Design of a 52-Seated Bus Shower Tester: Pressure Distribution Analysis

This study presents the redesign and hydraulic analysis of a shower tester system for 52-seated bus testing at Pragoti Industries Limited, Bangladesh. The existing setup, originally developed for SUVs, lacked adequate structural strength, uniform nozzle placement, and pressure regulation. A new configuration was designed, featuring an expanded 40 ft × 12.5 ft × 12.5 ft frame and dual centrifugal pumps to ensure sufficient flow and pressure distribution. Hydraulic calculations and CFD simulations in ANSYS were performed to analyze flow rate, head loss, and pressure variations across the network. Results revealed that the modified design achieved stable nozzle pressures of 2.0 bar for SUVs and 2.2 bar for buses, with theoretical and simulated data agreeing within 7%. The upgraded system effectively eliminates negative pressure zones, ensures uniform water coverage, and improves operational safety and efficiency. This research validates the feasibility of adapting existing shower tester infrastructure for large-vehicle applications through optimized hydraulic and structural design.