ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
EPA-330/2-76-022
Characterization and Evaluation
of Wastewater Sources
United States Steel Corporation
Homestead Main Works
Pittsburgh, Pennsylvania
OCTOBER 22-29, 1975
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
DENVER, COLORADO
AND
REGION III, PHILADELPHIA, PENNSYLVANIA
| ** x-
MARCH 1976 I
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Environmental Protection Agency
Office of Enforcement
CHARACTERIZATION AND EVALUATION OF WASTEWATER SOURCES
UNITED STATES STEEL CORPORATION
HOMESTEAD MAIN WORKS
PITTSBURGH, PENNSYLVANIA
October 22-29, 1975
March 1976
National Enforcement Investigations Center - Denver, Colorado
and
Region III - Philadelphia, Pennsylvania
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CONTENTS
I INTRODUCTION 4
II SUMMARY 10
III MONITORING PROCEDURES 23
IV MONITORING RESULTS . 26
OUTFALL 006 26
OUTFALL 010 69
OUTFALL Oil 79
OUTFALLS 012, 013 83
OUTFALL 014 ......... ... 85
OUTFALLS 015, 115 86
OUTFALL 016 94
OUTFALLS 017, 117 102
INTAKE 3-24 110
INTAKE 4-44 115
INTAKE 5-51 119
SCALE PIT MONITORING 121
V MONITORING REQUIREMENTS 127
OUTFALL 006 128
OUTFALL 010 131
OUTFALL Oil 131
OUTFALLS 012, 013, 014 132
OUTFALLS 015, 115 132
OUTFALL 016 133
OUTFALLS 017, 117 134
INTAKES 3-24, 4-44, 5-51 134
GROSS vs NET 135
REFERENCES 136
APPENDIX
A RECONNAISSANCE REPORT 139
B FIELD STUDY METHODS 173
C CHAIN OF CUSTODY PROCEDURES 183
D ANALYTICAL PROCEDURES, QUALITY CONTROL. . 195
E MARSH-McBIRNEY FLOW METER ........ 199
F WEEKLY PRODUCTION FIGURES 203
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Tables
1 Intake Structures 8
2 NPDES Outfall Description 9
3 Wastewater Monitoring Locations 24
4 Field Measurements and TSS Analyses 27
5 Metals Analyses 32
6 Oil/Grease, Phenol Analyses 38
7 Settleable Solids Analysis 53
8 Settling Basin Treatment Efficiency 57
9 Chloride and. Sulfate Analyses 60
10 Self-Monitoring Data 62
11 48-inch Structural Mill Daily Production (Oct. 17-29) 63
12 48-inch Structural Mill Production (Jan.-June) 64
13 Waste Loads per Unit Production, Outfall 006 (Oct. 22-25) 66
14 Waste Loads per Unit Production, Outfall 006 (Jan.-June) 67
15 Comparison of USSC Proposed Effluent Limitations; Survey Data .... 68
16 Structural Mill Scale Pits 71
17 Structural Mill Production (Jan.-June) 74
18 Structural Mill Daily Production (Oct. 17-29) 75
19 Waste Loads per Unit Production, Outfall 010 (Jan.-June) 77
20 Waste Loads per Unit Production, Outfall 010 (Oct. 22-29) 78
21 Organic Compounds 82
22 Chemical Usage, No. 2 Intake Water Treatment Facility 89
23 160-inch Plate Heat Treating Mill Production 91
24 Waste Loads per Unit Production, 160-inch Plate Heat Treating Mill
(Outfall 115) 93
25 45-inch Slab Mill Production 97
26 160-inch Plate Mill Production 98
27 Waste Loads per Unit Production (Outfall 016) . . 101
28 100-inch Mill Production 106
29 100-inch Mill Production 107
30 Waste Loads per Unit Production (Outfall 117) 109
31 Intake Water Volumes 112
32 Intake Water Quantities and Outfall Discharges
(3-24; 006, 010, Oil, 012, 013) 113
33 Intake Water Quantities and Outfall Discharges
(4-44; 014, 015, 016) 117
34 Intake Water Quantities and Outfall Discharges (5-51; 117) 120
35 Field Measurements and Analytical Results (Scale Pits) 123
36 Reconmended Monitoring Requirements 129
Figures
1 East End USSC Homestead 5
2 West End USSC Homestead 6
3 Wastewater Schematic Flow, 48" Mill 54
4 Wastewater Schematic Flow, Structural Mills 70
5 Wastewater Schematic Flow, Outfall Oil 80
6 Wastewater Schematic Flow, Outfall 015 88
7 Wastewater Schematic Flow, Outfall 016 95
8 Wastewater Schematic Flow, Outfalls 117 and 017 103
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I. INTRODUCTION
The United States Steel Corporation (USSC) Homestead Works consists
of three separate areas. The Carrie Furnaces Plant and the Homestead
Main Works are on the Monongahela River, about 14.5 km (9 mi) upstream
of the confluence of the Ohio, Monongahela, and Allegheny Rivers. The
Wheel and Axle Plant is on the Ohio River at McKees Rocks, Pennsylvania,
about 4.8 km (3 mi) downstream from the confluence of the three rivers.
The Homestead Main Works is on the south side of the Monongahela,
directly across the river from the Carrie Furnaces Plant. Steel making
and fabricating operations at the Main Works include:
Eleven open hearth furnaces
45-inch slab mill
54-inch bloom mill
44-inch bloom mill
48-inch steam driven structural steel mill
100-inch plate mill
160-inch plate mill
52-inch structural steel-hot rolling mill
36-inch structural steel-hot rolling mill
28/32-inch structural steel-hot rolling mill
Special plate heat-treating facilities
Pickling of stainless steel and titanium plate steel
Complete forging mill
Carburizing
Vertical furnace heat-treating
Slag reclamation
Wastewater is discharged from outfalls 006 and 010 through 017*
[Figs. 1, 2]. Process and cooling waters are pumped from the Monongahela
* Outfalls 002 to 005 and 007 to 009 are located at the Carrie Furnaces
Plants outfalls 018 to 020 are located at the Wheel and Axle Plant.
4 of
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V
CAMIE WORKS
009
n
1
no. 1 pump ho use %
5^/3-2-0
c A"
\ SHIPPING STORAGE YAKDS
V
\
\
HE AT TREATING 4
"FORGE 0EFT NO. 2
5^.44
bloom
,,// 5.r,r>°*
28-32 \ \
m.uA\
SPECIAL HATE
FINISHING
FACILITIES
STAINIESS
PROCESSING I
\
007
S&HITAKEH SEWER
004
00!
004
003
BASIN "B"
-INGOT YARD
48" Mill FUR. BLOC
EAST GATE
Flgvr* f. Hem«*l«ad Main Work*, Celt tnd USSC *•«in«yfvanio
en
o
ro
Ml
CO
-------
'nn'Vl».
-------
River through three river intake pumphouses. The outfalls served by
each pumphouse are listed in Table 1. All waste loads discharged
through the Main Works outfalls are computed on a net basis. Intake
water volumes for pumphouse No. 1 are in part derived from hour meters
which record operating times for each of the five intake pumps. For
pumphouses No. 2 and 3, intake water is calculated from operational
times that are recorded in the daily log sheets. The volumes of water
pumped for all three intakes are calculated from the capacity of the
pump reported by the manufacturer.
There are two terminal settling basins, intended for oil/grease and
solids removal, located on the banks of the Monongahela River. The
flows from these two basins are continuously measured and recorded. All
flows discharged from outfalls 011-017 are estimated by USSC. With the
exception of outfalls Oil and 017, the outfalls contain only USSC wastes
during dry weather conditions. Outfall Oil also contains domestic waste
originating in the Munhall Borough. Outfall 017 is the terminus of the
West Run storm culvert from the West Homestead Borough; USSC monitors
the discharge from the 100-inch mill in a manhole inside the mill before
discharge to the storm culvert. The monitoring location is designated
outfall 1*17. {A description of each outfall and USSC reported flows is
provided in Table 2).
On June 12, 1975, NEIC was requested to assist EPA Region III in
investigating specific USSC discharges. In-plant monitoring of all
waste sources and an evaluation of wastewater treatment facilities was
conducted on October 17-29, 1975. This report summarizes the results of
the survey. Additional data for the Homestead Main Works is reported in
the July 29, 1975 reconnaissance report, Inspection of V. S. Steel
Corporation, Homestead Main Worksj South Side of River> Homestead3
Pennsylvania [Appendix A], Survey results for the Carrie Furnaces Plant
and the Wheel and Axle Plant are summarized in individual USEPA reports.
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Table 1
•INTAKE STRUCTURES
USSC HOMESTEAD MAIN WORKS
Pumphouse
No.
Intake
Designation
Treatment
Units
No.
Pump
Type
Pump
Capacity
(mgd)
Outfalls
Served
1
3-24
Bar screens
1
Electric
25
006, 010, 011,
2
Electric
20
013
3
Electric
12
4
Steam
20
5
Steam
20
2
4-44
Bar screens,
1
Steam
35
014, 015, 115,
traveling
2
Steam
35
screens,
3
Electric
35
and strainers
4
Electric
35
5
Electric
15
3
5-51t+
Bar screens,
1
Electric
10
017, 117
traveling
2
Electric
10
screens,
3
Electric
7
and strainers
t USSC designation
tt During the reconnaissance, water from intake 5-51 was reported to be discharged through 016
and 017. During the October survey, it was reported by USSC personnel that water from intake
5-51 discharged only through 017 3 although water from intake 4-44 may also flow through 017.
There is also a possibility that water from intake 5-51 flows through intermediate 115 which
flows through outfall 015.
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Table 2
NPDES OUTFALL DESCRIPTION
USSC HOMESTEAD MAIN WORKS
Outfall
No.
Description
USSC
Reported
F1 ow
(mgd)
006
Process effluent from 48-inch structural mill
and the batch pickling operation which is
passed through a scale pit and then treated
in a settling basin at the edge of the river.
2.3
010
Process effluents from the 44-, 54-, 52-, 36-,
and 28/32-inch mills. All wastes flow through
their respective scale pits, and then are treated
in a terminal settling basin at the edge of the
river.
18
Oil
Munhall Borough storm sewer containing domestic
wastewaters and USSC process and cooling waters
from the press shop.
0.15
012
Untreated cooling water from the carburizing
shop and slag reclamation area.
1.9
013
Untreated process effluent from slag reclama-
tion area; cooling water from the vertical fur-
naces; cooling waters from the carburizing shop.
0.34
014
Cooling water from No. 2 forge shop
12
015
Cooling water from No. 5 open hearth building,
untreated process effluent from 160-inch plate
treating mill.
51
115
Untreated process effluent from the 160-inch
plate mill (discharged to outfall 015).
Not
Reportec
016
Process effluent from the 45-inch slab mill
and the 160-inch plate mill, each treated in a
separate scale pit.
29
017
Process effluent from the 100-inch plate mill
after passing through two scale pits operated
in parallel. Effluent is discharged into the
West Run storm culvert from the West Homestead
Borough (017).
19
117
Monitoring location for 100-inch mill process
waste and cooling waters prior to discharge to
the West Run culvert, outfall 017.
19
+ See Appendix A
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II. SUMMARY
1. During October 22-29, 1975, the wastewaters discharged from
outfalls 006, 010, Oil, 012, 013, 014, 015, 115, 016, 017 and 117 were
monitored. The Munhall Borough storm sewer and the Homestead Borough
West Run Culvert were monitored upsewer of USSC discharges to determine
the wastewater quality prior to mixing. The influents to the settling
basins for the 48-inch mill and the structural mill were also monitored
to determine treatment efficiencies. Flows were measured by NEIC by the
dye dilution technique for outfalls 011-017. The accuracy of the USSC
flow devices on outfalls 006 and 010 were checked by NEIC. Pollutant
loads were calculated for each location.
During October 17-19, the influents and effluents from six scale
pits were monitored to determine treatment efficiencies on a concen-
tration basis only. Flows were not measured.
2. According to USSC, all wastewaters from the 48-inch steam-
driven structural steel mill and the batch pickling operation neutral-
ization facility pass through a scale pit prior to discharge to Settling
Basin "B." The effluent from the basin is discharged through outfall
006.
The net TSS and 0/G loads discharged from 006 ranged from 0-80
kg/day (180 lb/day) and 8-36 kg/day (17-80 lb/day), respectively. The
o
flow averaged 4,600 m /day (1.2 mgd).
USSC collects aliquots for composite samples from outfall 006 on a
4-hour cycle schedule (six samples per 24-hour period) and combines the
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allquots into the composite sample on an equal-volume basis even though
the effluent flow is measured and recorded continuously. USSC stated
that the flows "remain fairly constant when considering a long time
period." However, instantaneous flows over the four-day monitoring
period, October 22-26, when the 48-inch mill was operating, varied by
60%. Therefore, composite samples comprised of equal-volume aliquots
may not be representative of the actual discharge. The total suspended
solids (TSS) and oil/grease (0/G) data collected during the survey and
the data submitted by USSC for January-June, 1975 were compared on a
unit production basis. The TSS load discharged per unit of production
during the survey was about 2.3 times greater than the TSS load/unit
production discharged January-June. It is reasonable to assume that as
production increases, the concentration of pollutants would also in-
crease. However, production during the survey was only 75% of the rated
capacity of the mill while daily production January-June averaged 16%
greater than capacity.
The 0/G load/unit production discharged during the survey was also
2.3 times greater than the 0/G load per unit production discharged
January-Jurie. The application of lubricants to the rolls in the mill
probably remains fairly constant and is not dependent upon production.
Since 0/G samples are collected on a grab basis, the concentrations
reported were representative of the effluent at the time of sampling.
The effluent was also analyzed for sulfates and chlorides because
of the pickling operation and descaling practices (salt is applied to
the slabs during descaling). Net sulfates were insignificant; however,
the average chloride concentration increased by 55 mg/1 over intake
levels.
USSC has proposed the following effluent limitations for TSS, 0/G
and dissolved iron. On a daily maximum basis, the TSS, 0/G and dissolved
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iron concentrations found during the NEIC survey were 9%, 23% and 20%,
respectively, of the proposed limitations.
Gross
Parameter
NEIC Survey Data
* USSC Proposed Limitations
Net Daily Average Daily Maximum Daily Average Daily Maximum
kg/day lb/day kg/day lb/day kg/day lb/day kg/day lb/day
TSS
N
NAf
NA
31
68
80
180
0/G
N
NA
NA
21
45
36
80
Fe (diss)
G
NA
NA
1.3
2.9
5.7
12.6
rag/1
TSS
N
77
231
6
20
0/G
N
NA
30
4
7
Fe (diss)
G
NA
7
0.3
1.4
t Not Applicable
According to USSC, the settling basin design treatment efficiencies
are 66% for TSS and 57% for 0/G. During the survey, about 45% of the
TSS and 80% of the 0/G were removed. However, the average influent
concentrations for TSS and 0/G were about 60% and 50%, respectively,
less than the design concentrations. The flow was about 50% of the
design flow.
At high river stages, the effluent launder is inundated and cannot
be monitored. Heavy material found deposited in the launder provided
evidence of the flooding conditions.
The Parshall flume was installed properly. However, the flow
recording device indicated an instantaneous flow about 16% less than the
actual flow.
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3. Process wastewaters discharged from the 54-inch bloom mill,
52-inch roughing mill, 44-inch bloom mill, 36-inch roughing mill and
28/32-inch structural steel mill flow to their respective scale pits and
then to Settling Basin "A." Cooling waters from the five mills also
flow to the basin. The basin's effluent is discharged from outfall 010.
Total average production for October 17-29, for the five mills was
2,255 m. tons (2,490 tons)/day. Each mill was operating below its rated
capacity:
Production Average % of
Mill Rated Capacity Oct. 17-29, 1975 Rated
m.tons/day
tons/day
m.tons/day
tons/day
Capacity
54-inch
2,844
3,136
877
967
31
52-inch
1,461
1,611
749
826
51
44-inch
1,007
1,110
619
682
61
36-inch
756
834
397
438
53
28/32-inch
756
834
397
438
53
For January-June, 1975, average total production was 4,515 m. tons
(4,977 tons)/day, about 75% of the daily rated capacity.
During the monitoring period, October 22-29, the net TSS and 0/G
loads averaged 480 kg (1,060 lb)/day and 190 kg (420 lb)/day, respectively.
Total and dissolved iron concentrations averaged 1.2 mg/1 and 0.07 mg/1,
respectively.
Based on production data submitted by USSC, the TSS and 0/G gross
unit waste loads averaged 0.76 kg/1,000 kg (1.51 lb/ton) and 0.12 kg/1,000
kg (0.23 lb/ton). As discussed above, USSC composite samples on an
equal-volume basis and does not consider variations in the instantaneous
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flows. During the NEIC survey, the flows varied by 30%; therefore, the
monitoring data submitted by USSC should be considered as an estimate of
effluent characteristics. Generally it would be expected that as
production increased, the pollutant load would also increase. However,
as was the case for the 48-inch mill, the gross TSS unit load was 60%
greater (during the survey than the gross unit load for January-June.
The 0/G unit load October 22-29 was 33% greater than for January-June.
Since the flow was approximately 22% greater during the survey than in
January-June, thus increasing the waste load, it appears that the 0/G
parameter does not depend on production, but rather on lubrication
procedures in the mill. On October 26, when all mills except the 54-
inch mill were shut down, there was no increase in TSS levels over
intake concentrations, indicating that the TSS levels and possibly other
pollutant concentrations depend on production.
USSC has proposed effluent limitations for TSS and 0/G parameters,
based on gross loads, from the present to June 30, 1977 and from July 1,
1977, to the expiration date of the NPDES permit.
Parameter
NEIC Survey Data
USSC Proposed Limitations •
Daily Average Daily Maximum Daily Average Daily Maximum
kg/day lb/day kg/day lb/day kg/day lb/day kg/day lb/day
Present to 6/30/77
TSS 4,568 10,050 13,704 30,150
0/G 1,221 2,685 3,662 8,055
7/1/77 to expiration
TSS 4,568 10,050 13,704 30,150
0/G NAt NA
1,540 3,400 2,715 5,990
235 520 340 750
1,540 3,400 2,715 5,990
235 520 340 750
+ Not Applicable
The gross daily average and daily maximum TSS loads discharged October
22-29 were about 34% and 20%, respectively, of the proposed limitations.
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The corresponding gross 0/G loads were 19% and 15% of the proposed
limitations.
USSC reported that Settling Basin "A's" design efficiencies for TSS
and 0/G are 44% and 27% respectively. Prior to the survey, adsorbent
pads had been secured to the effluent launders by USSC to remove additional
quantities of 0/G. About 10% of the TSS and 20% of the 0/G were removed
in the settling basin. The effluent TSS averaged 26 mg/1 and the 0/G 4
mg/1. However, the average influent TSS and 0/G concentrations of 29
mg/1 and 5 mg/1, respectively, were well below the design concentrations.
At high river stages, this outfall is inundated and representative
samples cannot be collected and flows cannot be measured.
The broad-crested weir was installed properly; however, the flow
recorder indicated a flow approximately 66% less than the flow deter-
mined by the dye dilution method. A head-discharge curve should be
developed for the weir and the flow recorder set accordingly. The flow
recorder should be calibrated periodically.
4. Outfall Oil is the terminus of the Munhall Borough storm
sewer. USSC discharges untreated process wastewaters and cooling waters
to the storm sewer. The wastewater from the Munhall Borough contained
raw sanitary wastes. The Borough's flow averaged 0.48 m /day (0.13) and
the TSS and 0/G averaged 41 mg/1 and 27 mg/1, respectively.
USSC contributed about 3,620 m^/day (0.96 mgd); the net TSS and 0/G
concentrations averaged 13 mg/1 and 6 mg/1, respectively. Net metal
concentrations were negligible.
Low levels of phenols, cresols, alcohols and a phthalate were found
in grab samples collected on October 22 and 27 from the Munhall Borough
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wastewater. These compounds were not detected in outfall Oil on either
day.
USSC does not monitor at the point where the Munhall Borough sewer
enters plant property. This upstream location should be monitored and
credit allowed for the upsewer constituents.
USSC has not proposed effluent limitations for this outfall.
5. Direct contact cooling waters from the Langenfelder Slag
Reclamation area and cooling waters from the carburizing shop and
vertical furnace operation are discharged from outfalls 012 and 013.
o
The flows through outfalls 012 and 013 averaged 32,500 m /day (8.6
mgd) and 5,400 m /day (1.4 mgd), respectively. USSC has estimated the
flows in their January-June self-monitoring data to range from 0-16,500
m^/day (4.37 mgd) for outfall 012 and from 1,090-20,800 m^/day (0.288-
5.5 mgd) for outfall 013.
There was no increase in 0/G or metals over intake concentrations
in either outfall. The TSS concentration increased an average of 2 mg/1
in outfall 012 and 9 mg/1 in outfall 013.
USSC has not proposed effluent limitations for either outfall;
however, USSC has proposed that the TSS and 0/G parameters not be
monitored at outfall 013.
6. Cooling water and process wastes from the No. 2 forge shop are
discharged from outfall 014. During the survey, the scale pit was dry,
thus all wastewaters were discharged untreated.
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o
USSC estimates the flow as 43,600 m (11.52 mgd); the flow during
the survey ranged from 11,700-23,200 m /day (3.1-6.1 mgd). There was no
net increase in O/G concentrations and only a minor increase in metal
concentrations over intake levels. The TSS concentration remained at
background levels for six of the seven monitoring days. On October 23-
24, the TSS concentration increased 18 mg/1 over the intake concen-
tration; the maximum daily flow also occurred on this date.
USSC has not proposed limitations for this outfall.
7. Wastewater discharged from outfall 015 originates in the No. 5
open hearth building, the 160-inch plate mill heat treating building and
the water treatment plant. Monitoring of the quenching water discharge
from the heat treating building is conducted at intermediate outfall
115.
Based on the daily average production data submitted by USSC,
production during October 17-29 for the heat treating line was about 85%
of the production level for January-June, 1975 and about 21% to 47%
greater than capacity, depending on whether stainless steel was being
processed. [Capacity with stainless steel is 292 m. tons (322 tons)/day
and without stainless steel is 241 m. tons (266 tons)/day.]
USSC estimates that the flows from outfalls 115 and 015 are 18,900
3 3
m /day (5 mgd) and 181,700 m /day (48 mgd) respectively. During the
NEIC survey, the flows from outfall 115 ranged from 45,000-53,700
3
m /day (11.8-14.2 mgd). Flows from outfall 015 ranged from 260,000-
305,000 m^/day (68.8-80.5 mgd).
On three of the seven monitoring days, there was a net increase in
TSS in the wastewaters in both outfalls; the increases occurred on the
same days. The seven-day average net increase in the TSS loads was
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190 kg/day (415 lb/day) and 1,100 kg/day (2,400 lb/day) for outfalls 115
and 015, respectively. The 0/G concentration increased on four of the
seven days at outfall 115 but was not evident in outfall 015. Metals
were increased in both discharges but were negligible.
USSC has proposed the following net 0/G load limitations for
outfall 015; concentration limits were proposed as NA (not applicable).
Limitations were hot proposed for outfall 115.
USSC Proposed 0/G Limitations
NEIC Survey Data (NET)
Daily Average Daily Maximum
kg/day lb/day kg/day lb/day
Daily Average Daily Maximum
kg/day lb/day kg/day lb/day
1,320 2,900 3,960 8,700
0 0 640 1,410
The daily maximum net 0/G load discharged during the survey was 15% of
the proposed limitation.
8. Process wastewaters from the 45-inch slab mill and the 160-
inch plate mill pass through their respective scale pits and then are
discharged to the river via outfall 016. During the survey, the 45-inch
and 160-inch mills were operating at approximately 37% and 70%, respectively,
of their rated capacities. Although production was down 44% in the 45-
inch mill and down 39% in the 160-inch mill from levels reported for
January-June, 1975, the flow from outfall 016 was about 70% greater
during the October survey than the first six months of 1975. The
October 22-29 flow averaged 106,800 m^/day (28.1 mgd).
The net TSS load during the survey averaged 1,865 kg/day (4,100
lb/day); the net 0/G load averaged 210 kg/day (470 lb/day); net metal
loads were negligible. Self-monitoring data indicate that the gross TSS
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and 0/G concentrations were about 40% and 60% greater, respectively, for
January-June, 1975 than during the NEIC survey.
USSC has proposed the following gross loads for outfall 016;
concentration limits were proposed as NA.
Parameter
USSC Proposed Limitations
Daily Average Daily Maximum
kg/day lb/day kg/day lb/day
NEIC Survey Data (Gross)
Daily Average Daily Maximum
kg/day lb/day kg/day lb/day
TSS
7,382 16,240 22,145 48,720
3,970 8,760 7,790 17,150
0/G
1,896 4,172 5,689 12,516
460 1,020 1,370 3,020
On a daily average basis, the gross TSS and 0/6 loads proposed were 46%
and 76% greater, respectively, than the loads discharged October 22-29.
The daily maximum gross TSS and 0/G loads proposed were 65% and 76%
greater, respectively, than the maximum loads discharged.
9. the Homestead Borough West Run Culvert flows under the west
side of the Homestead plant. The effluent from the 100-inch plate mill
discharges to the culvert where it combines with storm and sanitary
wastes from an extensive portion of the West Homestead Borough. The
terminus of the culvert is designated as outfall 017. Process waste-
waters from the 100-inch mill pass through either the east or west scale
pits and combine with the cooling water in the plant sewer. The 100-
inch mill's discharge to the culvert is monitored at outfall 117. USSC
only monitors outfall 117. During the survey, outfalls 017 and 117 and
the West Run Culvert, upstream of USSC's discharges, were monitored for
two days; the 100-inch mill shut down on October 24.
Production for October 22-24 was approximately 50% of the rated
capacity. During January-June, 1975, production averaged 90% of capacity.
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3
Flow from outfall 117 averaged 94,200 m /day (24.9 mgd) for October
22-24; practically all of the flow in otufall 017 originates in the 100-
inch mill. The net TSS load discharged from outfall 117 averaged 2,030
kg/day (4,475 lb/day); the net 0/G load discharged 195 kg/day (420
lb/day). The total iron concentration was increased by 4.6 mg/1 over
intake concentrations, corresponding to a net average load of 435 kg/day
(955 lb/day). Other metals were not increased significantly.
USSC has proposed the following limitations for gross loads at
outfall 117; concentration limits were proposed as NA.
Parameter
USSC Proposed Limitations
NEIC Survey Data (Gross)
Daily Average Daily Maximum
kg/day lb/day kg/day lb/day
Daily Average Daily Maximum
kg/day lb/day.kg/day lb/day
TSS
7,460 16,412 22,380 49,236
5,600 12,350 5,700 12,600
0/G
1,484 3,266 4,453 9,798
470 1,030 510 1,130
The daily average TSS and 0/G loads discharged October 22-24 were 75%
and 32% of the proposed limits; the daily maximum TSS and 0/G loads were
26% and 12% of the proposed limits, respectively.
On October 27, samples were collected from the upstream location
and outfall 017 and analyzed for organic compounds. A phthalate, about
0.30 mg/1, was found in the upstream location, but it could not be
confirmed by GC/MS.* Nine organic compounds were found in the discharge
from outfall 017. The source of these organic compounds is not known;
outfall 117 was dry. Samples were also collected from all three monitoring
locations on October 22. Organic compounds were not detected in any of
the samples.
* Gas Chromatograph/Mass Spectrometer
20 of 213
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Since most of the wastewater discharged from outfall 017 also flows
through outfall 117, monitoring of outfall 017 is not necessary by USSC.
10. For net load computations, USSC samples each of the three
intakes at the river. NEIC sampled these locations and also after the
strainers at intakes 4-44 and 5-51. There was essentially no difference
in the water quality before or after treatment. However, USSC should
monitor the intakes after treatment since the intake pipes are below the
water surface, thus precluding the possibility of higher 0/G concen-
trations which may be found in surface samples. This procedure would
also preclude giving credit for higher intake concentrations than
actually exist.
A water balance was calculated for each intake and the outfalls
through which the intake water was reported to discharge. Intake
volumes, calculated from the pump capacities and hours of operation,
were within 10% of the discharges.
The screen backwash waters from intake 4-44 are discharged through
outfall 015. The TSS concentrations in the backwash water were equiva-
lent to the concentrations in the intake water. All backwash waters
from the traveling screens at intake 5-51 are discharged directly to the
river without treatment through an unpermitted outfall. There are no
screens at intake 3-24; however, the intake pipes are equipped with
perforated end sections. The intakes are periodically back flushed
directly to the river.
11. Influent and effluent monitoring for TSS, 0/G and settleable
solids was conducted October 17-20 at six of the scale pits. The data
show that the TSS, 0/G and settleable solids remained unchanged entering
and leaving the scale pits. Although the data indicate little or no
21 of
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treatment, this conclusion may not be valid for the heavier material
since USSC reported that a total of 57,650 m. tons (63,560 tons) of mill
scale was recovered from the nine hot rolling scale pits for January-
June 1975.
The TSS concentrations represent minimum levels. Due to turbulence
in each of the scale pits, TSS remain in the suspended state and are
carried out in the effluent from the pits.
The scale pits did not remove appreciable amounts of 0/G. Since
the pits are not equipped with 0/G removal devices, any 0/G detained in
the pit would eventually be discharged.
12. Flows should be monitored continuously and recorded daily at
the following outfalls: 006, 010, 015, 016 and 117. A minimum of six
instantaneous flow measurements over 24 hours on monitoring days will
provide data to characterize the flows from the remaining outfalls.
Discharges from outfalls 010, 115, 016 and 117 should be monitored three
times per week. The discharges from outfalls 011, 012, 013, and 014
should be monitored once per week. Outfall 006 should be monitored
twice per week and outfall 015 should be monitored daily. The Munhall
Borough wastewater should be monitored once per week. Except for
periods when the outfalls are inundated due to high river conditions,
monitoring locations presently used by USSC are satisfactory.
All composite samples, including intake water, should be combined
on a flow-weighted basis. Monitoring should be conducted on days when
the mills are operational.
22 of
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III. MONITORING PROCEDURES
Twenty-one locations were sampled during the 7-day period, October
22-29, 1975, to characterize the wastewater sources and evaluate the two
terminal settling basins. In addition, six scale pits, influents and
effluents were sampled for 3 days (October 17-20) to determine efficiency
of treatment [Table 3].
Outfalls 017 and 117 serving the 100-inch mill and the upstream
location of the Homestead West Run storm sewer were sampled for 2 days.
On October 24, the 100-inch plate mill was shut down to replace and/or
repair rolling tables and conduct maintenance. All flow from the 100-
inch mill ceased. The shutdown had been scheduled, but the date had not
been established prior to the survey. In addition, the 48-inch mill,
which discharges from outfall 006, shut down on October 25 because no
work was scheduled for this mill. This mill does not operate every week
even under normal production schedules. According to USSC personnel,
the mill was expected to remain in the "down" status until December
1975. The remaining outfalls and river intakes were monitored for 7
days.
Samples for TSS, metals, chlorides, and sulfates were composited on
a flow-weighted basis.* Instantaneous flows for each outfall were
measured each time a sample was collected. The dye dilution technique
was used for all locations except 006 and 010. For these two outfalls,
the instantaneous flows were taken from the USSC flow recorders. Intake
flows were calculated from rated pump capacities and hours of operation.
* Scale pit composite samples were combined on equal-volume basis since
flows were not determined.
23 of
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Table 3
WASTEWATER MONITORING LOCATIONS
USC HOMESTEAD MAIN WORKS
October 17-29, 1975
Station Description
Dates
(Oct.)
Parameter
Intakes 3-24, 4-44,
and 5-51
Backwash from intake 4-44
Influent to 48-inch mill
settling basin
Effluent from 48-inch mill
settling basin (006)
Influent to structural
basin
Effluent from structural
basin
Munhall sewer, upstream
of Oil
Outfalls Oil, 012, 013,
014, 015, 115, 016
Outfall 117, West Run
culvert upstream of
8th Ave., West Run
culvert at river (017)
54-inch mill scale pit++
52-inch mill scale pit++
+ +
36-inch mill scale pit
4*+
45-inch mill scale pit
100-inch mill scale pits (2)
22-29
23-28
22-26
22-26
22-29
22-29
22-29
22-29
22-24
tt
TSS, 0/G, Settleable Solids,
Phenol, Organics, Metals,
Chloride, Sulfate, PCB's
TSS
TSS, 0/G, Settleable Solids
TSS, 0/G, Settleable Solids,
Phenol, Organics, Metlas,
Chloride, Sulfate, PCB's
TSS, 0/G, Settleable Solids
TSS, 0/G, Settleable Solids,
Phenol, Organics, Metals,
PCB's
TSS, 0/G, Settleable Solids,
Organics, Metals, PCB's
TSS, 0/G, Settleable Solids,
Organics, Metals, PCB's
TSS, 0/G, Settleable Solids,
Organics, Metals, PCB's
7-20
TSS, 0/G, Settleable
Sol ids
7-20
TSS, 0/G, Settleable
Solids
7-20
TSS, 0/G, Settleable
Sol ids
7-20
TSS, 0/G, Settleable
Sol ids
7-20
TSS, 0/G, Settleable
Sol ids
t Before and after treatment
tt Influent and Effluent
24 of
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Details on sampling procedures and flow measurement techniques are
contained in Appendix B. Chain of custody procedures [Appendix C] and
analytical quality control procedures [Appendix D] were followed.
25 of 213
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IV. MONITORING RESULTS
Monitoring results* are tabulated by individual sampling location
[Tables 4, 5, 6, 7] and are discussed by individual outfall. Organic
compounds** were found only in wastewater in the Munhall storm sewer
upstream of the USSC discharges (outfall Oil) and in the discharge from
outfall 017 and are discussed only in those sections. Polychlorinated
byphenyls (PCB's) were not detected in the three intakes or in any
discharge.
OUTFALL 006
This discharge contains process wastes from the 48-inch structural
mill and treated waste from the sheet, batch pickling operation. All of
the wastewater passes through a small scale pit prior to discharge to
the terminal settling basin [Fig. 3]. The inner dimensions of the scale
pit are 7.§ m (26 ft) long x 3.2 m (10.5 ft) wide x 1.8 m (6 ft) side
wall depth (SWD). The effective volume of the scale pit is 46 m
(12,250 gal). Based on the estimated design flow of 1,135 1/min (300
gpm), the calculated detention time is about 41 minutes. The TSS removal
was estimated by USSC to be 98.9% efficient, however, 0/G removal was
unknown.1 According to USSC personnel, the pit is cleaned once a day
when the mill is operating.
* Composite samples for TSS and metals were collected over a 24-hour
period measured from 6 a.m. to 6 a.m. The dates reported in the tables
for these data therefore reflect that samples were collected for a
portion of each day3 e.g., October 22-23, indicates the time period
6 a.m. to midnight October 22 and midnight to 6 a.m. October 23.
** Organic compounds other than oil.
26 of 213
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Table 4
SUMMARY OF FIELD MEASUREMENTS AND TOTAL SUSPENDED SOLIDS ANALYSES
VSSC HOMESTEAD MAIN WORKS
October 22-29, 1975
Station Description
Date8
(Oct.)
Flow
m3/day
X 103
mgd
PH
Range
Temp.
Range
CC]
Gross
Cone.
mg/1
Total Suspended Solids
Gross
Load
kg/day
lb/day
Net Net
Cone. Load
>g/l kg/day lb/day
Intake 3-24°
(sample collected
at river)
Influent to
48-1n. mill
settling basin
Influent to
structural mill
settling basin
22-23
23-24
24-25
25-26
26-27
27-28
28-29
7-Day Avg.
22-23
23-24
24-25
25-26
26-27
5-Day Avg.
Effluent from
48-1n. mill
settling basin (006)
22-23
23-24
24-25
25-26
26-27
27-28
28-29
7-Day Avg.
109.8
99.2
85.2
98.4
88.6
84.4
95.4
94.4
4.1
5.3
5.3
5.2
3.4
4.6
29
26.2
22.5
26.0
23.4
22.3
25.2
24.9
1.1
1.4
1.4
1.4
0.9
1.2
59.0
59.4
57.5
59.0
59.0
57.9
59.8
58.8
15.6
15.7
15.2
15.6
15.6
15.3
15.8
15.5
6.5-6.9
6.7-6.9
6.1-8.3
6.4-6.9
6.3-6.8
6.4-6.9
6.3-6.8
6.6-7.5
6.8-8.2
6.5-8.3
6.4-6.9
6.3-6.8
14-16.5
15.5-18
14.5-18
15.5-18
13-18
14-17
15-17
14.5-20
15-19
14-20
16-22
13-16
33
30
21
8
20
8
9
19
48
86
48
42
19
53
3,620
2,975
1,785
785
1,770
675
860
1,780
195
455
255
220
65
240
7,980
6,560
3,940
1,740
3,900
1,490
1,890
3,930
430
1,000
560
490
150
530
22-23
4.1
1.1
6.7-7.0
16-18
53
215
480
20
80
180
23-24
5.3
1.4
6.9-7.9
15-19
30
160
350
0
0
0
24-25
5.3
1.4
6.4-8.5
15-21
22
115
260
1
5
10
25-26
5.2
1.4
6.3-7.0
15.5-21
21
110
240
13
70
150
26-27
5.4
0.9
6.3-7.1
14-17
12
40
90
0
0
0
¦Day. Avg.
4.6
1.2
28
130
280
7
30
70
6.7-7.0
6.5-8.2
6.1-8.6
6.2-7.1
6.4-6.9
6.5-6.9
6.4-6.8
14-16.5
15-18
15.5-18
14-19
13-17.5
14-16.5
15-19
46
48
29
24
14
21
23
29
2,715
2,850
1,670
1,415
825
1,215
1,375
1,725
5,990
6,290
3,680
3,120
1,820
2,680
3,030
3,800
-------
Table 4 (continued)
SUMMARY OF FIELD MEASUREMENTS AND TOTAL SUSPENDED SOLIDS ANALYSES
Station Description
Date®
(Oct.)
Flow
,m3/day
X 103
mgd.
PH
Range
Temp.
Range
(°C)
Gross
Gross
Net
Net
Cone.
Load
Cone.
Load
mg/1
kg/day
lb/day
mg/1.
kg/day lb/day
46
2,715
5,990
13
765
1,690
42
2,495
5,500
12
710
1,570
22
1,265
2,790
1
55
125
16
945
2,080
8
470
1,040
17
1,005
2,210
0
0
0
17
985
2,170
9
520
1,150
23
1,375
3,030
14
835
1,845
26
1,540
3,400
8
480
1,060
40
25
55
55
37
82
45
27
60
35
19
41
38
12
25
35
11
25
25
8
18
41
20
44
23
105
235
20
80
180
26
145
325
22
no
243
16
70
150
11
40
90
12
45
100
8
27
59
15
30
70
11
20
45
16
35
85
13
27
60
16
40
90
15
33
72
19
70
150
13
49
107
35
1,985
4,380
2
115
250
34
1,340
2,950
4
155
345
28
565
1,240
7
140
310
12
275
605
4
90
200
14
530
1,170
0
0
0
10
300
655
2
60
130
9
185
405
0
0
0
23
740
1.630
2
SO
175
Effluent from
structural mill
settling basin
(010)
Munhall Sewer,
upstream of
outfall Oil
Outfall Oil"'
c.d
Outfall 012
22-23
23-24
24-25
25-26
26-27
27-28
28-29
7-Day Avg.
22-23
23-24
24-25
25-26
26-27
27-28
28-29
7-Day Avg.
22-23
23-24
24-25
25-26
26-27
27-28
28-29
7-Day Avg.
22-23
23-24
24-25
25-26
26-27
27-28
28-29
7-Day Avg.
59.0
59.4
57.5
59.0
59.0
57.9
59.8
58.8
0.62
0.67
0.61
0.53
0.30
0.30
0.34
0.48
4.66
5.64
4.31
3.71
2.12
2.35
2.54
3.62
56.8
39.3
20.1
22.9
37.9
29.8
20.4
32.5
15.6
15.7
15.2
15.6
15.6
15.3
15.8
15.5
0.16
0.18
0.16
0.14
0.08
0.08
0.09
0.13
1.23
1.49
1.14
0.98
0.56
0.62
0.67
0.96
15.0
10.4
5.3
6.1
10.0
7.9
5.4
8.6
6.8-7.2
6.8-7.9
6.4-8.7
6.5-7.2
6.2-6.9
6.5-6.9
6.6-6.9
6.8-7.0
6.8-7.7
6.5-7.8
6.6-6.9
6.7-6.9
6.7-6.9
6.5-7.1
6.3-6.9
6.5-8.0
6.4-8.1
6.1-7.0
6.8-6.8
6.7-7.2
6.5-6.9
6.7-8.6
7.0-8.9
6.9-9.0
7.0-7.5
6.9-7.5
6.6-7.4
7.3-11.2
15-17
14.5-17.5
15-19.5
15-18
14-17.5
14-16
15.5-18
16-18.5
17-19.5
16-19
17.5-19
15.5-18.5
14.5-18
17-19
16.5-19.5
18-21
16.5-21
15.5-19
15-18
14-20
15-21
14.5-20
14.5-19
16-18
15-18
15-19
15-19
15.5-20
-------
Table 4 (continued)
SUMMARY OF FIELD MEASUREMENTS AND TOTAL SUSPENDED SOLIDS ANALYSES
Flow Total Suspended Solids
Station Description Date® _3/A.V . pH Temp. Gross " Gross Net Ret
(Oct.) ? (nf Range Range Cone. Load Cone. Load
(°C) mg/1 kg/day lb/day mg/1 kg/day lb/day
Outfall 013
Intake 4-44
(sample collected
at rfver)
Intake 4-44
(sampled after
straining)
Outfall 014
22-23
7.87
2.08
7.2-11.3
15-21
25
195
435
0
0
0
23-24
14.35
3.79
7.5-10.7
17-21
44
630
1,390
14
200
440
24-25
3.41
0.90
7.3-11.2
17-19
45
155
340
24
80
180
25-26
2.76
0.73
7.3-8.0
16.5-17.5
18
50
110
10
25
60
26-27
2.84
0.75
7.2-7.7
15-16
9
25
55
0
0
0
27-28
3.60
0.95
7.0-7.8
15.5-20
22
80
175
14
50
110
28-29
3.26
0.86
7.2-9.3
17-20
7
25
50
0
0
0
7-Day Avg.
5.44
1.44
30
165
365
9
50
110
22-23
428
113
6.3-7.3
14-16
28
11,980
26,400
23-24
397
105
6.6-7.5
15-16.5
35
13,910
30,650
24-25
344
91
6.7-7.5
15.5-17
29
9,990
22,000
25-26
313
85
6.8-7.3
14.5-16.5
15
4,830
10,650
26-27
313
85
6.8-7.3
14-16
14
4,500
9,900
27-28
313
85
6.8-7.3
14-16
11
3,540
7,800
28-29
313
85
6.9-7.3
14.5-16.5
6
1,930
4,250
7-Day Avg.
351
93
21
7,230
15,950
22-23
428
113
6.2-7.0
15.5-16
30
12,800
28,300
23-24
397
105
6.3-7.1
15-16.5
22
8,750
19,300
24-25
344
91
6.9-7.4
16-18
33
11,400
25,000
25-26
313
85
6.8-7.4
15.5-17
13
4,180
9,200
26-27
313
85
6.8-7.3
14-16.5
7
2,250
4,950
27-28
313
85
6.8-7.4
15-17
19
6,100
13,500
28-29
313
85
7.1-7.2
15.5-16.5
12
3,860
8,510
7-Day Avg.
351
93
20
7,050
15,540
22-23
15.8
4.2
6.3-6.9
16-21.5
26
410
905
0
0
0
23-24
23.2
6.1
6.6-7.2
16.5-21.5
40
930
2,045
18
415
920
24-25
16.0
4.2
6.8-7.2
16-22
22
350
775
0
0
0
25-26
11.7
3.1
6.9-7.4
15-19.5
18
210
465
5
60
130
26-27
12.6
3.3
6.8-7.1
15-18
14
175
390
7
90
195
27-28
12.6
3.3
6.8-7.4
15.5-21
10
125
270
0
0
0
28-29
10.5
2.8
6.7-7.4
16.5-21
7
75
160
0
0
0
7-Day Avg.
14.6
3.9
22
325
715
6
80
175
-------
Table 4 (continued)
SUMMARY OF FIELD MEASUREMENTS AND TOTAL SUSPENDED SOLIDS ANALYSES
Flow Total Suspended Sol Ids
Station Description Date8 _3,j.„ __H pH Temp. Gross Gross Net Rlt
(Oct.) IJ ® Range Range Cone. Load Cone. Load
X 10 (°C) ,mg/1 kg/day lb/day mg/1 kg/day lb/day
Outfall 115
Outfall 015
Outfall 016
Intake 5-51
(sample collected
at river)
Intake 5-51
(sampled after
straining)
22-23
53.7
14.2
6.2-6.9
14.5-17
30
1,610
3,550
0
0
0
23-24
47.3
12.5
6.5-7.3
17-17.5
39
1,850
4,070
17
805
1,770
24-25
46.6
12.3
6.8-7.5
16-18
27
1,260
2,770
0
0
0
25-26
51.1
13.5
7.0-7.5
15.5-17
19
970
2,140
6
280
615
26-27
48.1
12.7
6.9-7.3
15-16
12
575
1,270
5
240
530
27-28
44.7
11.8
6.8-7.4
15-17
18
805
1,770
0
0
0
28-29
49.6
13.1
7.0-7.2
16.5-17
8
395
875
0
0
0
7-Day Avg.
48.7
12.9
22
1,065
2,350
4
190
415
22-23
305
80.5
6.2-7.1
15.5-21
30
9,140
20,140
0
0
0
23-24
276
72.9
6.3-7.1
19-22
41
11,320
24,930
9
2,480
5,470
24-25
320
84.5
6.4-7.4
20-21
28
8,960
19,730
0
0
0
25-26
260
68.8
6.5-7.5
18-20
25
6,510
14,340
12
3,115
6,865
26-27
298
78.6
7.1-7,5
17.5-20
14
4,160
9,180
7
2,080
4,590
27-28
284
75.0
6.5-7.3
18-20
17
4,830
10,630
0
0
0
28-29
284
75.1
7.1-7.3
20-22
9
2,560
5,640
0
0
0
7-Day Avg.
289
76.5
23
6,780
14,940
4
1,095
2,420
22-23
127.1
33.6
6.4-7.4
17-21.5
40
5,090
11,210
10
1,270
2,800
23-24
116.2
30.7
6.8-7.5
18-22.5
67
7,790
17,150
45
5,225
11,520
24-25
96.5
25.5
6.5-7.6
17-22
43
4,150
9,150
10
965
2,125
25-26
93.9
24.8
7.0-7.6
16-18.5
21
1,970
4,350
8
750
1,655
26-27
85.2
22.5
6.8-7.5
18.5-22.5
26
2,210
4,880
19
1,615
3,565
27-28
93.5
24.7
6.6-7.3
19-22
38
3,550
7,830
19
1,775
3,915
28-29
132.9
35.1
7.0-8.8
20-21.5
23
3,050
6,730
11
1,460
3,220
7-Day Avg.
106.8
28.1
37
3,970
8,760
18
1,865
4,115
22-23
88.9
24
6.4-7.0
14.5-17.5
27
2,400
5,290
23-24
102.2
27
6.2-7.3
15-17
39
3,990
8,780
24-25
102.2
27
6.5-6.9
15.5-17
27
2,760
6,080
25-26
102.2
27
6.8-7.5
15-20
16
1,630
3,600
26-27
102.2
27
6.9-7.3
14.5-16
10
1,020
2,250
27-28
102.2
27
6.9-7.1
15-16
18
1,840
4,050
28-29
102.2
27
7.0-7.7
15-16
14
1,430
3,150
7-Day Avg.
100.3
26.5
21
2,150
4,740
22-23
88.9
2.4
6.3-7.1
15-18
41
3,640
8,030
23-24
102.2
27
6.4-7.4
16-20
35
3,570
7,880
24-25
102.2
27
6.5-7.1
16-19.5
30
3,060
6,750
25-26
102.2
27
6.8-7.4
16-17.5
35
3,570
7,880
26-27
102.2
27
6.7-7.5
15-16.5
16
1,630
3,600
27-28
102.2
27
6.8-7.2
15-16.5
20
2,040
4,500
28-29
102.2
27
6.9-7.9
15.5-17
17
1,730
3,830
7-Day Avg.
100.3
26.5
27
2,750
6,070
-------
Table 4 (continued)
SUMMARY OF FIELD MEASUREMENTS AND TOTAL SUSPENDED SOLIDS ANALYSES
Flow Total Suspended Sol Ids
Station Description
Date
(Oct.)
m3/day
X 103
mgd
pH
Range
Temp.
Range
(°C)
Gross
Cone,
mg/l
Gross
Load
kg/day lb/day
Net
Cone.
mg/l
Net
Load
kg/day lb/day
Outfall 117
22-23
91.6
24.2
6.5-7.4
18.5-23
60
5,500
12,100
19
1,740 3,830
23-24
96.9
25.6
6.9-7.1
19-23
59
5,700
12,600
24
2,320 5,120
2-Day Avg.
94.2
24.9
59 .
5,600
12,350
22
2,030 4,475
West Run Culvert
22-23
3.75
0.99
6.6-7.2
17-19
49 9
0
0
upstream of
23-24
3.41
0.90
6.8-7.9
14-17.5
9
31
65
8th Ave.
2-Day Avg.
3.58
0.95
West Run Culvert
22-23
90.1
23.8
6.4-6.9
18-22
55
4,950
10,900
at river (017)
23-24
92.7
24.5
6.7-7.1
19-22
57
5,280
11,650
2-Day Avg.
91.6
24.2
56
5,115
11,275
Screen backwash
23
Not Determined
7.4
15.5
39
water from h
24
Not Determined
7.4
17
24
Intake 4-44
25
Not Determined
6.9
17
19
27
Not Determined
7.4
15.5
21
28 /
Not Determined
7.0
17
3
5-Day Avg.'
21
aTSS samples were collected from 6 a.m. to 6 a.m. and composited on a flow-weighted basis. The date 22-23 indicates the time period
6 a.m. to midnight Oct. 22 and midnight to 6 a.m. Oct. 23.
toIntake 3-24 data is used for NET calculations for outfalls 006, 010, Oil, 012, and 013.
0NET loads for outfall 022 calculated from background loads found in the Munhall Storm Sewer upstream location. The net concentra-
tions were calculated from the NET loads, based on the NET flow (NET flows = outfall Oil flow minus Munhall sewer upstream flow).
Only on Oct. 27-28 and 28-29 did the NET concentrations exceed the background TSS concentrations for Intake 3-24. The NET concen-
trations over the intake for Oct. 27-28 and 28-29 were 5 mg/l and 6 mg/l, respectively, corresponding to NET loads of 10 kg
(23 lb)/day and 13 kg (29 lb)/day.
^Flows reported are total discharged through outfall.
®Intake 4-44 data (sampled after straining) used for NET calculations for outfalls 014, 015, 115 and 016.
I Intake 5-51 data (sampled after straining) used for NET calculations for outfall 017.
9 Oct. 22-23 samples collected about 45 m (ISO ft) inside culvert, about 76 m (250 ft) downstream of flow measurement site. Moni-
tored at this location to determine background concentrations of domestic waste which was flowing into the culvert, apparently
from a broken sewer pipe. Waste loads were not calculated since flows not measured at sample site. However, samples were com-
posited on a flow-weighted basis as the domestic waste inflow'was assumed constant.
hScreen backwash sampled once/day on grab basis if discharge occurred.
' Arithmetic average
-------
Station Description Date Gross/ Total Iron
(Oct.) rog/i kg/day lb/day
Intake 3-24c
Effluent from
48-1n. mill
settling basin
(006)
Effluent from
structural mill
settling basin
(010)
22-23
G
1.4
154
339
23-24
G
1.3
129
284
24-25
G
1.6
136
300
25-26
G
1.3
128
282
26-27
G
1.8
159
351
27-28
G
1.3
110
242
28-29
G
1.3
124
273
7-Day Average®
G
1.4
134
296
22-23
G
3.6
15
32
23-24
G
1.9
10
22
24-25
G
2.5
13
29
25-26
G
2.6
14
30
26-27
G
1.1
4
8
5-Day Average®
G
2.4
11
24
22-23
N
2.2
9
20
23-24
N
0.6
3
7
24-25
N
0.9
5
11
25-26
N
1.3
7
15
26-27
N
0
0
0
5-Day Average8
N
1.4
5
11
22-23
G
3.5
207
455
23-24
G
2.9
172
380
24-25
G
2.6
150
330
25-26
G
2.8
165
364
26-27
G
2.4
142
312
27-28
G
2.6
151
332
28-29
G
3.7
221
489
7-Day Average®
G
2.9
173
380
22-23
N
*1.1
65
143
23-24
N
1.6
95
210
24-25
N
1.0
58
127
25-26
N
1.5
89
195
26-27
N
0.6
35
78
27-28
N
1.3
75
166
28-29
N
1.4
84
184
7-Day Average®
N
1.2
71
158
Table 6
SUMMARJ OF METALS ANALYSES8
USSC HOMESTEAD MAIN WORKS
October' 22-29, 197S
Dissolved Iron Total Chromium1' Zinc lead US
mg/l kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day
0.7
77
169
<0.01
-d
0.02
2.2
4.8
<0.05
.
<0.5
-
-
<0.01
-
.
<0.01
-
-
0.04
4.0
8.7
<0.05
-
-
0.7
69
153
0.01
1
2
<0.01
_
_
0.04
3.4
7.5
<0.05
-
-
<0.5
-
-
0.3
30
65
0.01
1.0
2.2
0.03
3.0
6.5
0.07
6.9
15
0.7
69
152
0.7
62
137
0.02
1.8
3.9
0.04
3.5
7.8
<0.05
.
-
<0.5
-
-
0.02
2
4
<0.01
_
-
0.02
1.7
3.7
<0.05
-
-
<0.5
-
-
0.1
10
21
<0.01
-
-
0.01
1.0
2.1
<0.05
-
-
<0.5
-
-
0.3
26
57
<0.01
0.4
0.9
0.028
2.7
5.9
0.01
1.0
2.1
0.2
20
44
1.4
6
13
0.01
0.04
0.1
0.04
0.2
0.4
0.08
0.3
0.7
<0.5
-
-
0.03
0.2
0.4
<0.01
.
.
0.02
0.1
0.2
0.05
0.3
0.6
<0.5
-
-
0.02
0.1
0.2
<0.01
_
-
0.03
0.2
0.4
0.05
0.3
0.6
<0.5
-
-
0.04
0.2
0.5
<0.01
-
-
0.03
0.2
0.4
<0.05
-
-
<0.5
-
-
0.08
0.3
0.6
<0.01
-
-
0.02
0.1
0.2
0.06
0.2
0.5
<0.5
-
•
0.3
1.3
2.9
<0.01
0.01
0.02
0.03
0.2
0.3
0.05
0.2
0.5
<0.5
0.7
3
6
0.01
0.04
0.1
0.02
0.1
0.2
0.08
0.3
0.7
o'
0
0
0.03
0.2
0*4
0
0
0
o'
0
0
0.05
0.3
0.6
0
0
0
0.01
0.05
0.1
0
0
0
0
0
0
0.05
0.3
0.6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.06
0.2
0.5
0
0
0
0
0
0
0
0
0
0
0
0
0.2
0.6
1.4
<0.01
0.01
0.02
0.01
0.02
0.04
0.05
0.2
0.4
0
0
0
1.2
71
156
<0.01
_
0.01
0.6
1.3
<0.05
_
_
<0.5
-
-
<0.01
.
.
<0.01
_
-
0.02
1.1
2.6
0.07
4.2
9.2
<0.5
-
-
<0.01
-
-
<0.01
.
-
0.03
1.7
3.8
0.07
4.0
8.9
<0.5
-
-
0.01
0.6
1.3
<0.01
-
-
0.02
1.2
2.6
<0.05
-
-
<0.5
-
-
0.02
1.2
2.6
<0.01
-
-
0.12
7.1
15.6
<0.05
-
-
<0.5
-
-
0.1
6
13
<0.01
_
.
<0.01
-
-
0.05
2.9
6.4
<0.5
-
-
<0.01
-
-
<0.01
-
-
<0.01
-
-
0.05
3.0
6.6
<0.5
-
—
0.19
11
25
<0.01
-
-
0.03
1.7
3.7
0.04
2.3
5.2
<0.5
-
-
0.5
30
65
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
¦ 0
0.07
4.2
9.2
0
0
0
0
0
0
0
0
0
0
0
0
0.07
4.0
8.9
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
. 0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0.05
2.9
6.4
0
0
0
0
0
0
0
0
0
0
0
0
0.05
3.0
6.6
0
0
0
0.07
4
9
0
0
0
0
0
0
0.03
2.0
4.4
0
0
0
-------
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Table S (Continued)
SUMMARY OF METAtS ANALYSES0
Station Description
Date Gross,/
(Oct.) ^Net
Total Iron Dissolved Iron Total Chromium6 Zlric Lead
mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day
Kunhall Sewer
upstream of
outfall 011
Outfall 011
Outfall 012
22-23
G
0.3
0.19
0.41
0.2
0.12
0.27
<0.01
.
_
0.03
0.02
0.04
0.07
0.05
0.10
23-24
G
0.6
0.40
0.89
0.1.
0.07
0.15
<0.01
.
-
0.04
0.03
0.06
0.05
0.03
0.07
24-25
G
0.4
0.24
0.54
0.07
0.04
0.09
<0.01
.
.
<0.01
-
.
<0.05
.
.
25-26
G
0.4
0.21
0.47
0.07
0.04
0.08
<0.01
-
-
0.02
0.01
0.02
0.07
0.04
0.08
26-27
G
0.4
0.12
0.28
0.3
0.09
0.20
0.02
0.006
0.013
0.01
0.003
0.01
0.05
0.02
0.03
27-28
G
0.4
0.12
0.28
0.07
0.02
0.05
<0.01
-
_
0.01
0.003
0.01
<0.05
.
28-29
G
0.3
0.1
0.22
0.1
0.03
. 0.07
<0.01
-
-
0.03
0.01
0.02
<0.05
-
-
7-Day Average*
G
0.41
0.20
0.44
0.12
0.06
0.13
<0.01
0.001
0.002
0.02
0.01
0.02
0.04
0.02
0.04
22-23
G
1.8
8.4
18.5
0.8
3.73
8.21
<0.01
m
0.01
0.05
o.io
<0.05
_
23-24
G
2.0
11.3
24.9
0.05
0.28
0.62
0.02
0.11
0.25
0.01
0.06
0.12
<0.05
.
_
24-25
G
1.6
6.9
15.2
<0.01
-
-
<0.01
-
.
<0.01
-
-
<0.05
.
_
25-26
G
1.4
5.2
11.4
0.3
1.11
2.45
<0.01
-
.
0.02
0.07
0.16
<0.05
.
.
26-27
G
1.0
2.1
4.7
0.05
0.11
0.23
<0.01
.
.
<0.01
.
_
<0.05
-
_
27-28
G
2.0
4.7
10.3
0.07
0.16
0.36
<0.01
.
-
<0.01
.
_
<0.05
.
-
28-29
G
2.5
6.3
14.0
0.06
0.15
0.34
<0.01
-
-
<0.01
-
-
<0.05
-
-
7-Day Average®
G
1.76
6.4
14.1
0.22
0.79
1.74
<0.01
0.02
0.04
0.01
0.02
0.05
<0.05
22-23
N
0.6
2.4
5.4
0.2
0.81
1.8
0
0
0
0
0
0
0
0
0
23-24
N
0.9
4.5
9.8
0.04
0.2
0.4
0.02
tu
0.2
0
0
0
0
0
0
24-25
N
0.2
0.7
1.6
0
0
0
0
. 0
0
0
0
0
0
0
0
25-26
N
0.3
1.0
2.1
0.34
1.1
2.4
0
0
0
0
0
0
0
0
0
26-27
N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
27-28
N
0.9
1.8
4.1
0.05
0.1
0.2
0
0
0
0
0
0
0
0
0
28-29
N
1.6
3.5
7.7
0
0
0
0
0
0
0
0
0
0
0
0
7-Day Average8
N
0.3
2.0
4.4
0.09
0.3
0.7
<0.01
0.01
0.03
0
0
0
0
0
0
22-23
G
1.7
97
212
0.8
45
100
<0.01
_
0.01
0.57
1.25
<0.05
_
23-24
G
1.6
63
139
¦0.01
0.4
0.9
<0.01
-
.
0.02
0.79
1.74
0.05
1.97
4.34
24-25
G
1.9
38
84
<0.01
.
-
<0.01
-
.
0.01
0.20
0.44
0.05
1.01
2.22
25-26
G
1.2
28
61
0.01
0.2
0.5
<0.01
-
_
0.02
0.46
1.01
0.06
1.38
3.03
26-27
G
1.4
53
117
' 0.04
1.5
3.3
<0.01
.
<0.01
.
-
<0.05
-
-
27-28
G
1.3
39
85
<0.01
-
-
<0.01
-
-
<0.01
-
-
<0.05
-
.
28-29
G
1.4
29
63
0.6
12.3
27
<0.01
-
-
<0.01
-
-
<0.05
-
-
7-Day Average9
G
1.5
49
109
0.26
8.5
18.8
<0.01
-
-
0.01
0.29
0.63
0.01
0.36
0.80
22-23
N
0.3
17
38
0.1
6
13
0
0
0
0
0
0
0
0
0
23-24
N
0.3
12
26
0.01
0.4
1
0
0
0
0
0
0
0.05
1.01
4.34
24-25
N
0.3
6
13
0
0
0
0
0
0
0
0
0
0.05
1.38
2.22
25-26
N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
26-27
N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
27-28
N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
28-29
N
0.1
2
5
0.5
10.2
23
0
0
0
0
0
0
0
0
0
7-Day Average®
N
0.16
5
12
0.07
2.4
5
0
0
0
0
0
0
0.01
0.43
0.94
-------
0
0
0
0
0
0
0
0
790
112
Table S (Continued)
SVHHARS OF METALS ANALYSES3
Station Description Date Gross/
(Oct.) /'Net
Total Iron
Dissolved Iron
Total Chromium
Zinc
Lead
mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day irg/1 kg/day lb/day
Outfall 013
Intake 4-44
at river
Intake 4-44
after strainers
Outfall 014
22-23
6
1.4
11
24
<0.01
_
.
0.01
0.08
0.17
0.02
0.16
0.35
<0.05
-
-
23-24
G
1.6
23
51
0.0*
0.29
0.63
0.01
0.14
0.32
0.04
0.57
1.26
<0.05
24-25
G
1.6
5
12
0.03
0.10
0.23
0.02
0.07
0.15
0.03
0.10
0.23
<0.05
25-26
G
1.2
3
7
0.01
0.03
0.06
<0.01
-
-
0.03
0.08
0.18
<0.05
-
-
26-27
G
1.2
3
8
0.05
0.14
0.31
<0.01
-
-
0.02
0.06
0.13
<0.05
-
-
27-28
G
1.1
4
9
0.03
0.11
0.24
0.03
0.11
0.24
0.02
0.07
0.16
<0.05
-
-
28-29
G
1.05
3
8
0.04
0.13
0.29
0.01
0.03
0.07
<0.01
-
-
<0.05
-
-
7-Day Average®
G
1.40
8
17
0.02
0.11
0.25
0.01
0.06
0.14
0.03
0.15
0.33
' <0.05
-
-
22-23
N
0
0
0
_
-
_
0.01
0.08
0.17
0
0
0
0
0
0
23-24
N
0.3
4.3
9
0.02
0.29
0.63
0.01
0.14
0.32
0
0
0
0
0
0
24-25
N
0
0
0
0.02
0.07
0.15
0.02
0.07
0.15
0
0
0
0
0
0
25-26
N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
26-27
N
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
27-28
N
0
0
0
0.01
0.04
0.08
0.03
0.11
0.24
0
0
0
0
0
0
28-29
N
0
0
0
0
0
0
0.01
0.03
0.07
0
0
0
0
0
0
7-Day Average®
N
0.1
0.6
1.3
0.01
0.06
0.12
0.01
0.06
0.14
0
0
0
0
0
0
22-23
G
1.7
725
1,600
0.01
4
9
<0.01
_
0.02
9
19
<0.05
-
-
23-24
G
1.8
715
1,575
0.02
8
18
0.01
4
9
0.02
8
18
<0.05
-
-
24-25
G
2.4
825
1,820
<0.01
-
-
<0.01
-
-
0.03
10
23
0.07
24
53
25-26
G
1.6
515
1,135
<0.01
.
-
<0.01
-
-
<0.01
-
-
<0.05
-
-
26-27
G
1.6
515
1,135
_
-
_
<0.01
-
-
<0.01
-
-
<0.05
-
-
27-28
G
1.4
450
990
0.1
32
71
0.01
3
7
<0.01
-
-
0.05
16
35
28-29
G
1.6
515
1,135 '
0.05
16
35
<0.01
-
-
0.01
3
7
<0.05
-
-
7-Day Average®
G
1.74
610
1,340
0.02
9
19
<0.01
1
3
0.01
4
10
0.02
6
13
22-23
G
1.8
770
1,700
<0.01
_
<0.01
_
0.02
9
19
<0.05
-
-
23-24
G
2.0
795
1,750
•0.04
16
35
<0.01
-
-
0.02
8
18
<0.05
-
-
24-25
G
2.6
895
1,970
<0.01
-
_
<0.01
-
-
0.02
7
15
<0.05
-
-
25-26
G
1.6
515
1,135
0.03
10
21
<0.01
-
-
<0.01
-
-
<0.05
-
-
26-27
G
1.6
515
1,135
0.10
32
71
<0.01
-
-
<0.01
-
-
<0.05
-
-
27-28
G
1.4
450
990
0.27
87
191
0.01
3
7
<0.01
-
-
<0.05
-
-
28-29
G
1.5
480
1,060
0.05
16
35
0.01
3
7
0.03
10
21
<0.05
-
-
7-Day Average®
G
1.8
630
1,390
0.07
23
50
<0.01
1
2
0.01
5
10
<0.05
-
-
22-23
G
1.7
27
59
0.06
1.0
2.1
0.01
0.16
0.35
0.01
.
.
0.05
0.79
1.74
23-24
G
1.9
44
97
0.02
0.5
1.0
0.02
0.46
1.02
0.02
0.46
1.02
0.05
-
-
24-25
G
1.9
30
67
0.04
0.6
1.4
0.02
0.32
0.70
0.01
-
-
0.05
-
-
25-26
G
1.4
16
36
0.04
0.5
1.0
0.01
-
-
0.01
-
-
0.05
-
-
26-27
G
1.4
18
39
0.03
0.4
0.8
0.01
-
•
0.01
-
-
0.05
-
-
27-28
G
1.3
16
35
0.06
0.7
1.6
0.01
-
-
0.01
-
-
0.05
-
-
28-29
G
1.2
13
28
0.06
0.6
1.4
0.01
-
-
0.01
0.11
0.23
0.05
-
-
7-Day Average®
G
1.6
23
52
0.04
0.6
1.3
0.01
0.13
0.30
0.01
0.08
0.18
0.01
0.11
0.25
-------
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Table S (Continued)
SUMMARY OP METALS ANALYSES8
Station Description
Date Gross/
(Oct.) /"Net
Total Iron
Dissolved Iron
Total Chromium
Z1nc
lead
mg/1 kg/day lb/day mg/.l kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day
Outfall 014
(cont.)
Outfall 115
Outfall 015
22-23
23-24
24-25
25-25
26-27
27-28
28-29
22-23
23-24
24-25
25-26
26-27
27-28
28-29
22-23
23-24
24-25
25-26
26-27
27-28
28-29
22-23
23-24
24-25
25-26
26-27
27-28
28-29
7-Day Average® N
7-Day Average® G
7-Day Average® N
2.0
2.0
1.9
1.6
1.7
1.7
1.5
0.2
0
0
0
0.1
0.3
0
0.1
2.0
2.3
2.1
1.8
1.6
1.4
1.5
108
95
88
82
82
76
74
1.8 86
11
0
0
0
5
13
0
610
635
670
470
475
395
425
237
209
195
180
180
167
164
190
24
0
0
0
11
30
0
1,340
1,400
1,480
1,030
1,050
875
940
0.06
0
0.04
0
0
0
0
1.0
0
0.6
0
0
0
0
0.02 0.2
0.04
<0.01
<0.01
<0.01
0.04
0.16
<0.01
2.2
1.9
7.2
0.03 1.6
0.04
0
0
0
0
0
0
2.2
0
0
0
0
0
0
0.01 0.3
0.05
0.01
0.04
0.02
0.05
0.06
0.06
15
3
13
5
15
17
17
2.1
0
1.4
0
0
0
0
0.5
5
4
16
5
0
0
0
0
0
0
0.7
34
6
28
11
33
38
38
0.01
0.02
0.02
0
0
0
0
0.1
<0.01
0.01
<0.01
<0.01
<0.01
<0.01
<0.01
0
0.01
0
0
0
0
0
<0.01
0.02
<0.01
0.02
<0.01
<0.01
<0.01
0.16 0.35
0.46 1.02
0.32 0.70
0 0
0.13 0.30
0.47 1.04
0 0
0.47 1.04
5.5 12
5.2 11
0.12
0.07
0.02
0.14
0.03
0.11
0.03
6.5
3.3
0.9
7.2
1.4
4.9
1.5
<0.01 0.07 0.15 0.08 3.7
0.10
0.05
0
0.14
0.03
0.11
0.02
5.4
2.4
0
7.2
1.4
4.9
1.0
<0.01 0.07 0.15 0.07 3.2
0.02
0.02
0.02
0.01
<0.01
<0.01
0.01
6.1
5.5
6.4
2.6
2.8
14
7
2
16
3
11
3
12
5
0
16
.3
11
2
13
12
14
6
0.05
0
0
0
0
0
0
0.79
0
0
0
0
0
0 •
<0.05
0
0
0
0
0
0
0
0.06
<0.05
<0.05
<0.05
<0.05
<0.05
<0.05
18
1.74
0
0
0
0
0
0
0.01 0.11 0.25
<0.05 -
<0.05 -
<0.05 -
<0.05 -
<0.05 -
<0.05 -
<0.05 -
40
7-0ay Average® 6
1.82 525 1 ,160
0.04 12
27
0.01 1.5
0.01 3.3
0.01 2.6
-------
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
>2!
Ill
41
Table S (Continued)
SUMMARY OF METALS ANALYSES*
Station Description Date Gross/' Total Iron Dissolved Iron Total Chromium1* Zinc Lead
(Oct.) /'Net kg/jay ib/day mg/1 kg/day lb/day ng/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day
Outfall 015
22-23
N
0.2
61
135
0.05
15
(cont.)
23-24
N
0.3
83
180
0
0
24-25
N
0
0
0
0.04
13
25-26
N
0.2
52
115
0
0
26-27
N
0
0
0
0
0
27-28
N
0
0
0
0
0
28-29
N
0
0
0
0
0
7-Day Average®
N
0.1
28
61
0.01
4
Outfall 016
22-23
G
3.6
455
1,010
<0.01
.
23-24
G
4.6
535
1,175
0.02
2
24-25
G
3.6
345
765
<0.01
-
25-26
G
2.0
185
415
<0.01
-
26-27
G
4.3
365
805
0.07
6
27-28
G
4.2
390
865
0.02
2
28-29
G
3.1
410
905
0.04
5
7-Day Average®
G
3.6
385
850
0.02
2
22-23
N
1.8
230
505
0
0
23-24
N
2.6
300
665
0
0
24-25
N
1.0
95
210
0
0
25-26
N
0.4
35
80
0
0
26-27
N
2.7
230
505
0
0
27-28
N
2.8
260
575
0
0
28-29
N
1.6
210
465
0
0
7-0ay Average®
N
1.8
195
430
0
0
Intake 5—51
22-23
G
1.6
140
315
0.01
0.9
at river
23-24
G
2.2
225
495
0.02
2.0
24-25
G
2.0
205
450
0.01
0.9
25-26
G
1.6
165
360
<0.01
-
26-27
G
1.4
145
315
0.02
2.0
27-28
G
1.2
120
270
0.16
16.4
28-29
G
1.4
145
315
0.01
0.9
7-Day Average®
G
1.6
160
360
0.03
3.4
Intake 5-51'
22-23
G
2.4
215
470
0.05
4.6
after strainers
23-24
G
3.2
325
720
0.04
4.1
24-25'
G
2.5
255
560
0.03
3.1
25-26
G
2.6
265
585
<0.01
-
26-27
G
2.1
215
470
0.02
2.0
27-28
G
1.6
165
360
0.09
9.2
28-29
G
1.9
195
425
0.09
9.2
7-Day Average®
G
2.3
235
515
0.05
4.6
34
0
0
0
0
0
0
0.06
18
40
0
0.02
5.5
12
0
0
0
0
0
0
28
0
0
0
0
0
0
0
0
0
0
0.02
5.2
11
0.01
2.6
6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
9
0.01
1.5
3
<0.01
0.4
1
0.01
2.6
5.7
<0.01
0.02
2.5
6
<0.05
_
.
5
0.03
3.5
8
0.02
2.3
5
<0.05
-
-
_
0.02
1.9
4
0.02
1.9
4
0.08
7.7
17
-
0.02
1.9
4
0.02
1.9
4
<0.05
-
-
13
0.02
1.9
4
0.02
1.7
4
<0.05
-
-
4
0.03
2.8
6
0.01
0.9
2
<0.05
-
-
12
0.03
4.0
9
0.01
1.3
3
<0.05
-
-
5
0.02
2
5
0.017
1.8
4
0.01
1.1
2
0
0
0
0
0
0
0
0
0
0
0
0.03
3.5
8
0
0
0
0
0
0
0
0.02
1.9
4
0
0
0
0.08
7.7
17
0
0.02
1.9
4
0.02
1.9
4
0
0
0
0
0.02
1.9
4
0.02
1.9
4
0
0
0
0
0.02
1.9
4
0
0
0
0
0
0
0
0.02
2.7
6
0
0
0
0
0
0
0
0.02
1.9
4
<0.01
0.5
1
0.01
1.1
2
2
0.01
0.9
2
0.01
0.9
2
0.06
5.2
12
5
<0.01
.
.
0.02
2.0
5
0.05
5.1
11
2
<0.01
_
-
0.02
2.0
5
0.05
5.1
11
-
0.01
0.9
2
0.02
2.0
5
<0.05
-
-
5
<0.01
-
-
0.01
0.9
2
<0.05
-
-
36
0.02
2.0
5
<0.01
-
-
<0.05
-
-
2
0.12
12.4
27
0.01
0.9
2
0.05
5.1
11
7
0.02
2.3
5
0.01
1.4
3
0.03
2.9
6
10
0.01
0.9
2
0.04
3.6
8
<0.05
_
_
9
0.03
3.1
7
0.05
5.1
11
<0.05
-
-
7
0.03
3.1
7
0.05
5.1
11
<0.05
-
-
-
0.04
4.1
9
0.05
5.1
11
<0.05
-
-
5
0.03
3.1
7
0.04
4.1
9
<0.05
-
-
20
0.02
2
5
0.03
3.1
7
<0.05
-
-
20
0.02
2
5
0.04
4.1
9
<0.05
-
-
10
0.026
2.6
6
0.043
4.3
9
<0.05
.
.
-------
Table 5 (Continued)
SUMMARY OF METALS ANALYSES 8
Station Description
Date Gross/
(Oct.) /Net
Total Iron
Dissolved Iron
Total Chromium
Zinc
Lead
Tin
mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day mg/1 kg/day lb/day
Outfall 117
22-23
G
6.3
575
1,270
0.05
4.6
10
<0.01
0.02
1.9
4
0.06
5.5
12
<0.5
23-24
G
8.5
825
1,815
0.02
1.9
4
<0.01
-
-
0.02
1.9
4
<0.05
-
-
<0.5
-
-
2-Day
Average®
G
7.4
700
1.545
0.03
3.3
7
<0.01
-
-
0.02
1.9
4
0.03
2.7
6
<0.5
-
-
22-23
N
3.9
355
785
0
0
0
0
0
0
0
0
0
0.06
5.5
12
0
0
0
23-24
N
5.3
515
1,130
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2-Day
Average®
N
4.6
435
955
0
0
0
0
0
0
0
0
0
0.03
2.7
6
0
0
0
West Run Culvert
22-23
G
0.4
1.5
3
0.07
0.3
0.6
<0.01
0.04
0.15
0.33
<0.05
m
m
1.2
4.5
10
upstream of 8th Ave.
23-24
G
0.6
2.0
5
<0.01
-
-
<0.01
-
-
<0.01
-
-
<0.05
•
•
0.7
2.4
5
2-0ay
Average
G
0.49
1.8
4
0.04
0.14
0.3
<0.01
-
-
0.02
0.07
0.16
<0.05
-
-
0.957
3.4
7.5
West Run Culvert
22-23
G
4.3
385
855
<0.01
<0.01
_
0.01
0.90
2
<0.05
m
<0.5
.
_
at rlner (017)'
23-24
G
6.1
565
1,245
0.04
3.7
8
0.01
0.90
2.0
0.02
1.9
4
<0.05
<0.5
-
-
2-Day
Average
G
5.2
475
1,050
0.02
1.8
4
<0.01
0.5
1.0
0.015
1.4
3
<0.05
-
-
<0.5
-
-
22-23
N
2.1
180
400
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
23-24
N
3.1
275
610
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
2-Day
Average
N
2.6
230
505
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
Based on 24-hr, flan-weighted, composite samples. Flows are listed in Table 4. Metal samples were collected from 6 a.m. to 6 a.m. and composited
on a flow-weighted basis. The date ZZ-ZZ indicates the time period 6 a.m. to nridnight Oat. 22 and midnight to 6 a.m. Oat. 23.
Hexavalent chromium concentrations were less than total chromium concentrations.
G Intake 3-24 data used to calculate NET loads for outfalls 006, 010, Oil, 012 and 013,
Whenever a value is reported as "<" (less than), the value is considered as zero and load was not calculated, but value included in the outraging.
• Flat-weighted average.
' For SET calculations, whenever GROSS concentration was equal to or less than the intake concentration, the value i>as reported as aero*
® HPT loads and concentrations calculated as follows:
(GROSS load discharged from Oil) - (GROSS load in Munhall Sewer) = CGROSS USSC load in Oil)
(GROSS USSC load) ~ (flcu from Oil-flow from Munhall Sewer) X 8.34 = (GROSS USSC concentration in Oil)
(GROSS USSC concentration) - (intake concentration) ¦» (NET USSC concentration)
(NET USSC concentration) X 8.34 X (flow Oil-flow Munhall Sewer) - (NET USSC load)
*Intake 4-44 after strainers used to calculate NET loads for outfalls 014, 015, 11S and 016.
' Intake SSI after strainers used to calculate NET loads for outfall 117.
I UST loads and concentrations calculated as follows:
(GROSS load in West Fun Culvert) - (GROSS load in West Run Culvert upstream 8th Ave.) = (NET lead West Run Culvert)
(NET load West Run Culvert) * (Flow West Run Culvert - Plan West Run Culvert upstream 8th Ave.) X 8.34 » (GROSS concentration
West Run Culvert)
(GROSS concentration West Run Culvert) - (Intake 6-61 concentration) • (NET concentration)
(NET concentration) X (FUxi fleet Run Culvert - flan West Run Culvert vpstrean of 8th Avenue) X 8. S4 • (BET load)
-------
Table 6
SUMAFY OF OIL AND GREASE AND PHENOL ANALYSESa
USSC HOMESTEAD MAIN WORKS
Oatober 22-29, 197S
Time of
Station Description Date Collection Instantaneous Flowb 011 and Greaseg(Gross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) mVday mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Intake 3-24rf
22
1040
140
37
2
280
615
<0.01
1435
95
25
2
190
415
<0.01
1850
121
32
1
120
270
<0.01
2250
95
25
<0.01
Dally Average'
110
29
2
195
435
<0.01
23
1030
140
37
3
420
925
<0.01
1450
140
37
<1
e
-
<0.01
1845
140
37
<1
-
-
<0.01
2245
95
25
<0.01
Daily Average
98
26
1
140
l
310
<0.01
24
1040
95
25
<1
<0.01
1455
95
25
• <1
.
-
<0.01
1855
95
25
<1
-
.
<0.01
2235
76
20
<0.01
Dally Average
87
23
<1
-
<0.01
25
1025
95
25
2
190
415
1455
95
25
<1
-
-
<0.01
1840
95
25
<1
•
-
<0.01
2240
95
25
<0.01
Dally Average
87
23
1
65
140
<0.01
26
1045
95
25
<1
m
1440
95
25
<1
-
-
<0.01
1830
95
25
<1
-
-
<0.01
2225
76
20
<0.01
Dally Average
<1
-
•
<0.01
27
0940
76
20
<1
1535
95
25
3
285
625
<0.01
1825
95
25
2
190
415
<0.01
2120
95
25
<0.01
Dally Average
87
23
2
160
345
<0.01
-------
Table 6 (Continued)
SUMMARY OP OIL AND GREASE AND PHENOL ANALYSES0
Time of
Station Description Date Collection
(Oct.) (hours)
Instantaneous Flowb Oil and Greasec(Gross)
m3/day mgd mg/1 kg/day lb/day
X 103
Oil and Grease (Net) Phenol (Gross)
mg/1 kg/day lb/day (mg/1)
Intake 3-24
(cont.)
Outfall 006
28
0925
95
25
<1
-
-
1535
95
25
1
95
210
<0.01
1820
95
25
1
95
210
<0.01
2120
76
20
<0.01
Dally Average
95
25
1
65
140
<0.01
7-Day Average5
95
25
1
90
195
<0.01
22
1215
4.2
1.1
6
25
55
1615
3.0
0.8
7
20
47
<0.01
2025
2.3
0.6
<0.01
23 h
0010
2.3
0.6
13
30
65
<0.01
Dally Average
4.2
1.1
6
25
56
4
17
37
<0.01
23
1220
5.1
1.4
8
41
90
1630
3.8
1.0
7
26
58
<0.01
2030
3.6
0.9
7
25
55
<0.01
24
0020
3.6
0.9
<0.01
Dally Average
5.3
1.40
6
31
68
5
26
58
<0.01
24
1210
5.7
1.5
5
28
63
1620
4.2
1.1
6
25
55
<0.01
2020
4.2
1.1
14
56
125
<0.01
25
0005
4.2
1.1
<0.01
Dally Average
5.3
1.4
7
36
80
7
36
80
<0.01
25
1210
5.9
1.6
5
29
65
1610
3.4
0.9
5
17
38
<0.01
2010
3.4
0.9
7
23
51
<0.01
26
• 0005
3.4
0.9
<0.01
Dally Average
5.2
1.4
4
23
51
3
16
35
26
1200
3.0
0.8
3
9
20
1615
3.0
0.8
3
9
19
<0.01
2005
3.0
0.8
2
6
12
<0.01
27
0005
3.0
0.8
<0.01
Dally Average
3.4
0.9
2
8
17
2
8
17
<0.01
5-Day Average'
4.7
1.2
5
25
54
4
21
45
<0.01
-------
Table 6 (Continued)
SUMMARY OP OIL AND GREASE AND PHENOL ANALYSES8
Time of
Station Description Date Collection Instantaneous F1owb Oil and Grease^tGross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Outfall 010
22
1120
56.4
14.9
7
395
870
1520
56.4
14.9
6
340
745
<0.01
1955
59.8
15.8
3
180
395
<0.01
2330
59.8
15.8
<0.01
Dally Average
59.0
15.6
5
305
670
3
175
390
<0.01
23
1110
62.8
16.6
6
375
830
1610
62.8
16.6
6
375
830
<0.01
1940
54.5
14.4
5
275
600
<0.01
2345
60.2
15.9
<0.01
Dally Average
59.4
15.7
6
340
750
5
295
655
<0.01
24
1125
57.9
15.3
4
230
510
1550
62.8
16.6
4
250
550
<0.01
1945
48.8
12.9
3
145
320
<0.01
2305
56.4
14.9
<0.01
Dally Average
57.5
15.2
4
210
460
4
210
460
<0.01
25
1130
59.8
15.8
2
120
260
1545
58.3
15.4
3
175
380
<0.01
1920
57.9
15.3
3
175
380
<0.01
2320
57.2
15.1
<0.01
Dally Average
59.0
15.6
3
155
340
2
120
260
<0.01
26
1125
59.8
15.8
3
180
395
1525
59.8
15.8
2
120
260
<0.01
1915
56.4
14.9
<1
-
-
<0.01
2315
59.8
15.8
<0.01
Dally Average
59.0
15.6
2
115
250
2
115
250
<0.01
27
1035
59.8
15.8
2
120
260
1635
56.4
14.9
6
340
750
<0.01
1905
54.5
14.4
4
220
480
<0.01
2315
56.4
14.9
<0.01
Dally Average
57.9
15.3
4
225
500
3
175
380
<0.01
28
1030
69.3
18.3
8
555
1,200
1610
62.8
16.6
4
250
550
<0.01
1900
59.8
15.8
2
120
260
<0.01
2155
55.3
14.6
<0; 01
Dally Average
59.8
15.8
5
310
680
4
240
530
<0.01
7-Day Average
58.7
15.5
4
235
520
3
190
420
<0.01
-------
Tab 'Ca i)
SUMMARY OF OIL AND CREASE AND PHENOL ANALYSES6
Time Of .
Station Description Date Collection Instantaneous Flow 011 and Grease0(Gross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/dav mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Munhall Sewer,
upstream of
Outfall Oil
Outfall Oil
22
1025
0.87
0.23
8
7
16
1420
0.64
0.17
8
5
12
1835
0.61
0.16
25
15
33
Dally Average
0.61
0.16
15
9
20
23
1015
0.79
0.21
25
19
41
1430
0.68
0.18
200
135
290
1830
0.68
0.18
14
9
21
Dally Average
0.68
0.18
80
53
120
24
1020
0.64
0.17
8
5
12
1435
0.57
0.15
23
13
28
1835
0.64
0.17
13
8
18
Dally Average
0.61
0.16
14
9
19
25
1010
0.72
0.19
14
10
22
1445
0.61
0.16
11
7
14
1830
0.64
0.17
15
10
21
Dally Average
0.53
0.14
16
9
19
26
1020
0.30
0.08
9
3
6
1425
0.34
0.09
<1
-
-
1820
0.26
0.07
29
8
16
Dally Average
0.03
0.08
11
3
7
27
0920
0.30
0.08
10
3
7
1515
0.38
0.10
4
2
3
1810
0.34
0.09
36
12
26
Dally Average
0.30
0.08
17
5
12
28
0910
0.34
0.04
14
5
11
1500
0.38
0.10
4
1
3
1810
0.34
0.09
7
2
5
Dally Average
0.34
0.09
9
3
6
7-Day Average
0.49
0.13
27
13
29
1040
6.0
1.6
10
60
130
1445
4.5
1.2
19
89
195
1855
4.5
1.2
8
36
79
Dally Average
4.5
1.2
13
62
135
23
1030
6.0
1.6
7
42
93
1450
7.2
1.9
9
64
140
1845
5.7
1.5
13
72
160
Dally Average
5.7
1.5
11
59
130
11
44
98
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES *
-P»
r\>
o
-h
r\j
u>
Station Description Date
(Oct.)
Time of
Collection
(hours)
Instantaneous Flowb
m3/day mgd
X 103.
011 and Grease °(Grossj
mg/1 kg/day lb/day
011 and Grease (Net)
mg/1 kg/day lb/day
Phenol (Gross)
(mg/1)
Outfall on1
24
1040
5.2
1.4
12
62
135
(cont.)
1455
4.5
1.2
6
27
60
1855
3.4
0.9
3
11
23
Dally Average
4.2
1.1
8
33
73
7
26 57
25
1030
4.2
1.1
6
24
54
1455
4.2
1.1
8
35
76
1845
4.5
1.2
8
37
81
Dally Average
3.8
1.0
9
32
70
6
19 42
26
1045
2.2
0.57
3
6
14
1440
2.2
0.58
2
4
10
1835
1.9
0.51
3
6
13
Dally Average
2.1
0.56
3
5
12
1
2 4
27
0945
2.8
0.75
6
17
38
1535
2.5
0.66
8
20
44
1830
2.2
0.57
6
13
29
Dally Average
2.4
0.62
7
17
37
4
8 18
28
0925
2.2
0.59
16
36
79
1535
3.4
0.89
12
40
89
1825
2.6
0.68
8
21
45
Dally Average
2.5
0.67
13
32
71
12
26 58
7-Day Average
3.6
0.96
9
34
76
6
18 40
Outfall 012
22
1140
24.6
6.5
2
49
110
1655
17.0
4.5
2
34
75
2350
68.5
18.1
2
136
300
Dally Average
56.8
15.0
1
73
160
0
0 0
23
1155
37.9
10.0
2
75
165
1510
57.9
15.3
1
•59
130
2000
37.3
9.9
2
75
165
Dally Average
39.3
10.4
1
70
155
0
0 0
24
1145
20.0
5.3
<1
_
_
1940
19.3
5.1
<1
-
-
2320
23.0
6.1
<1
-
-
Dally Average
20.0
5.3
<1
-
-
0
0 0
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES0
Time of
Station Description Date Collection Instantaneous Flowb Oil and ftreasec(Gross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Outfall 012
(cont.)
Outfall 013
25
1125
31.0
8.2
2
62
135
1925
15.5
4.1
3
46
100
2315
15.9
4.2
2
32
70
Dally Average
23.1
6.1
2
47
105
1
23
50
26
1040
23.8
6.3
2
48
105
1905
28.0
7.4
<1
-
-
2220
54.9
14.5
<1
-
-
Dally Average
37.9
10.0
<1
16
35
0
0
0
27
1330
21.9
5.8
<1
1905
21.6
5.7
<1
-
-
2220
38.2
10.1
<1
-
-
Dally Average
29.9
7.9
<1
-
-
0
0
0
28
1020
3.8
1.0
n
25
1905
26.1
6.9
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES*
Time Of
Station Description Date Collection Instantaneous Flow^ nil and Grease.0(Gross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Outfall 013
Intake 4-44
(at river)
26
1035
2.5
0.67
<1
-
1900
2.6
0.68
<1
-
-
2215
2.6
0.68
<1
-
-
Dally Average
2.8
0.75
<1
-
-
27
1330
2.8
0.75
1
3
6
1900
4.1
1.07
4
16
36
2155
3.8
1.00
2
8
17
Dally Average
3.6
0.95
2
9
20
28
1015
4.2
1.11
<1
_
1905
2.7
0.72
<1
-
-
2150
2.5
0.65
<1
-
-
Dally Average
3.3
0.86
<1
-
-
7-Day Average
5.5
1.44
1
7
15
22
1130
454
120
<1
_
•
2010
397
105
1
400
875
23
0425
397
105
5
1,990
4,380
Dally Average
428
113
2*
790
1,750
23
1150
397
105
5
1,990
4,380
2005
397
105
2
800
1,750
24
0015
397
105
<1
«.
Dally Average
397
105
2
930
2,040
24
1050
397
105
<1
_
_
1840
397
105
<1
-
-
2235
322
85
<1
-
-
Dally Average
344
91
<1
-
25
1035
322
85
2
640
1,420
1840
322
85
3
960
2,130
2225
322
85
2
640
1,420
Dally Average
322
85
2
750
1,660
26
0940
322
85
<1
_
1820
322
85
<1
-
-
2135
322
85
<1
-
-
Dally Average
322
85
<1
-
-
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES0
Time of
Station Description Date Collection Instantaneous Flow 011 and Grease^(Gross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Intake 4-44
(at river)
(cont.)
Intake 4-44
(after strainers)
27
1230
322
85
2
640
1,420
1825
322
85
<1
-
-
2125
322
85
2
640
1,420
Dally Average
322
85
1
430
950
28
0930
322
85
<1
_
_
1825
322
85
<1
-
-
2125
322
85
<1
-
-
Dally Average
322
85
<1
-
-
7-Day Average
350
93
1
415
910
22
1200
454
120
2
910
2,000
2020
397
105
4
1,590
3,500
23
0435
397
105
6
2,390
5,250
Dally Average
428
113
4
1,620
3,580
23
1200
397
105
2
800
1,750
2015
397
105
2
800
1,750
24
0035
397
105
2
800
1,750
Dally Average
397
105
2
800
1,750
24
1110
397
105
1
400
880
1850
397
105
1
400
880
2240
322
85
<1
-
-
Dally Average
344
91
1
270
590
25
1055
322
85
1
320
710
1845
322
85
<1
-
-
2235
322
85
<1
-
-
Oally Average
322
85
<1
110
240
26
1000
322
85
2
640
1,420
1830
322
85
2
640
1,420
2145
322
85
2
640
1,420
Dally Average
322
85
2
640
1,420
27
1300
322
85
<1
_
_
1840
322
85
<1
-
-
2125
322
85
<1
-
-
Dally Average
322
85
<1
-
-
-------
Table 6 (Continued)
SUMMARY OP OIL AND GREASE AND PHENOL ANALYSES6
Time of
Station Description Date Collection Instantaneous F1owb 011 and Greasec(Gross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Intake 4-44* 28 0945 322
(after strainers) 1835 322
(cont.) 2130 322
Dally Average 322
7-Day Average 350
Outfall 014 22 1215 11.4
2055 19.7
23 0515 22.3
Dally Average 15.9
23 1230 39.4
2100 20.8
24 0105 20.1
Dally Average 23.1
24 1120 20.4
1920 12.1
2305 12.5
Dally Average 15.9
25 1110 11.7
1905 12.5
2255 11.4
Dally Average 11.7
26 1040 12.9
1850 12.5
2205 12.1
Dally Average 12.5
27 1315 12.9
1855 12.1
2150 10.2
Dally Average 12.5
28 1000 10.2
1850 10.6
2145 12.1
Dally Average 10.6
7-Day Average 14.8
85
1
320
710
85
2
640
1,420
85
1
320
710
85
1
430
950
93
2
550
1,220
3.0
2
23
50
5.2
1
20
44
5.9
1
22
49
4.2
1
22
48
0
0
0
10.4
3
120
260
5.5
3
63
140
5.3
2
40
88
6.1
3
73
160
1
23
51
5.4
<1
3.2
<1
-
*
3.3
<1
-
-
4.2
<1
-
-
0
0
0
3.1
1
12
26
3.3
2
25
54
3.0
2
23
51
3.1
2
20
44
2
20
44
3.4
<1
_
_
3.3
<1
-
-
3.2
<1
-
-
3.3
<1
-
-
0
0
0
3.4
2
26
57
3.2
2
24
53
2.7
<1
-
-
3.3
1
17
37
1
17
37
2.7
2
20
44
2.8
<1
-
-
3.2
<1
-
-
2.8
1
7
15
0
0
0
3.9
1
20
44
0
0
0
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSESa
Time of
Station Description Date Collection
(Oct.) (hours)
Instantaneous Flow6 Oil and Grease0(Gross)
m3/day mgd mg/1 kg/day lb/day
X 10*
Oil and Grease (Net) Phenol (Gross)
mg/1 kg/day lb/day (mg/1)
Outfall 015 22 1120 264
1950 305
23 0405 413
Dally Average 305
23 1135 276
1950 276
2400 288
Dally Average 276
24 1035 347
1840 291
2230 326
Dally Average 320
25 1025 242
1840 235
2230 263
Dally Average 260
26 0940 335
1820 242
2135 259
Dally Average 298
27 1235 249
1825 281
2125 271
Dally Average 284
28 0925 300
1825 239
2125 388
Dally Average 284
7-Day Average 290
Outfall 115 22 1150 45.4
2035 71.5
23 0450 41.3
Dally Average 53.7
69.8
1
265
580
80.5
2
610
1,340
109
<1
80.5
1
290
640
0
0
0
72.9
2
550
1,220
72.9
2
550
1,220
76.1
2
575
1,270
72.9
2
560
1,240
0
0
0
91.7
2
690
1,530
76.9
4
1,160
2,570
86.0
2
650
1,430
84.5.
3
840
1,840
2
640
1.410
64.0
<1
62.1
<1
-
-
69.4
2
525
1,160
68.8
<1
175
390
0
0
0
88.5
1
335
740
64.0
<1
-
-
68.5
<1
-
-
78.6
<1
110
250
0
0
0
65.7
<1
•
74.1
<1
-
-
71.5
2
540
1,190
75.0
<1
180
400
0
0
0
79.2
<1
_
63.2
2
480
1,050
102.4
2
775
1,710
75.1
1
420
920
0
0
0
76.5
1
370
810
0
0
0
12.0
<1
45
100
18.9
3
215
475
10.9
9
370
820
14.2
4
195
430
0
0
0
-------
Table 6 (Continued)
SUMMARY OF OIL AND GFEASE AND PHENOL ANALYSES3
Time of
Station Description Date Collection Instantaneous Flow; Oil and fireasec(Gross) Oil and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X 103
Outfall 115 23 1215 48.1
(cont.) 2040 50.7
24 0040 .57.5
Dally Average 47.3
24 1100 42.8
1905 53.7
2250 51.5
Dally Average 46.6
25 1045 54.9
1850 46.2
2245 51.5
Dally Average 51.1
26 0950 52.2
1840 49.2
2150 48.1
Dally Average 48.1
27 1250 65.5
1840 41.3
2135 41.6
Oaily Average 44.7
28 0935 65.5
1840 57.2
2140 34.4
Dally Average 49.6
7-Day Average 48.7
Outfall 016 22 1040 109
1920 172
Dally Average 136
23 1050 176
1440 94
1915 85
2320 103
Dally Average 116
12.7
5
240
530
13.4
5
250
560
15.2
2
115
250
12.5
4
200
450
2
100
225
11.3
4
170
375
14.2
4
215
475
13.6
4
205
455
12.3
4
200
435
3
140
310
14.5
2
110
240
12.2
<1
-
-
13.6
<1
-
-
13.5
<1
35
80
0
0
0
13.8
<1
.
13.0
1
50
110
12.7
<1
-
-
12.7
<1
16
35
0
0
0
17.3
2
130
290
10.9
8
330
725
11.0
3
125
275
11.8
4
195
430
4
195
430
17.3
2
130
290
15.1
5
285
630
9.1
5
170
380
13.1
4
195
430
3
150
330
12.9
3
150
330
1
50
110
28.8
6
655
1,440
45.3
8
1,370
3,020
35.9
7
1,010
2,230
3
410
900
46.6
3
530
1,170
24.7
5
465
1,030
22.5
4
340
750
27.1
4
410
900
30.7
4
435
960
2
230
510
-------
Table 6 (Continued)
SUMMARY OP OIL AND GREASE AND PHENOL ANALYSES8
Time of
Station Description Date Collection
(Oct.) (hours)
Instantaneous Flow6 011 and Greasec(Gross)
m3/day mgd mg/1 kg/day lb/day
X 103
011 and Grease (Net) Phenol (Gross)
mg/1 kg/day lb/day (mg/1)
Outfall 016
(cont.)
Intake 5-51
(at river)
vo
o
ro
u>
24
1005
77.6
20.5
4
310
680
1810
92.7
24.5
6
555
1,230
2215
97.3
25.7
4
390
860
Dally Average
96.5
25.5
4
420
920
3
290
640
25
0955
98.8
26.1
3
295
650
1820
86.3
22.8
2
175
380
2210
92.3
24.4
5
460
1,020
Dally Average
93.9
24.8
3
310
680
3
280
620
26
0910
81.4
21.5
8
650
1,430
1805
85.2
22.5
4
340
750
2220
76.8
20.3
4
310
680
Dally Average
85.2
22.5
5
430
950
3
255
560
27
1200
79.1
20.9
5
395
870
1810
77.6
20.5
4
310
680
2115
92.7
24.5
4
370
820
Dally Average
93.5
24.7
4
360
790
4
360
790
28
0905
114
30.1
6
685
1,510
1810
137
36.2
5
685
1,510
2110
144
37.9
3
430
950
Dally Average.
133
35.1
5
600
1,320
4
530
1,170
7-Day Average
108
28.5
5
510
1,120
3
335
740
22
1110
76
20
<1
_
1930
76
20
2
150
335
23
0340
102
27
2
205
450
Dally Average
89
23.5
2
-
-
23
1120
102
27
<1
1930
102
27
1
100
225
2355
102
27
<1
-
-
Dally Average
102
27
<1
34
75
24
1025
102
27
<1
1830
102
27
<1
•
-
2220
102
27
<1
-
•
Dally Average
102
27
<1
-
-
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES 8
Time of
Station Description Date Collection
(Oct.) (hours)
Instantaneous Flow** 011 and Greasec(Gross)
m3/day mgd mg/1 kg/day lb/day
X 103
Oil and Grease (Net) Phenol (Gross)
mg/1 kg/day lb/day (mg/1)
Intake 5-51
(at river)
(cont.)
Intake 5-51'
(after strainers)
25
1010
102
27
2
205
450
1830
102
27
<1
-
.
2220
102
27
<1
-
-
Dally Average
102
27
<1
68
150
26
0915
102
27
<1
1810
102
27
<1
-
-
2125
102
27
<1
-
-
Dally Average
102
27
<1
-
-
27
1215
102
27
<1
100
225
1815
102
27
<1
-
-
2120
102
27
<1
•
_
Dally Average
102
27
<1
34
75
28
0915
102
27
<1
1815
102
27
<1
_
•
2115
102
27
1
100
225
Dally Average
102
27
<1
34
75
7-Day Average
100
26.5
<1
40
90
22
1110
76
20
5
380
830
1930
76
20
4
410
900
23
0340
102
27
4
410
900
Dally Average
89
23.5
4
400
880
23
1120
102
27
2
205
450
1930
102
27
2
205
450
2355
102
27
2
205
450
Dally Average
102
27
2
205
450
24
1025
102
27
<1
1830
102
27
<1
-
-
2220
102
27
<1
-
•
Dally Average
102
27
<1
-
-
25
1010
102
27
<1
1830
102
27
<1
-
2220
102
27
<1
•
-
Dally Average
102
27
<1
-
-
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSES*
Time of
Station Description Date Collection Instantaneous Flowb- Oil and Rreasec(Gross) 011 and Grease (Net) Phenol (Gross)
(Oct.) (hours) m3/day mgd mg/1 kg/day lb/day mg/1 kg/day lb/day (mg/1)
X It)3
Intake 5-51
(after strainers)
(cont.)
Outfall 117
West Run Culvert,
upstream of
8th Avenue
26
0915
102
27
<1
-
-
1810
102
27
<1
-
-
2125
102
27
1
100
225
Dally Average
102
27
<1
34
75
27
1215
102
27
<1
_
•
1815
102
27
<1
.
-
2120
102
27
<1
-
-
Daily Average
102
27
<1
-
-
28
0915
102
27
<1
_
_
1815
102
27
2
205
450
2115
102
27
5
510
1,125
Dally Average
102
27
2
240
525
7-Day Average
100
26.5
1
125
275
22
1005
74
19.5
5
370
810
1840
109
28.9
6
655
1,450
Dally Average
91
24.2
6.
510
1,130
23
0615
111
29.4
6
665
1,470
1020
79
20.8
3
235
520
1835
97
25.7
4
390
860
2245
101
26.7
4
405
890
Dally Average
97
25.6
4
425
935
2-Day Average
94
24.9
5
470
1,030
22
1015
4.0
1.05
20
m
1850
3.4
0.90
15
23
0230
3.2
0.84
8
Dally Average
3.7
0.99
14"
23
1020
3.5
0.93
1
4
8
1830
3.6
0.95
1
4
8
2235
3.4
0.90
2
7
15
Dally Average
3.4
0.90
1
5
10
185
405
195
190
430
420
-------
Table 6 (Continued)
SUMMARY OF OIL AND GREASE AND PHENOL ANALYSESa
Station Description
Date
(Oct.)
Time of
Collection
(hours)
Instantaneous Flowb
m3/day
X 103
mgd
011 and Greasec(Gross)
mg/1 kg/day lb/day
011 and Grease (Net)
mg/1 kg/day lb/day
Phenol (Gross)
(mg/1)
West Run Culvert
at river (017)
22
Dally Average
23
Dally Average
1025
85
22.5
5
425
940
1855
95
25.2
9
860
1,890
90
23.8
7
640
1,415
0640
78
20.5
6
465
1,025
1035
86
22.7
4
345
760
1845
100 .
26.3
6
600
1,320
2300
108
28.5
6
645
1,425
92
24.2
6
515
1,130
aAIL data baaed on grab samples,
b Loads are calculated on instantaneous flows.
c Freon-extractable material.
dIntake 3-24 data used to calculate NET loads for outfalls 006, 010, Oil, 012, and 013.
® Whenever a gross value is reported as <1 or <0.1, the value is considered as zero and loads not calculated. Zero was used in
calculating the daily average.
I Daily average flow is calculated from total of all flow measurements for day, not just the instantaneous flews when O/G and phenol
samples were collected. The GROSS daily average load is the arithmetic average of instantaneous loads. The GROSS daily average
concentration, mg/l, is calculated from GROSS daily load and daily average flou.
9 7-day average GROSS load is arithmetic average of the daily average loads. The 7-day average concentration calcualted from 7-day
average load and 7-day average flou).
h All daily average NET concentrations for outfalls 006, 010, 012, 013, 014, 015, 115, 016, and 117 (also known as 117) were calculated
by subtracting intake concentrations from outfall concentrations. NET loads were calculated from daily average flaw.
1 5-day averages were calculated in same manner as 7-day averages (see footnote #7).
I NET loads and concentrations calculated as follows:
(GROSS load discharged from Oil) - (GROSS load in Munhall Sewer upstream of Oil) = (GROSS USSC load in Oil)
(GROSS USSC load) * (flow from Oil-flow in Munhall Sewer upstream of Oil) X 8.34 = (GROSS USSC concentration in Oil)
(GROSS USSC concentration) - (intake concentration) = (NET USSC concentration)
(NET USSC concentration) X 8.34 X_ (daily average flow) = (NET USSC load)
* Intake 4-44 (after strainers) used to calculate NET loads for outfalls 014, 015, 115, and 016.
I Intake 5-51 (after strainers) used to calculate NET loads for outfall 117.
fnGROSS loads not calculated since samples were collected downstream from flow measurement location. Additional flow of domestio waste
included in samples, but flow not measured.
f> Arithmetic average.
-------
Table 7
SUMMARY OF SETTLEABLE SOLIDS ANALYSIS*
' USSC HOMESTEAD MAIN WORKS
Ootober 22-28, 1975
Station Description
Date
(Oct.)
Time of Sample
Collection
(range 1n hours)
Total No.
of Samples
Settleable
Solids for
Each Sample
(ml/1)
Intake 3-24
22-28
0625 - 0720
7
<0.1
Influent to 48-in.
mill settling basin
22-26
0600 - 0630
5
<0.1
Effluent from 48-in.
mill settling basin
(006)
22
23
24
25-26
0820
0820
0845
0820 - 0825
1
1
1
2
2.0
<0.1
0.4
<0.1
Influent to structural
mill settling basin
22-28
0710 - 0810
7
<0.1
Effluent from structural
mill settling basin (010)
22-28
0730 - 0830
7
<0.1
Outfall Oil
22-28
0625 - 0720
7
<0.1
Outfall 012
22-23
24
25-28
0800 - 0850
0800
0725 - 0750
2
1
4
<0.1
0.4
<0.1
Outfall 013
22
23
24
25-28
0750
0845
0805
0720 - 0750 .
1
1
1
4
0.7
0.1
5.0
<0.1
Outfall 014
22-28
0705 - 0830
7
<0.1
Intake 4-44 at river
22-27
28
0640 - 0745
0630
6
1
<0.1
0.1
Intake 4-44 after strainers
22-28
0630 - 0745
7
<0.1
Outfall 015
22-28
0625 - 0705
7
<0.1
Outfall 115
22-28
0645 - 0815
7
<0.1
Outfall 016
22-28
0600 - 0655
7
<0.1
Intake 5-51 at river
22-28
0610 - 0720t+
7
<0.1
Intake 5-51 after strainers
22-28
0615 - 0705t+
7
<0.1
Outfall 117
22
23
1415
0615
1
1
<0.1
0.1
West run culvert upstream
of 8th Avenue
22
23
1420
0615
1
1
2.0
<0.1
West run culvert at river
(017)
22-23
0615 - 1430
2
<0.1
t All data baaed on grab samples
++ Sample on Oat. 22 was collected at 3:05 p.m. at river and at 2:55 p.m. after strainers.
53 of 213
-------
6" PARSHALL FLUME MONONGAHELA RIVER
in
-P»
o
Figure 3. Wastewater Schematic Flow Diagram - 48" Mill
ro
co USSC Homestead Main Works
-------
The effective dimensions of the terminal settling basin, known as
Settling Basin "B," are 27.4 m (90 ft) long x 8.5 m (28 ft) wide x 2.7 m
(9 ft) SWD. The volume is 642 m3 (169,650 gal). At an estimated design
flow of 5,677 1/min (1 ,500 gpm),1 the calculated detention time is about
113 minutes.
Pickling is generally conducted for one turn per day. The operation
consists of two acid baths in series followed by a rinse bath. Hydro-
fluoric, nitric, and sulfuric acids are used. Fumes from the acid baths
are collected and exhausted to wet scrubbers; the scrubber effluents,
estimated by USSC as 19 1/min (5 gpm), are sent to outfall 006. Rinse
tank overflow, estimated at 3,540 m (936,000 gal)/month, is neutralized
prior to discharge. According to USSC, about 4.5 m. tons (5 tons)/year
of "Hi" calcium hydrated lime is used to neutralize the rinse water.
Sludges formed in the neutralization process flow to the settling basin.
Concentrated waste pickling acid is hauled away by an outside contractor.
Amounts of waste acid hauled away for January-June, 1975, were as
follows:1
Month
m3
gal.
January
51
13,500
February
119
31,500
March
102
27,000
April
170
45,000
May
-
-
June
85
22,500
Influent and effluent samples were collected at Settling Basin "B"
to determine treatment efficiencies and characterize the waste load
discharged through outfall 006. Since the effluent was well mixed as it
passed through the Parshall flume, samples were collected just below the
surface. It was observed that the launder channel bed, upstream of the
55 of
-------
Parshall flume, contained settled material. USSC personnel stated that
this material was deposited during high river stages. Since this
material was not observed in the wastewater flowing over the launder
weirs, samples were taken to avoid collecting any of the deposited
material. Based on USSC's statements about the deposited material, it
is reasonable to assume that treatment is minimal whenever the river
inundates the effluent launder.
According to USSC,1 Settling Basin "B's" design concentrations are
as follows:
Location
TSS
mg/1
0/G
Influent
86
67
Effluent
29
29
These design efficiencies correspond to TSS and 0/G removals of 66% and
57% respectively. During the survey, about 45% of the TSS and 80% of
the 0/G were removed by the treatment unit [Table 8]. The gross effluent
TSS averaged 28 mg/1, and the 0/G, 6 mg/1. However, the average influent
concentrations were less than design concentrations and the flow was
about 50% of the average design flow. On October 23-24, the influent
and effluent TSS concentrations were equivalent to the design concen-
trations, but the flow was only 65% of the average design flow.
Although USSC could not provide amounts of settleable solids, TSS,
and 0/G removed by each scale pit (records of recovered/reclaimed
quantities are not kept individually, but only for the total plant on a
weight basis), the monitoring data indicate that settleable solids are
insignificant and that influent TSS and 0/G concentrations were at or
below design concentrations. According to USSC, the flow through the
48-inch mill scale pit is 1,135 1/min (300 gpm) or 20% of the total flow
discharged from outfall 006.1 The actual flow through the scale pit was
56 of
-------
Table 8
EVALUATION OF SETTLING BASIN TREATMENT EFFICIENCY0
USSC HOMESTEAD MAIN WORKS
October 22-29, 197S
Station
Description
Settleable Solids
011 and Grease
(Oct.)
Influent Effluent
Influent Effluent
%
Influent Effluent
i
Influent Effluent
i
hour
mg/1
Removal
m
1/1
Removal
mg/1
Removal
22
24-hr
composite6
48
53
Increase
0600
0820
<0.1
2.0
Increase
1000
1215
24
6
75
1400
1615
57
7
88
1815
0010
37
13
-
23
24-hr
composite
86
30
65
W
0610
0820
<0.1
<0.1
NC •
1000
1220
34
8
76
1410
1630
64
7
89
1815
2030
38
7
82
24
24-hr
composite
48
22
54
0630
0845
<0.1
0.4
Increase
1000
1210
29
5
83
1410
1620
64
6
91
1815
2020
31
14
55
25
24-hr
composite
42
21
50
nc
0600
0820
<0.1
<0.1...
1000
1210
20
5
75
1410
1610
53
5
91
1810
2010
19
7
63
26
24-hr
composite
19
12
37
<0.1
NC
0620
0825
<0.1
1000
1200
5
3
40
1400
1615
4
3
25
1805
2005
51"
28®
3
2
33
¦Day Average
45
<0.1
<0.54
<81
32'
6'
81
22
24-hr
composite
46
46
NC
0710
0730
<0.1
<0.1
NC
48-Inch mill
settling
basin (006)
settling
basin (010)
1100
1500
1930
1120
1520
1955
23
24
24-hr composite
0715 0740
1045 1110
1545 1610
1915 1940
24-hr composite
0810 0830
1100 1125
1530 1550
1920 1945
48 42 13
29 22 24
<0.1 <0.1 NC
<0.1 <0.1 NC
6
6
3
10
7
S
5
7
2
7
6
3
4
4
3
Increase
NC
NC
40
14
NC
20
43
Increase
-------
Table 8 (Continued)
EVALUATION OF SETTLING BASIN TREATMENT EFFICIENCY0
Station Date Time of Collection Total Suspended Solids Settleable Solids Oil and Grease
Description (Oct.) Influent Effluent" Influent Effluent" 2 Influent Effluent I Influent Effluent" I
hour ~ mq/1 Removal ml/1 Removal mg/1 "Removal
Structure mill 25
24-hr
composite
24
16
33
settling
0740
0800
<0.1
<0.1
NC
basin (010)
1110
1130
3
2
33
1525
1545
3
3
NC
1900
1920
3
3
NC
26
24-hr
composite
14
17
Increase
0745
0805
<0.1
<0.1
NC
1105
1125
1
3
Increase
1500
1525
lfl
2
Increase
1855
1915
<1«
-------
not determined during the NEIC survey. It was noted by NEIC that
whenever large amounts of water were sprayed on the slabs, there was no
apparent increase in the flow through the scale pit. USSC plant per-
sonnel stated that all wastewater flowing to Settling Basin "B" also
flows through the scale pit.
Because wastes from the pickling operations and descaling enter
Settling Basin "B," the effluent was analyzed for sulfates and chlorides
[Table 9]. Net sulfates discharged were insignificant, less than 22
mg/1. The neutralized rinse water from the pickling operation averages
about 160 m^/day (42,500 gpd),* or about 4% of the flow from outfall
006. Thus, monitoring for sulfates does not appear warranted at the
current production level. The net chloride concentration discharged
averaged about 55 mg/1. The intake water averaged 6 mg/1 for October
22-26. This increase in chlorides most likely is due to the descaling
operations. Salt is manually applied to the slabs during descaling.
When the mill was not operating on October 26-27, the chloride concen-
tration was equivalent to the intake levels.
The net TSS loads discharged from Settling Basin "B" ranged from
0-80 kg/day (180 lb/day) [Table 4]. Oil/grease averaged approximately
21 kg/day (45 lb/day) [Table 6]. Metal concentrations were low
[Table 5] and phenol concentrations were less than 0.01 mg/1 [Table 6].
According to USSC,1 grab samples are collected as specified in the
NPDES** permit and all aliquots for composite samples are collected on a
4-hour cycle schedule (six samples per 24-hour period) and combined on
an equal-volume basis because measured flows are not available.*** USSC
* Based on 22 operating days per month
** National Pollutant discharge Elimination System (Public Law 92-500)
*** TSS data are determined from composite samples. Three O/G samples
were collected from outfall 006 over the 24-hour monitoring period.
59 of
-------
Table 9
SUMMARY OF CHLORIDE AND SULFATE ANALYSES
USSC HOMESTEAD MAIN WORKS
October 22-29> 1975
Station Description
Date
Gross^
-------
stated that the flows from the outfalls at Homestead "remain fairly
constant when considering a long time period."1 Over a long period of
time, total daily flows may remain constant; however, samples are
collected over a period of 24 hours, a short period during which flows
will fluctuate. Over the 4-day period of October 22-26 when the 48-inch
mill was operating, the daily flow discharged from outfall 006 averaged
5,000 m^/day (1.3 mgd) and ranged from 4,100-5,300 m^/day (1.1-1.4 mgd)
[Table 4], or a 21% variation in the daily flow. However, the instan-
3
taneous flows varied by about 60% and ranged from a low of 2,300 m /day
3
(0.6 mgd) to a high of 5.9 m /day (1.6 mgd). Since the volume of the
aliquot used in the composite sample is dependent upon the instantaneous
flow at the time of sample collection, a composite sample comprised of
equal-volume aliquots collected from a variable flow wastewater stream
will not be representative of actual conditions. The equal-volume
composite sample will only be representative if the instantaneous flows
are constant. The equal-volume composite sample will only provide an
estimate of the characteristics of a variable flow wastewater stream.
However, there is no way to determine if the data are less than, equal
to, or greater than the data obtained by flow-weighted composite samples
unless both compositing methods are used simultaneously.
Although the self-monitoring data reported by USSC for January-
June, 1975 [Table 10] fell within the range of concentrations found
during the NEIC survey, whether or not the self-monitoring data was
representative of the conditions which existed during January-June can
only be estimated. The data can be compared on a unit production basis.
It is reasonable to assume that as production increases, the concen-
tration of the various pollutants would also increase. Production for
the 48-inch mill is summarized in Tables 11 and 12 for October 17-29,
1975 and January-June, 1975, respectively. Production during October
22-26 averaged 237 m. tons (261 tons), or about 75% of the rated capacity
[312 m. tons (345 tons)]. The average daily production for January-
June, calculated by NEIC from the data submitted by USSC, was approximately
61 of 213
-------
Table 10
stumpy of self-komtorinc dataf
USSC HOHtSTEAD MAIN WORKS
January-June 1976
Parameter
Flow
TSS
0/G
cnt
CNa
Phenol
Fe
T0C
mgd
ing/1
006
Average
Range
No. of Samples
1.4
1-1.67
5
22
0-65
30
4
0-46
59
0.04
0.003-0.3
10
0.002
0-0.015
10
0.05
0.008-0.33
11
0.11
0.03-0.6
20
3.6
0-19
9
010
Average
Range
No. of Samples
12.7
10-16.4
5
39
4-79
18
9
0.4-42
40
0.002
0.003-0.7
11
0.005
0-0.022
11
0.03
0.01-0.04
11
9.4
0-26.5
11
Oil
Average
Range
No. of Samples
0-0.144
5
0.011
1
0.003
1
0.022
1
012
Average
Range
No. of Samples
lt+
0-4.37++
5
0.03
0.004-0.19
9
0.002
0-0.015
9
0.02
0.006-0.09
10
5
0-19.3
9
013
Average
Range
No. of Samples
2.6
0.288-5.5
5
25
0-109
5
4
0-6.3
11
0.022
0.003-0.087
11
0.008
0-0.05
11
0.019
0.004-0.036
11
7.6
0.1-28
8
014
Average
Range
No. of Samples
tV -2++ tt
9.8-11.52
5
0.015
0.005-0.027
10
0.0047
0-0.018
10
0.04
0.022-0.078
10
4
0-11
9
015
Average
Range
No. of Samples
48
7.2-61.2
6
74
1
4.4
0-38
36
0.017
0.003-0.043
10
0.007
0-0.028
10
0.019
0.01-0.038
10
7
0.5-22.5
9
115
Average
Range
No. of Samples
23
1
5
0.2-27.6
10
016
Average
Range
No. of Samples
16.7
14.4-21.6
6
62
7-177
18
10
0.8-104.2
37
0.017
0.003-0.034
9
0.-003
0-0.017
8
0.04
0.014-0.168
9
8.6
0-34.2
8
017
Average
Range
No. of Samples
20.1
18.72-25.65
5
70
0-375
14
8
0.2-21.6
33
0.03
0.01-0.044
8
0.01
0-0.031
8
0.02
0.005-0.04
8
18
1.6-49.5
8
Intake 3-24
Average
Range
No. of Samples
22.3
20.08-23.295
5
32
0-105
33
3.3
0-23.8
66
0.02
0.007-0.074
10
0.01
0-0.05
9
0.03
0.01-0.08
10
2.0
0.022-28.7
15
8
0.02-37.3
10
Intake 4-44
Average
Range
No. of Samples
94.12
85.51-105.12
5
28
2-123
16
6.8
0-44
35
0.02
0.004-0.081
10
0.01
0-0.05
10
0.02
0.008-0.03
10
13
1.2-24.8
8
Intake 5-51
Average
Range
No. of Samples
25.7
25.65-25.82
3
30
2-83
9
4
0-22.6
21
0.01
0.006-0.039
8
0.002
0-0.015
8
0.02
0.01-0.035
8
7.5
0.8-17.7
7
t Data frcm letter dated November 5, 197S vith attachments from Mr. James L, Hamilton III, Manager, Environmental Control - Mater*
USSC, to Mr* 5. ft. Vaeocraug, Directort Enforcement Divieion, USEPA, Region III, Philadelphia, Pa. and from the Discharge
Monitoring Reports submitted by USSC to USEPA Region III.
tt Estimated
62 of 213
-------
Table 11
48-INCH STRUCTURAL STEEL MILL DAILY PRODUCTION*
USSC HOMESTEAD MAIN WORKS
October 17-29, 197S
Date
Production
per operating day
(Oct.)
m. tons
tons
17
- ¦
-
18
-
-
19
-
-
20
160
176
21
342
377
22
228
251
23
306
337
24
202
223
25
211
233
26
-
-
27
-
-
28
-
-
29
27
30
Average
Daily Production
211
232
Data from letter dated December 17, 1975
with attachments from Mr. James L. Hamil-
ton III, Manager, Environmental Control -
Watery USSC3 to Mr. S. R. Wassersug,
Director, Enforcement Division, USEPA,
Region III, Philadelphia3 Pa.
63 of 213
-------
Table 12
SUMMARY OF 48-INCH STRUCTURAL STEEL MILL PRODUCTION^
USSC HOMESTEAD MAIN WORKS
January-June 1975
+ +
Month Production per Operating Day
Minimum Maximum Average
m. tons tons m. tons tons m. tons tons
January
338
373
457
504
402
443
February
259
286
423
466
354
390
March
139
153
421
464
349
385
Apri 1
320
353
423
466
376
414
May
340
375
375
413
356
392
June
294
324
430
474
365
402
6-month
average
364
401
t Letter dated November S3 1975 with attachments from Mr. James
L. Hamilton III, Managert Environmental Control - Water3 USSC}
to Mr. S. R. Wassersug3 Director3 Enforcement Divisiont USEPA}
Region III3 Philadelphia, Pa.
+t See Appendix F for weekly production.
ttt Average of weekly production, not monthly production.
64 of 213
-------
16% greater than the rated capacity. Loads discharged per unit production
during the survey and January-June are summarized in Tables 13 and 14,
respectively. The waste loads per unit production for TSS and 0/G were
each about 2.3 times greater during the survey than the average waste
loads for January-June. Because production during the survey was about
55% less than the average production for January-June, the waste loads
per unit production should have been less during the survey than during
January-June. It therefore appears that the TSS data reported in
January-June was not representative of actual conditions. It is also
apparent that the 0/G concentrations are not dependent upon production.
The amount of lubricants applied to the rolls in the mill probably
remains fairly constant; therefore, the concentrations in the effluent
would be dependent upon the degree of treatment achieved in the settling
basins rather than on production levels.
USSC has proposed net effluent limitations for TSS and 0/G and
gross limitations for dissolved iron [Table 15]. During the survey, the
daily maximum TSS, 0/G, and dissolved iron concentrations were 9%, 23%
and 20%, respectively, of the proposed limitations.
The monitoring location for outfall 006 is satisfactory when the
river stage is below the elevation of the Parshall flume. During the
reconnaissance [Appendix A], USSC reported that the flume is flooded
about three to four weeks each spring. When this occurs, an alternate
sampling location should be established. Flow measurement is satis-
factory, provided that USSC periodically calibrates the continuous flow
recorder. NEIC personnel found the recorder to be out of calibration
prior to the survey [Appendix B]. Because instantaneous flows are
measured, all composite samples should be combined on a flow-weighted
basis.
65 of 213
-------
Table IS
SUMMARY OF WASTE LOADS PER UNIT PRODUCTION+
* OUTFALL 006 (48-INCH MILL)
USSC HOMESTEAD MAIN WORKS
October 22-25, 1975
„ t ^ xx Date (Oct.) 4-Day Average
Parameter 22 23 24 25 VZ/T'timln—ThTtnn
kg/1,000 kg lb/ton kg/1,000 kg lb/ton kg/1,000 kg lb/ton kg/1,000 kglb/ton 9/ ' 9
TSS
0/G
Flow
laucnon
,000 kg
228
306
202
211
237
tons
251
337
223
233
261
gross
0.95
1.91
0.52
1.04
0.57
1.14
0.52
1.03
0.64
1.28
net
0.36
0.72
0
0
0.02
0.04
0.32
0.64
0.18
0.36
gross
0.11
0.22
0.10
0.20
0.18
0.36
0.11
0.22
0.13
0.25
net
0.07
0.15
0.08
0.17
0.18
0.36
0.07
0.15
0.10
0.21
1 Fe
gross
0.03
0.05
0
0
0
0
0
0
0.005
0.01
net
0.01
0.02
0
0
0
0
0
0
0
0
,000 kg
18
17
26
25
22
gal/ton
4,380
4,150
6,280
6,000
5,200
+ Sampling occurred between 6 a.m. and 6 a.m. for each 24-hour period while total production reported by USSC was for the period
of midnight to midnight. Therefore, waste loads per unit production are only approximate.
++ Data from letter dated December 17, 1975 with attachments from Mr. James L. Hamilton III, Manager, Environmental Control -
Water, USSC, to Mr. S. R. Wassersug, Director, Enforcement Division, USEPA, Region III, Philadelphia, Pa.
-------
Table 14
SUMMARY OF HASTE LOADS PER UNIT PRODUCTION
OUTFALL 006 (48-INCH MILL)
USSC HOMESTEAD MAIN WORKS
January - June 1975
Month
Average Daily
Production
4*+
Total Suspended Solids
Oil and
Grease++
Dissolved
Iron++
1,000 kg
tons
kg/1,000 kg
lb/ton
kg/1,000 kg
lb/ton
kg/1,000 kg
lb/ton
January
402
443
0.17
0.34
0.01
0.02
0
0
February
354
390
0.32
0.64
0.07
0.14
0
0
March
349
385
*
*
*
~
*
~
Apri 1
376
414
0.31
0.62
0.12
0.23
0
0
May
356
392
0.45
0.89
0.05
0.09
0.005
0.01
June
365
402
0.15
0.29
0.05
0.09
0
0
Monthly
average
364**
401**
0.28
0.56
0.06
0.11
0
0
t Letter dated November 5, 1975 with attachments from Mr. James L. Hamilton III3 Manager3
Environmental Control - Water3 USSC3 to Mr. S. R. VJassersug, Director3 Enforcement Division3
USEPA3 Region III3 Philadelphia3 Pa.
tt Gross loads.
* Flows not reported for March; therefore, load cannot be calculated.
** Average of weekly production.
-------
Table IS
COMPARISON OF USSC PROPOSED EFFLUENT LIMITATIONS AND SURVEY DATA
USSC HOMESTEAD MAIN WORKS
Outfall Parameter Gross USSC Proposed Limitations
Number Net Dally Average Dally Maximum Dally avg. Daily Max.
kg/day lb/day kg/day lb/day Units Specified
NEIC Survey Data No. of Days
Daily Average Daily Maximum Dally Avg. Dally Max. Limitations Exceeded
kg/day lb/day kg/day lb/day mg/1 mg/1 Dally Avg. Dally Max.
TSS
0/G
Fe (diss.)
006
(effective
date to
expiration
date)
010 TSS
(effective
date to 6/30/77)
(7/1/77 to TSS
expiration
date)
013
(effective
date to expiration
date)
015 0/G
(effective date
to expiration date)
016 TSS
(eff. date 0/G
to expiration date)
0/G
TSS
0/G
117*
TSS
0/G
(effective
date to expiration
date)
NA
NA
NA
NA
NA
NA
NA
NA
77 mg/1
NA
231 mg/1
30 mg/1
31
21
68
45
80
36
180
80
20
7
0/5
0/5
0/5
0/5
G
NA
NA
NA
NA
NA
7 mg/1
1.3
2.9
5.7
12.6
0.3
1.4
0/5
0/5
G
4,568
10,050
13,704
30,150
NA
NA
1,540
3,400
2,715
5,990
26
46
0/7
0/7
G
1,221
2,685
3,662
8,055
NA
NA
235
520
340
750
4
6
0/7
0/7
G
4,568
10,050
13,704
30,150
NA
NA
1,540
3,400
2,715
5,990
26
46
0/7
0/7
G
NA
NA
3,662
8,055
NA
NA
235
520
340
750
4
6
0/7
0/7
NSt+
NA
NA
NA
NA
NA
NA
165*
365*
630*
1,390*
31*
45*
NS
NA
NA
NA
NA
NA
NA
7*
15*
18*
40*
1*
2*
*
N
1,320
2,900
3,960
8,700
NA
NA
0
0
640
1,410
0
2
0/7
0/7
G
7,382
16,240
22,145
48,720
NA
NA
3,970
8,760
7,790 17,150
37
67
0/7
0/7
G
1,896
4,172
5,689
12,516
NA
NA
460
1,020
1,370
3,020
4
5
0/7
0/7
G
7,460
16,412
22,380
49,236
NA
NA
5,600
12,350
5,700 12,600
59
60
0/2
0/2
G
1,484
3,266
4,453
9,798
NA
NA
470
1,030
510
1,130
4
5
0/2
0/2
t Flew and temperature parameters were Hated as NA for all limitations. pB wag proposed as 6.0 minimum and NA maximum
tt Not Specified
* Grose values
** Company monitoring station for outfall 01?
-------
OUTFALL 010
Ingots are processed in two lines in the structural mill, the 44-
inch and 54-inch lines, which are operated in parallel. The 44-inch
line consists of the 44-inch bloom mill, the 36-inch roughing mill, and
the 28/32-inch structural steel mill. The 54-inch line includes the 54-
inch bloom mill and the 52-inch roughing structural steel mill. Blooms
from either of the two lines may also be routed to the 48-inch structural
mill.*
There are five scale pits in the structural mill, one serving each
individual mill. Process wastewaters from the 44-inch and 54-inch lines
flow to their respective scale pits and then flow to Settling Basin "A"
at the edge of the OTonongahela River [Fig. 4]. Cooling water from the
mills also flows to Settling Basin "A" prior to discharge.
The dimensions, design flows, and estimated treatment efficiencies
of the five scale pits are listed in Table 16. USSC reported that each
scale pit is cleaned once each day with a bucket; the scale is trans-
ported via trucks to the USSC Saxonburg plant. USSC does not maintain
records on the amount of scale recovered from each scale pit; records
are kept only on the total weight recovered from all scale pits.
Tonnage recovered on a plant-wide basis is as follows:1
* Wastewater from the 48-inch structural mill is discharged through
outfall 006.
69 of
-------
DOUBLE EFFLUENT LAUNDERS
° Figure 4. Wastewater Schematic Flow Diagram - Structural Mills
o
USSC Homestead Main Works
ro
CO
-------
Table 16
STRUCTURAL MILL SCALE PITS+
USSC HOMESTEAD MAIN WORKS
Calculated Design
Effective Dimensions Design. Detention TSS remova
Mill
Length
Width
SWD
Flow
Time
Efficiency
Remarks
m
ft
m
ft
m
ft
1/min
gpm
minutes
%
44-inch
8.7
28.5
3.0
10
1.9
6.3
5,680
1,500
9
98.8
Pit has two com-
partments separate*
by a bar screen.
Two influents.
36-inch
6.2
20.5
3.0
10
1.9
6.2
1,890
500
19
90.2
Receives finer
scale than 44-inch
pit. One influent.
28/32-
inch
6.2
20.5
3.0
10
2.5
8.3
7,570
2,000
6
90.2
Effluent bar
screen. Three
influents.
54-inch
8.5
28
3.0
10
2.2
7.3
1,890
500
31
99.8
Pit has two com-
partments. One
influent.
52-inch
8.8
29
3.0
10
2.0
6.5
9,460
2,500
6
88.5
One influent. Oil
and scale present
in liberal amounts
on sides of pit.
t See Appendix A for sketches of scale pits which cere included in the Reconnaissance Report.
tt Letter dated November 5, 1975 with attachments from Mr. James L. Hamilton III, Manager, Environmental
Control - Water, USSC, to Mr. S. R. Wassersug, Director, Enforcement Division, USEPA, Region III,
Philadelphia, Pa.
-------
Month
Tons of Scale
Recovered^
m. tons++
tons
January
2,625
2,894
February
12,089
13,326
March
13,120
14,462
April
9,651
10,638
May
10,422
11,488
June
9,753
10,751
+ Recovered from scale pits at 45-,
100-, 160-, 48-, 54-, 52-, 44-, 36-,
28/32-inch mills.
tt Calculated by NEIC.
Effective dimensions of Settling Basin "A" are 38 m (126 ft) long x
15 m (48 ft) wide x 3 m (9 ft) SWD. The estimated design flow1 is 48
m /min (12,708 gpm); the calculated detention time is approximately 32
minutes. The basin is divided lengthwise into two separate compart-
ments. Flow is diverted into one compartment while the other compart-
ment is cleaned by a clamshell. The mill sludge removed from the basin
is transported on a river barge to an approved disposal site. Cleaning
is scheduled every two months.
Influent and effluent samples were collected at Settling Basin "A"
to determine treatment efficiencies and characterize the wastewater
constituents. According to USSC,1 the design treatment efficiencies
are:
. TSS 0/G
Location - — '
mg/1
Influent 108 22
Effluent 60 16
Efficiency 44% 27%
72 of
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USSC has reported that the basin is primarily a solids removal facility
instead of an 0/G removal unit which is indicated by the removal effi-
ciencies. During the survey, adsorbent pads were secured to the efflu-
ent launders to remove the 0/G which had not been retained by the solid
baffle. Survey results indicate that about 10% of the TSS and 20% of
the 0/G were removed [Table 8]. The effluent TSS averaged 26 mg/1, and
the 0/G, 4 mg/1. However, the average influent TSS and 0/G concen-
trations of 29 mg/1 and 5 mg/1, respectively, were well below the design
concentrations.
The 7-day average flow was 58,800 m^/day (15.5 mgd),* or about 22%
greater than the flow reported in the self-monitoring data for January-
June, 1975 [Table 10]. The broad-crested weir was rated using the dye
dilution method; the actual flow was approximately 66% greater than the
flow indicated by USSC's BIF flow recorder [Appendix B]. The net waste
loads discharged were computed using the adjusted flows. The daily net
TSS and 0/G loads averaged 480 kg (1,060 lb) [Table 4] and 190 kg (420
lb) [Table 6], respectively. These loads correspond to net concen-
trations of 8 mg/1 and 3 mg/1, respectively. The total and dissolved
iron net cpncentrations averaged 1.2 mg/1 and 0.07 mg/1, respectively
[Table 5].
USSC has proposed effluent limitations for TSS and 0/G parameters
based on gross loads [Table 15]. The gross daily average and daily
maximum TSS loads discharged October 22-29 were about 34% and 20%,
respectively, of the proposed limitations. The corresponding gross 0/G
loads were 19% and 15% of the proposed limitations.
Production for the five structural mills for January-June, 1975,
and October 17-29, 1975, is summarized in Tables 17 and 18, respectively.
* Design flow is 6.9 x 104 m^/dccy (18.3 mgd).
73 of
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Table 17
SUMMARY OF STRUCTURAL MILL PRODUCTION+
USSC HOMESTEAD MAIN WORKS
January-June 1975
Hill/ .. January February
Month mTn max avg mm max avg
March
Production per Operating Day
April
May
June
min max
avg
mm
max
avg
mm max
avg
mm
max
avg
Monthly,
Average
+++
54-1nch
m. tons
tons
18
20
2,820 1,522
3,109 1,678
510
563
2,646 1,685
2,917 1,857
679
749
2,480 1,657
2,734 1,827
586
646
2,394 1,527
2,639 1,683
343
378
2,448 1,375
2,698 1,516
282
311
1,204 617
1,327 680
1,407
1,551
52-inch
m. tons
tons
17
19
2,706 1,584
2,983 1,746
334
368
2,477 1,591
2,730 1,754
659
726
2,409 1,473
2,656 1,624
558
615
2,326 1,412
2,564 1,557
307
338
2,230 1,527
2,458 1,683
395
435
1,038
1,144
704
776
1,448
1,596
44-inch
m. tons
tons
279
307
976
1,076
650
716
349
385
1,558 924
1,717 1,019
323
356
1,692 1,126
1,865 1,241
375
413
1,612 1,040
1,777 1,146
532
586
1,656 1,217
1,826 1,342
345
380
1,165
1,284
782
862
985
1,086
36- and
28/32-inch
m. tons
tons
228 597 413 275 1,091 694
251 658 455 303 1,203 765
187 1,167 748
206 1,286 825
221 1,213 718
244 1,337 791
310 1,239 838 211 884 514 675
342 1,366 924 233 974 567 744
Total Average
Production
m. tons
tons
6,589
7,263
4,894
5,395
5,005
5,517
4,696
5,177
4,958
5,465
2,617
2,885
4,515
4,977
+ Letter dated November S, 197S'with attachments from Mr. James L. Hamilton III, Manager, Environmental Control - Water, USSC, to
Mr. S. R. Uaseersug, Director, Enforcement Division, USEPA, Region III, Philadelphia, Pa.
tt See Appendix F for weekly production for each mill.
ttt Average of weekly production, not of monthly production.
-------
Table 18
STRUCTURAL MILL DAILY PRODUCTION+
USSC HOMESTEAD MAIN WORKS
October 17-29, 1975
Date Mill Production per Operating Day++ Daily
(Oct.)
54-inch
44-inch
52-inch
36-*and 28/32-inch
Totals**
m.tons
. tons
m.tons
tons
m.tons
tons
m.tons
tons
m.tons
tons
17
1,271
1,401
798
880
1,172
1,292
225
248
3,466
3,821
18
940
1,036
738
814
331
365
362
399
2,371
2,614
19
729
804
-
-
-
-
-
-
729
804
20
233
257
722
796
-
-
381
420
1,336
1,473
21
1,287
1,419
650
716
1,204
1,328
364
401
3,505
3,864
22
702
774
561
618
519
572
282
311
2,064
2,275
23
1,089
1,200
787
868
1,048
1,155
480
529
3,404
3,752
24
1,141
1,258
393
433
976
1,076
308
339
2,818
3,106
25
1,220
1,345
669
737
-
-
667
735
2,556
2,817
26
933
1,029
-
-
-
-
-
-
933
1,029
27
282
311
316
348
271
299
270
298
1,139
1,256
28
953
1,050
584
644
848
935
515
568
2,900
3,197
29
628
692
592
653
371
409
517
570
2,108
2,324
+ Letter dated December 17, 1975 with attachments from Mr. James L. Hamilton III,
Manager, Environmental Control - Water, USSC, to Mr. S. R. Wassersug, Director,
Enforcement Division, USEPA, Region III, Philadelphia, Pa.
tt Calculated from tons provided by USSC.
* Production for 36-inch mill was not provided for October 17-29. However,
production for 36-inch mill was included with the production for the 28/32-inch
mill for January through June 1975. Therefore, it was assumed that production
for both mills was the same for October 17-29.
** Calculated totals from USSC data. Daily totals were not provided by USSC.
75 of 213
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The total production was calculated by summing the production of each
mill. The tonnage processed through the 54-inch mill is also processed
in the 52-inch mill unless blooms are routed to another mill. Similarly,
tonnage processed through the 44-inch mill is also processed in the 36-
and 28/32-inch mills. For January through June, the tonnage for the 36-
and 28/32-inch mills was reported as a combined total.1 However, for
October 17-29, production for the 36-inch mill was not reported;1
therefore, it was assumed that the tonnage reported for the 28/32-inch
mill included the tonnage for the 36-inch mill.
As previously discussed under outfall 006, the composite samples
collected by USSC are comprised of equal-volume aliquots; variations in.
flow over the 24-hour monitoring period are not taken into consideration
even though the flow is continuously measured and recorded. During the
NEIC survey, the instantaneous flows varied by 30% and ranged from
48,800 m^/day (12.9 mgd) to 69,300 m^/day (18.3 mgd) [Table 6]. There-
fore, the self-monitoring data submitted by USSC for January-June, 1975
should be considered as an estimate of pollutant concentrations. In
order to compare the waste loads discharged from outfall 010, the gross
waste load-discharged per unit of production was computed for January-
June [Table 19] and October 22-29* [Table 20], based on the average
total production and self-monitoring data submitted by USSC.1*2 For
January-June, average total production was 4,515 m. tons (4,977 tons)/
day or about 75% of the mill's rated capacity;** for October 22-29, the
total production averaged 2,259 m. tons (2,490 tons)/day, or about 37%
of capacity. Generally it would be expected that as production in-
creases, the pollutant loads discharged would also increase. However,
as was the case for the 48-inch mill, the unit waste loads for 0/G and
TSS for October 22-29 were 33% and 60% greater, respectively, than the
corresponding unit waste loads for January-June. This indicates that
* Period when wastewater samples were collected
** Fated capacity = 6,068 m. tons (6,691 tons)/day
76 of
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Table 19
SUMMARY OF WASTE LOADS PER UNIT PRODUCTION
OUTFALL 010 (54-, 52-, 44-a 3628/32-inch Mills)
USSC HOMESTEAD MAIN WORKS
January - June 1975
Month
Average Daily
Production
+4*
Total Suspended Solids
Oil and
Grease++
1,000 kg
tons
kg/1,000 kg
1b/ton
kg/1,000 kg
lb/ton
January
6,589
7,263
0.32
0.63
0.03
0.06
February
4,894
5,395
0.59
1.17
0.04
0.08
March
5,005
5,517
*
~
*
*
April
4,696
5,177
0.30
0.59
0.16
0.31
May
4,958
5,465
0.42
0.84
0.06
0.12
June
2,617
2,885
0.72
1.43
0.17
0.33
Monthly
average
4,515**
4,977**
0.47
0.95
0.09
0.18
t Letter dated November 5, 1975 with attachments from Mr. James L.
Hamilton III* Manager, Environmental Control - Water, USSC, to
Mr. S. R. Wassersug, Director, Enforcement Division, USEPA, Region
III, Philadelphia, Pa.
tt Gross loads
* Flows not reported for March; therefore, load cannot be calculated.
** Average of weekly production, not of monthly production. See
Appendix F for weekly production for each mill.
77 of
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Table 20
SUMMARY OF WASTE LOADS PER UNIT PRODUCTION+
OUTFALL 010 (54-, 52-, 44-, 38-, and 28/32- INCH MILLS)
USSC HOMESTEAD MAIN WORKS
October 22-29, 1975
Date++
Total
Total Suspended Solids
Oil and
Grease
Production
Gross
Net
Gross
Net
Flow
(Oct.)
1,000 kg
tons
kg/1,000 kg lb/ton
kg/1,000 kg lb/ton
kg/1,000 kg lb/ton
kg/1,000 kg lb/ton
3
m'VI ,000 kg gal/ton
22
2,064
2,275
1.32
2.63
0.37
0.74
0.15
0.29
0.09
0.17
29
6,860
23
3,403
3,752
0.73
1.47
0.21
0.42
0.10
0.20
0.09
0.17
17
4,180
24
2,818
3,106
0.45
0.90
0.02
0.04
0.07
0.15
0.07
0.15
20
4,890
25
2,556
2,817
0.37
0.74
0.19
0.37
0.06
0.12
0.04
0.09
23
5,540
26
933
1,029
1.07
2.15
0
0
0.12
0.24
0.12
0.24
63
15,160
27
1,139
1,256
0.86
1.73
0.46
0.92
0.20
0.40
0.15
0.30
51
12,180
28
2,900
3,197
0.47
0.95
0.29
0.58
0.11
0.21
0.09
0.17
21
4,940
7-Day
Average 2,259
2,490
0.76
1.51
0.22
0.44
0.12
0.23
0.09
0.18
32
7,680
t Letter dated December 17, 1975 with attachments from Mr. James L. Hamilton III, Manager, Environmental Control - Water,
USSC, to Mr. S. R. Waseereug, Director, Enforcement Division, USEPA, Region III, Philadelphia, Pa.
t+ Sampling occurred between 6 a.m. and 6 a.m. for each 24-hour period (from 8 a.m. Oct. 22 to 6 a.m. Oct. 29) while
total production reported by USSC was for the period of 12 midnight to 12 midnight. Therefore, waste loads per unit
production are only approximate.
-------
the equal-volume method of compositing samples does not provide represen-
tative data. Also, the data indicate that the 0/G parameter is not
dependent upon production since the rolls in the mills are probably
lubricated on a constant schedule. On Saturday, October 26, only the
54-inch mill was operating, and there was no increase in TSS levels over
intake concentrations and 0/G concentrations were at minimal levels
which indicates that TSS concentrations and possibly other pollutant
concentrations are dependent upon production. Therefore, samples must
be composited on a flow-weighted basis to provide representative data.
The monitoring location for outfall 010 is satisfactory when the
river stage is below the effluent channel. The flow measurement device
is satisfactory; however, a head-discharge curve should be developed for
the broad-crested weir and the flow recorder set accordingly. The flow
indicator/recorder should also be calibrated periodically on a scheduled
basis to insure measurement accuracy.
OUTFALL Oil
Outfall Oil is the terminus of the Munhall Borough storm sewer
which enters USSC property next to the open hearth No. 4 building [Fig.
5]. Untreated process wastewaters and cooling waters are discharged to
the storm sewer and mix with the Borough wastewaters prior to discharge
to the river. The open hearth No. 4 building is virtually abandoned,
and supposedly there is no USSC flow upsewer of the manhole adjacent to
the narrow gauge railroad tracks.
Samples were collected upstream of all USSC discharges to the storm
sewer and at outfall Oil. Flows were determined at both monitoring
locations using the dye dilution method. Net USSC wastewater concentra-
tions and loads were calculated by subtracting the upstream wastewater
79 of
-------
MONONQAHEUA RIVER
OUTFALL 011
H.(^>
DYE INJECTION LOCATION
"From Munhall Borough
O.H. MAIN ©ATE
—J k—
8th Ave
PENCE
00
O
ro
CO
Figure 5., Wartewater Schematic Flew Diagram - Outfall 011
USSC Homattead Main Works
-------
and the intake water contributions from outfall Oil [Tables 4, 5,
6, 7].*
The upstream monitoring location contained wastewaters from the
Munhall Borough; the appearance and odor was characteristic of domestic
3
sewage. The flow was about 0.48 m /day (0.13 mgd) and contained average
TSS and 0/G concentrations of 41 mg/1 and 27 mg/1, respectively. Metal
concentrations were negligible.
3
The flow contributed by USSC sources averaged about 3,620 m /day
(0.96 mgd) for the 7 days. The net TSS and 0/G concentrations averaged
13 mg/1 and 6 mg/1, respectively, corresponding to loads of 49 kg/day
(107 lb/day) and 18 kg/day (40 lb/day).
USSC has not proposed effluent limitations for this outfall.
Self-monitoring data for January-June, 1975 is non-existent for
TSS, 0/G and metals [Table 15]. The only self-monitoring data reported
by USSC were cyanides and phenols for March.1 Total and amenable
cyanides were 0.011 mg/1 and 0.003 mg/1, respectively, and phenol was
0.022 mg/1.
On October 22 and 27, grab samples were collected at both monitor-
ing locations and analyzed for organic compounds [Table 21]. Low levels
of phenols, cresols, alcohols and a phthalate were found in the upstream
wastewater on both days. These compounds were not detected at outfall
Oil on either day, indicating that the USSC flow diluted the concen-
trations to non-detectable levels.
* Net eettleable solids were not calculated since levels were negligible.
81 of 213
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Table 21
SUMMARY OF ORGANIC COMPOUNDS
USSC HOMESTEAD MAIN WORKS
October 22 and 27 3 1975
Monitoring Location
Compound* Upstream of Outfall 011++ Outfall 017 at river
Oct. 22 Oct. 27 Oct. 27
m-Cresol
0.01
0.01
-
o-Cresol
-
-
0.06
2,4 Dimethyl phenol
<0.01
ND*
-
m+p-Ethylphenol
0.30
ND
-
o-Phenylphenol
0.14
ND
-
Diethyl Phthalate
<0.01
<0.01
0.01
1-Tetradecanol
0.02
0.01
-
1-Hexadecanol
0.09
0.02
-
1-Octadecanol
0.00
0.02
-
2-Terpineol
0.02
0.03
-
Caffeine
0.02**
0.01**
-
Dodecane
-
-
0.01
Tridecane
-
-
0.01
Tetradecane
-
-
0.01
Pentadecane
-
-
0.01
Hexadecane
-
-
0.01
Octadecane
-
-
0.01
1,2,3-Trimethyl benzene
-
-
0.01**
Distilled Water without Dye Distilled Water with Dye
Oct. 22 Oct. 27 Oct. 27
Butyl Benzyl
Phthalate 0.36 0.13 0.13
t Concentrations expressed as mg/l
tf Munhall Borough wastewater only
* Not detected
** Not confirmed with standards, values approximate
82 of 213
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The USSC monitoring location for outfall Oil at the river is satis-
factory. Flows are not measured; however, measurements are possible
using tracer techniques* or by installation of permanent structures,
protected from flooding by the river. USSC personnel do not monitor at
the upstream location.
USSC should monitor the upsewer location when outfall 001 is
monitored, and.credit should be given for the upsewer wastewater con-
stituents. Flow measurement at the upstream location is possible with
tracer techniques without requiring alterations to the storm sewer
structure.
OUTFALLS 012 AND 013
Direct contact cooling waters from the Langenfelder Slag Reclam-
ation area and cooling waters from the carburizing shop and vertical
furnace facility are discharged through outfalls 012 and 013 [Fig. 1].
The slag reclamation process consists of dumping slag from the open
hearth furnaces in an open area and spraying it with water for cooling.
Large pieces of steel are recovered with a magnetic separator; the slag
is crushed and hauled by truck to the Nine Mile Dump directly across the
river. Spent cooling water is collected in the yard drains and conveyed
to either outfall 012 or 013, depending on the slag cooling location in
the yard. Special products are heat-treated in furnaces in the carburiz-
ing shop while the vertical furnace facility consists of vertical heat-
treating furnaces (pieces are stacked vertically) and a vertical quenching
unit. Machine shops in the area also contribute cooling water to both
outfalls.
* Dyet lithium chloride or other tracers
83 of 213
-------
Analytical results for both outfalls are summarized in Tables 4, 5,
6 and 7.
The flows through outfalls 012 and 013 averaged 32,500 m^/day (8.6
q
mgd) and 5,400 m /day (1.4 mgd), respectively, during the survey [Table
4]. USSC estimated the flows from outfall 012 ranged from 0-16,500
m /day (4.37 mgd) in their self-monitoring reports for January-June,
1975 [Table 10]. The flows through outfall 013 ranged from 1,090-20,800
3
m /day (0.288-5.5 mgd) for the same period.
There was no increase in 0/G and metal concentrations over back-
ground levels in either outfall. The TSS concentration increased an
average of 2 mg/1 in outfall 012 and 9 mg/1 in outfall 013. USSC data
for January-June, 1975 only reported flow, pH, and temperature for
outfall 012. For outfall 013, the self-monitoring TSS and 0/G concen-
trations were similar to those found during the NEIC survey.
USSC has not proposed effluent limitations for either outfall;
however, they have proposed that the TSS and 0/G parameters not be
monitored at outfall 013. Although there was no net increase in 0/G
concentrations, the TSS concentration was increased. Steel production
was at low levels for the Monongahela Valley plants; thus, slag proces-
sed at the Langenfelder area would be reduced. Therefore, the quantity
of water used for cooling would be reduced along with pollutant concen-
trations. Since there are no solids recovery facilities, the TSS
parameter should be monitored at both outfalls if the slag reclamation
process is operational.
Monitoring for both outfalls is presently done at the river from
satisfactory locations. USSC does not measure flow, but flows can be
measured using tracer techniques or by installing permanent devices such
as flumes. However, to install permanent measurement devices at the
84 of
-------
river, extensive protective structures would be necessary for flood
protection.
OUTFALL 014
Codling water and process wastewaters from 18 reheat furnaces,
scale pit, and forging machines of the No. 2 forge shop are discharged
from outfall 014 [Fig. 2]. According to USSC,1 process wastewaters,
consisting of descaling water and cooling water leakage, are collected
in a sump under the 4,000-ton press (the foundation for the press serves
as the scale pit) and are then pumped to outfall 014. The pump operates
from a level control and pumps at a rate of 380 1/min (100 gpm). By
design, oil leakage from the 4,000-ton press and auxiliaries is directed
into a separate sump and is pumped to a 7.6 m. (2,000 gal) waste oil
storage tank. The waste oil is hauled away by a contractor. The waste
oil storage tank has an overflow that returns to the sump. Scale from
forging operations is collected, normally in a dry form, and is recycled
through the blast furnaces. Dimensions of the scale pit and sumps were
not provided; however, USSC did report that the SWD for the scale pit is
11 m (36 ft).
USSC estimates the flow as 43,600 m^/day (11.52 mgd) in their self-
monitoring reports for January-June, 1975 [Table 10], During the NEIC
3
survey, flows ranged from 11,700-23,200 m /day (3.1-6.1 mgd) and aver-
aged 14.6 m /day (3.9 mgd). The No. 2 forge shop was operational during
October 17-29; however, flow was not observed in the scale pit. Since
the reheat furnaces are not kept operational at all times (furnaces may
be banked or completely shut down), the lower flows experienced during
the survey may have been due to a number of the furnaces being shut down
and minimum processing.
85 of
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The TSS concentrations remained at or near background levels on six
of the seven days [Table 4]. On October 23-24, the gross TSS concen-
tration was 40 mg/1, an increase of 18 mg/1 over the background concen-
tration. This increase in solids occurred during the period when the
maximum flow was recorded.
There was no net increase in the 0/6 concentrations [Table 6] and
only a negligible increase in metal concentrations [Table 5] during the
survey period.
USSC did not report TSS, 0/G, or metal parameters in their self-
monitoring data for January-June, 1975. They did monitor cyanide,
phenol, and total organic carbon (TOC) in March, April, and May [Table
10]. Cyanides were less than 0.03 mg/1, phenols less than 0.08 mg/1,
and TOC less than 11 mg/1. USSC has not proposed limitations for
outfall 014.
Production data for the No. 2 forge shop was not submitted by USSC.
The wastewater is monitored at the discharge to the river. The
location is satisfactory. Flows are presently estimated by USSC personnel,
but can be measured using tracer techniques or by installing a permanent
flow device. For the latter installation, major construction would be
required since a protective structure would be necessary for flood
protection. Since the present pollutant parameters are equivalent in
outfalls 012, 013, and 014, the wastewater streams could be collected
and discharged through one flow device and single outfall location.
OUTFALLS 015 AND 115
Wastewater discharged through outfall 015 originates in the No. 5
open hearth building, the 160-inch plate mill heat treating building and
86 of 213
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3
the water treatment plant [Fig. 6]. Approximately 174,000 m /day (46
mgd) of cooling water is discharged from the eleven open hearth furnaces.
During the survey, only five of the open hearth furnaces were operating;
the other six furnaces were shut down. Five dry electrostatic pre-
cipitators (ESP's) treat the flue dust on the open hearths. This dust
is taken to the Taylor Dump.
The 160-inch plate mill heat treating operation consists of a heat
hardening process followed by quenching, then normalizing. In the
quenching operation, water under high pressure is applied to the hot
plate. Overflow from the 380 m (100,000 gal) quench reservoir, located
below the plate treating building, is discharged through outfall 015.
Monitoring of the quench water overflow is scheduled to commence on July
1, 1977, at an intermediate location designated outfall 115. Solids
which have settled in the reservoir are removed by a bucket and hauled
to the Saxonburg plant. USSC has reported that about 18,900 m /day (5
mgd) of overflow water is discharged to the river.
Water treatment consists of hot lime-soda ash addition, settling,
pressure filtration, zeolite softening and de-aeration. The amounts of
chemicals used for treatment are listed in Table 22. The treated water,
2,750 m /day (0.725 mgd), is used in eleven waste heat boilers and four
package boilers in the No. 5 open hearth building. Chemical sludges,
filter backwash solids and boiler blowdowns are discharged to the 015
sewer line. The wastewater volume discharged from the water facility
was not known by USSC.
Flows for outfall 015 and 115 are estimated by USSC; self-monitor-
ing data for January-June, 1975 [Table 10] show that flows ranged from
27,250-231,600 m^/day (7.2-61.2 mgd) and averaged 181,700 m^/day (48
mgd) for outfall 015. The self-monitoring reports do not contain flow
data for outfall 115; however, USSC has estimated the flow to be
87 of
-------
MONON0AHELA RIVER
—a
OUTFALL 115
¦A>
160—INCH PLATE HEAT
TREATING MILL
OUTFALL 018
WATER
TREATMENT
PLANT
i
~N-
I
OPEN HEARTH BUILDING NO. 5
->-o
(ELEVEN OPEN HEARTH FURNACES)
Figure 6. Wastewater Schematic Flow Diagram - Outfall 0)5
USSC Homestead Main Works
-------
Table 22
CHEMICAL USAGE AT NO. 2 INTAKE WATER TREATMENT FACILITY^
USSC HOMESTEAD MAIN WORKS
August 1975
Amount of Water Treated
Lnemlcal kg/1 X 10* lb/gal X 10*
Soda Ash
1.9
16
Hydrated Lime
1
9
Sodium Aluminate
0.1
1
Bentonite Clay
0.1
1
Polyphosphate
0.07
0.6
Organic Anti-foam
0.02
0.2
Sodium Sulfite
0.2
2
Salt Used 20,185 kg (44,500 lb)
in August for regeneration
of softeners
t Letter dated November 53 1975 with attachments from
Mr. James L. Hamilton III, Manager3 Environmental
Control - Watery VSSCs to Mr. S. R. Wassersug3
Directors Enforcement Division, USEPA, Region III3
Philadelphia3 Pa.
-------
3
18,900 m /day (5 mgd) [Appendix A]. During the NEIC survey, the flows
through outfall 115 ranged from 45,000-53,700 m^/day (11.8-14.2 mgd)
[Table 4]. The average flow of 48,700 m^/day (12.9 mgd) was about 2.5
times the USSC estimate. Flows from outfall 015 ranged from 260,000-
305,000 m^/day (68.8-80.5 mgd) and averaged 289,000 m^/day (76.5 mgd),
or about 1.5 times the average flow estimated by USSC.
The production capacity of the heat treating mill is 241 m. tons
(266 tons)/day without stainless steel processing and 292 m. tons
(322 tons)/day with stainless steel processing.1 Production for Jan-
uary-June, 1975 is summarized in Table 23; production during the NEIC
survey was as follows:2
Date
(Oct.)
Tons produced per day
m. tons
tons
17
279
308
18
-
-
19
-
-
20
278
307
21
278
307
22
314
346
23
492
542
24
378
417
25
-
-
26
-
-
27
288
317
28
494
545
29
378
417
Daily Average 353
390
USSC did not specify whether stainless steel was being processed during
the survey or the January-June period; however, during both periods
production was greater than the rated capacity of the mill. Based on
the daily average production calculated from the data submitted by USSC,
production during the NEIC survey was approximately 85% of the production
for January-June, 1975.
90 of
-------
Table 23
SUMMARY OF 160-INCH PLATE HEAT TREATING MILL PRODUCTION*
USSC HOMESTEAD MAIN WORKS
January-June 1975
Month Production per Operating Day
Minimum Maximum Average
m. tons tons m. tons tons m, tons tons
January
285
315
512
564
406
448
February
46
51
469
517
367
404
March
238
262
586
646
408
450
April
205
226
510
562
403
444
May
206
227
606
668
408
450
June
95
105
672
741
486
536
6-month+++
average 413 455
t Letter dated November 5, 1975 with attachments from Mr. James
L. Hamilton III, Manager, Environmental Control - Water, USSC,
to Mr. S. R. Wassersug, Director, Enforcement Division, USEPA,
Region III, Philadelphia, Pa.
tf See Appendix F for weekly production.
ttt Average of weekly production, not monthly production.
91 of
-------
On three of the seven monitoring days, there was a net TSS increase
in both outfalls; the increase occurred in both discharges on the same
days [Table 4]. The seven-day average net increase in the TSS loads was
190 kg/day (415 lb/day) and 1,100 kg/day (2,400 lb/day) for outfalls 115
and 015, respectively, corresponding to an average increase of 4 mg/1
for both outfalls. The increase occurred on two of the three days that
the 160-inch heat treating mill was not operating, October 25 and 26.
The oil and grease concentration in outfall 115 increased on four of the
seven days monitored, but this increase was not evident in outfall 015
[Table 6]. Metals also increased over background levels for both
discharges, but the increase was negligible [Table 5]. Settleable
solids were less than 0.1 ml/1 [Table 7].
Self-monitoring data [Table 10] for both outfalls is limited, and
comparisons with the survey data were not made.
USSC has proposed that the net oil and grease load be limited to
1,320 kg/day (2,900 lb/day) as the daily average, and 3,960 kg/day
(8,700 lb/day) as the daily maximum for outfall 015 [Table 15]. The
daily maximum oiland grease net load during the survey was 640 kg/day
(1,400 lb/day), or only 15% of the proposed limitation. There was no
net increase in oil and grease on a daily average basis.
Based on the production in the 160-inch plate heat treating mill,
the waste loads discharged per unit of production are summarized in
Table 24. Since the samples were collected from 6 a.m. to 6 a.m. and
production is reported from midnight to midnight, these unit loads are
only approximations.
The quenching reservoir overflow is monitored at a manhole on the
east side of the 160-inch plate heat treating mill (outfall 115). Due
to the magnitude of the flow and velocity, and limited access in the
92 of
-------
Table 24
SUMMAE1 OF WASTE LOADS PER UNIT PRODUCTION+
160-INCH PLATE HEAT TREATING MILL (OUTFALL US)
USSC HOMESTEAD MAIN WORKS
October 22-29, 1975
n t ++ Total Suspended Solids 011 and Grease Flow
» Total Production Gross Net Gross Net ,
* ' 1,000 kg tons kg/1,000 kg lb/ton kg/1.000 kg lb/ton kg/1,000 kg lb/ton kg/1,000 kg lb/ton m /1,000 kg gal/ton
22
314
346
5.2
10.3
0
0
0.7
1.3
0
0
23
492
542
3.8
7.5
1.7
3.3
0.4
0.8
0.2
0.4
24
378
417
3.3
6.6
0
0
0.5
1.0
0.4
0.7
25
-
-
-
-
-
-
-
-
-
-
26
-
-
-
-
-
-
-
-
-
-
27
288
317
2.0
4.0
0
0
0.7
1.4
0.7
1.4
28
494
545
0.8
1.6
0
0
0.4
0.8
0.3
0.6
5-Day
Werage
393
433
3.0
6.0
0.3
0.7
0.5
1.1
0.3
0.6
171
96
123
155
100
129
41,000
23,000
29,500
37,200
24,000
31,000
t Letter dated December 17, 1975 with attachments from Mr. James L. Hamilton III, Manager, Environmental Control - Water, USSC,
to Mr. S. R. Wassersug, .Director, Enforcement Division, US EPA, Region III, Philadelphia, Pa.
tt Sampling occurred between 6 a.m. and 6 a.m. for each 24-hour period while total production reported by USSC was for the period
of midnight to midnight. Therefore, waste loads per unit production are only approximate.
ftf October 25 and 26 not included in average.
-------
manhole, flow measurements can most easily be achieved with tracer
techniques. Samples collected at this location will be representative.
USSC monitors outfall 015 at the river. Representative samples can
be collected at this location. Flows are presently estimated by USSC.
However, measurements can be made by installing a permanent flow device
or by tracer techniques. The former would require a flood protection
structure.
OUTFALL 016
Process wastewaters from the 45-inch slab mill and the 160-inch
plate mill pass through their respective scale pits and are then dis-
charged to the Monongahela River through outfall 016 [Fig. 7]. The hot
scarfing operation in the 45-inch slab mill was reported during the
reconnaissance [Appendix A] to have a dry cyclone unit for air pollution
control; the solids from the cyclone are hauled to the Taylor dump
because they are too fine for pelletizing and recycle. In response to
the 308 Request,1 USSC stated that all air pollution control equipment
at Homestead is the dry type except for the wet precipitator at the hot
scarfer. Wastewater from the precipitator is discharged to the 45-inch
mill scale pit. The precipitator was not discussed during the recon-
naissance.
The scale pit serving the 45-inch mill is located outside the
building on the south side. Effective dimensions of the pit are 11.6 m
(38 ft) long x 4.6 m (15 ft) wide x 2.7 m (9 ft) SWD. The estimated
design flow1 is 15,150 1/min (4,000 gpm) or 21,800 m^/day (5.76 mgd);
the detention time is about 10 minutes. USSC estimates that 99.1% of
the suspended solids are removed in this scale pit.1 Wastewater enter-
ing the scale pit originates from roll cooling, shear cooling, descaling,
flume cleaning and the aforementioned wet precipitator.
94 of 213
-------
-------
The 160-inch mill scale pit has effective dimensions of 10 in (34.25
ft) long x 4.6 m (15 ft) wide x 2.8 m (9.25 ft) SWD. The estimated
¦5
design flow1 is 24,600 1/min (6,500 gpm) or 35,600 m /day (9.4 mgd); the
detention time is approximately 5 minutes. USSC estimates that 97.5% of
the suspended solids are removed.1 Scale removed from this pit and the
45-inch mill pit are hauled to the USSC Saxonburg plant.
USSC estimated the flow through the outfall to average 63,200
m^/day (16.7 mgd) for January-June 1975 [Table 10]. The USSC estimated
q
design flow from both scale pits totals 57,400 m /day (15 mgd). How-
ever, USSC has also reported in their NPDES permit application a total
flow of 109,800 m^/day (29 mgd) conrsisting of 45,400 m^/day (12 mgd)
from the 45-inch mill and 64,400 m /day (17 mgd) from the 160-inch mill.
During October 22-29, the total flow through outfall 016 averaged
106,800 m^/day (28.1 mgd) [Table 4], or about 70% greater than that
reported for January-June. This flow was similar in magnitude to that
reported in the NPDES application.
Production capacity of the 45-inch slab mill is 7,160 m. tons
(7,896 tons) and the 160-inch plate mill's capacity is 2,550 m. tons
(2,808 tons).1 Production for the 45-inch and 160-inch mills for
January-June, 1975 is summarized in Tables 25 and 26, respectively;
production during the NEIC survey for both mills was as follows:
96 of
-------
Table 25
SUMMARY OF 45-INCH SLAB MILL PRODUCTION*
USSC HOMESTEAD MAIN WORKS
January-June 1975
Month Production per Operating Day
Minimum Maximum Average
m. tons tons m. tons tons m. tons tons
January
2,236
2,465
6,622
7,299
4,754
5,241
February
1,816
2,002
6,162
6,792
4,549
5,014
March
2,159
2,380
7,041
7,761
4,851
5,347
April
2,702
2,978
6,487
7,151
5,030
5,545
May
2,051
2,261
6,514
7,181
4,545
5,010
June
2,212
2,438
7,067
7,790
4,423
4,876
6-month...
average
4,693
5,173
t Letter dated November 5, 1975 with attachments from Mr. James
L. Hamilton III, Manager> Environmental Control - Water, USSC3
to Mr, S. R. Wassersug, Director3 Enforcement Division, USERA,
Region III3 Philadelphia, Pa.
tt See Appendix F for weekly production.
ttt Average of weekly production, not monthly production.
97 of 213
-------
Table 26
SUMMARY OF 160-INCH PLATE MILL PRODUCTION+
USSC HOMESTEAD MAIN WORKS
January-June 1975
4,4'
Month Production per Operating Day
Minimum Maximum Average
• m. tons tons m. tons tons m. tons tons
January
1,966
2,167
3,861
4,256
2,942
3,243
February
2,058
2,269
3,944
4,347
2,958
3,261
March
1,309
1,443
3,863
4,258
2,802
3,088
April
1,827
2,014
3,687
4,064
2,895
3,191
May
2,446
2,696
3,992
4,400
3,053
3,365
June
380
419
3,362
3,706
2,700
2,976
6-month,,,
TTT
average
2,894
3,190
t Letter dated November 5j 1975 with attachments from Mr. James
L. Hamilton Illy Managerj Environmental Control - Water, USSC,
to Mr. S. R. Wassersugj Director, Enforcement Division3 USEPA,
Region III, Philadelphia> Pa.
ft See Appendix F for weekly production.
t+t Average of weekly production, not monthly production.
98 of 213
-------
Tons Produced Per Day^
45-inch Mill 160-inch Mill
Oct.
m. tons
tons
m. tons
tons
17
1,930
2,127
1,840
2,028
18
2,692
2,967
-
-
19
3,131
3,451
•
-
20
2,973
3,277
1,432
1,578
21
2,459
2,711
1,070
1,180
22
2,781
3,065
1,557
1,716
23
2,635
2,905
1,324
1,459
24
2,586
2,851
1,317
1,452
25
2,947
3,249
-
-
26
3,162
3,486
863
951
27
2,767
3,050
2,869
3,163
28
2,025
2,232
2,754
3,036
29
2,271
2,503
2,702
2,978
Daily
Average
2,643
2,913
1,773
1,954
During the NEIC survey, the 45-inch mill and 160-inch plate mill were
operating at approximately 37% and 70% of rated capacities, respectively,
compared to respective operating levels of 66% and 114% during January-
June.
Production during the October survey was about 44% lower for the
45-inch mill and about 39% lower for the 160-inch plate mill than the
first six months' production levels. However, the volume of wastewater
discharged from outfall 016 was about 70% greater in October than the
first six months, clearly indicating that the USSC-estimated flows and
pollutant loads do not represent actual conditions.
The average net oil and grease concentration discharged from
outfall 016 was 2 mg/1, corresponding to an average net load of 210
kg/day (470 lb/day) [Table 6]. The maximum net 0/G concentration was 4
mg/1, occurring on two of the seven monitoring days.
99 of 213
-------
Over the seven-day monitoring period, the net TSS load averaged
1,865 kg/day (4,100 lb/day) [Table 4]. The net TSS load ranged from
750-5,225 kg/day (1,655-11,520 lb/day); the minimum load occurred
October 25-26 (Saturday-Sunday) when the 160-inch plate mill was down.
Since both mills discharge from outfall 016 and no intermediate monitor-
ing location has been established, the contribution from each mill was
not determined. However, based on the data for the day that only the
45-inch mill was operating and assuming the solids discharged from the
160-inch mill were at background levels, and the seven-day average load
discharged from outfall 016, an estimated 40% of the total load was
discharged from the 45-inch slab mill. (This contribution may not
represent actual conditions when both mills are operational.). Monitor-
ing locations should be established on each mill if individual pollutant
contributions are required. There are manholes downsewer of each mill's
scale pits suitable for monitoring.
Waste loads discharged per unit production during the survey are
summarized in Table 27. Total production was calculated as the sum of
the individual production data for the 45-inch and 160-inch mills.
Since TSS samples were collected from 6 a.m. to 6 a.m. and production
data were reported from midnight to midnight, the unit waste loads are
approximations.
Self-monitoring data [Table 10] indicate that the average gross
concentrations of TSS and 0/G were 40% and 60% greater, respectively,
during January-June 1975 than during the NEIC survey. The average
combined production for both mills in January-June was approximately 42%
greater than levels during the survey. As discussed previously under
outfalls 006 and 010, USSC collects composite samples on an equal-volume
basis and does not consider variations in flow. Therefore, the com-
posite sample data should be considered as estimates of actual conditions.
The data submitted by USSC for outfall 016 when compared with the NEIC
data clearly indicate that the loads are dependent upon production.
100 of
-------
Table 27
SUMMARY OF WASTE LOADS PER UNIT PRODUCTION*
OUTFALL 016 (45-INCH SLAB MILL AND 160-INCH PLATE MILL)
USSC HOMESTEAD MAIN WORKS
October 22-29, 1975
Total .. Total Suspended Solids*** Oil and Grease***
Date
Production
Gross
Net
Gross
Net
Flow
(Oct.)
1,000 kg
tons
kg/1,000 kg lb/ton
kg/1,000 kg lb/ton
kg/1,000 kg lb/ton
kg/1,000 kg lb/ton
•»
m /I,000 kg gal/ton
22
4,337
4,781
1.17
2.34
0.29
0.59
0.16
0.32
0.03
0.06
29
7,030
23
3,959
4,364
1.96
3.93
1.32
2.64
o.n
0.22
0.06
0.12
29
7,030
24
3,904
4,303
1.06
2.13
0.25
0.49
0.11
0.21
0.07
0.15
25
5,930
25
2,947
3,249
0.67
1.34
0.25
0.51
0.11
0.21
0.10
0.19
32
7,630
26
4,025
4,437
0.55
1.10
0.40
0.80
0.11
0.21
0.06
0.13
21
5,070
27
5,636
6,213
0.63
1.26
0.32
0.63
0*06
0.13
0.06
0.13
17
3,980
28
4,779
5,268
0.64
1.28
0.31
0.61
0.13
0.25
0.11
0.22
28
6,660
7-Day
Average
4,227
4,659
0.96
1.91
0.45
0.90
0.11
0.22
0.07
0.14
26
6,190
t Production data from letter dated December 17, 1975 with attachments from Mr. James L. Hamilton III, Manager, Environmental
Control - Water, USSC, to Mr. S. R. Wassersug, Director, Enforcement Division, USEPA, Region III, Philadelphia, Pa.
+t Total of production for the 45-inch and 160-inch mills.
t+t Sampling occurred between 6 a.m. and 6 a.m for each 24-hour period (from 6 a.m. Oct. 22 to 6 a.m. Oct. 29) while total
production reported by USSC was for the period of midnight to midnight. Therefore, waste loads per unit production are
only approximate for TSS.
-------
When production increased, the TSS and 0/G loads per unit production
increased. The instantaneous flows varied by 45% during the NEIC survey
and ranged from 77,600 m3/day (20.5 mgd) to 176,000 m3/day (46.6 mgd)
[Table 6]. Therefore, the flow must be accurately measured on a continuous
basis and samples composited on a flow-weighted basis to determine
compliance with permit conditions.
USSC has proposed that the gross loads for TSS and 0/G be limited
for outfall 016 [Table 15]. On a daily average basis, the gross TSS and
0/G loads proposed were 46% and 76% greater, respectively, than the
daily average gross loads for October 22-29. The daily maximum gross
TSS and 0/G loads proposed were 65% and 76% greater, respectively, than
the daily maximum gross loads for October 22-29.
Representative samples of the discharge can be collected at the
present river location. Flows can be measured by the tracer method or a
permanent flow measuring device which would require flood protection.
Due to the high solids concentration reported by USSC, a self-cleaning
device, such as a flume, should be installed.
OUTFALLS 017 AND 117
The Homestead Borough West Run Culvert is on the west side of the
Homestead plant [Fig. 8]. The flow is in an open channel upstream of
8th Avenue. At 8th Avenue, the flow enters the culvert and remains
underground until it reaches the river. The effluent from the 100-inch
plate mill discharges to the West Run Culvert and combines with storm
and sanitary wastes from an extensive portion of the West Homestead
Borough. The terminus of the West Run Culvert has been designated
outfall 017. Process wastewaters from the 100-inch mill pass through
either the east or west scale pit and combine with the cooling water in
the plant sewer which discharges into West Run Culvert. The effluent
102 of 213
-------
Figure 8. Wastewater Schematic Flow Diagram - Outfalls 117 and 017
USSC Homestead Main Works
-------
from this sewer is monitored by USSC at a manhole located inside the
mill, downsewer from the two scale pits. This monitoring location has
been designated outfall 117. During the reconnaissance, USSC personnel
stated that additional USSC flows may be entering West Run Culvert
upsewer of the 100-inch mill connection. Total contribution from all
USSC sources was estimated by USSC as 80-90% of the total flow through
outfall 017.
An inspection of the West Run Culvert on October 14, 1975 revealed
that raw sanitary wastes were flowing into the culvert's invert about 46
m (150 ft) downstream from the entrance at 8th Avenue. It appeared that
there was a break in the sanitary line which runs underneath the culvert.
The east scale pit serves the roughing section of the mill. The
effective dimensions of this pit are 11.4 m (37.5 ft) long x 2.7 m (12
ft) wide x 1.9 m (6.2 ft) SWD. The design flow is 15 m^/min (4,000 gpm)
or 21,800 m /day (5.76 mgd);1 the detention time is approximately 5
minutes. USSC estimates that 98.3% of the influent suspended solids are
removed in the scale pit.
The west scale pit serves the finishing area. Effective dimensions
of this pit are 5.5 m (18 ft) long x 2.7 m (9 ft) wide x 1.7 m (5.5 ft)
SWD. The design flow is 13 m^/min (3,500 gpm)1 or 19,100 m^/day (5.04
mgd); the detention time is about 2 minutes. The estimated suspended
solids removal is 98.3%.
USSC only monitors outfall 117 and estimates all flows. During the
survey, outfalls 117 and 017 were monitored. The West Run Culvert,
upstream of 8th Avenue, was also monitored to determine if pollutants
are discharged to the culvert from USSC or other sources upsewer of the
100-inch mill connection. Samples were collected on October 22-23 about
3 m (10 ft) downstream from where the raw sanitary wastewater was
flowing into the culvert; flows were measured about 15 m (50 ft)
104 of
-------
upstream of the entrance to the culvert. On October 23-24, samples were
collected at the upstream flow measuring location.
The 100-inch mill was scheduled to be shut down on October 24 for
repair and maintenance. According to USSC personnel, the shutdown was
to last at least 15 days. During the period of October 24-29, the mill
did not operate. Production for the 100-inch mill during the survey is
summarized in Table 28. Although the mill did shut down.on October 24,
production figures (showing minor production levels) were still provided
for October 26-29 when the mill was down. The produciton capacity of
the mill is 3,265 m. tons (3,600 tons). Production during January-June
is summarized in Table 29. During the January-June period, average
daily production was about 92% of capacity and about 51% greater than
production for October 17-24. Since the mill was shut down on October
24, the two outfalls were not monitored after this date. Production for
October 22-24 averaged 1,477 m. tons (1,628 tons), about 51% of the
rated capacity.
The open channel flow, upstream of 8th Avenue, was gaged according
to standard methods.3 USSC has reported that the process wastewater
3
volume from the 100-inch mill averages approximately 71,900 m /day (19
mgd). Self-monitoring data for January-June, 1975 for outfall 117
report the flow to range from 70,850-97,100 m3/day (18.72-25.65 mgd)
[Table 10]. For October 22-24, the flows at outfalls 117, 017 and the
3
upstream monitoring station of West Run Culvert averaged 94,200 m /day
(24.9 mgd), 91,600 m3/day (24.2 mgd) and 3,580 m3/day (0.95 mgd),
respectively [Table 4]. The flow data indicate that practically all of
the flow in outfall 017 originates in the 100-inch mill.
The net TSS load discharged through outfall 117 averaged 2,030
kg/day (4,475 lb/day) corresponding to a concentration of 22 mg/1 [Table
4]. The 0/G concentration was only 2 mg/1 greater than background
105 of 213
-------
Table 28
SUMMARY OF 100-INCH MILL PRODUCTION+
USSC HOMESTEAD MAIN WORKS
October 17-293 1975
Date Production
(Oct.) per operating day
m.tons tons
17
1,150
1,268
18
_+t
-
19
1,141
1,258
20
2,114
2,331
21
1,307
1,441
22
2,268
2,500
23
926
1,021
24
1,237
1,364
25
-
-
26+++
152
168
27ttf
112
124
28t++
78
86
29+++
93
102
Daily
Average
962
1,060
t Letter dated. December 17 3 1 97 5 with
attachments from Mr. James L.
Hamilton IIIy Manager3 Environmental
Control - Water3 USSC3 to Mr. S. R.
Wassersug, Directory Enforcement
Division3 USEPA3 Region III3
Phi ladelphias Pa.
tt No data reported.
ttt Mill was shut down during this
period.
106 of 213
-------
Table 29
SUMMARY OF 100-INCH MILL PRODUCTION+
USSC HOMESTEAD MAIN WORKS
January-June 1975
Month++ Production per Operating Day
Minimum Maximum Average
m. tons tons m. tons tons m. tons tons
January
2,025
2,233
4,029
4,442
3,062
3,376
February
2,252
2,483
3,981
4,389
3,265
3,599
March
2,165
2,387
4,101
4,521
3,311
3,650
April
1,089
1,201
3,708
4,088
3,236
3,568
May
59
65
4,406
4,858
2,950
3,252
June
1,656
1,826
3,354
3,698
2,440
2,790
6-month,.,
average TT 3,009 3,317
t Letter dated November 5, 1975 with attachments from Mr. James
L. Hamilton III, Manager, Environmental Control - Water, USSC,
to Mp. S. R. Wassersug, Director, Enforcement Division, USEPA,
Region III, Philadelphia, Pa.
tt See Appendix F for weekly production.
ttt Average of weekly production, not monthly production.
107 of 213
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levels [Table 6]. The total iron concentration was increased by 4,6
mg/1 over background concentrations, corresponding to a net load of 435
kg/day (955 lb/day). The net increase of lead was insignificant and
there was no increase in the other metals [Table 5]. Settleable solids
were <0.1 ml/1 [Table 7].
The TSS load discharged through outfall 017 averaged 5,115 kg/day
(11,275 lb/day) or about 90% of the gross TSS load discharged from the
100-inch mill. The 0/G concentrations at the river outfall were similar
to the concentrations found in the USSC discharge. The total iron
concentration was 2.6 mg/1; all other metals were negligible.
The waste loads per unit production are summarized in Table 30.
Since the samples were collected from 6 a.m. to 6 a.m. and the production
was reported from midnight to midnight* the unit loads are only approxi-
mate. The waste loads remained essentially the same on both days even
though production on October 22 was more than twice the production on
October 23. The data is too limited to verify that the waste loads
depend on production.
Self-monitoring data for outfall 117 for the period January-June
[Table 10] were similar to those found during the survey.
.USSC has proposed that TSS and 0/G loads be limited on a gross
basis for outfall 117 [Table 15]. The daily average TSS and 0/G loads
discharged during the survey were 75% and 32%, respectively, of the
proposed limits. The daily maximum TSS and 0/G loads during the survey
were 26% and 12%, respectively, of the proposed limits.
On October 27 at 10:20 a.m., a sample was collected from outfall
017. The flow was about 3,780 m /day (1 mgd) since all flow from the
100-inch mill had ceased. A sample was also collected at 11:55 a.m.
from the upstream monitoring location of the West Run Culvert. Both
108 of
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Table 30
SUMMARY OF WASTE LOADS PER UNIT PRODUCTION
OUTFALL 117 - (100-INCH MILL)
USSC HOMESTEAD MAIN WORKS
October 22-24, 1975
Parameter
Date (1975)
Oct. 22
Oct. 23
Daily
Average
kg/1,000 kg lb/ton kg/1,000 kg lb/ton kg/1,000 kg lb/ton
Total Production
1 ,000 kg
tons
TSS
ft
gross
net
0/G
tt
gross
net
Total Fe++
gross
net
Flow++
m3/l,000 kg
gal/ton
2,268
2,500
2.4
0.8
0.23
0.08
0.5
0.16
4.8
1.5
0.45
0.16
0.51
0.31
40
9,680
926
1,021
6.2
2.5
0.46
0.21
0.89
0.55
12.3
5.0
0.92
0.42
1.78
1.11
105
25,000
1,597
1,760
4.3
1.6
0.34
0.15
0.57
0.36
8.6
3.3
0.69
0.29
1.15
0.71
73
17,340
t Letter dated December 17s 1975 with attachments from Mr. James L. Hamilton III}
Managert Environmental Control - Water, USSC, to Mr. S. R. Wassersug, Director,
Enforcement Division, USEPA, Region III, Philadelphia, Pa.
tt Sampling occurred between 6 a.m. and 6 a.m. for each 24-hour period while
production reported by USSC was for the period of midnight to midnight.
Therefore, waste loads per unit production are only approximate for TSS and
total iron.
109 of 213
-------
samples were analyzed for organic compounds. At the upstream location,
only one organic compound was found, but it could not be confirmed with
combined gas chromatograph/mass spectrometer analysis. Based on the gas
chromatograph retention time, the compound may have been a phthalate,
about 0.30 mg/1. Nine organic compounds were found in the discharge at
the river, only one of which could not be confirmed with GC/MS standards
[Table 21]. The source of these organic compounds is not known but may
be from additional USSC discharges to the West Run Culvert and/or from
other sources connected to the culvert. Samples were also collected
from the two locations and from the wastewater discharged from outfall
117 on October 22. Organic compounds were not found in these samples.
Outfall 117 is monitored at the manhole west of the scale pits.
Representative samples can be collected at this location. Flow measure-
ment can be made with tracer methods or by installing permanent devices
in the plant sewer. Since most of the wastewater discharged through
outfall 017 also flows through outfall 117, monitoring of outfall 017 by
USSC is not warranted.
INTAKE 3-24
The No. 1 water intake (3-24) is upstream of outfall 010 [Fig. 1].
There are no traveling screens or strainers; however, the suction side
of the intake pipes are equipped with perforated end sections. These
intake tubes are periodically back-flushed directly to the river. There
are five pumps serving the No. 1 pumphouse; normal sequence of operations
are Nos. 1, 2 and 3 on an as-needed basis.
110 of
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Pump No.
Type
Rated Capacity
(mgd)
1
Electric
25
2
Electric
20
3
Electric
12
4
Steam
20
5
Steam
20
o
Total pumping capacity is 367,000 m /day (97 mgd). According to USSC,1
intake volumes are determined from time elapse meters connected to the
individual pumps, rated capacity for each pump, and an estimated age
factor. During the survey, NEIC personnel were informed by USSC plant
personnel that the estimated age factor is not used to determine flows.
Only the rated capacity and hours of operation are used to calculate
f1ows.
The No. 1 intake supplies water for processes which discharge to
outfalls 006, 010, 011, 012 and 013.
Intake water volumes for January-June, 1975 are listed in Table 31.
The average daily intake volume for this period was 88,950 m (23.5
million gal). During the NEIC survey, the intake volumes averaged
94,400 m^/day (24.9 mgd) [Table 4].* The intake volumes fluctuated over
each 24-hour period due to the operational sequence of the pumps.
The total quantity of wastewater discharged from outfalls 006, 010,
011, 012 and 013 is compared with the daily intake volumes in Table 32.
* Daily flous calculated by NEIC from rated pump capacity and hours of
operation for the time period 6 a.m. to 6 a.m.
Ill of 213
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Table 31
INTAKE WATER VOLUMES*
USSC HOMESTEAD MAIN WORKS
January-June 197S
Water Pumped from the Monongahela River
Source January February March April May June
(m3 x TO3) (gal x 106)
Intake 3-24
Monthly total
Daily Average
2,624
84.6
693.21
22.4
2,790
99.6
737.04
26.3
3,124
100
825.31
26.6
2,280
76.0
602.44
20.1
2,733
88.2
722.17
23.3
2,536
84.5
670.08
22.3
Intake 4-44
Monthly Total
Daily Average
10,335
333
2,730.48
88.1
7,198
257
1,901.79
67.9
10,376
335
2,741.40
88.4
9,948
332
2,628.20
87.6
10,235
330
2,704.12
87.2
9,710
324
2,565.44
85.5
Intake 5-51
Monthly Total
Daily Average
2,530
81.6
668.48
21.6
2,718
97.1
718.20
25.7
2,470
79.7
652.65
21.05
.2,932
97.7
774.76
25.8
3,010
97.1
795.15
25.7
2,913
97.1
769.50
25.7
Potable Water
Purchased
Monthly Total
Daily Average
116
3.8
30.741
0.99
135
4.8
35.648
1.3
117
3.8
30.811
0.99
128
4.3
33.89
1.1
132
4.3
34.965
1.1
138
4.6
36.49
1.2
t Monthly totals (gal x 106J supplied by USSC in letter dated December 17, 197S with attachments from Mr. James L. Hamilton III,
Manager, Environmental Control - Water, USSC, to Mr. S. R. Waseersug, Director, Enforcement Division, USEPA, Region III,
Philadelphia, Pa. Other data calculated by HEIC.
-------
Table 32
COMPARISON OF INTAKE WATER QUANTITIES AND OUTFALL DISCHARGES
INTAKE 3-24 AND OUTFALLS 006, 010, Oil, 012 and 013
USSC HOMESTEAD MAIN WORKS
October 22-29j 1975
Date
Intake
3-24
NEIC
Measured
Total of i
Flows .
Outfalls1"
(Oct.)
m3/day
mgd
m3/day
mgd
22-23
110,000
29
131,700
34.8
23-24
99,200
26.2
123,400
32.6
24-25
85,200
22.5
90,100
23.8
25-26
98,400
26.0
93,100
24.6
26-27++
88,600
23.4
106,000
28.0
27-28++
84,400
22.3
97,900
25.9
28-29++
95,400
25.2
90,100
23.8
Daily Average
94,400
24.9
104,600
27.6
t Approximately 380 m^/day (0.1 mgd) potable water dis-
charged to the river.
tt Total for outfalls includes estimated flow for outfall
006 of 4t600 rn^/day (1.2 mgd) since monitoring ceased
on Oct. 26 when the 48-inch mill shut down.
113 of 213
-------
The average daily intake volume for the survey was within 10% of the
total average daily discharges.
Settleable solids [Table 7], 0/G and phenol [Table 6] and metal
[Table 5] concentrations were low and remained constant over the moni-
toring period. However, TSS concentrations varied daily and ranged from
8-33 mg/1.
Self-monitoring data [Table 10] are similar to the data collected
October 22-29. TSS concentrations ranged from 0-105 mg/1, and averaged
32 mg/1. 0/G ranged from 0-24 mg/1, and averaged 3 mg/1. Iron had a
maximum concentration of 28.7 mg/1 and averaged 2 mg/1.
Samples for self-monitoring analyses are collected at the river
from the boat dock. Due to fluctuations in the intake pumping rate, the
daily variability of suspended solids concentrations during the NEIC
survey, and the high concentrations reported in the self-monitoring
data, composite samples should be collected over the entire 24-hour
monitoring period and combined on a flow-weighted basis. 0/G concen-
trations may be higher in the samples collected at the river than in the
water pumped through the plant. The plant water is pumped from below
the surface while samples are collected at the surface of the river.
Since the 0/G concentrations are higher at the surface due to flotation,
the net 0/G loads discharged may receive credit for higher intake
concentrations than actually exist. A representative sample can be
collected directly from the intake line in the pumphouse. The method of
flow determination is adequate since flows are required only for deter-
mining aliquots of sample needed to prepare the composite sample.
114 of 213
-------
INTAKE 4-44
The No. 2 water intake is located upstream of outfall 015 [Fig. 2].
The pumphouse is about 76 m (250 ft) south of the intake structure; the
water treatment building is on the north side of the pumphouse. Bar
screens are located at the intake structure, traveling screens are
inside the No. 2 pumphouse, and strainers are on the discharge line from
the pumps inside the No. 2 pumphouse building. There are five pumps
serving this facility; normal sequence of operation is to run two
electric pumps and one steam pump, plus one additional pump during the
summer.
Pump No.
Type
Rated Capacity
(mgd)
1
Steam
35
2
Steam
35
3
Electric
35
4
Electric
35
5
Electric
15
Total pumping capacity is 511,000 m /day (135 mgd). Water intake volumes
are determined the same way as volumes for intake 3-24 — from the rated
pump capacities and hours of operation. The pump age factor is not used
in determining pumping capacity according to plant personnel.
Intake water supplied by intakes 4-44 and 5-51 (No. 3 water intake)
mix in the plant distribution system; water from intake 4-44 is used
exclusively in processes discharging to outfalls 014 and 016. Most of
the water discharged through 115 (and therefore outfall 015) originates
from intake 4-44; however, the possibility exists that some water from
115 of
-------
intake 5-51 also is discharged through 015 and 115. Some of the intake
4-44 water may also be discharged from outfalls 017 and 117.
The average daily intake water volume January-June, 1975 [Table
31], was 318,000 m^/day (84 mgd). During October 22-29, the intake
o
volumes averaged 351,000 m /day (93 mgd) [Table 4]. Except for two of
the seven days, the pumping rates remained constant. On October 22-23,
the pumping rate was 454,000 m /day (120 mgd) for the first 12 hours and
397,000 m^/day (105 mgd) for the last 12 hours. On October 24-25, the
pumping rate was 397,000 m /day (105 mgd) for the first 16 hours and
322,000 m^/day (85 mgd) for the last 18 hours.
The total quantity of wastewater discharged from outfalls 014, 015
and 016 is compared with the daily intake volumes in Table 33. The
average daily intake volume for October 22-29 was within 14% of the
total average daily discharges. This is only an approximate water
balance since the contributions from intakes 4-44 and 5-51 discharged
from outfalls 015 and 017 cannot be determined.
Samples of intake 4-44 were collected from the river on the intake
side of the bar screens (location where USSC monitors intake water for
net calculation), and also from the discharge side of the strainers to
determine if there was a difference in the water quality after treat-
ment. The 7-day average concentrations of TSS were essentially equiva-
lent; however, daily TSS concentrations for both locations varied
significantly [Table 4]. Settleable solids [Table 7], 0/G [Table 6] and
metal [Table 5] levels did not change from day-to-day for either location.
Therefore, it appears that for all parameters tested, except TSS, there
is no change in concentration after treatment. TSS data are inconclusive
to determine if treatment is effective since solids concentrations were
greater at the river intake only on three of the seven days. However,
surface water samples may not represent the actual intake water quality
116 of
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Table S3
COMPARISON OF INTAKE WATER QUANTITIES AW OUTFALL DISCHARGES
INTAKE 4-44 AND OUTFALLS 014, 015 > 016
USSC HOMESTEAD MAIN WORKS
October 22-29j 1975
Date
Intake
4-44
NEIC
Measured Flows
Total of Outfalls
(Oct.)
m3/day
mgd
m3/day
mgd
22-23
428,000
113
447,000
118
23-24
397,000
105
416,000
no
24-25
344,000
91
431,000
114
25-26
313,000
85
367,000
97
26-27
313,000
85
394,000
104
27-28
313,000
85
390,000
103
28-29
313,000
85
428,000
113
Daily Average
352,000
93
410,000
108
117 of 213
-------
since the intake is located below the water level and oils and greases
will float on the surface. Therefore, by collecting intake samples
after straining, the actual quality of the water being distributed
through the plant can be determined for net calculations.
All backwash waters from the screens are discharged to the river
via outfall 015. The backwash from the traveling screens was sampled
for TSS on a grab basis [Table 4]. The data are compared below with
intake data.
TSS
Date
Time
Backwash
Intake 4-44
(Oct.)
(hr)
(mg/1)
23
0800
39
35
24
1450
24
29
25
1435
19
15
27
0710
21
11
28
1235
3
6
5-Day Average
21
19
The TSS concentrations in the backwash were essentially equivalent to
the concentrations in the intake (samples collected at the river) over
the five days.
NEIC survey data for flow, TSS and 0/G fall within the ranges
reported by USSC for January-June, 1975 [Table 10] for intake 4-44.
The method of flow determination for intake 4-44 is adequate since
flows are only required to determine the aliquots of sample needed to
prepare the flow-weighted composite samples.
118 of 213
-------
INTAKE 5-51
The No. 3 intake is upstream of outfall 016 [Fig. 2]. The intake
is equipped with bar screens, two traveling screens, and strainers.
USSC collects samples for net calculations from the river between the
bar screens and traveling screens. There are three electric pumps
serving the facility, two rated at 10 mgd each and the third at 7 mgd.
The normal operating sequence is to run the two 10 mgd pumps. Water
intake volumes are calculated from an operator's log book which lists
hours of operation (determined from ammeters on each pump) and the rated
pump capacities. According to plant personnel, an age factor is not
applied to the pump capacities in flow calculations.
As previously reported under the intake 4-44 section, water supplied
by intakes 4-44 and 5-51 mix in the plant distribution system. Outfalls
117 and 017 are supplied directly by intake 5-51; however, some water
from intake 4-44 may also be discharged from these outfalls. Some of
the water from intake 5-51 may also be discharged from outfalls 115 and
015.
The daily average intake water volume for January-June, 1975
[Table 10], was 97,300 m^/day (25.7 mgd). During October 22-29, the
o
intake volumes averaged 100,000 m /day (26.5 mgd). Except for the 24-
hour period on October 22-23, all of the intake pumps were operational,
e.g., 102,000 m^/day (27 mgd). For the first 15 hours on October 22-23,
only the two 10-mgd pumps were operational. All three pumps were
operating the last nine hours.
The daily quantities of wastewater discharged from outfall 117 are
compared with the daily intake volumes in Table 34. The average daily
intake volume for October 22-24 was within 2% of the average daily flow
from outfall 117 (the 100-inch mill was shut down for repairs on October
24).
119 of
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Table 34
COMPARISON OF INTAKE WATER QUANTITIES AND OUTFALL DISCHARGES
INTAKE 5-51 AND OUTFALL 117
USSC HOMESTEAD MAIN WORKS
October 22-293 1975
Date*
Intake
5-51
NEIC
Measured
Outfall
Flows
117
(Oct.)
m3/day
mgd
m3/day
mgd
22-23
88,900
23.5
91,600
24.2
23-24
102,200
27
96,900
25.6
Daily Average
95,600
25.3
94,200
24.9
t The 100-inch mill was shut down for repairs on October
2'4> 1975.
120 Of 213
-------
Samples of intake 5-51 water were collected from the river and also
from the discharge side of the strainers to determine if there was a
difference in the water quality after treatment. The 7-day average TSS
concentration in the strained intake water was 6 mg/1 greater than in
the raw river water, and only on one day, October 23-24, did the raw
river water TSS concentration exceed the strained water concentration
[Table 4]. Oil/grease [Table 6] and settleable solids [Table 7] were
the same for both locations. Total iron concentrations [Table 5] were
higher on all seven days in the strained water; all other metal concen-
trations were essentially equivalent for both locations.
All backwash water from the traveling screens is discharged directly
to the river without treatment through an unpermitted outfall. For
safety reasons, the backwash was not sampled.
NEIC survey data falls within the ranges reported by USSC for flow,
TSS and 0/G for January-June, 1975 [Table 10].
The method of flow determination for intake 5-51 is adequate since
flows are only required to determine the aliquots of sample needed to
prepare the flow-weighted composite sample. The monitoring location
should be changed from the river location to the discharge side of the
strainers to reflect actual quality of the intake water.
SCALE PIT MONITORING
Proccss^wastewaters from the nine hot rollingjniJJ^_j,jn.d,the No. 2
forge shop flow through elp^v^"rrncTiiciing two pits in the
100-inch nrP_iiJ--^^ITTscharge to the river. The effluent from the 48-
1nrj^„
-------
The remaining five scale pits discharge directly to the Monongahela
River. The dimensions, design flows and estimated TSS removal efficien-
cies were discussed previously. Each scale pit is listed below with its
respective outfall number.
Facility Discharging to Scale Pit
Discharge Location
(Outfal1)
48-inch structural steam mill
006
54-inch structural mill
010
52-inch structural mill
010
44-inch structural mill
010
36-inch structural mill
010
28/32-inch structural mill
010
No. 2 forge shop
014
160-inch plate mill
016
45-inch slab mill
016
100-inch plate mill, roughing area
117
100-inch plate mill, finishing area
¦
117
Influent and effluent monitoring for TSS, 0/G and settleable solids
was conducted October 17-20, 1975 for six of the scale pits [Table 35].
The 48-inch mill was not operating and the No. 2 forge shop's scale pit
was dry during the monitoring period. Because of the hazards involved,
samples from the 44-, 28/32- and 160-inch mills' scale pits were not
collected. Access was limited to areas about 9-12 m (30-40 ft) directly
above the influents and effluents. The influent and effluent samples
were collected within the top 0.30 m (1 ft) vertical zone of the waste-
water stream. Flows were not determined; TSS samples were composited on
an equal-volume basis to provide an estimate of the wastewater characteristics.
122 of 213
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Table 35
SUMMARY OF FIELD MEASUREMENTS AND ANALYTICAL RESULTS*
SCALE PITS
USSC HOMESTEAD MAIN WORKS
October 17~20, 1975
Station
Description
Date Time of Collection
(Oct.) Influent Effluent
hour
pH Range Temperature Range TSS Concentration 0/G Concentration Settleable Solids
Influent Effluent Influent Effluent Influent Effluent Influent Effluent Influent Effluent
®C mg/1 " mg/1 ml/1
54-1nch mill
scale pit
52-Inch mill
scale pit
36-Inch mill
scale pit
45-1nch mill
scale pit
17 24-hr compos ite'1"''
1250 1250
2155 2205
18 24-hr composite
0055 0050
1550 1545
19 24-hr composite
0945 0945
1540 1545
2125 2130
20 0035 0030
17 24-hr composite
1310 1315
2215 2220
18 24-hr composite
0105 0110
1535 1540
19 24-hr composite
0935 0940
1530 1535
20 0040 0045
17 24-hr composite
1215 1215
2120 2130
18 24-hr composite
0020 0025
0915 0920
1510 1515
2115 2120
19 24-hr composite
0015 0020
1505 1510
20
17 24-hr composite
1335 1340
2250 2255
5.9-7.6 5.8-7.5 16-20 16-19.
31
34
6.5-7.6 6.9-7.4 15.5-19 16-19.5 73. 74
6.5-7.5 6.3-7.2 15-18.5 15-18.5 55 54
6.5-6.7 6.6-6.8 15-16 15.5-16
6.0-7.6 5.2-7.8 16-20.5 16-22.5 57 58
6.7-7.5 6.7-7.5 15-20 16-19 76 70
6.4-7.5 6.4-7.5 15-17 15.5-19 68 44
6.3-6.4 6.4-6.4 16-16 16-16
6.1-7.5 4.8-7.3 16.5-19 16-19 32 26
7.3-7.8 6.7-7.5 15.5-19 15.5-18 76 72
6.9-7.5 6.7-7.5 15-17 15-18.5 63 61
6.9-7.3 6.8-7.1 15-15 15-15
5.5-7.3 6.1-7.2 16-20 16-18 30 32
25
12
14
4
6
29
47
83
4
5
2
<1
7
10
2
3
6
5
9
13
19
7
4
37
39
21
3
10
5
<0.1
<0.1
<0.1
<0.1
0.1
<0.1
<0.1
<0.1
0.1
<0.1
<0.1
<0.1
<0.1
<0.1
0.1
<0.1
<0.1
<0.1
<0.1
<0.1
<0.1
-------
Table 35 (Continued)
SUMMARY OF FIELD MEASUREMENTS AND ANALYTICAL RESULTS
SCALE PITS
Station Date Time of Collection pH Range Temperature Range TSS Concentration 0/6 Concentration Settleable Solids
Description (Oct.) Influent Effluent Influent Effluent Influent Effluent Influent Effluent Influent Effluent Influent Effluent
hour mg/l mg/1 ml/1
45-1nch mill
18
24-hr
composite
6.9-7.3
6.9-7.3
16-20
16-19
87
92
scale pit
0140
0145
7
7
(cont.)
1000
1005
20
5
<0.1
1605
1610
<0.1
2215
2220
5
5
19
24-hr
composite
6.4-7.4
6.4-7.3
15-18
15-19
88
84
0105
0115
3
4
1555
1600
<0.1
<0.1
20
6.4-6.4
6.4-6.4
15-15
15-15
100-Inch mill
17
24-hr
composite
6.1-7.3
5.9-7.4
17-24.5
17-25
31
32
<0.1
<0.1
east scale pit
1420
1425
6
4
(roughing area)
18
24-hr
compos1te
6.8-7.2
6.7-7.2
16-19
17-19
80
81
1035
1040
3
2
1635
1640
0.2
0.2
2235
2240
2
4
19
24-hr
compos i te
6.4-7.2
6.5-7.2
19-25
18-24.5
81
87
0130
0135
4
3
1030
1030
2
2
1625
1630
0.25
0.15
2215
2220
3
4
20
0120
0125
6.5-6.6
6.5-6.5
22-23
23-23
4
5
100-Inch mill
17
24-hr
compos i te
5.8-7.3
5.9-7.5
17-24
17-22.5
35
46
<0.1
<0.1
west scale pit
1405
1410
5
4
18
24-hr
compos 1te
6.6-7.6
6.8-7.5
17-19.5
16.5-19
91
98
1025
1030
4
5
1620
1625
0.2
0.2
2250
2255
2
4
19
24-hr
composite
6.4-7.7
6.4-7.6
17-24
16.5-20
145
104
0145
0150
2
10
1020
1020
2
2
1615
1620
<0.1
<0.1
2225
2235
8
6
20
0130
0135
6.4-6.5
6.4-6.6
19-24
20-20
8
8
t Due to sampling limitations, data should not be considered as representative of actual conditions. TSS concentrations are minimum concen-
trations found. O/G concentrations in the effluent may be greater than concentrations at depth due to flotation; influent 0/G concentrations
are representative. Settleable solids levels are not representative since influent and effluent bed loads not sampled.
tt All 24-hour composite samples combined on an equal-volume basis. Sample collection began at 6 a.m. on October 17, 18, and IS. TSS concen-
trations are reported for date sampling began.
-------
Settleable solids data are not representative since the bed load
containing most of the heavier material was not sampled.
The influent and effluent TSS data represent the minimum concen-
trations in the wastewater since samples were not collected at depth.
Under quiescent conditions, solids would settle and become more concen-
trated with depth. However, conditions in the six scale pits were
turbulent and the solids would remain in suspension; the heaviest mill
scale would settle.
Influent 0/G concentrations are representative since the waste
stream was well mixed and turbulent, thus precluding the 0/G from
floating on the surface. The effluent stream was also well mixed, but
less turbulent than the influent; therefore, the 0/G concentrations may
have been greater at the surface due to flotation.
The data show that the TSS, 0/G and settleable solids remained
essentially the same'entering and leaving the scale pits. The data
indicate little or no treatment, but this conclusion may not be valid
for the heavier material since USSC reported that a total of 57,650 m.
tons (63,560 tons) of mill scale were recovered from the nine hot
rolling mills' scale pits for January-June, 1975.1 Treatment performance
for each scale pit will differ due to inlet velocities, degree of
turbulence, detention time, settling velocity, particle size distribution,
influent and effluent locations and configuration of the pit. Therefore
the data cannot be applied to other scale pits even though designs may
be similar. However, several conclusions can be made for all the scale
pits as a whole and several individual pits.
Heavy mill scale is obviously removed for the reasons cited above.
With the exception of the TSS concentrations for the 52-inch mill scale
pit and the 100-inch mill west scale pit, both for October 19, influent
and effluent TSS concentrations were essentially equivalent. Since
125 of
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there was no removal of the TSS, it can reasonably be assumed that the
TSS were not removed in any of the pits sampled. Due to the turbulence,
most of the material classified as TSS (particle sizes 1 micron or
larger) would remain in the suspended state and would be carried out in
the effluent, as indicated by the data.
The scale pits did not remove appreciable amounts of 0/G. The data
show that 0/G in the effluent is sometimes less than influent concen-
trations. However, since the pits are not equipped with 0/G removal
devices, the 0/G which was detained would eventually be discharged.
When the concentrations were 10 mg/1 or less, influent and effluent
concentrations were about the same.
The highest average concentrations of effluent TSS were in the
three scale pits which discharged to the river without additional treat-
ment. The 100-inch mill west scale pit had the highest influent and
effluent average TSS concentrations, 90 mg/1 and 83 mg/1, respectively.
Since this is a finishing area, the solids would be finer and therefore
more difficult to remove.
Schematics of the scale pits are included in the reconnaissance
report [Appendix A], The effluents from the 45-inch mill, 160-inch
mill, 100-inch mill and No. 2 forge shop's scale pits should receive
additional treatment to reduce solids and 0/G loads discharge to the
river.
126 of 213
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V. MONITORING REQUIREMENTS
Monitoring requirements include both sampling and flow measurement.
Due to the fluctuation in the daily wastewater flow, composite samples
should be collected on a flow-weighted basis.
During the NEIC survey, the dye dilution technique was used to
measure wastewater flows since the outfall locations were not amenable
to flow measurement using portable flow measuring equipment. Permanent
flow measurement devices can be installed on the outfalls. However,
modifications to the outfalls will be required and all river locations
must be protected from flooding conditions.
The tracer technique could be used by USSC to measure and record
flow on a continuous basis. The method requires an upstream injection
location and a sampling location downstream from all wastewater sources
where adequate mixing occurs. The Homestead Main Works is ideally
suited for the tracer technique; however, the method of continuous flow
measurement is costly and time consuming. The wastewater must be
continuously pumped through a measurement device, such as a fluorometer
if dye is used, and recorded on a strip chart. Each discharge location
would require a metering pump for controlled injection rates, a sampling
pump and a measurement device and recorder. These items would cost from
$2,700 to $3,000.* In addition, a suitable tracer such as Rhodamine WT
dye** would cost about $2.00/day per 3,800 m^/day (1 mgd) of flow.
* Costs do not include maintenance, extra parts3 manpowers protective
structures or power.
** Tracer used by NEIC for surveys October 17-29t 1975
127 Of 213
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Conventional flow measuring methods may be prefereable due to costs,
maintenance and ease of operation.
Recommended monitoring requirements are listed in Table 36. The
rationale for each outfall is discussed below.
OUTFALL 006
Process wastes are discharged from the 48-inch mill to Settling
Basin "B." Flows are continuously measured and recorded with a Parshall
flume and BIF circular chart. The flow device should be calibrated
periodically.
The EPA Permit Program Guidance document4 recommends a minimum
monitoring frequency of once per week for flows between 1-10 mgd;
however, TSS, chloride, 0/G and total iron should be monitored at least
twice per week because concentrations were increased significantly over
intake levels. Oils and greases are used generously in the mill for
lubrication. USSC reported that 2,700 kg/month (5,933 lb/month) of oil
was recovered from Settling Basin "B" from July 1974 to July 1975.1
Solids and chlorides are generated in descaling operations (salt is'used
in the descaling process); only the solids are treated since the chlorides
are soluble. Total iron should be monitored instead of dissolved iron.
The monitoring frequency must be more than once per week since production
varies daily.
OUTFALL 010
Process wastes are discharged from the five structural mills to
Settling Basin "A." Flows are continuously measured with a broad-
crested weir and recorded on a BIF circular chart. The weir must be
128 of
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Table 36
RECOMMENDED MONITORING REQUIREMENTS
VSSC HOMESTEAD MAIN WORKS
Outfall
Number
Effluent
Parameter
Measurement
Frequency
Sample Type
006
Flow
Daily
Measured continuously
PH
2/week
Grab
Temperature
2/week
Grab
TSS
2/week
Flow-weighted composite
0/G
2/week
3 grab samples per 24 hours
Total iron
2/week
Flow-weighted composite
Chloride
2/week
Flow-weighted composite
010
Flow
Daily
Measured continuously
pH
3/week
Grab
Temperature
3/week
Grab
TSS
3/week
Flow-weighted composite
0/G
3/week
3 grab samples per 24 hours
Total iron
3/week
Flow-weighted composite
Oil
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 per 24 hours
111++
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 per 24 hours
012
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
Settleable Solids 1/week
3 grab samples per 24 hours
013
Flow
1/week
Minimum of 6 instantaneous
measurements over 24 hours
P»
1/week
Grab
Temperature
1/week
Grab
TSS
1/week
Flow-weighted composite
Settleable Solids 1/week 3 grab samples per 24
hours
129 Of
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Table 36 (Continued)
RECOMMENDED MONITORING REQUIREMENTS
Outfall Effluent Measurement Sample Type
Number Parameter Frequency
014
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
015
Flow
Daily
Measured continuously
PH
Dally
Grab
Temperature
Daily
Grab
TSS
Daily
Flow-weighted composite
0/G
1/week
3 grab samples per 24 hours
115
Flow
3/week
Minimum of 6 instantaneous
measurements over 24 hours
PH
3/week
Grab
Temperature
3/week
Grab
TSS
3/week
Flow-weighted composite
0/G
1/week
3 grab samples per 24 hours
016
Flow
Daily
Measured continuously
PH
3/week
Grab
Temperature
3/week
Grab
TSS
3/week
Flow-weighted composite
0/G
3/week
3 grab samples per 24 hours
Total iron
3/week
Flow-weighted composite
017
None
NA
NA
117
Flow
Daily
Measured continuously
pH
3/week
Grab
Temperature
3/week
Grab
TSS
3/week
Flow-weighted composite
0/G
3/week
3 grab samples per 24 hours
Total iron
3/week
Flow-weighted composite
Intake 3-24
Flow
Daily
Measured continuously
4-44
PH
Daily
Grab
5-51
Temperature
Daily
Grab
TSS
Daily
Flow-weighted composite
0/G
3/week
3 grab samples per 24 hours
Total iron
3/week
Flow-weighted composite
Settleable
solids
1/week
3 grab samples per 24 hours
t Permit Program Guidance for Self-Monitoring and Reporting Require-
ments , April 30j 1973t Office of Permit Programs, USEPA.
+t NEIC designation for upsewer monitoring location on the Munhall
Borough storm sewer.
+++ Applies to Intake 3-24 only.
130 of 213
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rated and head discharge tables prepared to calibrate the flow recorder.
The flow device should be calibrated periodically.
TSS, 0/G and total iron should be monitored at least three times
per week as concentrations were increased over background levels.11
USSC reported that 1,450 kg/month (3,200 lb/month) of oil was recovered
from Settling Basin "A" from July 1974 to July 1975. Solids are generated
in all five mills from descaling operations. Since production varies
daily, monitoring frequency must be at least three times per week to
monitor peak production days as well as normal production days.
OUTFALL Oil
Cooling water and process wastes are discharged untreated to the
Munhall Borough storm sewer which flows into the river through outfall
Oil. An upstream monitoring location should be established to determine
quality of the Borough wastewater prior to mixing with the USSC dis-
charges. This upstream location was designated by NEIC as outfall 111
in Table 36. All parameters monitored at outfall Oil should also be
monitored at outfall 111.
The total flow from USSC averaged 3,150 m^/day (0.83 mgd) but
3
ranged as high as 4,960 m /day (1.3 mgd). Both locations should be
monitored. A minimum of six instantaneous flow measurements equally
spaced over 24 hours will provide the flow data required for composite
samples and total flow computation.
Both TSS and 0/G concentrations were increased over intake concen-
trations and the concentrations in the Munhall Borough wastewater; the
minimum monitoring of once per week is recommended.4
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OUTFALLS 012, 013 AND 014
Cooling waters and minor amounts of process wastes are discharged
through these outfalls. The Lengenfelder slag processing facility
discharges contact cooling water through yard drains to outfalls 012 and
013. The No. 2 forge shop's scale pit discharges process wastes to
outfall 014. All three outfalls showed an increase in solids over
intake concentrations. Therefore solids should be monitored at all
three outfalls. Settleable solids should be monitored at outfalls 012
and 013 since there are not treatment units upsewer of the outfalls to
collect settled material from the slag reclamation area.
Flows averaged 32,500 m^/day (8.6 mgd), 5,440 m^/day (1.4 mgd) and
14,600 m^/day (3.9 mgd) for outfalls 012, 013 and 014, respectively.
Flows and solids levels in outfalls 012 and 013 are dependent upon the
amount of slag recovered, which in turn is dependent upon production at
the USSC Monongahela valley plants. A minimum of six instantaneous flow
measurements equally spaced over 24 hours will provide the flow data
required for composite samples and total flow computations. The minimum
monitoring frequency of once per week is recommended.4
OUTFALLS 015 AND 115
Process wastes from the 160-inch plate heat treating line and the
open hearth furnaces discharge through outfall 015. Wastewater from the
160-inch plate heat treating line is monitored at outfall 115. The
wastewaters are not treated.
During the NEIC survey, the suspended solids were increased over
intake concentrations in both outfalls; metals and 0/G concentrations
increased slightly over intake levels. However, USSC self-monitoring
132 of 213
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data for January-June 1975 reported 0/G concentrations up to 38 mg/1 for
outfall 015 and up to 27 mg/1 for outfall 115.
The flows averaged 48,700 m^/day (12.9 mgd) for outfall 115 and
289,000 m^/day (76.5 mgd) for outfall 015 during the survey. At outfall
115, a minimum of six instantaneous flow measurements equally spaced
over 24 hours will provide the data required for total flow computation
and composite sample aliquots. For outfall 015, the flows should be
continuously recorded due to the fluctuations to determine total daily
flow and the aliquots required for the composite samples.
Due to the magnitude of the wastewater discharged from outfall 015,
TSS monitoring should be conducted daily. Outfall 115 should be moni-
tored for TSS at least three times per week. 0/6 should be monitored
once per week at both outfalls.'1
OUTFALL 016
Process wastewaters from the 45-inch slab mill and the 160-inch
plate mill pass through their respective scale pits and then discharge
through outfall 016. The total flow averaged 106,800 m^/day (28 mgd)
during the NEIC survey and fluctuated daily, depending on production.
Flows should be continuously measured and recorded on a daily basis.
TSS increased an average of 18 mg/1 over background levels during
the NEIC survey. Self-monitoring data showed gross TSS concentrations
up to 177 mg/1. The net 0/G concentrations increased by 2 mg/1 over
background levels during the survey which is essentially no increase
over background concentrations. However, self-monitoring data reported
0/G concentrations up to 104 mg/1. Total iron also increased over
background levels. Therefore these parameters should be monitored three
133 of 213
-------
times a week since their concentrations appear to be dependent upon
production in the two mills.
OUTFALLS 017 AND 117
Process wastes from the 100-inch mill discharge to the two scale
pits and then flow into the plant sewer. The plant sewer discharges
into the Homestead Borough West Run Culvert. The terminus of the
culvert is outfall 017. USSC wastes are monitored at outfall 117.
Since most of the wastewater discharged from 017 also flows through
outfall 117, monitoring of outfall 017 is not necessary.
The flow through outfall 117 averaged 91,600 m^/day (24.2 mgd) for
the two days of NEIC monitoring. Self-monitoring data also indicate
this magnitude of flow, although the flows are estimated. Since process
wastes are discharged from the 100-inch mill and the flows fluctuate,
continuous measurement is necessary to determine total daily flows and
composite sample aliquots.
Total suspended solids increased significantly over intake concen-
trations during the NEIC survey. The 0/G concentration increased only
2 mg/1 over background levels; however, self-monitoring data report
gross concentrations of 0/G up to 21 mg/1. The maximum increase of
total iron over background concentrations was observed at this outfall.
These parameters should be monitored at least three times a week.k
INTAKES 3-24, 4-44 AND 5-51
Flows are currently recorded in operator's log books from pump
capacities and hours of operation. Flows are only needed to determine
the sample aliquot required for composite samples. If the same pumps
134 of 213
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remain operational during the monitoring period, equal-volume composite
samples may be collected, otherwise flow-weighted samples should be
collected.
Intake samples must be collected on the same days that the monitor-
ing of the outfalls is conducted. The parameters analyzed in the
effluents should also be determined on all intake samples. The intake
samples should be collected after the pumps for intake 3-24 and after
the strainers for intakes 4-44 and 5-51.
GROSS vs NET
All parameters monitored by composite sampling should be limited on
a net basis. All parameters (0/G) monitored by grab sampling, should be
limited on a gross basis since the sample represents the condition for
one instant during the entire monitoring period.
135 of 213
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REFERENCES
1. Letter dated November 5, 1975 with attachments from Mr. James L.
Hamilton III, Manager, Environmental Control - Water, United States
Steel Corp., to Mr. S. R. Wassersug, Director, Enforcement Division,
U. S. Environmental Protection Agency, Region III, Philadelphia,
Pa.
2. Letter dated December 17, 1975 with attachments from Mr. James L.
Hamilton III, Manager, Environmental Control - Water, United States
Steel Corp. to Mr. S. R. Wassersug, Director, Enforcement Division,
U. S. Environmental Protection Agency, Region III, Philadelphia,
Pa.
3. Mater Measurement Manual, United States Department of the Interior,
Bureau of Reclamation, Denver, Co. 1974.
4. Permit Program Guidance for Self-Monitoring and Reporting Require-
ments, April 30, 1975, U. S. Environmental Protection Agency,
Office of Permit Programs, Washington, D. C.
136 of 213
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APPENDICES
A Reconnaissance Report
B Field Study Methods
C Chain of Custody Procedures
D Analytical Procedures, Quality Control
E Marsh-McBirney Flow Meter
F Weekly Production Figures
137 of 213
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138 of 213
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APPENDIX A
Reconnaissance Report
139 of 213
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140 of 213
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ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
NATIONAL FIELD INVESTIGATIONS CENTER-DENVER
BUILDING 53, BOX 25227, DENVER FEDERAL CENTER
DENVER, COLORADO 80225
Inspection of U. S. Steel Corporation, Homestead MAIN WORKS, South Side
of River, Homestead, Pa.
Date of Inspection/Visit: July 15-16, 1975
Attendees: NEIC-Denver - Barrett Benson
Jim Pennington
Ed Struzeski, Jr.
EPA, Region
III - Matt Miller
Pete Schaul
State of Pa.
Pittsburgh
Office - Bob Shilcosky
USSC - Dick McCarthy, Chief Environmental
Background
The Main Homestead Steel finishing Works extends along the South side
of the Monongahela River through the communities of Homestead, West
Homestead and Munhall. The Main Works is located from 7.5 to 9.5
miles upstream on the Monongahela above the point where the Monongahela
and the Allegheny Rivers come together to form the Ohio River at Pitts-
burgh. The Homestead facility constitutes a large steel making and
fabricating mill having open hearths; a 45" slab mill; a 54" and 44"
bloom mills; 48" steam driven structural steel mill; plate mills con-
sisting respectively of 100" and 160" mills; special plate heat-treating
buildings; and structural steel hot-rolling consisting respectively of a
44" mill, a 36" mill, and a 28/32" mill. The plant additionally has
pickling of stainless steel and titanium plate steel, a complete forging
mill, carburizing, vertical furnace heat-treating and slag reclamation.
Homestead receives electric furnace steel from the USSC Duquesne mill
(i.e.,"stainless steel and electro steel ingots) and BOP steel from the
Edgar Thomson mill. In contrast to BOP furnaces, the open hearth pro-
cess such as at Homestead can handle much larger proportions of scrap
and cold steel; the latter may comprise 20% up to as much as 80% to be
T. P. Gallagher, Director, NEIC-Denver
DATE: July 29, 1975
E. J. Struz
Industrial
Officer, Homestead Works
Bob Dunham, Corporate, Pittsburgh
S. A. (Jeff) Davis, Corporate, Pittsburgh
141 of 213
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T. P. Gallagher, Director
July 29, 1975
blended with molten iron. Production across the entire Homestead Works
has been given in the draft NPDES permit as 7,500 TPD iron; 23,600 TPD
hot formed metal; and 75 TPD pickled metal. We note that steel rolling
is many fold greater than blast furnace iron production. Other infor-
mation has been given which indicates production for the 48" mill to be
around 750 TPD (EPA & Steel meeting of 2/15/74); production for the
structural mill lines on Outfall 010 around 8,150 TPD; the 45" slab
mill and 160" plate mill production(s) approximately 10,500 TPD; and the
100" plate mill production amounting to 3,300 TPD (the last three manu-
facturing rates abstracted from PENDER sheets).
During our visit on the week of July 14, five of the eleven open hearths
were operational = 45%. Full operations were cited as follows:
45 inch slab mill
48 inch mill
Structural mill, 44 inch
bloom mill and subse-
quent mills, No. 1 Side
Structural mill, 54 inch
bloom mill and subse-
quent mills, No. 2 Side
100 inch plate mill
160 inch plate mill
160 inch plate (stain-
less steel, armor)
heat treating
Open Hearth
Current July 1975 production was quoted
above full operating schedules.
1 to 1 1/4 turns/day
(i.e. 10-11 hrs/day)
5 turns/week
12 to 14 turns/week, believed
to be the side making angles,
piling, etc. i.e. south side
15 to 16 turns/week, believed to
be the side making H-beams, i.e.
north side
10 to 12 turns/week
15 to 16 turns/week
10 turns avg and 15 turns
max./week
10 turns/week maximum
as being only about half of the
The Homestead Main or South Works has three water intakes off the
Monongahela River. These are Intake 3-24 or the No. 1 Water Intake
located upstream of Outfall 010; Intake 4-44 or the No. 2 Water Intake
just upstream of discharge 015; and Intake 5-51 or the No. 3 Water
Intake just upstream of Outfall 016. The No. 1 Intake is intended to
provide NET load calculations for Outfalls 006, 010, 011, 012 and 013
(22.7 MGD). The No. 2 Intake is intended to provide NET load calcula-
tions for Outfalls 014, 015, 016 and 017 (111 MGD); and the No. 3
Intake represents an alternate supply of water for operations contributing
to Outfalls 016 and 017; (principally 017). The three intake stations
are reported to have preliminary treatment as follows: No. 1 Intake-
rough screening only; Intakes 2 and 3 - bar screens, traveling screens
and strainer(s) in series at both locations.
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T. P. Gallagher, Director
July 29, 1975
All rolling operations at the Homestead, Main Works are described as hot
rolling. The old steam-driven 48" mill at Homestead dates back to the
1890's, the structural mills back to the 1920's, and the open hearths
and the plate mills are of early 1940 vintage. Some of the presses
in the Homestead Works are in the 4,000 to 10,000 ton category. Normal
employment at the overall Homestead Works is 8,000 to 10,000 persons but
as of mid-July it was down to 6,000 to 8,000 persons (note - this rates
out as 75-80% vs. reported production figures of 50% of less;).
The draft NPDES permit and various support materials describe the waste
Outfalls on the south side of the River at the Homestead Works as follows:
005 - Process water from the old steam-driven 48" structural mill
is passed through a scale pit, then a large settling basin
at the side of the River. Reported flow is 2.3 MGD. The
final C006) basin is intended for oil and solids removal.
010 - Process effluents from the 54 and 44 inch bloom mills, and
from the 52-inch, 36-inch, and 28/32" structural steel
rolling mills are sent to respective scale pits," one serving
each mill. The total flow estimated around 18.0 MGD is sent
to a terminal settling basin located at the edge of the
River. This C010) final basin is intended for oil and solids
removal.
011 - Appears to be untreated cooling waters from the press shop.
Flow is given as 0.15 MGD. A Munhall Borough storm sewer
is also included in Outfall 011.
012 - Permit support materials show this effluent to be untreated
cooling waters of about 1.9 MGD from the carburizing shop.
013 - Includes untreated process effluent of 0.1 MGD from slag
reclamation area, 0.02 MGD of cooling waters from the
vertical furnaces and 0.22 MGD of spent cooling waters from
the carburizing shop. Total 013 flow is estimated at 0.34
MGD.
014 - Untreated cooling waters of about 12.0 MGD from the No. 2
forge shop.
015 - A major Outfall listed as 51.0 MGD consisting of 46 MGD
untreated cooling waters from the No. 5 open hearth building,
plus untreated process discharge of 5.0 MGD from the 160"
plate mill heat treating building.
016 - Process waters from the 45-inch slab mill and process waters
from the 160-inch plate mill are each treated in a separate
scale pit. Respective flows of 12 MGD and 17 MGD = 29 MGD
which are discharged via Outfall 016.
143 of 213
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T. P. Gallagher, Director
July 29, 1975
017 - West Run storm culvert from West Homestead Borough
receiving USSC process waters from the 100 inch plate
mill after passing through two scale pits. Process
waters are estimated at 19.0 MGD.
115 - Separate discharge of untreated process wastewater from
the 160-inch plate mill heat treating building. Permit
limits for this location are effective only after 7/1/77.
At Homestead Main Works the open hearths represent the essential
starting operations in the overall process line. As many as 30 different
sizes of ingots are made from the open hearth steel and other ingots
received into the Homestead Works. Open hearth steel is poured into
ingots and delivered to the 45-inch slab mill and the 44 or 54-inch bloom
and roughing mills. Pit furnaces are available at these locations to
reheat the Ingots to red-hot temperatures. Products of the slab mill
are directed to the 100-inch and the 160-inch plate mills. Blooms are
converted into structural steel members such as H-beams, I-beams, angles?
piling, etc. in the tandem mills adjacent to the bloom mills. The 48
inch steam-driven mill receives rough steel from either the slab or the
bloom mills; most are received from the bloom mill building. Stainless
steel and titanium-type plate steel may be pickled in the Special Plate
and Stainless Processing buildings located directly west of the 48-inch
mill. Pickling prepares the plate metal for special surfacing.
On the subject of sampling and self-monitoring data being collected by
Steel, we asked what frequency of sampling was being employed. Dunham
and McCarthy stated at present that they are taking*grab samples every
four hours and compositing into a 24-hour sample. For oil and grease, they
collect their samples every 8 hours and report out 3 separate results for
the day.
Intake 4-44 and Outfall 015, 160-Inch Plate Mill Treating and Open Hearth
Operations
On Tuesday afternoon, July 15th, our field inspection was initiated for
the Main Homestead Works, focusing upon plate mill manufacturing facilities.
We started in the sector containing the.015 Outfall and the No. 2 Water
Intake Station and its attendant water treatment plant.
The No. 2 or 4-44 Intake is situated immediately upstream of the 015 Outfall.
Pump House No. 2 is about 250 feet south of the intake structure and the
water treatment building is attached on the north side of the Pump House
No. 2 Building, The 015 sampling point is just west of the No. 2 pump house
and Station 115 is SW of the pump house. The Open Hearth No. 5. line is about
500 feet south of the pump house. Immediately across the River from Intake
4-44, we observed a tremendously large dump area for USSC, operated by and
known as the Duquesne Slag Recovery operations. This site is also known as
Nine Mile Dump and is a tributary to Nine Mile Creek. SloDes of the slaa Dil
were as much as 60-65 degrees. The impression was gathered from Region III,
the State and Steel people that this dump site poses severe problems during
runoff and is a source of high surface and ground water pollution. Zinc was
cited as an extremely important parameter associated with these slag deposits
144 of 213
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T. P. Gallagher, Director
July 29, 1975
0
The 5-51 or the No. 3 Homestead Water Intake may be considered a backup to
the Mo. 2 Water Intake. The No. 3 Station is mainly used in the summertime.
In the summer months, No. 3 will run continuously. No. 3 intake watep does
not receive any water treatment before use in the mill.
Intake No. 2 (4-44) and Pump Station
Sampling of No. 2 Intake v/ater for NET waste load limits is conducted by
the. Company ahead of the intake screens on the River side.* The No. 2 Pump
Station has 5 pumps, 2 steam-powered and 3 electric-driven. Four of the
pumps are rated at 30 MGD each and the fifth (vertical-type) at 15 MGD.
Three 30 MGD pumps were operational during our visit. Thus, capacity of
the No. 2 pump station is 135 MGD; only around 90 MGD was being pumped
on July 15. Bar screens and traveling screens are located within the
tntake structure whereas the strainers are on the discharge line from
the pumps inside the No. 2.pump building. We noted the introduction
immediately downstream of the water intake structure of screenings back-
wash to the River. This particular discharge finding its way down the
hillside may join with the 015 discharge but it is most probable the dis-
charge reaches the River as a separate flow. Pump strainer backwash was
reported going to the 015 sewer.
Water Treatment Plant Primarily for Boiler Feed Supply
The volume of water passed through the water treatment plant is directed
almost entirely to the boiler house located immediately south of the Open
Hearth No. 5 building, i.e. the "open hearth boilers." The boiler house
produces both 150 and 250 psig steam at a temperature of 500°F or higher.
Water treatment consists of lime and soda ash addition, settling, pressure
filtration, zeolite softening,deaeration and storage in a clear well under
the Water Treatment building/ Chemicals are added to the settling basin(s)
together with steam. The plant has 7 pressure filters and 4 zeolite beds.
Meters are available before treatment and also thereafter; a totalizer is
also available. The two meters were not in real close agreement, i.e. 450
gpm into treatment vs. 500 gpm leaving storage. Average volume of water
treated is said to be close to 500 gpm = 0.725 MGD. Water treatment plant
personnel continuously monitor for hardness. Also at the treatment plant
is a third meter for measurement of city water. This meter was reading
about 120 gpm = 0.175 MGD during our visit.
All water treatment plant residues are released to the 015 sewer. Hot
soda ash and lime sludges, filter sludges, etc. are sent to the 015 waste
line. Solids are blown down on a rather frequent basis.
*Samples for NET load determination should be taken off the discharge
side of the pumps in the No. 2 Pump House.
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T. P. Gallagher, Director
July 29, 1975
Open Hearth No. 5 Cooling Waters
Besides water treatment plant solids and boiler house blowdowns, the 015
Outfall receives cooling waters from the open hearth operations and quench
reservoir excess overflow from the 160-inch plate treating building. In
the No. 5 Open Hearth area, these furnaces have a turnover time of 8-16
hours. The open hearth furnaces operate on recycled and cleaned open
hearth gases plus coke oven gas. Heavy reliance is made of waste heat
boilers directly adjoining the open hearth building. There are also three
"package" boilers independently-fired. These are fueled by No. 6 fuel oil,
natural gas or coke oven gas. The various boilers are not equipped with
atr pollution control equipment but the open hearth building is tied into
a manifold system in turn connected to five large, dry, electrostatic
precipitators. Flue dust collected off the open hearth ESP's is taken
together with cyclone-collected dry solids from the hot scarfing operation
at the 45-inch slab mill to Taylor Dump located near Lebanon Church Road
by the USSC Irvin plant. Dusts from the open hearth are reported less
amenable to recovery because of high zinc content. The old No. 4 open
hearth building has been largely abandoned except for some metal scrap
storage.
While inside the bottom level of the open hearth building, a manhole was
found in front of one of the open hearths about 1/3 the distance from the
east end of the Open Hearth No. 5 building which could be used for sampling,
but more likely applicable for dye diffusion flow determinations on the
015 sewer. Flows to and from this manhole are characterized as follows:
To 015 Outfall
More of /
same /
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T. P. Gallagher, Director
July 29, 1975
115 waste line. This effluent is not NCCW. Even though self-monitoring
is not called for on the 115 line until after 7/1/77, the Company is
believed to be sampling at a MH about 100 yards inside the east side of
the plate treating building. This point is located as depicted below
and said to consist of excess overflow from a 100,000 gallon quench
reservoir below the plate treating building. Plate quench water 1s
collected in this reservoir and reused for additional quenching. Makeup
fs added to this reservoir as necessary. Reservoir overflow proceeds
through MH 115 to the 015 sewer. The reservoir is cleaned out via bucket
by raising certain floor plates. Solids/scale are transported to the
Saxenberg plant.
•The. 015 Sewer at the River is extremely fast-moving, estimated to
be around 18 fps, and with very high flow 50 MGD. USSC collects self-
monitoring sampling data at this location. Conventional flow measurement
is extremely difficult if not impossible for Outfall 015. A ladder is ¦
available in order to descend from on-top the bluff to the outfall near
the River level. The outfall consists of a 5 foot diameter arch sewer.
Dye dilution will be necessary on the 015 line. On an EPA River run
of 6/21/75 in the PM, we observed significant floating material on the
River near the 015 Outfall,
Outfall 016 Including 45-Inch Slab Mill and 160-Inch Plate Mill
j
The 016 Outfall receives process wastes from the 45-inch slabbing mill
and from the 160-inch plate steel mill, both flows passing through
separate scale pits before release to the 016 sewer. For one reason
or another, we were not able to enter inside the slab mill. On our first
visit in the vicinity of the 45-inch slab mill on the AM of July 15,
Steel indicated since the slab mill was not operational, there was no
need for us to enter. In the afternoon of July 15 when we were passing
the slab mill a second time and it was operational, Steel strongly in-
ferred they did not want us going through the slab mill.
147 of 213
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T. P. Gallagher, Director
July 29, 1975
The 45-Inch Slab Mill
From the outside and west side of the slab mill, we observed the tall
stacks serving the (ingot) soaking pit building, otherwise known as
the pit furnace building. There are a total of 16 such stacks serving
some 34 soaking pits. From our discussions outside the slab mill, we
learned the rolling mill has a single line and is basically a single
stand, two high reversing mill together with vertical rolls. However,
the slab may make as many as 10 passes through this single stand. The
slab mill also employs a hot scarfing operation and conventional shear-
ing. It is believed the hot scarfer has a dry cyclone for air pollution
control. These solids are not recycled because Steel claims they are
too fine, i.e. like rouge dust or talc, and do not work well for
pelletiztng. These solfds are taken to the Taylor Dump.
The bottom flume underlying the slab mill (and the scarfing operation?)
contribute waste flows to the scale pits located directly outside and
on the south side of the slab mill. Our estimated field measurements
show that a first compartment was 48 feet long X 17 feet wide X unknown
depth. A second small compartment was estimated as 12 feet long X
10 feet wide X unknown depth. Depth of the pits was judged as 20 feet
or greater. Configuration of two compartment basin is as follows:
An upstream manhole to be possibly used for dye dumping into the 016
sewer was found below the 45-inch slab mill scale pits next to a series
of green-colored oxygen tanks (presumably for scarfing or shearing in-
side the mill). Depth of this manhole was judged about 25 feet. In-
terestingly enough, data in the State files as per Application 463124
shows overall dimensions for the main scale pit to be 48 feet long X
20 feet X 32 feet deep but effective dimensions are only 38 feet X 15 feet
X 9 feet SWD. Design flows were given as 4,000 gpm = 5.76 MGD which in
an effective volume of 38,750 gallons gives a theoretical detention time
of 9.7 minutes. The application describes the wastewater entering the
scale pit as originating inside the slab mill from roll cooling, shear
cooling, descaling and flume cleaning. All of this water is then collected
148 of 213
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T. P. Gallagher, Director
July 29, 1975
in a common flume located below the mill tables and flushed to the
scale pit. Results of composite samples collected of influent and
effluent to and from the 45-inch slab mill scale pit provided a
suspended solids removal rating of 36.5%. During July 1975, all
scale removed from the slab mill scale pit is reported as taken to
the USSC Saxenberg plant because the Sinter works have been shut
down since November 1974 at the Homestead-Carrie Works.
The 160-Inch Plate Mill
The 160-inch plate mill has continuous reheat furnaces, a scale breaker,
a single stand r.oll mill, followed by cooling sprays and a leveller.
The amount of fugitive dust inside the 16-inch plate mill was considered
quite high. We inspected the scale pit in the 160-inch plate mill which
is located adjacent to and on the SW side of the motor room, and just
NW of the reheat furnaces for the 160-inch plate mill. Bob Shilcosky
stated to us on a number of previous visits, oil dispersant in barrels-
has been observed in the vicinity of the 160-inch plate mill scale pit
or at the 016 Outfall. According to State Application No. 463129,
overall dimensions of this scale pit are approximately 37 feet long X
17 feet wide X roughly 38 feet deep. The application gives the "effective"
dimensions as 34,-;3" X-'l-5l*-0".-X 9'-3" SWD equal to 32,800 gallons.
Design flow v/as 6,500 gpm or 9.4 MGD giving a detention time of 5 minutes.
Analysis of composite samples collected from the influent and effluent
of this scale pit showed a 16.3% removal of suspended solids through this
basin. Steel personnel claim this scale basin as also others throughout
the Homestead Works, are cleaned out by clamshellbucket or otherwise
from one to three times a day. In our inspection of the Edgar Thompson-
Irvin Works and the Homestead Works, we have yet to see a single scale
basin in.the process of being cleaned. We note the design flow rates
of the 160-inch plate mill scale basin plus the 45-inch slab mill scale
basin add up to 9.4 MGD + 5.8 MGD = 15.2 MGD. This is less than half
the combined flow given by the draft NPDES for Outfall 016, i.e. some
29.0 MGD. A schematic of the 160-inch plate mill scale pit is given
below:
To 016
Outfall
/
/
149 of 213
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T. P. Gallagher, Director
July 29, 1975
Approximately 50 yards from outside the 160-inch plate mill building
containing the scale pit, we were shown a manhole which can possibly
be used for dye dumping on the 016 sewer. This manhole is however,
only about 100 yards from the terminus of the 016 sewer at the River.
This MH was judged some 30 feet down to water level and very fast-
moving.
The 016 Outfall is reached by an available ladder down the bluff. The
Company is believed to be sampling at this location. Flow out of a 60-
inch diameter sewer with about 16 inches of depth, was fast-moving and
veryroily between the outfall and the River. There appears to be some
evidence of previous oil spills possible at this outfall. On an EPA
River run of 6/21/75 in the afternoon, an oil boom was observed moored around
the area of the 016 Outfall, and oil was finding its way under the boom and
into the main River. Installation of a staff gage may be barely possible
at the 016 Outfall location; this will be determined later.
Intake 5-51 (No. 3 Intake), 100-Inch Plate Mill, Outfall 017 and West
Run Storm Culvert from M. Homestead Boro on Top End of 017 Outfall
As previously mentioned, Intake 5-51 or the No. 3 Intake is situated a
very short distance upstream of Outfall 016. No. 3 Intake is equipped
with bar screens, two traveling screens and strainers. Samples for NET
load determination are taken at Intake 5-51 ahead of the screens on the
River side. These samples should be taken on the discharge
side of the intake pumps. The 5-51 Pump Station is located relatively
close to the River and contains two electric pumps each rated at 10 MGD,
and a third pump, also electric, rated at around 7 "MGD-(total capacity
of 27 MGD). The pump house v/as locked during bur inspection trip. Two
discharge pipes were noted coming off the intake structure leading to
the River on the west side of 5-51. The top lfne contained screenings
washings going back to the River which may be considered an illegal dis-
charge. The bottom line was not running and the Steel people did not
know what may have been carried therein.
The 100-Inch Plate Mill was observed to be a very busy mill in
terms of activity. The 100-inch mill is about 700 feet long. There was
considerable movement of plate steel throughout the mill, and full process
operations were being conducted during our visit. Process steps consist
of descaling, one or two roughing stands, 4 or 5 finishing stands, followed
by shearing. A series of heat treating furnaces are also available in the
100-inch mill. The 100-inch mill is equipped with two scale pits in series
on the plant sewer leading into the 017 waste collection line. It is
importently noted that USSC samples from the manhole on the plant sewer
and not on the Main 017 waste Outfall line as had been previously believed.
The first scale pit approximately 15 feet X 40 feet X 25 feet deep
essentially serves the descaler and two roughing stands. The second
scale pit approximately 10 feet X 11 feet X 20 feet or more deep receives
waste drainage from the mill finishing stands. Steel personnel claim
both scale pits are cleaned once per turn with the scale retrieved and
sent to the Saxenberg sinter plant.
150 of 213
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T. P. Gallagher
Outfall 017
July 29, 1975
100-Inch Plate Mill
\—53-^r-
Company I
Samples
Scale pit
No. 2
\ 7£
Scale pit
No. 1
/
^Finish Process Li
/ FURNACI
BLDG.
ne
Roughing
Descaling
Stands
Stands
West Run Culvert
State application 463128 gives further detail on these two scale pits.
Water usage in the 100-inch mill is reported to amount to 7,500 gpm -
18.8 MGD for cooling of the reheat furnaces, roll cooling, slab descaling
and plate cooling. The spent water is then essentially collected into
a common flume beneath the mill tables and directed through the scale
pits to the plant sewerj subsequently reaching 017 Outfall. The No. 1
scale pit is described as a pit having two chambers. The pit has operating
dimensions of 37'-6" X 12* X 6'-2" SWD. Effective volume is given as
20,800 gallons. Based upon a design flow of 4,000 gpm = 5.76 MGD,
theoretical detention time in the basin is 5.2 minutes. Previous rating
of Scale Pit No. 1 (apparently by the State), showed a 71.2% removal of
TSS via this basin. The No. 2 scale pit is described as a pit with one
settling chamber, and operating dimensions of 18' X 9l X 5'-6" SWD.
Effective volume is given as 6,680 gallons. Based upon a design flow of
3,500 gpm = 5.04 MGD, detention time in the basin is calculated as
1.9 minutes. Rating of this scale pit (presumed by the State) showed
zero percent removal of TSS through this chamber.
The manhole at which the Company samples for 017 in the NPDES draft
permit was judged approximately 25 feet deep to the flowing sewer.
There is no guarantee as far as the permit is concerned that there may
not be additional waste contributions from USSC upstream on the 017
Main Sewer or on the downstream leg ' of the plant sewer coming out of
the 100-inch plate mill. Dunham and McCarthy did, however, verbally
report that the flow upstream in the 017 sewer ahead of the plate mill line
was probably about 80-90$ from Steel and only about 10% "other." The
manhole on the plant sewer can be used as a point of upstream dye dump for
017 but this is probably not necessary since it appears that the 017 Outfall
can be read ily gaged by conventional methods. From our present knowledge of
Homestead, it appears the NEIC Survey should sample both at Steel's self-
monitoring manhole in order to verify Company data, and additionally
sample at the very bottom of the 017 sewer to establish total waste
loads to the River.
151 of 2T3
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T. P. Gallagher, Director
July 29, 1975
For purposes of establishing upstream stormwater ,and NET loads for
Steel on the 017 sewer, Two Upstream Sampling Points for 017 were
selected as shown in the accompanying schematic. The two points are defined
as A and B.
Point A on Steel property is not a desirable sampling or gaging location
mostly because of great difficulty in getting any sampling apparatus down
into the sewer. This point is located in the middle of the road directly
south and across the pit furnace building for the 45-inch slab mill and
152 of 213
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T. P. Gallagher
July 29, 1975
in line with and north of a MESTA building on the other side. The
manhole is covered with a heavy steel plate and unfortunately is
offset at a fairly severe angle making access very difficult. Depth
of the manhole is judged around 20 feet. Flow measurement is impossible.
We will not use this point unless there is no other alternative.
Point B is approximately 1/4-1/2 miles south of the MESTA Works
and the USSC Homestead Works. One takes 8th Street West one block past
Howard Street. Turn left which is 8th av. with 7th Street continuing
west. Turn left again after a short distance along a large West Home-
stead Storm Sewer. The proposed sampling point would be on the stream
just before it enters a large culvert and goes underground. This culvert,
is 10 to 12 ft. in diameter and marked "1913." This point can be both
easily sampled and gaged. Bob Dunham indicates he has-walked inside this
sewer all the way to Steel property. Dunham stated there is at least
one small, 6 to 8 inch line discharging hot water into this stretch of
sewer which does not originate from USSC. There is reasonably good
natural flow in the stream before it enters the culvert. This would
seem to be our best location for upstream sampling control on the 017
sewer.
Our next stop was The 017 Outfall at the River. A ladder was
available down the bluff. It was cited above that the 017 Outfall
receives waste effluent from the 100-inch plate mill plus storm and area
drainage from an extensive portion of W. Homestead Boro via West
Run. Steel personnel indicated quite large flows can come down the
017 Sewer during wet weather which may also include_ALC0SAN bypassing.
Outfall 017 at the base of the bluff was seen to be"a semi-circular
conduit approximately 8 feet across and running about 18 inches deep.
Estimated velocity was 4-5 fps. Flow recorded in the permit for 017 is
19 mgd. The conduit empties into a natural drainway running for a few
hundred feet before reaching the Monongahela River. A short distance
below the end of the sewer, we observed an ALC0SAN bypass structure which
was dry during our visit. The 017 sewer at its terminus can be both
sampled and gaged.
Light oil film was observed in the area where the 017 Sewer,discharge
intermingled with the Monongahela River waters. On the PM of June 21,
during a river run with the State Fish Commission boat, a significantly
heavier oil film was observed. During our inspection of 017 on the PM of
July 15, we observed heavy black smoke emitted from the furnace building
on the 100 inch plate mill. This condition persisted for up to about 15
minutes. Dick McCarthy reported on this incident and action was taken
shortly thereafter to correct the black smoke plume. It is noted that
the fuel source on the 100 inch mill is No. 6 oil or "mixed" gas. Fuel
153 of 213
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T. P. Gallagher
July 29, 1975
sources are the same for the 160 inch plate mill. Possible chromium
sampling and analysis were cited as desirable, during our tour of the
017 Outfall and the plate fabrication operations on the 016 sewer.
The 48-Inch Steam-Driven Structural Steel Mill, Pickling of Stainless
Steel and Titanium-Type Steel Plate, The 006 Outfall and Its Respective
Settling Basin Built Into the Side of the River
The 48-inch structural steel plate mill built around the 1890's is
situated at the easternmost end of the Main Homestead property very close
to the East Gate. This mill characteristic of its era has dirt floors
throughout. The 48-inch mill receives blooms from the 54 or 44 inch mills,
may receive slabs from the 45-inch slab mill, and probably can also
take in ingots if necessary. This steel enters into a series of reheat
furnaces contained in the 48-inch mill furnace building just west of the
48-inch mill. We observed at least 8 large smoke stacks off the 48 inch
mill furnace building; 8 reheat furnaces are likely present. The furnerce
building is fueled most of the time by mixed gas.
The machinery in the, 48-inch mill besides being steam-driven,-also
incorporates use of the old-style flywheel on the prime movers. The
48-inch mill after receiving the slab or bloom is said to provide a
rolled-edge to the steel worked on. During our visit, mill personnel
were experiencing difficulty in freeing an incoming bloom at the front
end of the line. The 48-inch mill is generally operated one shift
per day and directed to production of fabricated structural steel. Some
of this steel goes into large H-beams; however, the pieces are generally
welded and assembled elsewhere. This mill is reported to have no scarfing
but does have a surface grinder. The grinder operation is served by a dry
cyclone for air pollution control. Primarily large chunks with some fine
materials are thusly collected. These solids are taken to the Taylor or
Taylorville dump. Processing steps in the 48-inch mill essentially include
descaling, a single roughing-finishing stand, cooling, levelling and then
shearing of the ends of the rolled pieces. Steel personnel are believed
to have reported the use of salt in descaling operations at the 48-inch
mill (?).
A scale pit is located at the SW corner of the 48-inch mill building.
Besides receiving scale from the 48" mill, neutralized pickling solution
from the adjacent Stainless Processing building and associated neutralization
plant, enter into the scale pit. Waste flow - mostly rinse water from the
neutralization station is estimated around 30 to 40 gpm. Effects of this
rinse water upon cleaning of the scale pit are not known. Configuration
of the mill sector is shown below.
154 of 213
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T. P. Gallagher
•"n5 fr0CeSS~
^ Jing
July 29, 1975
Waste
Neutralization
Plant
River
Furnace
Bldg.
4
/
/
To 006 Outfall & Settling Basin
48 inch mill
'Mill Stands
"Finishing
*Scale Pit
approx. 12' x 30'
According to State application 463132, the universal plate mill scale
pit receives a design flow'of around 300 gpm = 0.43 mgd. Water use
in the 48-inch mill is for furnace cooling, roll cooling and'flume
cleaning. The spent water is collected into a common flume below the mill
tables and directed to the scale pit. Overall inner dimensions of the scale |
are 26 feet X 10 feet,6 inches x 32 feet but SVID is only 6 feet. Effective
volume of the scale pit is 12,300 gallons and based upon the design flow
of 0.432 mgd, the calculated waste detention time is 41 minutes. Previous
performance rating of this scale pit apparently by the State showed
zero percent removal of TSS through the chamber. During our visit,
condition of the 48-inch plate mill scale pit was observed as being in
need of cleaning. USSC Personnel claim this pit is cleaned once each
day. The scale is placed into trucks and transported to the Saxenberg
sinter plant:
We requested to see and were shown the Pickling Operations on stainless
and other special plate steel inside the Stainless Processing building.
Pickling is deployed primarily to produce a highly desirable surface
finish on this more expensive plate steel. There are 2 acid baths in
series followed by a rinse bath (all batch tanks). The particular acids
used include nitric, sulfuric and hydrofluoric. The pickling operations are
generally conducted one turn/day. Many pieces of plate are inserted
into the tank at the same time and immersed for several minutes or longer
before transfer to the rinse tank. There is no collection nor countercurrent
reuse system between the various baths. Drippings simply drop back into
the same or next bath.
155 of 213
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T. P. Gallagher
July 29, 1975
The first two acid baths are served by two fume wet scrubbers (see
accompanying figure). These scrub effluents said to approximate 5 gpm
are sent in the direction of the 006 sewer. The rinse tank overflow
is caught in floor drains and sewered to the neutralization plant. On
the south side of the Stainless Steel and Furnace buildings are located
three overhead storage tanks. One is a storage reservoir for exhausted
pickling solution, and the other two for storing clean concentrated acids
for pickling. The waste acid is hauled out by private contractor to
Brown's Dump. Application No. 12179-IW dated 1956, cites waste rinse water as
amounting to 936,000*gallons per month. This acid storage area was noted
as having no circumferential diking. The neutralization plant receiving
pickling rinse solution is shown below. Slaked lime is used for neutralizing.
The objective is to reach a pH level of 7-8 in the neutralized rinse
waters carried into the 48 inch mill scale pit. Any sludges formed in
the neutralization process are carried over and into the 006 outfall.
The neutralization plant is equipped with automatic alarms in the event
of malfunction. The waste solution will find its way back into the sump
if trouble arises. The neutralization building was locked and we could
not see inside. However the interior is visualized as follows:
Fume
Inside
Stainless
Steel
Process
Bldg.
* To Neutralization Tank
Bldg. Wall
Sump
Mix Tank (with light
mixer)
Settling
Tank
Screw Conveyor
for Transporting
Slaked Lime Up and
Into Mix Basin.
156 of 213
Neutralization Building.
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T. P. Gallagher
July 29, 1975
The Settling Basin at the terminus of Outfall 006 and otherwise known
as Settling Basin "B" is 120 ft long X 30 ft wide by SWD of 14 ft.
Effective length, width and depth are respectively 90 ft x 28 ft x 9 ft
with an effective volume of 170,000 gallons. Average and maximum design flows
have been given as 1,500 gpm (2.17 mgd) and 2,300 gpm (3.33 mgd)
respectively. The draft NPDES flows for this outfall were 2.3 mgd.
Theoretical detention time is given as 113 minutes at average flow and
74 minutes at the maximum flow. The above data was mostly taken from
State Application No. 0269201 provided by USSC to the State on 9/8/69.
Settling basin 006 has a single compartment. The basin is cleaned according
to the above application, 'during mill down turns while uncontaminated
v/ater is bypassed to the River. Mill scale is removed .from the Basin
by clamshell bucket to a river barge and transported to an approved
dump site." The State application of 1969 stipulates that dissolved air
flotation is available in the Basin but from our observations of July 16,
1975, the amounts of air being applied were inconsequential. On the
subject of oil collection, Application No. 0269201 further states that
"oil scum will be held in basin with solid baffle extending 5 ft below
water surface. It will be removed with 24 inch wide belt skimmers
to holding tanks and pumped to storage tanks." It wilVthen.be
periodically hauled to a disposal area by truck. Settling Basin B
is also equipped with a bypass to .the River. Configuration of this
Basin is depicted below.
The 006 Settling Basin appeared much more effective for removals of
heavy oils compared to light oils. We noted only one vertical oil
adsorbent skimmer belt although the State application indicates two.
Flow through this basin seemed much larger than the 2.3 mgd cited in
the draft NPDES permit. The Parshall Flume on.the effluent is constructed
of steel plate and has a 9 inch throat. A float level is available tied into
a BIF continuous flow recorder and totalizer. Flow calibration was conducted
years ago but USSC has run a lithium chloride tracing only a few weeks ago.
006 Settling Basin
006
Influent
Hvy. Black Oil Behind Weir
157 of 213
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T. P. Gallagher
July 29, 1975
The flow recorder was believed verified for accuracy during the time
of the USSC lithium chloride study. It is our feeling the flow recorder
and float level should be additionally correlated by the NEIC field crew.
The 006 Basin oil skimmer belt travels about 6 inches under the water surface,
oil adheres to the belt and an oil scrapper bar partially removes the oil
into an oil collection box on the upper level of the basin. The belt
did not appear extremely effective. The USSC personnel claimed oil removal
at the 006 basin is better than at the 010 basin. The solids entering in the
006 sewer were judged finer than at 010 and hence solids removal appeared
on the low side. Dunham and McCarthy indicated the 48 inch mill had been
down yesterday, and today was having problems. Accordingly, it was
claimed oil on the basin was much lighter than usual. Dunham stated that
oil removal rates are roughly 60% through the basin and skimmer. We
desired to enter the control house where the oil collection box was located,
but the house was locked. Steel personnel could not provide us with
any estimate at all for the daily volume of oil collected. We observed a
pump manifold takeoff from the control house leading to a waste oil storage
tank on the bluff overlooking the basin. The recovered oil is sold to a
reclaimer.
The parshall flume during mid-July 1975 was sitting roughly 3 to 4 feet
(only) above the river level. Dunham claims this site including the
parshall is flooded out during but 3-4 weeks of the year at high springtime
levels, but we believe it may be considerably more. The Company collects
their 006 samples in the effluent flume just before final discharge next
to the access ladder, and just ahead of the Parshall flume. We would intend
to use the same sampling point for the NEIC sampling survey. During our
inspection, we noted an oil sheen around the perimeter of the settling
basin, inside the basin flowing into the launder at the discharge end
of the basin, and also in the Parshall flume going out; but not particularly
so in the discharge as it merged with the river.
At the influent to the settling basin, valves are available for manual
control of diversion or bypass to the river on the east side of the Basin.
A drain line was also found near the bottom of the basin by which the
contents of the basin could be emptied to the River. A partial bale of
straw covered with tarp was noted on the catwalk on the east side of the
Basin, used previously or as a future adsorbent measure in containing oil
spills.
Whitaker Storm Sewer (Not cited In draft NPDES permit)
A Whitaker Borough storm sewer traversing through USSC property enters the
Monongahela River about 150 feet or so downstream of Outfall 006. We
were not able to make our way to the mouth of the sewer which seems to be
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July 29, 1975
about 8 or so feet in diameter and probably oval in shape. As we found
out later, the terminus of this sewer can be reached only two possible
ways - by boat or somehow by climbing around the fence line enclosing
the 006 settling basin on the lower or downstream side. Boat is the
preferred choice. Viewing this sewer from a distance, there appeared
to be small discharge to the river. Steel claims they have no contributions
to this sewer. A possible upstream sampling control point on the Whitaker
sewer was visited later in the day. This location was in the area of
Ravine and Hall Streets, 1 block south of 8th Ave. The Hall Street location
however proved to have no flow. It is recommended that the Whitaker
storm sewer should be sampled during the NEIC Survey - but only near the
River.
The 3-24 Water Intake or No. 1 Pump Intake at Homestead Main Works
The No. 1 Water Intake is located upstream of Outfall 010 and about 500
feet upstream of the P&LE Bridge. The No.l Pump House is located only a
short distance from the river. Pumps at the No. 1 House are believed to
have neither traveling screens nor strainers. The suction side of the
intake pipes however are equipped with perforated end sections. The No. 1
Intake is equipped with five pumps having a maximum overall capacity of
97 mgd described as follows:
No. 1 Pump - Electric, 25 mgd
No. 2 Pump - Electric, 20 mgd
No. 3 Pump - Electric, 12 mgd
No. 4 Pump - Steam, 20 mgd
No. 5 pump - Steam, 20 mgd
During the time of our visit and in normal practice, the No. 1 Intake
station needs are supplied entirely by Pumps 2, 3 and 5. Upon going
down to the river, we noted intake pipe No. 3 was discharging rather than
drawing. McCarthy after consultation with his people at the pump station
stated that the'water storage tank on the bluff had become filled beyond
capacity and the excess overflow was bypassing around Pump No. 3 and return-
ing to the river. This story was convincing although quite unusual. At
the point where the intake pipes were drawing from the river was also
located a small boat moored to a slip. This is precisely the point where
the Company takes its samples for the 3-24 Intake. We could probably
rent this boat from USSC for limited river sampling during the NEIC survey,
for an appropriate stipend.
The Structural Steel Bloom Mills (54-inch and 44-inch Mills) and Three
Finishing Mills (52-inch Mill, 36-inch Mill and 28-32-inch Mill), Scale
Pits on Each, the 010 Outfall, and Its Respective Settling Basin Built
Into the Side of the River
Ingots are brought into either the 44 or 54-inch Bloom mill via a series
of 30 soak pits directly west and adjacent to the bloom mills. The bloom
and structural steel mills operate between 2 and 3 turns per day. During
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our tour of July 16th, the 44 inch bloom mill was operating but the
54 inch bloom was not. McCarthy indicated piling was probably being
rolled on the No. 1 side while we were passing through. The 54 inch
bloom mill is specially used on weekends for rolling of "rounds" for
wheel blocks.
On our tour we passed from west to east down the No. 1 or 44 inch line
and later came back up on the No. 2 or 54 inch side. Configuration of
the scale pits and their relation to the 010 sewer as described by Dunham
of USSC is depicted below.
010 Sewer
A
54" Mill
52" Mill
Scale Pit
Scale Pit
Soak
Pits
44" Mill
—
36" Mill
Scale Pit
[Scale Pit
Inside Bloom and Structural
Steel Mi 11s fj
28/32"
Scale Pit
The 44 Inch Bloom Mill and Scale Pit
V/e observed the 44 inch bloom mill to be essentially equipped with one
large roughing stand. McCarthy indicated that steel pieces may be
subjected to as many as 19 passes but he may have been referring to
more than just the 44 inch bloom mill. Shearing was present at the end
of the 44 inch line. The 44 inch mill scale pit had outside dimensions
approximately 12 feet x 40 feet and had two compartments separated by
+_ 1/2 inch bar screen. This pit is configured as seen below.
44-inch mill
scale pit
State permit application No. 436134 gives further detail on the 44 inch
blooming mill scale pit. Some 1500 gpm = 2.17 mgd is used at the 44 inch
bloom mill for roll cooling, sheer cooling and flume cleaning. This flow of
2.17 mgd compares to a flow of 4.5 mgd as given in support materials to
the NPDES draft permit. The State application describes the pit as having
a single chamber. Operating dimensions of the basin are given as 28 feet,
6 inches X 10 feet X 6 feet,3 inches SWD which in turn provides an effective
volume of 13,340 gallons. Resulting detention time is calculated as 8.9
minutes. Previous performance rating of this basin (believed to have been
made by the State) showed a 40.5% removal of TSS via this basin.
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The 36 Inch Roughing Mill and Scale Pit
Transfer of the 44 inch blooms to the 36 inch mill is generally made
through reheat furnaces centralized between the two mills. The 36 inch
roughing mill is equipped with only one rolling stand. The 36 inch mill Sjpale
pit having outer dimensions of roughly 20 feet x 10 feet is configured
below. We note that the outflow is heading in an easterly direction contrary
to the sketch given above. The 010 main sewer is likely situated on the
east side of the 36 inch scale pit rather than west of it.
"t"
/
Effluent
/
36-inch mill scale pit
The 36 inch mill scale pit was reported to have no bar screens. The •
36 inch mill pit appears to receive a much finer scale than the 44 inch
mill basin. State permit application No. 463131 provides further data on
this 36 inch roughing mill scale basin. Water use of approximately 500
gpm =0.72 mgd is deployed for roll cooling, shear cooling and flume
cleaning. Operating dimensions of the 36 inch mill scale pit have been
given as 20' 6" x 10' x 6' 2" SWD equivalent to a holding volume of 9,450
gallons. The draft NPDES flow for this system is listed as considerably
higher than design flows, i.e. 3.0 mgd vs 0.72 mgd. Calculated detention
time at design flow is 18.9 minutes. Previous performance rating of this
basin showed a 18.4% removal of TSS.
The 28"/32" Structural Steel Mill and Associated Scale Pit
Major operations in the 28/32 structural mill include a single finishing
stand, a cooling bed, a straightening section and an extensive shearing
section. The scale pit for this mill was approximately 24 feet long
x 12 feet wide - outer dimensions. Bar screen of 1/2" openings is present
in the basin. The basin is configured as shown.
~t—t
Effluent
. Influents
^pron
^ SrrPPn
/
/
28/32 mill scale pit
State application 463127 describes water use in the 28/32" structural mill
as amounting to 2,000 gpm =2.88 mgd. used for roll cooling, table
cooling and flume cleaning. The wastewaters are collected into a flume
located beneath the mill tables and then discharged to the scale pit. The
draft NPDES flow for this system is given as 1.5 mgd which is lower than
system design flows. Effective dimensions for this scale pit are 20' 6"
x 10' x 8' 3" SWD shown in the State permit application. Effective volume
is 12,700 gallons giving a theoretical detention time of 6.3 minutes. A
previous performance rating on this basin yielded a 81.7% removal of TSS.
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The 52 Inch Roughing Structural Steel Mill and Scale Pit
The 52 inch mill scale pit was roughly 35 feet deep and 12' x 30'. Oil
and scale were present in liberal amounts on the sides of the pit and on
the mill floor in the vicinity of the pit. This particular treatment
device seemed in need of improvement. This basin is configured as
shown: T- 010 Sewer
52-inch mill scale pit
Influent
State permit application 463125 describes water use in the 52 inch mill as
amounting to 2,500 gpm =3.6 mgd (compared to NPDES permit value of 4.5 mgd)
utilized for roll cooling, flume cleaning and descaling. Effective dimensions
of the scale settling chamber are given as 29 ft x 10 ft x 6 ft, 5 inches
SWD. Effective volume is 13,900 gallons producing a theoretical detention
time of 5.6 minutes. Performance rating of this basin (assumed to have been
made by the State) showed a 45.2% removal of TSS through the chamber.
The 54 Inch Bloom Mill and Its Associated Scale Pit
The 54 inch bloom mill together with shearing capability was observed to have
a relatively long scale pit 41 feet long x 12 feet wide - external dimensions
x approximately 30 feet deep, with the basin being separated into two com-
partments. The basin was configured as shown: j
State permit application No. 463126 describes water usage in the 54 inch
bloom mill as 500 gpm = 0.72 mgd (NPDES draft permit gives 4.5 mgd) used
for roll cooling, shear cooling, and flume cleaning. Effective dimensions of
the 54 inch mill scale pit are given as 28 ft x 10 ft x 7 ft, 4 in. SWD
producing an effective volume of 15,400 gallons and theoretical detention of
30.8 minutes. Performance of this basin had been previously rated and
whether due to sampling difficulties or otherwise, a zero percent TSS
reduction was recorded.
The Settling Basin at the terminus of Outfall 010 and otherwise known
as Settling Basin "A" is considerably larger than the 006 settling basin.
According to State permit application data, overall dimensions of the
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July 29, 1975
A Basin are 170 ft long x 50 ft wide x 14 ft SWD. Effective dimensions
are 126 ft long x 48 ft wide x 9 ft SWD. Effective volume is 407,000
gallons. Design flows from the various scale pit and structural steel
mill effluents coming into the A Basin are about 10 times larger than
flows coming into Basin B. Design flows are cited as 15,100 gpm =
21.90 mgd on an average basis and 17,800 gpm = 25.80 mgd on a maximum
basis. Detention times were calculated as 59 minutes at average flow
and 50 minutes at maximum flow. The majority of the above information was
taken from State application No. 0269201 provided by USSC to the State
on 9/8/69.
Settling Basin A has two separate compartments formed by the basin being
divided down its width. The permit application reports that mill scale
sludge is removed from Basin A by clamshell into a river barge and
transferred to an approved disposal site. Cleaning of Basin A is
accomplished while flow is diverted to the alternate compartment. Frequency
of cleaning for the A Basin is given as once every 2 months and that fdr the
B Basin (i.e. at 006 Outfall) once every 4-5 months. Similarly as for
Basin B, "oil scum will be held in basins with solid baffle extending
5 feet below water surface. It will be removed with 24 inch wide belt skimmers
to holding tanks and pumped to storage tanks." This basin is equipped with
two adsorbent belt skimmers and oil collection systems, one for each compart-
ment. The heavy black oil is pumped from the collection boxes to a
waste oil storage tank located on top of the river bank. This oil is
reported as sold to an oil reclaimer. Dunham stated that the 010 Basin
is intended more for TSS removal rather than for oil removal. The reverse
is true on' the 006 settling basin. Sketches are presented below for the
010 settling-skim basin and for the control house on the basin.
Contrary to information received previously in the week, the 010 settling
basin does not have a parshall flume. It however is equipped with a
broad-crested rectangular weir. Engineering details must be obtained
on the weir setup and NEIC is currently requesting such data. A BIF flow
recorder and totalizer are also available on site. The meter was reading
about 9 mgd during our July 16th visit. The stilling well for the float
leve.l and recorder is roughly about 6 feet from the crest of the weir and
guarantee should be sought that this flow device is properly calibrated.
Steel personnel intimated that weir details would probably be best retrieved
from the Company under 308 request. We are also cognizant that Steel
conducted some lithium chloride flow tracer studies only a few weeks ago
both on the 006 and 010 Outfalls. NEIC should if at all possible obtain
specific and complete results and conclusions of the lithium chloride work
performed by USSC. It is noted other than 006 and 010, every other waste
discharge at both the Carrie Works and the Main Homestead Works is estimated
rather than directly measured by the Company.
Just outside the point of final 010 discharge into the river, we noted
anchor points which we were told are used for attachment of an oil boom
when necessary. This oil boom is the same one previously seen at the 001
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T. P. Gallagher
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Monongahela River Flow
Oil present throughout this zone
Final 010 Effluent
to river
Soth skimmer belts operational Bypass to
^during our visit river
Weir
Oil on surfacej!^,^
ApprojL,
4 in.
sewer
\Double weir takeoffs
clamped by masonite boards
to keep oil down. Adsorbent
boards tied together with string -
replacements badly needed.
010 Settling - Skim Basin
can be
closed
flow
bypassed
Inflow
river
\
-tf'
\
N. side oil skimmer belt
and takeoff
Oil Collection Boxes
(Oil Pumps not operational during
our visit)
S. side oil skimmer belt
and takeoff
010 Control House on 010 Basin
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T. P. Gallagher
July 29, 1975
Outfall of the Carrie Works on Monday. We Noted sorbent plates tied
down at the outfall weirs of the basin and furthermore observed
loose-type sorbent material stored in bags (Sorbent C, Tom's River,
N. J.) near the control house. The 010 Basin is laden with floating oil on
the surface. The 010 Basin may additionally be drained through a port
at the bottom of the structure (on the south side) which should be used
only during times of emergency.
Outfall Oil From Press Shop and Upstream Munhall Boro Storm Sewer
We viewed possible sources of wastewater to the Oil Outfall. This
included the blacksmith and forging shop where tool steel was being worked
in the furnaces with some cooling waters directed to the sewer; the main-
tenance areas which contribute certain flows to Oil; Press Shop No. 1 which
was currently reported "dry" by USSC; and the cinder yard which had close
to zero flow at least during the time of our visit. Effluents to the Oil
sewer comprise in very large part untreated cooling waters but these may
contain appreciable contact cooling in addition to NCCW flows. There is no
direct access and no ladder from on top the bluff down to the Oil outfall.
We eventually worked our way down to the terminus of the Oil sewer by walking
the river shoreline upstream from 012. The Company'in collecting their samples
of 011 also traverses from the bottom of 012.
The 011 sewer ends abruptly at the river wall. The outfall is oval-shaped
approximately 6 ft in the vertical direction and 3' 2" across. Depth of
flow was 3 to 4 inches in the sewer. Velocity seemed in excess of 10 fps and
the flow was quite warm. This reasonably-sized discharge runs down a
concrete apron to the river. Flow during our inspection appeared higher
than the 0.15 mgd given by the NPDES draft permit. The 011 outfall appears
amenable to flow measurement utilizing a platform, sandbagging and/or
weiring inside the sewer. Appreciable black residue was observed on the
river bank below the concrete apron serving Outfall 011.
Later on the day of July 16th, we visited two possible upstream control
points on the Munhall Borough storm sewer. The first point is
preferred if the Company is eventually able to locate such. Both points
are inside USSC property relatively close to the OH 4 Main Gate on
8th Avenue.
The first proposed control point is a manhole in the yards on the
southeast side of the old abandoned Open Hearth No. 4 building. This
manhole however could not be immediately located by the Company because it
was thought to be covered by truck axles and/or has been surfaced over
by gravel and dirt. Dunham and McCarthy promised they would locate and open
this manhole for us if needed during the survey. We nevertheless selected
an alternate manhole. The latter location is reached by crossing over
the covered foot bridge near the OH 4 Main Gate, going under this bridge and
then west down the railroad tracks and crossing over a set of narrow gauge
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T. P. Gallagher
July 29, 1975
tracks. The MH was located directly alongside and on the south side
of the narrow gage tracks. This point was also directly across the
Shipping Yards for structural steel. We could not raise the steel plate
on the M.H. but perceived an odor almost similar to sewage. The access
to the M.H. is reported as 24 inches in diameter opening up to 4 feet.
The M.H. is believed 8-10 feet deep. Supposedly there is no flow from
USSC upstream on this sewer since the Open Hearth No. 4 building is
virtually abandoned. These two proposed control points are respectively
located 250 ft and 500 ft from the OH 4 Main Gate.
Outfall 012 Serving the Carburizing Shop, Vertical Furnace and Slag
Reclamation Area
The draft NPDES permit shows the three above sectors contributing to
both outfalls 012 and 013 as follows:
012 013
Carburizing shop, cooling water 1.9 mgd 0.22 mgd
Vertical furnace, cooling water 0 mgd 0.02 mgd
Slag reclamation, process flows 0 mgd 0.10 mgd
Total 1.9 mgd 0.34 mgd
We importantly observed during our field inspection that slag reclamation was
contributing waste flow to 012 and this flow was probably greater than that
going to 013. Location of the 012 outfall is directly in back of or to
the north of the vertical furnace building. Dunham and McCarthy in their
introduction to us Monday and Tuesday mentioned there was some similarity in
discharge characteristics between the 012, 013 and 014 outfalls. Some degree
of forging is conducted at sectors served by these three outfalls plus outfall
011. Reheat furnaces, maintenance and press cooling are found in all these
sectors and the majority of effluents at the three outfalls are considered
cooling waters. Quenches are prevalent in the Harvey or Harverizing Shop
(same as carburizing) and quenching is also used extensively in the
No. 2 Forge Shop.
Carburizing consists of large heat treating furnaces for handling special
products including forged products. Considerable cooling water is
employed. The Vertical Furnace building contains seven vertical (pieces
are stacked vertically) heat-treating furnaces plus one very large vertical
quench unit. Appreciable amounts of continuous-flowing NCCW are
deployed in this processing. Steel making rolls and other specially-forged
products are commonly treated in the Harvey shop and the vertical furnace
complex. Machine shops also exist around the Carburizing-Vertical Furnace
buildings, contributing cooling waters to the 012 and 013 Outfalls.
The Langenfelder Slag Reclamation process consists of dumping open hearth
slag in an open area just north of the new vertical furnace building and
spraying with water for cooling. This facility is also equipped with a
magnetic separator and slag crusher. We understood that essentially only
large chunks of steel are reclaimed. Slag residuals are taken and disposed
of to the Nine Mile Run Dump area directly across the river from the Homestead
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T. P. Gallagher
July 29, 1975
Works. We observed a significant fugitive dust situation around the slag
reclamation area and no air pollution controls. Drainage from this
rather wide open area is collected into nearby yard drains and conveyed
to either the 012 or 013 outfalls depending upon which part of the
Langenfelder yards the Company is working in.
Outfall 012 close to the river is reached by ladder down the river bank.
The 012 sewer at its bottom end is a 24 inch circular conduit which was
observed flowing about 12 inches deep. The discharge was running well but
Dunham stated it could be much higher; 012 was quite turbulent cascading
down a rock bed to the main river. Evidence of slag residue was greater
in the 012 discharge than 013. Appearance of the outfall ranged from
relatively clear to quite murky and heavily laden with solids. This location
will be difficult to gage but conventional flow measurement can probably
be managed with sandbagging or other methods. The Company is believed to
be collecting its self-monitoring samples at the bottom of the access ladder
to 012.
Outfall 013, Similar Waste Sources as 012
The 013 Outfall as with 012, is reached by descending an available USSC
ladder down the river bank to near river level. Access to 013 is at the
rear of a sand loading station for locomotives and is also marked by a sign on
a post reading "3-33." The ladder to 013 is reached by crossing over a dual
gas pipeline paralleling the railroad tracks and river.
The 013 outfall on July 16 seemed to be running greater than 0.34 mgd -
the NPDES permit flow. Water depth was about 3 inches in a horseshoe-shaped
conduit approximately 40 inches across and 63 inches high. The sewer has
an irregular bottom; making gaging more difficult. Gaging is possible but
sandbagging and/or a special platform may be necessary. The flow 1n
013 appeared only slightly less than that in 012. Sampling by USSC is
thought to be conducted at the very end of the 013 sewer.
Outfall 014 Essentially Originating From No. 2 Forge Shop
The Homestead Works has 2 rather extensive forging mill manufacturing items
all the way from very small machine or steel-making rolls up to the
largest of electromachinery housings. Outfall 014 is described in the draft
NPDES permit as containing up to 12 mgd cooling waters from the No. 2 forgfe
shop. We visited the major building served by 014, described by Homestead
nomenclature as the "No. 2 Forge EE Shop."
Forge building operations comprise 18 reheat furnaces, not all of which are
operating at any one time. These furnaces can be either kept running
continuously, banked, or otherwise completely shut down. Furnace cooling
water-is the result of necessarily cooling the steel work around the brick
in the continuously-heated furnaces. At least two forging machine stands
are available in this building. We observed a relatively new double-press
machine which was very large. We did not see the older forge machine located
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T. P. Gallagher
July 29, 1975
at the south end of Forge EE Shop. The latter machine was reported as
having considerably more leakage and wastage. Forged mill rolls are a
major product of the No. 2 Forge Shop. Rotors are another major specialty
item.
Compared to steel rolling, steel forging is a relatively long and
meticulous series of operations. Forging starts with the ingot form and
proceeds through a large number of different shaping steps. After
certain forging steps, the large steel piece may be quenched by auto-
matic means or by manual hosing down. Partial forgings may be sent back
to the reheat furnaces to aid subsequent press operations. We observed
an operator hosing down a forging in progress with the wash water and
scale being flushed directly into the scale pit. This scale pit was
located on the north side of the No. 2 Forge Shop. We could not obtain
approximate dimensions on this scale basin because of the intensity of
heat from the forge machine next to the pit. Engineering details will
be sought from Steel.
Outfall 014 is reached via a long ladder down the river bank. This
outfall is located immediately north of a metal chute serving as the
loading point for materials into the Open Hearth No. 5 building. The
flow in Outfall 014 appeared much less than the NPDES permit discharge
of 12 mgd. The 014 Outfall consists of a 42 inch circular conduit with
brick work about 3 feet back inside. Water depth was about 8 inches in
the sewer. This outfall was determined to be gagable by conventional
means. The Company samples the 014 Outfall near the bottom of the
access ladder.
Unknown Discharge Downstream of Outfall 017
While in the offices of U. S. Steel on July 15, we viewed an aerial
photo of the Main Homestead Works and noted what appeared from the photo
to be a major discharge entering the river below 017 but still on USSC
property. While on the field inspection on the Main Homestead Works we
did not visit this downstream site. Dunham and/or McCarthy indicated a
discharge was likely present where shown but could only be a storm or
combined sewer from one of the Boroughs or ALC0SAN. EPA-NEIC will
attempt to verify the nature and amount of possible waste discharge from
this sector of USSC property during our next visit to the Main Homestead
Works.
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T. P. Gallagher
July 29, 1975
Sampling Locations for Homestead Main Works Survey*.
A. Primary Stations
1) 006 Basin effluent
2) Whitaker Sewer at point of release to river
3) No. 1 Intake (3-24) on discharge side of water supply pumps
4) Influent to 010 Basin
5) 010 Basin effluent
6) Upstream control for 011 Sewer (i.e. Munhall Boro storm sewer)
at SE side of OH No. 4 Bldg. and approx. 250 ft from OH 4 Main
gate
7) 011 sewer at terminus with river
8) 012 sewer at terminus near river (below river bank)
9) 013 sewer at terminus near river (below river bank)
10) 014 sewer at terminus near river (below river bank)
11) No. 2 Intake (4-44) on discharge side of water supply pumps
12) Screenings backwash from No. 2 Water Intake structure close to
Outfall 015. If possible, obtain flow estimates from Company;
2-3 day sampling suggested
13) 115 Manhole sampling point on plate mill heat treating building
sewer approx. 100 yds. inside east end of plate treating
building. Flows probably can only be obtained as estimated
figures from Company.
14) 015 Sewer at terminus with river
15) No. 3 Intake (5-51) on discharge side of water supply pumps
16) 016 sewer at terminus with river
17) Screening washings or backwash from No. 3 Water Intake structure
close to Outfall 016. Obtain estimate of flows from Company;
2-3 day sampling suggested.
18) Sampling MH at west end of 100-inch plate mill known as Company
Sampling Point 017. Obtain flow estimate if possible from USSC
19) West Run Storm Culvert, i.e. upstream control on 017, off 8th
Ave. extension approx. 3/8 miles south of Mesta Works and
USSC Homestead Works
20) 017 Outfall at its terminus near the river
B. Tentative Stations
1) Influent to 006 Basin; isolation of influent must be further
investigated
2) - 11) Influents and effluents of 5 scale pits in the 5 structural
steel and bloom mills. No flow measurements hopefully required;
3-4 day sampling suggested . .
12) Influent to No. 2 Forge Shop Scale Pit. Obtain flow estimate
from Company; 3-4 Day sampling suggested
13) Effluent from No. 2 Forge Shop Scale Pit at exit from pit. Obtain
flow estimates from USSC; 3-4 day sampling suggested.
* Final selection of sampling stations, parameters and frequency, to be
made by project coordinator depending upon available resources, priority
of location, etc.
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T. P. Gallagher
July 29, 1975
14) Influent to 45 inch slab mill scale pit. Obtain flow estimates
from Company; 3-4 day sampling suggested
15) Effluent from 45 inch slab mill scale Pit at manhole below 45
inch mill in vicinity of "green" oxygen tanks. Verify with
Company that no flows are entering the waste line between
scale pit and M.H. If indeed, there are in between wastes,
move effluent point to bottom end of slab mill scale pit. Obtain
flow estimates from USSC; 3-4 day sampling suggested.
16) Influent to 160 inch plate mill scale pit. Obtain flow estimates
from Company; 3-4 day sampling suggested.
17) Effluent from 160 inch plate mill scale pit at Manhole
NW and just outside building housing the scale Pit. Verify
with company that no flows are entering the waste line between
scale pit and M.H. If indeed, there are in between wastes,
move effluent point to bottom end of plate mill scale pit. Obtain
flow estimates from Company; 3-4 day sampling suggested.
170 of 213
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•#/
el St.
o
-h
PO
go
Homestead Main Works,
West End, 11. S. Steel Corp.
Homestead, Pa.
July 1975
-------
o
Mon
0n9<3k
eh
l\3
Co
,St **
E*st 7 Ste*d Mw
1 U sai" w
0,nestJz steei r'
-------
APPENDIX B
Field Study Methods
173 of 213
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174 of 213
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FIELD STUDY METHODS
USSC HOMESTEAD MAIN WORKS
FLOW DETERMINATIONS AND MONITORING LOCATIONS
Outfall 006
The sampling location described in the NPDES permit is as follows:
"At the discharge of the 48-inch mill settling basin prior to discharge
to outfall 006." For monitoring purposes, the Company samples at the
Parshall flume. The NEIC samples were collected at the flume. Flows
were determined from the continuous recording chart. The Parshall flume
was evaluated by NEIC personnel and was found to be properly installed.3
However, the flow recorder indicated flows approximately 16% less than
flow indicated in standard tables for a given depth as measured at the
stilling well. USSC personnel were informed of this error and were
shown how to calibrate the device. The recorder was calibrated prior to
monitoring and the total and instantaneous flows recorded were used for
load calculating and compositing samples.
Outfall 010
The sampling location described in the NPDES permit is as follows:
"At the discharge of the Rolling Mill Complex settling basin prior to
discharge to outfall 010." For monitoring purposes, the Company samples
as the effluent flows over a broad-crested weir. The NEIC samples were
also collected at this location. Flows were determined from the con-
tinuous recording chart. The weir was rated by NEIC personnel using the
dye dilution method (see next section), and the flow by the dye dilution
method was found to be approximately 1.66 times greater than the flow
175 of 213
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indicated on the BIF recorder. The dye was injected into the effluent
launder at an upstream point. As a rough estimate, the height of the
flow over the weir was measured and instantaneous flows were determined
from standard charts.* Although the tabular flows were not actually
representative of true conditions, an estimated flow could be obtained.
The estimated flows were about 40% greater than the flows indicated by
the recorder.
For compositing purposes, the instantaneous flows indicated by the
recorder were used to determine individual aliquots. For load cal-
culations, the total daily flow was increased by a factor of 1.66 to
reflect actual flow conditions.
Outfall Oil
This sampling location is described in the NPDES permit as "at
outfall Oil." USSC samples this sewer at the river; NEIC personnel
collected samples at this location. Since the discharge from this
outfall also contains domestic and other wastes from the Munhall Bor-
ough, samples were collected upsewer of the USSC connections to the
storm sewer. The samples were collected from the manhole adjacent to
the narrow gauge railroad spur in the 28/32-inch shipping yards complex.
Instantaneous flows were determined at both locations using the dye
dilution method. Dye was injected in the manhole at the southeast side
of the No. 4 open hearth building.
* Standard tables apply to rectangular weirs with knife-like edges.
Broad-crested weirs must be rated since standard tables do not
apply due to head lossj approach conditions} etc.
176 of 213
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Outfalls 012, 013, 014 and 016
The sampling locations described in the NPDES permit are as
follows: "at outfall 012;" "at outfall 013;" "at outfall 014;" and "at
outfall 016." USSC collects samples from these outfalls at the river;
NEIC also collected samples at these locations. Instantaneous flows
were determined using the dye dilution method. Dye injection locations
were as follows:
Outfall
Injection Station Description
Number
012
Manhole in the parking area south
of Station 31, Forge Maintenance
Building
013
Manhole inside the "Harvey Shop"
014
Manhole on northeast corner of No. 2
forge ship in main roadway
016
Manhole adjacent to the green oxygen
tanks at the 45-inch slab mill
Outfalls 015 and 115
The sampling locations described in the NPDES permit are: "at
outfall 015;" and "at the discharge of the 160-inch heat treating
operation" prior to discharge to outfall 015. USSC monitors the waste
discharged from outfall 015 at the river. Outfall 115 is monitored at
the manhole located inside the 160-inch heat treating building, about 90
m (100 yd) west of the east side of the building; NEIC collected samples
at these locations. Instantaneous flows were determined using the dye
dilution method. Dye was injected in a manhole inside the 160-inch heat
treating building, about 180 m (200 yd) east of the west side of the
building for flow determinations at both outfalls.
177 of 213
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Outfalls 017 and 117
The sampling location described in the NPDES permit is: "at
monitoring station 117 prior to discharge to West Run Culvert from West
Homestead Borough, discharging through outfall 017." All USSC wastes
are monitored at the manhole downsewer from the west scale pit in the
100-inch mill. NEIC samples were collected from this location. In-
stantaneous flows were determined using the dye dilution method. Dye
was injected in the effluent from the east scale pit (roughing area) in
the 100-inch mill. NEIC personnel also collected samples from the West
Run 'Culvert at the river and at an upstream location, about 30 m (100
ft) upstream of the culvert at 8th Avenue. Instantaneous flows at the
sewer terminus were determined using the dye dilution method; instantaneous
flows at the upstream location were calculated from velocity measure-
ments (using an electromagnetic flow meter) [Appendix E] and the cross-
sectional area of the stream bed.
DYE DILUTION TECHNIQUE FOR FLOW MEASUREMENT
Flow determinations were made using dye dilution with fluorometric
detection technique. In this procedure, a dye of known concentration is
injected at constant rate upstream of the sample site, an adequate
distance to insure mixing. Downstream samples were collected for deter-
mining the dye concentration. The flow was calculated from the known
injection rate, initial dye concentration and the concentration of dye
after mixing with the wastewater.
The 6. K. Turner Model III fluorometer was used. Calibration of
the fluorometer was accomplished daily using dye standards prepared in
the NEIC mobile laboratory. Rhodamine WT dye was used due to its low
sorptive tendency and stability under varying pH conditions.
178 of 213
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Background investigations of all stations were conducted to .deter-
mine if any substances in the waste stream would fluoresce in the range
that could induce errors in flow determinations. Background samples
were taken each time samples for flow determination were collected. The
fluorescence measured in the flow samples was corrected for background
fluorescence.
Special precautions taken to insure against interference in flow
measurements consisted of: 1) cuvettes triple-rinsed with distilled
water between each sample; 2) cuvettes cleaned daily with solvent; 3)
cuvettes filled with distilled water and fluorescence measured twice
daily to insure against contamination from operator handling; and 4)
fluorometer checked for "0" reference blank.
SAMPLE COLLECTION PROCEDURE
Twenty-Four-Hour Composite Samples
Beginning at 6 a.m. on October 22, individual grab samples were
collected from each location on a 4-hour frequency and stored in ice
chests at 4°C. At the end of 24 hours, all samples except the two
influents to the settling basins and the two effluents (006 and 010)
from the basins were composited on a flow-weighted basis for each
station. The settling basins' influent and effluent samples were
continually composited on a flow-weighted basis. Beginning at 6 a.m. on
Saturday, October 25, and continuing for the duration of the survey, the
samples were collected on a 3-hour frequency for outfalls 014, 015, 115,
016, intake 4-44 and intake 5-51. Beginning at 6 a.m. on Sunday,
October 26 and continuing for the duration of the survey, the samples
were also collected on a 3-hour frequency for outfalls 010, 011, 012,
013, influent to structural mill settling basin, intake 3-24 and the
upstream location on the Munhall Borough storm sewer. The 100-inch
179 of
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plate mill shut down on October 24 and samples were not collected from
outfall 117 or from both locations on the West Run Culvert sewer after
this date. On the evening of October 25, the 48-inch mill shut down and
samples were not collected from Settling Basin "B" influent and effluent
(006) after 6 a.m., October 26. The time of collection was altered due
to the reduced number of sampling stations.
Grab Samples
Grab samples for oil/grease* and phenols (outfalls 006, 010 and
intake 324) were collected in 0.95 liter (1 qt) glass jars three times
for each 24-hour period; times of collection are listed in Table 6 of
the main text.
Settleable solids were collected once per 24-hour period in 1.9
liter (1/2 gal) plastic containers.
From 10 a.m. to 4:30 p.m. on Wednesday, October 22, and from 9 a.m.
to 12:30 p.m. on Monday, October 27, grab samples were collected for
analysis for organic constituents. All samples were collected in an
11.4 liter (3 gal) stainless steel bucket and then poured into a 3.79
liter (1 gal) brown glass bottle and sealed with a teflon cap. The
bucket was rinsed with solvent three times, then rinsed three times with
the waste stream water prior to sampling each outfall. On October 22,
freon was used as the solvent; on October 27, acetone was used as the
solvent. On October 22, a blank of distilled water was prepared identically
to the samples collected form the outfalls. On October 27, two blanks
* Freon extractable material.
180 of 213
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were prepared, one containing distilled water and the second containing
distilled water plus 0.36 ml of 20% dye per 3.79 liters (1 gal).
Individual grab samples were also collected on October 22 for
polychlorinated byphenyl analysis. Samples were collected in the same
stainless steel bucket used to collect organics. After the organics had
been collected, the bucket was rinsed three more times with the wastewater,
then 0.95 liter (1 qt) of sample was collected into glass jars and
preserved under ice at 4°C.
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182 of 213
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APPENDIX C
Chain of Custody Procedures
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ENVIRONMENTAL PROTECTION AGENCY
Office Of Enforcement
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
Building 53, Bo* 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
187 of 213
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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
in 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 thef.r 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 imtil it is required for trial.
Strip charts and other documentation of work will also be turned
over to the custodian.
188 of 213
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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
Station No.
Data
Time
Sequence No.
Station Location
romp,
_BOD
.Solids
.COD
.Nutrients
.Metals
.Oil and Grease
_D.O.
_Bact.
_Ottar
Samplers:
\
Remarks / Preservative*
Front
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF ENFORCEMENT
NATIONAL ENFORCEMENT INVESTIGATIONS CENTER
BUILDING 53, BOX 25227, DENVER FEDERAL CENTER
DENVER, COLORADO 80225
mA*-
Back
190 of 213
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EXHIBIT II
FOR
SURVEY, PHASE.
DATE
TYPE OF SAMPLE.
ANALYSES
STATION
NUMBER
STATION DESCRIPTION
TOTAL VOLUME
TYPE CONTAINER
PRESERVATIVE
NUTRIENTS
BOD
COD 1
TOC
TOTAL SOLIDS
SUSPENDED SOLIDS
ALKALINITY 1
O
O
*
X
a
CONDUCTIVITY* 1
TEMPERATURE*
TOTAL COLIFORM
FECAL COLIFORM 1
TURBIDITY
OIL AND GREASE
METALS
BACTl [
PESTICIDES
HERB 1
TRACE ORGANICS
PHENOL
LL
c
z
<
>
• t
E Q U I R E
REMARKS
-------
EXHIBIT III
rS Samplers:.
ro
co
FIELD DATA RECORD
STATION
NUMBER
DATE
TIME
TEMPERATURE
°C
CONDUCTIVITY
mhos/cm
PH
S.U.
D.O.
mg/l
Cage Ht.
or Flow
Ft. or CPS
-------
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: ISignature)
STATION
NUMBER
STATION LOCATION
DATE
TIME
Sample type
SEQ.
NO.
NO. OF
CONTAINERS
ANALYSIS
REQUIRED
Water
Air
Comp.
Crab
Relinquished by: (Signature)
Received by: (Signature)
Date/Time
Relinquished by: (Signature)
Received by: (Signature)
Date/Time
Relinquished by: (Signature)
Received by: (Signature)
Date/Time
Relinquished by: (SignafureJ
Received by Mobile Laboratory for field
analysis: (Signature)
Date/Time
Dispatched by: (Signature)
Date/Time
Received for Laboratory by:
Date/Time
Method of Shipment:
Distribution: Orig. — Accompany Shipment
1 Copy—Survey Coordinator Field Filet
193 of 213
CPO «9« - 80 t
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194 of 213
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APPENDIX D
Analytical Procedures and Quality Control
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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
Cr, Fe, Pb,
Sn, Zn
TSS
Cyanide
Phenol
Method
Atomic absorption
Gravimetric
Distillation,
colorimetric
Automated colori-
metric
Ammonia Automated phenate
Oil and grease 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
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.
* Federal Register3 Vol. 40, No. Ill, Jxme 9t 1975
197 of 213
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Those samples that showed adequate response were set aside for character-
ization by combined gas chromatography-mass spectrometry (GC/MS). The
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
appropriate, every tenth sample was spiked with a known amount of the
constituents 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.
198 of 213
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APPENDIX E
Marsh-McBirney Flow Meter
199 of 213
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200 of 213
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FLOW MEASUREMENT USING THE MARSH-McBIRNEY
ELECTROMAGNETIC FLOW METER
The flow meter is provided with a Faraday type electromagnetic flow
sensor which has two perpendicular axes so that both X and Y directional
vectors can be measured. The operator can obtain from the measurement
both the direction and magnitude of the water velocity. All sensors are
cylindrically shaped and have no moving parts which are susceptible to
clogging or fouling.
The sensor consists of a cylinder containing an electromagnet
internally and two pairs of external electrodes in contact with the
water. Flow around the cylinder probe intersects magnetic flux lines
causing voltages to be generated which are linearly proportional to the
water velocity. The voltages are detected by the electrodes, processed
at the signal conditioner and presented as analog voltages linearly
proportional to the X and Y components of the velocity vector.
The accuracy of an electromagnetic sensor includes linearity, zero
drift, and absolute calibration. Linearity allows direct reading
without a correction chart and accurate recording of steady flow in the
presence of fluctuations. All March-McBirney instruments are accurate
to at least +2% of reading or +0.07 feet per second, whichever is
larger.
201 of 213
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202 of 213
-------
APPENDIX F
Weekly Production Figures
203 of 213
-------
204 of 213
-------
EXHIBIT IV
Production Statistics
Ref: c-i U8" mil
Tons Per Operating Day
VJeek Ending Minimum Maximum Average
1/V75 -
l/H/75 373 504 h$2
1/13/75 356 481 434
1/25/75
2/1/75 333 466 393
2/8/75 346 462 396
2/15/75 286 439 37o
2/22/75 384 426 401
3/1/75 153 363 279
3/8/75 283 457 405
3/15/75 391 464 424
3/22/75 362 461 418
3/29/75 366 435 400'
V5/75 365 439 1*07
V12/75 377 450 409
4/19/75 409 466 457
V26/75 353 460 401
5/3/75 -
5/10/75 -
5/17/75 -
5/24/75 388 413 »»01
5/31/75 375 403 383
6/7/75 374 419 399
6/14/75 324 474 l»o6
6/21/75 395 436 ljOl
6/28/75 -
205 of 213
-------
Kef: C-l
54" Mill
Tons Per Operating Day
Week Ending Minimum Moxiiriuin Average
W75 365 2173 1440
1/1VT5 566 3109 1901
V.10/^ 20 3057 1666
l/25/75 859 2563 1707
2/1/75 709 2917 2128
2/8/75 644 2603 1819
2/15/75 672 2219 1629
2/22/75 563 2534 1852
3/1/75 1054 2212 1755
3/8/75 12c* 27314. 1928
3/15/75 7^9 2659 1771
3/22/75 1527 2043 1766
,3/29/75 1143 2287 1914
V5/75 646 1995 .137lf
4/12/75 1195 2309 17521.
V19/75 1.479 1913 1707
V26/75 793 2639 1896
5/3/75 545 2698 1677
5/10/75 483 2457 1I165
5/17/75 378 2022 1318
5/2^/75 515 2241 1554
5/31/75 869 2514 1546
6/7/75 3U .563 ;:4l0
6/14/75 471 771 581
6/21/75 654 1327 853
6/28/75 395 1323 915
206 of 213
-------
44" Mill
Ref: c-1
V/oek Ending
1/V75
1/11/75
1/18/75
1/25/75
2/1/75
2/8/75
2/15/75
2/22/75
3/1/75
3/8/75
3/15/75
3/22/75
3/29/75
V5/75
V12/75
V19/75
V26/75
5/3/75
5/10/75
5/17/75
5/24/75
5/31/75
6/7/75
6/14/75
6/21/75
6/28/75
Tons Per Operating Day
Minimum Maximum Average
Down
559
342
307
479
488
385
505
356
788
724
475
771
413
550
858
871
586
1031
1291
1221
818
836
380
550
588
Dovn
1076
1019
961
1655
1555
1717
1656
1865
1824
1788
1713
1585
1668
1777
1684
1573
1648
1509
1826
1731
1652
1284
1271
1016
831
Dovn
811
606
i 730
962
893
1031
1190
1248
1218
1307
1176
1255
999
1261
1208
1116
1221
1349
1516
1^33
1191
1019
880
827
720
207 of 213
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Ref: c-1
52" Mill
Tons Per Operating Day
Week Ending Minimum Maximum Average
1/V75
1/11/75
1/18/75
1/25/75
2/1/75
2/8/75
2/15/75
2/22/75
3/1/75
3/0/75
3/15/75
3/22/75
3/29/75
V5/75
V12/75
V19/75
V26/75
•5/3/75
5/10/75
5/17/75
5/2U/75
5/31/75
6/7/75 .
6/1V75
6/21/75
6/23/75
917
2091
1W7
1200
2983
2166
19
2826
17^5
836
2395
1587
1777
2730
2262
5^7
2lt26
1605
U90
2126
.368
2lf20
169^
821
2018
1509
1166
2656
1783
726
25^3
1578
865
1952
1U87
778
2550
1761
62^
183^
1230
615
18^3
1506
1205
17^
1555
761*
256^
1935
10^3
2^58
1875
1370
2389
1932
1052
1873
160^
1305
2085
1707
338
2305
1299
Dovn
Down
^95
957
7^5.
^35
3JM
806
208 of 213
-------
36 - 28/32" Mill
Ref: C-l
Tons Per Operating Day
V/eek Ending Minimum Maximum Average
613 k92
658 1^7
^73 U27
623 508
648 556
1203 1071
1127 926
1286 926
1250 766
II87 839
1029 723
1160 872
1332 683
H85 837
1337 875
1001 771
1254 823
1061* 935
1366 977
1126 950.
1115 937
- 931 731
974 689
. 588 4lo
535 439
1/V75
Down
1/11/75
397
1/18/75
251
1/25/75
338
2/1/75
303
2/8/75
515
2/15/75
905
2/22/75
704
3/1/75
597
3/8/75
206
3/15/75
391
3/22/75
477
3/29/75
513
4/5/75
244
4/12/75
265
4/19/75
531
4/26/75
2W
5/3/75
342
5/10/75
824
5/17/75
7^3
5/24/75
745
5/31/75.
728
6/7/75
^57
6/1V75
^31
6/21/75
233
6/28/75
378
209 of 213
-------
Ref: c-1
45" Mill
Tons per Operating Day
Week Ending Minimum Maximum Average
1/V75
1/11/75
1/18/75
1/25/75
2/1/75
2/8/75
2/15/75
2/22/75
3/1/75
3/0/75•
3/15/75
3/22/75
3/29/75
V5/75
4/12/75
4/19/75
V2^/75
5/3/75
5/10/75
5/17/75
5/24/75
5/31/75
6/7/75
6/14/75
6/21/75
6/28/75
4l62
6432
5294
21165
7149
4883
4173
7299
5411
2958
6584
5376
2002
6232
4624
2972
6792
5100
2867
6451
•4878
4605
6257
5453
4o8l
7761
5624.
1i694
6853
5566
2687
6494
5415
2380
5959
4993-
3113
6291
5139
4169
7151
6090
4280
7137
5701
2978
6746
5^52
3792
6331
4936
2364
7123
5359
4479
7181
5976
2939
6809
5137
2261
6148
4315
2323
5831
4262
3362
7790
5650
2831
7457
5623
2921
5332
4113
2438
5784
4116
210 of 213
-------
Ref: C-l
160" Mill
Tons Per Operating Day
Week Ending Minimum Maxinurn
Average
1/V75 2683 2915 2799
1/11/75 2167 4226 3210
1/18/75 3223 ii053 3^71
1/25/75 3129 4256 3493
2/1/75 2269 3990 3222
2/8/75 2423 4347 '3344
2/15/75 2k65 3662 3097
2/22/75 2669 4230 3379
3/1/75 2631 3692 3178
3/3/75 246o 4258 3366
3/15/75 2582 3920 3178
3/22/75 1443 3811 2961
3/29/75 2086 3486 2759
4/5/75 2532 3590 2980
4/12/75 2797 3772 3178
4/19/75 2014 4043 3220
4/26/75 2942 4o64 3387
5/3/75 2831 44oo 3478
5/10/75 2696 4074 3348
5/17/75 2740 3304 3021
5/24/75 2912 4059 34o4
5/31/75 3232 4032 3575
6/7/75 2935 3661 3335
6/14/75 2653 3346 3105
6/21/75 2818 3706 3170
6/23/75 3172 2294
211 of 213
-------
Ref: C-l 100" 14111
Week Ending
1/V75
l/n/75
1/10/75
1/25/75
2/1/75
2/8/75
2/15/75
2/22/75
3/1/75
3/3/75
3/15/75
3/22/75
3/29/75
4/5/75
4/12/75
4/19/75
4/26/75
5/3/75
5/10/75
5/17/75
5/24/75
5/31/75
6/7/75
6/14/75
6/21/75
6/28/75
Tons Per Operating Day
Minimum
Maximum
Average
2233
3125
2804
2893
4442
3522
2893
4o6o
3528
3084
^159
3650
2933
4039
3^1
2951
4379
3703
2463
3914
3318
3432 •
4389
3915
2700
3844
3^37
3702
4234
3896
2387
4521
3379
2874
4269
3635
3762
4088
39Q2
3762
4088
3902
3217
3902
3659
1201
4053
2942
3142
4045
3770
2783
4792
4046
3026
4o65
3551
65
4o42
2442
1615
4858
3386
1488
3975
2839
2744
3698
3344
1846
2663
2361
1826
3012
2540
2188
3118
2568
2123
3128
2636
212 of £13
-------
Ref:
C-l
160" Plate Treating Line
V/eek Ending
Tons Per Operating Day
Minimum Maximum Average
1/V75
1/11/75
1/16/75
1/25/75
2/1/75
2/8/75
2/15/75
2/22/75
3/1/75
3/0/75
3/15/75
3/22/75
3/29/75
V5/75
V12/75
4/19/75
4/26/75
5/3/75
5/10/75
5/17/75
5/2V75
5/31/75
6/7/75
6/14/75
6/21/75
6/2Q/75
315
3^
317
416
119
51
360
372
if 22
265
396
342
262
283
262
226
350
318
1*1*0
237
44o
227
if 11
1*36
444
105
516
508
564
563
506
485
fc93
517
514
61*6
464
580
631
516
562
542
561
526
519
668
524
491
741
537
586
692
438
419
440
493
365
382
424
445
456
419
**39
468
469
V39
454
4*40
444
456
487
450
483
374
569
487
513
575
213 of 213
------- |