ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
EPA-330/2-76-026
Characterization and Evaluation
of Wastewater Sources
United States Steel Corporation
National Plant
Pittsburgh, Pennsylvania
FEBRUARY 3-6, 1976
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
DENVER, COLORADO
AND
REGION III. PHILADELPHIA, PENNSYLVANIA
MAY 1976
% PBO^°
-------
Environmental Protection Agency
Office of Enforcement
CHARACTERIZATION AND EVALUATION OF WASTEWATER SOURCES
UNITED STATES STEEL CORPORATION
NATIONAL PLANT
PITTSBURGH, PENNSYLVANIA
February 3-6, 1976
May 1976
National Enforcement Investigations Center - Denver, Colorado
and
Region III - Philadelphia, Pennsylvania
1 of 111
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CONTENTS
I INTRODUCTION 4
II SUMMARY 11
III MONITORING PROCEDURES 15
IV MONITORING RESULTS 18
OUTFALL 001 18
OUTFALL 002 25
OUTFALL 003 32
OUTFALL 004 35
OUTFALL 005 36
OUTFALL 006 38
OUTFALL 007 39
OUTFALLS 008 and 009 40
OUTFALL 010 41
NO. 1 BLAST FURNACE THICKENER 43
NO. 1 BLAST FURNACE COOLING WAFER ... 45
RIVER INTAKE 45
V MONITORING REQUIREMENTS 51
OUTFALL 001 52
OUTFALLS 002, 003 and 010 52
OUTFALLS 004, 005, 006, 008 and 009 . . 52
OUTFALL 007 54
INTAKE 54
REFERENCES 55
APPENDICES
A Reconnaissance Report 57
B Field Study Methods 91
C Chain of Custody 99
D Analytical Procedures, Quality
Control 109
2 of 111
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TABLES
1 Outfall Description 9
2 Wastewater Monitoring Locations 16
3 Summary of Field Measurements and
Analytical Data 19
4 Cooling Water Discharged from Outfall 001 ... 24
5 Summary of Self-Monitoring Data 27
6 Oil Skimmed from Settling Basins 29
7 Scale Removed from Settling Basins 30
8 Proposed Effluent Limitations 31
9 Period of Operation and Condensing Water Usage . 37
10 Blast Furnace No. 1 Thickener Treatment
Performance 46
11 No. 1 Blast Furnace Thickener
TSS Removal Efficiencies 47
12 River Intake Water and City Water Volumes ... 49
13 Recommended Monitoring Requirements 53
FIGURES
1 USSC National Plant, Outfalls 001-003 5
2 USSC National Plant, Outfalls 004-009 6
3 USSC National Plant, Outfalls 009-010 7
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I. INTRODUCTION
The National Steel Plant and the Duquesne Steel Plant are operated
under a single management unit known as the National-Duquesne Works.
The National Plant is located on the Monongahela River at McKeesport,
Pa., immediately upstream of and across the river from the Duquesne
Plant.
The National Plant, also known as the National Tube Division Plant,
primarily produces finished tubular products and electric weld pipe for
steel plates and coils. Portions of the plant were originally construct-
ed in the late 18001s with improvement and expansion through the 1960's.
The plant currently consists of the following major operations:
Nos. 1 and 2 Seamless Tube Mills
Nos. 1 and 2 Bloom Mills
32-inch Bar Mill
Electroplating
Electric Resistance Weld (ERW) Mill
Submerged Arc Weld Mill
Three Blast Furnaces (Nos. 1, 2, 4)
(only No. 1 blast furnace is operational
and has been converted to ferromanganese
production)
Process water is pumped from the Monongahela River and is supple-
mented with treated water purchased from the City of McKeesport. Under
normal operating conditions, the theoretical intake volume would be
246,000 m3/day (65 mgd).
Wastewater is discharged from outfalls 001-010* [Figs. 1, 2, 3].
All wasteloads discharged from outfalls 002-010 are computed on a net
* Outfalls 011-017 are located at the Duquesne Plant.
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MONONQAHELA
001
/
1
S| 100.000 GAL
•"j SPENT OIL z
^jSTORAGE^ ~
Z
<1 cc
Ul
*
e
<
Z
I
TAN >1JI
Si
BASIN
SETTLING BASIN
FOR RINSE WATERS
I
WASTE OIL
STORAGE TANKS
ERW AND FINISHING
wl
=1
°l
Ol
COUPLING DEPT
1
BOILER SHOP
X
z
o
z
-J
a.
z
4
CO
UJ
SPENT
TORAG E
ACID
"TANKS'
SEAMLESS
| 1
r
PS
h-
C/>
o
o
o
o
z
a
o
oc
I-
u
UJ
—I
UJ
SUBMERGED WELD
PIPE
C"
\
\
SEAM LESS
M ILL
AREA
TREAM M.H.
n
GUARD HOUSE
¦~r~>
s
*!
i
w\
?i
111111111 M 11 M 1111111111
111 i,M 1111 M i M i M 11 M i
-4-
to
R.R. TRACKS
en
o
-+)
3
z
-J
<
$
I Li 1 1 1 1 M 1 M
if)
Figure ?. USSC National Steel Plant MeKeesport, Pennsylvania
-------
MONONGAHELA
RIVER
i
•N-
\
\ M.H.
V r. ef
—yT
V\bOOSTER PUMP,ftOUSE
\
1 11 1 M I 1 I M ! 1 1 If
R.R. tracks'
• dl St"1 flan' M1*"'"""*' p«"""'v°nla
fisu,. 2. ussc No,"",a' 5
-------
/
-------
basis. According to USSC,1 city water is used for air compressor cool-
ing water in the Coupling Tap Building and is discharged directly to
outfall 001 without recycle. Therefore, the wasteloads discharged from
outfall 001 are computed on a gross basis. Instantaneous flows are
measured over a 5-minute period by Company personnel, using lithium
chloride solution as a tracer.*1 The solution is injected upsewer of
the outfall and samples of the wastewater collected at 1-minute intervals.
The samples are analyzed on a photometer for lithium and the flow is
calculated from this concentration. The maximum of the five 1-minute
instantaneous flows is assumed to remain constant over 24 hours and is
reported as the daily flow.
There are three terminal settling basins (A, B, and C) on outfalls
002, 003 and 010, respectively, intended for solids and oil/grease
(0/G)** removal. The basins were constructed on the bank of the Monon-
gahela River; however, the effluent structures are not protected from
high river stages. When the river level exceeds elevation 720.2 ft,
river water flows into the effluent channel and floods the basins. The
three blast furnaces, Nos. 1, 2 and 4 are served by thickeners. Only
No. 1 blast furnace is operational; blast furnaces No. 2 and 4 and their
associated thickeners have been shut down. Process wastewaters from the
No. 1 blast furnace thickener are recycled to the blast furnace. The
other blast furnaces will only become operational if additional production
is required.1 Caustic and acid rinse wastewaters from the plating
operation are discharged to basin A after being detained in a concrete
basin. There are no provisions for the collection and removal of oils,
solids or other material from this concrete basin. All other wastewaters
are discharged without treatment. [A description of each outfall and
USSC-reported flows are provided in Table 1.] All domestic wastewater
* Technique used at all outfalls except 002.
used to determine flows for 002.
** Freon extractable material
The Manning Equation is
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Table 1
OUTFALL DESCRIPTION
USSC NATIONAL PLANT
Reported
No. Description Flow.
(mgd)
001 Cooling water from the boiler shop. Outfall 0.12
is the terminus of the Locust Street sewer
002 Process wastewater from the electric weld pipe 5.0
mill, treated in settling basin A.
003 Process wastewater from the seamless pipe mills, 6.0
treated in scale pits and settling basin B.
Outfall is terminus of Huey Street sewer.
004 Cooling water from the booster water pumping 8.0
station. Outfall is reported as terminus of
Armstrong Street sewer.
005 Barometric condenser cooling water from a 0.5
10,000 kW turbine-generator, plus air compressor
cooling water from the booster pump station.
006 Cooling water from the Central Boiler House. 5.0
007 Process water from the Central Boiler House. 1.0
008 Steam condensate from barometric condenser in the 12
Blow House plus cooling water from the No. 1 blast
furnace.
009 Excess cooling water from all blast furnaces. 10
Outfall is the terminus of the White Street
storm sewer.
010 Process wastes from sinter plant, gas washer 12
system, bloom and bar finishing mills, treated
in settling basin C.
+ USSC response to 308 request, dated November 17> 1975 from S. R.
Wassersug. Response dated January 28, 1976 from James L. Hamilton
III, Manager Environmental Control - Water.
9 of 111
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is discharged to the City of McKeesport sewers and treated at the
municipal treatment plant.1
Due to high river conditions, outfalls 002, 003, 004, 005, 006,
008, 009 and 010 were submerged and representative samples could not be
collected during the NEIC monitoring survey. In-plant monitoring of
outfalls 001, 007, excess cooling water discharged from the No. 1 blast
furnace, river intake water and screen backwash water, and the No. 1
blast furnace thickener influent and effluent was conducted February 3-
6, 1976. This report summarizes the results of the survey. Additional
data for the National Plant are reported in the reconnaissance report,
Report on EPA Reconnaissance/Inspection of September 22-27, 1975 and
Preliminary Evaluation for Prospective NEIC Sampling Survey, U. S. Steel
Corporation, National Steel Plant, McKeesport, Pa. [Appendix A]. The
Duquesne Plant survey results are summarized in a separate report.
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II. SUMMARY
1. Due to high river conditions, outfalls 002, 003, 004, 005,
006, 008, 009 and 010 were submerged during the NEIC monitoring period
February 3-6, 1976. Therefore only the wastewaters discharged from
outfalls 001 and 007 were monitored. In addition, the excess cooling
water discharged from the No. 1 blast furnace, the river intake water
and screen backwash water, and the No. 1 blast furnace thickener influent
and effluent were also monitored.
Flows were not determined for any wastewater discharge. Therefore
pollutant loads could not be calculated. All composite samples were
combined on an equal-volume basis and therefore represent only an estimate
of the pollutants contained in the daily discharges.
2. According to USSC, the only source of wastewater discharged to
the Locust Street storm sewer (terminus of the storm sewer is outfall
001) is cooling water from the air compressor in the Coupling Tap Building.
The water is purchased from the City of McKeesport.
Grab samples were collected once per day because prior to the
survey it was believed that only cooling water was being discharged.
The TSS and 0/G concentrations averaged 210 mg/1 and 200 mg/1, respectively.
Total iron concentrations averaged 6.7 mg/1. The concentrations are not
characteristic of cooling water. The high iron, TSS, and 0/G concentrations
discharged on all three days indicate that process wastewaters were
being discharged.
The NPDES* permit only requires that temperature and pH be monitored.
* National Pollutant Discharge Elimination System
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The high pollutant concentrations require that additional parameters be
limited and monitored. The monitoring location is adequate.
3. Outfall 007 contains blowdown water from the blow house and
sludges from the hot lime-soda ash process and filter backwashes. The
TSS increased an average of 53 mg/1 over intake concentrations; there
was no net increase in 0/G, total or dissolved iron concentrations.
USSC has proposed the following effluent limitations for TSS on a
net basis.
Daily Average
Daily Maximum
kg/day lb/day
kg/day lb/day
328 721
984 2,163
Based on the average flows reported by USSC, the estimated net TSS loads
discharged during the NEIC survey were only 60% and 39% of the proposed
average and maximum limitations. Since boiler blowdown wastes and
sludges are discharged from this outfall, net limitations for this
outfall may not be applicable. The sludges and filter backwashes are
not treated before discharge. • The boiler water is softened and filtered
and therefore the pollutants in the blowdown wastes are not influenced
by the intake levels. The outfall should be limited on a gross basis.
The monitoring location at the river is satisfactory.
4. During the NEIC survey, the No. 1 blast furnace was operating
at about 105% of its rated capacity for FeMn production. The influent
and effluent of the Eimco thickener serving the blast furnace were
monitored to determine the treatment efficiencies. According to USSC,
there is no blowdown from the thickener and feed water is only added to
make up for evaporation losses and the water removed with the settled
solids.
12 of 111
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Data submitted by USSC for 1971-1973 show that approximately 88% of
the TSS was removed by the thickener. The NEIC data show that only 46%
of the TSS was removed. Since flows were not measured by USSC or NEIC,
thus precluding flow-weighted composite samples, the data is only a
rough estimate of the treatment efficiencies. NEIC results show that
approximately 93% of the settleable solids, 12% of the cyanide, and 3%
of the phenol were removed. 0/G was not removed and there was an
increase in ammonia and total iron on all three days.
5. The characteristics of the excess cooling water from the No. 1
blast furnace, discharged to the White Street storm sewer, were equivalent
to the intake waters.
6. The river intake volumes during the survey averaged 217,800
m /day (57.5 mgd). The USSC-estimated volume of wastewater discharged
from outfalls 001-010 is 225,000 m^/day (59.6 mgd), or about 4% greater
than the total intake volume.
TSS and settleable solids concentrations of the intake screen
backwash water were equivalent to the intake water concentrations.
7. The National Plant personnel measure flows by injecting a
lithium chloride solution upsewer of the outfalls (except outfall 002)
over a 5-minute period and analyze the discharges for lithium. The
instantaneous flow is calculated and is used as the total daily flow.
The Manning equation is used to determine the instantaneous flow at
outfall 002. One instantaneous flow measurement over a 24-hour period
is not adequate to determine total daily flow. Continuous flow measur-
ing devices should be permanently installed at least on the major process
outfalls (settling basins A, B and C - outfalls 002, 003, and 010,
respectively). The effluent structures from these three basins should
be protected from high river stages so that flows can be measured con-
tinuously and to insure that the basins are not flooded.
13 of 111
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Outfalls 001, 002, 003, 007 and 010 should be monitored at least
once per week. If the No. 2 and 4 blast furnaces become operational,
then outfalls 008 and 009 should also be monitored at least once per
week. The minimum monitoring frequency for the remaining outfalls
should be once per month.
14 of
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III. MONITORING PROCEDURES
During the three-day monitoring period, only certain locations
could be sampled to characterize wastewater sources and evaluate treat-
ment units [Table 2]. Sampling locations were selected based on the
representativeness of the wastewater and conditions which would not bias
the data. Outfalls 002-006 and 008-010 were submerged or partially
submerged precluding the collection of representative samples due to
high river conditions. USSC reported that the effluents from settling
basins A, B and C (outfalls 002, 003 and 010 respectively) were
submerged for 48 days in 1975 and that the outfalls are affected by the
river stage 13% of the time.1 USSC has selected upsewer monitoring
locations for outfalls 001, 004, 006 and 008, whenever the river stations
are submerged. Alternate monitoring locations are not available for the
other outfalls. The upsewer locations for outfalls 001, 004, and 008
are used for lithium chloride injection for flow determinations during
normal river conditions; when the outfalls are submerged, samples are
collected from these alternate locations and flows are not determined.
During the reconnaissance in September 1975, USSC personnel were not
certain if the wastewater sampled at the alternate sites was well mixed
and contained the contributions from all sources. Although the plans of
all the sewers were requested,2 the information was not received by NEIC
until after the survey. Therefore, due to the uncertainties, samples
were not collected from the alternate locations.
Several of the National Plant's wastewater discharges flow into
city combined sanitary-storm sewers [Table 1; Figs. 1, 2, 3]. According
to the City of McKeesport officials, dry weather flow is intercepted by
weir structures and diverted to the municipal treatment plant. Downsewer
from the diversion weirs, only National Plant wastewaters enter the
storm sewers. During wet weather, an undetermined amount of upsewer
15 of 111
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Table 2
WASTEWATER MONITORING LOCATIONS
USSC NATIONAL PLANT
February Z-G3 1976
Station Description
Sample Type
Parameters
River Intake
Composite
Grab
TSS, NHV CN, Metals
Phenol, Settleable Solids,
Organics, 0/G
Intake Backwash
Grab
TSS, Settleable Solids
Outfall 001
Grab
TSS, 0/G, Metals
Outfall 007
Grab
TSS, 0/G, Metals
Thickener Influent
and Effluent
Composite
Grab
tss, mv CN
Settleaole Solids, Phenol,
0/G
Blast Furnace Excess
Cooling Water
Composite
Grab
TSS, NHV CN, Metals
Phenol, Settleable Solids,
0/G
16 of 111
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flow is not diverted but is discharged directly to the river. In
January 1976, the Pittsburgh area experienced one of its heaviest
recorded snowfalls; wet weather conditions continued during the survey.
The samples might not have been characteristic of the steel mill dis-
charges to the storm sewers; therefore the storm sewers were not monitored.
There are no permanently installed flow measurement devices on any
of the National outfalls. USSC uses a tracer method to measure flow.
Due to limited access to monitoring locations and safety considerations
during the survey, the tracer method was judged by NEIC to be the best
and maybe the only method for flow determination on a short-term basis.
To use the tracer technique, at least two sewer access points must be
available. The upstream location is used for tracer injection and the
downstream point for sample collection and tracer analysis. Adequate
mixing of the tracer must occur between the two access points. Since
none of the outfalls except 001 had more than one upsewer access point,
flows could not be measured by the tracer technique. Outfall 001 was
reported to contain city water used for non-contact cooling; therefore,
flow determinations were not considered warranted. A tracer could not
be introduced into the thickener wastewater for flow measurement due to
complete recycle of the wastewater. River intake volumes were deter-
mined from the USSC flow charts and gages.
Since flows were not determined, composite samples were collected
on an equal-volume basis. Details on sampling procedures are contained
in Appendix B. Chain of custody procedures [Appendix C] and analytical
quality control procedures [Appendix D] were followed.
17 of 111
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IV. MONITORING RESULTS
OUTFALL 001
The Locust Street storm sewer runs underneath the west side of the
National Plant; the terminus of the sewer is outfall 001. The outfall
is always submerged, therefore USSC monitors the wastewater in the storm
sewer at a manhole located on the northeast corner of the Coupling Tap
Building. According to USSC,1 the only source of wastewater discharged
from the National Plant to the storm sewer is cooling water from the air
compressor in the Coupling Tap Building. The water is purchased from
the City of McKeesport.
The sewer diagram for the seamless pipe mills (USSC drawing
T-15842) shows many storm water inlets on USSC property connected to the
Locust Street storm sewer. The drawing also shows the Blacksmith Shop,
Boiler Shop and the Carpenter Shop connected to the Locust Street sewer
upsewer of the USSC monitoring location. These connections may be floor
drains.
The wastewater was grab-sampled at the manhole once per day for
three days because USSC reported that only cooling water was being
discharged. The TSS and oil/grease concentrations averaged 210 mg/1 and
200 mg/1, respectively [Table 3]. Total iron concentrations averaged
6.7 mg/1. Although three grab samples are insufficient to characterize
the wastewater stream, the samples do give an indication of the character-
istics at the time of collection. These concentrations are not character-
istic of cooling water. The source of the pollutants is not known by
NEIC. The Locust Street storm sewer is 46 cm (18 in) in diameter at the
monitoring location. The flow was estimated by NEIC personnel to be
approximately 5 cm (2 in) deep. Although wet weather conditions were
18 of 111
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Table 3
SUMMARY OF FIELD MEASUREMENTS AND ANALYTICAL DATA
USSC NATIONAL PLAVT - Mo KEESPORT, PA.
February 3-6, 1376
Station
Datet
Time of
Collectlon
pH
Temperature
Gross/
/"Net
TSS
Settleable
Solids
0/G
NHVN
Phenol
Total
Cn
Total
Fe
Dissolved
Fe
Total
Zn
Total
Pb
Description
(Feb.)
fhr)
CC)
(mq/l)
River Intake
3
1450
1650
2045
8.8
8.3
7.4
2
2
2
G
G
G
<0.1
1
1
3
<0.005
<0.005
<0.005
4
Composlte
0205
1510
2025
7.4-9.1
7.5
7.9
7.8
1-2.5
1.5
3.0
1.5
G
G
G
G
11
<0.1
1
1
1
0.26
<0.005
<0.005++
<0.005tt
0.01
1.60
1.71
0.21
0.15
0.064
0.059
<0.04
<0.04
5
Composite
0230
1243
2025
7.3-7.9
7.6
7.6
7.7
1-3
1.5
0.5
1.5
G
G
G
G
8
<0.1
1
2
1
0.30
<0.005
<0.005
<0.005
0.02
1.49
0.19
0.045
<0.04
6
Composite
0230
7.4-7.8
7.6
0-1.5
1.5
G
G
14
2
0.22
<0.005
0.01
1.57
0.17
0.053
0.04
3-Day Average
G
11
<0.1
1
0.26
<0.005
0.01
1.55
0.19
0.054
<0.04
River Intake
Screen Backwash
3
4
5
1447
1505
1440
8.8
7.7
7.4
2.5
3.0
4.0
G
G
G
13
6
10
<0.1
<0.1
<0.1
3-Dv Average
G
10
<0.1
Outfall 001
3
1540
8.8
39.0
G
200
170
5.1
<0.05
4
1550
7.7
35.5
G
290ttt
280
5.9
<0.05
5
1530
7.2
31.0
G
140
150
9.2
<0.05
3-Day Average
G
210
200
6.7
<0.05
Outfall 007
3
1515
10.2
75
G
26
1
0.29
<0.05
4
1525
11.0
78
G
110
1
0.33
<0.05
5
1500
11.0
58
G
5G
<1
0.50
<0.05
3-Day Average
G 64
<1
0.37 <0.05
-------
Table 3 (Continued)
SUMMARY OP FIELD MEASUREMENTS AND ANALYTICAL DATA
ro
o
Station
Description
Datet
(Feb.)
Time of
Collection
(hrl
PH
Temperature
CO
Gross/
/Net
TSS
Settleable
Sol Ids
0/G
nh,-n
Phenol
Total
Cn
Total
Fe
Dissolved
Fe
Total Total
Zn Pb
(mq/1)
Outfall 007
3
1515
N
15
<1
<0.05
<0.05
(Continued)
4
1525
N
100
<1
<0.05
<0.05
5
\
1500
N
'42
<1
<0.05
<0.05
3-Day Average
N
52
<1
<0.05
<0.05
Ferromanganese
3
1420
9.0
63
G
2.0
Thickener
Infl uent
4
Compos 1te
9-9.
7
61-65
G
2.400
77
1,300
0235
9.7
65
G
0.30
0435
9.6
64
G
1
0.31
0515
9.1
66
G
3
0810
9.3
61
G
1
1014
9.4
65
G
1
1210
9.3
65
G
1
1425
8.8
66
G
2.5
2
0.49tt
1625
9.2
64
G
0.58tt
1845
9.6
64
G
0.53t+
5
Composite
9.1-9.
6
60-66
G
720
82
1,100
85
0210
9.3
64.5
G
0.55
0430
9.3
60
G
3
0.57
0610
9.3
62
G
1
0807
9.4
62
G
1
1415
9.5
62
G
7.5
1820
9.0
64
G
0.68
6
Composite
9-9.
6
60-66
820
78
1,100
78
0010
9.6
64.5
G
0.68
0210
9.3
62.5
G
0.71
0435
9.1
64
G
86
3-Day Average
1,300
4
2
79
0.54
1,170
83
Ferromanganese
3
1425
9.1
54
G
0.1
Th1 cleaner
Effluent
4
Composite
9-9.
7
52-56
G
750
91
1,200
0245
9.7
55
G
0.31
0445
9.6
55
G
3
0.34
0630
9.4
57
G
2
0815
9.2
56
G
1
1020
9.3
56
G
3
1215
9.1
56
G
2
1435
7.6
51
G
0.4
1
0.46tt
1635
9.4
53
G
0.47tt
1850
9.5
55
G
0.56tt
-------
Table 3 (Continued)
SUMMARY OP FIELD MEASUREMENTS AND ANALYTICAL DATA
Station
Description
Datet
(Feb.)
Time of
Collection
(hr)
pH
Temperature
CC)
Gross^
-^Net
TSS
Settleable
Solids
0/G
HH^-N
Phenol
Total
Cn
Total
Fe
Dissolved
Fe
Total
Zn
Total
Pb
(rnq/1)
Ferromanganese
5
Composite
7.6-9.5
51-57
G
480
87
1,000
89
Thickener
0220
9.4
51
G
0.55
Effluent
0435
9.3
54
G
1
0.57
(Continued)
0615
9.2
53
G
1
1418
9.5
52
G
0.1
1825
9.3
54
G
1
0.60
6
Composite
9-9.5
52-56.5
G
520
86
900
88
0020
9.3
55
G
0.68
0220
9.0
54
3
0.68
92
0420
9.4
55
G
3-Day
Average
G
580
0.2
2
88
0.47
1,050
89
Excess Cooling
Water, Ferro-
manganese Blast
Furnace
3
1440
8.3
7.5
G
<0.1
2
<0.005
1658
8.5
8.0
G
2
<0.005
2100
7.2
6.5
G
2
<0.005
4
Composite
7.2-8.9
6-8.5
G
16
0.10
1.69
0.18
0215
7.5
7.0
G
1
<0.005
1455
7.7
9.0
G
<0.1
<1
<0.005
2040
7.3
6.0
G
1
<0.005
5
Composite
7-7.8
6-10
G
11
0.05
1.60
0.10
0245
7.3
6.5
G
1
<0.005
1455
7.7
9.0
G
•
<0.1
1
<0.05
2040
7.3
6.0
G
2
<0.05
6
Composite
7.1-7.9
6-7.5
G
21
0.58
0.05
2.25
<0.05
0245
, 7.5
6.5
G
1
<0.005
3-Day Average G 16 <0.1 1 0.58 <0.005 0.07 1.85 <0.11
3 1440 N <0;1 1 0
1658 N 1 0
2100 N 0 0
-------
Table 3 (Continued)
SUMMARY OF FIELD MEASUREMENTS AND ANALYTICAL DATA
Time of
Settleable
Total
Total
Dissolved
Total
Total
Station
Datet
Collection
PH
Temperature
Grosj^
TSS
Sol Ids
0/G
NH,-N Phenol
Cn
Fe
Fe
Zn
Pb
Description
(Feb.)
(hr)
CC)
^"Net
I "*)/1)
Excess Cooling
4
Compos1te
N
5
0.09
0.09
<0.05
Hater, Ferro-
0215
N
<1
<0 005
manganese Blast
1455
N
<0.1
<1
<0 005
Furnace
2040
N
<1
<0.005
(Continued)
<0.05
5
Composite
N
3
0.03
0.21
0245
N
<0.1
<1
<0.005
1455
N
<1
<0.005
2040
N
1
<0 005
6
Compos1te
N
0.36
0.04
0.68
<0.05
0245
N
7
<1
3-Day Average
N
5
<0.1
<1
<0.005
0.06
0.33
<0.05
tAll composite samples collected between 6 a.m. and 6 a.m.; date 1s the day the sample was composited (I.e., 24-hour composite 0600 Feb. 3 to 0600 Feb. 4
1s dated Feb. 4). All composite samples were combined on an equal-volume basis.
¦H-Samples analyzed after recommended holding time because air freight personnel 1n Pittsburgh, Pa., did not place samples on the scheduled flight to Denver.
Data represent minimum values due to possible deterioration.
tttValue statistically out of the quality control limits of analysis. Allquots of the sample may not have been representative due to high solids concentra-
tion 1n sample. Value 1s a minimum value.
-------
prevalent prior to and during the survey, the depth of flow was not
indicative of a wet weather discharge. As previously discussed, dry
weather flow upsewer of the National Plant is diverted to the McKeesport
wastewater treatment plant. Therefore the pollutants were probably
discharged from the National Plant. High concentrations of iron on all
three days indicate that process wastewaters were being discharged.
Because the NPDES permit only requires monitoring of temperature
and pH and an estimation of flow, the survey data cannot be compared
with recent USSC monitoring data. The quantity of cooling water dis-
charged from outfall 001 for July 1974-July 1975 is summarized in Table 4.
USSC has not proposed effluent limitations for this discharge.
The monitoring location is at the last access point to the storm
sewer below all USSC connections, except one, according to USSC drawing
T-15842. There is a connection directly into the manhole, about 1.8 m
(6 ft) above the storm sewer invert, which apparently contains storm
water runoff. Contributions from this source would influence samples
collected for self-monitoring purposes. However, if runoff is not
occurring, the monitoring site is satisfactory if flows can be adequately
measured.
Flows can be measured using the tracer technique or by installing
permanent flow devices. Because the sewer contains storm waters, the
permanent structure should not obstruct the flow. A flume and stage
recorder could be installed to provide continuous flow data. If the
tracer method is used, the injection location should be evaluated.
Currently USSC injects a lithium chloride solution in the manhole
approximately 30 m (100 ft) upsewer of the monitoring location. Samples
should be collected from the sewer cross-section to determine if adequate
mixing occurs. If the tracer is not evenly dispersed, then the tracer
should be injected at another location further upsewer, possibly at the
23 of 111
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Table 4
COOLING WATER DISCHARGED FROM OUTFALL 001+
USSC NATIONAL PLANT
JULY 19 74-JULY 1975
Month
Cooling Water Discharged Per Month
m^+t
Gallons
July, 1974
9,725
2,569,380
August
9,315
2,460,920
September
7,885
2,083,180
October
10,330
2,729,642
November
8,645
2,283,644
December
10,060
2,658,392
January, 1975
8,900
2,350,696
February
8,020
2,118,336
March
8,030
2,122,076
April
10,305
2,722,720
May
8,900
2,350,452
June
7,830
2,068,968
July
9,330
2,464,660
Monthly Average
9,020
2,383,313
+ Letter dated January 28, 1976 with attachments from J, L. Hamilton
III, Manager, Environmental Control - Water, USSC, to Mr. Stephen
R. Wassersugj Director, Enforcement Division, USEPA, Region III,
Philadelphia, Pa.
tt Calculated by NEIC.
24 of 111
-------
air compressor, and the mixing should then be re-evaluated. Due to the
low flows and short distance between current injection and sampling
sites, the possibility exists that mixing will not be complete.
OUTFALL 002
Process wastewaters from the No. 1 and 2 seamless mills are dis-
charged to a central sewer which drains east to west under the mills.
The process wastewaters may flow to outfall 002 or 003; however, most of
the flow from outfall 002 originates in the No. 1 seamless mill.
Outfall 002 also receives process wastewaters from the Arc Weld Mill,
electroplating and painting of couplings, and the quench and temper
line. There are 13 scale pits located throughout the No. 1 seamless
mill to remove coarse particles from the first and second piercers, high
mill reelers, sizing mill and four cooling tables. Twenty-seven scale
pits serve various operations in the No. 2 seamless mill. Each of the
40 scale pits contains a removable bucket which is emptied when full.
All of the wastewaters flow to settling basin A, located on the
bank of the Monongahela River. The effluent from the basin is outfall
002. The effective dimensions of basin A are 30 m long x 6 m wide x 4 m
SWD* (100 x 20 x 13.5 ft) (USSC drawings T-118731 and T-118733).1 The
maximum detention time reported by USSC is 58 minutes.1 The basin has a
single inlet located approximately 5.4 m (17.8 ft) above the bottom of
the basin. There are no bypass provisions. [A sketch of the basin is
included in Appendix A.]
The effluent launder was submerged during the NEIC survey; there-
fore the discharge from outfall 002 could not be monitored. Because the
* Side water depth
25 of 111
-------
effluent weir was submerged and the entire settling basin flooded,
treatment of the wastewater was minimal.
Self-monitoring data for January-October 1975 [Table 5] indicate
that the influent flow ranged from 14,000 to 29,000 m^/day (3.7 to 7.7
mgd). The average daily flow is approximately 18,900 m /day (5 mgd).1
The net TSS and 0/6 loads discharged ranged from 0 to 1,334 kg (2,941
lb)/day and 0 to 773 kg (1,705 lb)/day, respectively. The data reported
is a rough estimate of the effluent characteristics because all samples
are collected on a grab basis. The flows reported are instantaneous
values measured for five minutes on the monitoring day; therefore the
loads reported are only indicative of conditions for a short time
period.
USSC does not have data on the treatment efficiency of basin A.
However, for calendar year 1975, the amount of oil skimmed from the
basin is summarized in Table 6 and the quantity of scale removed from
all three settling basins is summarized in Table 7.1
USSC has proposed gross effluent limitations for TSS and 0/G for
outfall 002 [Table 8]. For an average flow of 18,900 m^/day (5 mgd)
reported by USSC, proposed TSS load limitations would be exceeded when
the average daily TSS concentration was greater than approximately 75
mg/1. Proposed daily maximum load limitations for TSS and 0/G would be
exceeded when concentrations were greater than 225 mg/1 and 190 mg/1,
respectively. During the NEIC survey, the intake TSS and 0/G concen-
trations averaged 11 mg/1 and 1 mg/1, respectively. The maximum TSS
concentration reported for January-October 1975 was 117 mg/1. The
maximum 0/G concentration for the same period was 60 mg/1. Therefore,
it appears that the proposed limitations are not realistic for discharge
conditions. Furthermore, the TSS parameter should be limited on a net
basis. Because 0/G samples are collected on a grab basis, the limitations
should be on a gross basis since these samples cannot be composited.
26 of 111
-------
Table 5
SUmARX OF SELF-VOHITORIUG DATA*
USSC 11ATI0HAL PLANT
JAUUAR*-OCTOBER, 197 S
LOCATION
PARAMETER
(RANGE)
MONTH
JANUARY
FEBRUARY
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER OCTOBER
Intake
Flow, mgd
TSS, mg/1
0/G. rag/1
NR**
NR
NR
48.6-59.2
24-56
0.3-2.8
61.5-70
39-52
0.0-8.5
47.5-61.2
2-15
0.2-4.9
57.7-61.3
12-35
2.3-24.6
52 . 7-58.9
15-45
0.4-3.9
44.5-47.5
3-13
0.4-9.0
50.4-87.7
1-15
0.8-17.8
55.6-83.7
5-136
0.1-3.8
47.9-59.5
9-40
0.1-7.9
Outfall 001
Flow, rngd
NR
NR
0.12t
NR
NR
0.06t
NR
NR
O.lt
NR
Outfall 002
Flow, mgd
TSS, mg/1
TSS, lb/daytt
0/G, ng/1
0/G, lb/daytt
4.8t
NR
0-1,369
KR
112-528
4.8t
36-45
0-880
5.7-22.5
232-524
3.7-5.3
68-93
494-1 ,711
5.1-26.7
203-600
4.4-5.2
23-72
911-2,092
6.9-28.9
286-556
4.8-6.1
10-41
0-1,017
6.2-50.7
0-1,680
5.3-7.7
34-49
0-2.119
5.3-15.2
242-509
4.8-6 5
22-52
525-2,158
5.0-29.8
242-1,705
4.8-5.7
10-82
426-2.941
2.5-38
129-890
4.2-5.3
21-52
0-875
4.4-60.2
250-1 ,130
4.8-6.6
15-117
NR
0.1-18.9
NR
Outfall 003
F]cm, mgd
TSS, ng/1
TSS, lb/daytt
0/G, irtg/1
0/G, lb/daytt
5.71
NR
85-1,730
NR
0-294
5.7t
15-96
0-1.901
8.7-22.5
275-623
5.7+
42-76
95-1,188
0-19.9
124-375
5.7t
NR
285-1.283
NR
442-675
5,3t
23-59
0-1.105
5.5-28.2
0-552
1.57+
15-54
0-498
7.6-21.6
126-164
4.4-5.2
12-27
0-824
7.6-31.1
0-666
3.5-4.9
10-36
0-1,096
2.5-38
0-444
3.8-6.6
19-107
725-1 ,543
7.8-28.5
335-946
3.9-12.2
10-45
NR
1.2-18.3
NR
Outfall 004
IM
Flow,
mgd
Outfall
005
Flow.
mgd
Outfal1
006
Flow,
mgd
Outfall
007
TSS, ng/1
TSS, lb/daytt
Outfall 008
Flow, rngd
1.2t
KR
NR
0.3t
NR
55t
7.9t
1.2t
NR
NR
0.3t
71t
113t
7.9t
1.2t
NR
NR
0.35t
88-124
1,276-1,833
7.9t
1. 2t
NR
NR
0.37t
124t
0-225
17.9t
NR
NR
NR
0-35t
68+
0-158
10.8-17.9
4.5t
NOttt
0.6-1.7
0.24t
211
0-12
14.3t
6.5-9.8
NR
NR
0.26-0.27
114+
0-224
8.5t
NR
NR
0.26-0.27
34t
0-74
13.7-19.3 13.7-19.3
1.2t
UO
0.6-1.7
0.26-0.26
44t
0-31
7.9
1.2t
NR
NR
0.95t
74+
NR
-------
Tabic & (Continued)
SUMMARY OP SELF-MONITORING DATA«
ttJCOTflfl
MONTH
PARAMETER
(RAi'IGE) JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER
Outfall 009
Flow, mgd 2.3t 5.0+ 6t 16+ 5.2t 8.8t 5.4-8.1 6.5t 5.2t
Outfall 010
Flo*, mgd 5.9t 5.9+ 5.9t 5.9t 13.lt 11.2+ 7.2-11.6 7.5-11.8 8.5-13.8 8.8-15
TSS, mg/1 fIR 77-96 60-110 18-950 27-36 27-44 11-27 1-30 9-109 16-54
TSS, lb/daytt 0-10,620 1,468-3,329 979-2,839 787-46,500 0-2,403 0-2,719 0-1,454 0-1,305 0-365 HR
0/G, mg/1 NR 3.4-23 2.6-26.9 1.4-92.8 1.7-25.2 1.2-12.8 0.7-7.4 0.8-9.9 2.1-7.0 0.8-22.7
0/G, lb/day+t 44-1,155 83-2,560 39-372 221-1,653 0-284 112-562 15-218 0-231 71-456 NR
CN, mg/1 HR NR 0.4-0.9 0.03-0.3 0.003-0.02 NR 0.02-0 05 0.01-0 05 0.01-0.02 0.01-0.03
CH. lb/daytt 0-0.7 0.1-0.34 0.2-4.1 0-9.9 0-0 0-0.7 0.15-2.9 0-2.6 0-0.23 NR
*Data taken from the Discharge Monitoring Reports submitted by USSC to EPA, Region III, for January-September, 197S and fron Letter dated
January 28, 1978 from J. L. Hamilton, Manager, Environmental Control-Water, USSC, to Mr. Stephen R. Uaasersug, Director, Enforcement Division,
U.S. EPA, Region III, (USSC's response to EPA 308 Request of November 17, 197S). All data reported as gross values unless indicated as net.
**'IR - Not reported in either document ctlted above.
fOne value reported.
ttilet value.
tttitata not determined.
-------
Table 6
OIL SKIMMED FROM SETTLING BASINS*
USSC NATIONAL PLANT
1975
Basi n
Month
A
B
C
m3
Gal Ions
m^1
Gallons
nr*
Gallons
January
8.0
2,100
8.0
1,900
10.0
2,640
February
5.3
1,400
8.1
2,140
12.5
3,300
March
10.1
2,600
7.6
2,000
11.1
2,920
Apri 1
8.3
2,180
7.6
2,000
7.7
2,040
May
4.6
1,220
7.3
1,920
10.8
2,840
June
ft
ft
tt
July
12.0
3,180
9.3
2,460
17.1
4,520
August
5.2
1,380
5.4
1,420
10.0
2,640
September
5.0
1,320
4.9
1,300
9.3
2,450
October
4.4
1,160
4.8
1,260
8.5
2,240
November
3.8
1,000
4.2
1,120
7.7
2,040
December
5.5
1,440
6.7
1,760
10.5
2,760
t Letter dated January 28, 1976 with attachments from J. L. Hamilton III,
Manager, Environmental Control - Water, USSC, to Stephen R. Wassersug,
Director, Enforcement Division, USEPA, Region III, Philadelphia, Pa.
ft Data not available
29 of 111
-------
Table 7
SCALE RECOVERED FROM SETTLING BASINS+
USSC NATIONAL PLANT
1975
Scale Recovered
Dredging Basins A+B+C
Date
m. tons
tons
3-3-75
287
316.5
3-29
422
465
4-27
327
360
6-29
397
438
8-3
389
429
8-27
262
289
10-5
518
571
10-27
270
298
12-1
457
504
12-27
484
534
+ Letter dated January 28t 1976 with attach-
ments from J. L. Hamilton HI, Manager3
Environmental Control - Water, USSCj to
Stephen R. Wassersug, Directory Enforcement
Divisions USEPA} Region Illy PhiladeVphia}
Pa.
30 Of 111
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Table 8
PROPOSED EFLLUENT LIMITATIONS+
USSC NATIONAL PLANT
Discharge Limitations
Outfall Parameter Gross Dai ly Average Daily Maximum Daily Average Dai"ly Maxirr.u
No. Net kg/day lb/day kg/day lb/day (Unit Specified)
002
TSS
G
1,455
3,200
4,365
9,600
NA
NA
0/G
G
NA
NA
3,641
8,010
NA
NA
003
TSS
G
931
2,050
2,793
6,150
NA
NA
0/G
G#
685
1,506
2,055
4,518
NA
NA
007
TSS
N
328
721
984
2,163
NA
NA
010
TSS
N
2,413
5,310
7,239
15,930
NA
NA
0/G
G
NA
NA
4,023
8,850
NA
NA
CN (Total)
G
NA
NA
NA
NA
NA
NA
t Amended request for Adjudicatory Hearing.
tt Flou and temperature parameters were listed as NA for all limitations. pH was proposed as 6.0 minimum and NA maximum.
co
o
-------
USSC monitors outfall 002 at the effluent from the basin. The
monitoring location is only satisfactory when the effluent launder is
above the river level.
The wastewater flow from outfall 002 is determined at the influent
to basin A from the Manning equation
Q = A (1.5/n) R2/3 S1/2
where
Q = flow
A = cross-sectional area of flow
R = hydraulic radius
S = slope of the energy gradient (slope of
the flow channel)
n = Manning coefficient
USSC assumes that the slope of the sewer as installed is the same as the
design slope, 0.0059 ft/ft. The Manning coefficient used, n = 0.13, is
typical of ordinary concrete pipe. The cross-sectional area and hydraulic
radius are computed for various depths of flow. This method of computing
flow is satisfactory, provided that the USSC assumptions are correct for
S and n. Because USSC has the capability to measure flow by the tracer
technique, flows should be determined by both methods and the Manning
equation coefficients should be verified. A correction factor, if
required, could be derived for various flows to allow use of the equation
for self-monitoring purposes. A continuous-recording stage recorder
could be installed in the influent pipe to provide daily flows.
OUTFALL 003
The Huey Street storm sewer runs beneath the seamless mills and
discharges into settling basin B [Fig. 1]. The effluent from the basin
32 of 111
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is outfall 003. Process wastewaters from the No. 2 seamless mill are
discharged to basin B, although the wastewaters from the No. 1 seamless
mill may also be discharged to basin B since both mills discharge to the
central sewer beneath both of the mills.
The effective dimensions of settling basin B are 30 m long x 6 m
wide x 4.6 m SWD (100 x 20 x 15 ft) (USSC drawings T118745 and T118746).1
The maximum detention time reported by USSC is 48 minutes. The basin's
single inlet is below the effluent weir elevation; therefore the inlet
is always submerged. The basin cannot be bypassed. A sketch of the
basin is included in Appendix A.
The effluent launder, positioned at the same elevation as the
launders in basins A and C, was submerged during the NEIC survey.
Treatment during high river conditions would be minimal.
The self-monitoring data for January-October, 1975 [Table 5] show
that the flow ranged from 5,900 to 46,200 rrfVday (1.6 to 12.2 mgd). The
daily flow, reported by USSC, averages 22,700 nf* (6 x 10^ gal).1 The
net TSS and 0/G loads discharged ranged from 0 to 860 kg/day (1,901
lb/day) and 0 to 430 kg/day (946 lb/day), respectively. As previously
discussed, samples are collected on a grab basis and daily flows are
estimated from an instantaneous flow determined with a lithium chloride
solution; therefore the data reported was USSC's estimate of the effluent
characteristics.
Since the influent to the basin is submerged, the treatment efficiency
of basin B cannot be determined. However, the amounts of 0/G and scale
removed from the basin are summarized in Tables 6 and 7, respectively,
for the 1975 calendar year.
USSC has proposed gross effluent limitations for TSS and 0/G for
outfall 003 [Table 8]. Based on the average flow of 22,700 m^/day (6
mgd) reported by USSC, the average daily TSS and 0/G concentrations
33 of 111
-------
would be approximateey 40 mg/1 and 30 mg/1, respectively. Since intake
concentrations of TSS average 11 mg/1 and 0/6 average 1 mg/1 during the
NEIC survey, approximately 30 mg/1 of TSS and 29 mg/1 of 0/G could have
been added from processes to the intake water. On a daily maximum
basis, the TSS and 0/G concentrations would be 120 mg/1 and 90 mg/1,
respectively. The maximum TSS and 0/G concentrations for January-
October, 1975 were 107 mg/1 and 38 mg/1, respectively. The TSS and 0/G
limits submitted by USSC appear to have been proposed at levels that
would be rarely exceeded. The TSS samples should be collected on a
composite basis over 24 hours and net limitations applied. 0/G should
be limited on a gross basis since grab samples are collected.
USSC samples outfall 003 at the effluent from the basin. This
location is only satisfactory when the effluent launder is above the
river level.
The wastewater flow is measured with a lithium chloride solution
over a 5-minute period. The maximum instantaneous flow calculated over
this period is used to estimate the daily flow. The lithium chloride
solution is injected upstream of the settling basin; samples of the
basin's influent are collected from the upwelling zone in the basin and
analyzed for lithium for computation of the flow. This method of flow
measurement is not acceptable and is not dependable because of dilution
of the lithium with the wastewater in the basin, the build-up of lithium
in the upwelling zone over the 5-minute injection period, and the
dispersal or diffusion characteristics within the upwelling zone. The
flow should be measured on a continuous basis and recorded daily. This
would require the installation of a permanent flow measurement device
upsewer of the basin where all wastewaters are present, or at the
effluent launder. The latter would require the construction of a pro-
tective structure to prevent the river from backing up into the basin
during high water conditions. The protective structure should be
installed to protect the basin regardless of whether the flow is measured
at the effluent.
34 of 111
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OUTFALL 004
Cooling waters from four of the five air compressors in the booster
pumping station and the air compressors in the powerhouse are discharged
from outfall 004. The cooling water from the fifth air compressor is
discharged from outfall 005. The cooling water in the reservoir serving
the barometric condenser in the powerhouse is pumped to outfall 005.
The overflow from the reservoir may be discharged from outfall 004
according to USSC personnel during the reconnaissance.
USSC also reported during the reconnaissance that the Armstrong
Street storm sewer connects to the 004 sewer, however USSC has not been
able to locate the storm sewer on their property even though it is
indicated on USSC drawing T-15842. However, McKeesport Wastewater
Treatment Plant personnel are not aware of an Armstrong Street storm
sewer nor is it indicated on their sewer maps. Therefore, the discharge
from outfall 004 probably consists entirely of USSC's flow.
During the survey, the outfall was submerged and monitoring was not
conducted. USSC personnel stated that when outfall 004 is submerged,
the discharge is sampled at the upstream manhole on the northwest side
of the pumphouse, where the lithium chloride solution is injected for
flow determinations. According to USSC drawing T-15842, three sewer
lines enter the manhole. The possibility exists that the wastewater is
not completely mixed at this location and therefore does not represent
an acceptable sampling site for TSS, 0/G, iron and other pollutant
parameters. The location is adequate for tracer injection for flow
work, provided that mixing occurs in the pipe before discharge to the
river.
USSC has not proposed effluent limitations for this outfall.
The NPDES permit only requires monitoring of pH, temperature and
flow. In the self-monitoring data, USSC reported flow ranging from
35 of 111
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4,540 to 37,100 m^/day (1.2 to 9.8 mgd) [Table 5]. The daily flow
averages 30,300 (8 x 10^ gal).1
The monitoring location is adequate only when the outfall is not
submerged or partially submerged.
Flow measurements by the tracer technique are acceptable, however,
more than one measurement per day should be made to characterize the
fluctuations and determine the total daily flow.
OUTFALL 005
Cooling waters from the 10,000 kW turbine generator barometric
condenser and the air compressor in the booster pump station discharge
intermittently from outfall 005. During the survey, the outfall was
submerged.
USSC did not submit data for this outfall for January-October, 1975
[Table 5]. The NPDES permit requires quarterly monitoring of this
outfall. The quantity of condensing water used by the 10,000 kW turbine
generator is summarized in Table 9. On a quarterly basis, the discharge
from outfall 005 should be monitored in March, June, September and
December. Although there were discharges in three of these four months
in 1975, USSC personnel reported that the discharges did not occur on
monitoring days. Since the NPDES permit requires monitoring and does
not specify the day, USSC personnel should monitor the wastewater even
though the discharge occurs on non-monitoring days.
USSC determines flow by injecting a lithium chloride solution into
an upsewer manhole. USSC estimates the flow to be approximately 1,900
m^/day (0.5 mgd).1
USSC has not proposed effluent limitations for this outfall.
36 of 111
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Table 9
PERIOD OF OPERATION AND CONDENSING WATER USAGE+
10,000 KW TURBINE GENERATOR
USSC NATIONAL PLANT
1975
Total Hours
Month Operation
January
0
February
161
March
164
Apri 1
294.75
May
246
June
69.2
July
152.50
August
415.50
September
186.25
October
0
November
0
December
0
Condensing Water
mi X 1Q3T+ Gallons X 10J
0
0
380
100,193
385
101,613
700
184,890
690
182,155
350
93,042
550
144,524
110
287,157
630
165,684
0
0
0
0
0
0
t Letter dated January 28, 1976 with attachments from J. L. Hamilton III,
Manager, Environmental Control-Water, USSC, to Mr. Stephen R. Wassersug,
Director, Enforcement Division, USEPA, Region III, Philadelphia, Pa.
t+ Calculated from USSC data.
37 of 111
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The monitoring location at'the river is adequate only when the
river level is below the outfall.
OUTFALL 006
Spent cooling water from the boiler house and blowdown from the
water treatment plant is discharged from outfall 006. Water treatment
consists of hot lime-soda ash softening and filtering. There are 3
lime-soda ash reaction tanks (1 used as a spare), 14 pressure filters,
3 chemical feeders and 1 set of acid feed equipment for pH control.
o
Each reaction tank can continuously deliver 300 m /hr (80,000 gph) and
are blown down once per day. The treated water is routed to the boiler
house for use as boiler feed water.
During the reconnaissance, USSC personnel were not certain whether
or not the Martin Street storm sewer intercepted the flow to outfall
006. USSC drawing M-33461 does not show that the 006 flow is diverted
to the storm sewer.
During the survey, the outfall was submerged and samples were not
collected. USSC normally samples at the river location. If cooling
water is the only wastewater discharged from the outfall as reported by
USSC, the flow can be sampled from the first upsewer manhole between the
110-inch mill and the boiler house if pH and temperature are the only
parameters to be monitored. The river location is adequate for moni-
toring when the outfall is not submerged.
For January-October 1975, USSC estimated* the flow to range from
O
2,300 to 6,400 m /day (0.6 to 1.7 mgd). During the reconnaissance, it
* Lithium chloride tracer method
38 of 111
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3
was estimated by USSC that the flow averaged 2,800 m /day (0.75 mgd),
3
but it could also exceed 18,900 m /day (5 mgd); this was confirmed by
USSC on January 28, 1976.1
USSC has not proposed effluent limitations for this outfall.
OUTFALL 007
Outfall 007 contains blowdown water from the blower house and the
sludges from the hot lime-soda ash process and filter backwashes. For
January-October 1975, USSC estimated the flow to range from 900 to 3,600
nfVday (0.24 to 0.95 mgd) [Table 5], The net TSS load discharge ranged
from 0 to 830 kg/day (1,833 lb/day). The maximum TSS concentration
reported was 124 mg/1.
Since the outfall was above the river, grab samples were collected
once per day for three days to confirm that process wastes were not
being discharged [Table 3]. The net increase in TSS averaged 53 mg/1;
there was no net increase in 0/G, total or dissolved iron concentrations.
The pH was above 10.2 on all three days. The wastewater was characteristic
of boiler blowdown water.
USSC has proposed effluent limitations for TSS on a net basis
[Table 8]. Based on the average flow of 3,800 m /day (1 mgd) reported
by USSC,1 the net average TSS load* discharged during the survey would
have been 200 kg/day (440 lb/day); the daily maximum net TSS load* would
have been 385 kg/day (850 lb/day). These average and maximum loads are
only 60% and 39%, respectively, of the proposed limitations.
* Assuming that the TSS concentrations remained constant in the effluent
over the 24-hr period.
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Gross limitations should be applied at outfall 007 because the
boiler water has been treated and filtered (see outfall 006). Therefore
the pollutants in the discharge would not be related to intake water
parameters. In addition, the sludges and filter backwashes cannot
receive credit for intake levels.
Flows are estimated from lithium chloride measurements. The tracer
is added through a cover grate in the manhole on the east side of the
boiler house. Because steam is present in the manhole, neither USSC
personnel or EPA personnel were able to see the bottom of the manhole
during the reconnaissance or the survey. In addition, the cover cannot
be removed without breaking the concrete in which it is imbedded.
Therefore, during injection, it cannot be observed if all of the solution
is added to the wastewater flow or if the solution is adsorbed to the
manhole sides. If some of the solution is adsorbed, the flow will be
calculated greater than actual conditions.
The monitoring location at the river is satisfactory.
OUTFALLS 008 and 009
The No. 2 and 4 blast furnaces and associated Dorr thickeners are
no longer operational, and the wastewater in the No. 1 blast furnace
Eimco thickener is recycled; the flows from these units previously were
discharged from outfalls 008 and 009. Cooling waters from the No. 1
blast furnace are discharged from outfall 009 and are also used as
barometric condenser makeup water in the blow house. Additional water
is also supplied to the blow house condenser. The steam condensate from
the condenser is discharged from outfall 008. Process effluents from
the bar mill hot saws are also discharged from outfall 009. The terminus
of the White Street storm sewer is outfall 009.
40 of 111
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During the survey, both outfalls were submerged; there are no
alternate monitoring locations.
The NPDES permit requires monitoring for flow, pH and temperature.
The flows from outfall 008 ranged from 29,900 to 73,000 m^/day (7.9 to
19.3 mgd) for January-October 1975 [Table 5]. The flows from outfall
009 ranged from 8,700 to 60,500 m^/day (2.3 to 16 mgd) for the same
period. USSC estimated that the flows from outfalls 008 and 009 average
45,400 (12 mgd) and 38,000 m3/day (10 mgd), respectively.1
USSC has not proposed effluent limitations for either outfall.
Flows are measured instantaneously with a lithium chloride tracer,
over a 5-minute period. Although the technique is satisfactory, it can
be used only when the outfalls are not submerged. Due to the large
fluctuations in the daily flows in each outfall, a single flow measure-
ment is not sufficient to characterize the total flow.
Monitoring at the river location is satisfactory only when the
outfalls are not submerged.
If the No. 2 and 4 blast furnaces become operational, then process
wastewaters from the Dorr thickeners will be discharged from outfall 008
and 009 and continuous flow measurement and frequent effluent monitoring
should be required for both outfalls.
OUTFALL 010
The effluents from the sinter plant, two bloom mills and the bar
mill are discharged to settling basin C, located on the bank of the
Monongahela River. The effluent from the basin is outfall 010. Each
bloom mill is served by a scale pit while the 32-inch bar mill has a
centrally located scale pit followed by a smaller discharge scale pit.
41 of 111
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The effective dimensions of settling basin C are 30 m long x 6 m
wide x 4.5 m SWD (100 x 20 x 15 ft) (USSC drawings M-52003 and M-52004).
The maximum detention time reported by USSC is 24 minutes.1 The basin
has two influent pipes; the invert elevation of the 1.2 m (4 ft) diameter
pipe is the same as the crest elevation of the effluent weir on the
launder. The 76 cm (30 in) diameter pipe is submerged in the basin.
There are no bypass facilities for the basin.
The effluent launder was submerged during the survey as were the
two inlet pipes. Because of the influence of the river "backing up"
into the basin, treatment of the wastewater was minimal.
Self-monitoring data for January-October 1975 [Table 5] indicate
that the discharge flow ranged from 22,300 to 56,800 m3/day (5.9 to 15
mgd). The average daily flow is 45,400 m3 (12 x 10^ gal).1 The net TSS
and 0/G loads discharged ranged from 0 to 4,817 kg/day (10,620 lb/day)
and from 0 to 1,161 kg/day (2,560 lb/day). Cyanide net loads ranged
from O to 4.4 kg/day (9.9 lb/day). The maximum cyanide concentration
reported was 0.9 mg/1.
USSC does not have data on treatment efficiency; however, the total
quantities of oil and scale skimmed from the basin are summarized in
Tables 6 and 7, respectively.
USSC has proposed effluent limitations on a net basis for TSS and
on a gross basis for 0/G for this outfall. Limitations for total
cyanide were proposed as NA (not applicable). Based on the average flow
of 45,400 m /day (12 mgd), the net daily average and maximum TSS concen-
trations would be about 50 mg/1 and 150 mg/1, respectively. The maximum
gross 0/G concentration would be 90 mg/1. The maximum net TSS load
reported for January-October 1975 was 4,817 kg (10,820 lb)/day, which
was 67% of the proposed limitation. 0/G loads over the same period were
reported on a net basis. However, the maximum concentration reported
was 93 mg/1, which exceeded the proposed maximum concentration.
42 of 111
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USSC monitors outfall 010 at the effluent from the basin. The
monitoring location is only satisfactory when the effluent launder is
above the level of the river. There are no alternative monitoring
locations.
According to USSC, the flows are estimated using the lithium
chloride tracer technique. A flow measuring and recording device should
be permanently installed at the effluent channel; a protective structure
would be required to prevent the river from backing up into the basin.
NO. 1 BLAST FURNACE THICKENER
The No. 1 blast furnace has a rated capacity of 950 m. tons (1,047
tons)/day of basic iron and 345 m. tons (381 tons)/day of ferromanganese
(FeMn).1 The blast furnace has been converted to FeMn production and
is the primary producer of FeMn for USSC. Cooling water from the blast
furnace is used as makeup water for the barometric condenser in the blow
house. Excess cooling water is discharged from outfall 009. The blast
furnace is equipped with a dry dust catcher followed by a venturi scrubber
and cooling tower. The scrub effluents are treated in a 33.5 m (110 ft)
diameter Eimco thickener and then are recycled back to the venturi
scrubber and cooling tower. Underflows from the thickener are vacuum
filtered; the filtercake is landfilled and the filtrate returned to the
thickener. According to USSC, there is no blowdown from the system.1
Makeup water is added in quantities equivalent to the losses from
evaporation and solids removal. The system removes solids and other
pollutants contained in the solids particles. Additional treatment for
cyanide, phenol, metals, etc. removal is not provided.
During the NEIC survey, the blast furnace was operating at the
following levels:3
43 of 111
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Date Blast Furnace (Hot Metal Tons) Rated Capacity
(Feb.) m. tons/day tons/day (%)
3
379
418
110
(High Carbon FeMn)
4
364
401
105
5
330
364
96
6
376
414
109
Average
105
For 1975, the production levels were as follows:1
Parameter
Weekly Basis (net tons/day)
Maximum
Minimum
Average
m.tons tons
m.tons tons
m.tons tons
Basic iron
FeMn
1 ,282 1 ,414
399 440
1 ,050 1 ,157
240 264
1 ,122 1 ,237
335 369
Parameter
Monthly Basis (net tons/day)
Maximum
Minimum
Average
m.tons tons
m.tons tons
m.tons tons
Basic iron
FeMn
1 ,165 1 ,284
700 772
1,083 1,194
493 543
1,118 1,232
643 709
The influent and effluent of the thickener were monitored for three
days to determine treatment characteristics. Flows could not be measured
because any tracer introduced into the influent would be recycled and
the accumulative effect would yield erroneous flows. Therefore, TSS,
ammonia, total cyanide and total iron samples were composited on an
equal-volume basis. The flow through the thickener was assumed to
remain constant. However, because flows were not measured, the data
represents an estimate of the thickener's performance. Samples for 0/G,
settleable solids and phenol were collected on a grab basis.
44 of 111
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The results of the monitoring are summarized in Table 3. The
thickener's treatment performance is evaluated in Table 10. Over the
three-day monitoring period, approximately 46% of the TSS and 93% of the
settleable solids were removed. Total cyanide was reduced by 12% and
phenol by 3%. There was a net increase in ammonia and total iron on all
three days. 0/G remained at low levels and was not removed.
Data submitted by USSC for February 1971 to April 1973 show that
approximately 88% of the TSS was removed by the thickener [Table 11].
Additional parameters were not monitored.
NO. 1 BLAST FURNACE COOLING WATER
The No. 1 blast furnace cooling water is discharged to the White
Street storm sewer which flows to outfall 009. This discharge was
monitored at the manhole in the conditioning yard, next to the No. 4
blast furnace thickener [Table 5]. The flows were not determined. The
discharge was equivalent to the intake waters.
RIVER INTAKE
The intake pumphouse is located immediately upstream of outfall 008
[Fig. 2]. The intake structure consists of rough bar screens and two
traveling screens. The traveling screen backwash water is discharged
directly to the river without treatment via an unpermitted outfall.
Intake pumps are located at the pumphouse and the blow house. There are
three electric pumps at the pumphouse, each rated at 25 mgd. Only one
electric pump is used under normal operating conditions. During the
survey, pump No. 1 was operational, No. 2 was dismantled for repair and
No. 3 was ready for standby use. The three pumps at the blow house are
steam-driven; these pumps have rated capacities of 15, 20 and 40 mgd.
Only the 40 mgd pump is used, the other two serve as standby units.
45 of 111
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Tab le 10
BLAST FURNACE NO. 1 THICKENER TREATMENT PERFORMANCE
USSC NATIONAL STEEL PLANT
FEBRUARY 3-6s 1976
TSS (mg/1)
Influent
Effluent
% removal
Settleable Solids (ml/1)
Influent
Effluent
% removal
2
0.1
95
2,400
750
69
2.5
0.4
84
Date (FebT)
720
480
33
7.5
0.1
99
Average
820
520
37
46
93
Oil/Grease (mg/1)"
Influent
Effluent
% removal
Phenol (mg/l)+
Influent
Effluent
% removal
Total Cn (mg/1)
Influent
Effluent
% removal
Ammonia (mg/1)
Influent
Effluent
^removal
2
2
0
0.44
0.43
2
1,300
1,200
8
77
91
Increase
2
1
50
0.60
0.57
5
1,100
1,000
10
82
87
Increase
0.70
0.68
3
1,100
900
18
78
86
12
Increase Increase
Total Iron
Influent
Effluent
% removal
(mg/1)
85 78
89 88
Increase Increase Increase
t Average of daily grab samples.
46 of 111
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Table H
NO. 1 BLAST FURNACE THICKENER
TSS REMOVAL EFFICIENCIES
USSC NATIONAL WORKS
February 1971 to April 1973
Date
Influent
Effluent
Performance
(ppm)
(%)
2-22-71
4,315.6
218.8
94.93
3-01-71
7,205.6
440.2
93.89
4-01-71
13,229.4
557.0
95.79
5-03-71
11,296.0
500.6
95.57
6-01-71
6,709.0
244.4
96.36
7-01-71
13,391.6
76.6
99.43
3-24-72
268.6
250.2
6.86
4-03-72
108.2
73.6
31.98
5-03-72
8,432.6
106.0
98.74
6-23-72
17,795.6
327.6
98.16
7-05-72
6,006.4
266.0
95.57
8-03-72
9,122.0
628.0
93.12
9-04-72
7,902.2
1,032.4
86.94
10-02-72
3,809.6
236.4
93.79
11-06-72
10,734.8
883.2
91.77
12-04-72
4,552.8
270.8
94.05
1-04-73
6,037.0
276.0
95.43
2-05-73
7,597.6
260.0
96.58
3-05-73
9,333.6
50.0
99.46
4-02-73
1,258.0
48.4
96.15
Average 87.73
t Letter dated January 28, 1976 with attachments
from J. L. Hamilton III, Manager, Environmental
Control - Water, USSC, to Stephen R. Wassersug,
Director, Enforcement Division, USEPA, Region
III, Philadelphia, Pa.
47 of 111
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The theoretical intake volume under normal operating conditions would be
246,000 m3/day (65 mgd).
The intake water in the pumphouse is measured by venturi tubes and
manometers and the instantaneous flow is indicated on a control board in
the basement of the pumphouse. The flows are not recorded. During the
survey, the No. 1 pump flow gage was the only working unit. USSC
personnel stated that the venturi tubes and manometers for the other two
pumps were not working and needed to be cleaned. Intake flows at the
blow house are measured by orifice plates and continuously recorded on
circular charts.
The intake volumes pumped for February 3-6, 1976 were as follows:
Date
Pumphouse
+
Blow House
Total
(Feb.)
m3 gal
m3 gal
m3
gal
x 106
x 10G
x 106
3-4
86,300 22.8
131,700 34.8
218,000
57.6
4-5
86,300 22.8
131,300 34.7
217,600
57.5
5-6
85,900 22.7
131,700 34.8
217,600
57.5
+ Integrator flow for 24-hr period
The volumes of intake water pumped from the Monongahela River, and
treated water purchased from the City of McKeesport for July 1974-Oune
1975 are summarized in Table 12.1 River intake volumes ranged from 1.2 x
10^ to 1.9 x 10^ m^/day (32 to 50 mgd) and averaged 1.5 x 105 m^/day
3 3
(40 mgd); approximately 2.2 x 10 m /day (0.59 mgd) of City water is
purchased for process use. The USSC-estimated volume of wastewater
[Table 1] discharged from outfalls 001-010 is 2.25 x 105 m^/day (59.6
mgd). The intake water pumped from the river during the survey was
about 96% of the USSC-estimated wastewater discharged.
48 of 111
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Table 12
RIVER INTAKE WATER AND CITY WATER VOLUMES*
USSC NATIONAL PLANT
JULY 1974-JUNE 1975
Month
River Intake
"gal x 10g'
mJ x 10
ni"3" x
Sanitary
City Water
Process
10b gal x IP6 m3 x 10° gal x 10b
mJ x
To
Total River Intake+City Process
» gal x 10° x 10° cal x 10J
July 1974
3.8
1.0
118
31.2
85.9
22.7
204
53.9
3.86
1.02
August
3.8
1.0
105
28.0
76.1
20.1
182
48.1
3.86
1.02
September
4.2
1.1
100
25.5
73.1
19.3
173
45.8
4.24
1.12
October
4.2
1.1
117
30.8
82.9
21.9
199
52.7
4.24
1.12
November
4.2
1.1
100
26.5
67.4
17.8
168
44.3
4.24
1.12
December
4.2
1.1
121
32.0
78.7
20.8
200
52.8
4.24
1.12
January 1975
4.2
1.1
125
33.3
66.6
17.6
193
50.9
4.24
1.12
February
5.3
1.4
125
33.0
57.2
15.1
182
48.1
5.37
1.42
Ma rch
5.3
1.4
144
38.1
49.2
13.0
193
51.1
5.34
1.41
April
5.7
1.5
140
36.9
60.9
16.1
201
53.0
5.75
1.52
May
5.7
1.5
133
35.1
53.4
14.1
186
49.2
5.75
1.52
June
4.9
1.3
123
32.5
53.4
14.1
176
46.6
4.96
1.31
Monthly Average
4.5
1.2
121
32.0
67.0
17.7
188
49.7
4.69
1.24
t Letter dated January 28, 1976 with attachments from J. L. Hamilton III, Manager, Environmental Control - Water, USSC, to ttr. Stephen Vasser8\
Director, Enforcement Division, USEPA, Region III, Philadelphia, Pa.
-c*
o
-+>
-------
The river intake water was sampled from the discharge side of the
No. 1 pump in the pumphouse. The screen backwash water was also sampled
for TSS and settleable solids. The solids concentrations in the back-
wash water were equivalent to the intake concentration [Table 3].
50 of 111
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V. MONITORING REQUIREMENTS
Monitoring requirements include both sampling and flow measurement.
Because the daily wastewater flow varies, composite samples should be
collected on a flow-weighted basis over the 24-hour monitoring period
rather than a set of grab samples over a short period.
Because the outfalls were submerged, flows could not be measured by
the tracer technique and the alternate monitoring locations were not
amenable to flow measurement using portable flow measuring equipment.
Permanent flow measurement devices should be installed on all process
wastewater outfalls. This will require modifications to the outfalls
for protection from flooding conditions.
USSC currently uses the tracer technique to measure the flows from
all outfalls except 002.1 A lithium chloride solution is injected into
the wastewater stream at an upsewer location over a 5-minute period.
Samples are collected at 1-minute intervals for a minimum of 5 minutes
and analyzed for lithium. The instantaneous flow is calculated and is
used as the total daily flow, i.e., the flow is assumed to be constant.
Flows reported in the Discharge Monitoring Reports vary; therefore, the
wastewater flows undoubtedly vary over the 24-hour monitoring period.
If USSC personnel continue to measure flows with the tracer technique,
the flows should be recorded on a continuous basis at all process
outfalls, and at least six instantaneous flow measurements should be
made over the 24-hour period on the cooling water outfalls. The tracer
technique cannot be used whenever the outfalls are submerged; therefore,
protective structures are needed for sampling and flow measurement
purposes. Conventional flow measuring devices may be installed when the
protective structures are constructed to eliminate the problems involved
with the tracer method.
51 of 111
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Recommended monitoring requirements are listed in Table 13. The
rationale for each outfall is discussed below.
OUTFALL 001
If the wastewater in this discharge only contained cooling water
from the air compressor, then monitoring of flow, pH and temperature
would be adequate on a quarterly basis. However, all samples collected
for TSS, 0/6 and total iron had high concentrations of these constituents,
typical of process wastewaters. Therefore the discharge should be
monitored weekly14 to characterize the flow and pollutants discharged,
unless USSC is able to isolate and eliminate the source of the pollutants.
If this is done, monitoring should be conducted quarterly as recommended
by the Office of Permit Programs.
OUTFALLS 002, 003 and 010
The effluents from the three settling basins contain process waste-
waters. The flows ranged from 6,050 to 52,200 m^/day (1.6 to 13.8 mgd).
The three outfalls should be monitored for TSS and 0/6 a minimum of once
per week.4 Total cyanide should also be monitored weekly at outfall 010
since the No. 1 blast furnace discharges to basin C.
OUTFALLS 004, 005, 006, 008 and 009
These outfalls contain cooling water according to USSC; therefore,
monitoring should only be conducted once per month for flow, pH and
temperature. If blast furnaces No. 2 and 4 become operational, then the
flows from outfalls 008 and 009 should be measured continuously and the
effluent should be monitored at least once per week for the same constituents
as outfall 010.
52 of 111
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Table 13
RECOMMENDED MONITORING REQUIREMENTS
USSC NATIONAL PLANT
Outfall
Effluent
Measurement
Sample Type
Parameter
Frequency
001
Flow
1/week
Minimum of 6 instantaneous
measurements over 24 hours
PH
1/week
Grab
Temperature
1/week
Grab
TSS
1/week
Flow-weighted composite
0/G
1/week
3 grab samples/24 hours
Total Iron
1/week
Flow-weighted composite
002
Flow
Daily
Measured continuously
pH
1/week
Grab
Temperature
1/week
Grab
TSS
1/week
Flow-weighted composite
0/G
1/week
3 grab samples/24 hours
003
Flow
Daily
Measured continuously
PH
1/week
Grab
Temperature
1/week
Grab
TSS
1/week
Flow-weighted composite
0/G
1/week
3 grab samples/24 hours
004, 005
Flow
1/month
Minimum of 6 instantaneous
006, 008
measurements over 24 hours
009
pH
1/month
Grab
Temperature
1/month
Grab
007
Flow
1/week
Minimum of 6 instantaneous
measurements over 24 hours
PH
1/week
Grab
Temperature
1/week
Grab
TSS
1/week
Flow-weighted composite
010
F1 ow
Daily
Measured continuously
PH
1/week
Grab
Temperature
1/week
Grab
TSS
1/week
Flow-weighted composite
0/G
1/week
3 grab samples/24 hours
Total Cyanide
1/week
Flow-weighted composite
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OUTFALL 007
Monitoring for flow, pH, temperature and TSS should be conducted
at least once per week since USSC reports an average flow of 3,800
m3/day (1 mgd).4
INTAKE
The intake water should be monitored at the same time that the
outfalls are monitored. Samples should be collected after screening
instead of at the river. The intake pipes are below the surface of the
river where quality may be different from that at the surface. 0/G will
be higher at the surface due to flotation. Collection of intake samples
after screening will insure that the samples are representative of the
water distributed in the plant.
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REFERENCES
1. Letter - Jan. 28, 1976 with attachments from J. L. Hamilton III,
Manager, Environmental Control - Water, USSC, to Stephen R. Wassersug,
Director, Enforcement Division, USEPA, Region III, Philadelphia,
Pa.
2. Letter - Nov. 17, 1975 from Stephen R. Wassersug, Director, Enforcement
Division, USEPA, Region III, to Earl W. Mailick, Vice President,
Environmental Control, USSC, Pittsburgh, Pa.
3. Letter - Apr. 19, 1976 with attachment from James L. Hamilton III,
Manager, Environmental Control - Water, USSC, to F. L. Voight,
USEPA, Region III, Philadelphia, Pa.
4. "Permit Program Guidance for Self-Monitoring and Reporting Require-
ments," Office of Permit Programs, USEPA, Washington, D.C., Apr.
30, 1973.
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APPENDICES
A Reconnaissance Report
B Field Study Methods
C Chain of Custody Procedures
D Analytical Procedures, Quality Control
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APPENDIX A
Reconnaissance Report - USSC National Plant
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REPORT ON EPA RECONNAISANCE/INSPECTION OF SEPTEMBER 23-27, 1975 AND PRELIMIN-
ARY EVALUATION FOR PROSPECTIVE NEIC FIELD SAMPLING SURVEY, U. S. STEEL CORPOR-
ATION, NATIONAL STEEL PLANTt MCKEESPORT, PA.
The National Steel Plant is combined with the Duquesne Steel Plant
on the other side of the Monongahela River to give a single USSC management
unit known as the National-Duquesne Works. National is the upstream plant
located on the south side of the Monongahela River at McKeesport, Pa. and
about 1^.5 miles above the Ohio River at Pittsburgh. Duquesne is the down-
stream plant located on the west (or north) side of the River at Duquesne,
Pa. and about 12.5 miles above the start of the Ohio River. National Steel
is primarily a steel finishing facility producing hot and cold formed pro-
ducts including electric resistance weld pipe, submerged arc weld pipe,
seamless pipe, and bars and rounds. However, National also has primary hot
rolling in two bloom-billet mills and a series of blast furnaces. Only one*
blast furnace is currently operational directed entirely to ferromanganese
production. Capacity production figures for National appear to approximate
2550 TPD hot formed seamless pipe; 5600 TPD hot formed billets, blooms, bars
and rounds; and 500 TPD ferromanganese. Production figures are not certain
for cold formed steel products.
The Duquesne Plant basically produces iron and steel but also has con-
siderable hot forming of billets, bars and rounds and some slabs. Capacity
production at Duquesne approximates 7550 TPD basic iron via blast furnaces,
8100 TPD BOP steel, 800 TPD electric furnace steel and 6100 TPD hot forming
of primary and finished steel.
As best determined, water intake or the total of wastewater and cool-
ing water discharges for National are in the range of 28 to 60 MGD. National
is identified by a multitude of scale pits at various points throughout the
Plant and by three large settling basins which have been constructed along
the side of the Monongahela River for terminal treatment. V/aste outfalls at
National are also located in such manner so as to be seriously impacted by
high River stage.
National has ten known outfalls i.e., 001 to 010 plus a number of storm
sewers traversing USSC property. Four of these outfalls, 002, 003, 009 and
010 are thought to contain the majority of waste loads from USSC, National
Steel. A minimum field survey effort is tentatively suggested for National
placing top priority on but 12 sampling locations. Assuming reasonably dry
weather, only two of these locations might be impacted by the River whereby
sampling location may need to be moved from the River to an alternative up-
stream manhole on the sewer line.
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Persons In Attendance, during EPA Reconnaisance of September 23 ~ 27, 1975
at USSC, NATIONAL STEEL MILL included:
Roy Wei skircher, Chief Environmental Officer, USSC, National-Duquesne
Works (located at Duquesne Plant), Duquesne, Pa. '»66-8000 X2219
Robert D. Dunham, USSC, Corporate, Environmental Office, 600 Grant Street,
Pittsburgh, Pa.
Tom H. Johns, USSC, Plant Engineer, USSC, National-Duquesne Works (located
at Duquesne Plant), Duquesne, Pa.
George Sorona, USSC, In Charge, Spectrograph Lab at BOP Shop, Duquesne
Plant, National-Duquesne Works, Duquesne, Pa.
Walter T. Sarsfield, Engineer, Pennsylvania Dept. Environmental Resources,
(PENDER), Pittsburgh, Pa. 565"5091
Barrett Benson, NEIC, Denver, Colorado
Robert Harp, NEIC, Denver, Colorado
Ed Struzeski, NEIC, Denver, Colorado
Matt Miller, EPA, Region III, Philadelphia, Pa.
BACKGROUND
The National Steel Plant of USSC, i.e. the National Tube Division Plant
located at McKeesport, Pa. on the south side of the Monongahela River at the
intersection of the Youghioghany and Mon Rivers, primarily produces finished
tubular products and electric weld pipe from steel plates and coils. Sections
of this plant were originally constructed in the late 1800's with improvement
and expansion programs through the 19601s. National in the 1960's consisted
of k operating blast furnaces (nos. 1,2,3,^0 together with stoves, gas scrubbers
and a sintering plant. At that time there were 3 Bessemer Converters and an
open hearth shop of 3 furnaces, all of which have been discontinued. The Na-
tional Plant is also equipped with rolling mills, conditioning facilities, two
seamless tube mills, finishing mill, an electric weld pipe mill, electric re-
sistance weld pipe mill, and various other shops. In the mid-60's the plant
was reported as operating 2k hours/day with A,000 - 5,000 plus employees of
which 10% of the employees were on the first turn (shift), approximately 70%
on the second turn, and about 20% on the third turn. The newest section of
the Plant on the most recently acquired land, appears to be that containing the
electric resistance weld mill extending west or upstream at and above Outfall
001.
The National Plant currently consists of the following major operations:
Nos. 1 and 2 Seamless Tube Mi 1 Is(constructed in the 19301 s)
Nos. 1 and 2 Bloom Mills
32-inch bar mill and hot bar saws inside same mill.
Electric Resistance Weld (ERW) Mill
Submerged Arc Weld Mill (Electric Weld Mill)
Pickling-Galvanizing of Couplings(inside electric weld mill bldg.)
Three Blast Furnaces (Nos. 1,2 and A). Only BF No. 1 was operation-
al September 1975. No. 1 has been specially equipped with addi-
tional coolers to allow higher operating temperatures, and con-
sequently has been converted entirely over to FeMn production.
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This has made National the primary producer of "Fer ro" for
U.S. Steel Corp,
Fact Sheet and Permit Rational - The Fact Sheet accompanying the EPA
Dec. 197*» Draft NPDES Draft Permit gives production for the combined National -
Duquesne Works as 16,850 TPD of hot formed metal, 7>550 TPD of iron, and
8,900 TPD of steel. Two pumping facilities supply the overall facility with
153 MGD of water from the Monongahela River with all discharges going back to
the same stream.
The Rationale accompanying the Draft NPDES Permit of Dec. 197*» fur-
ther amplifies production as given below:
Outfall 002 (Electric Weld Pipe Hill, Basin "AM)-2,600 TPD hot
formed finishing
Outfall 003 (Seamless Pipe Mill, Basin "B")-2,550 TPD hot
formed finishing
Outfall 010 (Bloom and Bar Mill, Basin "C")~5,600 TPD hot
formed finishing, plus unspecified production of sinter
plant.
Outfall Description - The Draft Permit and Fact Sheet of December 197^
describes the 10 Outfalls and NPDES Monitoring points for the National Steel
P1 an t as fo 11 ows :
001 - Effluent from boiler shop, 0.12 MGD, untreated; reported as
containing Locust St. storm sewer. Monitoring to b6 carried
out on waste line prior to Locust St. sewer
002 - Effluent from electric weld pipe mill, treated via large
Settling Basin "A". Flow reported as 3.^5 MGD. Discharge to
be monitored at effluent from Settling Basin "A" to Monongahela
Ri ver.
003 ~ Effluent from seamless pipe mill(s), A.89 MGD, treated via
scale pits and large Settling Basin "B". Flow to be monitored
at effluent from Settling Basin B to Mon River. Outfall 003
also contains the Huey St. storm sewer.
00*» - Effluent from No. 1 Pump Station, 0.^7 MGD, untreated, to be
sampled at terminus of sewer with Mon River.
005 " Effluent from Power House, 0.50 MGD, untreated, to be sampled
on Outfall near discharge to River.
006 - Cooling water effluent from Central Boiler House, untreated,
0.75 MGD; to be monitored at manhole just prior to 006 sewer line.
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007 ~ Process water spent effluent from Central Boiler House,
untreated, reported as 0.45 MGD, to be sampled on Outfall
near its point of release to the River.
008 - Effluent from Blow House and No. 1 Blast Furnace, 7*98 MGD,
untreated. Monitoring point was specified at end of Outfall
008 into Monongahela River.
009 " Effluent from No. 1 Blast Furnace with estimated flow of
2.28 MGD. If Blast Furnaces 2 and 4 become operational, the
discharge is expected to increase to full flow of 12.51 MGD.
Outfall 009 also contains the White Street storm sewer. Permit
specifies that flow shall be sampled at end of Outfall 009.
010 - Effluent from sinter plant, gas washer system, bloom and
bar finishing mills, treated principally via large Settling
Basin "C". Flow reported as 7*50 MGD. Discharge to be moni-
tored at point of release from Basin C into the Mon River.
The ten waste flows cited above amount to 28.39 MGD. With Blast
Furnaces 2 and 4 in operation, total flows could increase to 38.62 MGD. The
National Steel Mill has a single water intake from the Monongahela River lo-
cated between Outfalls 007 and 008. Total water withdrawals from the Mon Ri-
ver for the National Plant are in the range of 28-40 MGD. At least, five storm
sewer networks(in addition to the 3 above) are reported inside the USSC-Na-
tional Plant grounds. These include the Walnut and Market St. storm sewers
upstream of Outfall 001; the Martin Street sewer situated between Outfalls 005
and 006; the Center Street sewer between 007 and 008; and the Crooked Run drain-
age course thought to contain both storm and sanitary sewage and located below
the furthest downstream Outfall of 010 and above the McKeesport car bridge.
The National Steel Mill is on the south side of the Mon River spread
over about 1.5 miles of river front between the Youghioghany River and the
McKeesport Bridge. National is located entirely inside the city of McKeesport.
River mileages of the various Outfalls are given below:
Outfall 001
Outfall 002
Outfall 003
Outfall 004
Outfall 005
Outfall 006
Outfall 007
Outfall 008
Outfall 009
Outfall 010
R.M. 15.25
R.M. 15.17
R.M. 15-00
R.M. 14.93
R.M. 14.84
R.M. 14.77
R.M. 14.71
R.M. 14.58
R.M. 14.51
R.M. 14.44
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Downstream municipal water supplies receiving water from the
Monongahela River include the North Versailles Township Waterworks about
2.5 miles below the USSC National Plant, and the Borough of Braddock Water-
works another mile further downstream. North Versailles provides filtra-
tion and chlorination as treatment for its water intake and Braddock is re-
ported as using softening, filtration and chlorination. The city of Duquesne
about 2 miles below National has a series of artesian wells directly ad-
jacent to or within the Monongahela River bottoms. No direct connection is
thought to exist between these artesian wells and the Hon River. The West
Penn Water Co. withdraws its water supply at River Mile *».6.
PRODUCTION
As mentioned above, the Fact Sheet for the complete Nationa1-Duquesne
Works gi ves- production as:
16,850 TPD hot forming operations
7,550 TPD i ron, and
8,900 TPD steel
The Duquesne Plant was said tq break down to:
7,550 TPD iron from the basic iron blast furnaces
8,100 TPD (BOP steel) + 800 TPD (Elec. furnace steel)
= 8,900 TPD total steel
6,100 TPD hot forming
/
The National Plant may therefore be calculated as having a production of
10,750 TPD hot formed, finished steel. This checks with previous figures for
National. These figures also show National to be almost entirely a steel fin-
ishing mi 11.
Addit ional production data obtained from Tom Johns and Roy Weiskircher
September 23 - 27 together with other inputs indicate the following:
DUQUESNE -
BOP: 2 kettles, one going and the other as standby;
e3£h kettle 215 tons per heat. Normally 3 turns/day
but currently running only two, 7 days/week. Capacity
is 36 heats/day with 2k heats going to the Duquesne
primary mills and 11 going to National primary mills.
Capacity = 36 x 215 tons = 77^0 TPD, or 35 x 215 tons =
7525 TPD BOP steel. These figures are noted as being
slightly lower than previous capacity figures. Current
2 turn operations means prevailing production is about
65% of capacity.
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Electric Furnace Steel: 5 furnaces available at
Duquesne, 4 rated at 85 tons each and 1 at 20 tons.
Electric furnace steel is produced in roughly 6 hours.
Johns estimated electric furnace production capacity
as 700 TPD. Of this, he predicted 200 TPD would re-
main at Duquesne and 500 TPD could go to Homestead.
Electric furnace steel is generally stainless or other
special-alloy steel. The permit specifies electric
furnace steel production as 800 TPD with 384 TPD re-
ported as passing through vacuum degassing at Duquesne.
Johns and Weiskircher could not provide us with an
equivalent figure for vacuum degassing.
Blast Furnaces: The draft NPDES permit specifies
Iron producrtoh at the combined works as 7>550 TPD
but does not give respective production for each facility.
Materials provided to the State in 1963 describe ttfe
four Duquesne Blast Furnaces as having the following
capaci ties:
No. 1 - 60 TPH = 1 M0 TPD i ron
No. 3 - 68 TPH = 1,632 TPD
No. 4 - 78 TPH = 1,872 TPD
No. 6(Dorothy)-116 TPH = 2,78k TPD
Total = 7,728 TPD
Currently only Blast Furnaces Nos. 4 and 6 at
Duquesne are operational (4656 TPD = 60%) with little
chance for Nos. 1 6 3 coming on line any time in the
near future. No basic iron is being produced at
Nat ional.
Primary Hot Roiling Mills, I.e. 46-Inch, 36-Inch & 21-Inch:
Slabs off the 46-inch mill which are not further processed
in the 36 and/or 21-inch mills may be cooled and forwarded
either to the USSC Irvin or Gary, ind. mills for subsequent
manufacture of sheet tin strip. Semi-finished steel out of
the 36 and/or the 21-inch mills can be forwarded to the No.
5 Bar Mill at Duquesne depending upon sizes needed or may
be converted to rounds. These rounds will vary from 3 1/2
to 10 inches in diameter. The Duquesne Nos. 6 and 7 bar
mills were discontinued in the late 60's. Equipment has
been removed even although the buildings still remain.
Support materials to the draft permit indicate a capacity
production of 5,000 TPD associated with the three primary,
hot-rolling mills and 1,100 TPD capacity production for
the No. 5 Bar Mill. The 46-inch mill also has a large
automatic scarfing machine. Approximately 34% of the 46-
Inch mill product passes through this scarfer.
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NATIONAL The National Mill is primarily a steel finishing
facility with ingots being shipped across a RR
crossover bridge from the Duquesne mill into a
series of 26 soak pits on the National side. Na-
tional is currently running 2 turns per day for most
operations and 5 days per week. Some operations' may
consist of one 1 turn daily whereas others may be
for 6 or 7 days rather than 5, e.g. the Blast Furnace.
Current employment at the National and Duquesne Plant
are each at around 3,000 persons with a peaking em-
ployment of around 3,600 persons.
Seamless Tube (Pipe) Mills: Two such hot rolling
mills are available, i.e. Hos. 1 and 2. No. 1 oper-
ates most of the time whereas No. 2 is utilized primar-
ily as standby. The draft NPDES permit specifies cap-
acity production in this sector as 2,550 TPD, which
may be slightly high. Capacity is reported by Tom Johns
for the seamless area as 2 turns daily. Johns' calcu-
lations showed on the No. 1 Seamless line approximately
2 heats/turn = kOQ tons and for No. 2 - 3 heats/turn =
600 tons. Two turns yield about 2,000 TPD. .It was
nevertheless indicated that production could be easily
raised to 2,500 TPD with about 500 TPD then going to
Lorraine, Ohio or one of the other USSC mills. Maximum
number of turns per week is about 18, which according
to Johns gives an equivalent 15 turns of actual produc-
tion.
Electric Weld Pipe Mill: This is mostly if not all,
Submerged arc weld pipe made by cold rolling operations
from Homestead plate. The permit specifies capacity
production of 2,600 TPD, which seems very high.
Electric Resistance V/cld Mill: This product is made
from coiled strip steel received from Irvin, Gary, and
even Fairless. This cold-rolled steel is bathed in water-
soluble oil which in turn is completely recycled for re-
use. The ERWM is essentially considered to be a no-
discharge mi 11 .
Primary Bloom/Billet Mills and Bar Mill: Ingots are
received either into the No. I or the No. 2 Bloom Mills
at National then sent to the Bar Mill for production of
bars or rounds. The rounds are hot sawed to yield
billets or short section rounds. The rounds are cooled
and peeled and may be hand-scarfed. The sections are
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then transferred to the Seamless Pipe Mills.
"Structural Hollows" were previously produced in
addition to seamless pipe but market conditions have
apparently caused discontinuance of this product.
The draft NPDES permit specifies hot forming steel
production capacity of 5600 TPD, but this could only
occur if all 11 heats of steel from Duquesne passed '
through the Bloom Mills, all of which in turn were
to pass through the Bar Mill.
Blast Furnace: Only the No. I Blast Furnace con-
tinues to operate at National devoted exclusively to
FeMn production. Capacity production of the No. 1
Blast Furnace is rated around 500 TPD FeMn(or 1,000
- 1,100 TPD equivalent basic iron-to be verified).
It is importantly noted that the FeMn Blast Furnace^
is said to operate as a closed circuit at least from
a water pollution control standpoint. FeMn is cast
Into sand beds at the National site.
OUTFALLS AND SPECIFIC PROCESSING
A highly-simplified schematic of National - Duquesne processing is shown
fn an attached figure to this report.
The National Plant waste outfalls described in previous materials, are
further depicted in accompanying figures and sketches with this report. In-
dividual outfalls are discussed together with specific industrial operations
served by each sewer line.
Upstream Storm Sewers - Market Street and V/alnut Street Sewers
Weiskircher reported the existence of two large storm conduits upstream
of the National 001 outfall. Both sewers cross USSC property in the area of
the ERWM which is reported to have essentially zero discharge. These storm
sewers also cross under the product storage yards and RR tracks. We saw an
abundance of yellow band steel in the National Steel storage yards. A spent
water soluble spent oil storage overhead tank of 100,000 gallon capacity is
noted directly adjacent and south of the alleged Walnut Street storm sewer
terminus with the Monongahela River. This storage tank serves the cold rolling
ERWM. The spent oils are hauled out by contractor service. Weiskircher indi-
cated that roof drains etc. from the ERWM and adjoining sectors are tied into
these storm sewers. We attempted to locate the storm sewers but whether due
to very high river flow the week of September 23 or that these sewers are deep-
ly submerged, we could not visually locate either line.
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001 Outfall and Locust Street Storm Sewer.
Locust Street is the location of 001 sewer and is also the site of the
Main Gate into the National Plant. Outfall 001 is sampled on the storm sewer
on the west side of Locust Street between the Coupling Department and the
Electric Weld (Submerged Arc Weld) Building. Flow serving this outfall is
believed to be derived entirely from city water rather than Mon River water,
hence Gross rather than Net limits should be used. Total city water use is
believed to be 1MGD or less throughout all of the National Plant. The single
source of wastewater to 001 is reported by the Company to be an air compress-
or contributing intercooler and aftercooler flows to the sewer. USSC considers
this discharge to be NCCW. Flow is judged quite small. The Company sampling
point is depicted below for an approximately 12 ft. deep (square box) manhole.
Company CO)
Sampling Htf
dooplindi
Bfdj.
AirCompressor
Flows
£oiler
Electn'rf Weld
Pipe Mill
sector -feeds
"fej Outfall 002)
Up stream MH AvailaUe
We did not raise the cover of the manhole. Distance from this sampling point
to the River was considerable, i.e. around 750 feet.
For Outfall 001 the draft NPDES Permit allows USSC to provide estimated
flows rather than directly measured flows. Due to high River stage, we were
not able to spot the 001 discharge at the River. The River bank is very steep
and undergrowth appreciable. This outfall although submerged both during NERC,
Las Vegas1 aerial reconnaisance mission of September 2A, 197** and EPA's Boat
Run of June 21, 1975, was indirectly "visible" during each of the two latter
inspections. On June 21, pictures taken of the 001 outfall showed a heavy k
soapy white layer on the surface of the water just below the River bank.
Lithium chloride flow measurement has been tried by' USSC adding the chemical
to the air compressor outflow box and capturing the effluent at the 001 sample
MH. The addition point was however only 70-100 ft. ahead of the measurement
point. Both the draft NPDES permit and Steel's self-monitoring provide a flow
for 001 of 0.12 MGD.
Outfall 002 Containing Electric Weld, Seamless Pipe and Electroplating.
Sewer 002 serves a sizeable sector of the west side of the National Steel
Works including the Arc Weld Mill, electroplating and painting of couplings at
the NW sector of the Electric Weld Building, Seamless Mills Nos. 1 and 2, and
also a quench and temper line. It was previously reported to Region III that
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the Seamless Mills entirely drained to Outfall 003- However we are now
told a central sewer drains the Seamless Pipe Building from east to west,
and the Seamless waste flows can go to either or both of 002 or 003- The
2600 TPD in the permit rationale for 002 would seem to have reference to
arc weld pipe production but the permit was written for hot forming rather
than cold forming and welding. Outfall 002 is now reported to have both
cold rolling from the submerged arc weld mill and an undefined hot forming
production from the Seamless Pipe Mills Nos. 1 and 2 side. Plant per-
sonnel more clearly explained that the No. 1 seamless flows generally end
up in 002 but nevertheless can find their way to 003- The No. 2 seamless
mill almost always flows to 003 but once in a while is captured by 002.
Seamless pipe product out of these various mills is beveled, finished, etc.
One also finds quench and temper facilities inside the seamless mills which
contribute further waste flow. These operations all serve to comprise a
relatively large pipe mill building. The submerged arc pipe runs up to
about 36 inches in diameter. It is cold-formed from Homestead plate steel
and most of the pipe is specially-lined.
The Electric Weld Mill conducts galvanizing of couplings and various
pipe conditioning operations. The couplings are the sleeves at the end of
the pipe sections serving to protect the end threading particularly during
transport. After shipment and field use, the buyer will normally return the
couplings back to USSC. The plating sequence is roughly explained as follows.
The couplings carried in large wire baskets are immersed in a caustic soda
bath which serves to basically remove oils off the coupling sections. This
oil winds up in the terminal settling Basin "A" at the end of the 002 outfall.
The caustic bath is changed every A weeks and utilizes *»300 lbs. caustic on
each new batch. The spent caustic bath is dumped to the sewer and finds its
way to Basin "A". After the concentrated caustic solution, the parts are
rinsed in continuously flowing hot water (second tank) and then enter a con-
centrated sulfuric acid solution bath where parts are immersed for cleaning
from one-two minutes. A fresh concentrated acid solution is rated around
60%. With repeated pickling, the sulfuric acid strength falls to about 46%
near which time the concentrated spent acid is replaced. This concentrated
waste acid is transferred to one of three available overhead tanks just
north and outside the electric weld building. This spent acid is scavenged
by Mill Service Inc. a special licensed contractor, who hauls the waste acid
to a dumping site at Yukon, Pa. Approximately 50,000 gallons of concentrated
spent acid is said to be scavenged annually. A fourth tank is available out-
side the building in this case for storage of "new" acid. Adjacent to the
four tanks is a small concrete basin approximately 10 ft. x 20 ft. which ser-
ves to provide limited detention to the caustic and acid rinses associated
with electroplating prior to their release to Settling Basin "A". Oils were
minimal in this small chamber. There were no provisions for the collection
and removal of oils, solids or other, from this chamber.
The coupling parts after pickling are inserted into a "Patent" tank.
The parts receive a cold water rinse, the couplings are arrayed in vertical
position and a lid is placed on the tank for zinc plating, utilizing a zinc
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anode. Plating is conducted for 12-15 minutes and this is followed by a
cold water rinse, then a hot water rinse. The lid is taken off the Patent
Tank, the tank overturned and the parts and liquid contents dumped. The parts
are subsequently stacked, painted, stored and/or shipped. All of the above
rinses are continuous. Painting of the various pieces is carried out in the
same plant area, the parts being painted by brush as they come down a discharge
chute. Electroplating and galvanizing at National have not previously
been reported to Region III.*
Steel members are received into the Seamless Pipe Mills from the Na-
tional Bloom and bar mills via a series of steps including conditioning,
peeling, scarfing, then over to the billet storage area. The pieces are trans-
ferred by rail to the seamless pipe sector, off-loaded by crane onto tables
and into the reheat furnaces preparatory to piercing and seamless tube oper-
ations. Finishing operations include bevelling, threading, quenching and tem-
pering, etc. The Bloom/Bar Mills employ hand scarfing of billets and/or rounds
which consists of manual torch spot treatment. It is noted that "Structura-l
Hollows" are no longer made in this or any part of the National operations.
Rudimentary waste treatment inside the Electric Weld and Seamless Tube Pipe t
Buildings consists of many small-sized scale pits below floor level spread
throughout plant processes. Most of the pits are overlaid with removable but
solid plate whereas others have open grating. As shown in an enclosed sketch
to this report, waste flows pass through some 30 scale pits enroute to Set-
tling Basin "A". The efficiency of these pits (arranged both in series and
parallel) in removing solids, oils and other contaminants, is not well known.
Additional information on scale pits primarily in the Nos. 1 and 2
Seamless Mills is given by State of Pennsylvania Industrial Waste Applications
A631M and *163136 for treatment facilities at USSC, National. This data was
prepared in the 1960*s.
For the No. 1 Seamless Mi 11, operations were reported to be serviced by
a total of 13 scale "settling"pits". These pits are located throughout the
mill in groups of one, two, three or four pits in series to provide treat-
ment facilities for the following operations: First Piercer, Second Piercer,
High Mill Reelers, Sizing Mill, and the four cooling tables. Each of the
pits contains a removable scale bucket which is "immediately" emptied when full.
^Earlier materials in the State files indicate further discharge of caustic
and acid rinse waters from "Pipe Conditioning". The current disposition of
these practices, if still existent, and their precise location in the plant,
are not known. Previous description relates that pipes, cylinder and specialty
items requiring conditioning are cleaned by immersing in a caustic soda solu-
tion and then rinsed in water. Next, the items are immersed in an acid pick--
ling bath and again rinsed in water to complete the process.
68 of 111
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The effluents from all these pits discharge to a common sewer which leads
to the Monongahela River. Design data showed that nine pits were 5,_9"x
V-9"x5' - 6" deep when empty, and the other four pits V-3" x 3,~3" x5l_0"
deep when empty. Flow was established as 3'^5 MGD from the No. 1 Seamless
Mill. Certain data in the 1960's showed that 30-5 TPD scale or gross solids
were being removed by various pits in the No. 1 seamless sector. The effluent
contained 1.8 TPD which roughly suggests according to the company, a solids
removal of Sk.bZ was achieved. Company design data for Basin A following
these pits projected 125 ppm or 1,80 TPD of TSS entering Basin A and a final
Basin effluent of 69 ppm or 0.805 TPD of TSS. Overall solids removal effi®
ciency calculated by USSC on this circuit was SS.S%. The effluent was pre-
dicted as containing less than 30 mg/1 oils and 0.993 TPD of suspended solids
to the River.
For the No. 2 Seamless Mill, there are 27 scale settling pits located
throughout the mill all of which discharge to a common sewer system. Each of
the scale pits contains a removable scale bucket which is emptied when full..
These scale pits are reported of two sizes: 21 pits are 5,-9" x 4'-9" x S'-G",
and 6 pits are V-3" x 3'~3" x 5'~0". Some of the pits are arrayed in groups
of two, three or four. Design flow was given as k.$ MGD.
Total waste flow for the 002 sewer was estimated by Weiskircher as h to
6 MGD, averaging about k.5 MGD. The 002 sewer drains into Settling Basin "A"
built into the side of the River. This basin has gross dimensions of 150 ft
x 20 ft x 13*5 ft deep. Net dimensions are 100 ft. x 20 ft. Design flow has
been given as 3.k5b MGD producing a waste detention time of 75 minutes. At
the prevailing flow of A.5 MGD (average), D.T. is calculated as 58 minutes.
The Basin has a single influent and a single outlet as depicted below.
\t a
QR>\/er
r
Weir
dynnj} ihsperten
4 s/24/7*
3ASIN A
Oil «SK
-------
Various data provided by USSC to the State of Pennsylvania around
1966 in preparation for the State Industrial Waste Permits commented that
design and operation of proposed Basins A, B and C (the three basins are
nearly all the same size) would provide a form of secondary treatment to
already-existing primary treatment processes inside the Mill.
In cleaning the Basins of solids, a hydraulic dredge was proposed.
Sludge was to be pumped to a river barge moored alongside the basin, the
pumped wastewater allowed to settle, and excess water from the barge re-
turned to the influent end of Basins A, B or C. Dewatered sludge would be
directed to an approved dumping site. Extensive cleaning by clam shell is
conducted every 6-12 months. More limited scavenging is carried out every
k to 8 weeks.
In removing oils from the Basin(s), a floating log baffle held in
place with counter-weighted cable stays was to be installed at an angle of
45° near the effluent end of the basin. Accumulated oils were planned to .
be drawn up and onto a neoprene belt skimmer with a predicted removal rate
of AO gallons/hr. The oils/greases were to be lifted vertically out of the
Basin. Plastic scrapper blades were designed to scrape the collected oils
into troughs, the oil to be temporarily stored in a 900 gallon tank situated
at/on the Settling Basin itself. When the holding tank is full, a 60 gpni
sludge pump was designed to transfer the waste oil to a 12,000 gallon stor-
age tank on the River bank. The entire system was to be steam-heated for
wintertime functioning. Oil recovery rates from the above system, i.e. Basin
A, were designed to average about 97 gallons per day.
On September 2k, 1975» the day of our field inspection at National,
highly significant amounts of oil were observed on the surface of Basin "A"
both black and of the milky, emulsified forms. USSC indicated flows in the
002 sewer have been measured using the lithium chloride method and also by
applying the Manning equation on the inflow pipe to the Basin. Judging by
high-water marks on the Basin, the River can and does largely innundate
Basin "A". The week of September 23, 1975 was very wet causing the River
to rise 5*6 ft. above normal. Since the effluent trough is only about 1.5
feet above low River water mark, the effluent trough leaving the Basin into
the River was submerged and under 3~k ft. water. The Company normally col-
lects their 002 samples at the end of the effluent trough. We asked USSC
personnel where they would sample if mandatory on September 2k. Their an-
swer was from the basin proper. A heavy zone of emulsified oil was observ-
ed leaving the Basin with the discharge. Further data obtained from Weis-
kircher the week of September 23 indicated current oil removal rates from
Basin A of 2,000 to 3»000 gallons/month. A single belt skimmer was exist-
ing and running as determined from direct observation. The Company almost
always samples 002 as the final effluent from Basin "A". Oils from the
Basin are transferred to a pair of 50,000 gallon(each) waste oil storage
tanks atop the River bluff in the vicinity of Basin "B" (003 Outfall) or to
a single 50,000 gallon oil storage tank in the proximity of Basin "C" (010
Outfall). This oil is reported as eventually being added to coal entering
the Clairton, USSC coking batteries.
70 of 111
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003 Outfall and Huey Storm Sewer
Current Seamless Mill Production was described by Johns and Weiskircher
as 2 turns per day for the No. 1 Seamless Mill, but the No. 2 Seamless Mill
(principally situated on the 003 sewer) serving only on a standby basis.
The No. 1 Mill was described as "active", and No. 2_as not. Overall Seamless
Pipe production at present time would seem to be in the range of 1,000-1,200
TPD. These figures are considered tentative pending Company verification.
USSC personnel stated that the Huey Street Storm Sewer which in essence
is also the 003 sewer, runs directly through the Settling Basin "B" to the
River. That portion of the east-west Seamless Mill main sewer contributing
to the 003 sewer was estimated by the USSC personnel as approximating 5-5 ~
6.0 MGD. Steel explained they thought all flow in the Huey Street sewer was
their flow. Many scale pits are available on these lines mostly of the
small A' x 5' size which are cleaned perhaps once a turn. Rather than one or
two tie-ins to the 003 sewer, there are probably several connections. The
single influent to Basin "B" is reported to be always under water, i.e.
the inlet is below low water level in the Mon River. National personnel re-
port that lithium chloride flow measurements are being made weekly. Indica-
tions were also given that there may be crossover waste flows from the 002
sewer to the 003 outfall. Basin "B" has a single belt skimmer which was
operational during our inspection. Weiskircher verbally reported an oil re-
moval rate of 2,000 to 3>000 gallons monthly. This compares to an oil re-
covery design rate of 96 gallons/day stipulated in USSC materials provided
to the State in the early 1960's. Gross dimensions of Basin "B" have been
given as 150 ft x 20 ft x 15 ft deep. Net or effective dimensions are 100 ft
x 20 ft x 13.5 ft deep. Design flow was expressed as 4.88 MGD which equates
into a waste detention time of 60 minutes. A schematic of Basin "B" is
depicted below. Configuration of various scale pits tied into sewer 003 and
Basin B are shown in an enclosed figure to this report. The single belt
skimmer on Basin B appeared to be taking relatively little oil. The Com-
pany reports use of lithium chloride "a couple of times" for flow measure-
ment with estimates of flow being made at other times. USSC samples via
drop bucket the final effluent leaving through the wall of the settling
basin. If the final weir is submerged(by the River) as very definitely was
the case during our inspection of September 24, 1975> the Company then samples
from the interior of the Basin. The effluent weir in Basin B is unfortun-
ately only 1.5 ft above low River stage. Very heavy amounts of black float-
ing and emulsified oil were observed over the surface of the Basin,
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State data of the early 19601s showed that scale pits on the 003 system
appeared capable of removing 37-7 TPD gross solids out of a total of kO TPD
for a 3k.3% TSS recovery. Subsequently, Settling Basin "B" was reported cap-
able of reducing TSS from 112 ppm ^ 2.28 TPD down to 62.3 ppm or 1.26 TPD.
Overall solids removal efficiency was computed by the Company equivalent to
96.9%. The effluent is said to contain less than 30 ppm oils and 61 mg/1
TSS = 1.26 TPD for the 003 final discharge. The recorded flows for 003 in the
draft NPDES permit and in USSC's 95"5 data presentation range from ^.9 to 5.9
MGD which are less than flows given during the EPA, September 1975 inspec-
tion.
Concerning the Huey Street storm sewer, we were unsuccessful in loca-
ting any upstream manhole or equivalent for purposes of establishing back-
ground control for USSC waste loads. Further contact will be necessary with
municipal officials of McKeesport.
Outfall 00^ and No. 1 (Booster) Pump Station
00*» is a relatively minor outfall reported as capturing cooling water
from a booster water pumping station. This flow approximately one-half MGD
and discharging untreated to the Mon River. The pump station containing
three pumps is located directly between the Seamless No. 2 Mi 11 and the Main
Power Plant at National. A transformer complex was seen both NW and NE of
this pump station. USSC reported that the Armstrong Street storm sewer ties
into the 00^ waste line which had not been previously reported to EPA, Region
III. However, USSC has not viewed the storm sewer per se anywhere on their
plant property. Associated with the Booster Pump House are 5 air compress-
ors each of which have cooling water discharge (from intercoolers and after-
coolers on these units). Four are Sullivan air compressors which discharge
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to the 005 sewer rather than 00*K The fifth air compressor does discharge
to the 00*» sewer. Additionally, cooling water from one or two air compress-
ors at the adjacent Power House is diverted over to the 00*1 sewer. USSC
personnel furthermore believe there is a probable connection between a
taiIwater sump or reservoir serving the Power House, the overflow from which
may find its way to the 00A sewer (See sketch below). The Company ordinar-
ily samples 00A at the River but frequently when the River level is up, will
sample the subject sewer at a manhole about AO yards up on the line. Lithium
chloride addition is also made at this latter manhole and measured at the
River in order to ascertain flow. Lithium chloride can also be added at up-
stream air compressors. This MH is situated directly NE of the No. 1 Booster
Pump House. No process flows are believed present in 00^. During our in-
spection, the River was high and the terminus of 00*» with the Mon River was
submerged. A series of barges, i.e. nine, were moored at the end of the 00^
sewer, making viewing difficult. The draft NPDES permit materials describe
00*1 as approximating 0.^7 MGD. This compares to 1.20 MGD in subsequent USSC
correspondence to EPA, Region III, and up to 8.0 MGD given us by V/eiskirche'r
the week of September 23, 1975 for 004.
005 Outfall - Intermittent Power House Effluent;.
Intake for the National Plant power house Is situated a short distance
upstream of the 005 Outfall. USSC reports this intake is used very infre-
quently. In 1975 so far this intake has been used only two weeks. 005 repre-
sents barometric condenser cooling waters from a 10,000 KW turbine-generator,
plus air compressor discharges from the Booster Pump station. Steel per-
sonnel said power generated internally at this power plant is 25 cycle, and
not easy to use, so the power plant is operated sporadically. Lithium chlor-
ide has been added to the 005 line to determine flow. Two manholes are avail-
able as illustrated on the following page. Lithium chloride has been added
twice to the MM closest the River. We were told the 005 sample is always
taken at the River (via drop bucket) but only 2 such samples have been taken
to date. The 005 line was judged to be not running and submerged during our
inspection. The draft NPDES support materials give flow for 005 as 0.50 MGD.
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On June 21st during the EPA boat run down the Hon River, the 005 outfall
was about half above and half below water.
A^mon river
1
Old no" Mill
1
(Now used for stcra
-------
but only 3 or k boilers are operational under normal circumstances. Waste
flow for 006 has been hitherto given as 0.75 MGD although Weiskircher indi-
cated this line could easily run 5«0 MGD or more. To the cast of the Boiler
House is located a 90 ft. diameter V/alker thickener now abandoned. In the
19601s, blast furnace gas was being burned in the boiler house as a primary
fuel and before burning was receiving cleaning via two Freyn gas washers and
two Koppers precipitators. Flue dust particles were captured in wash waters
which were sent to the Walker thickener for treatment. The boiler house now
utilizes a mixture of blast furnace gas, natural gas, coal or various blends.
007 Outfall from East Side of Central Boiler House
The 007 Outfall is reported as the smallest of the two sewers originating
from the Central Boiler House but certain observations indicate it may be the
larger of the two. The 007 outfall was the only waste line on September 2k,
1975 free flowing (and not submerged) into the Mon River. The line entered
the River about 70 yards east of the coal hoist and NW of Blast Furnace No.* 1.
USSC samples this flow once per month via drop bucket at the River. The ter-
minal flow on September 2k was observed whitish in cast and very hot. An ex-
tremely warm flow was also observed from aerial photos taken by EPA, NERC-
Las Vegas on September 2k, 197^ of this outfall; flow appeared considerable on
the latter date.
Steel reports that 007 contains the blower house blowdown. From a ma-
terial balance they have estimated 007 at 300,000 gpd. The draft NPDES support
materials provide a flow of 0.^5 MGD for 007. When the 90 ft. diameter Walker
thickener was operational it was discharging into 007- The dye dump point
and possible upstream sampling station for 007 is a manhole location just east
of the boiler house shown below.
Old BndK Thr»sfi>nr,r
Bid cy
Center Street Storm Sewer.
This sewer is located between Outfalls 007 and 008 and is also upstream
of the Water Intake Works at National. Size of this sewer is defined as being
2k inches in diameter. We could not visually locate this line which very much
75 of 111
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appeared to be submerged at its juncture with the Monongahela River.
National Water Intake Works
Three pumps for bringing Mon River water into the National Plant are
located inside the water intake structure building on the River bank and
three more water pumps are inside the Blow House approximately 200 ft. south
of the river pump house. The three pumps at the River pump house intake are
each electric and rated at 25 MGD. The three pumps in the blowing room are
steam-driven and these are of different sizes being rated at kO MGD, 20 MGD,
and 15 MGD. USSC prefers to operate most of the time with one electric and
one steamer. On September 2k during our visit the ho MGD steamer was oper-
ational giving a theoretical total intake of 65 MGDjtotal actual River water
intake during our inspection was running around 58 MGD. City water intake to
the National Mill accounts for an additional 1.0 to 1.1 MGD but the latter
figures must be verified. Within the mill proper USSC reports a number of
water meters may be available including a city water meter; their locations*
are, however, so far not known.
The pump house has two travelling screens. Backwash off the screens
was observed to be more or less continuous and comprising a significant flow.
The backwash is conveyed in an overhead channel along the top of the River bank
a short distance downstream before cascading into the Mon River as depicted
below. This discharge would appear to represent either an illegal or an un-
authorized discharge. The screen backwash should be relatively easy to sample
MOW RIVER >
Wafer Tn+aKa Cy it
Rhjct- J3srt< 4
Pump Station
C £creen Backwash
and gage within its discharge channel. The Company samples the intake for NET
NPDES waste load calculations at the River in the crib between the log boom
and the River wall. Inside' the pump station, only the No. 2 pump was oper-
ational of the three pumps available. Venturi meters plus manometers are re-
ported present on each of the pumps; Bristol instantaneous readout meters
were observed on each pump. The No. 2 pump can be sampled on the discharge
side via a stopcock on the vertical riser. The meter on No. 2 pump was read-
ing 23 MGD during our inspection. We noted a fourth meter was present for a
fourth pump which apparently had been pulled some time ago. The three steam-
driven water pumps at the blow house each have continuous flow recorders (using
orifice plates). The recorder for the ^0 MGD pump is below the main floor
level; it was reading 35 MGD during the visit. Recorders for the other two
units are on the main floor. From this sector, water is sent to various parts
of the National Plant. Boiler-feed water treatment is rated at 600,000 to
800,000 lb/hour feedwater. There is no reuse or recycling of boiler conden-
76 of 111
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sates. The water treatment plant is located directly south of the Central
Boiler House. Treatment consists of the hot soda ash process followed by
anthracite filters followed by deaeration. Sludges from the hot soda pro-
cess and filter backwashes are mixed with various "dirty water flows" and
together with boiler blowdowns are discharged to the Mon River via Outfall
007.
Outfall 008 From Blowing House and Excess Cooling V/aters Off Blast Furnaces
Spent flows in 008 originate primarily as steam condensed by a Wise
barometric condenser at the blow house. Total flow was specified by Weis-
kircher as around 8-12 MGD although the NPDES permit materials specify only
7.9 ~ 8.0 MGD. The correct flow was said to be likely close to 12 MGD.
Blast Furnaces Nos. 2 and as also Dorr thickeners connected to these two
blast furnaces are not in use and according to USSC personnel are not likely
to ever be used again. The No.~ 1 Blast Furnace now devoted entirely to
FeMn production, is the single remaining unit in this circuit. Cooling
waters off the No. 1 Blast Furnace go both to Outfall 009 and as barometric
makeup at the above-mentioned blow house. Excess at the blow house ends up
in the 008 sewer. An additional 3"^ MGD makeup water is supplied to the
Wise barometric to condense steam in the blow house. Mostly because of im-
perfections in the blast furnace return lines, more cooling water goes to
009 than desired. The two 50 ft. diameter Dorr thickeners once serving the
Nos. 2 and Blast Furnaces are now completely down. The Nos. 2 & h Blast
Furnaces have been closed since 1971. The Bessmer converters and once pre-
valent open hearths were discontinued at National about 10 years ago.
The 008 Outfall is ordinarily sampled by the Company at the River.
The terminus of this outfall with the River was apparently submerged during
our inspection of September 2A, 1975. On June 21 on the EPA River boat run
just the uppermost part of the 008 sewer was visible above River level. The
008 line can be alternately sampled at the hot well off the barometric at the
SE side of the blow house (outside). This hot well is also employed as a
lithium chloride drop point for the 008 line.
009 Sewer Draining Excess Spent Flows Off Blast Furnace Complex, and Part of
Hot Saws at 32-Inch Bar Mill
The 009 sewer at its top end receives the White Street storm sewer but
nobody seems to know where the storm sewer connects with the 009 line. The
proposition was made that the storm sewer connection was immediately SE of
the 50 ft. diameter No. A BF thickener but after inspection of manholes, no
conclusions were possible. Excess cooling waters from Blast Furnace No. 1
enter' 009, and a manhole was found for separate sampling of the Blast Fur-
nace excess flows, if so desired.
The No. 1 or ferromanganese Blast Furnace is notable because wet gas
cleaning on this furnace which is the only one currently operating at National,
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is reported as completely recycled. FeMn production is presently in the
range of 600 to 1000 TPD. Blast Furnace No. 1 is equipped with a dry
dust catcher followed by a Venturi scrubber followed by a cooling tower
(the latter primarily for gas rather than water cooling). The Venturi
scrub flows passing through 110 ft. diameter thickener (used for treat-
ing these scrub effluents) were cited by Weiskircher as around 1.25 MGD.
The gas cooling tower (3rd stage) is said to remove little dust because
the gas stream entering this unit is already down to .01 grains/SCF.
The Venturi effluent et. al. after leaving the 110 ft. diameter thickener
flows to a small adjacent box from which the treated water is pumped back
to the Venturi and cooling tower. A dispersing agent is reported to be
added at the Venturi and a flocculating agent at the thickener. Under-
flows are passed to a vacuum filter and these solids eventually find their
way to landfill via truck.
At National, the FeMn is cast into beds, the material hardens and
is then fractured. FeMn is essentially an additive for higher-grade steels*
whether made at the Duquesne Plant or other USSC plants. The BOP shop at
Edgar Thompson is also a likely recipient of this FeMn. The FeMn receives
classification and/or sorting before being transported elsewhere although
this sizing may be carried out at Duquesne rather than National. Slag from
the FeMn Blast Furnace No. 1 is drawn off into a dry slag pit at National.
We observed a rather large assemblage of now abandoned air pollution con-
trol equipment which was the former National Gas Cleaner System apparently
used for Blast Furnaces 2, 4 and possibly 3 when the latter were going
strong. USSC is contemplating conversion of this system to scrap.
The 50 ft. diameter thickener reported as once upon a time serving the
No. k Blast Furnace was receiving inflow during our inspection although the
thickener appeared to have no overflow. V/eislcircher appeared to show great
surprise that this unit could receive any flow. He said it was the first
time he had ever witnessed flow into this thickener. Some pumping of accum-
ulated storm flows from the yards may have been occurring.
We were slightly surprised as to bar mill hot saw process effluents
being present on the 009 sewer line. Three or more scale pits (3'~6"x
3'-6" x 2'-9")dnd two (7,-0Mx6'-0" x I'-ll" pits) are available following
the hot saws. A schematic layout showing the lithium chloride manhole used
by Steel for measuring 009 flows is given on the following page. USSC is
presently obtaining more accurate flow measurement on the relative contribu-
tion of the hot saw flows. The MM is inside the 32 inch bar mill just SE of
the hot saws. Design flow from the hot saw sector is 1.25 MGD. Most of this
flow is directed to 009 with some unknown portion going to 010.
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Billed
m+b
yards'
MQN RIVER
^009 here-*/
Of hr>u I
/
yAGDS
+
4-
fZhops hand. /
ScDr/m^etal, 3?-J«.
Par Mill
^ 90 turv> ihto
tar m>ll
MM for
Lithium Chkyidft
Addrv by uSSd.
This covlcl bd
T'outmg t>f Whtfa St.
Stem se*/er co9
?r*s/e c*btJfifr-
~ffa> StijM
WftJ
Primary
Rolling
Mill
No. 2
Primary
M.I I
The 009 Outfall intercepts the River directly to the rear of the billet-
bar mill complex. On September 23, 1975» this outfall at the River was com-
pletely submerged. September 197^ and June 21, 1975 photographs taken by EPA
show this outfall to be one of the more significant at National. During the
June 21, 1975 EPA river boat run, the 009 outfall was about 1/4 out of water
and approximately 3A submerged. The 009 Outfall from draft NPDES permit
materials was estimated to have a flow of 2.3 ~ 12.5 MGD. Weiskircher dur-
ing the week of September 20, 1975 indicated a probable flow of 5"6 MGD for
009 but indicated further that process and cooling water flows could easily
attain and exceed 10 MGD. The 009 outfall is believed sampled by USSC by
drop bucket off the end of the sewer. Considerable uncertainty still exists
as to disposition of the White Street storm sewer. Contact will be made with
Don Glenn of the City Engineer's Office of the City of McKeesport to possibly
secure pertinent details and break down the role of storm sewers traversing
the USSC, National Plant property.
In the 32-inch bar mill, the billets after being formed are cooled in
the yards. The pieces are subsequently passed through three peeling machines.
This process enables the exterior surface to be peeled off to the extent of
1/16 - 1/4 inch. A given portion of the billets, bars, rounds are brought
back into the mill for selective hand scarfing, a procedure otherwise known
as "filling in the seams". The 32 inch bar mill is equipped with a "centrally-
located" scale pit which actually has two compartments. The first compartment
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is described as 20 ft x 10 ft x k ft - 6 in SWD and the second as ft-6 in
x 10 ft x 't ft - 6 in SWD. Based upon a design flow of 2.6 MGD, detention
time is 3*8 minutes. It is noted most of these flows are diverted to the
010 sewer rather than the 009 outfall. The 32-inch bar mill as also the
No. 1 Bloom-Billet mi 11(s) generally operate 2 turns per day. Product of
the bloom-billet-bar mill complex is usually in the range of k 1/2 inch
rounds up to about 13 1/2 inch rounds. National can also roll rounds for
the Gary, Indiana and Lorraine, Ohio, USSC mills. Occasionally blooms and
slabs may also be turned out for use by the Clairton USSC finishing mills.
Outfall 010 - Sinter Plant Effluent (Currently inoperative), Nos. 1 and 2
Bloom/Billet Hills and Remaining Portions of 32-inch Bar Hill; Terminal
Settling Basin "C"
The National Sinter Plant establishment has been down since April, 1975»
Gas cleaning scrubbing flows from the sinter plant ordinarily receive treat-
ment in a 20 ft. diameter thickener with the overflow going to 010 and thee
sludge underflows being screened in a Dorr Oliver vacuum filter and the de-
watered solids eventually transferred to the ore yard. State Permit Appli-
cation ^631^2 indicates the thickener overflow is discharged to the River
whereas Weiskircher in September 1975 described gas cleaning from the venturi
as comprising a closed circuit. We could not verify specific conditions be-
cause the sinter plant was not operational and we did not manage to get into
proximity of the sinter plant during our inspection. Design flow for the
sinter plant thickener has been previously given as 50 gpm ^ wastewater de-
tention time of 5-9 hours but Weiskircher indicated current process flows are
now running 1200 gpm = 1.7^ MGD.
Configuration and type and duration of operations maintained in the
Nos. 1 and 2 Bloom - Billet Mills and ensuing bar mill at National have been
previously explained by this report. The Nos. 1 and 2, AO-inch bloom mills
are both 2-high reversing mills and the bar mill is likewise reported as a
2-high reversing mill. Our inspection did not cover the bloom mills and was
extremely limited through the bar mill.
The No. 1 Bloom mill has a single centralized, two-compartment scale
pit adjacent to the primary mill. Compartment A is described as 16 ft x
16 ft x 3 ft—7 In and separated by baffle from Compartment B. The latter
chamber is 16 ft x 6ft-6 in x 3 ft- 7 in, design flow for the No. 1 Mill
scale pit was given as 8.9 MGD yielding a detention time through the scale
pit of 1.5 minutes. This scale removal device is said to recover TPl)
of scale leaving 1.93 TPD of TSS in the effluent. Calculated TSS removal
is therefore 95.8%.
The scale pit at the No. 2 Bloom mill is reported as 12 ft x 7 ft x
7 ft. Design flow was given as 8.9 MGD yielding a waste detention time of
J»3 seconds at this flow. The No. 2 mi 11 is said to operate only when the
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No. 1 mill is inoperative or where relatively high production rates are
experienced. The 32-inch bar mill has a central1y-located scale pit com-
prising a main pit followed by a discharge pit. The main compartment is
20 ft x 10 ft x b ft-6 in., and the discharge chamber k ft - 6 in x 10 ft
x ft - 6 in. Design flow was cited as 2.6 MGD yielding a waste deten-
tion time of 3-8 minutes. Scale removal via this scale trapping facility
was described as amounting to 16.56 TPD. Effluent TSS was said to be 0.95
TPD ^ 88 mg/1 TSS thereby providing a TSS removal efficiency in the order
of 9*1.6%. All of the various scale pits (small and large) leading into the
010 sewer and to Settling Basin "C" are depicted in an enclosed sketch to
this report. Total flows on this circuit are around 8.9 MGD (Bloom mills)
plus 2.6 MGD from the bar mill together with 1.7^ MGD from the sinter plant,
possible effluent from the bar mill hot saws and other undefined. This
total of 13-2 MGD compares to 7-50 MGD given in the earlier NPDES draft
materials which was later modified by USSC down to 5.87 MGD. Weiskircher
during our inspection of the week of September, 1975 did indicate however
that 010 flows can easily run 10 MGD and up to and beyond 12.0 MGD. Maxi-
mum theoretical production capacity for the Nos. 1 and 2 primary mills and
the 32-inch bar mill was given in the NPDES draft permit as 5»600 TPD which
should be re-verified. No production figures have been received on the
National sinter plant.
The terminal Settling Basin "C" placed on the River bank but actually
jutting out and within the Mon River, has overall dimensions of 150 ft x
20 ft x 15 ft. deep. Effective dimensions are given as 100 ft x 20 ft x 13-5
ft. deep. There are two inflows into Basin C as depicted in the sketch below.
At the Basin design flow, estimated waste detention time has been estimated
in the order of 25 minutes. This basin is provided with a single belt skim-
mer and collection box similar to Basins A and B. Specs call for oil recovery
rates of 363 gallons/day from this device; Weiskircher reports A ,000 gallons
011 recovered monthly. A sign on the Settling Basin indicates that high River
stage in the past has completely covered the upper catwalk and the entire set-
tling chamber. During our inspection of September 2k, the final takeoff weir
in the basin was submerged below the River level. During the EPA river boat
run of June 21, 1975. the effluent weir was approximately 1.5 to 2.0 ft. above
River level. Freeboard is thereby minimal. Heavy black oil was observed on
the surface of Basin "C" during the September 2b, 1975 inspection. The Company
81 of 111
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Additional design criteria for Basin C has predicted with an influent
loading of 67 mg/1 TSS that approximately 1.56 TPD of TSS will be settled
and recovered. With these conditions, effluent was expected around 38 mg/1.
USSC currently adds lithium chloride for flow determination on the 010 waste
collection network.
Crooked Run Storm and Other Drainage
Crooked Run is a natural drainway intersecting the Mon River at the
lower end of the USSC, National Plant property roughly 150 yards upstream of
the high-level McKeesport car bridge. Besides storm runoff, we are fairly
certain that there is sanitary sewage bypass into Crooked Run. The outfall
coming out of the River bank was observed during the EPA river boat run of
June 21, 1975. However this sector was completely submerged by high water
on September 2k, 1975- Significant discoloration has been noted at the
point where Crooked Run enters into the Monongahela River. Entrance flows
and characteristics are unknown.
82 of 111
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SUGGESTED SAMPLING POINTS FOR PROSPECTIVE NEIC FIELD SAMPLING
OF USSC, NATIONAL STEEL MILL, MCKEESPORT, PA.
Primary Locations
001 at Box Manhole on Locust Street (I.Company sampling point)
002 at influent to Settling Basin "A" , .
002 at final discharge from Settling Basin "A" \ »
003 at final discharge from Settling Basin "B" '
006 Outfall at River pj
007 Outfall at River
008 at hot well of Blow House O . .
009 either at River or at upstream manhole
Water works Intake off discharge side of No. 2 Pump
Combined Screen Backwash off National Water Intake
010 at final discharge from Settling Basin "C'1 (2)
Crooked Run at point of discharge to River
Secondary Locations
Walnut Street Storm Sewer
Market Street Storm Sewer
00*» Outfall at River
Armstrong Storm Sewer at top end of 00*f Outfall
005 Outfall at River
Martin Street Storm Sewer
Center Street Storm Sewer
White Street Storm Sewer entering the top end of 009
Crooked Run upstream of USSC property.
(1) This outfall at River normally submerged in part or all.
(2) This sampling point or outfall not affected by River stage during
reasonably dry weather.
(3) Storm sewer sampling control point has not yet been found.
-------
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ussc fUt--*"-'
-------
Appendix B
FIELD STUDY METHODS
91 of 111
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FIELD STUDY METHODS
FLOW DETERMINATIONS AND MONITORING LOCATIONS
Due to the high river stage from winter snows and rain, all outfalls
except 007 were under water. USSC personnel have established alternate
sampling locations upsewer of the river locations, however, flow measure-
ments cannot be made at the alternate sites and USSC personnel are not
certain if all wastewater discharged at the river outfalls also flows
through the alternate sampling locations. For these reasons, flow
determinations were not conducted and only outfalls 001 and 007 were
monitored. Additional monitoring included the river intake water,
screen backwash water from the river intake, the influent and effluent
to the ferromanganese thickener and the ferromanganese blast furnace
excess cooling water overflow. A description of all outfall monitoring
locations and alternate sites, and the additional locations monitored
during the NEIC survey follows.
Outfall 001
The sampling location described in the NPDES permit is as follows:
"Before discharging to Locust Street Storm sewer, to Outfall 001." For
monitoring purposes, the Company always collects samples from the
manhole at the northwest corner of the Coupling Tap Building, since
outfall 001 is always under water. According to USSC personnel, this is
the only access location which contains all wastewater prior to discharge
to the storm sewer. USSC estimates the daily flow from an instantaneous
flow determined with lithium chloride over a 5-minute period. The tracer
is added at the manhole about 30 m (100 ft) upsewer of the monitoring
location.
92 of 111
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Samples of the wastewater were collected from the manhole at the
northwest corner of the Coupling Tap Building during the NEIC survey.
Outfall 002
The sampling location described in the NPDES permit is as follows:
"At the discharge from the settling basin to Monongahela River, outfall
002." USSC samples the wastewater in the effluent launder channel prior
to discharge. There is no alternate monitoring location for outfall
002. The depth of water in the parabolic shaped influent pipe is determined
and an instantaneous flow is calculated using the Manning formula. The
total daily flow is calculated from the instantaneous flow. Lithium
chloride has also been added upsewer by USSC to determine an instan-
taneous flow. The terminus of the influent pipe is above the basin
water level.
Samples of the effluent from the settling basin could not be collected
during the NEIC survey since the effluent launder was approximately 0.6
to 0.9 m (2 to 3 ft) under water.
Outfall 003
The sampling location described in the NPDES permit is as follows:
"At the discharge from the settling basin to Monongahela River, outfall
003." USSC samples the wastewater in the effluent launder prior to
discharge. There is no alternate monitoring location for outfall 003.
The influent to the settling basin is under water. Lithium chloride is
added upsewer of the influent pipe and samples collected from the up-
welling for flow calculations. Total daily flow is calculated from the
instantaneous flow.
Samples of the effluent from the settling basin could not be collected
during the NEIC survey since the effluent launder was under water.
93 of 111
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Outfall 004
The sampling location described in the NPDES permit is as follows:
"At the outfall 004." The outfall is the terminus of the Armstrong
Street storm sewer. USSC collects samples at the terminus when the
river level is below the invert of the pipe. When the river level is
above the outfall pipe, USSC personnel collect samples from a manhole
adjacent to the transformers on the northwest side of the pumphouse,
approximately 46 m (50 yd) upsewer of the river. Lithium chloride is
added at this manhole for instantaneous flow measurement. Total daily
flow is calculated from the instantaneous flow.
Samples of the discharge could not be collected during the NEIC
survey since the otufall pipe was below the water surface.
Outfall 005
The sampling location described in the NPDES permit is as follows:
"At the outfall 005." The outfall is located at the river and USSC
monitors at this location whenever there is a discharge. There is no
alternate monitoring location if the outfall is under water. There are
two locations where a tracer may be introduced for flow measurement.
The first location is the storage tank on the north side of the power
house; the second location is a manhole east of the storage tank next to
the transformer mobile poles. USSC personnel adds lithium chloride at
the first location and determines the instantaneous flow from the concen-
tration at the outfall. Total daily flow is computed from the instan-
taneous flow.
There was no discharge during the NEIC survey.
94 of 111
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Outfall 006
The sampling location described in the NPDES permit is as follows:
"At outfall 006." The outfall is located at the river. Under high
river levels, the outfall is inundated and USSC collects samples from a
manhole in the alley between the 110-in. mill and the boiler house.
USSC personnel add lithium chloride at this manhole and determine the
instantaneous flow at the outfall. Total daily flow is computed from
the instantaneous flow.
The outfall was under water during the NEIC survey.
Outfall 007
The sampling location described in the NPDES permit is as follows:
"At outfall 007." The outfall is always above the river surface and
samples are collected at the river. Lithium chloride is added at a
manhole on the east side of the boiler house; instantaneous flows are
determined at the outfall.
During the NEIC survey, grab samples were collected from the outfall
at the river once/day. Flows were not determined.
Outfall 008
The NPDES permit describes the monitoring locations as follows:
"At the outfall 008." USSC collects samples at the river when the
outfall is above the water surface. An alternate site is located on the
east side of the blow building at the condenser water discharge. Lithium
chloride is added at the alternate location and an instantaneous flow
determined at the outfall.
During the NEIC survey, the outfall was submerged.
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Outfall 009
The monitoirng location described in the NPDES permit is as follows:
"At outfall 009." The outfall is under water during high river levels;
there is no alternate sampling location. USSC injects lithium chloride
in a manhole adjacent to the hot saws inside the mill and determines an
instantaneous flow at the outfall.
During the NEIC survey, the outfall was under water.
Outfall 010
The monitoring location described in the NPDES permit is as follows:
"At the discharge from the settling basin to Monongahela River, outfall
010." USSC samples the wastewater in the effluent launder prior to
discharge. There is no alternate monitoring location for outfall 010.
The settling basin has two influents, both of which are visible only
when the river level is below the effluent launder. Instantaneous flows
have been determined by USSC personnel for both influents using lithium
chloride.
During the NEIC survey, the effluent launder and both influents
were under water.
River Intake
The plant is served by one river intake. USSC personnel collect
water samples from the river after the bar screens and ahead of the
traveling screens. Flows are measured by venturi meters and manometers
on each of the three electric pumps at the river. Only one of the three
pumps at the pump house is used during the week; the pumps are alternated
every three weeks. There are three additional steam driven pumps in the
96 of 111
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blow room. Only the 40 mgd pump is used; the 15 mgd and 20 mgd pumps
are used for standby purposes.
During the NEIC survey, pump No. 1 in the pump house was operational.
Samples of the river water were collected from the discharge side of the
pump.
River Intake Screen Backwash Water
The traveling screens are backwashed directly to the river via an
unpermitted outfall between the intake structure and outfall 008. USSC
personnel do not monitor this discharge.
During the NEIC survey, grab samples were collected once/day from
the discharge. Flows were not determined.
Ferromanganese Blast Furnace Thickener
USSC does not monitor the thickener since all wastewater is reportedly
recycled. NEIC monitored the influent and effluent to determine treatment
efficiency. The effluent was monitored at the overflow launder on top
of the thickener. The influent samples were collected from the influent
pipe after all contributory sources had mixed. The sampling location
for the influent pipe was inside the blast furnace building.
Ferromanganese Blast Furnace Excess Cooling Water
USSC does not monitor the excess cooling water since it is included
in the flow through outfall 009. NEIC sampled the excess cooling water
from the manhole in the conditioning yard, next to an old thickener (not
in use).
97 of 111
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SAMPLE COLLECTION PROCEDURE
Twenty-Four-Hour Composite Samples
Beginning at 6 a.m. on February 3, samples were continually com-
posited on an equal-volume basis every 2 hours for 24 hours for the
river intake, ferromanganese thickener influent and effluent, and the
excess cooling water discharge. Composite samples were analyzed for
TSS, cyanide, ammonia and metals.
Grab Samples
Grab samples for oil/grease* and phenols were collected in 0.95
liter (1 qt) glass jars. Settleable solids were collected in 1.9 liter
(1/2 gal) plastic containers. Grab samples for metals and TSS were
collected in 1 liter cubitainers. Organics were collected in a 3.79
liter (1 gal) brown glass bottle and sealed with a Teflon+-lined cap.
Preservation
Due to the hazard associated with fixing samples which contain high
concentrations of cyanide, all metal and 0/G samples collected from the
influent and effluent of the ferromanganese thickener were fixed with
acid at the mobile chemistry laboratory located at the McKeesport Waste-
water Treatment Plant. Phenols from the FeMn thickener influent and
effluent were preserved only with sodium hydroxide in the field. All
other 0/G and metal samples were preserved with H^SO^ and phenols with
CuSO^ and H^PO^ in the field. Cyanide samples were preserved with
sodium hydroxide in the field. No preservatives were used for the
organic samples.
* Freon extraotable material
t Trademark
98 of 111
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APPENDIX C
Chain of Custody Procedures
-------
ENVIRONMENTAL PROTECTION AGENCY
Office Of Enforcement
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
Building 53, Bon 25227, Denver Federal Center
Denver, Colorado 80225
July 24, 1974
CHAIN OF CUSTODY PROCEDURES
General:
The evidence gathering portion of a survey should be characterized by the
minimum number of samples required to give a fair representation of the
effluent or water body from which taken. To the extent possible, the quan-
tity of samples and sample locations will be determined prior to the survey.
Chain of Custody procedures must be followed to maintain the documentation
necessary to trace sample possession from the time taken until the evidence
is introduced into court. A sample is in your "custody" if:
1. It is in your actual physical possession, or
2. It is in your view, after being in your physical possession, or
3. It was in your physical possession and then you locked it up in
a manner so that no one could tamper with it.
All survey participants will receive a copy of the survey study plan and will
be knowledgeable of its contents prior to the survey. A pre-survey briefing
will be held to re-appraise all participants of the survey objectives, sample
locations and Chain of Custody procedures. After all Chain of Custody samples
are collected, a de-briefing will be held in the field to determine adherence
to Chain of Custody procedures and whether additional evidence type samples
are required.
Sample Collection:
1. To the maximum extent achievable, as few people as possible should
handle the sample.
2. Stream and effluent samples shall be obtained, using standard field
sampling techniques.
3. Sample tags (Exhibit I) shall be securely attached to the sample
container at the time the complete sample is collected and shall
contain, at a minimum, the following information: station number,
station location, date taken, time taken, type of sample, sequence
number (first sample of the day - sequence No. 1, second sample -
sequence No. 2, etc.), analyses required and samplers. The tags
must be legibly filled out in ballpoint (waterproof ink).
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Chain of Custody Procedures (Continued)
Sample Collection (Continued)
4. Blank samples shall also be taken with preservatives which will
be analyzed by the laboratory to exclude the possibility of
container or preservative contamination.
5. A pre-printed, bound Field Data Record logbook shall be main-
tained to record field measurements and other pertinent infor-
mation necessary to refresh the sampler's memory in the event
he later takes the stand to testify regarding his action's
during the evidence gathering activity. A separate set of field
notebooks shall be maintained for each survey and stored in a
safe place where they could be protected and accounted for at
all times. Standard formats (Exhibits II and III) have been
established to minimize field entries and include the date, time,
survey, type of samples taken, volume of each sample, type of
analysis, sample numbers, preservatives, sample location and
field measurements such as temperature, conductivity, DO, pH,
flow and any other pertinent information or observations. The
entries shall be signed by the field sampler. The preparation
and conservation of the field logbooks during the survey will
be the responsibility of the survey coordinator. Once the
survey is complete, field logs will be retained by the survey
coordinator, or his designated representative, as a part of the
permanent record.
6^ The field sampler is responsible for the care and custody of the
samples collected until properly dispatched to the receiving lab-
oratory or turned over to an assigned custodian. He must assure
that each container is in his physical possession or in his view
at all times, or locked in such a place and manner that no one can
tamper with it.
7. Colored slides or photographs should be taken which would visually
show the outfall sample location and any water pollution to sub-
stantiate any conclusions of the investigation. Written documenta-
tion on the back of the photo should include the signature of the
photographer, time, date and site location. Photographs of this
nature, which may be used as evidence, shall also be handled
recognizing Chain of Custody procedures to prevent alteration.
Transfer of Custody and Shipment:
1. Samples will be accompanied by a Chain of Custody Record which
Includes the name of the survey, samplers signatures, station
number, station location, date, time, type of sample, sequence
number, number of containers and analyses required (Fig. IV).
When turning over the possession of samples, the transferor and
transferee will sign, date and time the sheet. This record sheet
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Chain of Custody Procedures (Continued)
allows transfer of custody of a group of samples in the field,
to the mobile laboratory or when samples are dispatched to the
NFIC - Denver laboratory. When transferring a portion of the
samples identified on the sheet to the field mobile laboratory,
the individual samples must be noted in the column with the
signature of the person relinquishing the samples. The field
laboratory person receiving the samples will acknowledge receipt
by signing in the appropriate column.
2. The field custodian or field sampler, if a custodian has not
been assigned, will have the responsibility of properly pack-
aging and dispatching samples to the proper laboratory for
analysis. The "Dispatch" portion of the Chain of Custody Record
shall be properly filled out, dated, and signed.
3. Samples will be properly packed in shipment containers such as
ice chests, to avoid breakage. The shipping containers will be
padlocked for shipment to the receiving laboratory.
4. All packages will be accompanied by the Chain of Custody Record
showing identification of the contents. The original will accom-
pany the shipment, and a copy will be retained by the survey
coordinator.
5. If sent by mail, register the package with return receipt request-
ed. If sent by common carrier, a Government Bill of Lading should
be obtained. Receipts from post offices and bills of lading will
be retained as part of the permanent Chain of Custody documentation.
6. If samples are delivered to the laboratory when appropriate person-
nel are not there to receive them, the samples must be locked in
a designated area within the laboratory in a manner so that no
one can tamper with them. The same person must then return to the
laboratory and unlock the samples and deliver custody to the
appropriate custodian.
Laboratory Custody Procedures:
1. The laboratory shall designate a "sample custodian." An alternate
will be designated in his absence. In addition, the laboratory
shall set aside a "sample storage security area." This should be
a clean, dry, isolated room which can be securely locked from the
outside.
2. All samples should be handled by the minimum possible number of
persons.
3. All incoming samples shall be received only by the custodian, who
will indicate receipt by signing the Chain of Custody Record Sheet
in? 111
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Chain of Custody Procedures (Continued)
accompanying the samples and retaining the sheet as permanent
records. Couriers picking up samples at the airport, post
office, etc. shall sign jointly with the laboratory custodian.
4. Immediately upon receipt, the custodian will place the sample
in the sample room, which will be locked at all times except
when samples are removed or replaced by the custodian. To the
maximum extent possible, only the custodian should be permitted
1n the sample room.
5. The custodian shall ensure that heat-sensitive or light-sensitive
samples, or other sample materials having unusual physical
characteristics, or requiring special handling, are properly
stored and maintained.
6. Only the custodian will distribute samples to personnel who are
to perform tests.
7. The analyst will record in his laboratory notebook or analytical
worksheet, identifying information describing the sample, the
procedures performed and the results of the testing. The notes
shall be dated and indicate who performed the tests. The notes
shall be retained as a permanent record in the laboratory and
should note any abnormalities which occurred during the testing
procedure. In the event that the person who performed the tests
Is not available as a witness at time of trial, the government
may be able to introduce the notes in evidence under the Federal
Business Records Act.
8. Standard methods of laboratory analyses shall be used as described
in the "Guidelines Establishing Test Procedures for Analysis of
Pollutants," 38 F.R. 28758, October 16, 1973. If laboratory
personnel deviate from standard procedures, they should be prepared
to justify their decision during cross-examination.
9. Laboratory personnel are responsible for the care and custody of
the sample once it is handed over to them and should be prepared
to testify that the sample was in their possession and view or
secured in the laboratory at all times, from the moment it was
received from the custodian until the tests were run.
10. Once the sample testing is completed, the unused portion of the
sample together with all identifying tags and laboratory records,
should be returned to the custodian. The returned tagged sample
will be retained in the sample room until it is required for trial.
Strip charts and other documentation of work will also be turned
over to the custodian.
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Chain of Custody Procedures (Continued)
11. Samples, tags and laboratory records of tests may be destroyed
only upon the order of the laboratory director, who will first
confer with the Chief, Enforcement Specialist Office, to make
certain that the information is no longer required or the samples
have deteriorated.
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EXHIBIT I
EPA, NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
g
O
4
Station No.
Data
Time
Sequence No.
Station Location
\
Samplers;
.BOD
.Solids
_COD
Nutrients
_Mefals
.Oil and Grease
_D.O.
.Bact.
.Other
.Grab
_Comp.
Remarks / Preservative:
Front
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
BUILDING 53, BOX 25227, DENVER FEDERAL CENTER
DENVER, COLORADO 80225
?
' \
Back
105 of 111
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EXHIBIT II
FOR SURVEY, PHASE , DATE
TYPE OF SAMPLE ANALYSES REQUIRED
STATION
NUMBER
STATION DESCRIPTION
TOTAL VOLUME
TYPE CONTAINER
PRESERVATIVE
NUTRIENTS
BOD
COD
TOC I
TOTAL SOLIDS
SUSPENDED SOLIDS
ALKALINITY
O
Q
»
X
a
CONDUCTIVITY* |
TEMPERATURE*
TOTAL COLIFORM |
FECAL COLIFORM
TURBIDITY
| OIL AND GREASE |
METALS |
BACTI
PESTICIDES |
HERB I
TRACE ORGANICS |
PHENOL I
1 CYANIDE 1
106 ]
1
i
1
—¦ o
—' —h
REMARKS
-------
E T
Samplers:
FIELD DATA RECORD
STATION
NUMBER
DATE
TIME
TEMPERATURE
¦c
CONDUCTIVITY
(i mhos/cm
PH
S.U.
D.O.
mg/1
Gage H).
or Flow
Fl. or CFS
-------
EXHIBIT IV
ENVIRONMENTAL PROTECTION AGENCY
Office Of Enforcement
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
Building 53, Box 25227, Denver Federal Center
Denver, Colorado 80225
CHAIN OF CUSTODY RECORD
SURVEY
SAMPLERS: (Signature)
STATION
NUM8ER
STATION LOCATION
date
TIME
SAMPLE TYPE
SEQ
NO
NO OF
CONIAINERS
ANALYSIS
REQUIRED
Woler
Air
Comp
Crob
Relinquished by: (Signature)
Received by: (Signature)
Date/Time
Relinquished by: (Signature)
Received by: (Signature)
Date/Time
1
Relinquished by: (Signature)
Received by: fSignafurej
Date
/Time
Relinquished by: (Signature)
Received by Mobile Laboratory for field
QnolySIS: (Signature)
Date/Time
Dispatched by: (Signaturei
Date/Time
1
Received for Laboratory by:
Date
/Time
Method of Shipment:
Distribution: Orig. — Accompany Shipment "| Qg Q-f 11]
1 Copy—Survey Coordinator Field Files
r' ' CPO »S« - "1 •
-------
APPENDIX D
Analytical Procedures and Quality Control
109 of 111
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ANALYTICAL PROCEDURES AND QUALITY CONTROL
Samples collected during this survey were analyzed, where appro-
priate, according to procedures approved by EPA for the monitoring of
industrial effluents.* The analytical procedures for characterizing
trace organic chemical pollutants are described below. The remaining
procedures are listed in the following table.
Parameter
Fe, Pb, Zn
TSS
Cyanide
Phenol
Ammonia
Oil/grease
Method
Atomic absorption
Gravimetric
Distillation,
colorimetric
Automated colori-
metric
Automated phenate
Freon extraction
Reference
EPA Methods for Chemical
Analyses of Water and
Wastewater, 1971, p 83
ibid., p 278
ibid., page 41
EPA Methods for Chemical
Analyses of Water and
Wastes, 1974, p 243
ibid., page 168
Standard Methods, 13th Ed,,
p 254
Settleable Solids Volumetric
ibid., page 539
Samples for organic chemical pollutant analysis were collected in
clean, solvent-rinsed one-gallon glass containers. These samples were
air-freighted to Denver and extracted with methylene chloride. The
extract was dried with anhydrous sodium sulfate, concentrated, exchanged
into acetone and analyzed by hydrogen flame ionization gas chromatography.
Those samples that showed adequate response were set aside for character-
ization by combined gas chromatography-mass spectrometry (GC/MS). The
* Federal Register3 Vol. 40s No. Ill, June 9t 1975
110 of 111
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GC/MS analyses were carried out with a Finnigan Model 1015 Quadropole
Mass Spectrometer and a Systems Industries Model 150 computerized data
system. Mass spectra were compared to data files in the NIH Computer
System and also to listings in the Eight Peak Index of Mass Spectra,
Second Edition, 1974, compiled by the Mass Spectrometry Data Center.
All identifications are considered preliminary until authentic standards
of the suspected chemical compounds can be obtained and analyzed under
similar conditions to match the mass spectrum and gas chromatographic
retention time. This procedure does not detect highly volatile organic
chemical pollutants since their presence is masked by the extraction
solvent.
Reliability of the analytical results was documented through an
active Analytical Quality Control Program. As part of this program,
replicate analyses were normally performed with every tenth sample to
ascertain the reproducibility of the results. In addition, where appro-
priate, every tenth sample was spiked with a known amount of the con-
stituents to be measured and reanalyzed to determine the percent recovery.
These results were evaluated in regard to past AQC data on the precision,
accuracy and detection limits of each test. On the basis of these
findings, all analytical results reported for the survey were found to
be acceptable with respect to the precision and accuracy control of this
laboratory.
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