George's Chicken Wastewater Treatment System Improvements

Key Accomplishments

• JCC coordinated installation of a simplex submersible pumping system designed for approximately 1,050 GPM at 95 feet TDH, utilizing a 58 HP, 480-volt, three-phase pump.
• Constructed a new Flow Splitter Box and associated piping to distribute wastewater flow among multiple treatment-process destinations.
• The splitter structure incorporated one 12-inch influent line and four 12-inch outlet lines serving Reactor No. 1, the anaerobic lagoon, anaerobic lagoon short-circuit flow, and the emergency storage lagoon.
• JCC coordinated extensive excavation, trenching, foundation preparation, structural concrete, process piping, valves, gates, electrical systems, and instrumentation required for the new facilities.
• Installed variable-frequency-drive controls and ultrasonic level instrumentation for automatic pump operation and wet-well level control.
• Incorporated slide and weir gates, process valves, and associated piping into the upgraded wastewater-treatment process.
• Addressed challenging subsurface conditions at the Flow Splitter Box location through engineered excavation and foundation preparation.
• JCC coordinated construction while George’s Chicken’s wastewater-treatment operations remained active, requiring staged work and careful shutdown planning.
• Completed testing, startup, closeout, and integration of the new equipment into the existing treatment system.
• Johnston Construction Company served as Prime Contractor for the Wastewater Treatment System Improvements at George’s Chicken, LLC in Edinburg, Virginia. The project expanded and improved the facility’s industrial wastewater-treatment infrastructure through construction of a new clarifier effluent pumping system and a new flow-distribution structure. The contract documents were prepared by Reid Engineering Company, Inc. and defined the work as a single-prime construction contract.
• A major component of the project was construction of the new Clarifier Effluent Pump Station and force main. The station incorporated a simplex wet-pit submersible, non-clog wastewater pump designed to deliver approximately 1,050 gallons per minute at 95 feet of total dynamic head. The specified pump utilized a 58 HP, 480-volt, three-phase motor and was designed for operation through a variable-frequency drive.
• Pump operation was integrated with an ultrasonic level-monitoring system installed at the Clarifier Effluent Pump Station. The instrumentation continuously monitored wet-well level and provided control signals to the variable-frequency drive, allowing the pumping system to maintain the required operating level. The controls also incorporated low-low, low, high, and high-high level functions for pump operation and alarm conditions.