Document mgpLrJzm6eqK2KqZ6Y4a4XO4

n EA~Unitc<!Stotcs ~ Environmental Protection '' Agencv Region 6 Compliance Assurance and Enforcement Division INSPECTION REPORT Inspection Date(s): Media: Regulatory Program(s) 03/20-21/2018 Water NPDES Company Name: Facility Name: Facility Physical Location: (city, state, zip code) Mailing address: (city, state, zip code) County/Parish: Facility Contact: Tyson Poultry, Inc. Tyson Poultry, Inc.- Dardanelle Processing Facility 1291 North Highway 7 (OTFL location: 35.218089, -93.150961) Dardanelle, Arkansas 72834 P.O. Box 638 Dardanelle, Arkansas 72834 Yell County Lance Martin lance. martin@t~son .com I Tyson Complex Manager FRS Number: Identification/Permit Number: Media Number: NAICS: SIC: N/A AR0036714 N/A 311615 2015 Personnel participating in inspection: Dave Evans Tyson Lance Martin Tyson Wayne Spencer Tyson Jason Bolenbaugh ADEQ Amy Beck ADEQ Paul Juarez EPA R-6/6EN-WC Juan Ibarra EPA R-6/6EN-WC Environmental Manager Complex Manager Wastewater Manager Compliance Branch Mgr. Inspector Dist. 5 - Inspector Inspector 479-229-8715 479-229-8780 479-229-8764 501-682-0659 479-968-7339, x16 214-665-7247 214-665-8493 EPA Lead Inspector Signature/Date Supervisor Signature/Date L.. /. /,- ~#aif4..& {lnsp<;efor nameJ {." ~ "l... 1\ (A,.., ll {Supervisor name} //? d"'h I .:ZC/' Date,... I !, I -' fz., 11. Date 6ENFORM-019-R6 (10/6/14) 1 Tyson Poultry, Inc. I Dardanelle Processing Facility Inspection Date 03/21/2018 Section I -INTRODUCTION PURPOSE OF THE INSPECTION EPA Region 6 inspectors Juan Ibarra and Paul Juarez arrived at the Tyson Poultry Inc. I Dardanelle Processing Facility at 0932 on March 20, 2018, for an unannounced inspection. We were accompanied by staff from the Arkansas Department of Environmental Quality (ADEQ), Jason Bolenbaugh (Compliance Branch Manager) and Amy Beck (Inspector). We met with Lance Martin (Tyson Complex Manager), Dave Evans (Tyson Environmental Manager), and Wayne Spencer (Tyson Wastewater Manager) at the Opening Conference. I presented my credentials to the Tyson Managers and informed them that this was an EPA inspection to determine compliance with the facility's ADEQ discharge permit and the Clean Water Act. The scope of the inspection was a full compliance evaluation inspection (CEI) and included an evaluation of the facility's physical site conditions and applicable records as required by the ADEQ discharge permit. Dave Evans and Wayne Spencer accompanied the EPA and ADEQ inspectors throughout the course of the inspection. FACILITY DESCRIPTION The 1.3 MGD Tyson wastewater treatment plant (WWTP) treated wastewaters resulting from the slaughter, cleaning, and processing of poultry (chicken) and boiler blowdown. The processing plant, which operated three shifts per day (five days a week- closed on weekends), had two 8-hr production shifts and one 8-hr sanitation shift. The plant had an offal screening headworks (see the photo log found in Appendix 1) that consisted of six large rotating screens (two for meat, two for feathers and two final combined). The final screens sent wastewater to the 250,000 aerated equalization tank. The offal and feathers were shipped off-site in open top trailers, and the blood was shipped off-site in a tanker. All of these wastes were transported to River Valley Animal Byproducts (a division ofTyson) in Scranton, AR. Following the offal 250,000 gallon aerated equalization tank, wastewater flow was sent to the Dissolved Air Floatation (DAF) tank. The DAF removed solids using air and polymers. The DAF unit sent sludge to the DAF sludge tank where it was later removed from the facility by Denali Water Solutions tanker trucks, to be land applied under a separate ADEQ permit. Effluent from the DAF was sent to the two 7-day 1-MG equalization tanks (to balance flows from the 5day operating period over a 7-day wastewater treatment period). The equalization tanks equalized the flow that was sent to the 2-MG Complete Mix Activated Sludge (CMAS) aerated basin. The CMAS was followed by a 1.25 MG Final Clarifier, and thence the chlorine contact basin. The final effluent then discharged thru a shared underground City of Dardanelle storm drainage line to the Arkansas River. The use of an MS4 storm water line will be discussed later in the report. See the Plant Schematic found in Appendix 2. 2