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 UNIT OF NUMBER SOURCE SPECIFICATION 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 Irrigation system: water ER5 CR2 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 Provide Enviroment For Watering System Year Round Plant Growth Lighting System Thermodynamic Model Sustain Sustain Enclose Adequate Provide Water Adequate Light Garden Heating System Temperature Sustainable Energy Options Insulation Testing Plans Total Energy Consumption Total Cost Updated Risk Assessment Project Plan
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”
Overall System Progress Research Design 90% 80% Watering System Simulation Testing 95% 0%
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
Overall System Progress Research Design %% %% Lighting System Simulation Testing %% %%
Lighting Assumptions and Industry Standards Efficacy mols/m^2/ Typical Ballast (lumens/watt Light Source ) Sizes Other Notes Moles/day d High Heat, Min 15 120 V - 400 blue end of Metal Halide 65-115 W, 240 V - Max 60 spectrum and 1000W UV (leafy) Target 20 High heat, Runtimes Conversion to Conversion to yellow - High Pressure 85-150 120 V - 150 W orange end of Light Source FT-Candles (hours) μmol /m^2/s Sodium spectrum Metal Halide 0.152 6 0.0216 (flowery) HPS 0.131 Low heat 10 0.036 T5 0.146 T-5 120-277 V - output, blue 93-104 12 0.0432 Fluorescent 54 W end of LED ? spectrum 90-264 V - LED 150+ Low heat, $$$ 200 W
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 Energy Energy Energy Cost Costs of Requirements/ Energy Cost/day Cost/Year(365 for Winter (5 Light Source Runtime Cost Range/ Ballast # Ballasts Watts/Ballast day (KWh) days) months) Ballasts ($0.10/KWh) 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 Energy Energy Energy Cost Costs of Energy Cost/day Requirements/ Cost/Year(365 for Winter (5 Light Source Runtime Cost Range/ Ballast # Ballasts Ballasts Watts/Ballast day (KWh) ($0.10/KWh) days) 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
Winterized Layout Current Layout 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
Lighting BOM Notes: Lighting BOM QTY Cost per Total Cost Kits include: • KIT 8 $250.00 $2,000.00 Ballast • Ballast 8 $150.00 $1,200.00 Bulb • 600 W Metal Halide Bulb 8 $30.00 $240.00 Reflectors • Reflectors 8 $100.00 $800.00 Sometimes include: • Total for non KIT $2,240.00 Timers • Timers (optional) 2 $40.00 $80.00 Adjustable Hangers • Light Meter (optional) 1 $100.00 $100.00 Buying Bulbs in bulk will • save money.
Overall System Progress Research Design 95% 90% Thermodynamic Model Simulation Testing 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: R Panels = 2 m 2 *K/W R soil = 10 m 2 *K/W R LowTun = .85 m 2 *K/W β = .50
Design #2 Thermal Circuit Thermal Resistances
Results Design #2
Overall System Progress Research Design 95% 90% Heating Simulation Testing 80% -
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 3 120 360 930 Quote Pending Protection - 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 5 120 200 1550 162.95 Cables - No splicing 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
Overall System Progress Research Design 85% 70% Insulation Simulation Testing 95% -
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 Transmission of Transmission Material R-Value Visible Light (380 Hardness Cost/(4ft^2) Cost total Category after 10 years nm to 780 nm) Deglas Acrylic Panel, Sidewalls & 2.04 86% 83% $18.83 $3,955.00 Rigid 16mm Clear Endwalls Deglas Acrylic Panel, Sidewalls & 1.78 86% 83% $14.17 $2,975.00 Rigid 8mm Clear Endwalls 16mm Triple Wall Sidewalls & Experiment 2.50 74% $15.00 $3,150.00 Rigid Polycarbonate Endwalls Lexan Thermoclear Sidewalls & 2.40 75% 70%-75% $3.50 $3,393.60 Rigid 16mm 4RS Endwalls Lexan Thermoclear Sidewalls & 1.70 79% 74%-79% $1.95 $1,890.72 Rigid 8mm Triple Wall Endwalls Polyethylene Single 0.87 83% ~$70.00 Soft Roof Layer 5mm Polyethylene Double 1.50 <75% ~140.00 Soft Roof Layer 5mm Solexx 5mm 2.30 75% 70% $8.05 $1,951.32 Soft Roof Soil Insulation ft^2 m^2 Paneling Breakdown ft^2 m^2 4ft Depth 1504 139.7 Sidewalls 480 44.6 End Walls 360 33.4 Product R-Value Price Roof 969.6 90.1 Foamular 150 1" Thick 5 < $893.00 Update values • Foamular 150 2" Thick 10 $893.00 Add more insulations Foamular 150 3" Thick 15 > $893.00 •
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