user's manual on portable frp carp hatchery - Central Institute of ...

AUSER'S MANUALONPORTABLE FRP CARP HATCHERYB. C. MohapatraBikash SarkarK. K. SharmaN. Sarangi 'Central Institute of Freshwater Aquaculture(Indian Council of Agricultural Research)Kausalyaganga, Bhubaneswar - 751002, Ortssa, India

Copyright Q 2008, Central Institute of Freshwater Aquaculture.Kausalyaganga, BhubaneswarAll rights resewed. Neither this booklet not any part is reproducedor transmitted in any form or by any means, electronic ormechanical, including photocopying, microfilming, and recordingor information storage and retrieval system, without permission inwriting from the publisher.First Edition : 2008Published By: DirectorCentral Institute of Freshwater Aquaculture(Indian Council ofAgricultura1 Research)Kausalyaganga. Bhubaneswar-751 002, OrissaPhone:0674-2465421; 2465404; 2465446Fax:0674-1465407Email:cifa@or~.nic.inWebsite: http://www.stepbh.soft.netlcifaPrinted in: lndiaPrinted at: Cornpacta Sales (P) Ltd.75lA, BJB Nagar, BhubaneswarOrissa, lndiaTel. : 0674-2310959,3293623Email: compacta~in@yahoo.com

FOREWORDFreshwater aquaculture in lnd~a has witnessw significant development+ ' with an annual growth rate of over 6 % during the last decade and at %*country has tosustain a simliar growth in years to come The most basic and .: important component of aquaculture is qual~ty fish seed To accomp,,sh ;thls, hatcher~es have undergone a number of mod~fications for productionof better seed AICRP on APA center at CIFA has developed FiberglassReinforced Plastic (FRP) hatchery which can be transported from one placeto another for easy accessib~lity and timely production of quality fish seedThis FRP hatchery technology has been released as a technology package by ,1, CIFA in ZOO6 and suitable for producing 1 0 1 2 million carp spawn in onesuccessful operatton This FRP hatchery has got wide adoption among theusers and several hatchery units are be~ng installed at d~fferent parts of the'country At present technology is being managed through CIFA, and'.sometimes sclentlst and engineer from the lnstltute need to go to installand operate it on site Being the demand IS increasing day by day, it -becomes very difficult to go every place for the purpose To heip the usersto Instail and operate hatchery themselves, a Users Manual on "Portable 1, FRP Carp Hatchery" is being brought out This <strong>manual</strong> is self explanatoryand showlng the whole procedures of hatchery unlt installat~on and. assembly through pictorial as well as text presentations It also dep~cts the-- %hatchery operation procedures through various steps and Provides the, minor repalring procedures, wh~ch would be helpful tousersI am thankful to AlCRP on APA for f~nancial support and authors for bring~ngoutth~sveryuseful<strong>manual</strong>7- '7--,$ Kausalyaganga N. Saransi -%;*7th June 2038Director

A'ForewordIntroductionA WhyFRP 1i .Hatchery Components 2Salient Features 4. Hatchery Capacity 4Steps of Hatchery Operation 6Installation and Assembly 7Repairing of FRP Products 11Do's and Don't Do's12",$d~,;Y*.%'I," 5\>"L. i,&.*- I,"-k;y.'5- ":&' 4' **' >.+. -'A4.

IntroductionEarlier part of 20'h century has witnessed the carp seed collectionfrom bundhs and riverine resources by different devices andcollection methods. In India for the first time in 1957 carps wereinduced bred in captivity by administering carp (fish) pituitaryextract. The breeding of carps, hatching of eggs and rearing ofhatchlings up to spawn stage were carried out in differentrectangular hapa. They were fixed in the pond for clear oxygenatedwater. In hapa system, the entire operations were weatherdependent and subjected to various environmental hazards. Duringseventies, glass jar hatching units of various capacities weredeslgned and made to use successfully for hatching purposes. Thesystem had its own demerits for commercial seed production.During eighties, the Chinese carp hatchery technology got familiarin Ind~a. During nineties, different models of hatcheries withdifferent materials (HDPE, PVC, LDPE liner, Ferro-cement, etc, invarious shapes and sizes) came to the existence w~th certaindegrees of success at research level, but, they could not be used forcommercial seed production. Keeping in mind the needs of seedproduction in farmers fieid, the Co-operating Centre of ICAR-AICRPon Application of Plastics in Agriculture at CIFA, Bhubaneswar hasdes~gned and developed the complete unit of hatchery system inFRP for carp fish breeding and hatchery rearing of seed. The FRPcarp hatchery technology got commercial~zed and released to thenation durlng 2006. Then after several hatchery units arecommissioned for operation in different locations of the country.Constant demand exists for supply of hatcheries to different fishseed producers. To make aware the users of the technology, for easyinstallation, dismantling, operation and precautions to be takenhave been described in brief with simple words and figures.inforced Plastic (GRP), which is popularly known asFRP has emerged as an important class of construction materia! formaking load bearing structures and products. The Glass ReinforcedPlastic (GRP) composites have several properties and characteristic

features that make them to stand above all other conventionalmaterials both in their performance efficiency and manufacturingadaptability. Some of these attributes are as follows:J Fibrous composites have generally high specific strengthand specific modulusJ Composites are multifunctional materialsJ Composites are generally energy efficientJ Composites generally can be made corrosion and weatherresistantJ Composites can be designed to give properties for specificdesign conditions.' Proper orientation of fibres and directional properties canbe obtainedJ Products of complex shapes can be easily molded withoutany material wastageHatchery ComponentsThe FRP carp hatchery unit consists the following:1. Breeding1 spawning pool2. Hatching1 incubption pool3. Egg1 spawn collection tank, and4. Overhead storage tank1 water supply systemBreeding1 Spawning PoolShape: Cylindro-verticalDiameter: 21 50 mmHeight: 900 mmTotal volume: 3409 IOperational volume: 2950 1Bottom slope at the centre: 1: 22Wall thickness: 6.0 + 0.5 mmDuck mouth: Five numbers (I 5 mm diameter - Rigid PVC) fixed innerside at bottom of the pool in clockwisedirect~onMain water inlet: 25 mm diameter of GI1 PVC pipeWater sprinkler: One stainless steel1 plastic shower (Std. size)Breedingcapacity: 10 - 12 kg of carpsin normal conditionsWater flow rate: 1-1.5 lI sec, dependingonspecies B weightFittings: All the pipes and fittings as per IS1 standard

Hatching1 Incubation PoolOuter ChamberShape: Cylindro-verticalDiameter: 1400 mmHeight: 980 mmTotal volume: 1400 1Net egg incubation volume: 1200 1 (Space between outer andinner chamber)Side slope at the wall: 1 : 12Wall thickness: 5.5 i 0.5 mmDuck mouth: Five 15 mm diameter - rig~d PVC at the bottom ofthe pool in clockwise direct~on placedl fixed in between innerand outer chamberMain water inlet: 25 mm diameter of GI/ PVC pipe connected toali duck mouths at outer bottom wall of the poolWater sprinkler: Onestainlesssteel/ plastic shower (Std. size)Hatchingcapacity: 1 .O - 1.2 million eggs per operationWater flow rate: 0.3 - 0.4 I1 sec. depending on egg quantity/volumeHatching tlme: 14 - 18 hand remain in the pool for 72 h.Inner ChamberSocket diameter: 400 mmHeight: 890 mmChamber cover: Nylon bolting cloth of 0.25 mm meshEgg/ Spawn Collection TankShape: RectangularSize: 1000 x 500x 500 mmTotal volume: 250 1Operational volume: 225 1Wall thickness: 3.5 i 0.5 mmReinforce: Reinforced with MS angle of 25 x 25 x 5 mm at all sidesfrom the bottom at a height of 350 mm to avoid deflectionLevel of water: 450 mm in the tankWater outlet: Rigid PVC pipe of 63 mm diametk and 150 mmLength is fitted at a distanceof 387 mm from the bottom

Overhead TankOne tank of 2000 l or 2 tanks of 1OOO l capacity each can solve thepurpose. One 1.0 HP pump set is required to fill the storage tankperiodically to supply water to hatchery. Based on the capacity ofthe hatchery and operational needs, the storage capacity is to bedecided.Fittings: All the pipes and fittings as per IS1 standardSalient Features4 Easy to transport4 Easy toinstall4 Easy todismantle4 High abrasion resistance4 Light in weightIMaintenance freeEasy to repairEasy for operationSuitable for small andmarginal farmersDurable for 10-1 5 yearsHatchery unit of "one million spawn production per operation"consists of one breeding pool associated with one hatching pool. Inthis hatchery the spawn (final product from hatchery) is harvestedon 4th day during operatibn. Because the fertilized eggs are kept inhatching pool for incubation and it takes 14-18 hours for hatching,and then after 72 hours for transformation to spawn. Thus four daysare required for spawn production from one million capacity unit.Similarly hatchery for "two million spawn capacity" means onebreeding pool associated with two hatching pools and "three millioncapacity" includes one breeding pool with three hatching pools. Incase of two million capacity hatchery, the eggs produced from twoconsecutive fish breeding operations can be incubated in twohatching pools, thus two times the seed can be harvested (totalingto two million seed production from twooperations) i.e., on 4th and5th days from initial hatchery operation. Once one hatching pool isfreeafter harvest, the next breeding programme can be taken up. Incase of three million capacity hatchery, three times the seed can beharvested (totaling to three million seed production from threeoperations) i.e., on 4th, 5th and 6th days from initiation of hatcheryoperation. Then after operations can continue with serialharvesting of spawn from hatching pools.

8 .Layout diagram of FRP Carp Hatchery(with one breeding pool and one hatching pool)Layout diagram of FRP Carp Hatchery(with one breeding pool and three hatching pools), .,,, \, ., , , ,,, 8 , ,+ih

St-of Hatchery OperationStep-lStep-ll:Clean the breeding and hatching pools by potassiumpermanganate (KMnO,) solution and then by waterbefore the hatcheryoperation.:Close the outlet valve of breeding pool and then fill itwith desired water levelof water. Fix a clean cotton hapainside it.Step-Ill :Collect fish breeders (male to female ratio in 1:1),transport them to breeding pool, place them in hapa andrun theshower(s) for condition~ng.Step4 :After 1-2 hours of conditioning, inject the breeders withsuitable inducing agents and dose, release them to thebreeding pool, remove the hapa and run theshower(s).Step-VStep-VIStep.VII:After 4-5 hours of injection, allow water flow1circulat~on in the breeding pool, open the outlet valve,allow the water to pass from breeding pool through thehapa of the egg1 spawn collection tank to the outside. Ifeggs released from the fishes, collect them in hapain theegg/ spawn collection tank. Create water current in thebreeding pool by regulating the water flow through theinlets and outlet.: In hatching pool fix the screen on the inner chamber FRPsocket, fix the PVC drain pipe in the center of the tank todrain excess water, maintain the height of the drain pipein the pool at 900 mm or as needed so that up to thatheight water level is maintained, give water circulationin the egg incubation chamber through duck-mouths(inlets).: Collect the released eggs from the egg1 spawn collectiontank by hapa time to time, measure them, release themin the egg incubation chamber of the hatching pool. Theegg releasegenerally stopswithin 8-10 hr from injection.

Step-VIII :Remove the breeders from breeding pool once thebreeding is over, release them to the pond after dippingin 5 ppm KMnO, solution; clean the breeding pool byKMnO, solution and then by water.Step-IX5tep.XStep.XI: On release of eggs maintain the flow rate in the hatchingpool in such a way that the eggs float in the water (can bechecked by putting light from a torch from the top ofwater), periodically check the eggs1 spawn, clean thefiltering mesh by a brush with long handle from the inners~de of inner chamber toavoid waterchoking.:On 4"' day from egg release, collect the spawn throughhapa in the eggl spawn collection tank by opening theoutlet valve connected to the outer wall of the hatchingpool. Provide mild water circulation in the pool duringspawn collection.:After spawn removal clean the hatching pool and theeggl spawn collection tank by KMnO, solution and thenby water.Installation and AssemblyProper installation of the hatchery unit in one place for a longerperiod requires a platform of size 6.0 x 4.0 m. Make the height of theplatform in such a way that the eggl spawn collection pipes comingout of breeding and hatching pools placed on the platform can berested on the egg1 spawn collection tank which is kept at groundlevel. For better collection of egg/ spawn, maintain the height ofthe platform at about 0.5 m from ground level. For stabilityconstruct the periphery walls of the platform with bricks1 stonesand fill it with course sand. If the hatchery needs repeated shifting,platform construction is not required. Sand filling below thebreeding pool is required for providing better foundation to thepool. In case of 1:l ratio hatchery unit (one breeding pool with onehatchery pool) the water supply to the unit may be provided with25mm (ASTM) pipe from storage tank. In case of 1:3 unit it may bethrough 50mm (ASTM) pipe for getting required water flow.

Keep the breeding pool on theplatform (possibly to the leftside of the platform). Its bottomoutlet pipe should face towardsthe egg/ spawn collection tankFix the main water inlet and allthe duck mouths on the innerside wall of the pool in clockwisedirectionFix the egg collection pipe to thesocket provided at the bottom ofthe pool-.Fix the ball valve to the pipe linefor control of water flowtFixthe overflow pipe to thesocket provided on the outerside wall of the pool

Central water control valveConnection to duck-mouthsConnection to 25 mm inlet: Fix the central inleti assembly (water connection? lines for duck mouth, 25mme line and to shower)Connection to showerFix the shower on the top of the pool tothe pipeline which is connected to thecentral inlet assemblyKept the hatching pool on theplatform at a distance of 0.5-0.6m from, and on the right side of'the breeding pool. Its outlet pipeshould face towards the egg/spawn collection tank. Whileinstalling, tilt the pool slightlytowards the side wall outlet pipeof the pool for easy collection ofspawn.

IFix the central inlet pipeline forsupplying water flow to duckmouths and showerFix the central outtet pipe withthe socket provided at thebottom of the pool. Fix theinner chamber wall by pushfitting on the socket providedat the bottomFix the duck mouths to thenipple provided on the bottomof the pool in clockwisedirectionCover the inner chamber wallwith nylon-bolting cloth duringhatcheryoperation.

Place the tank on the ground andbelow the platform. The positionof the tank should be in betweenbreeding and hatching pools. Thetank has to be buried to theground as per requirement, andif the level of the platform andtank is not uniform. Fix a cottonhapa inside the tank during eggs/spawn collection time.Place overhead tank at a height of3.0 m from ground level. Connectthe breeding and hatching poolswith overhead tank for supply ofwater to the hatchery.Repairinqof FRP ProductsIf any portlon of the product is damaged or broken or leaked, thefollowing steps are to be adopted for repair.Step-l : Cut the damaged portion of FRP with metal cutting handtools/ Jig saw and give appropriate shape. Trim the edgeswith course hand file.Step-ll : Fix required size of plywood on the inner side, wheresmooth finish is required. Be sure, before fixing, plywoodshould be wax coated (Automotive wax), and after fewhours apply PVAcoat, which act as a releasing agent. Thenallow few hours for dryingStep-Ill : Mix the gel resin first with color pigments (lo%), add 1-2%accelerator (Cobalt naphthanate) to this mixture, thenadd 2% catalyst (MEK) peroxide and mix them again. Brush'I

the resin mixture in a thick coat. Wait at least 4.6 hoursfor curing.Step-IV : Apply resin coat with accelerator (1 -2%) and catalyst (2%)over the gel coat.Step-V : Cut chopped strand mat slightly larger than the requiredsize with scissors.Step-VI : Apply first layer of glass fibre1 over the resin coat, whichhas just been covered with resin. Lay it down from oneside to prevent air bubbles from being trapped in to it.Pull out all wrinklesfrom the laminates.Step-VII : Place additional layers of material either chopped strandmatt woven roving (3001 450 g/ml) over the product inthe same manner as the first ones.Step.VIII: Add final coat of resin with colours (10%) after thelaminate is cured. This coat is needed to get a betterfinish on theoutersideof the product.Do's and Don't Do's iJ Check alignment of the pools and tank while installation4 Use mallet in stead of hammer during fittings of the jointsJ Clean hatchery with KMnO, solution and water before and afteroperationJ Use water free from any tree leaves, grasses or waste materialsto avoid clogging of duck mouths. Clean the clogged duckmouths with old hacksaw bladei Be sure that the egg1 spawn collection tank is full with waterbefore collection of egg1 spawnMild water flow is required in hatching pool while collection ofegg1 spawn4 Open outlet control valves slowly during the hatchery operation.' Use M-Seal to stop minor leakage in FRP structure4 While cleaning1 washing usesoft cloth1 sponge4 Avoid any corrosive chemicalsduring cleaning/ washing4 Don't expose the hatchery unit to direct sunlight for long period4 Don't allow cattle and other animals near to the unit. They maydamage the structures/ pipelines.