NC0005126_Authorization to Construct_20021007

NPDES DOCUMENT !;CANNINe COVER SHEET
NPDES Permit:
NC0005126
Harmony Rendering Plant
Document Type:
Permit Issuance
Wasteload Allocation
uthorization to Construct (AtC)
Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
October 7, 2002
This document is printed on reuse paper - ignore any
content on the reYerse side

Michael F. Easley, Govemor
State of North Carolina
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
October 7, 2002
Mr. Andy Duvall
Tyson Foods, Inc.
P.O. Box 158
Fredricksburg, Virginia 22401
Subject: Authorization to Construct
ATC Number: 005126A01
Permit Number: NC0005126
Harmony Rendering Plant
Dear Mr. Duvall:
The Division of Water Quality's NPDES Unit has reviewed your request for an Authorization to Construct at the
Harmony Rendering Plant. The Division finds the proposed improvements to be satisfactory and hereby grants
authorization for the following:
• Installation of a 0.69 million gallon flow equalization basin/anoxic reactor (and all associated
pumps and aeration equipment) and a pump station from the anoxic reactor to the nitrification
reactor
• Installation of a 0.645 million gallon nitrification reactor (and all associated pumps and aeration
equipment)
• Installation of nitrate recycle gravity line
• Installation of a clarifier influent flocculation tank and a new final clarifier
• Installation of a return activated sludge/waste activated sludge pump station
• Modification of the existing aeration basin to create a waste sludge lagoon
• Installation and modification of chemical storage/feed equipment for the activated sludge process
This Authorization to Construct is issued in accordance with NPDES Permit No. NC0005126, issued
September 13, 1999, and shall be subject to revocation unless the wastewater treatment facilities are
constructed in accordance with the terms and conditions of the permit.
Upon completion of these improvements and submittal of the Engineer's Certification (see below), the approved.
average design capacity of the treatment facilities shall be 0.5-MGD. This does not represent any change from the
currently permitted flow limit.
The Permittee shall notify the Water Quality Supervisor of the Mooresville Regional Office, telephone number (704)
663-1699, at least forty-eight (48) hours prior to operation of the installed facilities, so that an in -place inspectiom can
be made. Notification shall be made during the normal office hours of 8:00 a.m. until 5:00 p.m., Monday through
Friday.
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
[phone]
FAX [phone]
On the Internet at htto://h2o.enr.state-nc.us/
NCDENR
Customer Service
1 800 623-7748

Page 2
Engineer's Certification
Upon completion of construction and prior to operation of the modified facility, the Permittee shall provide the
Division with a certification (copy enclosed) from a professional engineer registered in North Carolina certifying that
the permitted facility has been installed in accordance with the NPDES Permit, this Authorization to Construct, and the
approved plans and specifications. The Certification should be submitted to: NCDENR / DWQ, NPDES Unit, 1617
Mail Service Center, Raleigh, North Carolina 27699-1617.
Requirements for Certified Operator
The Permittee shall employ a certified wastewater treatment plant operator to be in responsible charge (ORC) of the
wastewater treatment facilities. The operator must hold a certificate of the type and grade at least equivalent to or
greater than the classification assigned to the wastewater treatment facilities by the Certification Commission. The
Permittee must also employ a certified back-up operator of the appropriate type and grade to comply with the
conditions of Title 15A, Chapter 8G, .0200. The ORC of the facility must visit each Class I facility at least weekly and
each Class 1I, III, and IV facility at least daily, excluding weekends and holidays; and must properly manage and
document daily operation and maintenance of the facility and comply with all other conditions of Title 15A, Chapter
8G, .0200.
Additional Requirements
The Operational Agreement between the Permittee and the Environmental Management Commission is incorporated
herein by reference and is a condition of this Permit. Noncompliance with the terms of the Operational Agreement
shall subject the Permittee to all sanctions provided by G. S. 143-215.6 for violation of or failure to act in accordance
with the terms and conditions of this Permit.
Failure to abide by the requirements contained in this Authorization to Construct may subject the Permittee to an
enforcement action by the Division of Water Quality in accordance with North Carolina General Statute 143-215.6A to
143-215.6C.
The issuance of this Authorization to Construct does not preclude the Permittee from complying with any and all
statutes, rules, regulations, or ordinances which may be imposed by other government agencies (local, state, and
federal) which have jurisdiction.
The Permittee shall maintain a copy of the approved plans and specifications on file for the life of the facility. One (1)
copy of the approved plans and specifications is enclosed for your records.
If you have any questions about this Authorization to Construct, please contact Natalie Sierra, at [phone],
extension 551.
Enclosures: Project Plans and Specifications (approved)
Engineer's Certification Form
cc:
Mooresville Regional Office, Water Quality
Technical Assistance and Certification Unit
Central Files
NPDES Unit Files
Mr, John Reid, P.E. — Reid Engineering Company, Inc.
1210 Princess Anne Street
Fredricksburg, Virginia 22401
Sincerely,
, Alan W. Klimek, PE

ATC SUMMARY
Tyson Foods, Inc.
Harmony, NC
ATC No. 005126A01
Hunting Creek, WS-III
Yadkin -Pee Dee River Basin, 030706
Iredell County
SCOPE
The scope of the project includes the installation of a nutrient removal system including an
equalization basin/anoxic reactor, a nitrification reactor, a nitrate recycle gravity line, a clarifier
influent flocculation tank, a final clarifier, a return activated sludge pump station and the
conversion of the existing aeration basin to a waste sludge lagoon.
RECOMMENDATIONS
1. Approve installation of new multi -stage activated sludge biological
treatment system.
REVIEW SUMMARY
Executive Summary
The treatment works currently consist of:
•Aerated lagoon with mechanical aerators
• Chemical pH adjustment
• Chlorine disinfection
• Flow monitoring
• Dissolved air flotation (DAF) pretreatment
Since this facility is upstream of High Rock Lake, they are interested in pursuing nitrogen removal
and more reliable treatment at the plant. Approval of this project is recommended.
- end -
Project Name: Installation of multi -stage activated sludge biological treatment system
Applicant:
Mr. Andy Duvall
Tyson Foods, Inc.
1225 W. Hudson Road
Rogers, Arizona 72756
Application/Plans Prepared by:
John Reid, P.E.
Reid Engineering Company, Inc.
Fredericksburg, Virginia
Project Location:
Harmony Rendering Plant
501 Sheffield Road
Harmony, North Carolina
Iredell County
Page 1

ATC REVIEW NOTES
Estimated Project Schedule:
To start construct immediately upon receiving the ATC
Submissions:
• Letter of Transmittal
• Engineering Plans
• Specifications and Calculations
Flow Equalization Basin/Anoxic Reactor #1
Number of tanks: one
Type: 83 ft. (diameter) x 17 ft (SWD) tank constructed of bolted steel
Capacity: 0.69 million gallons
Hydraulic detention time: 5.7-6.6 hours (depending on flow)
Tyson Foods, Inc.
ATC No. 005126A01
Iredell County
Mixing and Aeration Equipment - Reactor #1
Number of pumps: one
Pump type: 28 HP submersible jet recirculation pump
Mixer - One directional mix header
Aeration capacity: One 40 HP positive displacement blower and one 75 HP blower to produce 1,400
scfm at the high liquid level of 17.0 feet
During the summer, a 30 HP floating surface aerator will be installed in Reactor #1 for spray
cooling of the wastewater
Effluent Pump Station (Reactor #1)
Number of pumps for flow between reactor #1 to reactor #2: two
Pump type: self -priming, rated at 1.25 MGD at 50 feet TDH
A discharge magnetic flow meter is provided in the pump station to measure and control flow into
the nitrification reactor (reactor #2)
Nitrification Reactor (Reactor #2)
Number of tanks: one
Type: 61 ft. (diameter) x 29 ft. (SWD) tank constructed of bolted steel
Capacity: 0.645 million gallons
Mean Cell Residence Time: 14 days
Mixing and Aeration Equipment - Reactor #2
Number of pumps: two
Pump type: 40 HP submersible jet recirculation pumps
Mixer - Two directional mix headers
Aeration capacity: 3,200 scfm with both pumps and both directional mixers in operation with air
supplied by four 75 HP positive displacement blowers each rated at 800 scfm (at 12.3 psi).
Diffusers are to be installed approximately 3 feet above the basin floor with a centerline depth of 26
ft. The positive displacement blowers can be automatically operated on/off by a DO
sensor/controller in order to maintain high DO, oxic conditions in reactor #2
Clarifier Influent Flocculation Tank -
Number of tanks: one
Type: 5 ft. (diameter) x 20 ft. (SWD) tank for mixing of chemical coagulant and flocculent solution
Capacity: 2,950 gallons
Hydraulic Detention Time: 2.8-4.3 minutes
Final Clarifier
Surface Loading Rate: 288 gpd/ft2 at the maximum average 6 day throughput flow rate of .5 MGD.
Page 2

Solids Loading Rate: 25.5 pounds/ft2/day at flow of 0.5 MGD and 100% sludge recycle rate
Minimum hydraulic detention time: 6.3 hours
Return Activated Sludge (RAS)/Waste Activated Sludge (WAS) pump station
Number of pumps for RAS: two
Pump type: self -priming, rated at 347 gpm at 50 feet TDH (equal to 1000% of the maximum
throughput flow rate)
One pump will be operated to provide a sludge recycle rate between 50-100%. The second pump
will function as a standby.
WAS will be transferred via 3" force main from the RAS pump station discharge header to the
waste sludge lagoon. The pump head provided by the RAS pumps will pump WAS at a rate of 10
gpm to 50 gpm to the lagoon.
Flow meters have been provided for both the RAS pumps and the WAS discharge line.
Waste Sludge Lagoon
The existing activated sludge lagoon will be converted to a waste sludge lagoon.
The lagoon has approx. 4 MG of storage. It is anticipated that a maximum of 3 MG of sludge will
be stored here, with the remaining 1 MG to be used as emergency wastewater storage. The lagoon
is clay lined on the bottom and concrete lined on the sides.
Duality/Emergency Operation
The Permittee and the consultant have agreed to divert wastewater flow to the lagoon for temporary
storage in the case of any equipment failure in either of the two tanks. Backup mixing and
aeration will be available on site, so any repairs should take less time than the 7 day/24 hour
storage time available from the lagoon. The clarifier will be regularly maintained on days when the
plant is not in operation (one day per week - minimum). In a prolonged emergency situation, the
Permittee will shut the rendering plant down.
Review Notes:
Initially, I began by performing a quantitative review Upon meeting with the consultant and
Tyson, a more qualitative review was undertaken. The consultant, Reid Engineering, has installed
numerous treatment systems exactly like this one for rendering plants all along the East Coast and
they have exceeded performance expectations. In particular, the consultant pointed to a
comparable system for a 1MGD system for a rendering plant in Alabama. Effluent BOD and NH3-
N concentrations are below North Carolina standards. It is anticipated that this plant will have
similar performance. Tyson representatives assured DWQ staff that Tyson operated WWTPs of
comparable design all across the country and has sufficient experience with this method to assure
us that the plant will meet permit limits, even under emergency operating conditions (i.e. one of
the tanks going out of service). Tyson WWTP staff will be trained at the Alabama plant mentioned
above prior to commencing operation of the new treatment plant at Harmony. The level of
experience with this type of treatment system on the part of both Reid Engineering and Tyson
suggests that this is an appropriate installation for the Harmony Plant.
Recommendations
I recommend that the Authorization to Construct be issued for the installation of the multi -stage
activated sludge system at the Harmony Plant.
Page 3

Michael F. Easley, Govemor
State of North Carolina
William G. Ross, Jr., Secretary
Department of Environment and Natural Resources
Alan W. Klimek, P.E., Director
Division of Water Quality
September 3, 2002
Mr. John H. Reid, P.E.
Reid Engineering Company, Inc.
1210 Princess Anne Street
Fredricksburg, Virginia 22401
Subject: Authorization to Construct Applications
ATC Numbers: 005126A01
Permit Number: NC0005126
Harmony Rendering Plant
Return # 2175
Dear Mr. Reid:
In accordance with Division policy, we must hereby return the attached Authorization to Construct (ATC)
application. After reviewing the package, it has come to the Division's attention that the design of the project is for 0.3
MGD. Since the permitted capacity of the plant is 0.5 MGD, we cannot accept the proposed project. Please resubmit
plans, calculations and specifications for upgrades pertaining to the permitted flow of 0.5 MGD. Also, as per previous
discussions with NPDES staff, please be sure to address the following:
■ Duality of treatment units. If dual treatment trains are not selected for the project, please include
information on measures to be taken in the event of a treatment unit failure.
• Percent removal of TSS and BOD. Please provide a basis for the selection of percent removal of BOD
and TSS for each treatment units.
• Organic loading rates. Please provide a basis for selection of the provided loading rates. It would also
be helpful to provide data from a plant of similar design and permit Limits.
Attached please find one copy of our ATC guidance to assist you in your resubmittal. If you have any
questions or comments concerning this ATC return, please contact Natalie Sierra at [phone] extension 551 or
via e-mail at: [e-mail].
Sincerely,
David A. Goodrich
NPDES Unit Supervisor
cc: NPDES Unit Files
Mooresville Regional Office/Water Quality Section
Mr. Andy Duvall - Tyson Foods, Inc.
1225 W. Hudson Road
Rogers, Arizona 72756
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
[phone] NCDENR
FAX [phone] Customer Service
On the Internet at htti://h2o.enr.state.nc.us/ 1 B00623-7748

Reid Engineering Company, Inc.
7'sul�
ReidEngineering Company, Inc.
Consulting Environmental Engineers
Specializing in the Design and Operation of Water Pollution Control Systems
April 19, 2002
Ms. Christie Jackson
North Carolina Department of Environment
and Natural Resources
512 N. Salisbury St.
P. O. Box 27867
Raleigh, NC 27626
1,9
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Subject: Authorization to Construct , Prooposed Wastewater Treatment System
Upgrade, Tyson Foods/River Valley Animal Foods, Harmony, NC,
NPDES Permit #NC0005126
Dear Ms. Jackson,
Tyson Foods/River Valley Animal Foods desires to install an upgrade to their
wastewater treatment system in Harmony, NC to improve ammonia nitrogen, total
nitrogen and TSS removal capability. Reid Engineering Company is submitting the
attached Construction Drawings, Equipment Specifications, and Final Design Summary
Engineering Report to the NCDENR for approval of an Authorization to Construct this
proposed wastewater treatment system upgrade project.
The design flow capacity of the wastewater treatment system upgrade is 0.30
MGD. No increase in the wastewater discharge flow volume is proposed as part of this
project. The upgrade project includes the following wastewater treatment system
improvements:
1. One new Flow Equalization Basin Reactor #1 will be installed to provide
combined 7 day hydraulic flow equalization and activated sludge treatment for
first stage carbonaceous BOD removal and denitrification of nitrate nitrogen
contained in mixed liquor recycled from downstream Nitrification Reactor #2.
J
1210 Princess Anne Street • Fredericksburg, Virginia 22401 • 540-371-8500 • FAX [phone]
Registered Professional Engineers in Alabama, Arkansas, Califomia, Delaware, Florida, Georgia, Idaho, Illinois, Indiana, Iowa, Kansas, Kentucky, Louisiana, Maine, Maryland, Michigan, Minnesota,
Mississippi, Missouri, Nebraska, New Jersey, New York, North Carolina, Ohio, Oklahoma, Pennsylvania, South Carolina, Tennessee, Texas, Virginia, Washington, West Virginia

Ms. Christie Jackson
April 19, 2002
Page 2
2. One new FEB Reactor #1 Effluent Pump Station will be installed to pump the 7
day throughput wastewater flow rate plus the nitrate recycle flow rate plus the
sludge return flow rate from Reactor #1 into Nitrification Reactor #2.
3 One new Nitrification Reactor #2' second stage activated sludge treatment basin
will be installed for ammonia nitrogen removal and final carbonaceous BOD
removal.
4. One new circular gravity Final Clarifier will be installed with upstream
Flocculation Basin and with a rapid suction sludge removal mechanism for final
sedimentation of mixed liquor solids and TSS removal.
5. One new Return Activated Sludge (RAS) Pump Station will be installed to
recycle sludge from the new Final Clarifier to FEB Reactor #1 or Nitrification
Reactor #2.
6. The existing aeration lagoon will be converted into a new Sludge Lagoon for
storage and disposal of waste activated sludge (WAS).
Final clarifier effluent will be discharged by a new gravity flow pipeline to the
existing chlorine contact basin for disinfection prior to final discharge through the
existing outfall.
Tyson Foods desires to commence construction on the project therefore expedited
approval from the NCDENR would be appreciated. If you have need of additional
information please call.
Since
John 1-1. Reid, P.E., President
cc: Bo Watson
Danny Wyatt
Doug Baxter
Jim O'Gorek
Dan Crowe

Tyson Foods, Inc.
E N G 1 N E E R 1 N G T North Carolina Engineering Group
} 1600 River Road, P.O. Box 88 • Wilkesboro, North Carolina 28697-0088 • Phone [phone]
July 31, 2001
North Carolina Department of Environment
and Natural Resources
Division of Water Quality
NPDES Unit
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
SUBJECT: NPDES Permit No. NC0005126
ATC Project No. 005126ACB
Tyson Foods, Inc.
Harmony, NC
Dear Madam or Sir:
Enclosed is the professional engineer's certification for the above subject project and facility.
Please call me at [phone], extension 3615 should you have any questions or require
additional information.
Sincerely,
kw-1mA)
3k
Lawrence R. Sampson, Jr., .E.
Cc: Dan Crowe
Danny Wyatt
LS/dn