
load, the element temperature of Nichrome is
lower than that of other alloys.
 Non-magnetic
Nichrome is more non-magnetic when compared
to other air-stable resistance alloys. This makes it
to be the preferred choice over other alloys in
some low-temperature applications.
 Wet corrosion resistance
Nichrome alloys generally have a better corrosion
resistance at room temperature compared to

21. other non-oxidized air-stable resistance alloys
except some atmospheric conditions.
Nichrome is used as a heating element as it will
not burn easily and also it does not oxidise at
higher temperatures. It is because, Nichrome has
higher melting point as well as higher boiling point
than other metals. In the case of water heaters,
there is a chance of melting of heating elements as
there are chances of production of large amount of
heat. But as we use Nichrome wire which is having
higher melting and boiling points, it does not melt
even at higher temperatures.
Usage of Nichrome wire will help in the
development of heat transfer and along with that it
resist the flow of charges too. This is because of it’s
higher resistivity and thus the ability of higher
resistance against heat, corrosion as well as
oxidation.
Applications of Nichrome
Almost all wires that are good conductors can be
used for heating. Most metals conduct electricity
with great efficiency and this requires the metals to

22. be formed into thin wires so that there is enough
resistance to the generation of heat. During the
heating process of most metals, the process of
oxidation takes place quickly and this makes them
brittle and thus it can break when heated in air.
However, in Nichrome wire, there develops an outer
layer of chromium oxide and this can help in making
the wire stable in air thermodynamically. Also, this
helps the heating element from further oxidation. It
is due to it’s properties such as high-temperature
strength and good workability, Nichrome is used as
an ideal material for heating element in electric
appliances such as hair dryers, heat guns, electronic
cigarettes, ironing machines, water heaters, soldering
irons, infrared emitters etc.
These all applications of Nichrome wire are generally
based on the composition of elements present in it.
Based on the percentage of Nickel present, Nichrome
wires are classified into different types. They are :
 Nichrome 20
This alloy has 20 percent Nickel present in it.
This has moderate resistance to oxidation.
Applications include : refractory anchor bolts,
element fastener etc.

23.  Nichrome 30
This alloy has 30 percent of Nickel present in it.
This alloy is used for heating cables and rope
heaters in defrosting and de-icing elements,
resistors, floor heaters, electric blankets and
pads, baseboard heaters, car seats etc.
Applications include : heavy duty rheostats, open
coil heaters in HVAC systems, night-storage
heaters, solid hot plates, convection heaters, fan
heaters etc.
 Nichrome 40
This alloy has 40 percent of Nickel present in it.
Applications include : Night-storage heaters,
convection heaters, heavy duty rheostats, fan
heaters, heating cables, car seats, baseboard
heaters and floor heaters, resistors etc.
 Nichrome 60
This alloy has 60 percent of Nickel present in it.
It is ideal for use as heating elements in
household utilities and in moderate heat, high
humidity environments.

24. Applications include : metal sheathed tubular
elements used in, utensils like hot plates, grills,
toaster ovens and storage heaters. The alloy is
also used for suspended coils in air heaters in
clothes dryers, fan heaters, hand dryers etc.
 Nichrome 70
This alloy has 70 percent of Nickel present in it.
It is great for reducing atmospheres.
Applications : this type of Nichrome wire is used
in electrical heating elements in industrial
furnaces.
 Nichrome 80
This alloy has 80 percent of Nichrome present in
it. It has very good form stability. It has
excellent adhesion properties and due to that it
offers superior service life when compared to
other Nichrome wire types. It is commonly used
industrial furnaces and heating elements in home
appliances.
Applications include : water heaters, flat irons,
ironing machines, plastic moulding dies, soldering
irons, metal sheathed tubular elements etc.

25. Among these types of Nichrome wires, it is
desired to choose Nichrome 60 for the heating
element application. It is because, Nichrome 60
has superior coefficient of electric resistance than
any other types of Nichrome wires. It offers
great oxidation resistance as well as prolong
service life. It is an ideal resistance heating
material. It can operate upto a temperature of
about 1150 degree celcius. Nichrome 60 has
higher tensile strength and higher melting point
than other types. Also, Nichrome 60 is more
easily available as well as less expensive when
compared to other better types. So, from a user
as well as manufacturer point of view, usage of
Nichrome 60 for the heating element would be
the best choice as it provides better properties
and is easily available as well as less expensive
too.
Whirl flow technology
Whirl flow technology avoids direct contact
between hot and cold water flow and thereby

26. helps in faster heating and optimized energy
saving. It is a heat technology which is based on
performance. By using this technology, 20
percent more hot water output can be obtained.
SUMMARY
In this document we have included the problem
statement of existing water heaters and provided
solutions to solve the issues. The main problem
concerning water heaters is to provide better
efficiency by heating the water at a faster rate. This
issue is solved by implementing whirl flow technology
and the usage of nichrome wire.
Considering the market feasibility of the product, we
are ready to launch the water heater at RS9500. We
are targeting customers of look for long lasting,
efficient and quality water heaters.
We have concluded the part in providing innovative
solutions.
THANK YOU