Tunnel: P-14419 Detailed Design Review Chris Caradonna Dillon - - PowerPoint PPT Presentation

Year-Round High Tunnel: P-14419

Detailed Design Review

Chris Caradonna Dillon Jourde Kelsey McManus Matt Pellegrini

Expectation from today…

What have you not seen, that you would like to see, so that there is no doubt regarding the progress of the design?

Engineering Requirements

NUMBER SOURCE SPECIFICATION UNIT OF MEASURE MARGINAL VALUE IDEAL VALUE ER1 CR3 Adaptability of panles # of purposes 2 >2 ER2 CR1 Air and soil temperatures degrees F 40<T<100 50 ER3 CR1 UV light amount mol/day 15 60 ER4 CR1 UV spectrum transmittance % of spectrum 70 100 ER5 CR2 Irrigation system: water availability gal 250 500 ER6 CR4 Work area implementation ft^2 96 (12x8) 192 (24x8) ER7 CR6 Changover Time (2 people) min 60 10

Agenda

 Designs #1 and #2  Watering System  Lighting System  Thermodynamic Model  Heating System  Sustainable Energy Options  Insulation  Testing Plans  Total Energy Consumption  Total Cost  Updated Risk Assessment  Project Plan

Provide Enviroment For Year Round Plant Growth Sustain Adequate Temperature Sustain Adequate Light Provide Water Enclose Garden

Design Overview

Current State

 Steel hoop structure with 20’ x 48’ footprint  Polyethylene covering for roof and all walls

Design #1

 Existing planting beds are used,

covered in low tunnels

 12 hanging ballasts provide

additional light

 Heat put directly into soil beneath

beds via heating cables

Design #2

 Large “low tunnel” covers a

central bed (12’x40’)

 Six Metal Halide ballasts provide

supplemental light

 Mounted within “low tunnel”

Watering System

Overall System Progress

Research 90% Simulation 95% Testing 0% Design 80%

Watering System Notes

 Will still need a hose from city water

 Long period of no rain

 Cost Estimate $1500-1750  Decisions that remain:

 Suppliers  Final tank storage size  Decision if contractors are needed or wanted for install

 Remaining Concern: Winter Usage

Water Simulation (2012 – 2013)

Water BOM – Gutter/Storage

Item Quantity Item Quantity 115V industrial diaphragm pump 1 Downspout adapter 2 Gutters (10' sections) 12 Gutter end caps 2 Gutter brackets 36 Lumber ~~~~~~ Gutter slip joints 12 Water tanks(500 gallon?) 2 Gutter mounting screws 48 Tank outlet valves 2 Gutter seal lubricant 1 Hose adaptors to fit valves 2 Conduit clamps 2 Tank cap seals 2 High flow drop outlets 4 Wire nuts 16 Downspouts 2 Wire 25' Downspout elbow 2 Garden hoses 2

Water BOM - Irrigation

Item Quantity Filter 1 Power switch 1 Pump 1 Power source Pressure regulator 1 Header line 24' Connector tubing 8' Drip lines 4 Line emitter valves 8 Hose clamps 6 Drip line ends 4

Lighting System

Overall System Progress

Research %% Simulation %% Testing %% Design %%

Lighting

Light Source Efficacy (lumens/watt ) Typical Ballast Sizes Other Notes Metal Halide 65-115 120 V - 400 W, 240 V - 1000W High Heat, blue end of spectrum and UV (leafy) High Pressure Sodium 85-150 120 V - 150 W High heat, yellow -

• range end of

spectrum (flowery) T-5 Fluorescent 93-104 120-277 V - 54 W Low heat

• utput, blue

end of spectrum LED 150+ 90-264 V - 200 W Low heat, $$$

Moles/day mols/m^2/ d Min 15 Max 60 Target 20

Runtimes (hours) Conversion to μmol/m^2/s 6 0.0216 10 0.036 12 0.0432

Light Source Conversion to FT-Candles Metal Halide 0.152 HPS 0.131 T5 0.146 LED ?

Assumptions and Industry Standards

Lighting

Light Source Runtime Target μmol/m^2/s Ft-Candles Distance (ft) Lumens Needed Watts Area Coverage # Ballasts Metal Halide 10 556 3655 2.0 45930 528 6.5'x6.5' 12 HPS 10 556 4241 2.0 53292 455 6.5'x6.5' 12 T5 10 556 3805 2.0 47817 797 5'x12' 8 LED 10 556 Comparable to 1000W HID ~ 8'x8' ~8

Based on current layout

Lighting

Light Source Runtime Cost Range/ Ballast # Ballasts Costs of Ballasts Watts/Ballast Energy Requirements/ day (KWh) Energy Cost/day ($0.10/KWh) Energy Cost/Year(365 days) Energy Cost for Winter (5 months) Metal Halide 10 $100-$200 12 $1,800.00 600 72 $7.20 $2,628.00 $1,101.60 HPS 10 $100-$200 12 $1,800.00 600 72 $7.20 $2,628.00 $1,101.60 VHO T5 10 $150-$250 8 $1,600.00 760 61 $6.08 $2,219.20 $930.24 LED 10 $500-$800 8 $4,800.00 325 26 $2.60 $949.00 $397.80 Winterized Row Set Up- 12'x40' centrered Planting Row Light Source Runtime Cost Range/ Ballast # Ballasts Costs of Ballasts Watts/Ballast Energy Requirements/ day (KWh) Energy Cost/day ($0.10/KWh) Energy Cost/Year(365 days) Energy Cost for Winter (5 months) Metal Halide 10 $100-$200 8 $1,200.00 600 48 $4.80 $1,752.00 $734.40 HPS 10 $100-$200 8 $1,200.00 600 48 $4.80 $1,752.00 $734.40 VHO T5 10 $150-$250 6 $1,200.00 760 46 $4.56 $1,664.40 $697.68 LED 10 $500-$800 6 $3,600.00 325 20 $1.95 $711.75 $298.35

Lighting

Metal Halide Current Situation New Situation Changes* Growing Area 600 440 26.67% Number of Ballasts 12 8 Cost of Ballasts $1,800.00 $1,200.00 Energy Costs/day $7.20 $4.80 Yearly Energy Costs $2,628.00 $1,752.00 33.33%

*TRADE OFF: 27% loss in growing area (not including strawberry bed) 33% savings in electricity cost Current Layout Winterized Layout

Lighting BOM

Notes:

• Kits include:
• Ballast
• Bulb
• Reflectors
• Sometimes include:
• Timers
• Adjustable Hangers
• Buying Bulbs in bulk will

save money. Lighting BOM QTY Cost per Total Cost KIT 8 $250.00 $2,000.00 Ballast 8 $150.00 $1,200.00 600 W Metal Halide Bulb 8 $30.00 $240.00 Reflectors 8 $100.00 $800.00 Total for non KIT $2,240.00 Timers (optional) 2 $40.00 $80.00 Light Meter (optional) 1 $100.00 $100.00

Thermodynamic Model

Overall System Progress

Research 95% Simulation 90% Testing

• Design

90%

Changes in Model

 Completed Model of “as-is” High Tunnel  Two new thermal circuits created

 Design #1  Design #2

 Soil to Soil conduction fixed (again)  Energy balance updated  Auxiliary energy (energy needed to bring system up to

target temperature) calculated

Design #1 – Thermal Circuit

Lower half of circuit (radiation from non-low tunnel soil) has been ignored because it is unsolvable with thermal circuit method.

Results Design #1

 Parameters:  RPanels = 2 m2*K/W  Rsoil = 10 m2*K/W  RLowTun = .85 m2*K/W  β= .50

Design #2 Thermal Circuit

Thermal Resistances

Results Design #2

Heating

Overall System Progress

Research 95% Simulation 80% Testing

• Design

90%

Heating

 Radiation from lights

 The use of metal halide lights will produce a large amount of

excess heat energy that would usually be wasted.

 Design #2 aims to capture this ‘wasted’ heat and keep it

inside a smaller cavity

 Subsurface Heating

Sub Surface Heating Watts/Ft Voltage Required Length Heat Input (W) Price Chromalox - Freeze Protection 3 120 360 930 Quote Pending

• 5

120 270 1550 Quote Pending

• 8

120 215 2480 Quote Pending Heat Line - Retro Line 3 120 250 930 Quote Pending

• 3

240 550 930 Quote Pending Standard Plug Heating Cables - No splicing 5 120 200 1550 162.95 Raychem Wintergard 6 120 100 1860 663.89

Solar Options

 Halco

 Estimate -$125,000 for 6 pole mount system good for 24,300

kW-hr minus roughly $45,000 in eligible grants

Insulation

Overall System Progress

Research 85% Simulation 95% Testing

• Design

70%

Insulation

 The insulation of both the above ground structure and soil is

critical to the performance of the high tunnel

 i.e. doubling the R-Value of panels/roof will keep internal

temperature from dropping below target temperature for roughly half a month longer than current state R-values

 i.e. with no soil insulation, soil temperature drops below target

temperature by December. With mid-range soil insulation, soil temperature stays in target range until January.

 Insulation needed for:

 Rigid sidewalls  Soft roof  Low tunnels  Soil

Paneling – Detail Cost Estimates

Material R-Value Transmission of Visible Light (380 nm to 780 nm) Transmission after 10 years Hardness Cost/(4ft^2) Cost total Category Deglas Acrylic Panel, 16mm Clear 2.04 86% 83%

Experiment

$18.83 $3,955.00 Rigid Sidewalls & Endwalls Deglas Acrylic Panel, 8mm Clear 1.78 86% 83% $14.17 $2,975.00 Rigid Sidewalls & Endwalls 16mm Triple Wall Polycarbonate 2.50 74% $15.00 $3,150.00 Rigid Sidewalls & Endwalls Lexan Thermoclear 16mm 4RS 2.40 75% 70%-75% $3.50 $3,393.60 Rigid Sidewalls & Endwalls Lexan Thermoclear 8mm Triple Wall 1.70 79% 74%-79% $1.95 $1,890.72 Rigid Sidewalls & Endwalls Polyethylene Single Layer 5mm 0.87 83% ~$70.00 Soft Roof Polyethylene Double Layer 5mm 1.50 <75% ~140.00 Soft Roof Solexx 5mm 2.30 75% 70% $8.05 $1,951.32 Soft Roof Paneling Breakdown ft^2 m^2 Sidewalls 480 44.6 End Walls 360 33.4 Roof 969.6 90.1 Soil Insulation ft^2 m^2 4ft Depth 1504 139.7 Product R-Value Price Foamular 150 1" Thick 5 < $893.00 Foamular 150 2" Thick 10 $893.00 Foamular 150 3" Thick 15 > $893.00

• Update values
• Add more insulations

Concept Summary

Designs

Testing of Subsurface Heating

 Soil composition

 Density, water content  Moisture sensors

 Study the experiments of

 Oregon State University

Panel Hardness Testing

 Impact strength  No data on thickness > 1/8”  Establish vandalism proof through past ergonomic data  Conduct experiment in which kids vandalize small samples

Change-Over Time/Interaction

 Create small scale simulations

 How long does it take for us to hang a pseudo-low tunnel in the

high tunnel?

 How long does it take us to change a panel or pseudo-panel?

 Run trials and create distributions for change over times

Incident Radiation Testing

 Soil Albedo – Fraction of incident radiation reflected from soil  Real World testing

 Radiation from other sources  Albedo varies seasonally due to angle of sun

 Sensitivity testing via thermal model

Temperature Effects of Lighting Testing

 Testing using a single halide light setup

 Test both inside and outside of a low tunnel

 Measure effects on air temperature, soil temperature

 Measure time to equilibrium temperature  Measure how quickly heat dissipates when light turns off

Total Energy Budget and Cost

 Subsurface heating  Lighting  Water pump  Thermostat  $$$ of Food bought for  Total Avg Power per day/week/month

Risks

ID Risk Item Effect Cause Likelihood Severity Importanc e Action to Minimize Risk 18 Price estimates change after initial creation Project may be underfunded at time of purchase Not checking pricing after we return for MSDII 2 3 4 Check pricing when we return in the fall and before purchase 19 Contractor pricing ends up under estimated Project goes over budget Inadequate information given to contractors 2 3 6 Review plans with contractors, allow for site visits for contractors 20 Bill of materials incomplete or does not meet real world system Project given to client incomplete Incorrect or imcomplete analysis 2 3 6 Have all group members review designs and ask questions(inter- team design review) 21 Inaccurate information used in design Incorrect design paramets Sources providing incorrect information 3 3 9 Verify information independently

• r look for multiple sources for

confirmation

Design Costs

All Designs - 'Bare Bones' Design #1 Design #2 Design #3 Design #4 Design #5 Component Cost Component Cost Component Cost Component Cost Component Cost Component Cost Hard Side Panels (min) $2,975.00 Geothermal w/ Solar $175,000.00 Geothermal w/out Solar $50,000.00 Subterranean Heat $400.00 Subterranean Heat $400.00 Subterranean Heat $400.00 Hard Side Panels (max) $3,955.00 Lights (min) $1,200.00 Lights (min) $1,200.00 Grid Power Solar Power $125,000.00 Grid Power Soft Roof Cover (min) $70.00 Lights (max) $4,000.00 Lights (max) $4,000.00 Lights (min) $1,200.00 Lights (min) $1,200.00 Lights (max) $2,400.00 Soft Roof Cover (max) $1,951.00 Lights (max) $4,000.00 Lights (max) $4,000.00 Large Low Tunnel $80.00 Low Tunnel $60.00 Water System $1,100.00 Digging $2,200.00 Insulation $750.00 Total (min) $7,155.00 Total (min) $176,200.00 Total (min) $51,200.00 Total (min) $1,600.00 Total (min) $126,600.00 Total (min) $2,880.00 Total (max) $10,016.0 0 Total (max) $179,000.00 Total (max) $54,000.00 Total (max) $4,400.00 Total (max) $129,400.00

Delete non-useful designs Update Transform to pro-con list

Questions?