Showing posts with label research. Show all posts
Showing posts with label research. Show all posts

2016-05-15

Progress, and a Failed Experiment

Today I was able to procure many additional materials: plywood, polystyrene panels, 2x4s and 4x4s, plus some plumbing supplies for further experiments.  I assembled the three grow-bed support frames.  I had to obtain a larger container to carry out the siphon experiments.

As I had mentioned in my last post, I had a crazy idea:

A miserable failure - do not repeat it!!
Yes, this is a two-stage inside the same bell.  IT DOES NOT WORK.  This is why I take notes on these things...it's just too bad I didn't actually re-read them before attempting this hair-brained idea.

Why does it fail?  The small red pipe feeds directly into the large main pipe.  There is no way enough water can flow into that massive blue down-pipe to form a siphon, therefore the siphon simply never forms.  What made the original 2-stage experiment successful was that the starter siphon formed a full and fast siphon. With the additional water being pumped into the larger out-piping, there was sufficient volume to start the larger siphon.

That is not the case with the above illustration.  What you see above is simply a slow flow into a very large pipe, which would happen even without that extra red pipe sticking out the side.  Without an actual siphon forming with the smaller pipe, there is insufficient water flow to trigger the main siphon.

Some other bad points about the above design: it's huge, it requires a very large diameter bell (which equates to an even larger media guard - bleh), it doesn't work (as previously mentioned), it requires many more fittings than its worth, and so on.  I will be trying some more experiments soon.  Namely, I want to see if a 3/4" starter siphon will trigger a 2" main siphon.  If it does, my next experiment will test two 2" main siphons with the 3/4 starter.  I can also modify the diameter of the out-piping, to help ensure the flow is sufficient to trip the other siphons.  The catch is that the smaller the out-pipe, the less flow it can handle, so there may cease to be a reason to run 2" siphons.

2016-01-15

My Trial System Design and Project Plan

Very soon after I had devoured the book Aquaponic Gardening: A Step-By-Step Guide to Raising Vegetables and Fish Together, by Sylvia Bernstein (ISBN # 978-0865717015), I set out to draft my first system.  Here's a peek:

The trial system configuration

Goals

My goals for this system:
  • Keep it small, but large enough so that we can stabilize the system and keep it running for at least one whole season.
  • Minimal investment in structure - let's not build a huge greenhouse before we know we can actually make this work.
  • Use a nutrient solution transport scheme that has had high reported success and minimal impact on the fish.
  • Make the framing components extremely easy and cheap to build (the picture above is not accurate to the final specs)
  • Large plumbing for minimal cleaning.
  • Keep the pump accessible.
  • Design for maintenance.
  • Design to mitigate failures and fish-death.
  • Design for future expansion.

System Design - Overview

To achieve these goals, I have set out to do the following:
Plumbing View - Grow bed assembly removed for clarity
  • The system is a 200 gallon cone-bottom fish tank, a 100 gallon sump, and two 50 gallon grow-beds.  This technically gives me a 1:2 ratio of fish tank to grow-bed space, where the preferred ratio is 1:1 or 2:1.  I can compensate by simply not adding as many fish.
  • By putting this on my back porch, I have an enclosed space that I can manage and is convenient for monitoring and upkeep.  No structure builds required.  The downside is that I need to supply auxiliary lighting, which means either buying or building lights.
  • I toyed around with CHOP-1 and CHOP-2, and finally settled on CHOP-1.  While I'm not convinced of the problems that detractors of CHOP-2 go on about, CHOP-1 plumbing is easier by far.
  • The framing components for the grow-beds will be made of 2x4 lumber.  All the cuts are straight (again, ignore the portions of the picture where this does not appear to be the case, that was an early draft).  Assembly can take place with screws and carriage bolts, the latter for the most significant load-bearing members to add rigidity and strength.
  • I will have to double-check the size of the NPT fitting on the bottom of the fish tank, but I believe it's 2".  I plan to run the largest diameter reasonable from the fish tank to the grow-beds, to ensure good flow and minimal clogging.
  • All the plumbing should be sufficiently accessible.  Space is a bit cramped, but I have positioned the system components such that nothing is completely inaccessible.
  • All plumbing will be valve-governed.  The under-tank plumbing will probably be glued wherever slip fittings are used.  This is to mitigate a pressure disaster.  Not visible in the picture above is a valved outlet, which could be used to drain the majority of the system if things go very wrong.  The valves will allow me to disassemble whatever portions of the system I like - within reason - without having to move the fish and drain the fish tank.  Where pressure should not be a significant issue, I will probably use unglued slip joints, as is the common tendency (this allows easy cleaning of the smaller pipes, as they can be disassembled).
  • I have tried to design the plumbing such that if there is a pump failure, the entire tank doesn't drain to the sump.  The system is configured such that the water in the fish tank must rise sufficiently to spill over into the grow bed flood plumbing.  The spillover tube is open at the top (the blue vertical tube in the illustration above), so that no siphon can form.
  • Finally, with the size of the tank, grow beds and plumbing, it should be very easy to expand this system by adding upwards of 6 more grow beds, without changing out the tank.  Additional sump will be required, if/when we get there.

Related Topics and Research

In doing my extended research, I investigated the keeping of koi.  These fish have rather particular water clarity needs, and so I felt they would make a good study in just how clean one could keep a pond or tank, and in what methods would serve to best achieve this.  Some of the interesting tidbits I collected from the koi pond building guides were:
  • Large plumbing is essential.  Under-sizing leads to clogging, mainly due to the typically low flow rates.
  • In koi ponds, once practice is to feed into swirl filters first, then get to media filters - if you're interested in removing the maximum amount of contaminants and not growing plants with them, that is.  Multiple swirl filters can be attached in series.
  • Bottom drains work best, as they encourage the capture of just about everything that falls to the bottom (thus my choice in a cone-bottom tank).  These are usually built into the koi ponds during construction.
  • Pipe purging can be done by creating a fast water flow.  In some koi ponds, this is done by disabling the filter feed pipe, draining the swirl filter, then enabling the filter feed pipe.  This (theoretically) allows water to flood in rapidly, dragging accumulated contaminates through the pipe and into the filter.  I should be able to do the same with my valve system.
  • Ideally, the pump should be places after the filtration assembly.  This improves pump life and reduces clogging at the pump.
  • Any inline heaters, UV lights, anaerobic filtration equipment, water polishing, and such, tend to go after the filters, and either before or after the pump.
While some of these points will not be highly applicable to aquaponics, I think some practices may prove beneficial.  In a future iteration I would like to employ some swirl filters to clean the water in prep for delivery to a NFT or DWC array.

Lighting

One of the unfortunate side-effects of using the porch is the lack of direct sunlight.  There is plenty of diffuse lighting, but I do not believe that will be sufficient for even my trial plants.  I have been investigating various lighting options.  Here's what I've considered:
  • HIDs - low entry cost but high energy usage and possibly short lifespan of bulbs.  
    • Metal Halide - bluish light that is good for vigorous plant growth.
    • High Pressure Sodium - reddish light that is good for fruiting.
    • It is ideal to use both kinds for the different stages of plant growth, but this requires a ballast that can energize both kinds of bulbs (or more than one ballast).
  • T5 fluorescents - moderate investment, lower energy usage than HIDs.  
    • Bulbs reportedly need to be replaced after 6 months.
  • LED - higher initial cost, lowest energy usage.
    • Research is comparatively scanty on LEDs for plants, but there is a growing industry and community.
    • DIY LED lights are possible.
My ideal lighting solution will probably be LED, and by that I plan to manufacture my own grow-lights.  There are several how-tos and at least one excellently engineered build-guide.  WHen compared to the buy-and-install of HIDs and fluorescents, LED lighting construction is not trivial.
  • Power Supply
    • An LED driver is required.  You can get LED drivers and drive them with D/C power, or purchase an all-in-one driver unit.
  • LED Assembly
    • Some people use red/blue diodes, others use white.  
    • Power LED lights require heat dissipation measures - a heat-sink or metal backing plate.
  • Cooling
    • Passive cooling is obvious and easy.
    • Active cooling requires power; the LED power source might provide for this, otherwise separate power requirements must be met.

Aeration

To assist with aeration, I plan on eventually having two systems in place:
  • Venturi aerator - this will be driven off the return water feed, so pump-powered and run directly back into the fish tank.
  • Air-stone pump - ideally with a backup power supply, this could run air in both the fish tank and the sump.
There are several online examples of DIY venturi aerators.  The construction is extremely simple, so I will be experimenting with that as well.

Project Road Map

I will be performing the testing and evaluation step first.  All other steps will occur as time and materials become available, so the order of events will not necessarily be as listed.
  • Build, test, and evaluate critical system components:
    • Siphon construction
    • Venturi aerator construction
    • LED lighting
  • Install the electrical
  • Build the grow-bed support frame
  • Acquire:
    • Fish tank
    • Grow beds
    • Sump
    • Miscellaneous system components
  • Plumb the system
  • Build the full lighting fixtures
  • Grow Bed assemblies
    • Build, install, and test the siphons
    • Evaluate fill/drain times against estimates
  • Cycle the system
  • Acquire fish
  • Add plants
  • Grow!





2016-01-10

Research - Bell Siphons

I have begun experimenting with bell siphons.  The premise and examples of the bell siphon can be gathered from any number of sites and illustrations.  Here, I am going to be working through, in stream-of-consciousness, the basic functionality and problems of the bell siphon.

The basic construction is as follows:
  • Standpipe: the vertical portion of the siphon that extends from the base of the grow-bed to near the top of the bell.  The height of the standpipe dictates the highest point at which water will rise in the grow-bed.
  • Bell: A pipe enclosed at one end, open-end-down over the standpipe.  Holes or notches are cut near the bottom to allow water to flood into the bell.  The height of the notches dictates the lowest point water will drain to.  The bell is usually sized such that it is within 1/2" of the top of the standpipe.  Its diameter must be suitable to the standpipe construction.
  • Drain Pipe: The piping situated below the standpipe (and the grow-bed), which drains into either the fish tank or a sump, or in some cases other grow-beds.  Typical recommendations are for the drain pipe to contain at least two 90-degree angles, for back-pressure and outflow direction.
The "system" is the siphon and the container (grow-bed, tank, etc) it is situated in.  The system receives water at a fill rate that we will consider constant.  It drains at a rate determined by the size of the drain pipes.  The drain rate may, of course, be impacted by the size of the bell's intake holes, the size of the bell itself, the complexity of the drain plumbing, and other factors.  For sake of simplicity, we will assume the bell intakes are adequately sized to allow water through at a rate equal to or greater than the maximum flow rate of the drain pipes.


Let us consider system operation.  We'll consider four discrete phases:
  1. Filling
  2. Spillover
  3. Drain
  4. Siphon Break
Let's consider the four stages and discuss the potential problems in each.

Filling

The Filling stage is the simplest.  As long as there is no active siphon, this stage can proceed quite readily.  If the siphon-break from the previous iteration did not occur, then the filling stage generally cannot proceed.  More on that later.

It is recommended that the standpipe have an emergency drain hole, in case of pump failure.  The emergency drain hole is small, typically 1/8" in diameter.  This sizing is large enough to allow a reasonable rate of emergency drain, but small enough to not appreciably impact the fill rate.

This stage does not appear to have any other potential problems.

Spillover

The Spillover is the period between Filling and Drain.  Water has begun flooding into the standpipe, but the siphon has not yet started.

In some of my early testing, an insufficient fill rate would result in the siphon never starting.  I suspect a critical volume of water must accumulate in the standpipe or drain, in order to form the necessary suction.  Once suction is present, the air bubble at the top of the bell will be pulled down into the standpipe and proper siphoning action will commence.

Some outstanding questions:

  • Does the fill rate alone determine whether or not the siphon will start, or does the geometry of the grow-bed factor in?  The reason this may be a question is that the length and width of the grow-bed translate into a rate of ascension, measured in height, for the water.
  • What is the spillover rate, and can we calculate it based on the diameter of the standpipe?  If this rate can be calculated, it will quantify the spillover phase and we can ensure that the fill rate is sufficient.
Common solutions to the siphon-start problem:
  • Introduce back-pressure via one or more of the following:
    • Add 90-degree bends to the drain pipe - usually 2 are recommended.
    • Restrict the diameter of the standpipe near its base.
  • Flare the top of the standpipe, either by heating and shaping the PVC, or by adding a fitting such as a reducer coupling or union.
Those who introduce either a restriction of diameter into the standpipe, or flare the standpipe's top, both often hypothesize that this has the added benefit of introducing the Bernoulli Effect to the siphon.  Given the rates of flow and relative openness of the bell-and-standpipe assembly, this may or may not be true.  To be certain, using a sufficiently large reducer coupling seemed to benefit my test siphon, but more analysis is required before crediting the reducer exclusively.

I also started experimenting with a trap-style bend in the drain pipe.  I was not able to complete the trap, however, so water was left in the drain pipe after the siphon completed and air remained in the bell, causing the bell to float during refill.  It is likely that air was also being sucked in between the bell pipe and the cap, as I did not glue the pipe and cap together.  During one refill I was able to see air bubbles escaping from the bell.

Drain

Once draining has started, the two key factors are the fill rate and drain rate.  These two rates can be used calculate the time required to drain the system.  Effectively, it is the system working volume divided by the drain rate less the fill rate, or V / (D - F).  Mind your units.

Basic siphon physics (Bernoulli's equations) appear to adequately describe the bell siphon.  It is suggested that the length of the drain defines the siphon rate - the longer the drain, the faster the siphon.  I have yet to determine if this is actually the case for the bell siphon.  My calculations, nonetheless, appeared to predict the operation of the siphon.  I was able to determine the drain time to within 3 seconds of actual operation, and that error could be due to the fact that my timing and fill methods are very crude...as is my actual test apparatus.

More important than drain length appears to be pipe diameter.  For example, a 10 cm increase in pipe length adds - in my specific scenario - 126.7 cm3/sec of flow rate, whereas a 10cm increase in pipe diameter adds over 21,000 cm3/sec.  Of course, one would ideally not use a 10cm diameter pipe except in the most unique circumstances.

Siphon Break

At this final stage, the water level in the system has reached the top of the bell intakes, what we shall refer to as the low-mark, and air can now intrude into the bell.  Ideally, the air intake and fill rates are sufficiently balanced so as to break the siphon.  The remaining water in the bell and in the siphon discharge to the grow-bed and to the sump or fish tank, respectively, and the cycle continues.

This unfortunately appears to be fraught with problems, and there are a wide variety of solutions available.  Let us consider the problem in terms of stages:

  1. The water reaches the low-mark, and air begins entering the bell and siphon.
  2. The siphon action is perturbed, reducing the flow rate.
  3. The fill rate remains unchanged, thus with the reduced drain flow rate the water rises above the low-mark.
  4. The siphon recovers, and the level begins to drop.
  5. Repeat.
As you can see, we have the makings for a never-ending siphon.  Some solutions:
  • Reduce the fill rate - filling too fast means slow drains, and potentially unending siphoning.
  • Enlarge the drain pipe - basically the other component of the equation for the previous solution.
  • Add a "snorkel" - this is a vent pipe that defines the low-mark and injects air directly into the top of the bell.
  • Add a snorkel with an inverted bell - this appears to be an improvement or a fix to the snorkel method.
The first two solutions are obvious and can be observed in calculation, so we will omit discussion.  The third and fourth solutions deserve comment.

The basic snorkel potentially encounters the same problem as the unchanged bell: the water reaches the bottom of the snorkel, air invades the bell, the siphon is perturbed, the rate diminishes, the fill recovers the lost water, and the siphon recovers.  Some have tried to prevent this by cutting the snorkel end at an angle.

The fourth solution basically appears to provide some buffering between the time the water reaches the bottom of the snorkel, and the time at which the snorkel begins taking in air.  It also ensures that water from the grow-bed cannot enter the snorkel once the snorkel begins taking air.

This video demonstrates the action of the cup+snorkel bell siphon.  The author of the video also utilizes a trap in the drain plumbing.  The theory behind the trap is that it forces the water level inside the bell to remain lower than the water level outside the bell.  Once the water starts to flood the standpipe, the bell is quickly flooded thanks to the additional pressure.  For this to function, one expects that the bell does not float much.

Further Discussion and Future Testing

The snorkel+cup bell appears to be a very promising siphon-break mechanism.  The necessity of the trap is undetermined.  One criticism I can see for the trap is that it would make predicting the high-mark water level of the grow-bed difficult.

For siphon start, the trap may help.  Of course, so might the reducer fitting.  Using both is probably excessive.  I would be curious to examine the function of a loop in the drain plumbing.  In theory, the loop would capture and cause a stable column of water to exit the siphon drain, power-starting the siphon effectively.  The most ideal operation would have the loop completely empty once the siphon in the bell is broken - in effect, a double siphon.  This would perhaps eliminate the standing water in the trap, and the reducer on the standpipe.  Eliminating the reducer would equate to reducing the diameter of the bell, which becomes important when one considers that in addition to the bell you must add a media-guard to the whole setup, thus taking up more grow-bed space.

One alternative to the bell siphon is the "U" siphon, which is constructed as a single pipe with two 45-degree bends, and two 90-degree bends, for the standpipe.  The low-mark is determined by a piece of downward-facing pipe.  This pipe enters a 45, which then proceeds into the two 90s, which exits into the second 45 and into the drain pipe.  The drain pipe and entry pipe are therefore parallel, and the combination of the 45s and 90s make for a skewed upside-down U shape.  The function is the same as for the bell: water spills over the top of the U, and a siphon is formed.  I could foresee this alternative having similar problems with siphon start and stop, but fewer remedies as the space available for adding hoses and such is very limited.