WINERY UTILITIES

Planning, Design and Operation

David R. Storm Storm Engineering, Inc.

SPRINGER SCIENCE+BUSINESS MEDIA, LLC

The author has made every effort to ensure the accuracy ofthe information hereln. The author, editors, and the publisher cannot be held responslble for any typographical or other errors found in this book.

Library of Congress Cataloging-in-Publication Data

Cover design: Sai'd Sayrafiezadeh, emDASH inc. Art Direction: Andrea Meyer

Storm, David R., Winery Utilities : planning, design & operation 1 David R. Storm

p. cm. - (The Chapman & Hali enology library) Originally published : New York : Chapman & Hali. 1997.

Includes bibliographical references and index.

ISBN 978-1-4757-6975-3 ISBN 978-1-4757-6973-9 (eBook) DOI 10.1007/978-1-4757-6973-9

1. Wineries-Environmental englneering. 1. Title. II. Series. TH6057.W55S76 1996

658.2'6-dc20 96-27520

CIP

Library of Congress Cataloging-in-Publication Data

A C.I.P. Catalogue record for this book is available from the Library of Congress.

Copyright © 1997, 200 1 by Springer Science+Business Media New York Originally pub1ished by Kluwer Academic/P1enum Pub1ishers, New York in 2001

Softcover reprint ofthe hardcover 1st edition 2001

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To wine lovers everywhere, whose enthusiasm for and continued loyalty to the remarkable beverage, fuel the wine industry engine.

TABLE oF CoNTENTS

PREFACE ACKNOWLEDGMENTS LIST OF FIGURES LIST OF TABLES

1 INTRODUCTION Winery Classification Required Utility Services

Electrical Power Refrigeration and Air Conditioning Telecommunications Sanitation, Steam and Hot Water Potable Water Supply Irrigation Water Supply and Reclaimed Wastewater Sanitary Wastewater Process Wastewater Liquified Petroleum Gas Systems Fire Protection Systems Solid Waste Systems Winery Utilities and Health and Safety Programs

Glossary

xi xii

xiii xvi

1 1 4 4 6 7 8 8 9

10 10 11 12 13 14 14

v

vi Contents

2 ELECTRICAL SYSTEMS 17 Electrical Load Planning 17 Power Distribution System Alternatives 19 Voltage Considerations and Preferences 20 Electrical Requirements for Process Equipment 24 Electrical Requirements for Site Utility Equipment 25 Electrical Power Considerations for Non-U.S. Wine-Producing Countries 26 Analysis of Rate Structures and Service Contracts 27 Energy Considerations in Winery Lighting 29 Controls, Instrumentation, Utility Systems Monitoring Status, and Alarms 31 Power Loss and Surge Protection 34 Operation and Maintenance of Electrical Systems 35 Glossary 38

3 TELECOMMUNICATIONS 45 Definition 45 Business Aspects and Winery Communication Needs 45 Technology Changes Influencing Equipment Choices 46 System Choices, Limitations, and Advantages 50

Mobile Communication Systems 50 Cellular Telephones 51 Pagers 51 Facsimile Machines 52 Other Devices 53

Telecommunications Security 54 Computers and Wine-Industry-Focused Software 56 Maintenance and Operation of Telecommunication Systems 58 Glossary 58

4 SANITATION, STEAM, AND HOT WATER 64 Winery Design Concepts, Winery Age, and Sanitation 64 Cleaning System Options 67 Water Use Planning Guidelines (Cleaning) 75 Boilers and Boiler Water Quality 75 Primer on Boilers 77 Alternative Energy Sources for Hot Water 79 Maintenance and Operation of Steam/Hot-Water Systems 80 Glossary 84

5 REFRIGERATION, VENTILATION, AND AIR CONDmONING 86 Scope 86 Basic Principles 87 Refrigerants 93 Fermentation Heat Balance and Tank Thermal Stratification 96 Ventilation and Night-Air Cooling 98

Insulation and Solar Energy Considerations Operation and Maintenance Glossary

6 POTABLE WATER SUPPLY SYSTEMS Winery Site Water Resource Assessments

Prepurchase Winery Site Analysis Well Casings Well-Drilling Logs and Records Water-Quality Assessment Pump Efficiency Test Well Abandonment Land Use Conversion Water Use Equivalency Test Water Dowsers

Water Demand Calculations Winery Water Development and Environmental Impact Issues Pressure Requirements Water Meters Water Storage Water Treatment

Conventional Versus Package Treatment System Problem Minerals Disinfection

Water Conservation Piping Pipe Materials, and Secondary Contamination Bottled-Water Service Standby Emergency Power Economical Oversizing of Water System Components for

Future Expansion Water System Operation and Maintenance Glossary

7 IRRIGATION WATER SUPPLY SYSTEMS AND

Contents vii

100 104 107

112 112 112 119 120 124 128 133 134 135 136 141 143 147 151 161 162 163 165 167 170 171 171

173 174 175

RECLAIMED WASTEWATER 181 Integration of Winery and Vineyard Functions 181 Conflicts in Recycled Water Supply and Vineyard Irrigation Demand 181 Vineyard Water Requirements 183 Systems and Equipment 186 Operation and Maintenance of Reclaimed Wastewater Drip

Irrigation Systems 190 Glossary 191

8 WASTEWATER SYSTEMS 195 Overview and System Separation Philosophy 195 Treatment and Disposal of Sanitary Wastewater 196

Design Flows 197 Sanitary Wastewater Characteristics 198

viii Contents

Conventional Septic Tank and Leachfield System Components 201 Sewage Pump Stations 204 Package Treatment Plants and Other Above-Ground Alternatives

(Sanitary Wastewater) 212 Alternative Wastewater Systems (Specially Engineering Systems;

Sanitary Wastewater) 216 Operational and Maintenance of Sanitary Wastewater Systems 222

Winery Process Wastewater 225 Wastewater Flows 225 Process Wastewater Characterization 227 Aboveground Aerobic Waste Treatment Systems and

Performance Standards 236 Treatability of Winery Process Wastewater 237 Aerobic Treatment Options and Equipment Choices 242 Clarification and Settling Aids 245 System Expansion and Equipment Choices 248 Wastewater Metering 253 Winter Storage Requirements and Water Balance 254 Other Reclaimed Wastewater Reuse Options 257

Aquaculture 257 Landscape Irrigation 258 Fire Protection 258 Off-Site Use 259 Seasonal Wetlands and Wildlife Habitat Improvement 260

All-Weather Access 260 Fencing and Signage 260 Operation and Maintenance of Process Wastewater Treatment and

Disposal Systems 261 Responsibility of Wastewater System Designer 261 Elements of an O&M Manual 262 Staffing and Service Maintenance Contracts for

Wastewater Systems 268 Glossary 271

9 UQUIDED PETROLEUM GAS SYSTEMS 278 Introduction 278 Gaseous Fuel Characteristics 279 Design Details 280 Odorized LP Gas, Forklift Garaging, and Gas Leak Detection 283 Pressure Relief Valves 285 Operational Maintenance of LP-Gas Systems 285 Other Forklift Options 286 Glossary 286

10 FIRE PROTECTION SYSTEMS 288 Winery Fire Hazard and Occupancy Class 288 Fire Threats 290

Contents ix

Structural Features for Fire Prevention and Spread Containment 295 Fire Protection System Testing Institutes 296 Fire Protection Water Supply Systems 301

General Considerations 301 Fire Flow Rate and Duration 301 Fire Protection Storage Facilities 309 Fire Flow Pressure 315 Fire Pumps 316

Fire Alarms and Instrumentation 323 Sprinkler Systems 327

Overview 327 Sprinkler Design and Selection Considerations 329

Miscellaneous Fire Protection Equipment and Apparatus 335 Fire Hydrants 335 Interior and Exterior Fittings and Equipment 338 Portable Fire Extinguishers 340

Operation and Maintenance of Fire Protection Systems 341 Glossary 343

11 SOUD WASTE SYSTEMS 349 Overview 349 Laws and Regulations Governing the Handling of Solid Waste 350 Winery Solid Waste Characterization 352

Winery Solid Waste 353 Vineyard Solid Waste 366

Winery Waste Generation Rate Estimates 369 Solid Waste Containers and Equipment 372 Solid Waste System Operation and Maintenance 376 Wineries and Adopt-a-Highway Programs 377 Glossary 378

12 WINERY UTILITIES AND HEALTH AND SAFE1Y PROGRAMS 382 Introduction 382 Human Behavior and High-Risk Job Activities 384 Workers' Compensation Law (WCL) 385 Winery Operations and Air Resources 386

Utility Systems as Air-Pollution Sources 386 Indoor Air Quality 386 Respiratory Protection 389

Noise 391 Confined Space Regulations 393 Machinery Guards, Walking and Working Surfaces 393 Site Utilities and Health and Safety Planning 396

Electrical Systems 397 Refrigeration, Ventilation, and Air Conditioning 398 Telecommunications 399 Sanitation, Steam and Hot Water 399

x Contents

Potable Water Systems Wastewater Systems Liquified Petroleum Gas Systems Fire Protection Systems Solid Waste Systems Accident Prevention Plan

Glossary

Appendix

Index

399 400 402 402 402 402 421

425

428

PREFACE

This book has been written for an eclectic audience of winery developers (owners), winemakers with utility responsibilities (real or implied), winery design professionals (architects and engineers), and university-level enol­ogy professors, all of whom at sometime in their careers must address the subject of winery site utilities as a distinct and important element of their jobs.

Wine and other fermented beverages in one form or another are pro­duced commercially in almost all temperate zones of the world. Utility requirements for wineries, which use grapes as the fermentable sugar source, are the focus of this reference book, although similarities in fun­damental production processes for other subdivisions of the fermented beverage industry may find useful reference information in the chapters which follow.

Wine production methods may differ somewhat from country to coun­try, but the sizing, need for reliability, ease of operation, and cost-effec­tiveness of water, wastewater, electrical, fire protection, and other support systems remain nearly universally constant. Of necessity, the author's past planning and design experience with nearly 60 winery utility systems, will

xi

xii Preface

emphasize contemporary design fundamentals related to the U.S. wine industry. However, where possible, opportunities will be taken to relate American practice to, for example, European, Australian, and South Amer­ican wine industries where discrete differences in utility systems have been observed by the author or discovered in the literature research that was part of the production effort for this volume.

A glossary of terms has been included with each chapter, although the structure of the text, illustrations, and references presumes a limited tech­nical knowledge or experience with utilities nomenclature on the part of the reader.

Finally, this book is not meant to serve as a substitute for the services of competent design professionals. Architects and engineers must still play an important role in the planning, design, and construction of new wineries and their utility systems, and in the expansion of existing facilities to meet new and enlarged wine production goals.

The last decade has, more than any other time in recent history, coa­lesced worldwide thought to develop principles for the universal protec­tion of freshwater, marine, terrestrial, and atmospheric resources. The wine industry has an opportunity to lead in the development of utility systems which both conserve and protect land, air, and water resources, and at the same time remain cost competitive in domestic and world mar­kets.

AcKNOWLEDGMENTS

Special thanks to my family for their patience and forbearance during the preparation of the manuscript, and to Sally, my Springer Spaniel, who made absolutely no contribution, but was a silent companion during all the long hours of composition. My gratitude to Lorraine Lancaster for her exceptional word processing skills and to David and Kelly Gaskill for bring­ing the illustrations to life. Finally, thanks to Professor Roger Boulton, U.C. Davis, for his thoughtful review of the manuscript.

LIST OF FIGURES

1.1 Winery Utility System Schematic 5 2.1 One Line Diagram-Potable Water Pump Station 21 2.2 One Line Diagram-Potable Water Pump Station with Standby

Emergency Power (Feature) 23 2.3 Typical Utility System Alarm/Status Annunciator Panel 32 2.4 Portion of One-line Diagram for Utility System Monitoring and

Alarm Unit 33 2.5 Typical Electrical Machinery History Record 36 2.6 Typical Electrical Motor Preventative Maintenance Record 37 2.7 Electrical Parts Order and Inventory Control Card 38 3.1 Functional Sequencing for Typical Electronic Mail Cycle 48 3.2 Ideal, Optimally Equipped, Fully Automated Winery Communication

System and Sulrsystems 55 4.1 Concrete Floor Rehabilitation with Three-coat Polymer System 65 4.2 Typical Cold Water High Pressure Washer 68 4.3 Typical Electrically-Fired Hot Water Pressure Washer 68 4.4 Schematic of Typical Winery Clean-in-Place System Using Portable

Hose and Wine Transfer Pumps 69 4.5 Schematic of a Typical Winery Clean-in-Place System Using Fixed

Piping and Other Equipment for Product Conveyance and Tank/Pipe Cleaning 71

4.6 Wall-Mounted Hot Water Mixing Valve 73 5.1 Schematic Diagram of a Typical Vapor Compression Refrigeration

System with Secondary Coolant Loop for Fermenter Temperature Control 89

5.2 Refrigerant Temperature-Entropy Diagram for Vapor Compression Refrigeration System Operating as a Reversed Carnot Cycle 90

5.3a Vapor Compression Refrigeration System Operating as a Reversed Carnot Cycle (Cooling Winery Spaces) 91

5.3b Vapor Compression Refrigeration System Operating as a Conventional Power Carnot Cycle (Warming Winery Spaces) 91

5.4a Typical Refrigerant Recovery (Vapor Phase) 106 5.4b Typical Refrigerant Recovery (Liquid Phase) 106 6.1 Graphic Results of Pump Test Mode During Planning Phase for a

100,000-case Table Winery 115 6.2 Typical Spring Development Plan 117 6.3 Typical Well Drillers Confidential Completion Report 122 6.4 Visual Log Form for Video Camera Inspections of Well Casings 123 6.5 Typical Pump Performance Curve 130

xiii

xiv List of Figures

6.6 Schematic of Pump Efficiency Test Apparatus and Test Protocol 132 6.7 Submersible Pump Protection Device 133 6.8 Triplex-Type Water Booster Pump with Hydropneumatic Tank 145 6.9 Winery Potable and Irrigation Water Metering Plan 148 6.10 Graphical Method for Determination of Water Storage Requirements

for a 120..ton per Day Crush Capacity Winery 152 6.11 Concept Plan for Winery Potable Water System Storage Tank

(Gravity Flow) 158 6.12 Green-Sand Ion Exchanger 164 6.13 Typical Reverse Osmosis Unit for Demineralization and Specific

Ion Removal 164 6.14 Typical Softener, Dealkalizer, or Nitrate Reduction Unit 165 7.1 Semi-Non-Clog Emitters Best Suited for Use With Reclaimed

Winery Wastewater 187 7.2 Schematic Plan of Reclaimed Wastewater-Primary Irrigation Water

Blending System 188 7.3 Typical Control Headworks System for Drip Irrigation System

Arrangement (Reclaimed Wastewater Blending) 189 8.1 Typical Precast Concrete Two-Compartment Grease Trap 200 8.2 Typical Sanitary Wastewater Conventional Septic Tank and Leachfield

System Showing Required Setbacks and Duplicate Leachfield Arrangement 205

8.3 Principal Features of a Leach field Dosing Siphon 206 8.4 Configuration for Typical Concrete Septic Tank 207 8.5 Typical Septic Tank Effluent Pump Station Configurations Showing

Possible Wetwell Types and Pump Machinery Options 208 8.6 Typical Water Level Monitoring Wells for Installation Within and

Outside of Specially Engineered Soil Absorption Systems 220 8.7 Blow-OffValve Installation for Pressure Laterals in Mounds and

Shallow-Trench-Pressure-Distribution Systems 221 8.8 Typical Small Table Winery Process Wastewater Schematic Using

Soil Absorption Methods of Disposal 230 8.9 Strainer /Screen System Options for Winery Process Wastestream 232 8.10 Typical Aeration and Settling Cell Construction Details 239 8.11 Photograph of an Existing Aeration Cell for an 180,000 Case per

Year Annual Production Capacity Winery 240 8.12 Air Diffusion and Mechanical Aerators for Aerobic Reactors

(Aeration Cells) 241 8.13 Typical Large Winery Process Wastewater Schematic with Optional

Methods of Disposal 243 8.14a Poured Concrete Aeration Cell for 85,000 Case Annual Production

Capacity Winery Ready for Start-Up and Testing (See Paired Settling Cells Below) 244

8.14b Settling Cells that can be Operating in Series (Primary and Secondary) or in Parallel. Note Winter Reclaimed Wastewater Storage Pond in the Background 243

List of Figures xv

8.15 Circular Clarifier Used for Separating Solids from Treated Wastewater for 180,000 Case Annual Production Winery 245

8.16 Molecular Methods for Winery Process Wastewater Systems Expansion to Allow Doubling of Production Capacity 250

9.1 Typical Propane Fueling Tank Installation 281 9.2 Typical Design Details for LP-Gas Protective Bollards 282 9.3 LP-Gas Installation Schematic Showing Setbacks and Clearances 284

10.1 Typical Fire Stop and/or Temperature and Smoke Attenuator Detail for Wall or Floor Penetration by a Pipeline 297

10.2 Typical Fire Stop and/or Temperature and Smoke Attenuator Detail for Wall or Floor Penetration by a Busway 298

10.3 Typical Smoke and Fire Damper Detail for HVAC Duct Penetrating a Fire-Rated Curtain Wall 299

10.4 Fire Protection Storage Constructed as Part of Reclaimed Process Wastewater Winter Hold-over Irrigation Storage 310

10.5 Typical Area-Capacity Curve for Fire Protection Storage Pond of Non-uniform Geometry 312

10.6 Typical Flood-Discharge Rating Curve for Fire Storage Pond Emergency Spillway 313

10.7 Typical Pump Intake System for Fire Protection Storage Pond 314 10.8 Schematic Arrangement of a Diesel Powered Primary Fire Pump

System for a 190,000-Case Annual Production Winery 318 10.9 Fire Pump System Discharge Rating Using a Calibrated, "Hinds"

Test Nozzle 319 10.10 Schematic Layout of Typical Diesel-Powered Primary Fire Pump and

Secondary Fire Department Connection 321 10.11 Secondary Fire Department Connection Fire Flow Augmentation 322 10.12 Typical Industrial Hydrant and Sprinkler Plumbing Array 334 10.13 Wet-Barrel Hydrant; Typical Installation Detail 337 10.14 Dry-Barrel Hydrant; Typical Installation Detail 338 10.15 Interior and Exterior Fire-Fighting Equipment and Fittir.gs Commonly

Used in Wineries and Other Industrial Buildings 339 11.1 Solid Waste Balance for Table Winery Operations 354 11.2 Waste Aerosol Can Propellant and Residual Contents Capturing

System 361 11.3 Portable Vineyard Prunings Transport and Field Incineratory in

Burgundy, France 368 11.4 Solid Waste Balance for Vineyard Operations 370 11.5 Concept Design for a Typical Waste Segregation Container Arrange-

ment for Toxic Materials Generated by Winery and Vineyards 373 11.6 Solid Waste Container Configurations and Nomenclature 374 11.7 Winery Solid Waste Plan for Hypothetical Winery Complex 375 11.8 Winery Solid Waste Management Model: Source and Destination

Matrix 376 12.1 Typical Platform Ladder which Meets or Exceeds OSHA and ANSI

Standards for Safety 395

LIST OF TABLES

2.1 Typical Electrical and Gas Service Application and Load Estimate 18 2.2 Winery Electrical Loads and Primary Voltage Preferences 22 2.3 Motor Size/Rating and Recommended Service Voltages 22 2.4 Comparison of Operating Characteristics and Cost for a Typical

30 Horsepower "Standard" and "Energy Efficient" Motor 25

3.1 Winery Communication Needs and System Choices 47

4.1 Sanitizing Methods and Necessary Time-Temperature Parameters 74 4.2 Winery Cleaning Chemicals and Their Recommended Concentrations 75 4.3 Estimates of Water Use for Winery Cleaning Purposes 76

5.1 Partial List of Refrigerants that Meet or Exceed U.S. EPA Clean Air Act Standards 94

5.2 1992 Levels of CFC Use in the U.S. by Major Categories 95 5.3 Allowable Heat Loss/Gain in Chiller, Steam/Hot Water Piping as a

Function of Pipe Size 103

6.1 U.S. Primary Drinking Water Regulations 125

xvi

List of Tables xvii

6.2 U.S. Secondary Drinking Water Regulations 126 6.3 Selected Water Quality Parameters with the Potential for Adversely

Affecting Wine Quality 126 6.4 Estimated Typical Winery Water Requirements by Category of Use 137 6.5 Range of Water Use Rates for Various Winery Plumbing Fixtures

and Equipment 139 6.6 Crush Period Winery Water Use Estimates by Process and Subprocess

~p 1~ 6.7 Estimated Range of Unit Water Use in Gallons per Case of750 ml

Bottles 141 6.8 Typical Monthly Distribution of Annual Flows for Northern

Hemisphere Location 141 6.9 Comparing Two Methods for Peak Winery Water Demand Calculations

for Hypothetical 40,000 Case Facility 142 6.10 Methods for Metering Water Flow for Pipes Flowing Full 149 6.11 Summary of Water Tanks and Materials of Construction 154 6.12 Cylindrical Tank Volumes per Foot of Height 155

7.1 Calculated Supplemental Irrigation Requirements per Wine Grape Vine by Temperature Region 185

7.2 Water Balance Simulation for Reclaimed Wastewater Reservoir Sizing 187

8.1 Derivation of Maximum Sanitary System Wastewater Flows for Wineries with Tours and Tastings 198

8.2 Generally Accepted Design Criteria for Conventional Septic Tank and Leachfield Systems 202

8.3 Comparison of Spatial Requirement and Conventional Oxidation Pond and Conventional Septic Tank and Leachfield System for Winery Sanitary Wastewater 215

8.4 Characteristics of Typical Alternative (Specially Engineered) Winery Sanitary Wastewater System Disposal Options 218

8.5 Septic Tank and Soil Absorption System O&M Tasks 223 8.6 Typical Table Winery Process Wastewater Constituency (Qualitative) 228 8.7 Typical Composition of Table Winery Process Wastewater During the

Crush Season 233 8.8 Large Operating Table Winery Wastestream Constituency During

Bottling Operations 234 8.9 Range of Key Operating Parameters for an Aerobic Reactor for

Optimum Bioreduction of Winery Wastewater for a Given Solids Loading 237

8.10 Summary and Comparison of Above-Ground Treatment System Alternatives for Winery Wastewater 246

8.11 Water Balance Simulation for Reclaimed Wastewater Reservoir Sizing 254 8.12 Water Balance Calculations for a 50,000 Case Annual Production

Winery for Sizing the Storage Reservoir and Irrigated Pasture 256

xviii List of Tables

8.13 Outline and Principal Subject Headings for a Typical Wastewater System Operation and Maintenance Manual 263

8.14 Operating Data and Analysis 264 8.15 Record of Aerated Lagoon Operating Parameters 265 8.16 Solids Handling Report 265 8.17 Pump Station Performance 266 8.18 Reclaimed Wastewater Storage Reservoir 266 8.19 Irrigation Pump Station and System 267 8.20 Livestock Grazing Record 267 8.21 Log of Emergency Conditions 268 8.22 Equipment Service Record 269 8.23 Typical Maintenance Schedule Checklist for Table Winery Process

Wastewater System 270

9.1 Gaseous Fuel Characteristics 279

10.1 Flammable Properties ofWine (<14% Ethanol) 289 10.2 Fire Protection and Life Safety Requirements for Warehouse Spaces 290 10.3 Palletized Storage Limits 290 10.4 Fire Flow and Duration of Fire Flow Determination for a Hypothetical

Winery in Napa County, CA as Calculated from Their Design Guidelines 304

10.5 Fire Detectors: Their Capabilities and Limitations 324 10.6 A Comparison of Selected NFPA 13 Standards for the 1991 and 1994

Current Edition ( "Standards for the Installation of Sprinkler Systems") 328 10.7 Discharge for a Standard Sprinkler With a 1/2-in. Orifice Under

Various Discharge Pressures 331 10.8 Sprinkler Discharge Classification and Identification 332 10.9 Sprinkler Temperature Ratings, Classifications, and Color Codings 333

11.1 Guidelines for Recycling the Most and the Least Desirable Plastics under California Integrated Waste Management Law 357

11.2 Typical MSDS format 358 11.3 Estimates of Unit Solid Waste Generation for Three California

Wineries

12.1 Winery Utility Systems and Potential Air Pollutants 12.2 OSHA-Permissible Noise Exposures 12.3 Model Accident Prevention Plan

371

387 392 403