WQ0000884_Additional Information Received_20220826

BUTTERBALL – MOUNT OLIVE, NORTH CAROLINA
WATER RESOURCE RECOVERY SYSTEM IMPROVEMENTS
Operation and Maintenance Plan

Prepared for:
Lankford Ruffin
Director of Environmental Affairs and Sustainability
Butterball, LLC
1 Butterball Lane
Garner, NC 27529

Prepared by:
Fab Tech Wastewater Solutions
820 O’Fallon Road
Weldon Spring, MO 63044
314-478-3344

Table of Contents

1.0 Introduction ............................................................................................................................. 1
1.1. Objective ............................................................................................................................ 1
1.2. Scope of the Manual .......................................................................................................... 1

2.0 System Overview ..................................................................................................................... 2
2.1. Physical Description .......................................................................................................... 2
2.2. Drawings and Specifications ............................................................................................. 2

3.0 Routine System Operation ...................................................................................................... 3
3.1. General Discussion ............................................................................................................ 3
3.2. System Operating Strategy ................................................................................................ 3
3.3. Equipment Operation and Control ..................................................................................... 3
3.4. Operator Duties .................................................................................................................. 4

4.0 Maintenance ............................................................................................................................. 5
4.1. General ............................................................................................................................... 5
4.2. Site Access ......................................................................................................................... 5
4.3. Daily Maintenance Procedures .......................................................................................... 5
4.4. Periodic Maintenance ........................................................................................................ 5

5.0 Contact Information ................................................................................................................ 7
5.1. Emergency Services ........................................................................................................... 7
5.2. Butterball, LLC – Environmental Manager ....................................................................... 7
5.3. Regulatory Agency ............................................................................................................ 7

1

Introduction

1.1 Objective
This manual will provide insight into the operation and general maintenance of the secondary
equalization tank prior to the dissolved air floatation (DAF) system at the Butterball plant in
Mount Olive, North Carolina.

1.2 Scope of the Manual
This manual identifies various components of the equalization tank and general operation and
maintenance of said tank. Detailed operation and maintenance information for specific
components is supplied by the vendor of that equipment.

2

System Overview

2.1 Physical Description
The 2-million-gallon stainless steel equalization tank is approximately 120-ft in diameter and 24-
ft high with stairs to a lighted viewing and sampling platform at the top. There are two (2) 10-in
influent pipes with butterfly valves to control flow into the tank. Mixing is supplied by coarse
bubble aeration with a positive-displacement blower set next to the tank. A single 12-in effluent
line directs flow out of the tank to the existing pipe leading to the DAF building. An 8-in tank
pump out port with butterfly valve allows for residual liquid to be removed as needed. Liquid
level in the tank is monitored by a pressure transducer.

2.2 Drawings and Specifications
Detailed drawings and specifications may need to be referenced for significant maintenance
and/or repair. These documents are part of the plan set developed by 21 Design with the
assistance of Fab Tech Wastewater Solutions. A complete set of these plans shall be provided to
the owner and operator for future reference.

3

Routine System Operation

3.1 General Discussion
The equalization tank supports optimal function of the dissolved air flotation (DAF) system.

3.2 System Operating Strategy
The purpose of the equalization tank is to convert variable flow from plant processes to consistent
flow for optimal DAF performance. The overall strategy is to provide as consistent a flow rate as
possible to the DAF.

3.3 Equipment Operation and Control
Very little day-to-day hands-on operation of the equalization tank is to be expected. Blower
operation for mixing and liquid level for hydraulic management are the two primary operating
parameters.
The equalization tank is mixed by bubbles from a coarse-bubble diffuser grid. The diffusers
themselves are considered maintenance-free because there are no membranes that need to be
serviced at regular intervals.
Air to the coarse-bubble diffusers is provided by a positive-displacement blower. The blower is
designed for continuous operation, regardless of the water height in the tank, and is controlled
with hand switches. The operators should refer to the manufacturer’s IO&M manual for specific
maintenance information regarding air filters, oil and lubrication, and belts.
A pressure transducer is attached to the side of the tank and used to determine liquid level height
within the tank. The signal from the transducer is sent to the Operator’s SCADA system and
alarms for high- and low-water levels should be part of the programming for that system. The
high-water alarm should be set for 22-ft of liquid height, or 1-ft below the overflow pipe. The
low-water alarm should be set at 1-ft above the top of the effluent pipe to prevent the DAF feed
pumps from running dry. The Operator is encouraged to review the manufacturer’s IO&M
manual for specific maintenance information on the transducer, which may include routine
cleaning and/or calibration.
There are three sets of valves that control flow to and from the tank. Only one equalization tank
should be used at a time. Both influent and effluent valves should be closed to whichever tank is
in standby. The third valve set is for the tank drain. This valve should normally be closed. The
overflow pipe from the tank was designed without a valve to prevent operational error. All valves
should be exercised on a regular basis and the Operator is encouraged to review the
manufacturer’s IO&M for specific instruction.

4

3.4 Operator Duties
The Operator should visit the equalization tank daily, but no less than once per week, to ensure
blower is operating and to verify accurate liquid level feedback. The Operator must document the
operation, maintenance, and visitors to the system in a daily log and notify the Owner
immediately of any overflows or bypasses. The Owner, in turn, is required to notify the
Wilmington Regional Office (see Section 5) of an overflow or bypass within 24-hours of
becoming aware of the incident.
The Operator must provide written notification to the Owner if system repairs or modifications
are needed to ensure all regulatory compliance.
The main plant should be contacted if there is a power outage at the equalization tank, DAF, or
connecting pumps.
3.4.1 Daily Routine
The operator should log flows from the processing plant over the course of several days and
weeks to determine that average flow requirement for the DAF. That average flow can then be
adjusted as needed to account for the limitations of process water storage across the two
equalization basins (existing and new).
3.4.2 Emergency Power Plan
The only component solely obligated to the proposed equalization tank is the blower, which is not
a critical item for operation of the equalization tank. Power failure to effluent pumps could result
in the tank being overfilled if the influent pumps were to remain in operation, but over filling the
tank would result in a bypass discharge around the DAFs and directly into the receiving lagoon.
Therefore, no emergency power plan is necessary for the proposed equalization tank because the
system can tolerate septic wastewater due to prolonged detention and sufficient storage capacity
exists, between the equalization tank and receiving lagoon, that no potential for overflow exists.

5

Maintenance

4.1 General
Timely and prompt maintenance is imperative for the performance of any treatment system and
will extend the overall life of the components.
4.1.1 Tank Pump Out
A pump out station has been provided for removing residual water and solids when needed.
Contents of the tank should be pumped to the existing EQ tank or held in a tank. Bypass of the
DAF is not permitted without prior explicit written consent from NCDENR.

4.2 Site Access
Fences, gates, and security guards restrict access to the water resource reclamation facility for
safety and security.

4.3 Daily Maintenance
No daily maintenance is required. General daily inspection is suggested but should be conducted
no less than once per week. Inspection should consist of ensuring blower is operating, checking
for symmetrical mixing (free of dead zones), and checking water level in the tank.

4.4 Periodic Maintenance
The following sections provide general direction and notes. Please refer to the manufacturer’s
recommendations and IO&M manual(s) for detailed information.
4.4.1 Blowers
Refer to manufacturer’s instructions. General maintenance includes air filter, checking discharge
pressure and adjusting pressure relief valve, changing oil, inspecting belts, etc.
4.4.2 Valves
Exercising valves on a periodic basis is crucial to valve longevity. Please refer to the
manufacturer’s instructions for more information.
4.4.3 Diffusers
Each diffuser features a small duckbill valve to prevent water from backing up into the aeration
system. Failure of this valve is not operationally critical. There is the potential for plugging of the
aeration distribution lines should one or more valves fail, and if the blower is turned off for an
extended period. “Dead zones” will be apparent when blower function resumes. In this case the
lines will need to be purged and duckbill valves in the area of the dead zone should be inspected
and replaced as needed.

6

4.4.4 Pressure Transducer
Please refer to the manufacturer’s IO&M manual for periodic calibration and service
requirements.

7

Contact Information

5.1 Emergency Services
Duplin County E-911
Phone: 911

5.2 Butterball, LLC – Environmental Manager
Josh Batchelor
1628 Garners Chapel Road
Mount Olive, NC 28365
Cell: 252-560-8327
Email: [e-mail]

5.3 Regulatory Agency
North Carolina Department of Environment and Natural Resources
Division of Water Quality – Non-Discharge Permitting

Information Processing Unit
1636 Mail Service Center
Raleigh, NC 27699-1617

Wilmington Regional Office
Phone: [phone]
Fax: [phone]

Division of Emergency Response
Dean Hunkele (Regional Senior Environmental Specialist): 910-796-7380
Division of Emergency Management: 919-733-3300
Afterhours: 800-858-0368
BAR = 1" AT PLOT SCALE
BAR = 1" AT PLOT SCALE
AABBBAR = 1" AT PLOT SCALE
F/05F/05BAR = 1" AT PLOT SCALE
BAR = 1" AT PLOT SCALE
EEBAR = 1" AT PLOT SCALE
BAR = 1" AT PLOT SCALE
BAR = 1" AT PLOT SCALE