NC0005126_Inspection_20180703

s
Water Resources
Environmental Quality
3 July 2018
Mr. Gregg Wikstrom, Plant Manager
Tyson Foods, Inc.
Post Office Box 158
Harmony, North Carolina 28634
ROY COOPER
Governor
MICHAEL S. REGAN
Secretary
LINDA CULPEPPER
Interim Director
Subject: Compliance Evaluation Inspection
Tyson Foods, Inc./Harmony Rendering WWTP
NPDES Permit No. NC0005126
Iredell County
Dear Mr. Wikstrom:
Enclosed is a copy of the Compliance Evaluation Inspection Report for the inspection conducted
at the subject facility on June 29, 2018, by Mr. Wes Bell of this Office. Please inform the facility's
Operator -in -Responsible Charge (ORC) of our findings by forwarding a copy of the enclosed report.
Should you have any questions concerning this report, please do not hesitate to contact Mr. Bell at
[phone], or via email at wes.bell(c�r�,ncdenr.gov.
Enclosure:
Inspection Report
Sincerely,
DocuSigned by:
A14CC681 AF27425...
W. Corey Basinger, Regional Supervisor
Water Quality Regional Operations Section
Division of Water Resources, NCDEQ
State of North Carolina I Environmental Quality) Water Resources I Water Quality Regional Operations
Mooresville Regional Office 1610 East Center Avenue, Suite 310 1 Mooresville, North Carolina 28115
704-663-1699

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 15 I 3 I NC0005126 111 12 I 18/06/29 I17 18 I S i 19 i G i 201 I
211111 I I I I I I II I I I I I I I I I I I I I I I I I I I I I I I II I I I I I f6
Inspection
Work Days Facility Self -Monitoring Evaluation Rating B1 QA ---------------------- Reserved -------------------
67
2.0 70 71 [.. I 72 73 L_LJ74 751 I I I I I I I80
u u
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 oermit Number)
09:OOAM 18/06/29
14/06/01
Tyson Farms, Inc.
501 Sheffield Rd
Exit Time/Date
Permit Expiration Date
Harmony NC 28634
12:05PM 18/06/29
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
Gregg Wikstrom,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 & Maintenance Records/Reports
Self -Monitoring Program Sludge Handling Disposal Facility Site Review Effluent/Receiving Waters
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
DocuSigned by:
Wes Bell �� �e& MRO WQ//704-663-1699 Ext.2192/ 7/3/2018
A61696D90=43T
Signature of Management Q A Reviewer Agency/Office/Phone and Fax Numbers Date
W. Corey Basinger MRO WQ//704-235-2194/
EPA Form 3560-3 (Rev 9-94) Previous editions are obsolete.
DocuSigned by:
7/3/2018
Page#
E-Al4CC681AF27425...

NPDES yr/mo/day Inspection Type
NC0005126 I11 12, 18/06/29 117 18 JCJ
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: 06/29/2018 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
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0
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application?
Is the facility as described in the permit?
0
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# Are there any special conditions for the permit?
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0
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Is access to the plant site restricted to the general public?
0
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Is the inspector granted access to all areas for inspection?
0
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Comment: The facilitv has comDleted the WWTP uDarades. The influent waste stream is treated b
the following processes: rotary screening, EQ basin, dissolved air floatation (DAF) unit, two
anoxic tanks (operated in series), two oxic tanks (operated in series), polishing tank
(anoxic/oxic sections), secondary clarifier, chlorination/chlorine contact chamber,
dechlorination, and flow measurement.
The facility description will need to be updated during the next permit renewal process.
The last compliance inspection (Bio-monitoring) was performed at the facility on 1/10/17 by
DWR staff.
Record Keeping
Yes No NA NE
Are records kept and maintained as required by the permit?
0
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Is all required information readily available, complete and current?
0
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Are all records maintained for 3 years (lab. reg. required 5 years)?
0
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Are analytical results consistent with data reported on DMRs?
0
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Is the chain -of -custody complete?
0
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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?
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Has the facility submitted its annual compliance report to users and DWQ?
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(If the facility is = or > 5 MGD permitted flow) Do they operate 24/7 with a certified operator
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on each shift?
Is the ORC visitation log available and current?
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Is the ORC certified at grade equal to or higher than the facility classification?
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Is the backup operator certified at one grade less or greater than the facility classification?
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Is a copy of the current NPDES permit available on site?
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Facility has copy of previous year's Annual Report on file for review?
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Page# 3

Permit: NC0005126
Inspection Date: 06/29/2018
Record Keeping
Owner -Facility: Tyson Farms, Inc.
Inspection Type: Compliance Evaluation
Yes No NA NE
Comment: The records reviewed durina the insDection were oraanized and well maintained. Discharae
Monitoring Reports (eDMRs) were reviewed for the period May 2017 through April 2018. No
effluent limit violations were reported and all monitoring frequencies were correct.
The ORC and staff must ensure to include the "<" symbol on the eDMR when results (TSS,
ammonia, oil & grease, etc.) are below the analytical method's detection level. The ORC is
in the process of revising the April 2018 eDMR to correct transcription errors (TRC and
flow).
Laboratory
Yes No NA NE
Are field parameters performed by certified personnel or laboratory?
0
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Are all other parameters(excluding field parameters) performed by a certified lab?
0
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# Is the facility using a contract lab?
0
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# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
0
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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 analyses (dissolved oxygen, pH, temperature, total residual chlorine) are being
performed under the facility's field laboratory certification #5081. PAR Laboratories, Inc. (all
effluent parameters except field parameters and toxicity), Meritech, Inc. (toxicity), and ETT
Environmental (toxicity) have been contracted to provide analytical support.
Effluent Sampling
Yes No NA NE
Is composite sampling flow proportional?
0
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Is sample collected below all treatment units?
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Is proper volume collected?
0
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Is the tubing clean?
0
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# Is proper temperature set for sample storage (kept at less than or equal to 6.0 degrees
0
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Celsius)?
Is the facility sampling performed as required by the permit (frequency, sampling type
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representative)?
Comment: The subiect permit reauires composite and arab effluent samDles. The facilitv staff Derform
and document weekly aliquot verifications.
The ORC and staff must ensure of the following: the sampler is programmed to collect 100
mis. (minimum) per aliquot: composite samples are collected throughout a 24-hr. period:
and samples are properly preserved (chemically) within fifteen minutes following the end of
the 24-hr. composite sampling period.
Operations & Maintenance Yes No NA NE
Is the plant generally clean with acceptable housekeeping? 0 ❑ ❑ ❑
Page# 4

Permit: NC0005126 Owner -Facility: Tyson Farms, Inc.
Inspection Date: 06/29/2018 Inspection Type: Compliance Evaluation
Operations & Maintenance Yes No NA NE
Does the facility analyze process control parameters, for ex: MLSS, MCRT, Settleable ❑ ❑ ❑
Solids, pH, DO, Sludge Judge, and other that are applicable?
Comment: The wastewater treatment Dlant aDDeared to be Drooerlv oDerated and well maintained. The
ORC and staff incorporate a comprehensive process control program with all
measurements being properly documented and maintained on -site. Although not required,
the wastewater facility is staffed twenty-four hours per day, seven days per week with
certified operators on all shifts.
The facility is also equipped with a SCADA System that is accessible at three separate
locations throughout the wastewater facility.
Bar Screens
Yes No NA NE
Type of bar screen
a.Manual
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b.Mechanical
Are the bars adequately screening debris?
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Is the screen free of excessive debris?
0
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Is disposal of screening in compliance?
0
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Is the unit in good condition?
0
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Comment: Process wastewater is screened by a rotary type screening system. The screenings
(feathers, etc.) are returned back to the production facility for further processing.
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?
Yes No NA NE
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Page# 5

Permit: NC0005126
Inspection Date: 06/29/2018
Equalization Basins
Owner -Facility: Tyson Farms, Inc.
Inspection Type: Compliance Evaluation
Yes No NA NE
Comment: All process wastewater and waste activated sludae are directly conveved into the 845.000
(845K) gallon EQ basin. The stormwater from the sludge loading pad and the DAF Unit's
floor drainage system are also pumped to this EQ basin via a smaller EQ basin. The 854K
gallon EQ basin is equipped with surface and diffused aeration (all operational and in
service).
The 4.5 million gallon lagoon only receives stormwater, air scrubber system effluent, boiler
blowdown, and backwash from water softener system. The lagoon is equipped with surface
aerators (all operational and in service) and had approximately five to ten feet freeboard.
Wastewater from the lagoon is pumped into the 845K EQ basin during the weekends and/or
low influent flow periods to maintain lower lagoon water levels and provide organic loading to
the biological treatment system.
Solids Handling Equipment
Yes No NA NE
Is the equipment operational?
0
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Is the chemical feed equipment operational?
0
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Is storage adequate?
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0
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Is the site free of high level of solids in filtrate from filter presses or vacuum filters?
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Is the site free of sludge buildup on belts and/or rollers of filter press?
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Is the site free of excessive moisture in belt filter press sludge cake?
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0
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The facility has an approved sludge management plan?
0
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Comment: The wastewater in the 845K EQ basin is pumped to a DAF unit. The DAF effluent is
discharged into the first anoxic basin. The DAF solids are pumped into a tanker and land
applied by a contracted company (Terra Renewal Services) in South Carolina.
Nutrient Removal Yes No NA NE
# Is total nitrogen removal required? 0 ❑ ❑ ❑
# Is total phosphorous removal required? ❑ ❑ 0 ❑
Type Biological
# Is chemical feed required to sustain process? 0 ❑ ❑ ❑
Is nutrient removal process operating properly? SO ❑ ❑
Comment: The meat condenser condensate is currently being used as a supplemental carbon source
for the denitrification treatment process (anoxic tanks). Glycerin is also available on -site as
a carbon supplement.
Aeration Basins Yes No NA NE
Mode of operation Ext. Air
Type of aeration system Diffused
Is the basin free of dead spots? 0 ❑ ❑ ❑
Are surface aerators and mixers operational? ❑ ❑ ❑
Page# 6

Permit: NC0005126
Owner -Facility: Tyson Farms, Inc.
Inspection Date: 06/29/2018
Inspection Type: Compliance Evaluation
Aeration Basins
Yes No NA NE
Are the diffusers operational?
0
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Is the foam the proper color for the treatment process?
0
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Does the foam cover less than 25% of the basin's surface?
0
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Is the DO level acceptable?
0
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Is the DO level acceptable?(1.0 to 3.0 mg/1)
0
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Comment: Both aeration tanks were oDerational and in service. Each aeration tank is eauiDoed with a
surface aerator (mainly used in the summer months) and diffused aeration. Aqueous lime is
added to maintain appropriate alkalinity/pH levels.
The aeration tank effluent is conveyed into a 345K gallon polishing tank that is separated into
anoxic (300K gallon) and oxic (40K gallon) sections. The effluent from this polishing tank
flows into the secondary clarifier.
Chemical Feed
Yes No NA NE
Is containment adequate?
0
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Is storage adequate?
0
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Are backup pumps available?
0
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Is the site free of excessive leaking?
0
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Comment:
Secondary Clarifier
Yes No NA NE
Is the clarifier free of black and odorous wastewater?
0
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Is the site free of excessive buildup of solids in center well of circular clarifier?
0
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Are weirs level?
0
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Is the site free of weir blockage?
0
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Is the site free of evidence of short-circuiting?
0
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Is scum removal adequate?
0
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Is the site free of excessive floating sludge?
0
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Is the drive unit operational?
0
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Is the return rate acceptable (low turbulence)?
0
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Is the overflow clear of excessive solids/pin floc?
0
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Is the sludge blanket level acceptable? (Approximately'/ of the sidewall depth)
0
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Comment: A coagulant and flocculent are added to enhance settling in the secondary clarifier.
Pumps-RAS-WAS
Are pumps in place?
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Page# 7

Permit: NC0005126 Owner -Facility: Tyson Farms, Inc.
Inspection Date: 06/29/2018 Inspection Type: Compliance Evaluation
Pumps-RAS-WAS Yes No NA NE
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
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(Sodium Hypochlorite) Is pump feed system operational?
0
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Is bulk storage tank containment area adequate? (free of leaks/open drains)
0
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Is the level of chlorine residual acceptable?
0
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Is the contact chamber free of growth, or sludge buildup?
0
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Is there chlorine residual prior to de -chlorination?
0
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Comment:
De -chlorination
Yes No NA NE
Type of system ?
Liquid
Is the feed ratio proportional to chlorine amount (1 to 1)?
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M
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Is storage appropriate for cylinders?
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0
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# Is de -chlorination substance stored away from chlorine containers?
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0
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Are the tablets the proper size and type?
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0
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Comment: Aqueous sodium bisulfite is used for dechlorination. The chlorination and dechlorination
feed systems are flow proportional.
Are tablet de -chlorinators operational? ❑ ❑ 0❑
Number of tubes in use?
Comment:
Flow Measurement - Effluent
Yes No NA NE
# Is flow meter used for reporting?
0
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Is flow meter calibrated annually?
0
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Is the flow meter operational?
0
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(If units are separated) Does the chart recorder match the flow meter?
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0
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Comment: The flow meter is calibrated twice per year and was last calibrated on 5/23/18 by Horizon
Engineering & Consulting.
Page# 8

Permit: NC0005126
Inspection Date: 06/29/2018
Owner -Facility: Tyson Farms, Inc.
Inspection Type: Compliance Evaluation
Effluent Pipe
Yes No NA NE
Is right of way to the outfall properly maintained?
0
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Are the receiving water free of foam other than trace amounts and other debris?
0
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If effluent (diffuser pipes are required) are they operating properly?
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0
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Comment: The effluent appeared clear with no floatable solids or foam. The receiving
stream did not
appear to be negatively impacted.
Page# 9