COLLEGE OF ENGINEERING

UNIVERSITI TENAGA NASIONAL

SEMESTER 1 2019/2020
EEEB403 CAPSTONE DESIGN
CONCEPT GENERATION 3

COMPANY NAME: Agro F.A.H.Z.S

NAME OF LEADER (SID.): Sanjey A/l Ramakrishnan (EE0101334)

NAME OF MEMBER 1 (SID.): Mohamad Hazwan Bin Mustafa (EP0101199)
NAME OF MEMBER 2 (SID.): Mohamad Faizal Bin Ideris (EP0100984)
NAME OF MEMBER 3 (SID.): Muhammad Zul Aiman Bin Suhaimi (EE0100488)
NAME OF MEMBER 4 (SID.): Azam Azhari Bin Elias (EP0102083)

PROJECT TITLE: Smart Greenhouse Complex in Palm Oil Plantation

ADVISOR: Dr. Prajindra Sankar Krishnan

Chapter 1: Project Management and Layout

As had been discussed in the previous report, the smart greenhouse complex will be used to farm
four different kind of vegetables which are spinach, berries, cabbages and tomatoes. These four
fruits have been chosen as they have high return values and able to achieve the return of investment
(R.O.I) within a few years running the smart greenhouse complex.

In this report, we will be focusing on the interior of the greenhouses that will farm the
stated vegetables. The interior design of the greenhouse complex is similar to each other with the
difference only in the type of plant beds. Tomatoes will be the example for the interior design of
the greenhouse’s farmed vegetables in this report.

The software used to simulate the design of the greenhouse in 3-dimensional (3-D) is
Sketchup software. Sketchup is versatile in designing buildings which able us to design the
greenhouse and the vegetables inside it. With these 3-D design, it is now easier to comprehend and
visualize the design of the greenhouse for better understanding of the project.

Interior Design Inside the Greenhouse

Figure 1: Close-up view of the greenhouse

 Figure 2: Overall view for tomatoes’ greenhouses
Figure 1 and figure 2 above shows the isometric view of the greenhouses that farms
tomatoes. An average height man is placed in front of the greenhouses to act as a reference for the
size of the greenhouses. One type of vegetable will be farmed in four greenhouses that is placed
next to each other as shown in figure 2 for easier harvesting and maintenance. The canvas used for
the greenhouses is the polyvinyl chloride (PVC) fabrics which is translucent for sunlight admission
and wont rot from moisture.

Figure 3: Sawtooth rooftop for greenhouse with air ventilation

Sawtooth design has been decided to be used for the greenhouses. The vertical side of the
roof as shown in figure 3 permits good amount of natural ventilation for warmer air inside the
greenhouse to rise and escape. This leads to a cooler atmosphere inside the greenhouse. The
elevated portion of the sawtooth is also used in directing the prevailing winds to aid the ventilation
of the greenhouse.

Figure 4: Front view of the tomatoes’ greenhouses

Figure 5: Side view of the tomatoes’ greenhouses

 Figure 6: Top view of the tomatoes’ greenhouses
Figure 4, 5 and 6 above shows the different views for the tomatoes’ farmed greenhouses.
The greenhouse is built with the dimensions of 20.34 metres in length, 7.04 metres in width and
3.00 metres in height (excluding the sawtooth rooftop). The size of the greenhouse is able to
support up to 4 plant beds with a cupboard, preparation table and mini-size water tank stored inside
with ample space for workers to cultivate and maintain the plants.

Figure 7: Four Tomatoes beds planted inside the greenhouse

 Figure 8: Tomatoes beds with mini-size water tank

Figure 7 and 8 shows the inside of the greenhouse that farms tomatoes. The tomatoes are
being cultivated in a hydroponic system. This means the tomatoes are being cultivated by using
the mineral nutrient solutions in a water solvent and not soil. The water solvent is being supplied
by the mini-size water tank present in the greenhouse and connected via PVC piping system as
shown in figure 8.

Figure 9: Real life example of hydroponic tomatoes

 Figure 10: Double door system and preparation place
The greenhouse will feature a double door system which means the greenhouse is not
easily accessible to pest and unwanted organisms. The real door that will be used for the
greenhouse will be a pest-proof canvas door and this cannot be shown inside the design due to the
software’s limitations. A cupboard is also present inside the greenhouse for temporary storage
during cultivation process of the tomatoes. The cupboard used will be able to maintain the quality
of the crops for required amount of time for cultivation process. There is also a preparation table
present inside the greenhouse for the workers to prepare the necessary steps in maintaining and
cultivating the crops.

Figure 11: End to end view of the crops inside greenhouse

Chapter 2: Electrical and Power Services

Electrical and Power Services are one of the most important part for the smart greenhouse
complex. A reliable and continuous power supply is needed to ensure that business runs all the
time without any interruption. Therefore, planning for the electrical and power services to have
continuous supply and backup system so that there will be no issue of interruption of the power
supply is a must.

Power Supply

Main power supply is from Tenaga Nasional Berhad (TNB) via Bulk Supply Substations
located around the Felda Palm Oil Plantation Sungai Tengi. The initial supply option are low
voltage of 400/230V, 3 phase 4 wire system for load up to 100kVA. This supply is also needed to
charge up the backup UPS system.

Uninterruptible Power Supply (UPS) System

In case whenever the input power source or mains power fails, this system will support by
providing emergency power supply to essential equipment in the smart greenhouse complex such
as computers, data center and telecommunication equipment for only a short period of time. The
main ability of this system is to deliver backup power instantaneously. The capacity of the often
used to power an electronic system just long enough for the main power system to come online or,
failing that, allow for the equipment to be properly shut down.

Figure 12: Galaxy VM from Schneider Electric

Galaxy VM from Schneider Electric is a suitable UPS system for this smart greenhouse
complex. This is because this model provide three-phase power protection that seamlessly
integrates into electrical network to provide excellent power quality. It also have integrated parallel
capability up to five UPS units to easily increase capacity without the need to transfer the load to
bypass. By using the latest technology, it lowers energy costs through high efficiency and an
ECOnversion operating mode. Plus, installation made less hassle because it is easy-to-deploy
equipment. Smart power test feature that Galaxy VM have helps to test the UPS at full load without
the need to rent a load bank before installation process.

Galaxy VM offers lithium-ion battery compatibility. Lithium-ion batteries have lots of

benefits over traditional lead acid batteries. One of the benefits is a much longer life span up to 2
or 3 times longer. This would reduce the needs to replace batteries in the future. It also have smaller
size and weight which provide ease of installation and safe more space. Plus, lithium-ion batteries
can recharge 5 times faster and it can operate at a temperature compared to lead acid batteries.

This system will be located at the administration building since it would be easier for workers
to access and manage it. Moreover, this system has a low audible noise level thus less sound
pollution.

Protection System

A protection circuit is needed to ensure the safety of the circuit from voltage spikes,
backflow current, lightning and other various problems that could damage electrical equipment.
Damaged on property is a bad news for business.

Circuit Breaker

A circuit breaker is essential and widely used in all places including in industries. Circuit
breaker is an automatic switches that are specially made to protect electrical circuits from getting
damaged by actively interrupting current flow as soon as it detect an overload, a short circuit or
some other faulty condition. For this smart greenhouse complex, using low voltage circuit breakers
are good enough because it is designed for volts that are rated below 1kV. These are very common
in domestic and commercial applications as well as in industrial installations. Miniature circuit
breakers that have current ratings of less than 100 and molded case circuit breakers with a rating
not exceeding 2,500A are some examples of low volt circuit breakers.

Protective relay

As a sensing device, it senses the fault, then knows its place and lastly provides the circuit
breaker the tripping command. After removing the control from the protective relay, the circuit
breaker disconnects the failed component. By quickly clearing the fault with the assistance of a
fast-acting protective relay and related circuit breaker, the damage to the device is decreased and
the resulting risks such as fire are decreased, the risk of life is decreased, the particularly failed
section is removed.
 But the continuity of supply, while staying healthy section, is preserved by quickly clearing
the fault, fault time is lowered, and thus the system can be returned to ordinary state earlier. As a
result, the system's transient state stability limit is greatly improved, permanent damage to the
equipment is avoided, and the possibility of developing the simplest fault, such as single phase-to-
ground fault, into the most serious fault, such as double phase-to-ground fault, is reduced.

Surge Protector

A crucial component that must be figured into the systems of solar power generation is
surge protection. Malaysia is a country where rains with lightning can occur anytime especially
during monsoon season. The expected deterioration of exposed system components can be figured
into the cost of ongoing operations, and can be reduced through the manufacture of more robust
panels, however the damage caused by lightning strikes is both far more severe and far more
preventable through the integration of advanced surge protection devices (SPD) into the PV
system. Surge protection devices positioned at strategic linear points downstream can interrupt
and stop the flow of power before it comes in contact with sensitive equipment, thus salvaging
that equipment from the expected overload.

Capacitor Bank

Installing a capacitor bank is a must since there will might be a need to do power factor
correction due to a large number of induction machines that will be used in the smart greenhouse
complex such as motor to pump water and transformers. A poor power factor due to these
induction machines can be corrected by connecting suitable capacitors. A capacitor corrects the
power factor by providing a leading current to compensate the lagging current. Power factor
correction capacitors are designed to ensure that the power factor is as close to unity as possible.
The most commonly used types are constructed using a metallized polypropylene film while a few
employs metallized polyester film or paper. A poor power factor caused by distorted current
waveform is corrected by adding harmonic filters. The process of creating the magnetic field
required by an inductive load causes a phase difference between the voltage and the current.

Earthing system

Ground faults often go unnoticed and can cause many issues that lead to malfunctions of
machinery and risk to human lives. The potential difference will appear around the injection point
when the fault current is injected into Earth. The gradient of the potential difference may be
considerably high, endangering anyone in the vicinity of the fault standing on the floor. In addition,
all exposed metalwork such as fencing, railing, and tubes linked to the fault region in the substation
may result in hazardous touch voltage owing to the potential gap between the substation and
externally linked metalwork. Therefore, it is essential to have an appropriate earth protection
system (EPS) to guarantee secure and efficient operation in the electrical substations.
Total power demand
Total power demand and load schedule to be precise in an industry is important to
determine the size and type of electrical services required. Table below show the calculation of
assumed power demand and its total.

Place Item Power (W) No of unit Total Power (W)

Greenhouse Dome Camera 3.5 12 42
C-mount camera 2.8 4 11.2
Smoke detector 0.4 8 3.2
Fire suppression FM200 39 1 39
Double entry door 12 4 48
Ventilator 50 20 1000
Mini water pump 250 4 1000
Fan 443 8 3544
Light Sensor 0.48 4 1.92
Temperature sensor 1.2 4 4.8
Humidity sensor 0.01 4 0.04
Soil Mosture sensor 0.015 24 0.36
IoT Raspberry Pi 6.4 4 25.6
Lamp 1000 24 24000
Wifi 20 4 80
Administration Building Wifi 20 2 40
Air conditioner 1491 2 2982
Fluorescent lamp 21 12 252
Discrete Camera 3.5 4 14
Dome Camera 3.5 2 7
C-mount camera 2.8 2 5.6
Security door 6 3 18
Ventilator 50 4 200
Storage Ventilator 50 2 100
Fluorescent lamp 21 4 84
Discrete Camera 3.5 1 3.5
Smoke detector 0.4 2 0.8
C-mount camera 2.8 1 2.8
Dome Camera 3.5 1 3.5
Security door 6 1 6
Security station Ceiling fan 100 1 100
Dome Camera 3.5 2 7
Bullet camera 2.8 2 5.6
Others Big water pump 1100 1 1100
Bullet camera 2.8 12 33.6
Total Power 34765.52
Chapter 3: Renewable Energy

Solar Charge Controller

The charge controller is a device preventing solar batteries from overcharging and over-
discharging. One of the most common problems with batteries is that they cannot be discharged
excessively or recharged too often. A charge controller controls the charge by managing properly
the battery voltage and current. It manages the power going into the battery bank from the solar
array. It ensures that the deep cycle batteries are not overcharged during the day, and that the
power doesn’t run backwards to the solar panels overnight and drain the batteries. Some charge
controllers are available with additional capabilities, like lighting and load control, but managing
the power is its primary job. Charge controllers are intended to protect the battery and to deliver it
as longer life as possible while keeping the photovoltaic system efficiency. It should be noted that
charge controllers only control DC loads. AC loads are to be controlled (and disconnected, if
needed) by an inverter.

The key functions of charge controllers are:

▪ Protecting the battery from overcharging by limiting the charging voltage

▪ Protecting the battery from deep and/or unwanted discharging. The charge controller
automatically disconnects the loads from the battery when the battery voltage falls below
a certain depth of discharge value

▪ Preventing the reverse current through PV modules at night

▪ Providing information about battery state of charge

The main charge controller types available today are PWM (Pulse Width Modulation) and MPPT
(Maximum Power Point Tracking) ones. MPPT charge controllers are more expensive but they
can boost the performance of the solar array. PWM charge controllers are less expensive but they
can extend the battery bank’s lifecycle at the expense of solar panels performing lower than in
case of MPPT controller. Similar to inverters, charge controllers have a lifespan of about 15 years.
Inverter

An inverter converts the DC voltage to an AC voltage. The inverter does this through a complex
process of electrical adjustment. From this process, AC electric power is produced. Inverters are
used in any electric system where AC power output is needed. In most cases, the input DC voltage
is usually lower while the output AC is equal to the grid supply voltage of either 120 volts, or 240
Volts depending on the country. The inverter may be built as standalone equipment for
applications such as solar power, or to work as a backup power supply from batteries which are
charged separately. The other configuration is when it is a part of a bigger circuit such as a power
supply unit, or a UPS. In this case, the inverter input DC is from the rectified mains AC in the
PSU, while from either the rectified AC in the in the UPS when there is power, and from the
batteries whenever there is a power failure. During the conversion process, the voltage is also
increased. But due to Ohms Law we know that an increase in voltage also leads to a decrease in
current, so the overall output current is decreased when the DC Signal is converted into an AC
one.

In case of Grid Tie inverters, as their name indicates, the output AC power is supplied to a grid
type network, i.e. a larger scale supply unit. Afterwards, through this unit, the power is distributed
further. Due to this reason they have a complex construction and internal circuitry, because they
have to synchronize with the grid network.

There are primarily two types of power inverters - "True Sine Wave" (also referred to as "Pure
Sine Wave") inverters, and "Modified Sine Wave" (also referred to as "Modified Square Wave")
inverters. True Sine Wave Inverters have been developed to replicate, if not improve, the quality
of power provided by main power grids or power utilities. They are specifically recommended to
power high energy-consuming electronic gadgets and equipment. True Sine Wave inverters are
more expensive than Modified Sine Wave inverters, and is the more powerful and efficient option
of the two.
Figure 23: Solar charge controller

Figure 14: Inverter

Chapter 4: IOT and CONTROL SYSTEM

The Iot and Control system consists of an effective but basic algorithm that handles all
aspects. The machine brain is used with an Raspberry pi microcontroller. The low cost and fast
reaction of the microcontroller is used here. Three factors must be calculated to test the climatic
conditions of the green house.

Water pump Temperature

Fan Raspberry pi Humidity

Microcontroller

Light Soil Moisture

SMS GSM/GPRS HC05 Bluetooth Android

Module Application

Database Server Internet User

Figure 15: Block diagram of the system

 Start
v
Initialize GSM/GPRS + Bluetooth Module
NO

Connected?

YES
Collect Soil Moisture Data

NO
Moisture Level Normal? Stop Watering

Stop Watering

Collect Temp and Humidity Data

NO
Temp/Hum Normal? Fan/Spray ON

YES
Fan/Spray OFF

Collect LDR Data

NO Lights ON
Day?

YES
Lights OFF

Results in LCD

Send Data
NO
YES End
Data Sent?

Figure 16: Flowchart of the system

Chapter 5: Security Systems

Safety Features at Greenhouse

Staffed by greenhouse workers

Employ security guard at the entrance of greenhouse :

⚫ To make sure no one trespass greenhouse area without permission or go to restricted area

⚫ To act accordingly and fast if there are any emergencies involving safety of the users and
staff on duty
⚫ The choices of security guard is either we employ local workers or foreign workers.

⚫ Local workers:

Local workers are easy to train and communicate but higher demand in salary and low work
hours

⚫ Foreign workers:

Foreign worker are difficult to communicate but can work overtime and less demanding in
salary

Greenhouse entrance, surrounding area and greenhouse are well recorded and monitored by
CCTV

There are good choices of CCTV that can be used for the selected greenhouse area:

⚫ Internal and External Dome Camera

◼ Suitable for indoor and outdoor greenhouse area surveillance.

◼ Dome shaped CCTV make onlooker difficult to determine where the camera facing.

◼ Easy to install

◼ Vandal-resistant features. Good choices since greenhouse area might be attacked by

unauthorized man or wild animals such as monkey.

◼ Has IR night vision

 Figure 17: Dome Camera type CCTV

⚫ Bullet Camera

◼ Good for greenhouse outdoor area because of long and cylindrical shape.

◼ Suitable for long distance viewing.

◼ Dust, dirt and wind resistant

◼ Easily installed

◼ Features such as IR night vision, compact in sizes and high resolution images

◼ Suitable to install in solar farm area.

Figure 18: Bullet camera CCTV

⚫ C-mount Camera

◼ Detachable lenses can allow lens change according to variety of applications.

◼ Can cover distance up to 12 meters

◼ Support changes in technologies and effective for greenhouse indoor use and also
nearby entrance and the guard post.

Figure 19: C-mount camera type CCTV

⚫ Discreet CCTV

◼ Difficult to spot by onlookers since it resemble like water suppression.

◼ Suitable to use in Administration building and Tool shed and maintenance storage.

Figure 20: Discrete camera type CCTV

Safety System

Fire detector, alarms and fire extinguisher are well installed in greenhouse.

As a requirement by the fire department every building must have fire alarm system that
is certified by local fire and safety laws. There are good choices of detector that can be choose
for the greenhouse.

⚫ Ionization Smoke Detector

◼ Have a constant electrical current that occurs between two metal plates in the device.

◼ Electric current flow when smoke entered the detector chamber thus turn on the
alarm.

◼ Excellent at detecting fast burning fires.

Figure 21: Ionization Smoke Detector

⚫ Ionization/Photoelectric Smoke Detector

◼ A combination smoke detector is the best way to protect the facility and its occupants
from a fire.

◼ When both forms of smoke detection are together on one device it helps to ensure
that regardless of the type of fire, it will be detected as soon as possible.
 Figure 22: Ionization/Photoelectric Smoke Detector

Fire extinguisher is also a requirement for user or staff to react to fire quickly before
spreading. Several type of fire extinguisher needed to be consider since every type is effective
according to the type of combustion.

Figure 23 :Type of fire extinguisher

 Figure 24: Application of fire extinguisher according to its type

The new fire extinguisher product called ELIDE FIRE can extinguish four classes of
fire by just throwing it to the fire area. Although it is expensive, but the ball shape fire
extinguisher are easily to handle with lightweight and wide area of effect.

Figure: ELIDE FIRE, fire extinguisher ball

 In greenhouse area, both manual and automatic fire suppression system can be
considered since it is needed to control and extinguish any fire from spreading rapidly. Fire
department takes time to arrive to the incident area since the greenhouse is in the oil palm
plantation area. There are several automatic fire suppression that can be consider:

⚫ Gas System – FM200

◼ Stored as liquid, with nitrogen used to pressurize it.

◼ Released the FM200 chemical agent has a chemical reaction with the fire and
extinguishes it.

◼ Best suited to data rooms, greenhouse or control rooms.

Figure 25: Layout of Gas System-FM200

⚫ Water mist System

◼ Commonly replacing sprinklers in big data rooms, other large areas and local
applications.

◼ Can be used for flammable liquids and electrical rooms, the mist evaporates and
causes a starving of oxygen effect rather than cooling.
 Figure 26: Water mist layout

⚫ Foam Deluge System

◼ mainly suitable for large applications where you cannot use water or gas.

◼ Widely used for transformers, oil tanks and oil storage silo’s.

◼ A simple sprinkler type application disperses a foam concentrate mixed with the
water to provide the typical expanding agent (the same as with extinguishers

⚫ Pneumatic Heat Detection Tube

◼ An extinguisher with a valve and a length of heat detection tube which acts as the
detection and propellant feed for the agent.

◼ When the temperature reaches a certain level around the pipe it blows a small
pressurized hole in the pipe, which then propels the agent directly onto the risk.

Manual suppression system must be included since user and staff on duty can react
according to observation since automatic system sometimes cannot detect quick enough.
There is a problem that may be faced by this system that is user can vandalized the system.
To prevent this from happening, we can use glassed alarm that needed to be break in order
to activate the fire suppression system.
 Figure 27: Manual switch for fire suppression system

Workers safety and Greenhouse security from wild animal attacks and unauthorized people
Since the suggested area to build the greenhouse is in the palm oil plantation, the risk
of being attacked by wild animals such as snake and monkey are high. Therefore the fence
installation are highly recommended.
There are several type of fence:

⚫ Security Fence
▪ Has a contemporary design with spacing specification of 50mm x 150mm, it
makes the place looks safe, elegant and contemporary.

▪ Also known as ROLL TOP FENCE. The fence is designed to have a triangular
roll on the top and bottom of the fence make it more strong and tough. With wire
thickness of 5mm and spacing of 50mm x 150mm, ROLL TOP FENCE is very
strong that it cannot be bended easily.

▪ Help prevents anyone from easily climbing over the fence to reach the protected
area.

▪ With excellent see through visibility makes SECURITY FENCE / ROLL TOP
FENCE ideal to use in areas where CCTV is in operation.
 ▪ Hot dipped galvanised and does not get rusted easily in a short period of time. As
a result, low maintenance or maintenance free for a very long period.

Figure 28: Security Fence/ Roll Top Fence

⚫ Anti-Climb Fence
▪ Ultimate heavy duty welded mesh panel providing the highest degree of security
with excellent see through visibility. It has toe and finger proof profile.

▪ With spacing specification of 75mm x 12.5mm, it is impossible for fingers and toes
to go through. Hence, it prevents anyone from climbing over the fence to reach the
protected area.

▪ Also known as Anti Cut FENCE. The fence is designed to make it very difficult to
cut through the panel with simple hand tools. With wire thickness of 4mm and
spacing of 75mm x 12.5mm, intruders can never cut off the fence.

▪ With excellent see through visibility makes Anti Climb Fence ideal to use in areas
where CCTV is in operation.

▪ Hot dipped galvanised and does not get rusted easily in a short period of time. As a
result, low maintenance or maintenance free for a very long period.
 Figure 29: Anti Climb Fence/ Anti Cut Fence

Those type of fence can be combined with Barbed and Spike for more security and also avoid
wild animal attacks such as wild boar and monkey.

Figure 30: GI Barbed Wire

 Figure 31: Razor Barbed Wire

Security Door
Security door are necessarily for certain area of the greenhouse. Security door can be
installed at the Administration building, Product storage and also tool storage and maintenance
building storage. There are a few security door that can be choose to install in the greenhouse
building area.

Figure 32: Biometric security system door

This door required biometric (fingerprint, retina etc) to enter the building. This type of
door suitable to use at product storage room, power room and private entry area building or
room.
 Figure 33: Classic lock door
This type of building required a key to enter the room. This door can also installed
identification card and keyword pass key. This entrance door can be used as entrance of
administration building.

Figure 34: Double entry security door.

This type of door can be used in greenhouse area as entrance. This door also can
installed security system such as biometric or keyword lock system.