JOB SAFETY ANALYSIS Date: 06/1-/2007

Contractor Name: Jones & Smith Constructors. Project Plant Location: Lake Charles, LA Revised 06/26/2007
Sub-Tier Contractor Name: Acme Constructors
Prepared By: Ron Jones
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 Jones 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
  29 CFR 1910.120 17. Noise Exposure   ASP.653.3002
Operations
ASP.653.3000
2. Confined Space    ASP.653.3010 18. Temperature Extremes
/.3003
3. Hot Work   ASP.653.2308 19. Hoisting & Rigging   ASP.653.2202
20. Ergonomics:
Repetitive Motion /
4. Roof Work   ASP.653.2321  ASP.653.3011
Awkward Positions /
Same Position (s)
5. Fall Hazards (> 6 ft)    ASP.653.2001 21. Biological ASP.653.2102
22. Insects / Varmints /
6. Excavation/Trenching    ASP.653.2311 ASP.653.2102
Vermin
7. Scaffolds / Ladders    ASP.653.2302/2303 23. Signs and Barricades ASP.653.2300
24. Location Specific
8. Aerial Lifts    ASP.653.2205 Emergency  ASP.653.1007
Response Plan
9. Heavy Equipment   ASP.653.2200 Series 25. Air Effluent Discharges  ASP.653.4003
26. Water/Liquid Effluent
10. Lock and Tag    ASP.653.2315
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 28. Associated w/Significant ASP.653.4000
13. Asbestos Work    ASP.653.3001 Environmental Aspects? Series
14. Lead Work    ASP.653.3005  = Requires formal/special training
15. Hazardous
 ASP.653.2100/.3007  = Requires a permit/form/report
Materials/MSDS
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
 JOB SAFETY ANALYSIS Project: XXXX-0000
(Continuation Page) Contract/P.O./Release No.: XXXX-2
Work Activity Hazards Present Required Safety Measures/PPE
Electrical Inspection Electric Shock Hazard if contacted Maintain safe working distance (per NFPA
Bridge Arc Hazard from exposed electric equipment 70E, stated as "AVOID CONTACT" for 120
Trolley volts and one (1) foot for 480 volts for qualified
Anode Hoist workers) and wear level 1 (Category 1) PPE
Suction Pipe Equipment. This equipment consist of:
Filling Pipe Hardhat, Safety Glasses, Cotton
Blower Long Sleve Shirt and Pants, Safety
Shoes
Electrical Testing and verification of 120 volt Electric Shock Hazard if contacted. Arc Maintain safe working distance (per NFPA
Control system in the MCC Room. Hazard from exposed electric equipment 70E, stated as "AVOID CONTACT" for 120
Bridge Panel 120 VAC and 480 VAC components are in volts and one (1) foot for 480 volts for qualified
Trolley Panel close proximity workers) and wear level 1 (Category 1) PPE
Anode Hoist Panel Equipment. This equipment consist of:
Suction Pipe Panel Hardhat, Safety Glasses, Cotton
Filling Pipe Panel Long Sleve Shirt and Pants, Safety
Blower Panel 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 Electric Shock Hazard if contacted Maintain safe working distance (per NFPA
the MCC Room to the following: Arc Hazard from exposed electric equipment 70E, stated as "AVOID CONTACT" for 120
Main Crane Power 120 VAC and 480 VAC components are in volts and one (1) foot for 480 volts for qualified
Bridge Motor close proximity workers) and or wear level 2 (Category 2) PPE
Trolley Motor Equipment. This equipment consist of:
Anode Hoist Motor Hardhat, Safety Glasses, Cotton
Suction Pipe Motor Long Sleve Shirt and Pants, Safety
Filling Pipe Motor 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
 JOB SAFETY ANALYSIS Project: XXXX-0000
(Continuation Page) Contract/P.O./Release No.: XXXX-2
Work Activity Hazards Present Required Safety Measures/PPE
Electrical verification of 480 Power feeders in Electric Shock Hazard if contacted Maintain safe working distance (per NFPA
Panels 3K & 8K: Arc Hazard from exposed electric equipment 70E, stated as "AVOID CONTACT" for 120
Motorized valves 120 VAC and 480 VAC components are in volts and one (1) foot for 480 volts for qualified
Lighting Transformer close proximity workers) and/or wear level 2 (Category 2) PPE
Compressor Motor 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.
Ergonomics awkward position - working on
hands and knees.
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
Back strain Stretching before start of work. Take frequent
Cumulative knee trauma breaks to stretch back.Use some type of
padding under knees, take frequent breaks

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

Fatality prevention Alcoa Fatality Prevention Program training

Fixed ladder use
Congestion and trip hazards
Working in high-noise areas
Barricade and sign area
Slips, trips, and falls
Trips and falls
Exposures to occupational noise
Unauthorized personnel entering into electrical
work area that could be exposes to electrical
energy
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.
Area in crane is congested. Be aware of trip
hazards in area.
All areas of the furnace are designated as
hearing protection area. Wear foam/rubber ear
plugs with NRR of at least 26
Barricade work area with RED barrier tape and
post signs to prevent unauthorized entry
 JOB SAFETY ANALYSIS Project: XXXX-0000
(Continuation Page) Contract/P.O./Release No.: XXXX-2
Work Activity Hazards Present Required Safety Measures/PPE
 PREJOB SAFETY PLANNING SIGNOFF

Job Specific JSA review Task Specific JSA review

I have read the attached JSA (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

S-AF-073 20 July 06