Engineering Solutions

Last few days were quite busy in closing smaller aspects of the infrastructure setup. But these smaller aspects are typically large in numbers and you end up spending a lot of time on closing them.

In the last post, I mentioned about the installation of the fogger system. Though the system was installed, the testing was still pending. After I procured the motor for the fogger, the entire system was ready to test.

The pump was switched on and voila ... the fogger system was working. But the next minute it stopped. The motor was still on... and I could hear the water flowing. And then we realised that the fogger line end caps had come off, thereby dropping the pressure in the entire line and stopping the fogger. Thinking that the end cap was not fitted properly, we again “properly” fitted the end caps. However the same sequence continued, Motor on, fogger works for a minute and then the end caps pop off..... leaving me perplexed...

Now it was time to approach this in a more scientific way. The fogger line, connections, fittings were checked ok. And then, the pressure gauge reading at the pump output, in the fogger line surprised us. The foggers were to be operated at rated pressure of 4.5 kg/cm2. But the foggers were activated when the gauge showed a pressure of 2.5kg/cm2. And as the pressure approached 4.5kg/cm2, the end caps popped off. This observation was indeed surprising since the foggers were getting activated well before the rated operating pressure.

That took me back to the drawing board, to analyse the design of fogger system. Each fogger is designed to operate at 4.5kg/cm2 and discharges 22lit/hr. With nearly 60 foggers, the discharge is about  1320 lit/hr. But the fogger pump discharges upto 1800 lit/hr, at the desired pressure of 4.5kg/cm2.

This implied excess water of 480lit/hr was getting accumulated in the fogger line, and creating the additional pressure which was getting built up in the fogger line.

Now with the problem identified, it was down to getting a solution for the same. The solution we zeroed on was to provide a return path to the excess water in the fogger line. With the pressure release valve in place the fogger system was now up and running.

Other smaller issues like connecting the main line to the power fence (as alternate power source, especially during rainy season), tweaking of the drip lines, electrical connection inside the polyhouse etc. were also completed during the last few days. Waiting for the next round of challenges that nature is going to throw at me during the rainy season.

Get Set Go ....

While the “battle” was on with the dogs, the internal work of the polyhouse was continuing. A mixture of red soil, cowdung and rice husk was spread inside the polyhouse. Red soil is used since it drains the water easily. Cowdung adds to the fertility of the soil. Rice husk ensures that the porosity of the planting medium is maintained.

 

Rice husk added to the soil

After the soil mixed with cowdung and rice husk was spread, planting beds were prepared.

 

Beds are ready

On these beds, the drip lines were laid. The drip lines ensure that only enough water is given to the plants and unlike conventional farming methods, water wastage is avoided. The Fogger system was also installed, that would help in maintaining the temperature and humidity inside the polyhouse.

 

Drip irrigation lines installed

The final step in the infrastructure preparation was fumigation of the beds. The fumigation was carried out with a 3.5% solution of Hydrogen peroxide. This would reduce the incidences of soil borne diseases.

And so finally after much trails and tribulations, the polyhouse is ready. And I am ready to plant the vegetable seeds in it. As already decided, I am adopting the organic method of vegetable cultivation.

Now there is a huge debate on what exactly is “Organic” – check out this article that appeared in Mint few days back. http://www.livemint.com/Leisure/3XsC4njkOUmz29mZGlKeQO/Trend-Tracker--The-great-green-wash.html

At my farm, vegetables will be grown without use of chemicals. The inputs used would be certified organic inputs and I am also planning to go for an organic certification for my vegetables.

In the coming few weeks, the organic produce will be ready for consumption.  And Yes this can be a part of the food on your table too. Watch this space for more details

Who let the dogs out

That planning alone doesn’t yield best results was something that I had learnt quite the hard way in the corporate world . Therefore to not expect such a thing on my entrepreneurial venture would have been foolhardy to say the least. But I hadn’t expected it to come so soon!

My external structure for the poly house was ready; work had started on the work to be done in the internal section of the polyhouse.

But unfortunately, we had a new problem on hand.

We have few wild dogs around the farm that have had a history of creating trouble. Anticipating this, I had planned an electric fencing for the polyhouse. But with a lot of material movement expected during the polyhouse installation, I had only put the foundation for the supports and the fencing was scheduled for a later date.

With the plastic structure in place, the dogs found an easy target. They did not stop at just rolling in the soil. They forced their way into the structure by tearing off the plastic at 2 places on the first day.

I was disappointed to see that when I visited the farm the next day. Assuming that the dogs are intelligent, I thought they would use this as the path to enter the polyhouse on subsequent day till I take care of the fencing part.Guess that was asking too much out of them!. I was not too worried about the dogs at that point since there were bigger issues to tackle then.

However to my surprise, the next day, the dogs tore off the plastic at 2 more places. This was enough to trigger a “war-like-crisis” situation. I quickly reached out to the vendor who had to complete the  wiring work. However it took 2 more days before the guys could come over and fit the fencing wire. Till then the dogs inflicted further damage. In all the dogs had damaged the plastic at 7 places.

It surely was a bit of a setback  and frankly I didn’t know how to fix the damn thing. I was already delayed on the sowing season and didn’t want such irritants to crop up. It needed some quick thinking on my part. 

With some inputs from experts, the problem was ironed out…literally. We used a clothing iron to stick together plastic sheet pieces, covering the damaged sections.

The fence that I have now put around the polyhouse is a solar powered electric fence. The details are fascinating so here goes

• The Security Fence System produces a high voltage in the range of 6.0 KV to 9.9KV to deter, detect and deny physical intrusion by giving the intruder a short, sharp and painful shock.
• The Energizer will be able to check the fence around 50 times a minute and the instant the pulsated wires are cut or tampered, a built-in-alarm will immediately alert the monitoring personnel and the seucrity authorities.
• External Audio Alarm will be activated if anyone touches/ breaks the fence.
• Solar PV Module will charge the Lead Acid Battery. For handling the issue of lack of sun in rainy season, Auxiliary supply of 230V AC is also provided.

Post the installation of the fence, the dogs have tried to intrude but they have been unsuccessful.  Mission accomplished.. Phew!