5. WARMWATER PRODUCTION AND DISTRIBUTION SYSTEM

5.1 Basic description/location

The system should preferably be centred round existing production/distribution sites on the Sepik/Ramu catchment. For zone II (cool-water, middle section) species, the existing carp centre at Aiyura, just on the edge of the main Sepik/Ramu catchment, would be the most appropriate, and could be upgraded or modified quite simply to meet the needs of the project. For zone III species the main options would appear to be the CRI (Christensen Research Institute) research station at Madang, or the Sepik river project site at Wewak. A third site, the old fishponds at the St Xavier's island missionary school some 40–60 minutes by boat from Wewak, might also be considered. However, although an island site is attractive for quarantine, it is rather inaccessible, would need considerable physical development, and would not have readily available skilled staff.

The main functions for both species groups would be to hatch out introduced egg stocks, to grow on or produce fry or fingerling for distribution by road or helicopter, and to build up and spawn broodstock from the introduced eggs. At least one section of the facilities should be able to be kept isolated for later stage quarantine operations.

Additional ancillary sites - eg river or lakeside areas could, if secure, be used for low-cost holding of potential broodstock, which could then be spawned locally for stocking in the vicinity or for transfer elsewhere. Possible sites might include Angoram, Kanduanam, Kapaimeri (for Chambri lake), Ambunti, Bowami and one or more sites on the Ramu river such as Bunapas, Tsumba, Kwanga or Annenberg.

5.2 Design characteristics

The system would use existing water supplies and other facilities wherever possible. In the case of Aiyura the existing and/or proposed new facilities could be used with little further modification, though flexibility could be improved by using simple ‘hapas’ - suspended fine mesh nets - within various ponds, to separate particular broodstock, hatch out eggs, and rear fry or fingerling. For some species, simple pond-side enclosures can also be constructed to make suitable breeding nests.

If necessary, small portable tanks can be used, together with a simple pump and pipe assembly, as header tanks, to hold certain stocks, provide spawning tanks, or to operate as a simple fry or fingerling rearing facility. Such a system could easily be converted for water recycling by incorporating a simple filter tank. Additional items such as hatching jar assemblies, hapas, simple cages and enclosures could be used as needed. Figure 10 illustrates typical details.

Figure 10: portable hatching facilities

For the Madang or Wewak sites, a purpose-built assembly would have to be set up, based fundamentally on simple tanks with: pumped groundwater or stream supplies, or a recycle system supplemented by collected rainwater. The availability and reliability of water supplies could be critical in final site selection. These systems should be adequate for holding most stocks, and for spawning the smaller or less demanding species.

Depending on species characteristics, separate, self-contained spawning tanks might be feasible for larger-sized species. Alternatively - better for larger quantities of spawners - enclosures or cages could be set up at suitable freshwater locations nearby. The ponds at St Xaviers could also be reclaimed if necessary and used for occasional stock storage.

Cages or enclosures could also be used at ancillary sites, made as much as possible from local materials. These could be used for growing and possibly spawning broodstock, and for egg hatching and fry and fingerling rearing, using smaller ‘hapas’ inside the main structures. If necessary, portable tanks could also be used for pre-spawning and spawning, and simple land-based hatching facilities could be set up adjacent to the cages or enclosures using a solar or petrol pump/reservoir tank water supply, battery powered aerators, and simple plastic hatching jars or troughs, set up within a basic shade structure.

Table 13 outlines typical requirements for using/upgrading the facilities at Aiyura. Table 14 gives typical specifications/ dimensions for purpose-built warm water facilities such as those required for Zone III species at Madang or Wewak, while Figure 11 shows suggested layouts. Should Aiyura be unsuitable or unavailable for Zone II requirements, details and layouts would be similar to these.

Table 13: using/upgrading Aiyura facilities: Zone II centre

Basic description:
Hatchery area, pref under cover, with water/air/drainage/light/power, concrete floor min. 15m3 At least one separate small isolation/recycle system assembly, pref. under cover, approx 12 by 2001 At least 2 outside flow-through tanks or ponds for fry/broodstock, minimum 10m3. alternatively static ponds at least 1000m2, with hapas, dividing nets as required Additional glass, plastic tanks, plastic jars, trays for assembly as required to main services, etc. At least 6 recycle or flowthrough tanks, approx 1m3, shaded. Basic inspection/analysis clean area Internal areas easily cleanable, etc, with concrete/tile finishes. Gravel/concrete round outside tanks for reasonable hygiene conditions. Additional facilities/materials for cages and enclosures

Land area required:
Preferably existing site. Site should be securely fenced, etc, and should have reasonable access, staff accommodation, etc. Additional ancillary river, lake or pool sites to be be identified as needed, preferably with good access, reasonably secure.

Holding facilities:
1 × (12 × 2001) flowthrough or recycle system, glass or GRP tanks, with recycle equipment as shown, etc 2 × flowthrough ponds/tanks, approx 10m3, with aeration, earth, GRP or frame and liner type alternate 2 × 1000m2 earth ponds, min 1m deep, with monk outlets, hapa frames, dividing nets. 6 × flowthrough or airlift operated recycle tanks, GRP, corrugated steel or frame and liner Additional tanks, jars, troughs, 50 to 5001, plastic, glass, etc for assembly as needed. Additional materials - netting, poles, rope, etc sufficient for at least 2000m3 cages, enclosures

Water supply:
Existing water supply, aerated if needed. Also collected rainwater tank if possible. Upgrades may be needed for supply lines, control valves, piping, etc. Portable pumps can be used to allow pond water to be used for spawning tanks etc. Shallow pond area possibly useful for pre-warming water. Shaded storage tank/pump may supply cool water for spawning. Recycled systems if used need 2 to 3% flow as fresh input, also new water to recharge systems after drainage/cleaning.

Aeration system:
Twin blower unit, continuous operation, approx 0.5kW, feeding 60–75mm main with droppers to ponds, tanks, header tanks, filters, etc. Conventional diffusers, cleanable as required. Backup oxygen system plus bottles for charging delivery bags, etc.

Power supplies:
Mains power if present and/or backup generator; approx 5kW required for aeration, pumps, misc equipment. Internal area power line run above tanks, with earth leakage circuit breakers. Pref at least one external power line.

Waste system:
Settling/soakaway area with medium screens, approx 5m3 preferable before discharge to watercourse. Drum incinerator for packaging, etc, as needed. Lime pits to be dug as required for solid wastes.

Laboratory services:
Approx 15 to 20m2 lab/inspection area with cleanable work surfaces, floor and walls can be hosed down. With fridge/freezer, equipment store, clean area for sampling, microscope, etc. stainless steel sink, solid waste collecting bin.

Vehicles/boats:
At least one pickup truck, pref 500kg or more payload, 4wd, back must be completely washable, with transport tank, fixing lugs, air/oxygen system. If possible small service boat, eg rubber hull, 200kg payload, or shared with zone III centre (see next table)

Figure 11: outline layouts, Madang/Wewak

Table 14:- specifications, purpose-built Zone III centre

Basic description:
As for basic Aiyura facility, but established on new site, may require access road, security fencing, staff accommodation, dam and water supply pipe or channel, or groundwater supply system, plus basic hatchery, lab and storage buildings, etc. Accommodation for at least one staff member/family plus watch/guard and store building, small office.

Land area required:
At least 200m2, pref 500m2, plus access area, accommodation, access to water supply, etc. have Water should be secure, safe from tampering/contamination, etc. Site should have good general access, available infrastructure, eg power, communications.

Holding facilities:
1 × (12 × 2001) flowthrough or recycle system, glass or GRP tanks, with recycle equipment as shown, etc 2 × flowthrough ponds/tanks, approx 10m3, with aeration, earth, GRP or frame and liner type alternate 2 × 1000m2 earth ponds, min 1m deep, with monk outlets, hapa frames, dividing nets. 6 × flowthrough or airlift operated recycle tanks, GRP, corrugated steel or frame and liner Additional tanks, jars, troughs, 50 to 5001, plastic, glass, etc for assembly as needed. Additional materials - netting, poles, rope, etc sufficient for at least 2000m3 cages, enclosures

Water supply:
Either stream, dam and sluice with year-round water available, minimum 2001/min or equivalent groundwater supply, with pump and header/distribution tank. If not available, collection tanks/ponds with recycled systems, which if used need 2 to 3% flow as fresh input, also new water to recharge systems after drainage/cleaning. Other systems- cages, enclosures, etc could be set into river/lake/pools, etc.

Other systems, vehicles, etc:
Note: some or all of these could be shared with Aiyura: at least one pickup truck, pref 500kg or more payload, 4wd, back must be completely washable, with transport tank, fixing lugs, air/ oxygen system. At least one transport boat, min 500kg payload, preferably rigid hull, flat deck. If possible small service boat, eg rubber hull, 200kg payload.

Figures 8 and 9 and Table 15 describe typical cages and enclosures, suitable for ancillary sites, while the items shown in Figure 10 can be used for a simple hatchery. Table 16 outlines requirements for upgrading the pond system at St. Xavier's.

Table 15:- dimensions/specifications, cages and enclosures

Basic description:
Cages, enclosures made from local materials - bamboo/timber/plant fibre, etc set at river edges, backwater lakes, pools typically 2–3m water depth, moored or attached to shore Simple food and gear storage, local supervision/maintenance

Land area required:
Minimal: access paths or tracks only; local hut for storage, etc

Holding facilities:
Cages; typically 3m × 3m × 2m deep, rigid frame or square top frame only with flotation units, or fixed to river/lake bed on standing timber/bamboo frame; with covered top area, inner nylon net bag, weighted if needed, outer wire protection net; alternatively one or more cages can be placed inside a protective wire net stockade. If possible, access platform or work deck should be provided, to which cages are attached. Enclosures; typically 10m × 10m × local water depth; rigid pole frame driven into river or lake bed approx 1.5m intervals, well cross and corner-braced, usually with simple access platform from shore Internal nylon net attached to bottom pole, which is pinned securely to floor, or alternatively, cage type bag can be used. External protection wire net at least 1m outside.

Materials required:
Framing: bamboo poles, eg 3–3.5m × 50–75mm, or as required for cage frames, or local timber, eg poles as bamboo or rough-quartered or sawn, eg 50 × 75mm, etc. Fixings: rope, plant fibre for lashings, bolts for timber Flotation: encased polystyrene or plastic, metal 50–200litre fuel or chemical drums Netting: preferably knotless nylon, medium-grade antifouled, or flexible plastic mesh, typical sizes 10–25mm square or diamond depending on stock size, etc. For cages, normally mounted in panels to form bag, with top, side, bottom lifting ropes, etc, Protective netting: standard wire ‘pig-netting’.

Table 16: specifications: upgrading ponds at St Xavier's

Basic description:
Existing dam and water supply upgraded, with repaired water channel and new piping to pond areas. Existing ponds to be dug out and/or other ponds established uphill nearer the dam site. Simple food and gear storage, local supervision/maintenance

Land area required:
Minimal: existing pond areas, access paths or tracks only; local hut for storage, etc

Holding facilities:
Ponds, 3 × approx 20m × 10m × 80–100cm deep, with hapas, etc as required.

Materials/work required:
Excavation of approx 300m3 earth; concrete/brick for simple water outlets; cement/grouting for repair of supply sluice; approx 200–300m of 150–200mm PVC or similar water supply pipe, plus fittings, control valve, etc, trenching/protection of pipeline.

5.3 Operation and logistics

The same principles for stock transfer apply as for the cooler water species, though some of the warmer water stocks may be more tolerant of poor environmental conditions, and may be more easily transported, in higher stocking densities. Better access, and the probable ability oSsf most stocks to spread themselves throughout the lower river system, should simplify the task. However it may be desirable to introduce particular stocks at several locations - to increase chances of striking favourable habitats, or to increase the overall rate of spread from multiple ‘node’ points.

Depending on species, temperatures, etc, stock from Aiyura can be transported directly by road or 'plane to Madang or by road and plane to Wewak for further holding and/or distribution, or can be taken directly to the upstream part of the Ramu lowlands. For the lower areas of the Ramu stock could be transferred by boat. For direct stocking to the Sepik, 'plane or helicopter could be used.

From Madang, stock can be transferred by boat, road and boat, or by 'plane or helicopter to Wewak and to the Sepik, and by road, 'plane or helicopter to the Ramu.

From Wewak, stock can be transferred by boat, plane or helicopter to the Sepik, and by plane or helicopter to the Ramu.

The facilities at Aiyura are relatively well developed and should be expected to form part of the system, as the costs and time involved in establishing an alternative would be unacceptable. Existing infrastructure at Madang is excellent, but there may be problems with site availability and water supply. A limited site area may be available at Wewak, but would probably also face water supply limitations. St Xaviers would be expensive to upgrade relative to its capacity.

In most respects, the Madang and Wewak options are quite similar, would be relatively expensive to develop and might not offer too many logistic advantages over good ‘ancillary’ sites if these could be identified. In practice the options in order of cost, complexity and development time involved, might be;

1. - basic system; Aiyura plus one or more simple ancillary sites; eg Angoram, for simple spawning, fry rearing;

2. - intermediate system; as above, plus an initial scale development - simple recycle system/tank storage facilities and basic laboratory - at either Wewak or Madang;

3. - developed system; as above, with Wewak or Madang system more completely developed, eg with hatching facilities, increased broodstock capacity;

4. - full system; Aiyura, plus - mainly for the Ramu - Madang and ancillary sites, plus - mainly for the Sepik - Wewak and ancillary sites.

5.4 Outline costs

Clearly, the choice for developing the warmwater systems would depend on the specific availability of sites, on the actual costs of developing them, and on the budgets available. Outline costs for the different system components are shown in Tables 17 to 19. The actual cost of establishing the system will depend greatly on how many centres are used, and how they are set up. For guidance, Table 20 provides a summary of the options defined earlier. The cheapest and simplest approach, as with the other centres, will be by direct supervision from project staff, using local labour and minor works contractors or tradesmen, and making use of relatively simple structures and simple techniques. Specialist equipment will have to be imported, but could be assembled and put into operation locally with competent supervision.

Table 17: - outline capital costs; development of Aiyura and ancillary site

(1) - base on upgrade of existing buildings/construction of simple shadeor fenced area where required.
(2) - base on upgrade of existing facilities/adding new equipment/ponds etc, plus materials and equipment for ancillary centre.
(3) - including boats, etc

Table 18: - outline capital costs; initial development of Wewak or Madang sites

(1) - simple shaded area, storage space, modifications to existing facilities, etc
(2) - simple tank/recycle systems, miscellaneous materials

Table 19: - outline capital costs; full-scale development of Wewak or Madang sites

(1) - base on new buildings including accommodation, stores, etc
(2) - new facilities and new equipment/tanks/ponds etc,
(3) - including boats, etc

Table 20: Outline capital costs of main options

Typical operating costs, excluding capital charges, for the main components and stages of the system are shown in Tables 21 and 22, and are summarised in Table 23.

Table 21:- outline operating cost, initial level: option (a)

(1) allow for part-time involvement of management and technician staff, driver, etc.
(2) for additional vehicle, boat or other hires

Table 22:- outline operating cost, developed level: option (c)

(1) allow for part-time involvement of management and technician staff, driver, etc.
(2) for additional vehicle, boat, 'plane or other hires

Table 23: Summary operating costs of various options

* estimated by extrapolation from other cost schedules.

5.5 Summary

A system for holding, production and distribution of zone II and III species is described. For zone II species, use of the Aiyura centre is the simplest option. For zone III species some central capacity will be required either at Wewak or Madang, together with simple ancillary centres - cages, enclosures and/or simple transportable hatchery facilities - on the river system itself. Although the St Xavier's island site may be useful for quarantine, its relative costs limit its feasibility. The availability of space at either Wewak or Madang would have to be confirmed.

A number of options were assessed for capital and operating costs. At the basic level; upgrading Aiyura and running a very restricted zone III operation, capital and operating costs are around K100,000 (96,300) and K80,000 (76,900) respectively, based on local construction and supervision, and some shared operating costs with the existing system. Developing some zone III facilities would result in capital and operating costs of about K115,000 (112,600) and K100,000, while a fully developed zone III system would raise these to K250,000 (245,500) and K130,000 (129,100), again based on a relatively simple approach to construction and installation. Finally a complete development of both Wewak and Madang (or eg an alternative to Aiyura plus one of these) would give capital and operating costs of around K350,000 to 500,000 and K200,000 respectively. In all these cases, these estimates could be considerably exceeded if large contractors and complicated administration and supervision procedures were involved.

The facilities at Aiyura could if made available be used at any time, with relatively simple modifications. The development of the zone III facilities may take some time if site availability is problematic. Technically, the Madang site is perhaps simplest to develop as considerable infrastructure already exists, though the Wewak site could be established relatively quickly with self-contained recycle systems. Simple river-based facilities could be established quite rapidly as soon as stocks became available.