NC0005126_Authorization to Construct_20040406

NPDES DOCUMENT 5CANNINO COVER SHEET
NPDES Permit:
NC0005126
Harmony Rendering Plant
Document Type:
Permit Issuance
Wasteload Allocation
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Authorization to Construct (AtC
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Permit Modification
Complete File - Historical
Engineering Alternatives (EAA)
Correspondence
Owner Name Change
Instream Assessment (67b)
Speculative Limits
Environmental Assessment (EA)
Document Date:
April 6, 2004
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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
April 6, 2004
Mr. Dan Crowe
Tyson Foods, Inc.
P.O. Box 158
Harmony, North Carolina 28634
Subject: Authorization to Construct
ATC No. 005126A02
NPDES Permit No. NC0005126
Harmony Rendering Plant WWTP
Iredell County
Dear Mr. Crowe:
The Division of Water Quality's NPDES Unit has reviewed the Tyson Foods, Inc.'s request for an
Authorization to Construct improvements at the Harmony Rendering Plant WWTP, as well as
additional information provided by Reid Engineering. The Division finds the proposed
improvements and design to be satisfactory and hereby grants authorization for the following:
• installation of one 92 ft. diameter x 17 ft. SWD, bolted steel tank with three 50 HP surface
aerators, to serve as an aerated flow equalization basin (FEB),
• installation of one 350 gpm rotary drum screen upstream of the new 1~t•;>i,
• relocation of the existing DAF influent pump station, to serve as the FEB effluent/ DAF feed
pumping station,
• removal of the existing FEB tank from service, and • construction or installation of all related structures, equipment, piping, controls, and other
appurtenances, as described in the approved plans and specifications.
This Authorization to Construct is issued in accordance with Part III, Paragraph A of 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 conditions and limitations specified in
that perrnit.
Upon completion of construction and submittal of an acceptable Engineer's Certification (see below),
the approved design capacity of the facility shall remain at 0.040 MGD.
In the event that the facilities fail to perform satisfactorily, including the creation of nuisance
conditions, the Permittee shall take immediate corrective action, including those as may be required
by this Division, such as the construction of additional or replacement wastewater treatment or
disposal facilities.
Notification Requirements
The Permittee shall notify the Mooresville Regional Office, telephone number [phone], at least
forty-eight (48) hours in advance of operation of the installed facilities, so that an in -place inspection
can be made. Such notification to the regional supervisor shall be made during the normal office
hours of 8:00 a.m. until 5:00 p.m. on Monday through Friday, excluding State Holidays.
North Carolina Division of Water Quality
1617 Mail Service Center
Raleigh, North Carolina 27699-1617
[phone]
FAX [phone]
On the Internet at http://h2o.enr.state.nc.us/

Mr. Dart Crowe
Harmony Rendering Plant WWTP
ATC No. 005126A02
Page 2
Engineering Certification
Upon completion of construction and prior to operation of the modified facility, the Permittee shall
provide the Division with a certification 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
mailed to the NPDES Unit, 1617 Mail Service Center, Raleigh, North Carolina 27699-1617.
ORC Requirements
The Permittee must continue to employ a certified wastewater treatment plant operator 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 II, 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 Conditions
Failure to abide by the requirements contained in this Authorization to Construct may subject the
Permittee to 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 relieve the Permittee from its responsibility
to comply with any and all statutes, rules, regulations, or ordinances that 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.
If you have any questions about this Authorization to Construct, please contact Mike Templeton at
[phone], extension 541, or by e-mail at [e-mail].
Sincerely,
r.A1an�W. Klimek,1 L.
�^ Director
Enclosures: Approved plans and specifications
Engineer's Certification Form
Copies: John H. Reid, P.E. (w/ engr. cert.) - Reid Engineering Company, Inc.
1211 Princess Anne Street
Fredericksburg, VA 22401
Mooresville Regional Office, Water Quality
Technical Assistance and Certification Unit
Central Files
NPDES Unit Files

Reid Engineering Company, inc.
Teahn 24:1
Reid engineering Company, Inc.
Consulting Environmental Engineers
Specializing in the Design and Operation of Water Pollution Control Systems
September 3, 2003
Mr. Charles Weaver
North Carolina Department of Environment
and Natural Resources
512 N. Salisbury St.
P. O. Box 27867
Raleigh, NC 27626
DENR-WATER O'JALJTY
POINT SOURCE BRANCH
L �tt-')
OCT 3 1 2003 121
Subject: Authorization to Construct, Proposed New Flow Equalization Basin at
Wastewater Treatment System, Tyson Foods/River Valley Animal
Foods, Harmony, NC, NPDES Permit #NC0005126
Dear Mr. Weaver:
Tyson Foods/River Valley Animal Foods desires to install a new Drainage
Wastewater Screen and new Flow Equalization Basin (FEB) at their wastewater treatment
system in Harmony, NC. Reid Engineering Company is submitting the attached
Construction Drawings and Specifications, to the NCDENR for approval of an
Authorization to Construct this proposed new FEB.
The design flow capacity of the wastewater treatment system is 0.50 MGD. No
increase in the wastewater discharge flow volume is proposed as part of this project. This
project includes the following wastewater treatment system improvements:
1. One new Drainage Wastewater Screen will be installed to remove grit, solids and
rocks from the drainage wastewater stream.
2. One new Flow Equalization Basin (FEB) will be installed to provide 7 day
hydraulic flow equalization of all raw wastewater upstream of the existing
dissolved air flotation (DAF) pretreatment system.
1210 Princess Anne Street • Fredericksburg, Virginia 22401 • 540-371-8500 • FAX [phone] • Www.reidengineering.com
Registered Professional Engineers in Alabama. Arkansas. California, Delaware, Florida. Georgia, Idaho, Illinois. Indiana. Kansas. Kentucky, Louisiana, Maine. Maryland, Michigan. Minnesota,
Mississippi, Missouri. Nebraska, New Jersey, New York, North Carolina, Ohio, Oklahoma. Pennsylvania, South Carolina, Tennessee,'Icnas, Virginia. Washington, West Virginia, Wisconsin

Mr. Charles Weaver
Authorization To Construct
September 3, 2003
3. The existing DAF Cell influent pump station will be relocated to function as the
new FEB Effluent Pump Station to pump equalized wastewater from the new FEB
to the existing DAF Cell.
Installation and operation of this proposed new screen and FEB will result in a
significant improvement in wastewater pretreatment upstream of the new activated sludge
final treatment system, and a significant reduction in slug loadings on the activated sludge
system.
Tyson Foods desires to commence construction of this project immediately
therefore expedited approval from the NCDENR wou d be appreciated. If you have need
of additional information please call.
Sin
John H. Reid, P.E., President
cc: Bo Watson
Kelly Pogue
Dan Crowe
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