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Home My WebLink AboutHISTORICALj DIVISION OF ENVIRONMENTAL MANAGEMENT May 9, 1994 ME.MQRANDUM TO: John Seymour Permits and Engineering FROM: Grady Dobson, Environmental Engineer Fayetteville. Regional Office SUBJECT: Application No. WQ0009305 Valley Proteins, Inc. Sludge Land, -Application Anson County 'It -is my assumption that the application (WQ0009305) received by the Fayetteville Regional Office in April pertains to the pathogen reduction for Valley Proteins' sludge permit (WQ0007504). The -description provided by ' Reid Engineering references an NPDES permit.- Valley Proteins does not have an NPDES permit. The heat treatment process appears to be an acceptable, alternative to meet. the 40 CFR Pathogen Reduction Criteria (PSRP),..and these new units should be included in the existing spray irrigation permit (WQ0000957). The report also states that once the sludge is processed or, meets the PSRP criteria, it will be pumped, from the tanks to the sludge sites. The existing sludge permit (WQ0007504) has no .- provisions for spray irrigating the sludge: All the sludge sites are on Valley Proteins' property, but a pipe system does not exist -to spray, irrigate the sludge. A piping network .for this type of application would be complicated. The existing sludge permit was issued based on sludge application from a tank pumper truck. Should y u have any questions, feel_ free. to contact me. GD/tf DIVISION OF ENVIRONMENTAL MANAGEMENT May 9, 1994 MEMORANDUM TO: John'Seymour Permits and Engineering FROM: Grady Dobson, Environmental Engineer Fayetteville Regional Office SUBJECT: Application No. WQ0009305 Valley Proteins, Inc. Sludge Land Application Anson County It'is my assumption that the application (WQ0009305) received by the Fayetteville Regional Office in April pertains ' to the pathogen reduction for Valley Proteins' sludge permit (WQ0007504). The description provided by Reid Engineering references an NPDES permit. Valley Proteins -does not have an NPDES permit. The heat treatment process appears to be an acceptable alternative to meet the 40 CFR 'Pathogen Reduction Criteria (PSRP), and these new units should be included in the existing spray irrigation permit (WQ0000957). - The report also states that once the sludge is processed or meets the PSRP criteria, ,it will be pumped from the tanks to the sludge sites. The existing sludge permit (WQ0007504) has no provisions for spray irrigating the sludge. All the sludge sites are on Valley Proteins' property, but a pipe system does not exist to spray irrigate the sludge. A piping network for this type of application would be complicated. The existing sludge permit was issued based on sludge application from a tank pumper truck. Should y u have any questions, feel free to contact me. GD/tf St t f 'KI r+h r", linn Department of -EnVironment, Health, -and Natural Resources... Division of Environmental,Management , OMW% OOWA% James-8. Hunt, Jr., Governor Johath -an B. Howes, Secretary Jr., A. Preston Howard, P.E., Director May 4, 1994 Mr. Michael A. Smith ENV. MANAGEMENT Valley Proteins, Inc." WUMILLE RML QFFICE D fW-r.- 'D 'lCQQ VOL ILI VA Winchester, Virginia .1 22604 Dear Mr. Smith: ' Subject: WQ(M9305 Modification for Permit WQ0007504- Additional -Information Valley Proteins, Inc. Wadesboro N.C. 'Land Application of Sludge Stabilization Anson County The Permits and Engineering. Unit has' completed a prelirminary,engineering review of the subject application. It isunderstood,that the subject application -is to modify the sludge stabilizati-oll procesg in,the existing land application of sludge permit from lime stabilization to heat treatment stabilization. The, land application method and la nd application site will remain the same. Please inform this Office if this is not completely -correct. The'following items must be addressed before we can complete our review: L- 'The submitted plans are not P.E. Sealed as required by N.C. State Regulation for permitting: The plans have to be stamped approved as part of,the permitting process. Please provide -a set of proposed plans that are P.& sealed by a 14ofth :Carolina registered P.E. or a P.E. with reciprocity.' 2-. The submitted application proposes to use heat ,pasteurization to meet stabilization requirements for pathogen reduction. iis, not clear how the stabilizationfor vector attraction reduction requirements are to be met by the proposed heat method. This. is in reference to the.federal register requirements under part 503 for stabilization, (40 CFR, Part 503 sections 503.32 and. 5.03.33) Please provide details on how,the propose& stabilization, method will meet stabilization requirements for -vector attraction.' Please include an, explanation of how each batch will be monitored to ensure the stabilization -process has succeeded. Refer to the subject p6r-mit. application number when providing the requested information.; Also; please note that failure to provide this additional information on or before June. 6,1994, will.. subject your application to being returned as incomplete in accordance with 15 NCAC 211 .0208. If you have any questions on this matter, please call me at 919/ 733-5083. Sincere ly, john Sey Environmental Engineer I cc: Fayetteville Regional Office, Water Quality Reid Engineering Company, Inc. P.O. Box 29535, Raleigh, North Carolina 27626-0535 Telephone 919-733-5083:, - FAX 91 9-733-991.9 An Equal Opportunity Affirmative Action Employ6r, 50%,recycled/ 10% posi=co'nsurner paper State of North Carolina Department'of 'Environment, 4 '' Health and- Natural Resources Division of Environmental Management • James ,B. -Hunt, Jr., Governor. Jonathan B., Howes, Secretary. A. Preston Howard, Jr:, P:E., Director April ,14, _1:994 R 1994 MR MICHAEL A. SMITH EN-V. MANAGEMENT VALLEY- PROTEINS' INC. r-AYETTEVILLE RCG. OFFICE PO BOX, 3588 WINCHESTER, VIRGINIA 22604 Subject:, Application No. WQ0009305 A Sludge/Anson Co. Sludge -Land Application Anson County Dear MR SMITH: yvlG of i (r cq o� ,s %a S, The -Division's Permits and Engineering Unit acknowledges receipt of your permit. application and supporting materials'bn April 11,,1994, This application has. been assigned the number shown above. Please refer to this number when making inquiries on this project. Your project has been assigned to John Seymour for a de�ail`ed engineering review. Should there be any questions concerning your project, the reviewer will contact you with an additional information letter. Be awarethatthe,Division's regional office,'copied below, must provide recommendations from the d Regional Supervisor or a. Procedure Four Evaluation for this project, prior to final action by the Division: 14 If you have any questions, please contact John Seymour at (919) 733-5083. S' erely, 41L all Carolyn Mc kill Supervisor, State Engineering Review Group cc: Fayettei ille-Regional Office- . Reid Engineering Pollution Prevention Pays - P.O: Box, 29535, Raleigh,North Carolina 27626=0535, Telephone 919-733-7015" An Equal Opportunity' Affirmative -Action Employer. tvrtb is the 4ds id Engineering Company, Psalm 24:1 ReidEngineefing Company, Inc.. Inc, Consulting Environmental Engineers Specializing in the Design and Operation of Water Pollution Control Systems March 9, 1994 Mr. John Seymour North Carolina Department of Natural Resources P. O. Box 27867 512 N. Salisbury Street Raleigh, North Carolina 27626 SUBJECT: VALLEY PROTEINS, INC., WADESBORO, NORTH CAROLINA WASTEWATER TREATMENT SYSTEM BIOLOGICAL SLUDGE DISPOSAL PLAN Dear Mr. Seymour: The attached Drawings, Design Summary Engineering Report and NPDES permit modification application -prepared by Reid Engineering Company are submitted on behalf of Valley Proteins, Inc., to the North Carolina Department of Natural Resources for review. and approval to obtain a permit to' construct a proposed new biological sludge heat treatment system to comply with pathogen reduction requirements of the DNR and US :_ EPA sludge disposal regulations. This existing wastewater treatment facility presently generates an average of �J approximately 6,000 gpd of waste activated sludge which has been disposed by land application on the approved spray irrigation wastewater disposal site. Valley Proteins proposes to install and operate a new heat treatment process for pathogen reduction in the waste activated sludge prior to ultimate disposal by spray irrigation. The proposed sludge heat treatment system will use a batch heating process with waste heat supplied from the rendering plant into two 7,000 gallon sludge storage - heat treatment tanks. Sludge will be pumped into either of the 7,000 gallon sludge storage tanks until the tanks are approximately full containing a volume between 5,500 to 7,000 gallons after which the sludge contained in the tank will be heated to over 1800 F and retained for a minimum detention time of 30 minutes prior to ultimate disposal by spray irrigation. �I C ��) 1210 Princess Anne Street • Fredericksburg, Virginia 22401 • 703-371-8500' • FAX 703-371-8576 Registered Professional Engineers in Alabama, Arkansas, California, Delaware, Florida, Georgia, Illinois, Indiana, Iowa, Kentucky, Louisiana, Maine, Maryland, Michigan, Minnesota, Mississipi, Missouri, Nebraska, New Jersey, New York, North Carolina, Ohio, Oklahoma, Pennsylvania, South Carolina, Tennessee, Texas, Virginia, Washington, West Virginia r -Mr. John Seymour North Carolina Department of Natural Resources March.9, 1994 Page Two At the present waste activated sludge production rate, it is estimated that between one sludge batch per day ranging from 6,000 to 7,500 gallons must be heat treated. prior to ultimate disposal by land application. In the future, if the daily,waste activated sludge production volume increases to '10,50.0 gallons/day as estimated Yon- page 17 of the original design summary report attached - (see Appendix #1) approved by the North Carolina Department. -.of Natural Resources for this facility, then the number of sludge batches will be increased to accommodate the .additional ,sludge volume. If required in the future, additional sludge batch heating .tanks can be installed. A process flow schematic and details of the proposed new sludge heat treatment _system_ are attached for .review and'. approval by. -the DNR. If additional submittal information is required by the DNR please advise. Since Valley Proteins desires to place this sludge heat treatment system in operation as soon, as possible, expedited approval of this design submittal by the DNR would be appreciated. Sincerely, REID E INEERING COMPANY, INC. ohn H. Reid; P.E: President cc: Mike Smith Tom Gibson Clayton Gregson Doug Brown CVP06C. JAR/ca 1" - - ` DESIGN SUMMARY OF WASTEWATER PRETREATMENT FACILITIES VALLEY PROTEINS, INC. Wadesboro, North Carolina February 1989 . (Revised March 1994) Prepared by: REID ENGINEERING, COMPANY, INC. 1210 Princess Anne Street Fredericksburg, VA 22401. Phone:703/371-8500 Fax:7031371-8576 DESIGN. SUMMARY _ OF WASTEWATER PRETREATMENT FACILITIES VALLEY- PROTEINS,- INC.- Wadesboro,:NC TABLE. OF CONTENTS` A. GENERAL 1. B., SCREENING 1 C. DRAINAGE WASTE FLOW EQUALIZATION BASIN (FEB. #1) 2 D. FEB #1 EFFLUENT. PUMP STATION _ 2- E.' DISSOLVED AIR. FLOTATION PRETREATMENT SYSTEM,:- • . 3 F. ". FLOW EQUALIZATION BASIN (FEB.42) 5 G.' FEB *2 EFFLUENT PUMP STATION 7 - - - H. DAF SYSTEM.CHEMICAL FEED SYSTEM 8 I.— TOTAL BARRIER OXIDATION DITCH (TBOD).:ACTIVATED SLUDGE - CLARIFIER FINAL TREATMENT SYSTEM 9 J. FINAL CLARIFIER ° 16 K. SLUDGE` RETURN AND WASTE -."PUMPING STATION 17 L. CHEMICAL STORAGE - FEED'EQUIPMENT FOR ACTIVATED " SLUDGE PROCESS 17 M'. 'SPRAY IRRIGATION PUMP STATION 18 N. EFFLUENT FLOW METER 19 O. REQUIRED EFFLUENT, QUALITY BASED ON WASTEWATER LAND APPLICATION. SYSTEM DESIGN 19 DESIGN SUMMARY OF WASTEWATER.: PRETREATMENT FACILITIES VALLEY PROTEIN8--1NC. Wad esbom, •North Carolina X, GENERAL,- 1,. Three- basic types of wastewater will_6e discharged -by -the rendering plant. a. Wastewater generated ' by- truck washing .and, plant drainage and washdown will contain high concentrations of oil and grease, suspended solids, TKN and' BOD...This washdown ' and; drainage wastewater must be pretreated by a'fat flotation .unit and a dissolved air flotation -cell to reduce. these high_ concentrations. of suspended pollutants before flowinginto the downstream , final .;biological . treatment -process.. _ b.. Cooker condensate wastewater generated' by the rendering operation =4' will contain high concentrations of ammonia and other dissolved or_. = , soluble poll utants.'compared to washtlown and drainage wastewater. This wastewater is pumped directlyjo'.Flow Equalization Basin #2 to, be- blended with pretreated drainage wastewater, prior to .final biological treatment. - c.- Sanitary wastewater. generated- from the bathroom facilitiesc-.at the rendering plant will flow directly to the biological treatment plant since solids in this type of wastewater should -not be removed by screening. and flotation. and; there rendered. ... B. SCREENING 1. Wastewater generated by plant washdown and truck drainage activated will flow by gravity sewer lines into a collection -well and from there be pumped into a Sweco vibrating.circular screen with .03 inch openings with a capacity of .200 gpm.: DESIGN SUMMARY VALLEY PROTEINS,INC. Wadesboro, NC. Prepared by: REID ENGINEERING COMPANYJC. s 1 2. Screenings will be rendered for ultimate disposal. C. DRAINAGE WASTE FLOW- EQUALIZATION BASIN (FEB #1) 1. Design Assumptions: a. - Wastewater Flow Rate & Volume (1) Maximum daily -influent flow rate = 100 gpm - (2) Average -daily influent flow volume = 50,000 gpd, 5 "to 6 days/week b. Pollutant Concentrations and Loads-.- (1) The following influent wastewater characteristics are assumed in the design of the Drainage Waste Flow Equalization Basin.... Pollutant Concentration Loading BOD = 9000-mg/L 2,252#/day TSS = 6000 mg/L. 1,501 #/day O&G ' = 2000-mg/L .500#/day TKN 900 mg/L 225,#/day " 2. FEB Basin Dimensions and Volume: Number of -Tanks _ 1 Tank`Diameter = 12.0 ft. Tank Height = 20.0 ft. Average Depth @ HWL = 17.5 ft. Volume .@ HWL = 15,000 gallons Average Depth @ LWL = 6.0 ft.' Volume @ -LWL = 5,000 gallons D. FEB #1 EFFLUENT PUMP STATION 1. Wastewater equalized in Flow Equalization Basin #1 (FEB #1) will be DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NO Prepared by: REID" ENGINEERING COMPANY, INC. 2 pumped ;to the DAF Cell 24 hours per day, approximately 5 to 6 days per week. Two end suction wastewater pumps are provided each rated at 50 to 100 gpm @ 35 ft. total head, with operation of- one pump required.to pump the. design maximum flow of 90 gpm from the FEB into 'the DAF Cells. The second, pumpis provided as an installed. standby. 2. A ' Flow Meter is provided in the pump discharge force main with downstream flow control valves to.accurately measure, indicate; and totalize the wastewater flow pumped from the FEB',into the DAF Cells. 3. In the event of power failure, wastewater can be .restored in the FEB until normal f power is resumed. E. DISSOLVED -AIR.FLOTATION PRETREATMENT SYSTEM 1. Design Assumptions a. Wastewater Flow Volumes: (1) Drainage Wastewater < '55,000 gpd, 35 gpm,"5 to 6 days/week b. Pollutant characteristics and loadings in the screened drainage -wastewater: (1) Rendering plant drainage wastewater @ 50,0.00 gpd, 5 to 6 days per week:. Pollutant Concentration (mq/L) #/day BOD 9000 mg/L 3753#/day TSS 60.00 mg/L 2500#/day O&G , 1400 mg/L 5834/day TKN 900 mg/L 375#/day (2) Expected pollutant removals in the DAF Cell with chemical coagulation -flocculation @ .05 MGD maximum 5 day design flow:. i' DESIGN SUMMARY VALLEY PROTEINS, INC. J Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 3 _ `�- Estimated Average Effluent Concentrations Pollutant: %Removal and Loads BOD < 75% to 80% < 2000 m.g/L; 834#/day TSS < 90% to 95% < 500- ng/L; 210#/day O&G < 85% to-90%-- < 150 mg/L; 63#/day TKN < 25% to 30% < 650 mg/L; 271 #/d ay 2. DAF Cell Design a. DAF Cell design solids "load approximately = 200#/HR assuming a BOD removal efficiency of 70% in the-DAF cell. b. The required air dissolving rate for solids loading rate'of 200#/HR 200(.03) 60 _ .10# air/min The required air supply rate @ 90OF inlet air density @ the 300' site altitude > .0712#/ft3 .10#/min. - .0712 = 1.4 cfm < 2 cfm ` C. Calculate the, minimum pressurized flow required @ 90 psi air dissolving pressure @ wastewater temperature = 80°F. AC = air dissolving capacity = .184 [.8 so + -1] _ 184- 1a.7 AC = .864# air/min. @ 90 psi QR = .10#/min. (1,000) _ 11.6 gpm, use,2 - 150 gpm recycle .864 pressurization pumps d. 'One 2V dia. DAF Cell #2 to be used with 600 ft2.of effective surface area DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesb°ro, NC 4 Prepared byc REID ENGINEERING COMPANY, INC. e. The calculated hydraulic loading rate @ QT = QR + QI = 90 gpm + 150 gpm 240 gpm is: 240 gpm 600 ft2 .40 gpm/ft2 f. The calculated solids loading rate @ 200#/HR ,is: 200#/H R 600 ft2 _ .33 #/ft2/HR. g. Calculate chemical pretreatment sludge production rate in "the DAF Cell at the "design capacity flow of ..05 MGD assuming an average BOD removal efficiency, of .70% and assuming a'solids concentration of 12% after decanting in the DAF sludge holding tank: DAF Sludge Volume = (9000 mg/L(.70)(8.34)(.05 MGD) = 2625 gpd (.12)(8.34) < 3000 gpd . (estimated Range = 2000 to 3000 gpd @ 10% to 18% solids) F. FLOW EQUALIZATION BASIN (FEB #2) 1. Design Assumptions a. Wastewater Flow (1) Maximum Design Average Daily Combined Influent Flow Volume - .125 MGD; 5 to, 6 days/week including 50,000 gpd of pretreated plant drainage wastewater and 75,000 gpd of raw condensate wastewater b. Pollutant Concentrations and Loads (1) Maximum Daily,.Influent Pollutant Loadings from .pretreated drainage waste water.discharged from the upstream DAF Cells @ .05 , MGD, -5 to .6 days/week:.. DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 5 BOD < 2000 mg/L; 834#/day TSS < 500 mg/L; 210#/day O&G < 150 mg/L; 63#/day TKN' < 650 mg/L; 271 #/day (2) Maximum- Daily Influent Pollutant Loading from raw condensate wastewater discharged from rendering plant @ .075 MGD,. 5 to 6`days/week: BOD < 2000 mg/L; 1251 #/day TSS < 200 mg/L; 125#/day JKN < 650 mg/L; '407#/day O&G < . 150 mg/L; 94#/da.y (3) Combined, Wastewater Pollutant Loadings-.@ .125 MGD total flow volume, 5 -to 6 days/week: BOD < 2000 mg/L; 2085#/day TSS . < 325 mg/L; 335#/day. TKN < -650 mg/L; 709#/day O&G < 150-'mg/L;' 157#/day. 2. FEB #2 Basin Dimension .and Volume: Number of Basins..-, 1 Tank Diameter = 60 ft. Average. Depth @ HWL = 17.5 ft. Volume @ HWL = 250,000 gallons Average Depth @ LWL = 4.0 ft. Volume '@ LWL _ 84,500 gallons/tank, Equalization Volume = 165,500 gallons 3. Aeration and Mixing Requirements for the -FEB #2 Basin _is calculated as follows: a. HPM = Power Required for Mixing: Average 60 HP/MG will , --be required ..@ < 1000 mg/L suspended solids concentration in the Equalization Basin for mixing: DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 6 HPM = 60 (.25 MG) :< 15 HP (approx.) b. HPA = Power Required for Aeration: Assume the required oxygen transfer requirement of .60#02/#BOD in FEB #2 = AOR = .60 (3,648#BOD/day) = 91# 02/hr 24 AOR < 100#02/#hr C. One 60 HP high speed floating surface aerator is provided in FEB #2 for oxygen transfer mixing. The field oxygen transfer capacity of the 60 HP aerator assuming an oxygen transfer rate from the aerator into the FEB wastewater of 2.0#02/HP/hr = 60 HP (2.0#02/hr/HP) = 120#02/hr vs. 100#02/hr required Therefore, aeration power requirements govern aerator. selection. HPA=60HP vs HPM=15HP G. FEB #2 EFFLUENT PUMP STATION 1. Wastewater aerated and equalized in the Flow Equalization Basin (FEB #2-) will be pumped to the Total Barrier Oxidation Ditch (TBOD) at a relatively uniform rate approximately 7 days per week, 24 hours/day. 2. The required average 7 day FEB effluent pumping rate = .125 MGD (5.5 days) = .098 MGD < .10 MGD < 70 gpm 7 The required maximum 5 day FEB effluent pumping rate = 125 MGD = 87 gpm 3. Two self -priming wastewater pumps are provided, each rated at 50 to 100 gpm @ 35 ft. total head with operation of one pump required to pump the DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 7 } gpm from the FEB into the TBOD: The second pump is provided as an installed, standby. 4. A Flow Meter 'is provided in the pump discharge force main with downstream flow control valves to accurately measure, indicate, and totalize the .wastewater flow pumped from the FEB tank into the TBOD Basin. 5. In the event of -power failure,_ wastewater can be stored in the FEB until normal power is resumed. H.- DAF SYSTEM. CHEMICAL FEED SYSTEM 1. The following equipment is provided for mixing, storage . and pumping chemical solutions . that are necessary for . operation of the coagulation -flocculation process -in the DAF pretreatment system:. a. For chemical coagulation of wastewater being pumped into the DAF. Cell: (1) One 5,000 gallon bulk storage tank for coagulant solution (2) Two coagulant solution pumps,, each rated @ .4 to 4 gphr @ 50 psi; One pump, @ A.to 4 gphr will inject coagulant at the rate of up to 500 .mg/L:(dry basis) into the .05 MGD design max. &,day drainage wastewater flow .rate generated by the Rendering Plant; the normal dosage requirement is expected to be between 2 to 3 gphr, 200 to' 400 mg/L, (dry. basis). b. For anionic polymer flocculation. of coagulated. wastewater being pumped into the DAF Cell: (1) One 250 gallon .anionic polymer -flocculant solution mix -storage tank with 1 HP mixer (2)- One anionic polymer solution pump rated.@ 5 50 gphr @ 50 psi; one pump @ 5' - 50 gphr will inject anionic polymer, flocculent at the rate of up to, 10 mg/L (dry basis) into the '.05 MGD-,maximum design 5 day drainage -wastewater -flow rate DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NO $ Prepared by: REID ENGINEERING COMPANY, INC.- assuming a .1% by weight anionic -polymer solution strength is made .up in the, 25.0 gallon mix tank; the normal anionic polymer dosage requirement is expected -to be between 4-6 ; mg/L (dry basis) I. TOTAL BARRIER OXIDATION .DITCH (TBOD) ACTIVATED SLUDGE - CLARIFIER FINAL TREATMENT SYSTEM 1. Design Assumptions a. Wastewater Flow Volumes: (1) Design maximurn daily influent flow rate = .125 MGD, when wastewater is .pumped from the FEB, to, DAF Cell, 5 to 6 days/week, 24-' hours/day- for final.. pretreatment prior to discharging by. gravity into the, TBOD , (2) Design -average-. daily influent flow rate = .1.0 MGD, 7' days/week when .upstream FEB ,used for 7 day, 24 hour hydraulic flow equalization' Pollutant Concentrations and Loads... (1) Influent pollutant loadings when influent wastewater @ .125 MGD, 5 to 6 days/week from FEB #2: BOD < 2000 mg/L; 20004/day - TSS < 325 mg/L; 335#/day TKN < 650 mg/L; 678#/day O&G ..< 150' mg/L; 157#/day (2) Influent pollutant loadings. when influent. wastewater @ .100 MGD, 7 days/week from FEB#2: „ BOD < 2000 mg/L; 1668#/day TSS < . 325 mg/L;, 271 #/day TKN ' < 650 mg/L;:. 542#/day O&G < 150 mg/L;' 125#/day DESIGN SUMMARY ( _ VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING"COMPANY, INC. 9 C. Treatment Requirements @ 10 MGD 7 day discharge flow -rate from spray'storage lagoon to land application fields: BOD < 424/day; . 50 mg/L TSS < 42#/day; 50 mg/L TKN < 33#/day; 40 mg/L TN < 75#/day; 90 mg/L NH3 N < 21 #/day; 25 .mg/L- NO3 + NO2 < 42#/day; 50 mg/L 2. Total Barrier Oxidation Ditch Design a. Basin volume .= 15 MG (approx) @ normal liquid level b. Calculate MLVSS- and- MLSS concentrations required for BOD and ammonia removal @ the minimum winter -season expected design mixed liquor temperature - 150Cat the maximum design inflow rate = .125 MGD,when -pretreated-wastewater is pumped from FEB #2 into the TBOD 5 days/week: (1) For.BOD removal assuming -a carbonaceous BOD removal rate = .20#BOD/#MLVS8 (aerobic) @ 150C: 2000#BOD/day .20 < 10,000#MLVSS @ 150C (2) For TKN removal assuming a nitrification' rate = .03#TKN/#MLVSS (aerobic) @ 15°C, and assuming a nitrogen uptake by the biomass of approximately 3 mg/L. N/100 mg/L BOD (2000 mg/L BOD) = 60 mg/L = 62.5#/day- 678 - 62.5 .03 < 21,000#MLVSS@ 150C (3) For NO3 N ' removal assuming a denitrification ''rate = .04#NO3 N/#MLVSS (anoxic) @ 150C _ DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 10 615.5 .05 < 15,500#,MLVSS @ 15°C . (anoxic biomass volume)', (4) The required total MLVSS ,and MLSS concentrations in the 1.5 MG aeration basin for BOD removal, nitrification and denitrification assuming MLVSS/MLSS = .80 21,000# + 15.500# (8.34)(1.5 MG), = 2,914 mg/L MLVSS. 2,914 m L .80 < 4,000 mg/L MLSS @ 150C C. Design F/M (food to biomass) ratios in Barrier Oxidation Ditch Activated Sludge -Basin:• (1') @ .125 MGD 5 day design inflow rate: F/Mt < 2,000#/day (8.34)(1.5 MG)(4,000 mg/L). < .04#BOD/#MLSS @ 4,000 mg/L MLSS d. Calculations indicate that the proposed 1 5 MG' Total Barrier Oxidation Ditch Activated Sludge Treatment- System is of adequate -volume for accomplishing the required,BOD and TN (total nitrogen) removal down to an activated sludge basin temperature of 1.5°C. e. Evaluate Mixing and Aeration Requirements in the Activated Sludge Aeration Basin:, (1) bhp required for mixing a 4,000 MLSS concentration 60 bhp/MG bhp required = 60 (1.5) < 90 bhp (2) Calculate the maximum'' summer season average daily oxygen transfer requirement in the TBOD activated sludge aeration basin: AOR = .60#0j#80D applied + 4,57#OJ#TKN applied + .06#0j.#MLSS under aeration DESIGN SUMMARY i VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY,, INC. 11 AORs = 6(2000#BOD/day)+4.57(678#TKN/day)+.06(36,500/.80#MLSS) _ > 24 1200#/day + -3,098#/day + 2,736#/dav 24 = 1200#/day + 3098#/day + 2736#/dav 24 _ - 7,034#/dav = 293#0)hr_. 24 < . 300#0)hr in summer season (3) Calculate the maximum winfer'season.average daily oxygen transfer requirem ent in the -activated sludge aeration basin: AORW= .,60#02/#BOD applied ''+ 4.57_#0W#T_ KN applied + ,03#02/#MLSS under aeration i AORW= 6(2000#BOD/day)+4.57(678#TKN/day)+.031(36,500/.80#MLS5) 24 _ 1200#/day+ 3,098#/dy + 1,368#/dav 236#02/hr 2 250#02 in winter- season (4) Calculate the required corresponding maximum standard oxygen transfer rates.(SOR):- Css T-20 .SOR = AOR_ B ( C., -DO)a .(1.024) Where DO = .75 mg/L (average DO in the aeration basin) 8 = .90 DESIGN SUMMARY r VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 12 a = .80 @ 3,500 to 4,500 mg/L ML-SS T-20 1.024 = 1.394 @ 340C Cw = 7.2 @ sea level, 340C 'Cs = 9.2 @ sea"level, 200C Site Altitude = 300 feet (Approx. ) Pressure Correction Factor < .95 14.7 + (.5)(.433)(16)* Css = 9.2 14.7 9.2 (1.2356) = 11.37 mg/L (95)(14.7) + (.5)(.433)(16)* Csw = 7.2 14.7 7.2 (1.1856) _: 8.53 mg/L * Oxygen Contact Chamber Centerline Depth = 16.0 ft. (AOR) 11.37 SOR = [(.90(8.53) - ..75] .80 (1.394) SOR = 1.47 (AOR) SOR (Max.) < 1.50 (300) <"450#02/HR (5) Calculate subsurface draft tube aeration equipment air sparging requirements: (a) X = . .23 (.075#/ft200 min/H R) " 1.035#02/cfm/HR @ 68° -inlet air DESIGN SUMMARY VALLEY PROTEINS, INC. J Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 13 (b) .Draft tube aerator oxygen stripping or transfer efficiency at 16' oxygen contact'duct depth = 24.0% for conservative design (c) acfm required = ' SOR (x) (e) cfm =_ 450 (1.035) (.24) < 1800 acfm (total) (d) This air sparging and oxygen transfer requirement can be provided by two 50 HP, 48" dia. draft tube induction aerators which are each capable of sparging approximately 540 cfm of air operating in parallel with 1-100 HP, 84" dia.- draft tube..' aerator capable of sparging 1000 to 1200 cfm with air supplied by 2 - 40 HP two speed blowers each rated at 700 cfm @ 8 psi. These two 50 HP draft .tube induction aerators plus one 100 HP draft tube aerator.can sparge a total air flow of over. 2000 cfm vs. the 1800 cfm required. _(e) AOR capacity of each 50 HP, 48" dia. draft tube induction aerator. > _ (540 cfm) .(1.035#02/cfm) (.24)/1.50 > 90#0jhr.- t4� AOR capacity of the 100 HP, 84" dia., draft tube aerator > (1000 cfm): (1.035#02/cfm) (.24)/1.50 > 165#02/hr. -Total AOR capacity= 90(2)+165 = 345#02/hr vs .300#0jhr AOR required. (f) - TBOD channel mixing velocities and:oper.ating Volumes: 1. TBOD channel length .. = 655 ft-. Channel HWL depth = 11.6 ft. Channel volume @ HWL = 1.50 MG - : Channel area = 28 x 11 _ 308 cfs .. 2.. DTA pumping rate = 98.cfs for each 50 HP 48" ,dia. draft tube induction aerator + 300 cfsfor the 100 HP, 84" dia. draft tube aerator Channel velocity = 'Vc DESIGN SUMMARY i' VALLEY PROTEINS, INC. j Wadesboro, NC Prepared by: REID ENGINEERING,COMPANY, INC. 14 Vc with 2-50 HP 48" dia..DTA @ HWL= .64,fps k Vc with 1-100 HP 84°. dia. DTA @- HWL = 1.0 fps Vc with 1-50 HP + 1=100 HP DTA. @ HWL = 1.3 fps Vc with 2-50 HP + 1.400 HP. DTA @ HWL = 1.6 fps These velocities will be increased if. the barrier wall Slide gates are lowered to allow induced flow. generation in the TBOD 3. Evaluate Sludge Wasting Requirements from the Activated Sludge Process a. Calculate waste activated sludge, production at the maximum daily BOD loading rate: (1) F/Mv = 2000#BOD/day A4,000 mg/L)(1.5 MG)(8.34) .04#BOD/#MLVSS (2) Y Expected Activated Sludge Production Rate @ < .01 - .10 F/Mv ratio _ .35# waste sludge/#BOD (3), # Waste Sludge = (.35)(2000) = 700#/day '(4) Volume to be wasted from sludge return flow @ 8000,mg/L to the proposed new Sludge Heat' Treatment System for sterilizing prior to ultimate disposal, -by land application: = 700#/d ay (.008)(8.34)` = 10,500 gpd (Approximately) DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 15 J. FINAL CLARIFIER 1. Pollutant -Loads a. Maximum 5 day inflow rate with ,100% sludge recycle rate = (.125 MGD) (2) < .25 MGD b. Maximum .5 day inflow- rate with 200 sludge recycle rate_ (.125 MGD)(322)*<,.375 MGD 2. Calculate Clarifier Loading Rate a. One 45.0' diameter x 14:0' -side water depth circular clarifier is provided forfinal clarification. b: Circular clarifier effective surface overflow diameter 45.0 ft:; effective surface overflow area = 1400 ft2 and effective clarifier, floor area = 1500 ft2 c:. ..Circular clarifier volume-= 165,000 gallons d. Hydraulic surface loading rate: -' 125,000 god ._ 89 gpd/ft2 @' maximum 5 day throughout flow 1400 ft2 rate of -.125 ,MGD 100.000 qpd = 70' gpd/ft2 @ average-7 day - 1400 ft2 throughput flow ;rate -of .10.0 MGD e. Maximum solids loading rates assuming a 1.00%o-sludge recycle rate at design MLS.S concentrations: (.125 MGD)(2)(8.34) (4000 mom) 1500 :.ft2 , 5.6#/ft2/day @maximum 5 day inflow rate of .1'25 MGD including 100%o.sludge..recycle rate f. Hydraulic detention times assuming,a 100% sludge- recycle rate: DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NC . Prepared by: REID ENGINEERING COMPANY, INC. 16 HDT(min) _ (165,000 -gallons) (24) (125,000 gpd)(2) HDT(min) = (165,000 gallons)(24) (100,000 gpd)(2) " = 15.8 hrs. @ 5 ;day inflow rate =..250 MGD including - -100% sludge recycle rate 19.8 hrs @ 7-day inflow rate = .200 MGD includes 100% sludge recycle rate K. SLUDGE RETURN AND WASTE PUMPING` STATION 1. Two self -priming sludge return pumps are used with the 45' dia. clarifier. Each pump isl rated at 200 gpm @ 15 feet'total head which is equivalent to a sludge recycle rate _ 230%'of the average throughput flow rate 87 gpm. _ .125 MGD. Under normal conditions, one of these sludge -return pumps will be operated and manually, throttled to provide a sludge recycle rate of about 100 gpm (115% recycle rate): Two pumps operated in parallel can . provide a sludge recycle rate of up to approximately 200 gpm (over 200% recycle ,rate) 2. One self -priming waste sludge pump is,provided-rated at 10 to 20-gpm-@ 70 ft. to pump waste,activated sludge from -the clarifier sludge return -line to the upstream DAF cell onto the land application site at a controlled rate 24 hours/day. 3. -Magnetic flowmeters are provided on the sludge. recycle and waste sludge force mains with downstream flow control valves to accurately regulate and indicate the sludge recycle flow to the activated sludge aeration basin and the waste sludge, flow to the DAF cell or land application site. L. CHEMICAL STORAGE -FEED EQUIPMENT FOR ACTIVATED SLUDGE PROCESS 1. Cationic polymerflocculant solution mixing, storage and pumping equipment - is provided .for dosing settling aid polymer, solution into the final"clarifier, influent mixed liquor when required. DESIGN SUMMARY VALLEY PROTEINS, INC. ' Wadesboro, NC Prepared by: REID ENGINEERING COMPANY,'INC. 17 t a. One 800 -gallon fiberglass tank -with A. 1.5 HP- mixer is provided for make-up and storage -of cationic polymer floccuiant solution. -Up to '1254 of liquid cationic polymer can be weighed and manually added to the 800 gallon tank, filled with water.and mixed to make up a 1% by 'weight cationic polymer solution to be pumped to the injection point in the clarifier influent line.. b. , One cationic polymer solution -pump is provided rated to pump from 2.5 to 25 gphr- of solution, resulting in a dosage capacity of 2 to 20 mg/L in the clarifier influent mixed liquor inflow of .25 MGD at the design 5 day, 24-hour flow. -rate = .125 MGD + 1'00°Io sludge -recycle rate. Lower dosage rates can be -pumped if a lower solution strength is made up in the.mix tank. -A second uninstalled cationic polymer flocculant solution pump is provided for standby service. 2. .Caustic solution storage and --pumping equipment is provided 'for dosing caustic solution into the TBOD basin influent flow if required for mixed liquor alkalinity and pH control. in the.'biological nitrification process. a. -A 5000 gallon, tank is provided for bulk storage of 48% strength caustic' solution. If "required in order 'to maintain mixed liquor pH r above 6.8 units in the TBOD biological nitrificationprocess,, up to , ' 600#/day of caustic can-be..pumped into the wastewater -influent line' to the TBOD Activated. Sludge Aeration Basin. b:. One caustic solution pump will be installed for this purpose rated to pump -from '.4 to.4 gphr`of solution- resulting in a dosage capacity of _ = 45 to 450. mg/L at .the design 5 day flow rate = .125 .MGD. A. second uninstalled caustic solution pump is provided for, standby service.' M. SPRAY IRRIGATION PUMP STATION . 1. Treated wastewater stored in the -spray irrigation -storage lagoon' --will be pumped by the spray irrigation pumps to the spray irrigation fields. One 75. HP vertical turbine pump is provided rated at 300 gpm ' @ 240 feet total head with operation of one pump.normally required .to pump the.maximum irrigation rate from the storage fagoon to the spray fields. The second pump is,provided as.an installed -standby. DESIGN SUMMARY VALLEY PROTEINS, INC.. _ Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 18 - N. EFFLUENT FLOW METER 1. One 4" magnetic flow meter is provided to in to and record the total flow pumped from the spray storage lagoon and discharged to the spray irrigation fields. 2. The flow meter will use a 24-hour circular flow indicating -recording chart. O. REQUIRED EFFLUENT QUALITY. BASED ON WASTEWATER LAND APPLICATION SYSTEM DESIGN PARAMETER DAILY AVERAGE mg/L BOD No Limit Estimated Quality < 50 mg/L TSS No Limit Estimated Quality < 50 mg/L O&G No Limit Ammonia No Limit (NH3) Estimated Quality 5 25 mg/L TKN No Limit Estimated Quality < 40 mg/L. Nitrate -Nitrite No Limit Nitrogen Estimated. Quality < 50 mg/L Total No Limit Nitrogen Average annual TN concentration < 90 mg/L required due to TN loading allowable on land application fields. pH 6.5 to 9.0 Units DESIGN SUMMARY VALLEY PROTEINS, INC. Wadesboro, NC Prepared by: REID ENGINEERING COMPANY, INC. 19 HEUEIVED [AFAR 7 1999 PERMITS & ENGINEERING' t 3F. DESIGN SUMMARY WASTEWATER -PRETREATMENT FACILITIES VALLEY PROTEINS, INC. WADESBORO, NORTH CAROLINA February 1989 ® CITYii�`1911711itf .APR 25 1989 ;•`�,��ssr��•e,G,rw�M l v ENV. MANAGEMENT SEAL e OFFICE FAYETTEVILLE REG. ;e 78so w' v ,o e d • • °m •.FNGIP1EE�o°` gb N H ' !lffl C9iii i 1 Prepared By Reid Engineering Company 1211 Caroline Street Fredericksburg, Virginia 22401 A. DESIGN SUMMARY.OF WASTEWATER PRETREATMENT FACILITIES VALLEY PROTEINS, INC. { t Wadesboro, North Carolina I WASTEWATER- PRETREATMENT - Three basic types of - -wastewater will be discharged -by -the rendering plant. 1. Wastewater generated by truck -washing and ,plant drainage and washdown will contain high -concentrations' of oil -and grease, - susp'ended- solids, TKN and BOD. This washdown and drainage wastewater- must be pretreated by a fat -flotation unit and a dissolved air 'flotation cell to redu.c.e these high concentrations of suspended, pollutants before flowing into the downstream biological treatment process. I 2.: Cooker condensate wastewater generated -by the rendering. operation Will contain high concentrations of ammonia and 'other dissolved or soluble pollutants compared to washdown and drainage wastewater: This wastewater can.. be pretreated along with drainage wastewater by dissolved -air flotation' or can be pumped directly to the downstream -biological treatment process..' 3. Sani.tary was tewater.g.enerated from the bathroom facilities at the rendering plant will flow directly to' the biological treatment plant -since -solids in this - type of .wastewater should not be removed by screening and flotation and then rendered. DRAINAGE WASTE FLOW EQ:UALIZATiON BASIN (FEB #1)- 1. Design Assumptions: a. Wastewater Flow' {l) Maximum daily influent flow rate = 100 g,pm -(2) Average- daily influent flow volume = 50,000 gpd, 5 to 6 days/week )0�� b. 'Pollutant Concentrations and Loads _ (1) T.he,, following influent wastewater characteristics are assumed 'in the design of the Drainage Waste Flow Equalization Basin:: Pollutant Concentration. Loading ; BOD = 9000 mg/1.. 3,754#/day TS$ _ 600Q mg/l 2,502#/day .O&G = 2000 mg/1 584#/day TKN. = 900 mg/1 376#/day 3. FEB Basin Dimensions and Volume: Number of Tanks = 1, G " Tank Diameter = 12 0 ft. _rT� Tank Height = 20.0 ft. "C �;7 Average Depth @ HWL = 17.5 ft. Volume @ HWL 15,000 gallons/tank Average Depth @ LWL = '6.0 ft.•' { Volume @ LWL = 5,000 gallops/tan.k," 1 4' Aeration and Mixing Requirements for the FEB Basins ;are calculated" as follows•; a. HP. = Power Required for Mixing: M Assume _ 150 .HP/MG will be, required @ 6,000 mg/l If suspended solids concent-ra.tion in the Equalization Basin for mixing : ,. HP 150 (. 0l5 MG.) < 2.5 HP (approx.) per'tank { . b:.--HPA = Power Required for ,.e.ration: Assume the required oxyge:n transfer' requirement; of .15#02/#BOD in each FEB = I, AOR = .15(3.,754#BOD/day) llf 24 AOR 25#02/hr (approx. field oxygen transfer rate required) S.OR 2:0 (25) 50402/hr ' 1 Calculate subsurface .aeration equipment air sparging requirements -at 909F inlet air: t (1) The oxygen available per cfm per hour X = '.23 (.075#/ft3) (60 min/HR) = 1.035#02/cfm/hr (2) Diffused aeration system oxygen stripping or transfer efficiency at 15.0 feet air sparge depth > 150 (3) acfm required = SOR .(X) (e) acfm = ___50_#02/hr '(1.035) (.15) < 322 cfm (4)For conservative design use two - 20 HP, 350 cfm positive displacement air supply blowers for supplying diffused air for oxygen transfer and mixing in the FEB tanks. Since 2.5 HP per tank is required for mixing and 20 HP for aeration, power requirements for aeration govern. HPA < 20 HP total = 10- HP (approx) per tank C. SCREENING 1. Wastewater generated by plant washdown and truck drainage activated will flow by gravity sewer lines into a collection well and from there be pumped into a rotating fine screen with .03 inch openings with a capacity of 200 gpm. 2. Screenings will be rendered for ultimate disposal. D. DRAINAGE WASTE FEB #1 EFFLUENT PUMP STATION 1. Wastewater aerated and equalized in the Drainage Waste Flow Equalization Basin (FEB #1) will be pumped to the Fat Flotation Unit 24 hours per day, approximately 5;to 6 days per week. Two end suction wastewater pumps are provided, each rated at 15 to 60 gpm @ 35 ft. total head with operation of one pump required to pump the design average flow of 35 gpm and operation of two pumps required to pump the design maximum flow of 100 gpm from the FEB into the Fat Flotation Unit. The second pump is provided as'an installed standby for the average daily equalized flow 35 gpm = .05 MGD. 2. A Flow Meter is. provided in the pump discharge force main with downstream flow control valves in order !to accurately measure, indicate, record and totalize the wastewater flow pumped from the FEB tanks into the Fat Flotation Unit. 3 3., In theevent of power failure-, wastewater, can be.. stored in the -,FEB until normal power is resumed. E. FAT FLOTATION UNIT (FFU) DAF CELL #1 1. 2. Design. Assumpt,ions ! . a. Wastewater Flow Design Maximum influent flow pumping rate 100 gpm; average daily throughput flow volume 50,000 gpd = .050,MGD 35 gpm. b. Pollutant concentrations and Loads .,(l) Influent Wastewater Pollutant Loadings i ni Plant Drainage and Truck Drainage Wastewater. @ 100 gpm- maximum -influent flow. 'rate and 3$, gpm average flow ratei. Maximum Average '.doncentrzition- 'Pollutant Loading BOD 9000 mg/l 450#/hr 158#/hk TSS 6000 mg/1- ..300#/hr 105#/hi, 0 &.G 1400-mg/l 150#/hr -52,.5#/hk NH3-N, '900-mg/l .45#/hr I 5.8#/hi Expected Pollutant Removals in the Fat Flotation Unit: Pollutant % Removal Effluent Concentration BO - D 35% 9000('.65),,, < 6000 mg/l TSS 60% 6000(.40) < 2400-mg/l O&G 6003000(.40) Z 1200 mg/1 TKN 20%- 900(.80) < 720 mg/l 3. Fat Flotation unit design average solids "load @ 35 g inflow rate (.05 MGD)(600 mg/1)(-.60)(8.34) 62.. 5#/hr < 100#/hr 4. The required air. dissolving- rate for a maximum solidis. -loading rate of 200#/bt into the dissolved air enhanced fat.flotation -unit = ..Io# air/min.. .5- to 1.-5. cfm @ 9!0 psi. 4 5. FFU design 'maximum .solids loading rate on, the 291 'dial: . = FFU DAF Cell # 1' with- ah-effective surface area 600 qO f t 200t/fir --------- 2 600, ft .33#/ft,/hr. i. 6. Calculate the minimum pressurized flow required @ 9t, 0 psi air dissolving pressure @ wastewater temperature 100OF • AC Air Dissolving Capacity, -AC .864# air/min., @ '90 psi. QR (.10 ft3/min) ------(1000) 115 gpm t,wo 150 g,pm. recycle pumps w 1 1 1- b, e provided with the FFU .7., The FFU maximum calculated hydraulic loading rate using recycle'pre-ssurization design .35-qpm-+ O gpm T 60IHP30 gpm/ft? 8.1 The calculated fat sludge volume produced per dayj= 1,500#.solids/d-ay = 1,000 gpd to 1,500 gpd @ 15% to 20% solids concentration,. 'assuming approximately 60% TSIS removal in the FFU. Fat sludge will be disposed- by. rendering along with other by-products. F. AERATED FLOWEQUALIZATIONBASINJFEB #2) 1. Desiqfi Assumptions ------------- ----- a.. Wastewater Flow- (1).Maximum Design Average Daily Combined Influent Flow. Volume .125''MGD, 5 to 6 days/wee-k including 50,000-gpd of prdtr"eated plant. drainage -wa-stewa-ter and 75,000 gpd of raw .condensate wastewater - b. Pollutant Concentrations and Loads (1) Maxi mum Daily Influent Pollutant Loadings from pretreated-dr,al-nage-wastewater discharged from upstream; Flotation Unit @ .05 MGD, 5 ', Fat to 6 clays/week: 5 BOD < 6000-mg/.1; _ 2500#/day TSS <_ 24bQ mg/I; 1000#.%day. ;. TKN < 720 mg/l;, 300#/day F. O&G < .120.0 mg/l;: 500#/day (2) Maximum Daily- Influent Pollutant Loading from raw condensate wastewater discharged, from.{ rendering .plant -@ '.075- MGD, 5 to 6 days/week: L_ BOD <_ 4500 mg/l;- -2814#/day f TSS" <- '200 mg/ 1;., 125#/.day" t TKN < .1500 mg/l 938#/day 0&G < 300•mg/l; 188#/day j (3)- Combined Wastewater Pollutant Loadings:: ! _BOD < 5100 mg/_1.; 5314#%day TSS <_ -1800 mg/l; 1125#/day � - TKN < 1188 mg/l; 1238#/day •'.0&G < 1-100 mg/l;: 688#/day j i 2. FEB #2 Basin Dimension and Volumee Number of Basins = 1 Tank Diameter = 60 ft. .Average Depth @ HWL-' = 13 ft. ". Volume @ HWL = 250,00-0'gallons 1 Average Depth @ LWL 4 ft." E•. Volume @ LWL _ 84,500 ft. Equalization Volume 165,500 gallons 3." Aeration and Mixing Requirements for the FEB. #2. Basin is calculated as follows: a. 'HP M = Power Required for Mixing: Average 60 HP/MG will be required @ 2000 mg/l suspended solids concentration in the Equalization -I Basin for mixing: HPM = 60 (.25 MG). < 15 HP (approx.) -- b. HPA Power Required.for Aeration: -,Assume the required oxygen transfer requirement of, .50#02./#BOD in FEB #2 = AO ft = 50_(5,314#BOD/daa) I" -- -24 � - . l AOR 110#02/#hr (Approx. field oxygen transfer, I. rate required) i G. c.. Field oxygen transfer capacity of one new 6'0 .HP two speed; surface aerator assuming an oxygen transfer rate from these aerators into 'the FEB wastewater of' 2.0.#02./HR _ 1' 60 HP. (2) 120#0�2/HRvs.. 110#02/HR required 60 HP ,( - 42) (2) = 5`0#02/HR -@ Low Speed j HPA < 25 HP to ' 60 HP Therefore, aeration power requirements govern aerator selection. FEB 42 EFFLUENT PUMP STATION. I. Wastewater aera-t'd and- equalized -in 'the 24 Hour Flow Equalization Basin (FEB) will' be pumped to the. DAF Cell.- Pipeline Flocaulator -24 hod-rs per day,. approximately 15 to 6 days per 'week. Two end suction wastewater pumps are provided each rated at-'.50 to- 100 gpm @ 35 ft. total' head with operation of one pump required, to pump the design maximum flow of 90 gpm from the FEB into the Flocculation'Unit upstream of the DAF cell.- The second pump,is provided as an installed standby. - 2: A Flow Meter .'is' provided -in- the pump discharge -force main .,with downstream flow control valves in order to. accurately measure, indicate,, record and totalize the wastewater flow pumped from the FEB into each' of the DAF Cell. 3. In -the event -of power -failure, wastewater can, tie restored' -in the FEB unt'il'normal power is resumed. j DISSOLVED AIR FLOTATION CELL#2 DESIGN 1. Design Assumptions a Pollutant Volumes:' (1) Condensate Wastewater = 75,000 gpd, 5 to{ 6 days/week j { } (2) Drainage Wastewater = 50,000- gpd, 5 to 6 'days/week— (3) Maximum daily total wastewater volume_ 125,000 gpd; 5.to 6 days/week 7 I (4-)Average daily-tota-1 wastewater volume = :(-.125_MGD),(5.5_daYs) i --- -7 --- - < 100,000 gpd, 7 days/wee.k� r Pollutant characteristics following upstream' pretreatment' of drainage wastewater by screening and by removal of settleable solids and .free fat E in a fat flotation. unit: (1). Combined 'rendering plant drainage wastewater and condensate wastewater @ 125,000 gpd'., 5 to } 6 days per week.:total wastewater.volume; Pollutant -Concentration, (mg/1) BOD 5-100 mg/1 5314#/day TSS 1800 mg/1 1125#/day i O&G 1.100 mg/1 688#/day TKN 1188 mg/1" 1238#/day 4• (2)..Ass ume.a daily maximum of 30#/HR of wastezi activated sludge solids loading will be wasted+ into the DAF' in addition to the solids load 'from the,.Rendering Plant (3) Expected pollutant- removals in _the DAF Celli with chemical coagulation -flocculation @ ..1251 MGD maximum 5 day -design flow: Estimated Average- �- Effluent Concentrations Pollutant %'-Removal and Leads BOD-- -< 60% to 70% < 2000.mg/l 2000#/day TSS < 80% to 85% < 360 mg/l; 375#/day, O&G < 85% to 90% < 137.5 mg/-l; -143#/day TKN < 45% to -55% < 650 mg/1; 678#/day DAF Ce11 Design a-. -DAF Cell• design solids load approximately -� .200#/HR including 170#/hr from the raw waste flow; assuming a" .BOD removal ef,f iciericy of 70% in the' DAF cell and up. to 30#/HR.. from waste activatedi sludge pumped to the DAF cell. b. The required air di-ssolving rate for a solids loading rate of 2.00#/HR i 8 a. e . f 90 200 03) '10C air m in 60 The required air supply rate @ 90OF inlet air s density @ the 3001 site'altitude' > .0712-#/ft3 .10#/min. 0-712 1.4 cfm < 2'cfm . calculate the minimum pressurized flow. required- 90 psi air dissolving pressure @ wastewater temperature = 80OF max. after. wastewa-ter cooling in the 24 hour FEB #2. ACair dissolving capacity L= i184 [.80 IZO 14.7 ' OLI -.184 AC = .864#_ air/min. @ .9. 0 _psi Q = .10#/min. R .864 (11000) 116'' gpm, use 2 = 1,50 gpm, recycle pressdrizatioh, pumps One 291 dia. DAF Cell #2 to be used with 600 f t2 j of effective"surface area The calculated hydraulic loading rate @ QTQR + QIJ 90 gpm + 150 gpm 240 gpm is: 240 600,Ft -.40 gpm/ft2 The calculated solids'loading.rate @ 200#/HR is: 200#/HR -------- 2 2/ijR 600 ft -.33-#/ft, Calculate chemical pretreatment sludgt production rate in the DAF Cell at the .,design capacity flow ,of .125 MGD assuming an average BOD removal 1 efficiency of . 74% and assuming umihg -a solids concentratli.o,n 12% after, decanting in the DAF sludge holding tank:''-- DAF Sludge Volume ='.200#/HR(.70)(24 HRS/da Y_ .12) (8.34). '3500 gpd (approx) (estimated Range =_2500 to 4500 gpd@ 10% 'to 18% solids) j 9 h. i. ! Additional waste sludge production rate in. the DAF I - Cell if waste activated sludgeis pumped into the ! ` DAF for flotation thickening 24 hours/day, 5 to 7. " days/.week @ < 30#/HR,, 2500 gpd @ 3% to 4%. soli_as (See Section,,J3) F. The. combined pretreatment sludge and thickened ! waste -activated sludge removed from the DAF Cell anticipated to have`a 10% to ,.13%-so'1ids i concentration resulting in a' -total sludge volume - [ (200) (.70). + 30] 24 (.115) (8.34) 4250 gpd .@ 11.5 % solids concentration 1 (Estimated Range "4000 to 5000 gpd @ 10% - 130 solids) I. DAF SYSTEM CHEMICAL FEED SYSTEM DESIGN 1. The following equipment is provided for mixing, storage and pumping chemical solutions that are hecessa.ry for operation -.of the coagulation-fl;occulation process in 4 the DAF Cell: ,a. For -pH, adjustment of the wastewater pumped out -of -the 24-hour. FEB into packed plate DAF ,system: (1) One 5,000 gallon bulk storage tank for 50% caustic solution (2).Two caustic solution pumps, each rated @ .2 - 2 gphr` @ 50 psi;' ca-ustic can be dosed at "the following rates into the .125 MGD design max. 5 day flow rate of drainage and wasldown wastewater and condensate wastewater generated by the-' Rendering, Plant : One pump @ .4-. 4 gphr will inject caustic at! the, rate �of up to 240 mg/1 (d-ry. basis) } , operation- of. t-wo pumps will doublethis j caustic.do'ag,e rate; the normal caustic dosage; requirement -is expected to be between .5 toj 1.0 gphr', 50 - 100 mg/1 (dry basis) i I (3) One automatic ,pH sensor=controller unit will; be provided to.'.automatically regulate on -off{ operation',of .the caustic solution pumps in, order -to cont-rol the caustic solution- dosingi rate .into the Flocculation Unit before! coagulant solution is injected. Each caustic, solution pump has a variable stroke drive that; must be manually adjusted.-- The.'pH controller'. 10 i I will, automatically turn -on 'or ` off the cau'sa_ic I' solution -pump as required to maintain "the -DAF _f Cell, - influent wastewater pH within manually - adjustable high -low'., set points. When turned on automatically by the -the pH controller, the caustic solution pump will pump at the -feed rate manually selected by the Plant Operator` by setting the % pump rate control knob on the pump. b. -Yor chemical coagulation. of wastewater' being{ pumped into 'the DAF Cell:' { l) One 5.,000 gal.l.on bulk storage tank for coagulant solution t (2) _ Two coagulant solution pumps; each rated.@ .4 to 4 gphr-@ 50 psi; coagulant solution can be dosed at the following 'rate, into the .125 MGD' design max. 5, day flow rate generated by the Rendering Plant; One pump @ .4-to 4 gphr will inject coagulant at the rate of up to 500 mg/1 -(dry, basis) operation of two, pumps will double - thin coagulant solution dosage .rate; the normal dosage requ.iremen't is expected to, be between 2 to 3 gphr, 200 to 400' mg/l (dry basis)- I c. For anionic polymer flocculation of coagulated wastewater being pumped into the DAF Cell: I (1)-one 2,0.00 gallon anionic polymer flocculant solution mix -storage tank'with 2 HP mixer = (2) Two anionic .polymer solution pumps, each rated" @ 5 - 50.gphr @ 50 psi; anionic polymer can be. dosed at. the following rate into the'.125 MGD design' max. 5- day flow, rate generated by the Rendering Plant; Gne pump• @ 5 - =50 gphr will inject anionic polymer f locculant at the - rate of up to 10 mg/1 (dry basis) °assuming a - .1% by weight anionicpolymer solution strength is ,made up in .the 2,000:'g61lon mix tank; operation of two'". pumps -w'ill double- this anionic" polymer solution dosage rate; the normal anionic polymer,. dosage, requirement is '._expected to , be between 4-6 mg/1 (dry -basis) F t ll l 2.. Pipeline Flocculation Unit Design One Pipeline Flocculation Unit i"s provided upstream of the -DAF Cell to mix" coagulant solution and , the ."wastewater".pumped,from the 24 hour Aerated FEB #2 prior to entering the DAF-Cell. J. TOTAL -BARRIER OXIDATION DITCH (TBOD) _ACTIVATED SLUDGE CLARIFIER.FINAL TREATMENT,SYSTEM 1. Design —Assumptions .I a. Pollutant Flows: } (1) Design maximum .daily influent' flow rate _ .125 MGD, when,wastewater is pumped from the FEB to DAF .Cell 5 to "6 days/we,ek, 24- hours/day for final 'pretreatment prior to discharging by -gravity into the TBOD (2) Design average daily influent flow rate .10- MGD, ,7 days/week `when upstream FEB used for 17 day, 24 hour hydraulic flow equalization b. P'ollutant' Concentrations and` Loads (1) Influent pollutant loadings when ink luehlt' wastewater -@ .125 ' MGD., 5 to 6 days/week from, the DAF Cell:". BOD < 2000 mg/l; 2000#/day j TSS <_ 360 mg/1.; 37.5#/day TKN <_ 650 mg/1; 678#/day O&G < 137.5 mg/l; 143#/day (2) Influent pollutant loadings when influent, wastewater @ .100 MGD, 7 days/week. from,the DAF cell BOD < 2000 mg/1; 1460#/day TSS < 360 -mg/l; -300#/day TKN <_ 650 mg/1;. 542#/day O&G < 137.5 mg/l; 114#/day j "c. Tr_eat_men_'t_ Requirements_@_.10_MGD,, 7_day ischarge flow rate_from spraY_storage_lagoon_to_land application_fi,eldS: BOD" < 42#/day.; 50 mg/'1 TSS < 42#/day; SO mg/1 �. TKN E_ 33#/day; 40.mg/l TN < 75#/day; 90 mg/1 NH3-N <'21#/day; 25 mg/1 NO3 + NO2 <. 42#/day; - 50 -mg/1 12 i season.expected design mixed liquor temperature -1 -150C at the maximum design inflow rate 12 5. MG D' 'when-pretreated,wastewater is discharged from the!' :'upstream DAF.dell into removal rate �20#BOD/#MLVSS, (-aerobic) @ o biomass o assuming a nitrogen uptake by the -biomass ofi (aerobic biomass volume), 615.5 (anoxic '.biomass volume for BOD r'emoval,' nitrification and! oxidation.Ditdh Activated Sludge Basin: 13 F/Mt < _____ ___2_,000#/. day---- (8.34) (1.5 MG) (4,000 m— T71 < .04#BOD/#MLSS @ 4,200 mg/l MLSS d. Calculations indicate that the proposed 1.5 MG Total Barrier Oxidation Ditch Activated Sludge; Treatment System will be .of adequate volume for accomplishing the required BOD and TN (total, nitrogen) removal down to an activated sludge', basin temperature of 150C. e. Evaluate Mixing and Aeration Requirements in the Activated Sludge Aeration Basin: (1) bhp required for mixing a 4,000 MLSS! concentration = 60 bhp/MG bhp required = 60 (1.5) < 90 bhp ti - (2) Calculate the maximum summer_ season average, daily oxygen transfer requirement in the TBOD' activated sludge aeration basin: i AOR = .60#0 /#BOD applied + 4.57#02/#TKN applied +; .06#02f#MLSS under aeration AORs = _6(2,000#BOD/day)+4_57(248#TKN/day)+.06(36,500/_80#MLS.S) 1200#/day_+_3, 098#/day_+_2,736#/day 24 1.200#/day_+_3098#/day+_2736#/day ----- -- ---24 - _ = 7,034#/day 24 , 293#02/hr in summer season (3) Calculate the maximum winter season average, daily oxygen transfer requirement in the activated sludge aeration basin: AORW = .60#02/#BOD applied + 4.57#02/#TKN applied + .03#02/#MLSS under aeration AORw = _6(2000#BOD/day)_+4_57(624#TKN/day)+_031(36,500/_80#MLSS;) 14 = 1200#/day_+3,098#/daY_+_1,368#/daY .5666#/day - _2 4 = 2.4 236#02.in -winter-season (4) Calculate the required, corresponding maximum standard oxygen transfer rates (.SOR).:. Css ---------------------------------- SOR AOR ( Csw-00)0,r'(1.024) Where DO = .75 mg/l (average DO in the aeration basin) _ - .90 _ .80 @ '3,500 to 4,500 mg/1 MLSS ,T-20 -1.024 = 1.394 @ 340C - Cw = 7.2 @ sea level, 34oC Cs = 9.2 '@ sea level, 2O0C site Altitude -- 300.fee.t (Approx.) { J Pressure Correction Factor < .95 1_4_7_+_(•5_) (:.4_33) (16) * Css = 9.2 1.4.7 = 9-Z (1.2,356) = 11.37 mg/1 i (.95) (14.7) + . (.5.)-( .433) (16) * Csw = 7.2 14.7 = 7.2 (1:1856) = 8.53 mg/l j *-Oxygen Contact Chamber Centerline Depth = 16.0 ft. -- ___ - _ 11.3 7 _ _ ______ __ SOR = [(•90'(8.53) - .751 .8-0 _(1.394) (AOR) SOP = 1_ 47 (AO'R) SOR (Max..) 1.47 (293) < 430#.02/HR (5) Calculate subsurface draft tube aer:ation equipment air sparging, requirements: (a) 'X _ .23, (.075#/ft.2) (60 min/HR) 15 ! f = 1.035#02/cfm/HR @ 680 inlet air (b) Draft tube aerator oxygen stripping or transfer efficiency at 16' oxygen contact duct depth = 24.0% for conservative design (c) acfm required = SOR (x) (e) cfm = ___4_3_0______ (1.035) (.24) < 1731 acfm (total) (d) This air sparging and oxygen transfer requirement can be provided by two 50 HP, 48" dia. draft tube induction aerators which are each capable of sparging approximately 540 cfm of air operating in parallel with 1-100 HP, 84" dia. draft tube aerator capable of sparging 1000 to 1200 cfm with air supplied by 2 - 40 HP two speed blowers each rated at 700 cfm @ 8 psi. These two 50 HP draft tube induction aerators plus one 100 HP draft tube aerator can sparge a total air flow of over 2000 cfm vs. the 1731 cfm required. (e) AOR capacity of each 50 HP, 48" dia. draft tube induction aerator > (540 cfm) (1.035#02/cfm) (.24)/1.47 > 91#02/hr. AOR capacity of the 100 HP, 84" dia. draft tube aerator > (1000 cfm) (1.035#02/cfm) (24)/1.47 > 169#02/hr (f) Additional oxygen transfer capacity can be provided by 4 - 30 HP high speed floating surface aerators that will be installed in the TBOb channel. The supplemental oxygen transfer provided by these surface aerators, ,assuming a field oxygen transfer rate of 2.0#02/HP/hr = (4)(30 HP)(2.0) _ 240#02/hr into the mixed liquor. (f) TBOD channel mixing velocities and operating volumes: 1. TBOD channel length = 655 ft. Channel HWL depth = 11.0 ft. Channel volume @ HWL = 1.50 MG Channel area = 28 x 11 = 308 cfs 16 2. DTA pumping rate = 98 cfs for each 50 HP 48'" dia. draft tube induction aerator Channel velocity = 308 cfs for each 100 HP, 84" dia. draft tube aerator Channel velocity = Vc ' Vc with 2-50 HP, 48" dia. DTA @ HWL = 64 fps Vc with 1-100 HP, 84" dia. DTA @ HWL = 1.0 fps Vc with 1-50 HP + 1-100 HP DTA @ HWL = 1.3 fps Vc with 2-50 HP + 1-100 HP DTA @ HWL = 1.6 fps These velocities will be increased if the barrier wall slide gates are lowered to allow induced flow generation in the TB OD 3. Evaluate Slud e Wastin Requirements from the Activated Sludge -Process a. Calculate waste activated sludge production at the maximum daily BOD loading rate: (1) F/Mv = _ 2000#BOD/day__________ (4,000 mg/1)(1.5 MG)(8.34) .04#BOD/#MLVSS (2) Y = Expected Activated Sludge Production Rate @ < .01 - .10 F/Mv ratio .35# waste sludge/#BOD (3) # Waste Sludge = (.35)(2000) < 700#/day (4) Volume to be wasted from sludge return flow @ 8000 mg/1 to the DAF cell for flotation thickening for storage and gravity thickening;: _7_0_0_#/day_ (.008)(8.34) 10,500 gpd (Approximately) 700#/day/24 hours < 30#/hr if pumped 24 hours/day to the upstream DAF Cell for flotation thickening with raw wastewater skimmings or chemically coagulated solids!. 17 a (5),Annual accumulation -weight .and -,volume to, be -- land disposea,if thickened to 4% solids in the,# upstream DAF Cell 'on weekends and hauled to an" approved land disposal, -site-. Weight = 700#/day(260) = 182,'000#/Year., Volume = 182'000#/year_ = (.04)(8.34) < 550,000 gallons accumulated/year } (6)' Thickened. waste activated sludge will 'be! removed from the DAF Cell: and. .transferred to the Rendering_ Plant for ultimate- disposal by; drying and burning., iK. FINAL CLARIFIER 1. ..Pollutant' Loads ! a. Maximum 5 'day inflow -rate .with 100% sludge recycle.) rate = (.125 MGD) (2.)-< .25 MGD b. Maximu,m 5 day inflow rate with 200$ sludge recycle!. rate.= (.125 MGD)(322) < .375 MGD 2... Calculate Clarifier Loading Rate a. ,One new 45.0' diameter x 14.0' side water depthy circular clarifier will be' utilized for final) clarification., b. Circular cl.ari-fier.�' effective surface overflow; diameter = 45 Oft.,; effective surface overflow area = 14�0.ft� and -effective clarifier floor area' =. 1500 ft c. Circular clarifier volume'= 165,000 gallons d. a Hyd-raulic surface loading rate,: 125,0_0o_�c�.pa _ = 89 gpd/ft2 @ maximum 5 day 1- ft throughout .flow rate,of .125 MGD 10,0,000 gpd = 70 gpd/ft2 @ average' 7 day 1'400 ft� throughput""flow rate of .100 MGD e. Ma:ximumsolids loading rates assuming a 100W; sludge recycle rate at design MLSS concentrations: (,.125_MOD) (2-) (8.34) (4000_md/1) 1500 ft I - .-i 18 L M. 5.6#/ft2/day @ maximum 5'day inflow rate of- .125 MGD including :1.00% "sludge recycle rate f. Hydraulic detention times assuming -a 100% sludge recycle rate: (165,000_gallons) (24) (125,000 gpd-)(2) = 15 . 8 hrs. 5. day i n f low rate of . 125 -MGD. including 100% sludge recycle rate SLUDGE -RETURN AND WASTE PUMPING STATION 1 Two self -priming sludge return pumps will be used with j the 45' dia. clarifier. Each pump is rated at 200 gpm; 15 feet total head which. is' - equivalent to a sludge recycle rate = 230% of the average throughput flow rate! 87 gpm = .1.25 MGD. Under normal conditions, one of j these -sludge return pumps will be operated and manually;" throttled to provide a sludge recycle rate=of about 100 gpm (115% recycle'rate). Two pumps' operated in! parallel can provide a- sludge recycle:; rate of up to! approximately 200 -gpm ,(over 20.0 o recycle rate) 2. One self -priming waste sludge pump will be provided rated at 10 to-20 gpm @ '70 ft. to pump waste -activated] sludge -from the clarifier sludge -return line to the DAPF cell- pipelinee-flocculator at a controlled rate 24, hours/day. 3. Magnetic flowmeters are provided on the sludge recycle; and waste sludge force mains. _with downstream flow" control valves in order to accurately regulate .and. indicate the sludge recycle flow to the activated:' sludge aeration basin and the, wastesludgeflow to the;, . DAF cell . i CHEMICAL STORAGE -FEED EQUIPMENT FOR_ACTIVATED SLUDGE PROCESS; 1.- Cationic polymer flocculant solution,mixing, storagel and- pumping equipment -will be provided . for dosingf settling aid polymer solution into the, f inal clarif ier! influent mixed -liquor when required a. One 800 gallon fiberglass -tank with a 1.5 HP mixer; is provided for make-up and storage of cationic polymer f;locculant. solution'. Up to 125# of liquid, cationic polymer can be weighed and manually added to the 800 gallon tank, . f illed with water and mixed to make- up a - 2% by weight .cationic polymer, solution to be pumped to - the injection point if the clarifier influent line. I 19 ll - 1 b. One cationic polymer solution pump will be. "n.•stalled ":rate.d to pump _f rom 2 to 20 gphr of solution, res.ul_ting in a dosage capacity of.. 4 to r 40 ;mg/1 in the clarifier influent mixed liquor" inflow of .25 MGD ,at the design 5 _day, 24 hour -I:, .flow rate .125 MGD`+ 100% sludge recycle `rate.1 Lower dosage rates can be pumped' if a lower solution strength is- made up; in the mix tank.- k second -uninstalled cationic polymer flocculant i. solution'pump is provided for standby service. 2. -C'austic solution storage and pumping equipment .will be installed at , ,the prett,eatment' DAF cell for dosing caustic , solution into the TBOD basin -influent flow if I required for mixed liquor alkalinity and pH control in the biological nitrification process. a. A_ 5000 gallon tank -will be provided for bulk storage of 48% strength caustic solution. If G required in order to -maintain mixed liquor" pH ab'ove 6.8 units i,n- the'. TBOD b-iologicali nitrification process, up to 600#/day of caustic can be pumped into --the wastewater influent line to, the.new TBOD•Activated Sludge Aeration Basin. k b. One caustic solution pump will be installed for; this purpose rated to pump from .4 to 4 gphr of solution resulting" in a dosage capacity of = 45 to 450 mg/1 at the design.5,day flow rate = .125 MGD.f A second uninsta'lled caustic solution pump is I. provided for standby service. l N. SPRAY. IRRIGATION PUMP. :STATION f 1. Treated wastewater' stored" in the spray: irr"igation., storage 'lagoon .will -be pumped by the spray, irrigationj pumps to the spray , it-r igati.on f iel.ds . Two, 75 HPI vertical turbine pumps are Iprovided each rated -75 HP vertical' turbine @ 240 feet total head 'with operation! of one pump normally required-' to pump the maximum irrigation rate from the storage lagoon., to the spray! i fields. The second pump is provided as an installed!! standby. f O. EFFLUENT FLOW METER - 1. One '4" magnetic flow meter will be provided to indicate, totalize and record the total flow - pumped! .-:from the spray storage lagoon and discharged to thei spray "irrigation fields. ' I t 20 i i 2. The flow meter will use a 24-hour circular flow indicating -recording chart. P. REQ.UIRED EFFLUENT QUALITY BASED ON WASTEWATER -LAND APPLICATION SYSTEM DESIGN ------------------------- Parameter -------------------------------- Daily Average ----------------------- ------- - -------------- BOD No Limit Estimated quality < 50 mg/l ------------------------- TSS --------------------------------' No Limit Estimated quality < 50 mg/1 ------------------------- 0&G --------------------------------- No Limit Ammonia No Limit (NH3) Estimated quality < 25 mg/l --------------------------------' No Limit ------------------------- TKN Estimated quality < 40 mg/l ------------------------------------------------------------ pH ------------------------- 6.5 to 9.0 units -------------------------------- Total Nitrogen No Limit Average annual TN concentration < 90 mg/1 required due to TN loading allowable on land ----------------------------------------------------------- application fields 21 I f i APPENDIX 11 RESPONSE TO QUESTION 16, 17, 18 & 19 PREPARED BY ROBERT KENDALL & ASSOCIATES, INC. ... ROBERT KENDALL & e � A CG!)!'iA7F6 INS' JM \/ V/ VI V s� a i iW '%/ + isW `/ W Soil and Waste Management Consultants January 17, 1989 Reid Engineering Co. 1211 Caroline Street Fredricksburg, VA 22401 Attention: Mr. John H. Reid, P.E. Subject: Valley Proteins, Inc. Wastewater Irrigation System Anson County, North Carolina Response to DEM Comments Dear Mr. Reid: Attached are responses to specific comments by Jack Floyd of the North Carolina Division of Environmental Management regarding the wastewater treatment system at the facility referenced above. We have addressed comments 6, 7, 8 and 9 which relate to the irrigation system. Calculations that have been requested by Mr: Floyd are also attached. Please let us know if any additional response is required. Sincerely, ROOBERTKKENDALLL & ASSOCIATES, INC. pka-1 oJik Robert L. Kendall President RLK/msk Attachment 109 Anderson Street, Suite 100 Marietta, Georgia -30060 (404) 423-7224 Valley Proteins, Inc. j Spray Irrigation System Anson County, North Carolina RESPONSE TO DEM REVIEW COMMENTS Comment No. 6 Explain discrepancy in irrigation pump capacity requirements. Response: The irri ation pump is required to pump 900 GPM in order to apply wastewater within the limits of the soils at the site. The figure of 100-300 GPM was a preliminary estimate that was made before the soils investigation was completed. Comment No. 7 Provide head calculations for each zone in the spray field. Response: See attached calculations Table 1-4. Comment No. 8 Show where the irrigation pump force main ties into the -force main given on Page M9 of the plans. Response: The irrigation plan has been revised to include; the storage lagoons and pump station which wills be located east of the wastewater treatment system. ! Valley Proteins, Inc. - Spray Irrigation System -Anson County, North Carolina RESPONSE TO DEM-REVIEW COMMENTS. Comment No. 9 Estimate downslope drainage -volume .from spray !- irrigation system after pumps are.shut off. Response: The system is designed with automatic zone. control valves that willclose when the irrigation pump is shut off. Therefore, the I volume of wastewater that will drairi'from the { system will'be limited to the volume contained within.the pipes in each -zone. Calculations j "are provided for the worst case which is Zone 8 ! in which there is the greatest elevation. difference between the upper and lower lateral. The total volume of effluent in the piping in } Zone 8 at shut -down is about 2100 gallons. One i third of this volume is estimated to drain from " the lowest later."al and the balance -will drain from the other laterals.(excluding the highest lateral). At an average pressure: of 4 psi the seven sprinklers on the lowest lateral will each deliver 100 gallons` -at about 4 gpm over a radius of about-20 feet. This volume ` represents about 0'.13 inch -of application over �. approximately 1250 ft2 during a 25, minute period. j I ih- J-� OA ...... . .... H Les bd� C) 00,144 vm:vVi�r- zl:� B&ACL-9, II�Ju�.fbeY� .��l�c.• Dy,��. TTY .._� � � ! �.��G�E}�—�•p�-��n��«`Rti��/ � lh�b�•�--F-�lhr�--�-��t---Lo'-'1` Ei•k-S� _ � i•4� WQ• ��i LUe.se.; 1 I — � �— r— � J l ��—�• is , 'a Vn -� �a 4=-r-7q.Ll -•—.•_s- I�5 ate- S"_ 01-G.�t--o1- I-� `��-- r fi u _' e. ;.' . • O -:1: i ; ; u —q dp GO 00 ........ . .. III W CEO C) tqoo I cll"K-A- 2--t 0 d). . .. ........ ...... 7-910 op, r--ve'suf e-.--A:Ur Ar a... es Z too.. q.P. ....... . . . .. ........ .... ...... . ...... 7, c(1.5a3 (3 if 1. PUMP Number of Pumps: 2 Type: Vertical Turbine Manufacturer: Fairbanks Morse i Size and Model: 12M=7000 i t . Number of -Stages: 3 Design Capacity: 1,000 GPM Design TDH: .240 Feet Maximum Pump Speed: 1,770 RPM f Minimum Efficiency-at.Design: 83% `Minimum Shut -Off -Head: -.300.psi: Type -of Motor: U.S. Maximum Motor Horsepower: 75 HP Number of Phases-:- 3 Cycle: ' 60 Hz i.- • 11f, -Voltages 460 Volts I Motor Enclosure: Water, Protected Type I Diameter of Discharge Column:.--. 8 inches - Discharge 'Size: 8-inches Pump Material of Construction: Bowl Assembly:, All Bronze,.Epoxy Coated Column and- Shaft:. Stainless Steel, Expoxy Coated- :.. _:......Inside and outside-. Impeller:, Bronze., j Strainer: Stainless, Steel 4 Alternative Pump: American Turbine Pump,. 12=H-120, 3 .Stage, 1760.RPM, 1000 GPM, 250 Feet TDH, 81% Efficiency 2. VALVES: Silent Check Valve: Manufacturer: Valve and'Primer Corp. i Model: APCO Series 600 Sizes 6 Inches Pressure Rating: 225 psi l Material: Cast,Bronze, ASTM 962 Field Automatic Remote Control Valve: Manufacturer:, Ames Company,.In.c., i Model: A830-06 Size: 6 Inches Pressure Rating: .225 psi i Material: Cast Bronze ASTM B62 High Pressure Relief Valves: Manufacturers OCV Control Valves- --, ,Model: 108-2, Size: 6 Inches I Materials Cast Bronze, ASTM B62 Pressure Rating: 150 Class, 225 psi Pump Control Valves. Manufacturer: OCV Control Valves j Model:. 127-420A Size: 6 Inches Material: Cast_Br,onze, ASTM B62 Pressure Ratingi .150 Class, 225 psi Isolating Butterfly Valves: Manufacturer: Quatrol Model: Q1351 Lug Style Size: 6 Inches i Material: Cast Bronze, ASTM B62 f Pressure Rating: 225 psi Air and Vacuum Release Valves: - I Manufacturer: Bermad.Control'Valves Model:, 4415 i.. Size: 2-Inches - f Pressure Regulating Valves: Manufacturer: Dole Model: GX Series (2 to 30 GPM), Size: 1 Inch Threshold Pressure Rating: 15-25 psi Automatic Drain Valves: Manufacturer: Nelson Model: 2314AS (short), Spring -Loaded Size: 1 1/2 Inches 3. SPRINKLERS Full Circle: Manufacturer: Senninger Model: 7025RDB-1 Size: �1/4" (#16 Nozzle) Operating Pressure: 60 psi Discharge Rate: 14.2 GPM Throw Diameter: 139 Feet Alternative: Nelson # F70PV (Brass) with 1/4" Nozzle 60 psi, 14.0 GPM, 132 feet. Part Circle: i Manufacturer: Rain Bird Model: 35PJADJ-TNT Size: 3/16" Nozzle Operating Pressure: 60 psi Discharge Rate: 7.8 GPM Throw Diameter: 102 Feet 4. PVC PIPES Pressure Rating: Class 200 psi 5. POLYETHYLENE TUBINGS (RISERS): Manufacturer: Rain Bird Model: PPS-Flex-100 Size: 1 Inch (1.315 O.D.) Wall Thickness: 0.179 Inches 6. PRESSURE GAUGES: Manufacturer: Rain Bird Model: 41017 (Water Filled) Pressure Range: 0'-160 psi 7. Manufacturer: Rain Bird Model: RMG-106 Size: 6 Inches I.D. Flow Range: 90-1200 GPM Maximum Operating Pressure: 250 psi Bearing Material: Stainless Steel Bearing Type: RMO-119 Register Type: RMO-103 8. METAL ANCHOR STAKES: Stake Dimensions: 1 1/2" x 1 1/2" x 1/8" L Stake Length: 5 Feet Material: Iron 9. COMPUTER CONTROL STATION: Manufacturer: Rain Bird Model: ISC-12 (12 Stations) Epoxy Coated Pedestals 69 - 12M 7000 1770 RPM ENCLOSED IMPELLER T7EAB2 Via] too 'Vag 1=_q>fl tso 2-0 40 V1111101. LUI111M 111M IS' SINGLE STAGE PERPORMANCE 0 loo R00 900 . 400 600 000 .700 Boo 900 t000 1100 1200 . 1000 1400 V•9. GPM ' �U N�+! -fir .a l,.l �- / �� -. 2 40' - i'1� ��. Z•.S� f`f 1 '�^ t LI i�'f'� EPPIOENCY CORRECTIONS111 , DIMENSIONS TECHNICAL DATA (Inches) 1" 8" COLUMN 17.50 0.00 {-- -- - MINIMUM WATER BOWL EFFICIENCY MATERIAL CHANOC 1Z,29 D. LEVEL S RON .2.0 P INTS. 25.040 ' I 21.23' DATA VALUN . MAXIMUM OPERATIN SPEED 2700 RPM _ 'e" MAXIMUM NUMBER OF STAGE PUMP SHAFT DIAMETER 1+N11 IW IMPELLfR EYE AREA MAXIMUM SPHERE SIZE 19.40 SO, INS „�� IN. Kt (THRUST FACTOR) 6.3318S.iFT. K• (ROTOR Wt. PER STAGE) 2g.so LBS. BOWL WT. IFIRST STAGE) Z$fl-LBS• BOWL WT. )EACH Apol. STAGE 106 LBS. ALLOWABLE BIIAFI. TRET H 9 IN. K IFIRST BTA WK•Se/1CH AOD'L. Sig\GE! 1N _I.e7itS .-FT.' 11 •• " Information lu_rther IMPELLER EFMIE'NCY MATERIAL CMNr71l � 4.ee These are nominal values. Rotor to Applicelion and tt.ao _ Reterance Data for Inlorme limiting of CAST IR N •1.0 POINTS 11 -- # 6.13 extending these values. nR NZ } NO CHANGE —.-1• I —I_ - I ENAMELED C.I. 9.e2 D.•• H F+ • 13.00 D.This value Is the minimum 90mergence required to li) RNtr to "Applicsllon and FtllIrence -- 8" COLUMN prevent vorlexing- only. This value may! need to be Dili" for herd corticllot' •Add,10.76 for aech pdd)tlonnl etnge Increased to provide adequate NPSHA. 1 FAIRSANKS MORSE PUMPS ' - _ 4 , • I f IMPELLER DATA IMPELLER NO. 12-120-.TYPE Enc. ,DIAMETER: A 10.03 ", B9,33 2, C A', e3 EFFICIENCY CORRECTION: ONE STAGEDEDUCT 4. %, TWO STAGE DEDUCT 3 ' THREE STAGE 'DEDUCT '.?� %, FOUR 'STAGE DEDUCT_% EFFECTIVE EYE AREA 20. 66 sq. Inches. NUMBER OF VANES 7 THRUST CONSTANT K 6.8.2 IbsJft. of head. WEIGHT 14,aIb9: 'WR2 • g19 Ibs._ft... EYE FLUID VELOCITY CK�n2c;7 ftJ$seJ,GPM. PERIPHERAL VELOCITY 7.67 ft.IsecAnch of Impeller dla. Ns 2421- BOWL DATA BOWL NO. H- 120:. CONNECTION TYPE Oo iteMOMINAL DIAMETER (E), 12 35'. MINIMUM. DIAMETER' (E) 112.121. , COLUMN PIPE"SIZE 8 "STANDARD 1,..—"MAXIMUM, a "MINIMUM. SUCTION PIPE SIZE 8 'STANDARD, 8 "MAXIMUM. PUMP SHAFT DIAMETER —'I. 687 "STANDARD 1 :.,790 -"MAXIMUM. LATERAL -.750 "STANDARD,, 'MAXIMUM. SHAFT BEARING CLEARANCE • 010 . IMPELLER SKIRT CLEARANCE • 01 5 MAXIMUM NUMBER OF STAGES (std. construction). MAXIMUM HEAD 62o It. (std. construction). MAXIMUM SPHERE.SIZE 77a "• -' PROJECTIONS ABOVE COLUMN PIPE -BUTT: TUBE; SHAFT • FO.R EITHER OPEN OR ENCLOSED LINESHAFT. DIMENSION A • Length one stage assembly With discharge bowl. 9 • Length one stage assembly less discharge bowl. C • Length one stage assembly with discharge bowl and bell. D • Length one stage assembly less discharge bowl with bell. E ,Bowl Diameter: ) F Length of additional stage. G •,Hub•projection,on bell suction. S H • Length of discharge bowl. J • Length of Impeller eye above bottom of bowl. K • Minimum required submergence. . R ••Length submersible suctlon Inlet. S • Length one stage submersible assembly. T ". Height of cable guard. l DIMENSION A 1, B C I D E F G H J K R I S- T INCHES 30'.3 1 2 1 61 30.3 21.6 112.3 110.8 1 7 1 J5—� K illil l� _I E 11E �-- F H ^ A