Creature Morpheus - 3,000+ gallon multi-tank system (Canada)

Time Schedule - It gets morphed too !

Time Schedule - It gets morphed too !

@JanVelazquez

What's Involved:

Doing a salt water project involves a lot and is a challenge as most on this site can attest. I have put a lot of effort and thought into it, but still find it an overwhelming and daunting task. There are days I wonder whether I took on too much of a project. Yet like any large project consisting of many sub-systems (I am use to designing and constructing buildings and houses), design it as a system of components, have to break it down, take it one component at a time and integrate them to function as a unit. Many fields of engineering are more black and white to the physical nature of things. You can apply a set of laws or practices which apply or have proven y experience to work. With salt water aquaria, it is as much an art as it is a science. There isn't an agreed upon blue print to follow. Why I find reading the experiences of many here on Reef Central and other web sites very enlightening and because this is my first experience, design and build, listening to the debates, suggestions, ideas discussions open things to much more. Questions people ask, problems that have arisen, mistakes and successes can spur research, posing of more questions, thoughts, design modifications/changes/additions and even deletions.

"Project Completion"

All these things imply that the system will likely never be "complete", but constantly under revision, experiments, tweaking, unknown dynamics all influenced by living creatures and a sensitive environment susceptible to so many variables. I read several threads of builds that have taken years and still being worked on everyday. Everyone wants to do things right, liked to build the best they can, regrettably we all have many constraints of space, time and financial resources. I am frugal, have taken pride in finding the best deals or ways to save, building things not only to save money, but for the same limited resources build in quality or advanced technology, or necessity because I can not afford to pay other to do them.

The Planning ....

I guess the statements above are somewhat general, yet I am trying to answer your question as to completely the project. One of Eisenhower's famous quotation was "the plan is nothing, the planning is everything" and it holds so true to everyone's aquarium builds. In a nutshell, it shall take as long as it takes in trying to do it right with the least number of mistakes. I usually am pretty good at project time tables with set goals or project benchmarks, yet the steep learning curve for saltwater aquaria forces us to take more time than we would like. I thought I would be a lot further along by now and even having a working system started. Yet patience has allowed for many more discussions with people, reads of other projects, exposure to other tanks and systems, thinking about details, trying to think outside the box, adapting technologies, confirming things, all which benefit the project performance.

Progression of Tasks:

Right now I am hoping this month to:

- get my RODI unit operational to provide base water;
- build a full size wood skeleton of the main display tank
- within it, compose a few aquascape mock ups of dry rock
- purchase several piping components to assemble in the mock up
- building a working temporary set up to cure the rock, which also involves trying different pumps, components (eductors, seaswirls, MP60s, VFD and pumps, etc.), and piping circulating
- gain more knowledge to help complete the design and specifications for the final fabrication of the main display tank.

This fall I need to finish many sub-projects within the house to modify and/or renovate for the installation of the complete system which I expect shall delay the display tank installation into the new year. Yet hope to get portions of the filtration system and several of the multiple tanks in the basement operational, including the frag tank and 330g to begin growing life.

Posting of Video Clips

As for posting clips/videos onto the web sites, will do so.
 
Sounds like a very involved project. As you are relatively new to the hobby, have you considered the mountainous task of daily and weekly maintenance that this aquarium will require? 3000 gallons of water is nothing to scoff at. I would safely say that you are into this aquarium for maintenance at least several hours a week, if not much more. Each water change of 10% will cost you 2 buckets of instant ocean at $50 each. Filling it with salt initially will cost you a small fortune. Money may not be much of an issue, but perhaps your time will be. What will you do when you go on vacation? Do you have someone you can count on to do the necessary hours of maintenance on a behemoth such as this? Do you have the time?

I know you're all gung-ho about it, but step back a moment and think of the project you are undertaking. Having a giant aquarium like this in your home is going to change your life, whether you think so or not. Whatever you choose, good luck and all the best.
 
Awesome build! I found your website several months ago and was amazed with the undertaking. Engineer + Reef system = years of planning, planning and more planning! I'm a ChE and spent 5 years thinking about and planning my system. Google sketchup was a great asset and helped my build tremendously. My system has only been up and running since April and one of the outstanding items for the build has been the incorporation of the ventilation system. That will be this fall's project. What model HRV did you choose? Why did you go with a HRV vs. an ERV? We live in similar climates, so I look forward to hearing your insight on that aspect of your build. Thanks in advance!
 
Ventilation system: That will be this fall's project. What model HRV did you choose? Why did you go with a HRV vs. an ERV?

For general understanding for those not familar with HRVs:

An HRV is installed as a mechanical continuous (all year 24 hours/day), low volume (100 cfm in smaller homes to 300 cfm in larger homes) ventilation in a home, its usual purpose is for bringing in "fresh" air and exhausting "bad" or contaminated air as close to the sources as possible (like bathrooms, laundry rooms, kitchen areas). There are commercial HRV/ERVs but discussions are beyond the scope of this post.

Haffs09:

HRV Systems: I use to design HRV systems, as well as sold them for a number of years in Canada where they are used a lot more in home construction. Each situation should be looked at individually because these units are of lower velocity/air flow and aspects of ductwork lengths/sizes and elbows can greatly influence performance.

As for aquarium applications, what works (sizing) for normal applications in houses goes out the window with continuous moisture generation from things like open surface water tanks and moving water. So "rules of thumb for HRVs" do not apply.

You asked about HRV (Heat Recovery Ventilators) vs ERVs (Energy Recovery Ventilators):

Mechanically HRV and ERV units are typically the same, in that they bring in "fresh" air from the outside and exhaust "poor" air from the inside and do so by passing the two air streams by one another in an internal "heat exchanger" that does not mix the two air streams. It works like the radiator of your car, but instead of water and air, it is an air to air exchanger.

The primary difference is in the "core" or "heat exchanger" which is constructed of various materials. Some are thin metal (aluminum or galvanize) or plastic which do not allow a transfer of moisture through the material and these are used in HRVs. ERVs on the other hand utilize a cloth or paper material that do not like the air streams mix as the air passes through the exchange transferring heat (tempering the air temperatures), yet in addition, the cloth or enthalpic core, also allows for the transfer of moisture between the two air streams. The moisture transfer may be good for homes in areas where you want to maintain or increase moisture levels (in the range of 35%-45% RH) of a home, particularly in colder climates in the winter and houses with hardwood flooring. So ERV are appropriately selected. There are other factors too for selecting ERVs too and advise those thinking of units to contact the technical department of HRV manufacturers like Fantech.net (Bernie is a good tech to speak with) to learn about the one best suited for your application.

In the case of a high humidity generation and corrosive contaminated air like a salt water aquarium, we wish to expel the "bad" air from the source and do not wish to typically keep moisture within the space. Therefore, in my opinion, I wish to utilize HRV which remove the moisture laden air from the interior without an enthalpic core to bring up the moisture content in the air being returned into the environment.


Units Chosen:

I choose to go with two additional HRVs dedicated to the aquarium system (one has been operating in the home since it was built 10+ years ago), each with dedicated ductwork for exhaust locations and fresh air return supply back to these areas for balanced ventilation. The two selected units are:

(a) The main display tank area: Fantech (140 cfm) HRV
- venting the hood enclosure
- the underside cabinet because of through floor piping could not be sealed to the crawl space below
- around the entertainment centre as it is close to the tank

(b) The Aquarium Room and Filtration Area: Fantech SHR 3000 (300 cfm) HRV
- venting exhaust registers over open water sumps/tanks and the service/cleaning sink and where the closed loop pumps are
- fresh air supply returns to opposite sides of exhaust to force air movement across the areas

Important or Notes to consider:

The trick to making things work is to isolate the areas with a continuous vapour barrier and heavy gauge plastic drop walls to prevent dissipation or migration of moisture into the wood joist area or elsewhere in the home. Without the areas being air tight, sealed and isolated to effectively draw the moisture from the sources, the ventilation system won't work effectively.

Two things are critical, is the proper ductwork sizing and the balancing after installation.

These units have multiple fan speeds for varying the air flow which can be controlled manually, programed and even set on humidistats.
 
Wow, who is starting w a 3000 gallon system into the reefing hobby? Well apparently you are :-) good luck, I'll be following your thread. But the earlier stated question how you plan to do water changes and maintenance would be interesting for me.
Btw I really enjoy your cad designs, keep them coming :-)
 
Project Takes Every Resource I have

Project Takes Every Resource I have

Sounds like a very involved project. As you are relatively new to the hobby, have you considered the mountainous task of daily and weekly maintenance that this aquarium will require? 3000 gallons of water is nothing to scoff at.

Hi HalpoChromine

Appreciate the caution (you are not the first, nor likely the last).
This is a long haul hobby and encompassing of all my resources - time, money and efforts. Figure it will be a year before I can get anything established that looks like the beginnings of a reef tank.

There is a great deal of maintenance expected, as there is involved in the installation of a complicated large filtration. Yet also being built-in as best possible are components for easier maintenance and longevity. Also things have been engineered and revamped to access and provide daily/weekly maintenance tasks. Such things as: customizing my Bashsea Skimmer with additional unions and separation plates; fabricating my service station and sink adjacent to the ATS and sump for direct access of weekly scrubbings; pull outs for scaffolding walking boards around the main display and 330g; support frames on wheels and flex piping to pullout for access and service.

Automation is being considered where ever possible to assist.

Yet have to agree, it is life changing and requires at least 2 hours per day for attention and maintenance, as well as a some regular half days for more encompassing tasks. I work out of my home (self-employed), so am able to be around more than most people can be.

As for watching the system (besides the APEX monitor to my PDA), I do have a few people close by familiar with aquariums to rely on routinely as when needed while away.

Each water change of 10% will cost you 2 buckets of instant ocean at $50 each. Filling it with salt initially will cost you a small fortune.

As for the salt .... already made the initial purchase of some 24 boxes of salt, so learned about the cost. The intent of the larger centralized system is to minimize water changes and rely on more live rock/dsb/ATS and filtration to the point hopefully only requiring make up water for evaporation.


Money may not be much of an issue, but perhaps your time will be.

Money is definitely an issue. When I originally got into this venture, I expected to spend/budget about $20,000 to $25,000 which I thought would provide enough for a decent aquarium system. Of course as almost every aquarist knows by experience, things do not go as planned, especially budgets. Even though I have tried to save at every turn, my original numbers were unrealistic and the system evolved into far more than originally planned or anticipated. Every dollar I make short of paying regular bills, goes into this project. I have to be selective in my purchases, buy what I need to work with, been doing over time (major purchases every couple months as can be afforded). The rework of the home will have alone burnt up my original expected budget. The large sumps are fabricated from 3/4" acrylic by me in my home shop because otherwise I could not afford to do them. Each is designed to maximize the standard acrylic sheet sizes with minimal waste. Most things I buy I buy used because I have to be penny wise.

Did I expect to spend this much? HECK NO ! Had I known, I probably would never have started down this path. Yet once you jump, you can bail half way down. So somehow I will have to manage.

The extra fabrication, involved build and design also taxes my time.

So, if you don't think money is an issue ... is most certainly is. I am no different than most of you, I struggle to survive in this economy. I have to make a 3 year commitment to this project without being able to take trips, doing other projects/hobbies, or buy things we might like, and hope that there are no major set backs. Every spare moment and resource I have is dedicated to this project and has been over he past 18 months.
 
RE: HRV Ventilation (edited post with added photos)

RE: HRV Ventilation (edited post with added photos)

Ventilation will be this fall's project. What model HRV did you choose? Why did you go with a HRV vs. an ERV? We live in similar climates, so I look forward to hearing your insight on that aspect of your build. Thanks in advance!

Haffs (and noted for others)

Although I did respond to your questions about HRVs and ERVs, in re-reading the thread post there were some important points that I thought were important, (plus some poor writing - hey I am sorry I am an engineer, not english major), so I re-edited the post and uploaded to my web site along with a few photos. Debated whether to repost the entire thing or just link to site. As many may not visit other sites, I shall repost here and add the photos.

For general understanding for those not familiar with HRVs:

What is an HRV:

An HRV (abriviated for "ล“Heat Recovery Ventilator"ย) is installed as a full house (or building) mechanical ventilation system that operated continuously (all year & 24 hours/day) at a low volume (typically 100 cfm in smaller homes to 300 cfm in larger homes). Its usual purpose is for bringing in "fresh" air and exhausting "bad" or contaminated air as close to the sources as possible (like bathrooms, laundry rooms, kitchen areas). There are commercial HRV/ERVs but discussions are beyond the scope of this post. They are also used for some other specialized purposes such as in high humidity areas (pools, spas, aquariums, finger nail finishing studios or hair dressers, manufacturing processes, etc.).

ExteriorHRV.JPG


HRV Systems:

I use to design HRV systems, as well as sold them for a number of years in Canada where they are used a lot more in home construction. Each situation should be looked at individually and appropriate selection and its installation design because these units are of lower velocity/air flow and aspects of ductwork lengths/sizes and elbows can greatly influence performance.

As for aquarium applications, what typically works for sizing for normal applications in houses, goes out the window, due to continuous excessive moisture generation from things like open surface water tanks and moving water. So "rules of thumb for HRVs" do not apply.

It was asked the difference between selecting an HRV (Heat Recovery Ventilators) vs. ERVs (Energy Recovery Ventilators):

Mechanically HRV and ERV units are typically the same, in that they bring in "fresh" air from the outside and exhaust "poor" air from the inside and do so by passing the two air streams by one another in an internal "heat exchanger" that does not mix the two air streams. It works like the radiator of your car, but instead of water and air, it is an air to air exchanger.

Photograph of the Interior of a Heat Recovery Ventilator (Dual Core 300 cfm)

InsideHRV.JPG


The primary difference is in the "core" or "heat exchanger" which is constructed of various materials. Some are thin metal (aluminum or galvanize) or plastic which do not allow a transfer of moisture through the material and these are used in HRVs. ERVs on the other hand utilize a cloth or paper material that do not like the air streams mix as the air passes through the exchange transferring heat (tempering the air temperatures), yet in addition, the cloth or enthalpic core, also allows for the transfer of moisture between the two air streams. The moisture transfer may be good for homes in areas where you want to maintain or increase moisture levels (in the range of 35%-45% RH) of a home, particularly in colder climates in the winter and houses with hardwood flooring. So ERV are appropriately selected. There are other factors too for selecting ERVs too and advise those thinking of units to contact the technical department of HRV manufacturers like Fantech.net (Bernie is a good tech to speak with) to learn about the one best suited for your application.

Photo of a HRV Dual Core (more energy efficient - double by-pass)

InsideCoreHRV.JPG


Check Out Specific Unit "โ€œ Most units not suitable for Salt Water Environments:

Please note: There are different styles of HRV/ERV (rectangular cores, drum wheel types) produced by a wide variety of manufacturers (Fantech, Venmar, Vanee, Lifebreath and many more). Definitely contact the manufacturers' technical department directly (as opposed to the distributing seller or sales person) when choosing a unit that it can handle salt water environments otherwise the unit may rapidly deteriorate, rust, electronic controls fail or adversely affect the fans or motors. Also find out about the necessary routine maintenance required, especially for salt water air.

PURPOSE
In the case of a high humidity generation and corrosive contaminated air like a salt water aquarium, we wish to expel the "bad" air from the source and do not wish to typically keep moisture within the space.

Therefore, it is in MY opinion for MY application, I wish to utilize HRV which remove the moisture laden air from the interior without an enthalpic core to bring up the moisture content in the air being returned into the environment. Your situation may warrant differently.


Units Chosen:

I choose to go with two additional HRVs dedicated to the aquarium system (one has been operating in the home since it was built 10+ years ago), each with dedicated ductwork for exhaust locations and fresh air return supply back to these areas for balanced ventilation. The two selected units are:

(a) The main display tank area: Fantech (140 cfm) HRV
- venting the hood enclosure
- the underside cabinet because of through floor piping could not be sealed to the crawl space below
- around the entertainment centre as it is close to the tank
- and an extra lead for possibly for a smaller minor display tank

(b) The Aquarium Room and Filtration Area: Fantech SHR 3000 (300 cfm) HRV
- venting exhaust registers over open water sumps/tanks and the service/cleaning sink and where the closed loop pumps are. Each with in-line duct dampers for balancing and adjustments
- fresh air supply returns to opposite sides of exhaust to force air movement across the areas

Important or Notes to consider:

Treat as a "ล“whole ventilation system of integrated sub-systems or components"ย which requires that the room be isolated, ductwork designed appropriately, outside intakes and exhausts located correctly, the controls located and programable as you desire, the HRV unit is sized correctly, and is balanced after installation (an important step).

The trick to making things work is to isolate the areas with a continuous vapour barrier system. In my case I used double-bubble vinyl vapour barrier and a series of heavy gauge plastic drop walls to prevent dissipation or migration of moisture into the wood joist area, other basement areas or elsewhere in the home. Without the areas being air tight, sealed and isolated to effectively draw the moisture from the sources, the ventilation system won't work effectively and can result in building moisture problems (e.g. Mould, accelerated deterioration, destruction of plywood sub-floors or drywall, wood rot, etc.)

Two things are critical and you should take into account: the proper ductwork sizing; and the balancing after installation which refers to the balancing of fresh incoming air equalling that being exhausted (is important so the isolated rooms or areas are not positively pressurize, potentially forcing moisture laden air into walls and floor cavities.

Know how you would like to control these units which have multiple fan speeds for varying the air flow which can be controlled manually, programmedd and even set on humidistats.

Another note, like your pumps and lights, these take energy to run. Check out the energy to run the unit as it does operate 365 days a year for years. Typically, in our area (your local climate may vary) a HRV can run about $200 to $350 per year to operate.

Hope that helps.
Joe
 
Just a few photos of the on-going work in progress.

Below is a tape marked out layout on the floor. When you map it out some days it looks some, others days big. Can't make it any bigger. Going to start making a wood frame skeleton next week and start toying with some dry rock formations (aquascapes).

DSC_9081.JPG



The main display tank with all the incidentals of supporting frame, water, rock, sand, lighting and hood structure shall weight over 10,000 pounds and shall be supported by approximately (10) 2-3/8ths round steel columns that penetrate through the floor. However, pin pointing these locations is another challenge because the floor area around the display tank has radiant in-floor heating which is easier to locate when it has not been tiled over a few years earlier. Luckily I at least had some photos taken doing the floor renovation in 2009.

DSC_4034.JPG


Below are a few pictures of the basement/crawl space. The first shows the future aquarium room. Basic layout shall be: to the right shall be a series of 800g tanks; on the far wall shall be service and cleaning station; the new platform being built (left/front) are for the Bashsea Simmer and Bio-filter, and return pumps; and on the upper raised level (the crawl space) will be the filtration system and sumps.

DSC_0040.JPG


The next picture shows batching of sand, cement and a latex binder. There were over 50 bags of cement batched with 18 shovels of sand to re-level and slope to drain the crawl space and the basement floor (took over three weeks). There were new floor drains installed and additional plumbing for sinks and tank over flows. Next I have to core drill several locations in the 14" think concrete walls for drains, plumbing piping, water lines and electrical (Not looking forward to that). Also have to cut the floor to put into several electrical conduits and four 1-1/2" PVC lines for tank siphons from the 330g and other tanks to the main sump across the room onto the upper level (by doing so eliminates several main return pumps in the system).

DSC_0043.JPG


Will post more photos to show other areas.
 
WOW those pictures are HUGE! Your attention to detail is incredible! You have literly planned this tank down to the inch! Good Luck!
 
Thanks for the HRV/ERV info. I'll definitely go the HRV route and I'll likely dedicate one to the fish room / fish tank.
 
@Haffs - Keep me posted on your progress and when you are attempting the HRV system, you may wish to give me a call to discuss your house and its installation.
 
Thanks for the offer! I'll keep you in the loop. It probably won't be for a little while, but it's high on the priority list.
 
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