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Home My WebLink AboutNC0005126_Compliance Evaluation Inspection_20200820 (2)United States Environmental Protection Agency Form Approved. EPA Washington, D.C. 20460 OMB No. 2040-0057 Water Compliance Inspection Report Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction Code NPDES yr/mo/day Inspection Type Inspector Fac Type 1 IN 1 2 u 3 I NC0005126 I11 121 20/08/07 I17 18I � I 19 I s I 201 I 211IIIII 111111III II III III1 I I IIIII IIIIIIIII II r6 Inspection Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved ------------------- 67 2.0 701d I 71 I„ I 72 I r., I 71 I 74 79 I I I I I I I80 L—I ty L-1 I I Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include Entry Time/Date Permit Effective Date POTW name and NPDES permit Number) 09:05AM 20/08/07 14/06/01 Tyson Farms, Inc. 501 Sheffield Rd Exit Time/Date Permit Expiration Date Harmony NC 28634 12:25PM 20/08/07 19/03/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) Other Facility Data Kevin Todd Haynes/ORC/704-546-2602/ Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Steven Smith,PO Box 158 Harmony NC 28634/Plant Manager/704-546-2602/ Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit 0 Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran 0 Sludge Handling Dispo: Facility Site Review Effluent/Receiving Wate Laboratory Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) (See attachment summary) Name(s) and Signature(s) of Inspector(s) Agency/Office/Phone and Fax Numbers Date Wes Bell Docusigned by: DWR/MRO WQ/704-663-1699 Ext.2192/ 8/20/2020 2r6& A61696D90CC3437... Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date W. Corey Basinger DWR/Division of Water Quality/704-235-2194/ EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# NPDES yr/mo/day Inspection Type NC0005126 I11 12I 20/08/07 117 18 i c i Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# Permit: NC0005126 Owner - Facility: Tyson Farms, Inc. Inspection Date: 08/07/2020 Inspection Type: Compliance Evaluation Permit Yes No NA NE (If the present permit expires in 6 months or less). Has the permittee submitted a new 0 ❑ ❑ ❑ application? Is the facility as described in the permit? ❑ ❑ 0 ❑ # Are there any special conditions for the permit? ❑ ❑ 0 ❑ Is access to the plant site restricted to the general public? 0 ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? 0 ❑ ❑ ❑ Comment: The Division received the permit renewal package on 8/19/18. The facilitv descriDtion noted in the Dermit will need to be uDdated to include all wastewater treatment upgrades. The last compliance evaluation inspection at this facility was performed bV DWR staff on 6/29/18. Record Keeping Yes No NA NE Are records kept and maintained as required by the permit? 0 ❑ ❑ ❑ Is all required information readily available, complete and current? 0 ❑ ❑ ❑ Are all records maintained for 3 years (lab. reg. required 5 years)? 0 ❑ ❑ ❑ Are analytical results consistent with data reported on DMRs? 0 ❑ ❑ ❑ Is the chain -of -custody complete? 0 ❑ ❑ ❑ Dates, times and location of sampling Name of individual performing the sampling Results of analysis and calibration Dates of analysis Name of person performing analyses Transported COCs Are DMRs complete: do they include all permit parameters? ❑ ❑ ❑ Has the facility submitted its annual compliance report to users and DWQ? ❑ ❑ 0 ❑ (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operatc ❑ ❑ ❑ on each shift? Is the ORC visitation log available and current? ❑ ❑ ❑ Is the ORC certified at grade equal to or higher than the facility classification? ❑ ❑ ❑ Is the backup operator certified at one grade less or greater than the facility classification' ❑ ❑ ❑ Is a copy of the current NPDES permit available on site? 0 ❑ ❑ ❑ Facility has copy of previous year's Annual Report on file for review? ❑ ❑ 0 ❑ Page# 3 Permit: NC0005126 Owner - Facility: Tyson Farms, Inc. Inspection Date: 08/07/2020 Inspection Type: Compliance Evaluation Record Keeping Yes No NA NE Comment: The records reviewed during the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed for the period July 2019 through June 2020. Nc effluent limit violations were reported all monitoring frequencies were correct. The ORC and staff must ensure that the ambient temperature inside the composite sampler is documented to verify proper preservation (less than or equal to six degrees Celsius) during the 24-hr. sampling period. Laboratory Yes No NA NE Are field parameters performed by certified personnel or laboratory? 0 ❑ ❑ ❑ Are all other parameters(excluding field parameters) performed by a certified lab? M ❑ ❑ ❑ # Is the facility using a contract lab? 0 ❑ ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? ❑ ❑ 0 ❑ Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? ❑ ❑ 0 ❑ Comment: On -site field analvses (dissolved oxvaen. DH, temDerature. total residual chlorine) are performed under Tyson Farm's field laboratory certification #5081. PAR Labs (all effluent parameters except field and toxicity), Meritech (toxicity) and ETT Environmental (toxicity) have also been contracted to provide analytical support. A five -point verification with primary standards (ultra -low range) must be performed initially on the new total residual chlorine meter (DR 3900) and every twelve months while this meter is being used for effluent analyses (Reference: North Carolina Wastewater/Groundwater Lab Certification approved procedure for analysis of total residual chlorine — DPD Colorimetric by SM 4500 Cl G-2011). Effluent Sampling Yes No NA NE Is composite sampling flow proportional? 0 ❑ ❑ ❑ Is sample collected below all treatment units? 0 ❑ ❑ ❑ Is proper volume collected? 0 ❑ ❑ ❑ Is the tubing clean? ❑ 0 ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees 0 ❑ ❑ ❑ Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type 0 ❑ ❑ ❑ representative)? Comment: The subject permit requires composite and grab effluent samples. The sampler tubing needed to be cleaned/replaced; however, the facility was not sampling during the inspection In addition, the aliquot volume was slightly below 100 mis. during the inspection and previou aliquot volume checks by on -site staff (multiple occasions). The ORC corrected the sampler program to ensure a minimum of 100 mis per aliquot will be collected during future samDlina events and later notified DWR staff that the tubina was chanaed. Page# Permit: NC0005126 Owner - Facility: Tyson Farms, Inc. Inspection Date: 08/07/2020 Inspection Type: Compliance Evaluation Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑ Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑ Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The facilitv was beina DrODerIv oDerated and well maintained. The ORC and staff incorporate a comprehensive process control program with all measurements being properly documented and maintained on -site. The facility is equipped with a SCADA system to assist the wastewater staff in the operations of treatment processes/units. Although not required, the wastewater treatment facility is staff with certified operators twenty-four (24) hours per day, seven (7) days per week. Equalization Basins Is the basin aerated? Is the basin free of bypass lines or structures to the natural environment? Is the basin free of excessive grease? Are all pumps present? Are all pumps operable? Are float controls operable? Are audible and visual alarms operable? # Is basin size/volume adequate? Comment: The facilitv continues to eaualize waste streams with the 4.5 MG I tanks (.845 MG and .034 MG). Solids Handling Equipment Is the equipment operational? Is the chemical feed equipment operational? Is storage adequate? Is the site free of high level of solids in filtrate from filter presses or vacuum filters? Is the site free of sludge buildup on belts and/or rollers of filter press? Is the site free of excessive moisture in belt filter press sludge cake? The facility has an approved sludge management plan? IY47111111111►[•7►/_9►1:4 • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ and two circular Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ■ ❑ ❑ ❑ Comment: The DAF unit treats all process wastewater and waste activated sludge from .845 MG EQ tank. DAF effluent is conveyed to the first anoxic treatment tank. The DAF solids are stored in a tank prior to being transported and land applied to permitted sites located in either Wilkes County or South Carolina by Terra Renewal Services. Chemical Feed Yes No NA NE Page# 5 Permit: NC0005126 Inspection Date: 08/07/2020 Owner - Facility: Tyson Farms, Inc. Inspection Type: Compliance Evaluation Chemical Feed Yes No NA NE Is containment adequate? 0 ❑ ❑ ❑ Is storage adequate? 0 ❑ ❑ ❑ Are backup pumps available? 0 ❑ ❑ ❑ Is the site free of excessive leaking? 0 ❑ ❑ ❑ Comment: Nutrient Removal Yes No NA NE # Is total nitrogen removal required? 0 ❑ ❑ ❑ # Is total phosphorous removal required? EIN ❑ ❑ Type Biological # Is chemical feed required to sustain process? ❑ ❑ 0 ❑ Is nutrient removal process operating properly? 0 ❑ ❑ ❑ Comment: The facility is equipped with three anoxic reactors and three aerobic reactors. Glycerin is available as a carbon supplement (not being added at time of inspection). Aeration Basins Mode of operation Type of aeration system Is the basin free of dead spots? Are surface aerators and mixers operational? Are the diffusers operational? Is the foam the proper color for the treatment process? Does the foam cover less than 25% of the basin's surface? Is the DO level acceptable? Is the DO level acceptable?(1.0 to 3.0 mg/1) Yes No NA NE Ext. Air Diffused ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ Comment: Aqueous lime is added to maintained appropriate alkalinity/pH levels. The foam coveraae in both aeration tanks was areater than twentv-five Dercent: however. nc foam carry-over was observed in the clarifier. The foam was later attributed to a surfactant. The small amount of foam on the ground adjacent to one of the aeration tanks was in the process of being cleaned up. Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? 0 ❑ ❑ ❑ Is the site free of excessive buildup of solids in center well of circular clarifier? 0 ❑ ❑ ❑ Are weirs level? 0 ❑ ❑ ❑ Page# 6 Permit: NC0005126 Owner - Facility: Tyson Farms, Inc. Inspection Date: 08/07/2020 Inspection Type: Compliance Evaluation Secondary Clarifier Yes No NA NE Is the site free of weir blockage? 0 ❑ ❑ ❑ Is the site free of evidence of short-circuiting? 0 ❑ ❑ ❑ Is scum removal adequate? 0 ❑ ❑ ❑ Is the site free of excessive floating sludge? 0 ❑ ❑ ❑ Is the drive unit operational? 0 ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? 0 ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? 0 ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) 0 ❑ ❑ ❑ Comment: A coagulant and flocculant are added to enhance settling. Pumps-RAS-WAS Yes No NA NE Are pumps in place? 0 ❑ ❑ ❑ Are pumps operational? 0 ❑ ❑ ❑ Are there adequate spare parts and supplies on site? 0 ❑ ❑ ❑ Comment: Disinfection -Liquid Yes No NA NE Is there adequate reserve supply of disinfectant? 0 ❑ ❑ ❑ (Sodium Hypochlorite) Is pump feed system operational? 0 ❑ ❑ ❑ Is bulk storage tank containment area adequate? (free of leaks/open drains) 0 ❑ ❑ ❑ Is the level of chlorine residual acceptable? 0 ❑ ❑ ❑ Is the contact chamber free of growth, or sludge buildup? 0 ❑ ❑ ❑ Is there chlorine residual prior to de -chlorination? 0 ❑ ❑ ❑ Comment: De -chlorination Yes No NA NE Type of system ? Liquid Is the feed ratio proportional to chlorine amount (1 to 1)? 0 ❑ ❑ ❑ Is storage appropriate for cylinders? ❑ ❑ 0 ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ ❑ 0 ❑ Are the tablets the proper size and type? ❑ ❑ 0 ❑ Comment: Sodium bisulfite is used for dechlorination. Are tablet de -chlorinators operational? ❑ ❑ 0 ❑ Page# 7 Permit: NC0005126 Inspection Date: 08/07/2020 De -chlorination Number of tubes in use? Comment: Flow Measurement - Effluent # Is flow meter used for reporting? Is flow meter calibrated annually? Is the flow meter operational? Owner - Facility: Tyson Farms, Inc. Inspection Type: Compliance Evaluation (If units are separated) Does the chart recorder match the flow meter? Yes No NA NE Yes No NA NE ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ■ ❑ ❑ ❑ ❑ ❑ ■ ❑ Comment: The flow meter is calibrated annuallv and was last calibrated on 6/5/2020 by Carotek. Effluent Pipe Yes No NA NE Is right of way to the outfall properly maintained? ❑ ❑ 0 ❑ Are the receiving water free of foam other than trace amounts and other debris? 0 ❑ ❑ ❑ If effluent (diffuser pipes are required) are they operating properly? ❑ ❑ 0 ❑ Comment: The effluent appeared clear with no floatable solids or foam. Page# 8