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S-AF-059 19 Aug 04

JOB SAFETY ANALYSIS Date: 06/1-/2007


Contractor Name: J ones & Smith Constructors. Project Plant Location: Lake Charles, LA Revised 06/26/2007
Sub-Tier Contractor Name: Acme Constructors
Prepared By: Ron J ones
Project: South Bake Furnace Rebuild Project No.: XXXX-0000 Contract/PO No.: XXXX-2
Location (e.g., building, area, etc.): South Bake Furnace East and West Crane
Work Scope/Description: Electrical Check-out and Testing in live panels
Specific Work Location(s): South Bake Furnace East and West Crane
Name Primary/Phone # Secondary/Phone #
Contractor Contact Person(s): Ron J ones 555-555-2222 555-555-3333
Alcoa SPA: Tom Smith 555-555-4444 555-555-5454
Plant Emergency No.: 333 555-555-4545
Prejob Walkthrough Conducted: Yes No
KNOWN OR POTENTIAL HAZARDS
Yes No Reference Yes No Reference
1. Hazardous Waste
Operations
29 CFR 1910.120 17. Noise Exposure ASP.653.3002
2. Confined Space ASP.653.3010 18. Temperature Extremes
ASP.653.3000
/.3003
3. Hot Work ASP.653.2308 19. Hoisting & Rigging ASP.653.2202
4. Roof Work ASP.653.2321
20. Ergonomics:
Repetitive Motion /
Awkward Positions /
Same Position (s)
ASP.653.3011
5. Fall Hazards (>6 ft) ASP.653.2001 21. Biological ASP.653.2102
6. Excavation/Trenching ASP.653.2311
22. Insects / Varmints /
Vermin
ASP.653.2102
7. Scaffolds / Ladders ASP.653.2302/2303 23. Signs and Barricades ASP.653.2300
8. Aerial Lifts ASP.653.2205
24. Location Specific
Emergency
Response Plan
ASP.653.1007
9. Heavy Equipment ASP.653.2200 Series 25. Air Effluent Discharges ASP.653.4003
10. Lock and Tag ASP.653.2315
26. Water/Liquid Effluent
Discharges
ASP.653.4004
11. Site/Vehicle Traffic ASP.653.1005/.2300 27. Fatality Prevention ASP.653.1400
12. Electrical Hazards ASP.653.2309/.2310
13. Asbestos Work ASP.653.3001
28. Associated w/Significant
Environmental Aspects?

ASP.653.4000
Series
14. Lead Work ASP.653.3005 = Requires formal/special training
15. Hazardous
Materials/MSDS
ASP.653.2100/.3007 = Requires a permit/form/report
16. Respiratory Hazards ASP.653.3008 = Requires certification or Competent/Qualified Person
SPECIFIC HAZARD ANALYSIS AND SAFE WORK REQUIREMENTS
Known and/or potential hazards are further evaluated, and specific measures are identified on subsequent pages. This discussion must include
identification of the work activity, the specific hazards present, and the safe work requirements/controls (including a hazards assessment for PPE)
to be used to alleviate/control the hazard(s).
MINIMUM DRESS/PPE REQUIREMENTS: hard hats, safety glasses, electrical hazard-rated metatarsal boots with hard toes, and long pants
and shirt with sleeves made of 100% cotton or wool (or cotton/blend).

REVIEW
KNOWN AND/OR POTENTIAL HAZARDS ARE FURTHER EVALUATED, AND SPECIFIC CONTROL MEASURES
ARE IDENTIFIED ON SUBSEQUENT PAGES

Project Engineer Date Alcoa Single Point Accountable Date

Contractor Supervision Date (Optional) Date

S-AF-059 19 Aug 04

Project: XXXX-0000
JOB SAFETY ANALYSIS
(Continuation Page)
Contract/P.O./Release No.: XXXX-2
Work Activity Hazards Present Required Safety Measures/PPE
Electrical Inspection
Bridge
Trolley
Anode Hoist
Suction Pipe
Filling Pipe
Blower
Electric Shock Hazard if contacted
Arc Hazard from exposed electric equipment

Maintain safe working distance (per NFPA
70E, stated as "AVOID CONTACT" for 120
volts and one (1) foot for 480 volts for qualified
workers) and wear level 1 (Category 1) PPE
Equipment. This equipment consist of:
Hardhat, Safety Glasses, Cotton
Long Sleve Shirt and Pants, Safety
Shoes
Electrical Testing and verification of 120 volt
Control system in the MCC Room.
Bridge Panel
Trolley Panel
Anode Hoist Panel
Suction Pipe Panel
Filling Pipe Panel
Blower Panel

Electric Shock Hazard if contacted. Arc
Hazard from exposed electric equipment
120 VAC and 480 VAC components are in
close proximity
Maintain safe working distance (per NFPA
70E, stated as "AVOID CONTACT" for 120
volts and one (1) foot for 480 volts for qualified
workers) and wear level 1 (Category 1) PPE
Equipment. This equipment consist of:
Hardhat, Safety Glasses, Cotton
Long Sleve Shirt and Pants, Safety
Shoes
All 480 volt components must be guarded to
shield from accidental contact.

Complete form S-AF-061 Energized Electrical
Work Permit.

Electrical Testing and verification of 120 volt
Control system in Panels 3K & 8K:
Suction Pipe Controls
Filling Pipe Controls
Motorized valve Controls
Lighting Systems
Controls General

Electric Shock Hazard if contacted
Minimal Arc Hazard from exposed electric
equipment
120 VAC and 480 Volt AC components are in
close proximity

Maintain safe working distance (per NFPA
70E, stated as "AVOID CONTACT" for 120
volts and one (1) foot for 480 volts for qualified
workers) and wear level 1 (Category 1) PPE
Equipment. This equipment consist of:
Hardhat, Safety Glasses, Cotton
Long Sleve Shirt and Pants, Safety
Shoes
All 480 volt components must be guarded to
shield from accidental contact.

Complete form S-AF-061 Energized Electrical
Work Permit.


Electrical Testing and verification of 120 volt
Control system in New Crane Cab:
General Controls

Electric Shock Hazard if contacted
Minimal Arc Hazard from exposed electric
equipment

Maintain safe working distance (per NFPA
70E, stated as "AVOID CONTACT" for 120
volts and one (1) foot for 480 volts for qualified
workers) and wear level 1 (Category 1) PPE
Equipment. This equipment consist of:
Hardhat, Safety Glasses, Cotton
Long Sleve Shirt and Pants, Safety
Shoes
Complete form S-AF-061 Energized Electrical
Work Permit.

Electrical verification of 480 Power feeders in
the MCC Room to the following:
Main Crane Power
Bridge Motor
Trolley Motor
Anode Hoist Motor
Suction Pipe Motor
Filling Pipe Motor

Electric Shock Hazard if contacted
Arc Hazard from exposed electric equipment
120 VAC and 480 VAC components are in
close proximity

Maintain safe working distance (per NFPA
70E, stated as "AVOID CONTACT" for 120
volts and one (1) foot for 480 volts for qualified
workers) and or wear level 2 (Category 2) PPE
Equipment. This equipment consist of:
Hardhat, Safety Glasses, Cotton
Long Sleve Shirt and Pants, Safety
Shoes, FR Smock Cal Rating of 8,
1000 volt rated gloves, arc face shield
Complete form S-AF-061 Energized Electrical
Work Permit.

S-AF-059 19 Aug 04

Project: XXXX-0000
JOB SAFETY ANALYSIS
(Continuation Page)
Contract/P.O./Release No.: XXXX-2
Work Activity Hazards Present Required Safety Measures/PPE
Electrical verification of 480 Power feeders in
Panels 3K & 8K:
Motorized valves
Lighting Transformer
Compressor Motor

Electric Shock Hazard if contacted
Arc Hazard from exposed electric equipment
120 VAC and 480 VAC components are in
close proximity

Maintain safe working distance (per NFPA
70E, stated as "AVOID CONTACT" for 120
volts and one (1) foot for 480 volts for qualified
workers) and/or wear level 2 (Category 2) PPE
Equipment. This equipment consist of:
Hardhat, Safety Glasses, Cotton
Long Sleve Shirt and Pants, Safety
Shoes, FR Smock Cal Rating of 8,
1000 volt rated gloves, arc face shield
Complete form S-AF-061 Energized Electrical
Work Permit.

.

Lock out disconnects at column S-1 and S-3 for
west crane and column S-17 and S-20 for the
east crane per MES procedure.
Verify zero energy at the crane buss or at
power terminal blocks in panel 1K.
Arc hazard during verification. Maintain safe working distance (per NFPA
70E, stated as "AVOID CONTACT" for 120
volts and one (1) foot for 480 volts for qualified
workers) and wear level 1 (Category 1) PPE
Equipment. This equipment consist of:
Hardhat, Safety Glasses, Cotton
Long Sleve Shirt and Pants, Safety
Shoes
Voltage test both sides of the disconnect to
verify the power is off and no voltage is
present
Ergonomics awkward position - working on
hands and knees.
Back strain
Cumulative knee trauma
Stretching before start of work. Take frequent
breaks to stretch back.Use some type of
padding under knees, take frequent breaks

Emergency events Exposure plant emergencies such as imclement
weather
Site specific training - Alcoa Lake Charles.
Site-specifc Emergency Plan is attached
including map of evacuation and staging areas

Fatality prevention Alcoa Fatality Prevention Program training

Fixed ladder use Slips, trips, and falls Use caution in and around ladder wells. Do not
carry tools while climbing ladders. Use a tool
belt or rope to pass up tools. Maintain three
point contact.
Congestion and trip hazards Trips and falls Area in crane is congested. Be aware of trip
hazards in area.
Working in high-noise areas Exposures to occupational noise All areas of the furnace are designated as
hearing protection area. Wear foam/rubber ear
plugs with NRR of at least 26
Barricade and sign area Unauthorized personnel entering into electrical
work area that could be exposes to electrical
energy
Barricade work area with RED barrier tape and
post signs to prevent unauthorized entry











S-AF-059 19 Aug 04

Project: XXXX-0000
JOB SAFETY ANALYSIS
(Continuation Page)
Contract/P.O./Release No.: XXXX-2
Work Activity Hazards Present Required Safety Measures/PPE















S-AF-073 20 J uly 06


PREJ OB SAFETY PLANNING SIGNOFF

J ob Specific J SA review Task Specific JSA review
I have read the attached J SA (and attachments) and understand the hazards and controls associated with this job.
Prejob meeting general Energized Electrical Work Permit
Fall Protection Work Plan
Hoisting & rigging prelift Confined space pre-entry meeting
Asbestos/Lead work plan
Lock/Tag/Try

Other (specify): _ ______________________________________________________________________________
Project Number ___ ____________________________ Project Location _ ____________________________
Date ID No. (optional) Name (Print) Signature





















Person Conducting Briefing ___________ __________________ __________________________________
Print Name Signature