Design of Hot Air Balloon System: Defence Institute of Advanced Technology, Pune

DEFENCE INSTITUTE OF ADVANCED TECHNOLOGY,PUNE
Design of Hot Air Balloon System

Report

Hot Air Balloon System 2013

Page | 2

INDEX

1. Introduction 3
2. Life Cycle Model 4
3. Structure of Hot Air Balloon System 5-10
3.1 The Envelope 5
3.2 The Basket 7
3.3 The Burner/Heating System 8
3.4 Fuel Tanks 8
3.5 Other Ballooning Gear 9
4. Assumptions 11
5. Necessary Calculations 12-17
5.1 Volume and Surface Area of Envelope 12
5.2 Lift of Balloon 13
5.3 Fuel and Energy Requirements 15
6. Materials Required 18-21
7. Instruments Required 22-24
8. Cost Analysis 25-27
9. References 28


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1. INTRODUCTION
Hot air balloons are an ingenious application of basic scientific principles. The basis of
how the balloon works is that warmer air rises in cooler air. This is because hot air is
lighter than cool air as it has less mass per unit of volume. Mass can be defined by the
measure of how much matter something contains. The actual balloon (called an envelope)
has to be so large that it takes such a large amount of heated air to lift it off the
ground. To help keep the balloon in the air and rising, hot air needs to be propelled
upwards into the envelope using the burner.
The following optimum requirements should be taken care of:
1. How the balloon works, what makes it rise and fall and how a pilot is able to
maneuver it when it is in the air?
2. Design and construct of a hot air balloon system.
3. The balloon has to carry one person.
4. The fuel supply to provide flight duration of one hour.
5. The unit capable of flying at the 6000ft.
6. The size, weight and cost of the balloon assembly should be optimal.


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2. LIFE CYCLE MODEL

Requirement
specification
Design
Supporting
Calculations
Implementation
Verification
Maintenance

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3. STRUCTURE OF HOT AIR BALLOON SYSTEM

A hot air balloon is an exclusive flight craft that functions as a result of hot air rising.
There are two major kinds of hot air balloons that were created in the 18th century and
continue to be utilised now days.
The most popular kind is known as Montgolfier and it utilises fire to warm the internal
air to increase lift. The second kind is a cross balloon that utilises hot air in an identical
manner, although it has a section of helium or hydrogen gas in the top. A further type is
an unadulterated gas balloon that does not make use of warm air plus its height is just
capable of being managed by releasing bulk or expelling the gas.
The part of the aircraft that looks like a balloon is actually called an envelope. Some
pilots also affectionately refer to it as "the bag." It is connected to the gondola, or basket,
in which pilot and passengers ride, by means of stainless steel suspension cables.
Balloons are categorized by the Federation Aeronautique Internationale (FAI), according
to how much air their envelopes can contain.


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3.1 The Envelope
The part of the aircraft that looks like a balloon is actually called an envelope. Some
pilots also affectionately refer to it as "the bag." It is connected to the gondola, or basket,
in which pilot and passengers ride, by means of stainless steel suspension cables.
The fabric is woven in panels, two panels making up what is a gore. The gores are held
together by stitching and by heavy duty load tapes, webbing similar to the material used
in seat belts in automobiles, which help support the weight of the balloon and minimize
strain on the fabric, thus prolonging the useful life of the vessel.
The envelope is usually treated with a polyurethane coating to reduce porosity, and in the
coating is an ultraviolet inhibitor to help the fabric withstand the rays of the sun.
The top cap or crown of the balloon may be designed in one of two ways. The standard
top features a circular deflation port that is closed off by a circular panel, which is held
sealed during flight by a flexible hook and-loop closure.
A deflation port line, usually called the rip line and colored red, extends from the top to
the basket and is pulled by the pilot upon landing to effect an instantaneous deflation of
the envelope. Pull on the line, and the hook-and-loop closure comes open, and the hot air
rushes out.
The parachute top also features an opening in the crown, along with a similar circular
panel to fill the opening. In this case, the panel is rigged up with lines, as the name
suggests, exactly like a parachute. It is used both for effecting a complete deflation of the
envelope after landing, and also during flight to vent a limited amount of hot air as a
means for controlling vertical ascent or descent.
After landing, the pilot pulls on the top line of the parachute top and holds it open for as
long as he can until the envelope has been deflated.
Balloons built with the standard deflation port also feature an opening in the side known
as the maneuvering vent, also initially sealed, like the deflation port by hook-and-loop
closure. This vent is operated by a rope called the maneuvering vent line, which extends
from the vent to the basket. The pilot pulls the line, causing the side vent to open and
allowing the hot air to escape to stop a rate of ascent or initiate a rate of descent. Once the
line is released, the vent automatically recloses.
A skirt is connected to the bottom section of the envelope with peelable tabs and helps
create a stovepipe effect when the burner system is running, channelling the warm air into
the balloon and improving fuel efficiency, especially on windy days, by protecting the
burner from the wind.
Attached to the inside of the balloon envelope, near the top or crown, are temperature
indicators known as telltales. These telltales are white when installed but turn black if the

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air in the envelope exceeds a certain temperature. This permits the pilot to tell at a glance
when his balloon may need repair.
Crown Line: A handling line some 100 feet long attached to the apex or crown of the
balloon. It is used to steady the balloon during inflation and deflation.
Load Tapes: Horizontal and vertical tapes incorporated in the structure of the envelope
used to bear loads and provide a place for attaching the balloon fabric.
Deflation Port: The rip panel or section of the envelope that separates from it to allow
hot air to escape quickly.
Mouth: The opening at the base of a hot air balloon.
Skirt: An optional extension of the envelope usually made of flame resistant material. Its
purpose is to help channel hot air in to the mouth of the balloon.
3.2 The Basket
The basket is the bottom part of the balloon which carries the passengers, pilot and
propane gas cylinders. Baskets come in a variety of different shapes and sizes.
There are two main types of basket, Open and T-partition. The difference is fairly self
explanatory here, open is obviously an open space where the passengers, pilot and fuel
are all housed in the basket in just 1 compartment and T-partition is where the basket is
split into sections so the passengers can be separated from the pilot and canisters. The T-
partitions main advantages over the open are that it is fact a stronger structure due to the
extra struts and also that the balloon remains more balanced overall as weight can be
spread evenly over each compartment.
The desirable attributes/characteristics for basket are as follows:
a) Should be as light as possible.
b) Should be sturdy, strong, durable and reliable.
c) Adequate tensile strength.
d) Should be shock and impact resistant.
e) Should be flexible to endure the landing load.

Capacity: Only one person

Type: Since the design is to accommodate only the pilot, it is recommended to use the
open type, where the passenger and fuel container assembly can be accommodated.
Material: An Aluminium skeleton is recommended to provide sturdiness to the basket.

In addition it serves the following:
1. It supports the burner system, which is installed overhead at the top of the basket.
2. Provides stability and reduces the tendency to tip over during landing
3. It supports the burner which is installed overhead at the top of the basket

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3.3 The Burner System
The Burner is the engine of the hot air balloon. It is what propels the hot air up into the
envelope to make the balloon rise. There are many different types of burner available -
single, double, up to quad systems, depending on the size of the balloon flying.
Modern hot air balloons use propane in the burner to heat the air. The propane is highly
compressed in the cylinders and flows to the burner in a liquid form. When the pilot starts
the burner up, the propane flows to it and is ignited by a pilot light. As the flame burns, it
heats up the metal in the surrounding tubing and when the tubing becomes hot it heats the
propane flowing through it.
The most popular burner is the double burner which is made up of 2 burner coils. A
balloon can be powered by just a single burner; it all depends on the size of the envelope.
On smaller balloons, with 1 or 2 passengers, a single system will normally suffice.
The burner unit gasifies liquid propane mixes it with air, ignites the mixture, and directs
the flame and exhaust into the mouth of the envelope. Burners vary in power output; each
will generally produce 2 to 3 MW of heat with double, triple, or quadruple burner
configurations installed where more power is needed. The pilot actuates a burner by
opening a propane valve, known as a blast valve. The valve may be spring-loaded so that
it closes automatically, or it may stay open until closed by the pilot. The burner has a pilot
light to ignite the propane and air mixture. The pilot light may be lit by the pilot with an
external device, such as a flint striker or a lighter, or with a built-in piezoelectric spark.
Where more than one burner is present, the pilot can use one or more at a time depending
on the desired heat output. Each burner is characterized by a metal coil of propane tubing
the flame shoots through to preheat the incoming liquid propane. The burner unit may be
suspended from the mouth of the envelope, or supported rigidly over the basket. The
burner unit may be mounted on a gimbal to enable the pilot to aim the flame and avoid
overheating the envelope fabric. A burner may have a secondary propane valve that
releases propane more slowly and thereby generates a different sound. This is called
a whisper burner and is used for flight over livestock to lessen the chance of spooking
them. It also generates a more yellow flame and is used for night glows because it lights
up the inside of the envelope better than the primary valve.

3.4 Fuel Tanks
Propane fuel tanks are usually cylindrical pressure vessels made from aluminium,
stainless steel, or titanium with a valve at one end to feed the burner and to refuel. They
may have a fuel gauge and a pressure gauge. Common tank sizes are 10 (38), 15 (57), and
20 (76) US gallons (litres).They may be intended for upright or horizontal use, and may
be mounted inside or outside the basket.
The pressure necessary to force the fuel through the line to the burner may be supplied by
the vapor pressure of the propane itself, if warm enough, or by the introduction of an inert

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gas such as nitrogen. Tanks may be preheated with electrical heat tapes to produce
sufficient vapor pressure for cold weather flying. Warmed tanks will usually also be
wrapped in an insulating blanket to preserve heat during the setup and flight.
Navigation
Balloons cannot be steered in the normal sense of the word so they travel in the direction
of the wind, which varies at different altitudes. Pilots skillfully use this as a way of
changing direction by burning to go up, or allowing the air to cool to go down, and catch
different airstreams at different heights.

3.5 Other Ballooning Gear
There are other items of equipment that pilots need and sometimes use frequently. Some
of these are required (by the FAA), some recommended, and some optional in the same
sense that mud flaps and FM radios are optional on new cars.
Required Equipment
Altimeter: This tells you how high you are above the ground, normally giving readings in
feet above sea level, and can be adjusted to the local ground elevation where the ascent is
taking place.

Variometer: This is basically a rate of-climb meter and lets you know first of all if you
are moving up or down. That may sound ridiculous, but at altitudes of 1,000 feet or more,
where visual references are few and far between, it is often quite difficult to judge such
basic facts of life as whether you are on the way up, or on the way down. The variometer
also measures the vertical speed of the balloon in feet per minute or second.

Pyrometer: An electrical sensor installed near the top or crown of the envelope sends
information to this meter in the basket. It tells the temperature of the air in that area. As
with RPM's in an automobile, there is a "red line" not to exceed in terms of envelope
temperature, beyond which you risk damaging fabric strength. The pyrometer helps you
monitor this important factor.

Fuel gauge: This shows how much propane is left in the tanks on board, and because fuel
supply is important to a safe and sane balloon flight, such gauges should be as reliable
and visible as possible.

Sparker: This gadget comes in handy for quickly reigniting a pilot light that has
inadvertently gone out. Most pilots carry two sparkers-plus a cigarette lighter and a pack
of dry matches, to be on the safe side Sparkers are also used by welders and by campers
for starting up Coleman lanterns, so they are readily available.


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Headgear: Protective hats or helmets are vital safeguards in the event of a fast or bouncy
landing. As with lifeboats on a ship, there should be enough on board for all occupants.

Recommended Equipment
Fire Extinguisher: It should be of the type useful in combating propane fueled fires, and
carried not only in the chase vehicle but on board balloon. The 2A10BC is the type often
recommended.

First Aid Kit: It should include silver compound medication for burns and, like the fire
extinguisher, be carried both on board and in the chase vehicle.

Balloon Log Book: The pilot records the date, place, and other pertinent details of every
one of his flights in the given balloon.
Optional Equipment
Electric Blast Valve: This is a push-button valve control that can be operated from
anywhere in the basket.

Electronic Ignition: Similar to above, this operates off a battery and keeps the pilot light
going.

Compass: Until recently, FAA regulations required balloonists to carry a magnetic
compass on board, but this device plays no practical role, at least not on short flights. On
long flights in unfamiliar country, it does give you an idea of the exact direction in which
you are gradually getting lost.

Communication System: On short flights there is no particular need to be in touch with
Houston Control. Aviation radios and transponders are useful on board for long flights at
high altitudes, and radios are required to be carried if you are flying through any airport
traffic control zone.


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4. ASSUMPTIONS

a. Hot Air Balloon is used for designing the system.
b. Height at which balloon can reach is 6000ft.
c. Fuel used is propane for lifting the balloon.
d. Only one person can be accommodated in the balloon.
e. Flight duration of balloon is nearly one hour.
f. Optimal cost for material and equipment is considered.
g. Ground temperature is taken as 10
o
C(drastic conditions).
h. Burner to be used is MK21 single burner system.


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5. NECESSARY CALULATIONS

5.1 Volume and Surface Area of envelope

Vulume (V) = n -
h
12
(D
2
+d
2
+Dd)
Slant Length (s) = (R -r)
2
+h
2

SurIae Area (SA) =
n
4
(2s(d +D) +d
2
+D
2
)

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5.2 Lift of the balloon

FORMULAS TO BE USED

The formula for calculating lift is:

The formula for calculating Pressure at a particular altitude is:
P
h
= P
0
*e
(-h/a )
Where,
h= Altitude (m)
P
h
= Atmospheric pressure at altitude h (Mbar)
P
0
= Atmospheric pressure on the ground (Mbar)
Section
No.
Height
(in
meters)
D D Volume V
(in m
3
)
Slant
length s
(in
meters)
Surface
Area SA
(inm
2
)
S1 1.5 3.8m 4.3m 19.36 1.52 45.17
S2 6 4.3m 13.0m 382.37 7.41 348.44
S3 1.5 13.0m 13.5m 207.00 1.52 360.63
S4 1.5 13.5m 14.0m 223.93 1.52 362.55
S5 1.5 13.4m 14.0m 221.32 1.53 360.63
S6 1.5 11.4m 13.4m 181.67 1.80 313.05
S7 1.5 5.0m 11.4m 83.30 3.53 212.53
Total 15 1320 1981

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a = Scale height of the atmosphere= 7400 m

Formula for calculating Temperature at a particular altitude is:
T
h
= T
0
h/166.67 (for every 1000m ascent temperature drops by 6
o
C-source
NASA)
Where,
H = Altitude (m)
T
h
= Temperature at altitude h (K)
T
0
= Temperature on ground (K)

Lift calculations
Volume of balloon (V) = 1350m
3

Weight Schedule

Weight of balloon (with cords) 65 Kg

Basket and Burner 60 Kg

Weight of Fuel Tank (Filled) 90 Kg

Weight of Pilot 100 Kg
Misc weight 50 Kg
GROSS WEIGHT 365 Kg

Max altitude, h = 6000ft or 1829 m

Air Pressure at ground level, P
0
=1013.25 Mbar
Temperature at ground level, T
0
=10
o
C or 283 K

Envelope Temperature, T
env

=100
o
C or 373 K

Pressure at altitude h, P
h
=P
0
*e
(-h/a )

=1013.25*e
(-1829/7400)

P
h

=791 Mb

Temperature at altitude h, T
h
= T
0
h/166.67
= 283-1829/166.67

T
h

= 272 K

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Lift at ground level,L
0
= P
0
* V/2.87 * (1/T
o
1/T
env
)

= 1013.25 * 1350/2.87 * (1/283 -1/373)
= 406.36 Kg

Lift at altitude h (6000 ft), L
h
= P
h
* V/2.87 * (1/T
h
1/T
env
)
= 791 * 1350/2.87 * (1/272 1/373)
= 370.40 Kg
The lift at ground level and at an altitude of 6000 ft is 406.36 Kg and 370.40 Kg
respectively.
Since both lift values are more than the gross weight of the balloon will be able to fly.

5.3 Fuel and Energy requirements

Air to be heated to 100
o
c or373 K,
Ambient air 10
o
or 283 k,
V, Volume of air to be heated=1350 m
3

D, Density of air at earth surface=1.2 Kg/m
3

Mass of the air to be heated =Density*Volume
=1.2*1350
=1620 Kg
C,Specific heat of air=1.00 KJ/Kg.K
Formula used for calculating energy
E=m*c*T
=1620*1*(100-10) KJ
=145800KJ
Now,
Calorific value of propane = 46350 KJ/Kg
Mass of propane required = 145800 / 46350 = 3.14 Kg
Thus the amount of fuel required to raise the temperature of air balloon to 100
0
c is
3.14 Kg.

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Now,
By Newtons law of cooling dq/dt =h*A*dt
Where, h = heat transfer coefficient (25 W/m
2
k),
A = Area of the skirt (45.1 m
2
) ,
dt = Temperature of flame Ambient temperature
= 1920
o
C -10
o
C = 1910
o
C
Therefore,
dq/dt = 2153525 J/Sec
Time required to heat air from 10
o
C to 100
o
C is = E/(dq/dt)
=145800*1000 / 2153525
=67.70sec
(This is starting time of balloon)
Now if we consider the proper operation of the balloon then the temperature inside the
balloon should be always greater than 90
0
C.
We need to calculate the time required dropping of the temperature from 100
0
C to
90
o
C due to heat dissipation.
Formula used, Heat dissipation = m*c
p
*dt
m = 1620 Kg
c
p
= 1 KJ/Kg
dt = 10
o
C
Heat dissipated = 16200000 J
Time required to raise the heat from 90
o
C to 100
o
C is = Heat dissipated/(dq/dt)
=7.52 sec
Now heat transfer from the material dq/dt = A*h*dt
A = surface area of balloon (1981.34 m
2
)
h = .25W/m
2
k
dt = 90
0
C
dq/dt = 44580.15

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Time required = heat dissipated/(dq/dt)
=363.39 Sec
From the above calculations we conclude that time required for blowing the burner
again is 181.69 Sec just half the time required for raising the temperature from 90
o
C
to 100
o
C.
Therefore, one cycle of burner will be at (181.69+60) = 241.69Sec
241.69 Sec was the time where the burner is on for 60Sec and off for 181.69Sec.
Now for this 60Sec in which burner was on the fuel required is. = (Energy required to
raise temperature from 90
o
C to 100
o
C)/(calorific value of fuel)
=16200000/46350*1000
=0.349514Kg
For the flight for 1 hour of travelling the fuel required = fuel required for starting +
fuel required for total time travelling.
For starting fuel required = 3.14 Kg
For 1 hour of travelling we required = (1*60*60)/241.69
=14.895 = 15 cycles approximately
For one cycle we need a fuel of = 0.349514 Kg
Therefore for 15 cycles we need = 5.242 Kg
So the total fuel required = (5.242+3.14)
=8.382 Kg
Now as we consider the efficiency of the engine to be 30% fuel required will be 27.94
Kg ~30 Kg
As the weight of the fuel cylinder consider to be 15 kg,
Then the total weight of the fuel and cylinder is 45Kg is required.


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6. MATERIALS REQUIRED
Comparison of various polymer fibres w.r.t conventional nylon and polyester for hot air
Properties Acrylic
Coated
Ripstop
Nylon fabric
(used for hot
gas)
.35mil
Mylar film
laminated
to ripstop
nylon(used
for hot
gas)
FEP Fabric
for both hot
air and light
gas
Poly(p-
phenylene
benzobisoxa
zole)[PBO]
Zylon
AS(avg.
strength)
Aramid
fibre(Kevlar)
m-aramid fibre
i.e NOMEX
Poly Ether ether Ketone
(PEEK)
Density
(gm/cub. Cm)
~1 ~1 2.15 1.54 1.38 1.320
Tensile
Strength(kg/s
q. mm)
~900 ~1500 ~130 590 1020
Elongation at
break(%)
~20 ~20 ~300 3.5 2.4 50
Gas
permeability(
std
cc.cm/atm*se
c
Unavail Unavail.
But equal
to mylar
CO2=1.7*10
exp-10
N2=1.7*10e
xp-10
H2=1.2*10e
xp-10
unavailable unavailable CO2=4.86*10exp-3
N2=1.736*10exp-4
H2=1.6*10exp-2
Radiation abs.
Characteristic
s
Unavailable Unavailabl
e
But have
absorption
characteris
tics equal
to mylar
plus nylon
Transmits
more UV
visible
radiation
than window
glass,no
absorption
bands in
regions of
maxm solar
radiation
High and
affected
80 % retained at
uv radiation
6.04x10
-2
W/sq.
in
Not affected
Temp Range
in which
material
remain
useful(Maxm
&Min.)
>120
<-80
>120
<-80
~220
~-250
650 400-550 140
Chemical
Effects
exposure to
ozone
Unaival. unavail Does not
appear to
weather on
exposure in
open upto 5
years
Not affected
mostly
Stable against
wide range
chemical
attacks
Unaffected
Effect of
water vapour
Unavailable Slight-
none
Unaffected Strength
decreases on
absorption
little 0.150% in 24 hrs and not
affected

Page | 19

UV radiation
effect
Slight Slight Unaffected
after high
intensity
exposure to
uv for 6100
hrs at >55
deg C
Effects unaffacted Unaffected
Ionizing
Radiation
e
unavailable Unavailable
but affects
greatly
Unavailable Unavailable
Storage Unavailable Unavailabl
e
unavailable unavailable Unavailable Unavailable
Abrassion
Resistance
e
Tear
strength 125
gm pull for
tear in 1 mil
thick sheet
excellent high High
Thickness
Range for
balloon use
~0.008 cm
used to date
~0.008c m
used to
date
~0.001cm N/A N/A N/A
Manufacturin
g Problems
Sealed by
sewing
fabrics to the
seals with
50% tensile
strength to
that of fabric
Sealed by
sewing
fabrics to
the seals
with 50%
tensile
strength to
that of
fabric
Type A
cannot be
adhesive
bonded but
can be heat
bonded
Type B can
be adhesive
bonded
N/A N/A N/A
Remarks Appears
useful for
hot air apps
needs more
tests vs uv
and ozone
Appears
useful but
heavier
than
acrylic
coated
nylon and
may
deteriorate
at uv
exposure
and ozone
need more
tests
Potentially
excellent for
equal
pressure and
hot air
balloons;fre
e of pin
holes,good
radiative
characteristi
cs,good for
future study
High tensile
strength and
flame
resistance
than other
fibres but
not UV and
water restant
as on
absorption
to moisture
it becomes
heavy and
uv makes it
week
-Excellent
flame resistance
and
thermalprotecti
on
-Stands up to
flametemperatu
res in excess of
2,000F
-Fibers do not
melt or drip
-Outstanding
resistance to
degradation by
radiation&cryo
genic
conditions
,chemicals and
industrial
solvents
And insects and
High price

Page | 20

fungi.
-Low stiffness
of fiber due to
chemical
bonding
arrangement
-High
elongation
-Cut resistant
-Abrasion
resistant
Thermal
conductivity
1-10 3-5.8 unavailable 0.25 W/m*k

Discarded polymers for hot air apps due to above properties are- polyethylene, Poly ethylene
terephthalate( due to softening at 150 deg C)
Conclusion- On Overall property the most advantageous is Type B(sealant and adhesive
bonded) Fluorinated ethylene propylene polymer for fabric design excluding skirt . For
equator region PEEK polymer (with highest tensile strength) strip is required for extra
tensile strength as it is the zone of maximum tensile stress due to expansion. Bonding
between FEP polymer and PEEK can be easily done by acrylic bonding agent.
Material Selection of Air Sealant
Acrylic resin as air sealent with ZnO nano particles embedded 1-2%wt/wt. is obvious choice.
Description-
The advantages of acrylic resins are:
Better stain protection (washability)
Water resistance
Better adhesion
Better blocking ('strap down')
Resist cracking and blistering better
Resistance to alkali cleaners
UV Resistant
Choice of Resin
B/w Acrylic resin, Epoxy Resin and Polyester resin
Description-
Acrylic resin (but not acrylic emulsion, which is the basis of acrylic paint) is a thermoplastic,
which means it is one of a group of plastics which can be heated and manipulated repeatedly,

Page | 21

whereas polyester resin and epoxy are thermosetting plastics, which use heat or a catalyst to
solidify into a solid mass that wont melt down. Acrylic is mixed from acrylic polymer, a dry
powder, a methyl methacrylate monomer, a thin liquid, and usually an organic peroxide
hardener of some sort. If pieces of any size are contemplated, an autoclave or hydraulic press
is necessary for reducing air-bubbles and counteracting the internal stresses created by the
strongly exothermic reaction. The dust is toxic, as is the monomer and its vapors. And the
organic peroxides are especially poisonous, some of them being explosive and others causing
instant blindness if they get in eyes.
Polyester resin, a syrupy clear liquid, is mixed with a small but variable amount of a strong
catalyst, which causes the curing mass to heat up (and to craze if youve added too much.) It
is versatile stuff, being useful for coating, casting, and building up composites, usually in
conjunction with fiberglass cloth. It is not as hard or as clear as acrylic, having a somewhat
yellowish tinge to it. And itand especially the catalystis also highly toxic, and is
persistently evil-smelling as well.
Epoxy resin works similarly, doesnt smell as bad, but itand the hardener that makes it
setis a sensitizer, meaning that you can get a nasty allergic reaction after repeated
exposure. Some hardeners are not as bad as others in this respect. Epoxy wont set water-
clear like acrylic, and doesnt resist sunlight (UV) degradation as well, but works better
with high-tech cloths, like Kevlar and graphite.
Silicone coating- for inside top surface for thermal resistance
Material Selection for Wires and Seams around the envelope.-NOMEX fibre is best
opted due to high tensile strength and weather stability.
Material Selection for Basket Frame upto balloon skirt Duplex Steel. For framing and
wiring because of both light, strong and weather resistant.


Page | 22

7. INSTRUMENTS REQUIRED

This report is based on DGCA Regulation 11-690/93-AI(2) for Requirements for
manufacture, registration, and airworthiness control of hot air balloons.
In above mention regulations point 15 (Instruments & Equipment to be carried by
Balloons in flight) DGCA has made following minimum requirement for Onboard
Instruments:-

(1) An altimeter

(2) A rate of climb indicator.

(3) An envelope temperature indicator.

(4) Two way R/T Communication Equipment.

Apart from above Many times it is helpful to have whether forecaster with flyer so
that in case of unfortunate change in whether one can get back to earth Station within
Time Limit

Based on above regulation following Instruments are recommended for our Hot Air Balloon
Name/Model Meter/Indication Need Technical Specs Remark
Flytec 3040

Altimeter Displays the
altitude of the
balloon.

Managing the
altitude is
important for
many reasons
including air
traffic control,
obeying
regulations, and
avoiding ground-
based
obstructions.
Absolute altitude up to 26,000
ft (8,100m).
Zero adjustment within
weather dependent tolerance
28.00 - 31.30 inHg
(950 - 1,060 hPa)
Barometric air pressure
correction in inHg or hPa.
Remote envelope
temperature sensing

Real-time clock and stop
watch

Accurate, rugged and reliable
Light, compact, aerodynamic
and ergonomic

Descent alarm

Two temperature alarms

Weight: 350 grams

Size: 6-5/8" x 3-1/2" x 2"
(170 x 90 x 50 mm)

Two independent 9v
(primary and backup) user
replaceable

RF shielding

Stainless steel clip and elastic
Velcro strap for rapid and
easy attachment to uprig

Real-time display in 24 hour
format
Stopwatch with start-stop-
lap-reset function

Price $1750
Approx 1.00 Lacks

Variometer
Indicates the
speed at which the
balloon is
climbing or
descending
Analog display - 2000 ft/min
(10 m/s), resolution: 40 ft/min
(20 cm/s)
Digital display: 2000 ft/min
(10 m/s), resolution: 20 ft/min
(10 cm/s)
Descent tone (pitch decreases
with rate of descent
Temperature The temperature
of the air inside
the balloon is
controlled to
avoid over
temping the
balloon which can
damage the fabric
and reduce the life
of the balloon.
Digitally coded receiver and
transmitter to eliminate
interference and
erroneous readings
Automatic and manual
recognition of transmission
code for TT34
Envelope 68F to 311F
(20C to 155C)
Ambient -22F to 158F (-
30C to 70C)
Max continuous alarm

Page | 23

Never Exceed alarm

Mapmyindia Lx140ws

GPS receiver

To assist in
navigation.

Intuitive Touch Screen With
Multiple Navigation Options

Built-in GPS for powerful
navigation
Lightweight

10.9cm navigation device
with all India maps on In-
built 2GB Flash memory

Dimension :
118*82*12.5mm

Net weight :
124 g

Battery: 950mAH
rechargeable lithium battery
rechargeable li-polymer

Price 10000 INR

Avionics IC-A24 / IC-A6
VHF Air Band Transceiver

Communication
Equipment
Used to
communicate with
air traffic control
and other aircraft.

Freq
Tx

Rx

Weather
A24
118.000-136.975
MHz
108.000-136.975
MHz
161.650-163.275
MHz

Mode
WX
AM (6K00A3E)
FM (16K0G3E)
Channel
spacing
25 kHz
Frequency
stability
5
ppm
Transmitter
Output
power(at7.2
V DC)
5.0 W typ. (PEP)
1.5 W typ. (CW)
Modulation
system
Low level
modulation
Modulation
limiting
70-100%
AF
harmonic
distortion
Less than
10% (at 60% mod
Hum and
noise ratio
More than 35 dB

One-handed operation

stores the last 10 channels
used

ANL (Auto Noise Limiter)
for noise reduction

Low battery alert

7.4/7.2V DC (Battery pack)

54(W) x 129.3(H) x 35.5(D)
mm;

430 g

Windwatch Pro

Weather Meter

Used To pre
Barometer: 6.49 inHg to
37.80 inHg

Thermometer: -11.2F to
140F (-24C to 60C)
Resolution: 0.1F, 0.1C
Accuracy for temperature:
1.5C
Wind speed: 2 mph to 89

Weight: 2.3 oz, 67 g

Size: 4.68x2.28x0.75in
(11.9x5.8x1.9cm)

Price:- 11000.00 INR

Page | 24

mph, 3km/h to 144km/h,
Accuracy for wind speed:4%

Hygrometer: 1% RH to
100%RH, Resolution: 1% RH

Dew point: -60 C to 60 C (-
76 F to 140F) Resolution:
0.1 F (0.1 C)

We can also add Li ion batteries and lights but at present these are not allowed . but if we want to add
them then following are details-
Li ion Battery - 2 nos 12 V each , CFL - 2 nos 11 V each ,Wires and connectors.
Total weight of these will be 25 Kgs. And cost around 20000 Rs.
To reduce this weight we can provide separate torches for each person. We can add motors for
balloon direction control. It will add a cost of around 10,000 and additional weight of 5 Kgs.


Page | 25

8. COST ANALYSIS

Duplex Stainless Steel(DSS) Basket for Hot Air Balloon

0.61m

2m

150cm

150cm

Diameter of burner sitting =75cm
Circumference =pi*75*10
-2

=2.356m

Total length of steel frame used in basket = 4*0.610+2*22.1213+12*1.5+2.356m
=27.038m

Volume, V =27.038*pi/4(2.54-0.77)
2
*10
-4
*7.8*1000
=51.89Kg

Envelope Fibre Calculation
1. Selected fibre = Florinated Ethylene Propylene copolymer film [FP 341.25]
2. Density = 2.15g/cm
3
= 2150 Kg/m
3

3. Surface Area of Envelope = 1936.17m
2

4. As per model No. FP341.25 choosen size = 300 * 300 mm
2
= 300 * 300 * 10
-6
m
2

75 cm

Page | 26

Cost for 5 pieces = Rs 1230.00
5. No of Size films required for covering whole envelope = 1936.17/(300 * 300 * 10
-6
)
= 21513 films/pieces
Cost = (123/5)*21513 = Rs 5.29219*10
5
= Rs 5.3 lacs
6. Weight calculations :
Thickness (t)= 0.015mn = 1.5*10
-5
m
Area = 300*300*10
-6
m
2
Density = 2150 Kg/m
3
Total Weight = 21513*300*300*10
-6
*2150*1.5*10
-5
= 62.44 Kg

Skirt Fibre Calculation
1. Material choosen : Polyaramid film (polymetaphenylene isophthalamide)
AR311050
2. Size of sheet = 300*300mm
2
= 300*300*10
-6
m
2

3. Price for 20 sheets = Rs 219
4. Thickness = 0.05mm
5. Density = 1.35g/cm
3

6. Surface area of skirt = 45.17m
2

Therefore number of film sheets applicable = 45.17/(300*300*10
-6
) = 501.88
7. Weight calculation = 501.88*1.35*10
3
*300*300*10
-6
*5*10
-5
= 3.048 Kg
8. Total cost of skirt = 291/(20)*501.88 = Rs 5495.50

Wiring of envelope for strengthening
1. Material chosen = polyaramid fibre (polyparaphenylene terephthalamide) [AR
3.5762]
2. Cord diameter = 3*10
-3
mm
3. Total length = 18.83m + 18.83m + 5m = 42.66m
4. Density = 1.35*10
3
Kg/m
3

5. Breaking load = 72 Kg
6. Available length as per product dupont [AR3.5762] is 50m
7. Cost for 50m length is Rs 231

8. Total weight = Volume*Density
Pi * (1.5)
2
* 45 * 10
-6
* 1.35 *10
3
= 0.4194 Kg
9. For 12 such cords the total weight will be = 0.4294 * 12 = 5.152 Kg
10. Price for 12 cords = 231 * 12 = Rs 2772

Page | 27

Basket Frame Material Calculation

Aalco Steel Selection of Tube Dimensions
Outer diameter = 25.4mm
Thickness = 0.5cm

Properties Density Thermal
expansion
Modulus
of
elasticity
Thermal
conductivity
Proof
stress
Tensile
strength
elongation Hardness
(brinell)
Aalco Steel [2250] 7.85g/cm
3
13.7 * 10
-
6
m/K
200GPa 19.0w/m.k 450Min
MPa
620
Min
MPa
25% 290 Max HB

Cost for Hot Air Balloon

1. Envelope =Rs 5,30,000
2. Basket(steel rods, nomex flooring, bamboo fencing, etc)=Rs 2,11,400
3. Chords and tapes(nomex) =Rs 2,772(12 nos)
4. Burner =Rs 2,53,680
5. Skirt(Nomex) =Rs5,495.50
6. Silicon coating, acrylic coating, polyurethane coating =Rs 11,000
7. PEEK strip supporting the equator =Rs 50,000
8. Fuel Tanks =Rs 1,69,120
9. Miscellaneous (Equipments, parachutes etc) =Rs 1,00,000
Total =Rs 13, 33,467.5


Page | 28

9. REFERENCES

https://www.brisbanehotairballooning.com.au/faqs/education/123-hot-air-balloon-
lift.html
http://www.real-world-physics-problems.com/hot-air-balloon-physics.html
http://www.planoballoonfest.org/pilots-balloons/anatomy-of-a-hot-air-balloon
http://www.cameronballoons.com/nopartition.html
http://science.howstuffworks.com/transport/flight/modern/hot-air-balloon.htm
http://en.wikipedia.org/wiki/Hot_air_balloon
http://www.eballoon.org/history/history-of-ballooning.html
http://www.real-world-physics-problems.com/hot-air-balloon-physics.html
One Man Hot Air Balloon System Development A report for office of Naval
Research.
Balloon Flying Handbook by U.S. Department of Transportation Federal Aviation
Administration.

Design of Hot Air Balloon System: Defence Institute of Advanced Technology, Pune

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Design of Hot Air Balloon System

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