The URL can be used to link to this page

Home My WebLink AboutNC0005126_Compliance Evaluation Inspection_20221005ROY COOPER Governor ELIZABETH S. BISER Secretary RICHARD E. ROGERS, JR. Director Steven Smith, Plant Manager Tyson Farms, Inc. P.O. Box 158 Harmony, NC 28634 NORTH CAROLINA Environmental Quality October 5, 2022 SUBJECT: Compliance Evaluation Inspection Tyson Farms, Inc./Harmony Rendering WWTP NPDES Permit No. NC0005126 Iredell County Dear Mr. Smith: Enclosed is a copy of the Compliance Evaluation Inspection (CEI) Report for the inspection conducted at the subject facility on September 29, 2022, by Mr. Wes Bell of this Office. Please advise the facility's Operator -in -Responsible Charge (ORC) of our findings by forwarding the enclosed report. Should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at (704) 235-2192 or at wes.bell@ncdenr.gov. Enclosure: Inspection Report Cc: NPDES Program Files - Laserfiche DILLORIN _E Sincerely, ,-DocuSigned by: A4.14tw N P414 F161 FB69A2D84A3... Andrew H. Pitner, P.G. Assistant Regional Supervisor Water Quality Regional Operations Section Mooresville Regional Office Division of Water Resources, NCDEQ North Carolina Department of Environmental Quality I Division of Water Resources Mooresville Regional Office 1610 East Center Avenue. Suite 301 1 Mooresville. North Carolina 28115 704.663.1699 United States Environmental Protection Agency E PA Washington, D.C. 20460 Water Compliance Inspection Report Form Approved. OMB No. 2040-0057 Approval expires 8-31-98 Section A: National Data System Coding (i.e., PCS) Transaction 1 IN Code I 2 IL NPDES yr/mo/day Inspection Type Inspector Fac I 3 I NC0005126 111 121 22/09/29 117 18 i i 191 S I 201 Type 21 1 1 1 1 1 1 1 1 1 11 1 1 1 I I I 1 1 1 1 1 1 I I I I I I I 1 1 1 1 11 1 1 1 I 1 P6 Inspection 67I2.0 Work Days Facility Self -Monitoring I 70I4 Evaluation Rating I 71IN B1 I 72 QA I N I 73I I I I Reserved 74 751 1 I I I I I I 180 l Section B: Facility Data Name and Location of Facility Inspected (For Industrial Users discharging to POTW, also include POTW name and NPDES Dermit Number) Harmony Rendering Plant 501 Sheffield Rd Harmony NC 28634 Entry Time/Date 09:OOAM 22/09/29 Permit Effective Date 21/08/01 Exit Time/Date 12:OOPM 22/09/29 Permit Expiration Date 26/07/31 Name(s) of Onsite Representative(s)/Titles(s)/Phone and Fax Number(s) /// Kevin Todd Haynes/ORC/704-546-2602/ Other Facility Data Name, Address of Responsible Official/Title/Phone and Fax Number Contacted Steven Smith,PO Box 158 Harmony NC 286340158/Plant Manager/704-546-2602/ Yes Section C: Areas Evaluated During Inspection (Check only those areas evaluated) Permit Flow Measurement Operations & Maintenar Records/Reports Self -Monitoring Progran Sludge Handling DispoFacility 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) Wes Bell of Inspector(s) Agency/Office/Phone and Fax Numbers Date DocuSigned by: DWR/MRO WQ/704-663-1699 Ext.2192/ 10/5/2022 Llee4, 3e,11 A61696D90CC3437... Signature of ManaO49reiewer Andrew Pitne Agency/Office/Phone and Fax Numbers Date 4.414 H P+NfR/MRO WQ/704-663-1699 Ext.2180/ 10/5/2022 F161FB69A2D84A3... EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete. Page# 1 NPDES yr/mo/day 31 NC0005126 111 121 22/09/29 I17 Inspection Type 18 [j 1 Section D: Summary of Finding/Comments (Attach additional sheets of narrative and checklists as necessary) Page# 2 Permit: NC0005126 Inspection Date: 09/29/2022 Owner - Facility: Harmony Rendering Plant 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 El El ❑ application? Is the facility as described in the permit? • El El El # Are there any special conditions for the permit? El El • El Is access to the plant site restricted to the general public? • ❑ ❑ ❑ Is the inspector granted access to all areas for inspection? • El El El Comment: The last compliance evaluation inspection at this facility was performed by DWR staff on 8/7/20. Record Keeping Are records kept and maintained as required by the permit? Is all required information readily available, complete and current? Are all records maintained for 3 years (lab. reg. required 5 years)? Are analytical results consistent with data reported on DMRs? Is the chain -of -custody complete? 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? (If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator 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? Facility has copy of previous year's Annual Report on file for review? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • • ❑ ❑ ❑ ❑ ❑ • ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ Comment: The records reviewed during the inspection were organized and well maintained. Discharge Monitoring Reports (eDMRs) were reviewed from August 2021 through July 2022. No effluent limit violations were reported and all monitoring frequencies were correct. Page# 3 Permit: NC0005126 Inspection Date: 09/29/2022 Owner - Facility: Harmony Rendering Plant Inspection Type: Compliance Evaluation Laboratory Are field parameters performed by certified personnel or laboratory? Are all other parameters(excluding field parameters) performed by a certified lab? # Is the facility using a contract lab? # Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees Celsius)? Incubator (Fecal Coliform) set to 44.5 degrees Celsius+/- 0.2 degrees? Incubator (BOD) set to 20.0 degrees Celsius +/- 1.0 degrees? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ ❑ ❑ • ❑ Comment: On -site field analyses (dissolved oxygen, pH, temperature and total residual chlorine) are performed under Tyson Farms Inc.'s field laboratory certification #5081. PAR Labs has been contracted to perform all permit -required analyses except field and toxicity. Meritech and Pace Analytical Services, Inc. have been contracted to perform the chronic toxicity tests. Effluent Sampling Yes No NA NE Is composite sampling flow proportional? • El El El Is sample collected below all treatment units? • ❑ El El Is proper volume collected? • El El El Is the tubing clean? • El ❑ ❑ # Is proper temperature set for sample storage (kept at less than or equal to 6.0 ■ El El El degrees Celsius)? Is the facility sampling performed as required by the permit (frequency, sampling type • El El El representative)? Comment: The subject permit requires composite and grab effluent samples. The sampler aliquots are checked (and documented) by the facility staff on a weekly basis. Operations & Maintenance Yes No NA NE Is the plant generally clean with acceptable housekeeping? • El El El Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ▪ El El El Solids, pH, DO, Sludge Judge, and other that are applicable? Comment: The wastewater treatment facility appeared to be properly operated and well maintained. The facility staff incorporate a comprehensive process control program with all measurements being properly documented and maintained on -site. The wastewater facility is equipped with a SCADA System to assist the wastewater staff in the operation of all treatment processes/units. 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? • Yes No NA NE ❑ ❑ ❑ Page# 4 Permit: NC0005126 Inspection Date: 09/29/2022 Owner - Facility: Harmony Rendering Plant Inspection Type: Compliance Evaluation Equalization Basins Yes No NA NE 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 facility is equipped with a circular equalization tank and a one million gallon pond. The pond receives stormwater and the waste streams from the scrubber, boilers (blowdown) and water softener (backwash) systems. The pond is aerated and the wastewater is normally pumped into the wastewater treatment plant during the weekends when there is no production. Grease Removal # Is automatic grease removal present? Is grease removal operating properly? • Yes No NA NE ❑ ❑ ❑ Comment: The influent waste stream is initially pretreated by a DAF unit for the reduction/removal of grease, etc. The DAF sludge is transported to Mathis Farms (Wilkes County) for land application. DAF sludge is also transported (infrequent basis) to South Carolina for disposal via land application. Chemical Feed Is containment adequate? Is storage adequate? Are backup pumps available? Is the site free of excessive leaking? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ Nutrient Removal Yes No NA NE # Is total nitrogen removal required? • El El El # Is total phosphorous removal required? ❑ • El El Type Biological # Is chemical feed required to sustain process? El • El El Is nutrient removal process operating properly? • El El El Comment: The facility is equipped with two anoxic reactors both equipped with aeration and mixing. Both reactors were in service. Aeration Basins Yes No NA NE Page# 5 Permit: NC0005126 Inspection Date: 09/29/2022 Owner - Facility: Harmony Rendering Plant Inspection Type: Compliance Evaluation Aeration Basins Yes No NA NE Mode of operation Ext. Air Type of aeration system Diffused 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? El • El El Is the DO level acceptable? • ❑ ❑ ❑ Is the DO level acceptable?(1.0 to 3.0 mg/I) • ❑ ❑ ❑ Comment: The foam did cover greater than 25% of the aeration basin's surface; however, no foam carryover was observed in the final clarifier. Lime is added to maintain appropriate alkalinity/pH levels. Secondary Clarifier Yes No NA NE Is the clarifier free of black and odorous wastewater? • ❑ El El Is the site free of excessive buildup of solids in center well of circular clarifier? ■ ❑ ❑ ❑ Are weirs level? • ❑ ❑ ❑ Is the site free of weir blockage? • ❑ ❑ ❑ Is the site free of evidence of short-circuiting? • ❑ ❑ ❑ Is scum removal adequate? • El El El Is the site free of excessive floating sludge? • ❑ ❑ ❑ Is the drive unit operational? • ❑ ❑ ❑ Is the return rate acceptable (low turbulence)? • ❑ ❑ ❑ Is the overflow clear of excessive solids/pin floc? ■ ❑ ❑ ❑ Is the sludge blanket level acceptable? (Approximately'/4 of the sidewall depth) • ❑ ❑ ❑ Comment: Polymers are added to enhance settling. Pumps-RAS-WAS Are pumps in place? Are pumps operational? Are there adequate spare parts and supplies on site? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ Disinfection -Liquid Yes No NA NE Page# 6 Permit: NC0005126 Inspection Date: 09/29/2022 Owner - Facility: Harmony Rendering Plant Inspection Type: Compliance Evaluation Disinfection -Liquid Is there adequate reserve supply of disinfectant? (Sodium Hypochlorite) Is pump feed system operational? Is bulk storage tank containment area adequate? (free of leaks/open drains) Is the level of chlorine residual acceptable? Is the contact chamber free of growth, or sludge buildup? Is there chlorine residual prior to de -chlorination? Comment: Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ De -chlorination Yes No NA NE Type of system ? Liquid Is the feed ratio proportional to chlorine amount (1 to 1)? ❑ ❑ • ❑ Is storage appropriate for cylinders? ❑ ❑ • ❑ # Is de -chlorination substance stored away from chlorine containers? ❑ ❑ • ❑ Are the tablets the proper size and type? ❑ ❑ • ❑ Comment: The feed rates for the chlorination and dechlorination systems are flow proportional. Are tablet de -chlorinators operational? ❑ ❑ • ❑ 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? (If units are separated) Does the chart recorder match the flow meter? Yes No NA NE • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ ❑ ❑ • ❑ • ❑ Comment: The flow meter is calibrated annually and was last calibrated on 1/6/22 by Horizon Engineering & Consulting, Inc. Effluent Pipe Is right of way to the outfall properly maintained? Are the receiving water free of foam other than trace amounts and other debris? If effluent (diffuser pipes are required) are they operating properly? Yes No NA NE • ❑ ❑ ❑ ❑ ❑ • ❑ Comment: The effluent appeared clear with no floatable solids or foam. The receiving stream did not appear to be negatively impacted. Page# 7