Weston Site Inspection Report for Rouge Steel Company/Ford Motor Complex

RIVER ROUGE OIL SPILL, DEARBORN, MICHIGAN APRIL 2002 SITE INSPECTION REPORT FOR ROUGE STEEL COMPANY / FORD MOTOR COMPANY (ROUGE STEEL / FORD COMPLEX) DEARBORN, WAYNE COUNTY, MICHIGAN us EPA RECORDS CENTER REGION 5

548464

Prepared for

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Emergency Response Branch Region V 77 West Jackson Street Chicago, Illinois 60604

Prepared by

Roy F. Weston, Inc. 750 East Bunker Court, Suite 500 Vernon Hills, Dhnois 60061

Date Revised 30 September 2002 TDD Number S05-0204-010 Document Control Number 252-2A-ACDJ Contract Number 68-W-00-119 START Program Manager John W. Thorsen, P.E. Telephone No. (847)918-4102 U.S. EPA On-Scene Coordinator Ralph DoUhopf

r ‘ I I RIVER ROUGE OIL SPILL, DEARBORN, MICHIGAN APRIL 2002 SITE INSPECTION REPORT FOR ROUGE STEEL COMPANY / FORD MOTOR COMPANY (ROUGE STEEL / FORD COMPLEX) DEARBORN, WAYNE COUNTY, MICHIGAN

Prepared for

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY Emergency Response Branch Region V 77 West Jackson Street Chicago, Illinois 60604

Prepared by

Roy F. Weston, Inc. 750 East Bunker Court, Suite 500 Vernon Hills, Illinois 60061

30 September 2002

Prepared by Date r Stephen X! Wolfe START Member

Reviewed & Approved by ______Date John W. Thorsen, P.E. START Deputy Program Manager viy«AGtHS X—X

Table of Contents

Section Title Page

1 INTRODUCTION...... 1-1

2 SITE BACKGROUND ...... 2-1

2.1 Site Description...... 2-1 2.2 Site History...... 2-2 2.3 Historical Assessment and Investigation Activities ...... 2-3

ENVIRONMENTAL INVESTIGATION ACTIVITIES...... 3-1 3.1 Site Observations and Sampling...... 3-1 3.2 SPCC Plan Review...... 3-9 3.3 Migration Pathway Discussion...... 3-9

FINDINGS AND CONCLUSIONS ...... 4-1

! r

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This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or In part without the express, written permission of U.S. EPA. I

List of Attachments

Attachment

A Site Location Map A-1 Topographic Site Location Map A-2 Aerial Site Location Map

B Facility Layout Map

C Select Photo Documentation

D Select Photo Documentation Location Map

E Sample Location Map

F Sample Results Table for Rouge Steel / Ford Complex

G U.S. EPA / ERT & USCG MSL Oil Match Criteria

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SECTION 1 INTRODUCTION

On 10 April 2002, the Roy F. Weston, Inc., (WESTON®) Superfund Tecluiical Assessment and Response

Team (START) was directed by the United States Environmental Protection Agency (U.S. EPA) to assist

U.S. EPA On-Scene Coordinator (OSC) Jason El-Zein in conducting emergency response activities at the

River Rouge Oil Spill Site in Dearborn and Detroit, Wayne County, Michigan. The emergency response activities were conducted under Technical Direction Document (TDD) number S05-0204-010.

As a part of the ongoing investigation into the source ofthe oil spilled into the River Rouge in April 2002, numerous facilities in Dearborn and Detroit, Michigan, were inspected, and each facility’s Spill Prevention

Countermeasures and Control (SPCC) Plan was reviewed, when available. During site inspection activities, samples were collected fixim select sewers, tanks, and facility sumps and submitted for chemical analysis at the U.S. EPA Emergency Response Team (ERT)-contracted laboratory at WESTON- subcontracted laboratories. The majority of samples START collected were split with the U.S. Coast

Guard (USCG) and analyzed by the USCG Marine Safety Laboratory (MSL). Results from USCG sampling are provided in the River Rouge Spill Response Site Files. Sample Plans, Sample Quality

Assurance Project Plans (QAPPs), and ERT and WESTON-subcontracted laboratory QAPPs are also provided in the Rive Rouge Spill Response Site Files. Potential sources of the spilled oil were identified as those facilities that handled the type and quantity of oil found in the river and that had a potential migration or discharge pathway to the suspected spill or release area on the River Rouge.

I:\WO\STARTRIVERROUGE\31651 .WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. E3*A. It shall not be released or disclosed in whoie or in part without the express, written permission of U.S. EPA. Site Inspection Rqx>rt Rouge Steel / Fotd Complex PE«tCPt<l>4rS Section; 1 Revision: 1 Date: 30 September 2002 Page: 1-2 of 3

The objective ofthis site inspection was to gather facility-specific information to determine if the Rouge

Steel Company / Ford Motor Company (Rouge Steel / Ford Complex) is a potentially responsible party

(PRP) to the release that occurred on the River Rouge and Detroit River in April 2002.

Specific tasks of the site inspection were as follows:

Compile background information, including analytical data fi-om samples START and the USCG collected by regarding the quantity and kind of oily wastes or types of products present at the facility;

Conduct an on-site reconnaissance and document existing volumes and types ofoils and oily wastes at the site;

Collect samples to determine ifthe oils and oily wastes at this site match the oils collected fi-om the River Rouge; I ii • Evaluate the potential for releases of oily materials or products fiom the site and their , i potential off-site migration pathways;

Conduct a review ofthe facility’s SPCC Plan and determine if the facility is environmentally compliant or is a risk for spillage;

Prepare a Site Inspection Report that documents the findings.

This Site Inspection Report is part of the River Rouge Spill Response Site File and is organized into the

following sections:

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This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written permission of U.S. EPA.

I Site Inspection Rqrort Rouge Steel / Ford Con^jlex niSia>ttftS«OKSu.iA?<« Section: 1 Revision; 1 Date; 30 Septemba- 2002 Page: 1-3 of 3

Section 1 - Introduction - The introduction provides a brief description of the objective and scope of the assessment activities.

Section 2 - Site Background - The site background provides a site description and a compressed site history of historical ownership, work activities, and operations at the site.

Section 3 - Environmental Investigation Activities - This section includes site observations and sampling, an SPCC Plan review discussion, and an engineering evaluation of sewers and potential I pathways for discharge to the River Rouge.

Section 4- Findings and Conclusions - This section summarizes the findings ofthe investigation activities.

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SECTION 2

SITE BACKGROUND

2.1 SITE DESCRIPTION

The Rouge Steel / Ford Complex is located at 3001 Miller Road in Dearborn, Michigan (Attachment A-1,

Topographic Site Location Map and A-2, Aerial Site Location Map). The geographical coordinates for the area of the site included in this investigation are latitude 42°18'41" N and longitude 83°09'40" W. The faciUty is located within an industrial area and occupies qjproximately900 acres. The facihty is bordered on the east by Miller Road, to the south by the River Rouge and the Dix Street Bridge, to the north by

Interstate 94 (1-94) and Rotunda Drive, and to the west by Schaefer Road. The River Rouge, a navigable waterway, is located to the south of the facility.

The Rouge Steel / Ford Complex consists oftwo companies, the Rouge Steel Company (Rouge Steel) and the Ford Motor Company (Ford Motor), operating within the same facihty. These companies share the facihty with separate operations and buildings. Rouge Steel is a fiiUy integrated steel miU consisting ofthree blast furnaces (for iron making); two basic oxygen furnaces (for steel making); two ladle metallurgical facihties; three continuous casting machines; one hot strip mill; and one cold roU mill. The Rouge Steel portion of the facihty also includes three decommissioned coke oven batteries, a decommissioned powerhouse, and a byproducts recovery plant. Ford Motor operates several process buildings within the

Rouge Steel/Ford Complex including a frame plant, engine plant, stamping plant, assembly plant, and a wastewater treatment plant (WWTP).

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Site Inspection Report Rouge Steel / Ford Complex MWiAGiflS 065iC^iii3«Cf45U.tMra Section: 2 Revision: 1 Date: 30 Sqiteinber 2002 Page: 2-2 of 3

According to a U.S. EPA Region V draft Multimedia Inspection Report from 1998, there are

^proximately 86 aboveground storage tanks (ASTs) with a combined capacity of2,865,520 gallons; two

15,000-gallon underground storage tanks (USTs); and approximately 500 small containers, including transformers, drums, totes, and lugs, containing oil or oily wastes located at the facility. The facility has a combined total oil storage capacity ofq)proximately2,965,520 gallons. A Facility Layout Map showing the Rouge Steel/Ford Complex is included in Attachment B.

2.2 SITE HISTORY

The Rouge Steel / Ford Complex, formerly part of the Ford Motor Company - Rouge Complex, has operated at the present location since 1919. Ownership of the steel manufacturing processes and operations were transferred entirely to Rouge Steel in 1989. Ford Motor continues to maintain automobile manufacturing operations at the sprawling complex.

Between 1989 and 1999, Rouge Steel and Ford Motorjointly owned a coal-fired powerhouse, which was located at the Rouge Steel facihty. This plant was decommissioned in February 1999 as a direct result of a fire. The powerhouse is currently being dismantled.

Coke making operations at the on-site coke oven batteries ceased in 1988. Presently, Rouge Steel purchases its coke for use in the blast furnaces from New Boston Coke Company in Portsmouth, Ohio.

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This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part mthout the express, written permission of U.S. EPA. Site Inspection Report Rouge Steel / Ford Complex Section: 2 Revision: 1 Date: 30 Sqjtember 2002 Page: 2-3 of 3

2.3 HISTORICAL ASSESSMENT AND INVESTIGATION ACTIVITIES

AU.S. EPARegion Vmultimediainspectionwas conducted at the facility in the fall of1998 attherequest

oftheU.S. EPARegion V Enforcement Compliance Assistance Team. A draft co^yofihe Multimedia

Inspection Report, dated 26 February 1999, is available in the River Rouge Spill Response Site Files.

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SECTION 3

ENVIRONMENTAL INVESTIGATION ACTIVITIES

3.1 SITE OBSERVATIONS AND SAMPLING

Between 10 April and 3 May2002, a Field Investigative Team composed ofpersonnel fromU.S. EPA,

USCG, Michigan Department of Environmental Quality (MDEQ), and START contractors conducted several inspections of the Rouge Steel/Ford Complex. Mr. Donald Windeler, Manager of the

Environmental Engineering Department for Rouge Steel, and Mr. David O’Coimor, Supervisor of

Environmental Services for Ford Motor, accompanied the inspection teams as his respective company’s representative. The inspections focused on the Ford Tailrace (Outfall 006) and the associated storm sewer lines; on the sanitary sewers that are tributary to the Miller Lift Station (Outfall 021); on the on-site oil polishing lagoons and their discharge to the River Rouge (Outfall 001); and on the Ford Boat SUp and all associated outfalls.

Select photo documentation for this inspection and a Select Photo Location Map are provided in

Attachment C and Attachment D, respectively. A complete photo log for this site is available in the River

Rouge Spill Response Site Files. A Sample Location Map is provided in Attachment E, and a summary table of sample results is provided in Attachment F.

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Ford Trailrace (Outfall 006)

The Ford Tailrace serves as a storm sewer and discharge route for cooling water and excess water drawn

from the Detroit River for use in the Rouge Steel / Ford Complex. The discharge point for the Ford

Tailrace is Outfall 006 (Attachment C, Photo 1), which is located southeast ofDix Street along Miller Road

and across from the Miller Lift Station. Outfall 006 has a discharge rate between 60 and 90 milhon gallons

per day (as reported by Mr. Donald Windeler, Rouge Steel, April 2002). The drainage area for the Ford

Tailrace is confined to the southeast portion ofthe Rouge Steel / Ford Complex (Attachment B). This area

was surveyed, and three potential sources of oil were identified: an abandoned gas holding tank; a

decommissioned powerhouse; and a catch basin in the old coal storage area.

The abandoned gas holding tank, located in the southeast comer of the complex, is currently being

dismantled. During the dismantling process, waste oil was discovered and removed from the tank and

stored in a fractionation tank for disposal. On 30 April 2002, START collected a sample ofthis oil from

the braker box located near the gas holding tank (ROS-JJ-083) and oil from a sump located at the base

ofthe gas holding tank (ROS-JJ-084) (Attachment C, Photo 77 and 78). U.S. EPA/ERT analytical results

indicate that neither sample matched the oil released into the River Rouge in April 2002. U.S. EPA/ERT

criteria for determining match vs. no match to the spill material is provided in Attachment G.

The second potential source area within the Ford Tailrace drainage area was the decommissioned

powerhouse located in the eastern portion of Rouge Steel. The Tailrace runs directly imder the

powerhouse. U.S. EPA was concerned that oil and material from the fire at the powerhouse in 1999 could

I:\WO\START\RIVERROUffi\31651 .WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whoie or in part without the express, written pertrission of U.S. EPA. Site Inspection Report Rouge Steel / Ford Conplex Section; 3 Revision; 1 Date; 30 September 2002 Page; 3-3 of 11 have entered the Tailrace and have been discharged to the River Rouge. Ford Motor provided manifests

detailing the quantities and types of materials removed from the powerhouse as a part of its demolition.

U.S. era’s requests to inspect the powerhouse were postponed by active demolition activities; however,

Ford Motor condueted an inspection of the areas of concern within the powerhouse and submitted a

written report with photos. Ford Motor’s report is available in the River Rouge Spill Response Site Files.

Ford Motor did not report any significant accumulations ofoil or areas ofoil staining during their inspection.

The third potential source area within the Ford Tailrace drainage area was an outdoor catch basin located

in an open area of the southeast comer of the Rouge Steel / Ford Complex. Oil staining was observed

in and around the catch basin in the old coal storage area near the parking area for Doetsch Industrial

Services, contractors for Rouge Steel (Attachment C, Photo 26). Three vacuum boxes filled with oily

wastes were observed outside in the same area (Attachment C, Photo 24). On 15 April 2002 sample

RSROT-01 was collected by START at this location (Attachment C, Photo 36); U.S. EPA/ERT

determined that it was not a match for the material spilled in the River Rouge. Analytical results from the

USCG spht sample 02-112-13, which was analyzed by MSL, indicated that the sample did not match the

oil in the river; however, it did contain a key contaminant present in the spill material.

No free oil was observed in the Ford Tailrace or its tributary storm sewers; however a slight sheen was

observed in the wet well (Attachment C, Photo 25) on the Ford Tailrace (Outfall 006). This sheen was

sampled by START (ROS-TJ-055) and the USCG (02-127-1) on 25 April 2002. At the direction of

U.S. EPA, the sample collected by START was not analyzed, however, the USCG sample,which was

analyzed by MSL, did not match the oil released to the River Rouge. A USCG sample (2-101-8)

FWONSTARriUVERROUGEVS 1651 .WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written permission of U.S. EPA. Site Inspection Report Rouge Steel / Ford Complex Section: 3 Revision: 1 Date: 30 Septentber 2002 Page: 3-4 of 11 collected on 11 April 2002 consisting of pieces of absorbent a boom in the river near Outfall 006 did, however, match the material spilled into the river (see Attachment E).

Sanitary Sewers (Outfall 021)

After completing the inspections ofthe Ford Tailrace drainage area, START began inspecting the sanitary

sewer lines within the Rouge Steel / Ford Complex. The inspections ofthe sanitary sewer line’s tributary

to theMillerLift Stationidentified a single locationwith an accumulationofoil. On 15 April 2002, START 14 and USCG collected samples (RS-01, RS-02, and 02-112-12) fi-om this sanitary sewer, located 20 feet

northwest ofthe Rouge Steel Training Center (Attachment C, Photo 29). U.S. EP A / ERT and USCG

MSL analytical results indicate that this material did not match the oil released to the River Rouge.

Oil Polishing Lagoons (Outfall 0011

Following the inspections ofthe sanitary sewers, START inspected and conducted sampling at the Oil

Polishing Lagoons (also referred to as Schaefer Road WWTP). The Oil Polishing Lagoons serve as an

oil treatment process for Rouge Steel. Wastewater containing oil is discharged into two clarifiers, where

oil is skimmed fi-om the surface. Water is then pumped into the first of two lagoons, where the water

passes through two baffles to contain any residual oil. Water then passes through the second lagoon, where

four additional containment stmctures serve to contain oil prior to the lagoons’ discharge to the River Rouge

via Outfall 001. Samples were collected fiom an oil skimmer at Outfall 001 (ROS-CG-056 and 02-127-

2) and the second lagoon’s discharge to the river (ROS-CG-057 and 02-127-3) on 25 April 2002. U.S.

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EPA/ERT and USCGMSL analytical results indicated that samples ROS-CG-056,02-127-2, and 02-

127-3 did not match the oil spilled in the river (Attachment C, Photo 10). At the direction of the U.S.

EPA, sample ROS-CG-057 was not analyzed.

On 14 April 2002, the USCGcollectedasample(02-l 10-13) from the clarifiers near the lagoons. MSL

analytical results indicated this sample contained the key contaminant present in the oil spilled into the River

Rouge. START also collected sample ROS-LK-087 from the final oil polishing lagoon during night

operations on 2 May 2002. At U.S. EPA’s direction, this sample was not analyzed.

U.S. EPA noted several deficiencies in the Oil Polishing Lagoons’ operation, including the following;

• The presence of vortices at the final contaimnent baffle (Attachment C, Photo 54);

• Bypass routes through a containment boom (Attachment C, Photo 56 and 57);

• Poor attachment ofthe edges of aboom allowing oil to flow through die system (Attachment C, Photo 61 and 67);

• Nonfunctioning oil skimmers (Attachment C, Photo 63).

Ford Boat Slip and Associated Outfalls

START inspections found that Ford Motor operates and maintains oil recovery systems from the Roulo

Creek Outfall (Outfall 017) to the Ford Boat Slip. The Roulo Creek Enclosure serves as the discharge

point for the North Rouge WWTP (Outfall 004E) and is a combined sewer overflow discharge point for

I:\WO\STARTVRIVERROUaE\31651. WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written permission of U.S. EPA, Site Inspection Report Rouge Steel / Ford Conqilex «SI3.‘tf^CCNSl=ulJWrS Section: 3 Revision: 1 Date: 30 Sqjtonbo- 2002 Page: 3-6 of 11 theCityofDeaibom. U.S. EPA/ERT determined that none ofthe samples collected from the wet well at

OutfaU 004E (ROS-CG-060) and the North Rouge WWTP clarifier (ROS-USCG-001 andROS-TJ-104) matched the oil released into the River Rouge in April 2002.

Rouge Steel Mill Plant (Tandem MilH

In addition to the four areas of focus discussed above, START collected three samples of material associated with the pickling process in the Rouge Steel Mill Plant (Tandem Mill). Sample RSTP-01 was collected by START on 15 April 2002 from the #2 Tandem Mill sump. U.S. EPA/ERT’s analysis of this material indicated that it was not a match to the oil spilled into the river. However, USCG collected four samples from this location on 15 April 2002 (02-112-1, 02-112-2, 02-112-3, 02-112-4); MSL determined that these samples contained the key contaminant present in the oil spilled into the River Rouge.

Sample ROS-CG-058, which consisted of Rouge Steel RO-60 oil used in the pickling process, was collected by START on 25 April 2002. Sample ROS-CG-059, which consisted ofthe Rouge Steel LTD 1 detergent used in the pickling process, was also collected by START on 25 April 2002. Split samples were collected by USCG (02-127-5 and 2-127-6, respectively). Analytical results from both U.S.

ERA/ERT and USCG MSL indicated that none of these samples matched the oil released into the River

Rouge in April 2002.

I:\WO\START\RIVERROU(E\31651 .WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. FT A. It shall not be released or disclosed in whole or in part without the express, written pernission of U.S. FT A. Site Inspection Report Rouge Steel / Ford Complex MUiAGfJiS neSKirC.^0345CUA.>

Sampling Summary

A summary table presenting all analytical results discussed in this section is provided in Attachment F.

START collected 29 samples (including one diqilicate) fixim the Rouge Steel/Ford Complex fiom 15 April

2002 to 30 April 2002. Six of these samples were splits the USCG provided from their sampling event on 16 April 2002 (ROS-USCG-001, ROS-USCG-002, ROS-USCG-003, ROS-USCG-004, ROS-

USCG-005, and ROS-USCG-006). At the direction ofU.S. EPA, samples ROS-USCG-003 and ROS-

USCG-005 were not analyzed. U.S. EPA/ERT analytical results for the remaining samples indicated that none of these samples matched the oil released into the River Rouge.

The USCG collected 43 samples from various areas within the Rouge Steel / Ford Complex from 10 April

2002 to 25 April 2002 (including the above mentioned splits). Analytical results from MSL indicated that six ofthese samples (02-110-13,02-112-1,02-112-2,02-112-3,02-112-4, and 02-112-13) contained the key contaminant found in the spilled oil but did not match the oil spilled into the river in April 2002.

Sample 02-110-13 was collected from the clarifying pools near the oil polishing lagoons on 14 April 2002.

Samples 02-112-1,02-112-2,02-112-3, and 02-112-4 were collected from the Rouge Steel #2 Tandem

Mill sump on 15 April 2002 (Attachment C, Photo 32). Sample 02-112-13 was collected from a vacuum box near the Doetsch staging area on 15 April 2002.

On 10 April 2002 and 11 April 2002, the USCG collected three samples from the area around Outfall 006

(02-100-6,02-101-5, and 02-127-1) following observations of oil staining along the river banks in the vicinity of Outfall 006. Analytical results from the USCG MSL indicated “clean water” for samples 02-

I:\WO\START\RTVERROUGEV31651 .WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written pernission of U.k EPA. Site Inspection Report

Rouge Steel / Ford Complex MAtiAGcH6 ^ W.SGHEHS.'CCWSU.I^re Section: 3 Revision: 1 Date: 30 Septembo- 2002 Page: 3-8 of 11

100-6 and 02-101-5 and “no match” for sample 02-127-1. The USCG collected a sample on 11 April

2002 (02-101-8) comprised ofpieces of sorbent boom deployed around Outfall 006. Analytical results fiom MSL indicated that this sample matched the oil released into the River Rouge in April 2002; however, this apparent match maybe associated with oil already present in the river that had accumulated around

Outfall 006.

As part oftheU.S. EPA’s ongoing civil investigation, START collected eight samples from 9 May2002 to 15 May2002 from VAC-ALL pump trucks transporting material from various areas within the Rouge

Steel portion of the complex to U.S. Liquids (ROS-SM-148, ROS-SM-149, ROS-SM-150, ROS-SM-

163,ROS-SM-164,ROS-SM-165,ROS-SM-166,ROS-SM-167). Samples ROS-SM-148 and ROS-

SM-149 weresplitwith the USCG(02-144-1 and 02-144-2). Analytical results from U.S. EPA/ERT and

MSL indicated that the samples did not match the oil released into the River Rouge. For more information regarding the sampling and analytical results for U.S. EPA’s civil investigation at the Rouge Steel / Ford

Complex, refer the River Rouge Civil Investigations Summary Report, which is part of the River Rouge

Spill Response Site Files.

MDEQ investigations indicated an oily deposit on the concrete River Rouge channel below Outfall 001.

On 25 April 2002, MDEQ provided START with a sample (ROS-EF-061) of oily concrete and sediment from this area ofthe River Rouge channel. ERT’s analysis ofthis material indicated that it was not amatch to the oil released into the River Rouge and Detroit River in April 2002.

I:\WO\START«IVERROUGE\31651 .WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written pernission of U.S. EPA. Site Inspection Report Rouge Steel / Ford Complex iTesj3>t^iSJC04SUi.iA?(rs Section: 3 Revision; 1 Date; 30 Septembo- 2002 Page; 3-9 of 11

3.2 spec PLAN REVIEW

An SPCC Plan review was not performed at this facility because a review was performed on 30

September 1998. The SPCC review is provided in the 26 February 1999 Multimedia Inspection

Report, which is located in the River Rouge Spill Response Site Files.

3.3 MIGRATION PATHWAY DISCUSSION

Wastewater and storm water fiom Rouge Steel follows a number ofpathways within the Ford River Rouge

Complex Subdistrict. Generally, waste streams from the western area of the subdistrict flow west to the

Schaefer Road Wastewater Treatment Plant (WWTP), which subsequently discharges to Outfall 001, located about 1,200 feet upstream from the Schaefer Road Bridge. Waste streams originating from the central area of the subdistrict are generally treated and discharged through Outfall 004 in the Ford Boat

Slip or Outfall 002, located near the turning basin, about 1,500 feet upstream from the Dix Street Bridge.

Waste streams from the southeast quadrant ofthe faciUty, including the gas holder^ flow through the Ford

Tailrace to Outfall 006, located about 1,150 feet downstream from the Dix Street Bridge. Any oil discharged at these outfalls could be released into River Rouge. Wastewater and storm water discharges from specific facilities are described below.

1. Pretreated process wastewater from the Cold Mill and the Hot Strip Mill discharges into the River Rouge at Outfall 001.

2. Pretreated process wastewater from the Continuous Caster along with some process wastewater from the Cold Mill discharges into the River Rouge at Outfall 002a.

I:\WO\START\RIVERROUGE\31651. WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written pernission of U.S. EPA. Site Inspection Report Rouge Steel / Ford Complex Section: 3 Revision: 1 Date: 30 September 2002 Page: 3-10 of 11

3. Storm water, pretreated process wastewater from Blast Furnace B, and non-contact cooling water from the power generation plant discharge into the Ford Boat Slip at Outfall 004b.

4. Some process wastewater and non-contact cooling water from the Basic Oxygen Furnace discharge into the Ford Boat Slip at Outfall 004c.

5. Non-contact cooling water from the Cold Mill discharges into the Ford Boat Slip at Outfall 004d.

6. Storm water and non-contact cooling water from Blast Furnace C discharges into the Roulo Creek Enclosure at Outfall 004e; the Roulo Creek Enclosure discharges into the Ford Boat Slip.

7. Storm water and non-contact cooling water from the Power House flows through the Ford Tail race and discharges into the River Rouge at Outfall 006.

In addition, some sanitary wastewater discharges into the East Dearborn Interceptor upstream from the

Miller Road Pumping Station. Combined sewage in the East Dearborn Interceptor flows into the

Oakwood Interceptor, which discharges into the Detroit WWTP. Under wet weather conditions, the

WWTP wet well elevations rise, increasing the hydraulic head in the East Dearborn Interceptor. If the

hydraulic head in the East Dearborn Interceptor exceeds the overflow weir elevation at the Miller Road

Pumping Station, combined sewage will discharge into the River Rouge at Outfall 021, located

approximately 1,200 feet downstream from the Dix Street Bridge and approximately 50 feet downstream

from Outfall 006. Hydraulic modeling and level sensor data indicate, however, that sewage did not

overflow at the Miller Road Pumping Station during the first half of April 2002.

I:\WO\ST ART^UVERROU($\31651 .WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written pernission of U.S. EPA. Site Inspection Rqx»t Rouge Steel / Ford Complex lX.Sl3^«:^3.COf4fOLTA.>

For a more detailed discussion ofthe possible migration pathways from the Rouge Steel / Ford Complex, refer to the Sewer Pathway Analysis Report, which is part of the River Rouge Spill Response Site Files.

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SECTION 4 FINDINGS AND CONCLUSIONS

U.S. EPA established three primary criteria for determining if a specific facility may be accountable for the

River Rouge oil spill. The criteria consist of the following:

• A positive match on the oil analysis; • Adequate oil handling volumes (greater than 100,000 gallons); • A pathway to the suspected release points on the River Rouge.

START andMDEQ collected a total of 29 oil samples, which were analyzed by U.S. EPA/ERT. None of these samples were considered a match with the oil spilled into the River Rouge in April 2002

(Attachment G). The USCG collected and submitted a total of 43 samples to MSL for analysis. Six of the samples were found to contain a key contaminant linked to the oil in the river (02-110-13,02-112-1,

02-112-2,02-112-3,02-112-4, and 02-112-13). The single oil sample that matched oil in the river (02-

101-8) was taken finm an absorbent boom locatedjust outside of Outfall 006. These results indicate that some ofthe oil in the Rouge Steel/ Ford Complex and in the river had similar trace contaminants, but none of the oil sampled inside of the complex matched the oil in the river.

Review of oil storage and handling records indicated that adequate volumes (approximately 3 million gallons) could be stored at the facility. This volume is enough to account for a major oil spill.

Hydraulic calculations of sewer configurations and wet weather scenarios indicated that oil spills could reach the River Rouge through outfalls and combined sewers under rare conditions but not through sanitary

I:\WO\STARrRIVERROUGE\31651. WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written permission of U.S. EPA. Site Inspection Report Rouge Steel / Ford CcHiiplex Section: 4 Revision: 1 Date: 30 Septembo- 2002 Page: 4-2 of 2 sewer lines. Visual inspections found several containment barriers that were not sound. Therefore, based on all of these findings, the Rouge Steel/Ford Complex cannot be eliminated as a PRP for the April 2002

River Rouge oil spill.

I:\WO\STARTiRIVERROUGE\31651. WPD 252-2A-ACDJ

This document was prepared by Roy F. Weston, Inc., expressly for U.S. EPA. It shall not be released or disclosed in whole or in part without the express, written pernission of U.S. EPA. ;-.r,rtxy

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CENTRAL LABORATORY ROUGE STEEL / FORD COMPLEX Roy F. Weston, Inc. FACILITY LAYOUT MAP 750 East Bunker Court RIVER ROUGE OIL SPILL DEARBORN, MICHIGAN Suite 500 f CESKJHBB /COMSU.TAMTS SCALE: DRAWN; DATE: ATTACHMENT: Vernon Hills, Illinois 60061 T.M. O' 100'200' 400' 600' SEPTEMBER 2002 ' ff.SI3^eKS^»^SlOAfflS

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PHOTO NO: 1

PHOTOGRAPHER: A. Betancourt

DIRECTION: SW

DATE: 25 April 2002 (0910) SUBJECT: A view of Outfall 006 sampling location. Sample ROS-TJ-055. trrm

SITE: Rouge Steel DATE: 25 April 2002 (1008)

PHOTO NO: 10 DIRECTION: Down SUBJECT: A view of sampling in progress at Outfall 001 oil skimming basin. Sample ROS-CG-056. PHOTOGRAPHER: A. Betancourt i^lijj: -1 Itl- "t J I.,

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SITE: Rouge Steel DATE: 15 April 2002 (0932)

PHOTO NO: 24 DIRECTION: S SUBJECT: A view of vacuum boxes near the catch basin in the oil coal storage area, adjacent to the parking area for Doetsch Industrial Services. PHOTOGRAPHER: J. Justice Sample RSROT-01 taken from northernmost vacuum box.

SITE: Rouge Steel DATE: 15 April 2002(1111)

PHOTO NO: 25 DIRECTION: Down SUBJECT: A view of the wet well at Outfall 006. PHOTOGRAPHER: J. Justice Wi I Sg^i

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SITE: Rouge Steel DATE: 15 April 2002 (0922)

PHOTO NO: 26 DIRECTION: N SUBJECT: A view of a catch basin near the old coal storage area, adjacent to the Doetsch Building. PHOTOGRAPHER: J. Justice W

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SITE: Rouge Steel DATE: 15 April 2002(1350)

PHOTO NO: 29 DIRECTION: SE SUBJECT: A view of the location of the sanitary manhole near the training building. PHOTOGRAPHER: J. Justice ^ 'I

SITE: Rouge Steel DATE: 15 April 2002(1613)

PHOTO NO: 32 DIRECTION: N SUBJECT: A view of sampling in progress of the steel roll oil tank tandem mill sump. Sample RS fP-Ol. PHOTOGRAPHER: J. Justice m. .■wv - si

SITE: Rouge Steel DATE: 15 April 2002(1755) PHOTO NO: 36 DIRECTION: W SUBJECT: A view of sampling in progress at the vacuum boxes near the old coal storage area, adjacent to the Doetsch PHOTOGRAPHER: C. Greene Building. Sample RSROT-01. t-'.y- ,:.W V. . .

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SITE: Rouge Steel DATE: 30 April 2002(1524)

PHOTO NO: 54 DIRECTION: Down SUBJECT: A view of a vortex at final baffle before diseharge to the River Rouge from Supplemental Oil PHOTOGRAPHER: J. Justice Polishing Lagoon.

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SITE: Rouge Steel DATE: 30 April 2002(1537)

PHOTO NO: 56 DIRECTION: NE SUBJECT: A view of a gap in the boom located in the Supplemental Oil Polishing Lagoon. PHOTOGRAPHER: J. Justice ,r',

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SITE: Rouge Steel DATE: 30 April 2002(1535)

PHOTO NO: 57 DIRECTION: N SUBJECT: A view of a gap in the boom attachment for the Supplemental Oil Polishing Lagoon. PHOTOGRAPHER: J. Justice

^ . •• ■. „ , jft,- SITE: Rouge Steel DATE: 30 April 2002 (1533)

PHOTO NO: 61 DIRECTION: S SUBJECT: A view of a bypass route for oil past two containment booms located in the Supplemental Oil PHOTOGRAPHER: J. Justice Polishing Lagoon. Ki« mm

SITE: Rouge Steel DATE: 30 April 2002 (1540)

PHOTO NO: 63 DIRECTION: W SUBJECT: A view of the final baffle, oil skimmer, and accumulated oil in the first Oil Treatment Lagoon. PHOTOGRAPHER: J. Justice

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SITE: Rouge Steel DATE: 30 April 2002 (1554)

PHOTO NO: 67 DIRECTION: E SUBJECT: A view of oil staining on the side of the second Oil Treatment Lagoon. PHOTOGRAPHER: J. Justice m. A

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SITE: Rouge Steel DATE: 30 April 2002(1716)

PHOTO NO: 77 DIRECTION: Down SUBJECT: A view of sampling in progress from the pit at the base of the Gas Holding Unit. Sample ROS-JJ-084. PHOTOGRAPHER: S. Meyer

SITE: Rouge Steel DATE: 30 April 2002 (1720)

PHOTO NO: 78 DIRECTION: Down SUBJECT: A view of sampling in progress from the pit at the base of the Gas Holding Unit. PHOTOGRAPHER: S. Meyer V-a:’"

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