Multifos Job Safety Analysis Index - The Mosaic · PDF fileMultifos Job Safety Analysis Index JSA # AREA NAME DELETE ? DRAFT COMP SHIFT REVIEW Safety Review FINAL REVIEW 1 AFI MAINTENANCE

Multifos Job Safety Analysis Index

JSA # AREA NAMEDELETE ? DRAFT

COMPSHIFT

REVIEWSafetyReview

FINAL REVIEW

1 AFI MAINTENANCE REPLACE LIMESTONE ROTARY FEEDER 01/19/09 COMPLETE

2 AFI MAINTENANCE REPAI R AND REPLACE LIMESTONE BELT 01/19/09 COMPLETE

3 MULTIFOS MAINTENANCE REMOVING AND INSTALLING SCRUBBERS DOWN LEGS 01/20/09 COMPLETE

41 MULTIFOS MAINTENANCE CAHNGE "A,B,&C"GRATE COOLER SIDE SUPPORT ARMS 01/20/09 COMPLETE

4 AFI MAINTENANCE CHANGE PREMIXER PADDLES 01/19/09 COMPLETE

24 MULTIFOS MAINTENANCE CHECK OUT AGITOR GEARBOX 01/20/09 COMPLETE

6 MULTIFOS MAINTENANCE REPLACE TAILSHAFT ON CONVEYOR BELTS 01/20/09 COMPLETE

8 AFI MAINTENANCE OPEN AND CLOSE PEMIXER HEADER 01/21/09 COMPLETE

9 AFI MAINTENANCE CHANGING PUGMILLS PADDLES 01/21/09 COMPLETE

10 AFI MAINTENANCE REPLACE EAST PUGMILL BEARING 01/21/09 COMPLETE

11 AFI MAINTENANCE REPLACE WEST PUGMILL BEARING 01/21/09 COMPLETE

12 AFI MAINTENANCE REPLACE PUGMILL GEAR BOX 01/21/09 COMPLETE

13 AFI MAINTENANCE REPLACE PUGMILL LOGS 01/21/09 COMPLETE

14 AFI MAINTENANCE REPLACE DYER DRIVE MOTORS 01/21/09 COMPLETE

15 MULTIFOS MAINTENANCEREPLACE # 1, # 2 & # 3 SCREEN VIBARATOR MOTOR 01/22/09 COMPLETE

16 MULTIFOS MANITENANCECHANGING STAIR STEPS 01/22/09 COMPLETE

17 MULTIFOS MAINTENANCEREPLACE SHEAR PINS ON "A, B OR C" COOLER CRUSHER 02/02/09 COMPLETE

18 MULTIFOS MAINTENANCESHEAR PINS ON UNSIZED DRAGFLIGHT 02/02/09 COMPLETE

19 MULTIFOS MAINTENANCE BUMPPING & JOGGING EQUIPMENT 02/03/09 COMPLETE

20 MULTIFOS MAINTENANCE PERSONAL LOCK ELECTRICAL LOCKOUT IN MOTOR CONTROL CENTER 02/03/09 COMPLETE

21 MULTIFOS MAINTENANCE TANK ENTRY 02/05/09 COMPLETE

22 MULTIFOS MAINTENANCE ADJUST # 2 PRIMARY AND SECONDARY CRUSHER 02/05/09 COMPLETE

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23 AFI MAINTENANCE REPLACING BELTS ON LUMP BREAKER 02/09/09 COMPLETE

24 AFI MAINTENANCE REPLACE PRIMARY SCREENS (DOWNDAY)_ 02/09/09 COMPLETE

25 AFI MAINTENANCE REPLACE PRIMARY SCREENS ON THE RUN 02/09/09 COMPLETE

26 AFI MAINTENANCE REPLACE PRIMARY SCREEN VIBRATOR MOTOR 02/10/09 COMPLETE

27 AFI MAINTENANCE REPLACE CHAIN MILL BELTS 02/10/09 COMPLETE

28 AFI MAINTENANCE REPLACE CHAIN MILL BEARINGS 03/02/09 COMPLETE

29 AFI MAINTENANCE REPLACE CHAIN MILL ROTOR. 03/02/09 COMPLETE

30 AFI MAINTENANCE REPLACE FLIGHTS IN DRAGFLIGHT CONVEYOR 03/02/09 COMPLETE

31 AFI MAINTENANCE REPAIR CHAIN IN DRAGFLIGHT CONVEYOR 03/02/09 COMPLETE

32 AFI MAINTENANCE REPLACE DEDUSTING SCREENS 03/02/09 COMPLETE

33 AFI MAINTENANCE REPLACE DEDUSTING SCREEN GEAR BOX 03/02/09 COMPLETE

34 AFI MAINTENANCE REPLACE ELEVATOR BUCKETS 03/02/00 COMPLETE

35 AFI MAINTENANCE REPLACE ELEVATOR COUNTER WEIGHT BEARING, & GLIDE RAIL 03/03/09 COMPLETE

36 AFI MAINTENANCE REPLACE ELEVATOR HEADSHAFT 03/03/09 COMPLETE

37 AFI MAINTENANCE REPLACE ELEVATOR CHAIN 03/03/09 COMPLETE

38/39 AFI MAINTENANCE REPLACE BEARING ON SCREW CONVEYOR 03/23/09 COMPLETE

40 AFI MAINTENANCE REPLACE OR REPAIR COUPLING "STUB" SHAFT ON SCREW CONVEYOR 03/25/09 COMPLETE

42 AFI MAINTENANCE REPAIR OR REPLACE SCREW CONVEYOR 03/25/09 COMPLETE

43 AFI MAINTENANCE REPLACE FLUID DRIVE COUPLING 03/26/09 COMPLETE

44 AFI MAINTENANCE ALIGN PUMP MOTORS AND GEAR BOXES 03/27/09 COMPLETE

45 AFI MAINTENACNE MAKE UP PRIMARY SCREENS 04/13/09 COMPLETE

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FINAL REVIEW

46 AFI MAINTENANCE REPLACE SKIRTS ON CONVEYOR BELTS 04/13/09 COMPLETE

47 AFI MAINTENANCE REPLACE IDLERS ON CONVEYOR BELTS 04/13/09 COMPLETE

48 AFI MAINTENANCE REPLACE DUST SEAL ON FULLER KENYON PUMP 04/13/09 COMPLETE

49 AFI MAINTENANCE REPAIR OR REPLACE ACID LINE 04/13/09 COMPLETE

50 AFI MAINTENANCE REPAIR OR REPLACE VALVES 04/15/09 COMPLETE

51 AFI MAINTENANCE REPAIR OR REPLACE PUMPS AND COUPLING 04/15/09 COMPLETE

52 AFI MAINTENANCE REPLACE EVAPORATOR CIRCULATING PUMP 04/15/09 COMPLETE

53 AFI MAINTENANCE REPLACE EVAPORATOR CIRCULATING PUMP SHAFT SLEEVE 04/15/09 COMPLETE

55 AFI MAINTENANCE OPEN AND CLOSE EVAPORATOR 04/15/09 COMPLETE

56 AFI MAINTENANCE PLUG EVAPORATOR TUBES 04/15/09 COMPLETE

57 AFI MAINTENANCE REPLACE BATCH TANK AGITATOR GEAR BOX (LIGHTNIN) 04/15/09 COMPLETE

58 AFI MAINTENANCE REMOVE BATCH TANK AGITATOR GEAR BOX (PHILADELPHIA) 04/15/09 COMPLETE

59 AFI MAINTENANCE REPAIR AND REPLACE ROOTS BLOWER 04/15/09 COMPLETE

60 AFI MAINTENANCE REPLACE STAIRS AND GRATING 04/15/09 COMPLETE

62 MULTIFOS MAINTENANCE REPLACE CONVEYOR BELTS 04/15/09 COMPLETE

64 MULTIFOS MAINTENANCE REPLACE ROTARY FEEDERS 04/15/09 COMPLETE

63 MULTIFOS MAINTENANCE PLOW DRIVE SHAFT AND BEARING REPLACEMENT 04/15/09 COMPLETE

65 MULTIFOS MAINTENANCE CHANGE CRUSHER ROLLS (NEW SYSTEM #2) PRIMARY & SECONDARY CRUSHER 04/15/09 COMPLETE

66 MULTIFOS MAINTENANCE REPLACE IDLERS ON CONVEYOR BELTS 04/15/09 COMPLETE

67 MULTIFOS MAINTENANCE CHANGING OUT AIR OPERATED VIBRATORS 04/15/09 COMPLETE

68 MULTIFOS MAINTENANCEPULL & REPLACE A,B,& C KILN SCRUBBERS,HEADERS & EQUIPMENT 04/15/09 COMPLETE

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69 MULTIFOS MAINTENANCE CHANGING SCREEN PANELS ON # 1 SCREEN SYSTEM 04/15/09 COMPLETE

70 MULTIFOS MAINTENANCE REPLACING BEARINGS ON SCRUBBER FANS 04/15/09 COMPLETE

71 MULITFOS MAINTENANCE CHANGE OUT ROLLERS IN DRAGFLIGHT 04/15/09 COMPLETE

72 MULTIFOS MAINTENANCE CHANGING OUT ELECTRIC MOTORS 04/15/09 COMPLETE

73 MULTIFOS MAINTENANCECHANGING OUT HOT POND WATER BOOSTER & ONCE THRU WATER PUMPS 04/15/09 COMPLETE

74 MULTIFOS MANTENANCE CHANGEOUT AND REPAIR ACID PUMPS 04/15/09 COMPLETE

75 MULTIFOS MAINTENANCE REPLACE SPINNER SEPARATOR GEAR BOX 04/20/09 COMPLETE

76 MULTIFOS MAINTENANCE PATCHING HOLES IN CHUTES 04/20/09 COMPLETE

77 MULTIFOS MAINTENANCE CHANGE ELEVATOR BUCKETS 04/20/09 COMPLETE

78 MULTIFOS MAINTENANCE REPLACE BEARINGS ON COUNTERWEIGHT, HEAD SHAFT, AND/OR TAIL SHAFT 04/17/09 COMPLETE

79 MULTIFOS MAINTENANCE REPLACE HANDING BEARING, CONNECTING SHAFTS AND/OR SCREW SECTION 04/17/09 COMPLETE

81 MULTIFOS MAINTENANCE CHANGE OUT FAN EXPANSION JOINTS 04/17/09 COMPLETE

82 MULTIFOS MAINTENANCE REPLACE VIBRA SCREW 05/11/09 COMPLETE

83 MULTIFOS MAINTENANCE CHANGE OUT HEADSHAFT ON ELEVATOR 05/01/09 COMPLETE

84 MULTIFOS MAINTENANCE REPLACE ELEVATOR CHAIN A&B UNSIZED PRODUCT, MIX FEEED, RECLAIM DRY 04/17/09 COMPLETEROCK AND EMERGENCY FEEED

85 MULTIFOS MAINTENANCE REPLACE HEADSHAFT ON CONVEYORS 05/11/09 COMPLETE

86 MULTIFOS MAINTENANCE CHANGE OUT OR REPAIR ACID LINES OR VAVES 04/17/09 COMPLETE

87 MULTIFOS MAINTENANCECHANGE CAGE MILL BELTS 05/11/09 COMPLETE

88 MULTIFOS MAINTENANCE REPLACING BEARING ON EQUIPMENT SCRUBBER FAN 04/22/09 COMPLETE

89 MULTIFOS MAINTENANCE ADJUSTMENT OF KILN TRUNNIONS 04/22/09 COMPLETE

90 MULTIFOS MAINTENANCEREMOVING KILN DUST COOLECTOR FAN DAMPER 04/22/09 COMPLETE

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91 MULTIFOS MAINTENANCE START UP COOLER FOR SPRING ADJUSTMENTS 04/27/09 COMPLETE

92 MULTIFOS MAINTENANCE "C" KILN--REPLACING AUX DRIVE UNITS (DIESEL, MTR, FLUID DRIVE & GEARBOX) 04/20/09 COMPLETE

93 MULTIFOS MAINTENANCE "A & B" KILN--REPLACING AUX DRIVE UNITS (FLUID DRIVE & GEARBOX) 04/20/09 COMPLETE

94 MULTIFOS MAINTENANCE CHANGE CAGE MILL SHAFT 05/11/09 COMPLETE

95 MULTIFOS MAINTENANCE CHANGE CAGE MILL CAGES 05/11/09 COMPLETE

101 AFI MAINTENANCE REPLACE OR REPAIR CONVEYOR BELT 05/05/09 COMPLETE

102 AFI MAINTENANCE REPAIR DIVERTER GATES 05/06/09 COMPLETE

103 AFI MAINTENANCE PATCH CHUTES 05/06/09 COMPLETE

Page 5 5/12/2009

MOSAIC AREA DATE WRITTEN: Feb-91

NEW WALES OPERATIONS AFI MAINTENANCE JSA REVIEWED: 1/19/2009

AFI -M- 001 Written By: V. COOK

TOPIC:Approved By: ASC

WORK STEP POTENTIAL HAZARDS

1 LOCKOUT ROTARY FEEDER, LIMESTONE BELTAND THE MANUAL VALVE BELOW THELIMESTONE BIN.

1 LOCKING OUT WRONG EQUIPMENT GETTINGCOVERED WITH LIMESTONE.

1

2 HANG CHAIN FALL AND COM-A- LONG 2 SLIPPING, FALLING, AND PINCHED FINGERS 2

3 REMOVE GUARD, DRIVE CHAIN, SPROCKET,AND BOLTS FROM FEEDER.

3 PINCHED FINGERS, FALLING, AND DROPPINGGUARD ON FEET.

3

4 REMOVE FEEDER USING CHAIN HOIST. 4 PINCH POINTS FEEDER SWINGING AND HITTINGSOMEONE

4

5 INSTALL NEW FEEDER USING CHAIN HOIST. 5 SAME AS STEP 4 ABOVE 5

6 INSTALL BOLTS, SPROCKET, BOLT AND CHAINGUARD

6 SAME AS STEP 3 ABOVE 6

7 REMOVE CHAIN FALL AND COM-A-LONG. 7 SAME AS STEP 2 ABOVE 7

8 REMOVE LOCKS, NOTIFY PRODUCTION,RETURN PERMIT TO CONTROL ROOM.

8 NONE 8

Please review this JSA. Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review: 1/19/2009DAVID BAKER 2-13-09 Committee Review -STEVE COLE 2-13-09 JACK BLEDSOE 2-13-09

MIKE RANGEL 2-13-09

SAME AS STEP 4 ABOVE

WEAR GLOVES AND BE AWARE OF PINCH POINTS, STAY CLEAROF FEEDER WHILE IT IS HANGING ON HOIST,

PLACE FEET IN SECURE POSITION. WEAR GLOVES AND BEAWARE OF PINCH POINTS.

WEAR GLOVES . BE AWARE OF PINCH POINTS. GET HELPREMOVING GUARD.

NONE



JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCH AND SIGN ''SAFE WORK'' PERMIT. MAKESURE MANUAL VALVE IS COMPLETELY CLOSED AND LOCKEDOUT.

REPLACE LIMESTONE ROTARY FEEDER

MOSAIC AREA DATE WRITTEN: May-92


AFI - M- 002 Written By: V. COOK / M, WING



1 LOCKOUT BELT AND ROTARY FEEDER . SIGN''SAFE WORK'' PERMIT.

1 LOCKING OUT WRONG EQUIPMENT. 1

2 LOOSEN TAKE UPS AND PULL CONNECTINGRODS, REMOVE OLD BELTS.

2 WRENCH SLIPPING. BACK STRAIN. 2

3 INSTALL LACING ON NEW BELT. INSTALL NEWBELT AND CONNECTING ROD TO BOTH ENDSOF BELT.

3 BACK STRAIN, DRILL MOTOR SLIPPING. 3

4 INSTALL BOLTS ON CORRUGATED SIDES OFBELT TIGHTEN TAKE UPS.

4 WRENCH SLIPPING. 4

5 CLEAN - UP WORK AREA, REMOVE LOCKS.INFORM PRODUCTION THAT JOB IS COMPLETE.RETURN TO CONTROL ROOM.

5 BACK STRAIN. 5

6 6 6

7 7 7

8 8 8

Please review this JSA,sign and date in the appropriate section below:Superintendant & Supervisor Review Safety Committee Review:

DAVID BAKER 2-18-09 JACK BLEDSOE 2-18-09

STEVE COLE 2-18-09 MIKE RANGEL 2-18-09

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCHES AND EQUIPMENT NUMBER ONSWITCHES.

REPAIR AND REPLACE LIMESTONE BELT

WEAR GLOVES. LIFT PROPERLY, KEEP BOTH HANDS AWAYFROM THE DRILL BIT.

LIFT PROPERLY.

WEAR GLOVES. USE PROPER TOOLS.

WEAR GLOVES. LIFT PROPERLY, KEEP BOTH HANDS AWAYFROM THE DRILL BIT.

MOSAIC AREA DATE WRITTEN: Jun-90

NEW WALES OPERATIONS MULTIFOS MAINTENANCE JSA REVIEWED: 1/20/2009

MM 008 Written By: REIBSOME / GAINEY

TOPIC:REMOVING AND INSTALLING SCRUBBER DOWN LEGS Approved By: ASC


1 CHECK WITH PRODUCTION SUPERVISOR. 1 NONE. 1

2 USING CABLE COM-A-LONG TO REMOVE DOWNLEGS FROM SUMP. RIG FROM FRAME WORKOVER WATCH DOWN LEG.

2 POSSIBLE BROKEN STRANDS IN CABLE.TRIPPING OR SLIPPING ON WET GRATING.

2

3 UNBOLTS FROM FLANGES. 3 WRENCH SLIPPING,BACK STRAIN, AND PINCHPOINTS.

3

4 COM-A-LONG EACH DOWN LEG OUT. MOVETHEM CLEAR OF SUMP.

4 BACK STRAIN AND PINCH POINTS. 4

5 REMOVE FIBERGLASS GRATING. 5 BACK STRAIN AND PINCH POINTS. OPENTRENCH.

5

6 REVERSE STEPS # 5-4-3-2. 6 REVERSE STEPS # 5-4-3-2. 6

7 7 7

8 8 8

Please review this JSA. Sign and date in the appropriate sectiion below:Superintendant & Supervisor Review: Safety Committee Review:

DAVE BAKER 2-13-09 JACK BLEDSOE 2-13-09CAARON FORTE 2-13-09 MIKE RANGEL 2-13-09

WEAR WORK GLOVES. POSITION BODY SO NO STRAIN WILL BEON BACK

WEAR WORK GLOVES. POSITION BODY SO NO STRAIN WILL BEON BACK . ROPE OFF AREA.

REVERSE STEPS #5-4-3-2.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

INSPECTS CABLES AND CLEAN AREA.

POSITION WRENCH FIRMLY ON NUTS. POSITION BODY SO NOSTRAIN WILL BE ON BACK.

MOSAIC AREA DATE WRITTEN: Sep-90

NEW WALES OPERATIONS Multifos / MAINTENACE JSA REVIEWED: 1/20/2009

MM 020 Written By: RAYFORD/REIBSOME

TOPIC: CHANGE ''A, B & C GRATE COOLERApproved By: ASC


1 CHECK WITH CHIEF OPERATOR 1 NONE. 1

2 LOCKOUT COOLER. 2 LOCKOUT WRONG EQUIPMENT. 2

3 JACK UP COOLER USING 100 TON JACK TOREMOVE SIDE SUPPORT ARMS.

3 JACK SLIPPING, BACK STRAIN, AND PINCHPOINTS.

3

4 REPLACE SIDE SUPPORT ARMS WITH NEW ORREBUILT ARMS.

4 BACK STRAIN, PINCH POINTS, AND WRENCHSLIPPING.

4

5 REMOVE JACK. REMOVE LOCK AND RETURN TOPRODUCTION.


6 6 6

Please review this JSA. Sign and date in the approppriate section below:Superintendent & Supervisor Review: Safety Committee Review:DAVE BAKER 2-13-09 JACK BLEDSOE 2-13-09CAARON FORTE 2-13-09 MIKE RANGEL 2-13-09

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38).

PLACE JACK IN FIRM POSITION, WORK IN PAIRS AND WEARPROPER P.P.E.

SIDE SUPPORT ARMS

WEAR PROPER P.P.E., WORK IN PAIRS AND PLACE WRENCHFIRMLY IN BOLTS OR NUTS.

WORK IN PAIRS AND WEAR PROPER P.P.E.



AFI - M- 003 Written By:

TOPIC:CHANGE PREMIXERS PADDLES Approved By: ASC


1 VERIFY LIMESTONE BELT, PUGMILL,PREMIXER, RECYCLE ELEVATOR, AND ACIDSLURRY VALVE OR REACTOR DISCHARGEPUMPS ARE LOCKED OUT. PLACE LOCK ONLOCKBOX.

1 LOCKING OUT WRONG EQUIPMENT AND VALVE. 1

2 REMOVE COVER FROM CONE AND SECUREPADDLES WITH COM-A-LONG.

2 BACK STRAIN, PINCHED OR CUT FINGERS. 2

3 REMOVE BOLT FROM THE BOTTOM PADDLE. 3 PADDLES FALLING. 3

4 REMOVE COM-A-LONG, KNOCK OLD PADDDLESOFF SHAFT WITH A LONG BAR FROM THE TOPOF THE CONE.

4 SCRAP HANDS, PINCH POINTS, AND BACKSTRAIN.

4

5 REMOVE OLD PADDDLES FROM PUGMILL. 5 BACK STRAIN, PINCH POINTS, AND SHARPEDGES ON PADDLES.

5

6 INSTALL NEW PADDLES ON SHAFT ONE AT ATIME.

6 PADDLES FALLING OFF SHAFT. BACK STRAINAND PINCH POINTS.

6

7 INSTALL BELT IN BOTTOM PADDLE. 7 SCRAPED HANDS AND PINCH POINTS. 7

8 REMOVE COM-A-LONG AND REPLACE CONECOVER.

8 BACK STRAIN HANDS AND PINCH POINTS. 8

9 CLEAN UP AREA. 9 BACK STRAIN AND PINCH POINTS. 9 USE PROPER LIFTING PROCEDURES AND PROPER P.P.E10 REMOVE LOCKS. RETURN PERMITS TO

CONTROL ROOM. 10 NONE. 10 NONE.

Please review this JSA Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:DAVE BAKER 2-23-09 JACK BLEDSOE 2-23-09STEVE COLE 2-23-09 MIKE RANGEL 2-23-09

GET HELP REPLACING COVER. WATCH POSITION OF HANDSAND WEAR PROPER P.P.E

WEAR PROPER P.P.E., USE PROPER LIFTING PROCEDURE. DONOT ENTER PUGMILL WHILE PADDLES ARE BEING KNOCKEDOFF SHAFT.

SECURE WITH COM-A-LONG

WATCH POSITION OF HANDS AND WEAR PROPER P.P.E.

LIFT PROPERLY AND WEAR PROPER P.P.E.

SUPPORT EACH PADDLE WITH CABLE COM-A-LONG ASINSTALLED. (PADDLES ARE NUMBERED, INSTALL IN CORRECTORDER.) USE PROPER LIFTING PROCEDURE AND WEARPROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCH AND SIGN ''SAFE WORK'' AND ''CONFINEDSPACE'' PERMITS. REFER TO EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURES SECTION (38).

GET HELP WITH COVERS. USE PROPER LIFTING PRODCEDURE,WEAR PROPER P.P.E.

MOSAIC AREA DATE WRITTEN: Jan-91


MM 024 Written By: CARTER/DEAN


WORK STEP POTENTIAL HAZARDS1 CHECK WITH CHIEF OPERATOR. THEN LOCKOUT

AGITATOR.1 LOCKOUT WRONG EQUIPMENT. 1

2 UNBOLT GEAR BOX AND LIFT TO INSTALL CLAMP. 2 PINCH POINTS, WRENCH SLIPPING AND BACKSTRAIN.

2

3 LOWER GEAR BOX TILL CLAMP RESTS ON FLOOR.REMOVE COUPLING BOLTS.

3 PINCH POINTS,WRENCH SLPPING AND BACKSTRAIN.

3

4 SET GEAR BOX ON GROUND. 4 SOMEONE UNDER SUSPENDED LOAD . OPENHOLE ON TOP OF TANK.

4

5 REPLACE AGITATOR GEAR BOX BY REVERSINGSTEPS # 4-3-2 AND 1.

5 SAME AS STEPS # 4-3-2 AND 1. 5

6 6 6

7 7 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:DAVE BAKER 2-16-09 JACK BLEDSOE 2-16-09CAARON FORTE 2-16-09 MIKE RANGEL 2-16-09

KEEP AREA CLEAR. BARRICADE AREA OF TOP OF TANK.

SAME AS STEPS # 4-3-2 AND 1.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONSREFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURES SECTION (38).

WEAR PROPER P.P.E. SECURE WRENCH PULL EVENLY AND USELIFTING EQUIPMENT.

WEAR PROPER P.P.E.SECURE WRENCH, PULL EVENLY AND USELIFTING EQUIPMENT.

CHECK OUT AGITATOR GEARBOX



MM 037 Written By: CARTER/GAINEY



1 CHECK WITH CHIEF OPERATOR. LOCKOUTCONVEYOR.


2 LIFT COUNTERWEIGHT OR LOOSEN BELTADJUSTMENTS.


3 CLAMP OF BELT AND REMOVE TAILSHAFTGUARD.

3 PINCH POINTS AND BACK STRAIN. 3

4 REMOVE BEARING BASE BOLTS AND DRIFTTAILSHAFT OUT.

4 PINCH POINTS, BACK STRAIN AND CABLESLIPPING OFF SHAFT.

4

5 DRIFT TAILSHAFT AND BEARING IN. 5 SAME AS NO. 4 ABOVE. 5

6 REMOVE CLAMPS . LOWER COUNTERWEIGHTAND ADJUST BELT.


7 CLEAN AREA. TURN OVER TO PRODUCTION. 7 PINCH POINTS AND BACK STRAIN. 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendent & Supervisor Review: Safety Committee Review:DAVE BAKER 2-16-09 JACK BLEDSOE 2-16-09CAARON FORTE 2-16-09 MIKE RANGEL 2-16-09

JOB SAFETY ANALYSIS

REPLACE TAILSHAFT ON CONVEYOR BELTS

CORRECTIVE ACTIONS

WEAR PROPER P.P.E., AND WORK IN PAIRS. USE TWO CABLECOM-A-LONG TO DRIFT TAILSHAFT. CONNECT THE TWOLIFTING CABLES TOGETHER PARALLEL TO TAILSHAFT TO KEEPCABLES FROM SLIPPING OFF SHAFT.

REFER TO EMPLOYEE SAFETY MANUAL. LOCKOUTPROCEDURES. SECTION (38).

WORK IN PAIRS, WEAR PROPER P.P.E, AND USE TWO COM-A-LONG TO LIFT COUNTERWEIGHT.

WORK IN PAIRS AND USE PROPER P.P.E.

WEAR PROPER P.P.E., AND WORK IN PAIRS.

SAME AS NO, 4 ABOVE.

WEAR PROPER P.P.E., AND WORK IN PAIRS.



AFI-M- 004 Written By: J.WOLF



1 LOCKOUT ACID SLURRY BLOCK VALVES TO THEPREMIXER (CONE) HEADER.

1 LOCKING OUT WRONG VALVE AND SLURRYSTILL GOING THROUGH THE HEADER.

1

2 SIGN "SAFE WORK" PERMIT. 2 NONE. 2

3 REMOVE BOLTS FROM BLIND FLANGES WITH1/2" IMPACT

3 THERE MAY STILL BE SOME ACID LAYING IN THELINE. NOISE FROM IMPACT. WRENCH SLIPPING.

3

4 AFTER LINES ARE CLEARED. REPLACE BLINDSAND INSTALL ALL THE BOLTS.

4 PINCH POINTS. 4

5 TIGHTEN ALL BOLTS WITH 1/2" IMPACT 5 NOISE FROM IMPACT. WRENCH SLIPPING. 5

6 REMOVE LOCKS. RETURN PERMITS TOCONTROL ROOM.

6 NONE. 6

7 7 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review Safety Committee Review:

DAVE BAKER 2-23-09 JACK BLEDSOE 2-23-09


WEAR PROPER P.P.E.

WEAR PROPER P.P.E.

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

WEAR SAFETY EQUIPMENT AS SPECIFIED ON "SAFE WORK"PERMIT. WEAR PROPER P.P.E.

OPEN AND CLOSE PREMIXER HEADER

CHECK MAKE SURE CORRECT VALVE IS LOCKED OUT. REFERTO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38).

JOB SAFETY ANALYSISMOSAIC AREA DATE WRITTEN: Sep-90


AFI -M- 005 Written By: WOLF / WINGTOPIC:

Approved By: ASC

WORK STEP POTENTIAL HAZARDS1 VERIFY PUGMILL, PREMIXER, RECYCLE

ELEVATOR, LIMESTONE BELT, AND VALVE ONBOTH SLURRY HEADERS ARE LOCKED OUT.PLACE LOCK ON LOCKBOX.

1 WRONG EQUIPMENT AND VALVES LOCKED OUT. 1

2 CHECK AREA AROUND PUGMILL. 2 SLIPPNG OR TRIPPING. 2

3 SIGN "CONFINED SPACE" PERMIT. 3 NONE. 3

4 CLEAN BOLTS AND PADDLES WITH AIRCHIPPER.

4 PRODUCT FLYING INTO EYES, AIR HOSE COMINGAPART, BIT BREAKING, AND HIGH NOISE LEVEL.

4

5 CUT BOLTS THAT HOLD PADDLES ON. 5 BURNS, FLASH FROM WELDING ARC. 5

6 REMOVE OLD PADDLES FROM MILL. 6 PINCH FINGERS. BURN FROM HOT METAL ANDBACK STRAIN.

6

7 INSTALL NEW PADDLES. 7 BACK STRAIN. 7 USE PROPER LIFTING PROCEDURE.

8 TIGHTEN BOLTS WITH 1" IMPACT. 8 BACK STRAIN, NOISE AND PINCH POINTS. 8

9 CLEAN UP AREA. 9 BACK STRAIN AND PINCH POINTS. 9 USE PROPER LIFITNG PROCEDURES AND PROPER P.P.E.

10 REMOVES LOCKS AND RETURN PERMIT TOCONTROL ROOM.

10 NONE. 10 NONE.

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:DAVE BAKER 2-23-09 JACK BLEDSOE 2-23-09STEVE COLE 2-23-09 MIKE RANGEL 2-23-09

CORRECTIVE ACTIONS

WEAR PROPER P.P.E.

CHECK FIELD SWITCH. HAVE CHIEF OERATOR CHECKFROM CONTROL ROOM. "SIGN SAFE WORK PERMIT". REFERTO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38).

WEAR PROPER P.P.E.

CHANGING PUGMILL PADDLES

WEAR PROPRER P.P.E, AND USE PROPER LIFTINGPROCEDURE.

AREA AROUND MILL SHOULD BE CLEANED.

NONE.

PUT PIN IN AIR HOSE COUPLING AND WEAR PROPER P.P.E.



AFI-M- 006 Written By: WOLF / McCULLERS



1 LOCKOUT PUGMILL. 1 WRONG EQUIPMENT LOCKOUT . 1

2 CHECK AREA AROUND PUGMILL. 2 SLIPPING HAZZARDS. 2

3 REMOVE GUARD AND PACKING. 3 BACK STRAIN. 3

4 REMOVE BEARING CAP AND JACK UP SHAFT. 4 BACK STRAIN AND PINCH FINGERS. 4

5 REMOVE OLD BEARING , SLIDE HOUSING OUTWITH OLD BEARING.

5 MASHED FOOT, PINCHED FINGERS, AND BACKSTRAIN.

5

6 CLEAN AND INSPECT SHAFT AND HOUSING.PLACE NEW BEARING IN HOUSING. SLIDE ITINTO POSITION AND TIGHTEN.

6 MASHED FOOT, PINCHED FINGERS, AND BACKSTRAIN.

6

7 REMOVE GUARD. 7 SAME AS # 3. 7

8 REMOVE LOCKS AND CLEAN UP AREA. 8 NONE. 8


VERIFY RIGHT EQUIPMENT IS LOCKED OUT. CHECK FIELDSWITCH AND HAVE CHIEF OPERATOR TRY TO START FROMCONTROL ROOM. "SIGN SAFE WORK PERMIT." REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38).

SAME AS # 3.

LIFT PROPERLY (WITH KNEES) AND STAY ALERT WHEREHANDS AND FEET ARE POSITIONED. WEAR PROPER P.P.E.

GET HELP LIFTING OFF BEARING CAP. WEAR PROPER P.P.E.

LIFT PROPERLY (WITH KNEES) AND STAY ALERT TO WHEREHANDS AND FEET ARE POSITION. WEAR PROPER P.P.E.

LOOSE PRODUCT AND MUD SHOULD BE CLEANED.

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

GET HELP TO REMOVE GUARD.

REPLACE EAST PUGMILL BEARINGS

MOSAIC AREA DATE WRITTEN: Nov-91


AFI -M- 007 Written By: WING



1 LOCKOUT PUGMILL AND SIGN "SIGN WORKPERMIT."

1 PUGMILL STARTING UP. 1

2 REMOVE GUARD AND BREAK COUPLING. 2 WRENCH SLIPPING OR PINCH FINGERS. 2

3 INSTALL RIGGING TO RAISE SHAFT. 3 RIGGING SLIPPING OR FALLING. 3

4 REMOVE TWO BOLTS HOLDING BEARING CAPAND RAISE SHAFT.

4 WRENCH SLIPPNG AND RIGGIING FAILURE. 4

5 REMOVE BOLTS FROM BEARING HALVES ANDROLL BEARING OUT.


6 ROLL IN NEW BEARING ASSEMBLLY AND BOLTHALVES TOGETHER.


7 LOWER SHAFT AND INSTALL BEARING COVER. 7 RIGGING FAILURE AND WRENCH SLIPPING. 7

8 CHECK TIMING ON LOGS AND RECOUPLE ANDREINSTALL GUARD.

8 GRID SPRINGING LOOSE AND WRENCHSLIPPING.

8

9 REMOVE LOCKS AND CLEAN UP AREA. 9 NONE. 9 NONE.

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Shift Supervisor Review: Safety Committee Review:DAVE BAKER 3-23-09 JACK BLEDSOE 3-24-09STEVE COLE 3-26-09 MIKE RANGEL 3-25-09

WEAR PROPER P.P.E, AND USE PROPER TOOLS.

CHECK RIGGING, WEAR PROPER P.P.E, AND USE PROPER

WEAR PROPER P.P.E, CHECK RIGGING AND USE PROPERTOOL.

WEAR PROPER P.P.E, AND USE PROPER TOOL.

WEAR PROPER P.P.E, AND USE PROPER TOOL.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCHES AND CONTROL ROOM. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURES SECTION(38).

USE PROPER TOOL AND WEAR PROPER P.P.E.

CHECK OUT RIGGING BEFORE USING.

REPLACE WEST PUGMILL BEARING

MOSAIC AREA DATE WRITTEN: Oct-90


AFI-M- 008 Written By: WING / DONALDSON

TOPIC:

Approved By: ASC


1 LOCKOUT PUGMILL. 1 LOCKOUT WRONG EQUIPMENT. 1

2 REMOVE BOTH GUARDS. 2 BACK STRAIN AND PINCH POINTS. 2

3 REMOVE FLUID DRIVE COUPLING. 3 PINCH POINTS AND BACK STRAIN. 3

4 BREAK FALK COUPLING. 4 GREASE CAUSING SLIPPING. BACK STRAIN. GRIDPROPPING LOOSE AND HITTING HAND ORSOMEONE.

4

5 REMOVE BASE BOLTS AND RIG GEAR BOX. 5 WRENCH SLIPPING, BACK STRAIN AND BADRIGGING EQUIPMENT.

5

6 REMOVE OLD GEAR BOX. INSTALL NEW GEARBOX AND BOLTS.

6 BACK STRAIN AND SLIPPING. 6

7 INSTALL FALK COUPLING. 7 GREASE CAUSING SLIPPAGE. 7

8 INSTALL FLUID DRIVE COUPLING. 8 PINCH POINTS AND BACK STRAIN. 8 WEAR GLOVES AND LIFT PROPERLY.

9 INSTALL GUARD. 9 BACK STRAIN AND PINCH POINTS. 9 LIFT PROPERLY AND WEAR PROPER P.P.E..

10 REMOVE LOCKS. 10 NONE. 10 NONE.


WEAR PROPER P.P.E.. CHECK CHOKER AND LIFTINGEQUIPMENT.

CLEAN UP GREASE AND COVER GRID WITH HAND.

REPLACE PUGMILL GEAR BOX


WATCH FOOTING AND POSITION BODY PROPERLY.

BE AWARE OF POSSIBLE GREASE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCH HAVE CHIEF OPERATOR CHECK IN THECONTROL ROOM. "SIGN WORK PERMIT." REFER TO EMPLOYEESAFETY MANUAL LOCKOUT PROCEDURES SECTION (38).

WEAR PROPER P.P.E. AND LIFT PROPERLY.

MOSAIC AREA DATE WRITTEN: Apr-91


AFI-M- 009 Written By: COOK / WING



1 CHECK THAT THE PUGMILL, PREMIXER,RECYCLE ELEVATOR, LIMESTONE BELT ANDVALVES ON BOTH SLURRY HEADERS ARELOCKED OUT. PLACE KEY ON LOCK BOX. "SIGNSAFE WORK PERMIT"

1 WRONG EQUIPMENT AND VALVES LOCKED OUT. 1

2 INSTALL RIGGING. REMOVE HOOD AND GUARDON BEARINGS.

2 HOOD FALLING, RIGGING FALLING AND BACKSTRAIN. NOISE FROM IMPACT.

2

3 BREAK COUPLINGS AND REMOVE CAPS ONCOOPER SPLIT BEARINGS.

3 BACK STRAIN AND SLIPPING. PINCH POINTS. 3

4 REMOVE EAST BEARINGS AND PACKINGGLANDS. (SEE JSA # 6 OR #7 ON PUGMILLBEARINGS).

4 BACK STRAIN AND SLIPPING. PINCH POINTS. 4

5 INSTALL RIGGING ON LOGS. REMOVE FROMPUGMILL AND BRING TO GROUND.

5 RIGGING FAILURE, PINCH POINTS, BACK STRAINAND SLIPPING.

5

6 TRANSFER COUPLING AND COOPER SPILTBEARING.

6 BACK STRAIN, GETTING BURNED WITH TORCHOR HOT COUPLING

6

7 RIG NEW LOGS AND REINSTALL IN MILL. 7 BACK STRAIN, PINCH POINTS, AND LOGSFALLING.

7

8 REPLACE EAST BEARINGS AND GUARD. (REFERTO JSA #6 OR # 7 ON PUGMILL BEARINGS.)

8 BACK STRAIN, SLIPPING AND PINCH POINTS. 8

9 REPLACE CAP ON COOPER SPLIT ANDCOUPLING. MAKE SURE LOGS ARE TIMED.

9 BACK STRAIN, PINCH POINTS, AND SLIPPING. 9 LIFT PROPERLY, WEAR PROPERP.P.E, AND WATCH FOOTING.

10 INSTALL PADDLES. 10 NOISE, BACK STRAIN, AND PINCH POINTS. 10 WEAR PROPER P.P.E. AND LIFT PROPERLY.11 REINSTALL HOOD 11 HOOD FALLING AND NOISE. 11 CHECK RIGGING AND WEAR PROPER P.P.E.12 REMOVE LOCKS AND CLEAN UP. 12 NONE. 12 NONE.


LIFT PROPERLY, WEAR GLOVES AND WATCH FOOTTING.


WATCH HANDS, WEAR PROPER P.P.E. AND CHECK ALL RIGGING.

LIFT PROPERLY, WATCH FOOTING AND WEAR PROPER P.P.E.

INSPECT ALL RIGGING ,WATCH FOOTING AND WEAR PROPERP.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK THE CONTROL ROOM & FIELD SWITCHES. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38).

REPLACE PUGMILL LOGS

INSPECT ALL RIGGING. LIFT PROPERLY WITH LEGS AND WEARPROPER P.P.E.

LIFT PROPERLY AND WEAR GLOVES. WIPE UP OIL AND GREASESPILLS.



AFI-M- 010 Written By: NcCULLERS



1 CHECK WITH CHIEF OPERATOR AND LOCKOUTBOTH DRIVE MOTORS. GET SAFE WORKPERMIT.

1 DRYER BEING STARTED. 1

2 SPOT 8 TON CRANE UNDER THE DRYER. 2 HITTING PIPES AND / OR EQUIPMENT. 2

3 HAVE ELECTRICAN DISCONNECT MOTOR. 3 ELECTRICAL SHOCK. 3

4 REMOVE COUPLING GUARD WITH CRANE ANDDISCONNECT COUPLING AND BASE BOLTS.

4 PINCH POINTS. 4

5 HOOK TO MOTOR WITH SHACKLES ANDCHOKERS. LOWER TO THE GROUND.

5 RIGGING BAD AND PINCH POINTS. 5

6 PLACE NEW MOTOR ON BASE. ALIGN ANDTIGHTEN BASE BOLTS.

6 RIGGING BAD AND PINCH POINTS. 6

7 HAVE ELECTRICIAN CONNECT MOTOR. 7 ELECTRICAL SHOCK. 7

8 REMOVE LOCKS FOR ELECTRICIAN TO CHECKMOTOR ROTATION.

8 SOMEONE WORKING ON UNIT WHEN IT ISSTARTED.

8

9 REPLACE LOCKS AFTER ROTATION IS CHECK. 9 EQUIPMENT STARTING. 9 FOLLOW EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURES SECTION(38).

10 BOLT UP COUPLING AND REPLACE GUARD.REMOVE LOCKS.

10 PINCH POINTS. 10 WEAR PROPER P.P.E. AND WATCH POSITION OF HANDS ON GUAR


DAVE BAKER 3-23-09 JACK BLEDSOE 3-24-09STEVE COLE 3-26-09 MIKE RANGEL 3-25-09

CHECK ALL RIGGING AND WEAR PROPER P.P.E.

WEAR PROPER P.P.E., AND WATCH POSITION OF HANDS.

CHECK ALL RIGGING AND WEAR GLOVES.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK EQUIPMENT NAME AND NUMBER. CHECK STARTERSWITCHES IN CONTROL ROOM AND THE FIELD. SIGN WORKPERMIT. REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURES SECTION (38).

HAVE A FLAGMAN AND BE CAREFUL.

FOLLOW EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38).

REPLACE DRYER DRIVE MOTORS

FOLLOW EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38).

MAKE SURE EVERYONE KNOWS MOTOR ROTATION WILL BECHECKED.

ARD.

MOSAIC AREA DATE WRITTEN: Nov-90


MM 011 Written By: REIBSOME / GAINEY



1 LOCKOUT SCREEN VIBRATORS ON BANK TO BEWORK ON. GET A PERMIT.

1 LOCKING OUT WRONG SCREEN VIBATORS. 1

2 TRANSPORT MOTOR TO SCREENS. 2 FALLING, TRIPPING AND BACK STRAIN. 2

3 REMOVE SAFTEY CABLE. 3 WRENCH SLIPPING SCRAPPING HANDS. 3

4 REMOVE MOTOR BOLTS. 4 FALLING OFF SCREENS AND DROPPING MOTORON FEET.

4

5 REMOVE MOTOR. 5 BACK STRAIN AND FALLING. 5

6 INSTALL NEW MOTOR AND REINSTALL SAFETYCABLE.

6 BACK STRAIN AND FALLING. 6

7 RMOVE LOCKS AND TURN IN PERMIT. 7 NONE. 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendent & Supervisor Review: Safety Committee Review:DAVE BAKER 3-26-09 JACK BLEDSOE 3-26-09CAARON FORTE 3-26-09 MIKE RANGEL 3-27-09

REPLACE # 1, # 2 & # 3 SCREEN VIBARATOR MOTOR

NONE.

WORK IN PAIRS AND WEAR P.P.E.

KEEP BALANCE ON SCREEN AND BRACE FOOT AND KNEEAGAINST MOTOR.

HOLD ON AND KEEP BALANCE. PASS MOTOR TO PARTNER.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

REFER TO SAFETY MANUAL. LOCKOUT PROCEDURES SECTION(38).

WALKWAYS AND STEPS SHOULD BE CLEARED. WORK IN PAIRS.

WEAR PROPER P.P.E.

MOSAIC AREA DATE WRITTEN: Jan-95

NEW WALES OPERATIONS Multifos MAINTENANCE JSA REVIEWED: 1/22/2009

MM-048 Written By: GAINEY



1 CHECK WITH OPERATIONS AND GET HOTWORK PERMIT.

1 NONE. 1

2 REMOVE BOLTS AND REMOVE STEP. (MAY BENECESSARY TO BURN BOLTS TO REMOVESTEP).

2 WRENCH SLIPPING. POSSIBLE BURN BY SLAG. 2

3 INSTALL NEW STEP AND BOLTS. 3 WRENCH SLIPPING. 3

4 CLEAN UP AREA, SIGN AND RETURN PERMIT TOOPERATIONS.

4 NONE. 4

5 5 5


NONE.

JOB SAFETY ANALYSIS

CHANGING STAIR STEPS

CORRECTIVE ACTIONS

WEAR PROPER P.P.E.

PLACE WRENCH SECURELY ON BOLTS AND NUTS. WEARSLEEVES AND WEILDING GLOVES TO BURN . WEAR A DARKFACE SHIELD.

NONE.


NEW WALES OPERATIONS MULTLIFOS MAINTENANCE/JSA REVIEWED: 2/2/2009

MM - 007 Written By: RAYFORD/ GAINEY



1 CLEAR WITH PRODUCTION CHIEF OPERATORAND LOCKOUT COOLER CRUSHER. FILL OUTPERMIT.


2 TRY START AND STOP BUTTONS. REMOVEGUARD.

2 PINCH POINTS, BACK STRAIN, AND WRENCHSLIPPING.

2

3 USE TORCH TO BURN SHEAR PINS AND USEDBULL PINS TO REMOVE SHEAR PINS.

3 FLAMMABLE MATERIAL AND PINCH POINTS. 3

4 ALIGN SHEAR ASSEMBLY TO MATCH SHEARPIN HOLES AND REPLACES SHEAR PINS.

4 PINCH POINTS, AND WRENCH SLIPPING. 4

5 REPLACE GUARD. 5 POSSIBLE BACK STRAIN AND PINCH POINTS. 5

6 CLEAN UP AREA, REMOVE LOCKS AND SIGNPERMIT RETURN IT TO PRODUCTION.

6 NONE. 6

7 7 7

8 8 8

Please review this JSA Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:DAVE BAKER 3-26-09 JACK BLEDSOE 3-26-09CAARON FORTE 3-26-09 MIKE RANGEL 3-27-09

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURES SECTION (38).

USE TWO PEOPLE FOR LIFTING GUARD, WEAR PROPER P.P.E.,AND SECURE WRENCH ON NUT AND PULL EVENLY.

REPLACE SHEAR PINS "A , B OR C"COOLER CRUSHER

NONE.

WEAR PROPER P.P.E.

WEAR PROPER P.P.E., SECURE WRENCH ON NUT AND PULLEVENLY.

USE TWO PEOPLE FOR LIFTING GUARD, WEAR PROPER P.P.E.,SECURE WRENCH ON NUT AND PULL EVENLY.

JOB SAFETY ANALYSIS


NEW WALES OPERATIONS MULTIFOS MAINTENACNE JSA REVIEWED: 2/2/2009

MM - 005 Written By: RAYFORD/ GAINEY



1 CLEAR WITH PRODUCTION CHIEF OPERATOR,LOCKOUT DRAGFLIGHT AND FILL OUT PERMIT.


2 TRY START AND STOP BUTTONS, REMOVEGUARD.

2 PINCH POINTS, BACK STRAIN, AND WRENCHSLIPPING.

2

3 USE TORCH TO BURN SHEAR PINS AND TOMOVE SHEAR PINS.

3 FLAMMABLE MATERIAL AND PINCH POINTS. 3

4 ALIGN SHEAR ASSEMBLY TO MATCH SHEAR PINHOLES AND REPLACE SHEAR PINS.

4 PINCH POINTS AND WRENCH SLIPPING. 4

5 REPLACE GUARD. 5 POSSIBLE BACK STRAIN AND PICH POINTS. 5

6 CLEAN UP AREA, REMOVE LOCKS AND SIGNPERMITS RETURN IT TO PRODUCTION.

6 NONE. 6

7 7 7

8 8 8

Please review this JSA Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:


CAARON FORTE 3-26-09 MIKE RANGEL 3-26-09

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL. LOCKOUTPROCEDURES SECTION (38).

USE TWO PEOPLE TO LIFT GUARD. WEAR GLOVES SECUREWRENCH ON NUT AND PULL EVENLY.

WEAR PROPER P.P.E.

SHEAR PINS ON UNSIZED DRAGFLIGHT

WEAR GLOVES, SECURE WRENCH ON NUT AND PULL EVENLY.

USE TWO PEOPLE TO LIFT GUARD, WEAR GLOVES AND SECUREWRENCH ON NUT AND PULL EVENLY.

NONE.

MOSAIC AREA DATE WRITTEN: Mar-07


MM - 002 Written By: STEWARD/ COLGATE



1 NOTIFY CHIEF OPERATOR TO AS WHATEQUIPMENT IS TO BE WORKED ON AND HAVECHIEF TO STOP EQUIPMENT.

1 NONE. 1

2 HAVE PRODUCTION PERSONNEL PHYSICALLYIDENTIFY EQUIPMENT BREAKER. DESIGNATEDEMPLOYEE PLACE PRODUCTION LOCK ONBREAKER.

2 WRONG EQUIPMENT BEING LOCKED OUT ANDPOSSIBLE START UP.

2

3 HAVE MECHANICS PUT THEIR LOCKS ONEQUIPMENT AFTER PRODUCTION.

3 EMPLOYEE DOES NOT HAVE EQUIPMENT LOCKOUT.

3

4 REVERSE STEP # 3 FOR BUMPING ANDJOGGING.

4 GETTING CAUGHT IN ENERGIZED EQUIPMENT. 4

5 5 5

6 6 6

7 7 7

8 8 8

Please review this JSA Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:DAVE BAKER 2-18-09 JACK BLEDSOE 2-18-09CAARON FORTE 2-18-09 MIKE RANGEL 2-18-09

CLEAR WORK AREA OF TOOLS & STAND CLEAR OF EQUIPMENT.KEEP IN CONTACT WITH DESIGNATED EMPLOYEES.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

HAVE CHIEF TRY PANEL BOARD SWITCH .

HAVE EMPLOYEES PUT LOCK ON CORRECT BREAKER AND TRYFIELD SWITCH.

BUMPING AND JOGGING EQUIPMENT

MOSAIC AREA DATE WRITTEN: Aug-90


MM - 001 Written By: L. ANDREWS

TOPIC: PERSONAL LOCK, ELECTRICALApproved By: ASC


1 PLACE LOCK ON BREAKER. 1 WRONG EQUIPMENT LOCK OUT. 1

2 GO TO EQUIPMENT AND COMPLETEELECTRICAL LOCKOUT PERMIT.

2 TRIPPING GOING TO AND FROM MOTORCONTROL CENTER AND EQUIPMENT FIELDSWITCH. ELECTRICAL DISCONNECT FAILURE.WRONG EQUIPMENT LOCKED OUT.

2

3 3 3


LOCKOUT IN MOTOR CONTROL CENTER

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

KEEP WALKWAYS CLEAR AND USE HAND RAILS WHILE USINGSTAIRS. TRY FIELD SWITCH AND HAVE CHIEF OR SUPERVISORTRY START SWITCH ON PANEL BOARD.

VERIFY WITH CHIEF OR SUPERVISOR AS TO NAME ANDEQUIPMENT NUMBER TO BE LOCKED OUT.



MM - 003 Written By: STEWARD / COLGATE



1 OBTAIN TANK ENTRY PERMIT FROMPRODUCTION SUPERVISOR OR CHIEFOPERATOR AND HANG PERMIT AT TANKENTRY.

1 PERMIT ISSUED FOR WRONG TANK. 1

2 MAINTENANCE PERSONNEL HANG THEIR LOCKON ELECTRICAL EQUIPMENT AND NECESSARYVALVES.

2 COULD LOCK OUT WRONG MOTOR ANDVALVES.

2

3 TRY START AND STOP BUTTON. 3 WRONG EQUIPMENT LOCKED OUT. 3

4 ENTER TANK AREA TO PERFORM JOB ANDOPEN TANK FOR WORK REQUIRED.

4 RESIDUE BUILD UP AND LEFT OVER ACID. 4

5 CLEAN UP AREA. REMOVE LOCKS AND INFORMPRODUCTION THAT YOU ARE THROUGH. SIGNPERMIT AND RETURN IT TO CONTROL ROOM.

5 NONE. 5

6 6 6

7 7 7

8 8 8


STAY OUT OF THE LINE OF FIRE AND KEEP EYES ON TASK.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

FIELD VERIFY ELECTRICAL AND IN THE CONTROL ROOM. ACIDVALVES MAKES SURE THEY ARE DOUBLE BLOCK, BLEED ANDLOCK.

TANK ENTRY

HAVE OPERATOR VERIFY THAT IS THIS THE TANK TO BEWORKED ON. VERIFY THAT THE ATMOSPHERE IS SAFE TOENTER. REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURES SECTION (38).

NONE.

NONE.



MM- 004 Written By: STEWARD / COLGATE



1 GO TO CONTROL ROOM TO INFORM CHIEF OFJOB TASK AT HAND.

1 COULD WORK ON WRONG EQUIPMENT. 1

2 OBTAIN PERMIT FROM DESIGNATED EMPLOYEEAND START WORK.

2 NONE. 2

3 LOOSEN LOCK NUT ON TURN - BUCKLE. MAKEADJUSTMENT UNTIL CONTACT WITH ROLLERSIS MADE.

3 WRENCH SLIPPING AND PINCH POINTS. 3

4 LOCK JAM NUT BACK DOWN. 4 WRENCH SLIPPING AND PINCH POINTS. 4

5 SIGN AND RETURN PERMIT TO THE CONTROLROOM.

5 NONE. 5

6 6 6

7 7 7

8 8 8




KEEP EYES AND HANDS ON TASK AND USE CORRECT BODYPOSITION.

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

GO WITH DESIGNATED EMPLOYEE TO WORK AREA TO VERIFYRIGHT EQUIPMENT TO BE WORK ON.

KEEP EYES AND HANDS ON TASK AND USE CORRECT BODYPOSITION.

NONE.

ADJUST # 2 PRIMARY OR SECONDARY CRUSHER

MOSAIC AREA DATE WRITTEN: Jul-91


AFI - M - 011 Written By: WING



1 LOCKOUT LUMP BREAKER AND DYER. GET ASAFE WORK PERMIT.

1 LOCKINIG OUT WRONG EQUIPMENT. LUMPSFALLING CAUSING LUMP BREAKER TO SPIN.

1

2 OPEN GUARD AND REMOVE OLD BELTS. 2 MASHED HANDS, BACK STRAIN, AND SECTIONOF GUARD FALLING.

2

3 INSTALL NEW BELTS. 3 MASHED HANDS AND SLIPPING. 3

4 REMOVE LOCKS. 4 NONE. 4

5 5 5

6 6 6

7 7 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:



NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


REPLACING BELTS ON LUMP BREAKER

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38). WEAR PROPER P.P.E. CHECK CONTROL ROOMAND TRY FIELD SWITCHES.

WEAR PROPER P.P.E. AND WATCH FOOTING.



AFI - M - 012 Written By: McCULLERS / WOLFE



1 PLACE LOCKS ON SCREEN, VIBRATORS,DIVERTER AND SCREEN FEED ELEVATOR."SIGN SAFE WORK PERMIT."

1 WRONG SCREEN LOCKED OUT. 1

2 REMOVE SIDE COVERS AND TIE UP TOPCOVERS.

2 FALLING DOWN STAIRS AND PINCH FINGERS. 2

3 REMOVE BOLTS FROM SIDE RAILS ANDVIBRATOR FOOT.

3 NOISE FROM IMPACT WRENCH. FALLING(SLIPPING).

3

4 REMOVE BAD SCREEN. 4 PINCHED FINGERS, CUTS, AND STRAIN BACK.SCREEN COULD SPRING OPEN CAUSINGPERSON TO LOSE BALANCE.

4

5 INSTALL NEW SCREEN. 5 FALLING, PINCHED FINGERS, CUTS ANDSTRAINED BACK.

5

6 REPLACE SIDE RAILS AND VIBRATOR FOOTBOLTS.

6 NOISE FROM IMPACT WRENCH AND FALLINGDOWN.

6

7 REPLACE SIDE AND TOP COVERS. 7 FALLING AND PINCHED FINGERS. 7

8 REMOVE LOCKS, SIGN AND RETURN PERMIT. 8 NONE. 8


NONE.

WEAR PROPER P.P.E. AND BE AWARE OF FOOTING.

BE AWARE OF FOOTING AND PINCH POINTS. WEAR PROPERP.P.E..

WATCH FOOTING. WEAR PROPER P.P.E. WORK IN PAIRS TOREMOVE SCREEN.

WATCH FOOTING. WEAR GLOVES. WORK IN PAIRS TO INSTALLSCREEN.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

HAVE CHIEF OPERATOR VERIFY SCREEN AND ELEVATOR CANNOT BE STARTED IN THE CONTROL ROOM. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURES SECTION(38) AND WEAR PROPER P.P.E.

WEAR PROPER P.P.E. KEEP AREA AROUND SCREEN SHOULDBE CLEAN.

WEAR P.P.E. AND KEEP WORK AREA CLEAN.

REPLACE PRIMARY SCREENS (DOWNDAY)



AFI - M - 013 Written By: McCULLERS



1 LOCKOUT SCREENS TO BE CHANGED. 1 SCREEN VIBRATOR STARTING UP. 1

2 LOCKOUT DIVERTER GATE ON CHUTE ANDCHECK THE SAW TOOTHED DISTRIBUTOR ATTOP OF SCREEN.

2 LUMPS FALLING. 2

3 REMOVE SIDE COVERS AND TIE UP TOPCOVERS.

3 PINCHED FINGERS. 3

4 REMOVE BOLTS FROM SIDE RAILS ANDVIBRATOR FEET.

4 NOISE FROM IMPACT. FALLING. 4

5 REMOVE OLD SCREENS. 5 CUTS, SCRATCHES, MASHED, OR BROKENFINGERS.

5

6 INSTALL NEW SCREENS, SIDE RAILS, ANDVIBRATOR FEET.

6 CUTS, SCRATCHES, MASHED OR BROKENFINGERS.

6

7 REMOVE LOCKS AND CLEAN UP AREA. 7 NONE. 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review Safety Committee Review:DAVE BAKER 3-26-09 JACK BLEDSOE 3-26-09STEVE COLE 3-27-09 MIKE RANGEL 3-27-09

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38) AND WEAR P.P.E.

REPLACE PRIMARY SCREENS ON THE RUN

MAKE SURE GATE IS CLOSE SECUELY.

WEAR PROPER P.P.E. AND WATCH POSITION OF HANDS.

WEARING HEARING PROTECTION. KEEP WORK AREA CLEAN ANDBE AWARE OF BODY POSITION.

WEAR PROPER P.P.E..

WEAR PROPER P.P.E..

NONE.



AFI - M - 014 Written By: J WOLFE



1 LOCKOUT SCREEN VIBRATORS ON BANK TO BEWORK ON. GET A PERMIT.

1 LOCKING OUT WRONG SCREEN. 1

2 TRANSPORT MOTOR TO SCREENS USING AHAND TRUCK.

2 FALLING AND TRIPPING. 2

3 REMOVE SAFETY CABLE. 3 WRENCH SLIPPING AND SCRAPING HANDS. 3

4 REMOVE MOTOR BELTS. 4 FALLING OFF SCREENS AND DROPPING MOTORON FEET.

4

5 REMOVE MOTOR. 5 BACK STRAIN AND FALLING. 5

6 INSTALL NEW MOTOR AND REINSTALL SAFEFTYCABLE.

6 BACK STRAIN AND FALLING. 6

7 REMOVE LOCKS AND RETURN PERMIT TOCONTROL ROOM.

7 NONE. 7

8 8 8


KEEP BALANCE ON SCREEN AND BRACE FOOT AND KNEEAGAINST MOTOR.

HOLD ON AND KEEP BALANCE AND PASS MOTOR TO PARTNER.

NONE.

HOLD ON AND KEEP BALANCE AND PASS MOTOR TO PARTNER.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

WALKWAYS AND STEPS SHOULD BE CLEARED.

WEAR PROPER P.P.E.

REPLACE PRIMARY SCREEN VIBRATOR MOTOR

CHECK FIELD SWITCHES. REFER TO EMPLOYEE SAFETYMANUAL LOCKOUT PROCEDURES SECTION (38) AND WEARPROPER P.P.E.



AFI - M - 019 Written By: McCULLERS



1 LOCKOUT BOTH MOTORS ON MILL. GET A SAFEWORK PERMIT.

1 LOCKING OUT WRONG MILL. 1

2 REMOVE GUARD. 2 GUARD FALLING AND BACK STRAIN. 2

3 LOOSEN BASE BOLTS ON MOTOR AND BACK OFF.USE 3/4" DRIVE IMPACT TO REMOVE BOLTS.

3 WRENCH SLIPPING, PINCH POINTS AND HEARINGDAMAGE.

3

4 REMOVE OLD BELTS AND INSTALL NEW ONES.TIGHTEN AND ALIGN.

4 WRENCH SLIPPING, PINCH POINTS AND HEARINGPROTECTION.

4

5 INSTALL GUARD. 5 GUARD FALLING. 5

6 REMOVE LOCKS AND SIGN OFF PERMITS. 6 NONE. 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCHES. REFER TO EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURES SECTION (38) AND WEAR PROPER P.P.E.

HOLD GUARD IN PLACE. LIFT USING PROPER LIFTING PROCEDURE.WORK IN PAIRS.

REPLACE CHAIN MILL BELTS

WEAR PROPER P.P.E. AND WATCH HAND POSITIONS .

WEAR PROPER P.P.E. AND WATCH HAND POSITION.

GET HELP AND USE PROPER LIFTING PROCEDURE.

NONE.

MOSAIC AFI MAINTENANCE JSA DATE WRITTEN: Feb-91

NEW WALES OPERATIONS AFI-M-020 REVIEWED: 3/2/2009

Written By: J. WOLFE



1 LOCKOUT EQUIPMENT AND GET A PERMIT. 1 LOCKING OUT WRONG EQUIPMENT. 1

2 REMOVE GUARD IF BEARING IS ON DRIVESIDE.

2 WRENCH SLIPPING AND PINCH POINTS. BACKSTRAIN.

2

3 REMOVE BELT AND SHEAVES IF BEARING ISON DRIVE SIDE.

3 WRENCH SLIPPING AND POSSIBLE SHEAVESFALL ON FEET.

3

4 REMOVE BEARING COVER AND BEARING BASEBOLTS.

4 WRENCH SLIPPING, PINCH POINTS, ANDDROPPING COVER ON FEEET.

4

5 LOOSEN LOCK NUT, SLIDE OLD BEARING OFFSHAFT (TORCH MAY BE REQUIRED).

5 HITTING HAND WITH HAMMER, AND DROPPINGBEARING ON FEET.

5

6 SLIDE NEW BEARING ON SHAFT AND TIGHTENLOCK NUT.

6 PINCH POINTS, DROPPING BEARING ON FEETAND HITTING HAND WITH HAMMER.

6

7 REPLACE BEARING COVER ON BASE BOLTS. 7 WRENCH SLIPPING AND PINCH POINTS. 7

8 REPLACE BELT, SHEAVES AND GUARD IFBEARING IS ON DRIVE SIDE.

8 BELT, SHEAVES SLIPPING AND GUARD IN BADSHAPE.

8

9 REMOVE LOCKS AND TURN IN PERMIT TOCONTROL ROOM.

9 NONE. 9 NONE.

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:DAVE BAKER 3-30-09 JACK BLEDSOE 3-30-09


JOB SAFETY ANALYSIS

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECETION (38) AND WEAR PROPER P.P.E.

USE PROPER TOOLS, WEAR PROPER P.P.E. AND WORK INPAIRS.

CORRECTIVE ACTIONS

WEAR PROPER P.P.E. AND WORK IN PAIRS.

REPLACE CHAIN MILL BEARINGS

USE CORRECT TOOLS FOR JOB. WATCH YOUR FOOTING ANDWEAR P.P.E. WORK IN PAIRS.

USE PROPER TOOLS , WORK IN PAIRS AND WEAR PROPERP.P.E.

WORK IN PAIRS, USE PROPER TOOLS AND WEAR P.P.E.


WEAR PROPER P.P.E. AND REPAIR OR REPLACE GUARD.


NEW WALES OPERATIONS AFI MAINTENACE JSA REVIEWED: 3/2/2009

AFI - M - 021 Written By: DONALDSON / WING



1 LOCKOUT BOTH SIDES OF CHAIN MILL. GET APERMIT.

1 LOCKOUT WRONG EQUIPMENT. 1

2 REMOVE GUARD, BELT, AND BEARING BOLTS.(REFER TO JSA ON REPLACING CHAIN MILLBELTS).

2 BACK STRAIN, GUARD FALLING, PINCH POINTSAND NOISE.

2

3 REMOVE DOOR AND SIDE PLATES. 3 DOOR FALLING AND PINCH POINTS. 3

4 REMOVE ROTOR. 4 ROTOR FALLING. 4

5 INSTALL NEW ROTOR AND BEARINGASSEMBLY.

5 ROTOR FALLING AND PINCH POINTS. 5

6 INSTALL BOLTS IN BEARING, TIGHTEN TAPERLOCK NUT AND CAPS.

6 WRENCH SLIPPING AND HITTING HAND WITHHAMMER.

6

7 INSTALL SIDE PLATES AND DOOR. 7 DOOR FALLING, NOISE, PINCH POINTS ANDBACK STRAIN.

7

8 INSTALL BELT AND GUARD (REFER TO JSA ONREPLACING CHAIN MILL BELTS).

8 BACK STRAIN AND GUARD FALLING. 8

9 REMOVE LOCKS AND TURN IN PERMIT. 9 NONE 9 NONE.


JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK SWITCHES IN CONTROL ROOM AND IN THE FIELD.REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38). WEAR PROPER P.P.E.

LIFT PROPERLY, SUPPORT GUARD, WEAR PROPER P.P.E. ANDWATCH HAND PROTECTION.

CHECK ALL RIGGING, WEAR PROPER P.P.E. AND WATCH HANDPOSITION.

REPLACE CHAIN MILL ROTOR

CHECK RIGGING AND WORK IN PAIRS.

CHECK RIGGING, WEAR PROPER P.P.E., AND WATCH HANDPOSITION SO THEY DON’T GET CAUGHT.

LIFT PROPERLY, SUPPORT GUARD AND WEAR PROPER P.P.E.

WEAR PROPER P.P.E.

CHECK RIGGING, WEAR PROPER P.P.E., AND LIFT CORRECTLY.


NEW WALES OPERATIONS AFI MAINTENACNE JSA REVIEWED: 3/2/2009

AFI - M - 022 Written By: COOK / CASTRO

TOPIC: REPLACE FLIGHTS IN DRAGApproved By: ASC


1 SPOT FLIGHT BY A DOOR, NOT LOCATEDUNDER A CHUTE AND GET A PERMIT.

1 NONE. 1

2 LOCKOUT DRAGFLIGHT CONVEYOR ANDSCREEN FEED ELEVATOR.


3 BURN BOLTS OUT OF OLD FLIGHT. 3 BURNS AND PINCH POINTS. 3

4 REMOVE OLD FLIGHT FROM DRAGFLIGHT. 4 BACK STRAIN AND PINCH POINTS. 4

5 INSTALL NEW FLIGHT FROM DRAGFLIGHT. 5 BACK STRAIN AND PINCH POINTS. 5

6 INSTALL FLIGHT WITH BOLTS AND TIGHTEN. 6 NOISE FROM IMPACT AND PINCH POINTS. 6

7 REMOVE TOOLS FROM DRAGFLIGHT. 7 PINCH POINTS AND BACK STRAIN. 7


8 NONE. 8



CHECK FIELD SWITCHES AND CONTROL ROOM. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURES SECTION(38) AND WEAR PROPER P.P.E.

WEAR P.P.E.

NONE.

WEAR P.P.E. AND BE CAREFUL.

GET HELP LIFTING FLIGHT INTO POSITION AND WEAR PROPERP.P..E.

FLIGHT CONVEYOR

GET HELP LIFTING (FLIGHT) AND WEAR PROPER P.P.E.

JOB SAFETY ANALYSIS

WEAR PROPER P.P.E. KEEP HAND AND FEET CLEAR.

CORRECTIVE ACTIONS

NONE.



AFI - M - 023 Written By: SPURGEON



1 SPOT CHAIN AT REPAIR DOOR AND GET APERMIT.

1 NONE. 1

2 LOCKOUT DRAGFLIGHT AND SCREEN FEEDELEVATOR. GET A PERMIT.


3 REMOVE MAGNET. 3 PREVENT METAL FROM FALLING. 3

4 REMOVE BOLTS OUT OF CHAIN. 4 PINCH POINTS. 4

5 REMOVE OLD CHAIN. 5 BACK STRAIN AND PINCH POINTS. 5

6 INSTALL NEW CHAIN. 6 BACK STRAIN AND PINCH POINTS. 6

7 INSTALL BOLTS IN NEW CHAIN. 7 PINCH POINTS. 7

8 REMOVE TOOLS FROM DRAGFLIGHT. 8 PINCH POINTS. 8

9 REPLACE MAGNET. 9 PINCH POINTS. 9 WEAR P.P.E.


10 NONE. 10 NONE.




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

CHECK SWITCHES IN CONTROL ROOM AND IN THE FIELD. WEARPROPER P.P.E. REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURES SECTION (38).

WEAR P.P.E.

REPAIR CHAIN ON DRAGFLIGHT CONVEYOR

WEAR PROPER P.P.E. KEEP HAND AND FEET CLEAR.

GET HELP WITH A CHAIN AND WEAR PORPER P.P.E.

WEAR P.P.E.

GET HELP WITH CHAINS AND WEAR PROPER P.P.E.

WEAR P.P.E.






1 LOCKOUT SCREENS, "A, B, OR C" ASREQUIRED. GET A PERMIT.


2 LOOSEN LID HOLD DOWN BARS AND REMOVECOVERS.

2 NOISE FROM IMPACT WRENCH. BACK STRAINAND PINCH POINTS.

2

3 LOOSEN JAM BOLTS AND REMOVE TOPSCREENS.

3 PINCHED FINGERS AND BACK STRAIN. 3

4 REMOVE CENTER DIVIDER AND LOWERSCREENS.


5 INSTALL NEW SCREENS IN BOTTOM. 5 PINCHED FINGERS AND BACK STRAIN. 5

6 INSTALL CENTER DIVIDER AND TOP SCREENS.TIGHTEN JAM BOLTS.


7 INSTALL LIDS, CROSS BARS AND TIGHTEN. 7 BACK STRAIN, MASHED HANDS AND NOISEFROM IMPACT.

7

8 REMOVE LOCKS TURN IN PERMIT TO CONTROLROOM.

8 NONE. 8




NONE.

REPLACE DEDUSTING SCREENS



LIFT PROPERLY AND WEAR PROPER P.P.E. WATCH POSITION OFHANDS.


JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK SWITCHES IN CONTROL AND IN THE FIELD. SIGNLOCKOUT PERMIT. REFER TO EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURES SECTION (38).








1 LOCKOUT SCREENS AND GET A PERMIT. 1 POSSIBLE STARTING UP OR LOCKING OUTWRONG EQUIPMENT.

1

2 REMOVE ONE END OF TORQUE ARM. 2 WRENCH SLIPPING, NOISE FROM IMPACTWRENCH.

2

3 REMOVE BEARING COVER, SAFETY WIREBOLTS, AND RING.

3 NOISE FROM IMPACT WRENCH, GETTING STUCKWITH SAFETY WIRE.

3

4 INSTALL RIGGING AND RAISE BOX AS HIGH ASPOSSIBLE. REMOVE BELT GUARD.

4 BOX FALLING AND IMPROPER RIGGING. 4

5 REMOVE MOUNTING BOLTS AND RAISEGEARBOX OUT OF FRAME.

5 NOISE FROM IMPACT, WRENCH SLIPPING ANDRIGGING FAILURE.

5

6 REMOVE DRIVE SHEAVES AND INSTALL ONNEW GEAR BOX.


7 INSTALL GEAR BOX IN FRAME AND MOUNTINGBOLTS. INSTALL BELT GUARD.

7 RIGGING FAILURE, NOISE FROM IMPACT ANDWRENCH SLIPPING.

7

8 LOWER BOX, INSTALL RING, AND BOLTS.SAFETY WIRE BOLTS AND INSTALL COVER.

8 RIGGING FAILURE AND NOISE FROM IMPACT. 8

9 INSTALL TORQUE BAR. 9 WRENCH SLIPPING AND NOISE FROM IMPACT. 9 WEAR PROPER P.P..E.

10 REMOVE LOCKS AND TURN IN PERMIT. 10 NONE. 10 NONE.




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK SWITCHES IN CONTROL ROOM AND IN THE FIELD. REFERTO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESSECTION (38).

WEAR PROPER P.P.E.

WEAR PROPER P.P.E.

REPLACE DEDUSTING SCREEN GEAR BOX

CHECK ALL RIGGING AND MAKE SURE EVERYTHING IS SECURE.

WEAR P.P.E. AND CHECK ALL RIGGING.

CHECK RIGGING AND WEAR PROPER P.P.E.

WEAR PROPER P.P.E. WORK IN PAIRS.

CHECK RIGGING AND WEAR PROPER P.P.E.






1 NOTIFY PRODUCTION THAT THE ELEVATORWILL BE WORKED ON. GET A PERMIT.

1 PRODUCTION STARTING EQUIPMENT.PERSONNEL WORKING DOWNSTREAM OF THEELEVATOR.

1

2 SPOT ELEVATOR SO THAT THE BUCKET IS INTHE PROPER POSITION. ( REFER TOEMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURES SECTION (38.4) ON BUMPING &JOGGING.

2 FALLING PRODUCT AND NOISE. 2

3 LOCKOUT ELEVATOR. USE THE LOCKBOXPROCEDURE.


4 BURN BOLTS OFF AND REMOVE BUCKET. 4 BURNS FROM SPARKS AND HOT BOLTS.BUCKET FALLING AND PINCHED FINGERS.

4

5 INSTALL NEW BUCKETS. REPLACE BOLTS ANDTIGHTEN.

5 BUCKET FALLING, PINCHED HANDS, NOISEFROM IMPACT AND BACK STRAIN.

5

6 REMOVE LOCKS AND REPOSITION TO NEXTBUCKET. REPEAT STEPS NO. 1 - 4 ABOVE, ASOFTEN AS REQUIRED.

6 FALLING PRODUCT AND NOISE. 6


7 NONE. 7

8 8 8


STAND BACK AND WEAR PROPER P.P.E.

NONE.

WEAR PROPER P.P.E., STAY ALERT AND STAY OUT OF BUCKETSWAY. WORK IN PAIRS.

STAY ALERT, WEAR PROPER P.P.E. AND LIFT BUCKETSPROPERLY.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

MAKE SURE ALL PERSONNEL ARE CLEAR AND AWARE OFMAINTENANCE WORKING ON EQUIPMENT. REFER TO EMPLOYEESAFETY MANUAL LOCKOUT PROCEDURES SECTION (38).

ALWAYS STAND BACK WHILE ELEVATOR IS MOVING AND WEARPROPER P.P.E. REFER TO EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURES SECTION (38.4) ON BUMPING ANDJOGGING.

CHECK FIELD SWITCH AND SIGN LOCKOUT TAG.

REPLACE ELEVATOR BUCKETS




TOPIC: REPLACE ELEVATOR COUNTERApproved By: ASC


1 LOCKOUT ELEVATOR AND SIGN PERMIT. 1 LOCKING OUT WRONG EQUIPMENT ANDELEVATOR STARTING UP.

1

2 OPEN SIDE DOORS ON ELEVATOR. 2 PINCH POINT AND BACK STRAIN. 2

3 REMOVE THE FOUR BOLTS HOLDING SIDE RAILAND REMOVE RAIL. (POSSIBLE USING TORCH TOBURN BOLTS).

3 SPARKS FROM TORCH OR NOISE FROM IMPACTAND BACK STRAIN.

3

4 REMOVE OLD BEARING AND INSTALL NEW ONE.(POSSIBLE USING TORCH).

4 SPARKS FROM TORCH AND NOISE FROMIMPACT.

4

5 INSTALL SIDE RAIL AND REPLACE BOLTS. 5 BACK STRAIN, NOISE FROM IMPACT AND PINCHPOINTS.

5

6 CLOSE SIDE DOORS. 6 NOISE FROM IMPACT AND PINCH POINTS. 6


7 NONE. 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCHES AND CONTROL ROOM. REFER TO EMPLOYEESAFETY MANUAL LOCKOUT PROCEDURES SECTION (38).

USE COM-A-LONG TO REMOVE RAIL OR WORK IN PAIRS AND WEARPROPER P.P.E.

WEAR PROPER P.P.E. AND USE COM-A-LONG TO PULL DOORS OPEN.

WEIGHT BEARINGS AND GLIDE RAIL

WEAR PROPER P.P.E.

NONE.


WEAR PROPER P.P.E.






1 LOCKOUT ELEVATOR AND USE LOCKBOX IFNEEDED.

1 LOCKING WRONG EQUIPMENT. 1

2 REMOVE GUARD, CHAIN AND SPROCKET. 2 GUARD FALLING, PINCHED HANDS AND CHAINFALLING.

2

3 CHECK AND INSPECT HOIST. 3 EQUIPMENT FALLING. 3

4 REMOVE BOLTS IN HOOD AND LIFT OFF. 4 BACK STRAIN, PINCHED HAND, AND HOOKFALLING.

4

5 INSTALL "H" BEAMS TO SUPPORT CHAINS ANDREMOVE ENOUGH BUCKETS TO SEPARATECHAIN.

5 BACK STRAIN, PINCHED FINGERS, BURNS ANDFALLING DOWN ELEVATOR SHAFT.

5

6 GET PROPER RIGGING TO SUPPORT CHAINAND DRIVE PINS OUT AND LAY CHAIN BACKOUT OF WAY OF HEADSHAFT.

6 DAMAGED OR UNDERRATED RIGGING. MASHEDHANDS AND FINGERS.

6

7 HOOK UP TO OVERLOAD HOIST, REMOVEBEARING BOLTS AND LIFT TO GROUND.

7 IMPROPER RIGGING, MASHED HANDS ANDFINGERS.

7

8 RIG NEW SHAFT INTO PLACE AND BOLT DOWN.REPLACE SPROCKET AND DRIVE CHAIN.

8 IMPROPER RIGGING AND PINCH POINTS. 8

9 MAKE UP CHAIN. ROTATE TO GROUND LEVELAND REPLACE BUCKETS.

9 PINCH POINTS. 9 WEAR PROPER P.P.E.

10 REPLACE GUARD AND HOOD. 10 BACK STRAIN AND PINCHED FINGERS. 10 LIFT PROPERLY AND WEAR PROPER P.P.E.


LIFT CORRECTLY AND WATCH YOUR FOOTING.

INSPECT RIGGING AND WEAR PROPER P.P.E.

CHECK THE WEIGHT OF THE LOAD AND USE PROPER RIGGING.WEAR PROPER P.P.E.

INSPECT RIGGING AND WEAR PROPER P.P.E.


JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK SWITCHES IN CONTROL ROOM AND IN THE FIELD. SIGNPERMIT. REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURES SECTION (38).

REPLACE ELEVATOR HEADSHAFT

HOOKUP TO OVERHEAD HOIST AND WEAR PROPER P.P.E.

INSPECT HOIST AND RIGGING.



AFI - M - 030 Written By: CASTRO / WING / COOK



9 REMOVE LOCKS AND REPLACE BUCKETS. 9 PINCH POINTS AND BACK STRAIN. 9

10 REMOVE LOCKS AND CLEAN UP AREA.CONTACT PRODUCTION AND TURN IN PERMIT.

10 PINCH POINTS AND BACK STRAIN. 10 WATCH HAND AND BODY POSITION. LIFT PROPERLY AND WEARPROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

WATCH HAND AND BODY POSITION. LIFT PROPERLY AND WEARPROPER P.P.E. REFER TO EMPLOYEE SAFETY MANUAL ONBUMPING AND JOGGING SECTION (38.4) AND JSA #27 REPLACEELEVATOR BUCKETS.

REPLACE ELEVATOR CHAIN (CONTINUED)



AFI - M - 030 Written By: DONALDSON / COOK

TOPIC: CASTRO / WING

Approved By: ASC


1 LOCKOUT ELEVATOR AND SIGN PERMIT. 1 LOCKING OUT WRONG ELEVATOR OREQUIPMENT.

1

2 REMOVE HOOD ON TOP AND OPEN BOTTOMDOORS. USE PROPER RIGGING.

2 WRENCH SLIPPING AND NOISE FROM IMPACTFALLING.

2

3 RIG A CHAIN WITH CHAIN COM -A-LONGCHOKERS AND ATTACH HOIST TO CHAIN ANDBREAK CHAIN. (POSSIBLE USING TORCH).

3 PINCH POINTS, RIGGING BREAKING, FALLING,BURNS FROM TORCH AND BACK STOP NOTWORKING.

3

4 LOWER HOIST. CUT OFF AND REMOVE CHAINSECTIONS USING FORK-LIFT OR CRANE.(POSSIBLE USING TORCH).

4 PINCH POINTS AND BURNS. EQUIPMENT (FORK-LIFT OR CRANE) BACKING INTO EMPLOYEE.

4

5 RIG NEW CHAIN TO HOIST AND LIFT IT INADDING NEW SECTIONS AS IT GOES IN.

5 RIGGING BREAKING, PINCH POINT, AND GETTINGHIT WITH SLEDGE HAMMER WHILE INSTALLINGPINS.

5

6 TIE OFF CHAIN AT HEAD SPROCKET ANDREPEAT STEP 5 FOR SECOND HALF OF CHAIN.

6 SAME AS STEP 5 ABOVE. 6

7 MAKE UP HEAD AND TAIL SPROCKETS. 7 SAME AS STEP 5 ABOVE. 7

8 REPLACE HOOD. 8 PINCH POINT. 8


JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCHES AND CONTROL ROOM SWITCHES.REFER TO EMPLOYEE SAFETY MANUAL ON BUMPING ANDJOGGING SECTION (38.4)

REPLACE ELEVATOR CHAIN

WEAR PROPER P.P.E.

WATCH BODY AND HAND POSITION. USE PROPER P.P.E. ANDSTAY CLEAR OF MOVING EQUIPMENT.

WATCH POSITION OF HANDS, CHECK ALL RIGGING FOR PROPERSIZE, "DO NOT DEPEND ON BACK STOP" AND WEAR PROPERP.P.E.

WATCH HAND AND BODY POSITION.

SAME AS STEP 5 ABOVE.

CHECK RIGGING, WATCH BODY AND HAND POSITION AND STANDCLEAR OR EQUIPMENT.

SAME AS STEP 5 ABOVE.



AFI - M - 031Written By: McCULLERS / WOLFE



1 LOCKOUT EQUIPMENT AND GET A PERMIT. 1 LOCKING OUT WRONG EQUIPMENT. 1

2 REMOVE SCREW COVERS. 2 PINCH POINTS. 2

3 UNBOLT HANGER AND REMOVE BEARING. 3 SCRAPING HANDS, WRENCH SLIPPING, ANDPINCHED FINGERS.

3

4 INSTALL NEW BEARING AND BOLT UP HANGER. 4 SCRAPING HANDS, PINCHED FINGERS, ANDWRENCH SLIPPING.

4

5 REPLACE COVER. 5 PINCH POINTS. 5

6 CLEAN UP AREA AND RETURN PERMIT TOCONTROL ROOM.

6 NONE. 6

7 7 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review Safety Committee Review:DAVE BAKER 4-14-09 JACK BLEDSOE 4-1409STEVE COLE 4-14-09 MIKE RANGEL 4-14-09

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

GET HELP MOVING COVERS AND USE PROPER TOOLS. WEARPROPER P.P.E.

REPLACE BEARING ON SCREW CONVEYOR

CHECK FIELD AND CONTROL ROOM SWITCH. SIGN PERMIT.REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38).

USE PROPER TOOLS AND WEAR PROPER P.P.E.

GET HELP MOVING COVERS AND WEAR PROPER P.P.E.


NONE.




TOPIC: REPLACE OR REPAIR COUPLINGApproved By: ASC


1 LOCKOUT SCREW CONVEYOR AND SIGNPERMIT.


2 REMOVE COVERS. 2 PINCH POINTS AND COVER FALLING. 2

3 REMOVE HANGER BEARING, STUB SHAFTBOLTS, AND BEARING ON END OF SCREW.(POSSIBLE USING TORCH).

3 SLAG FROM TORCH AND WRENCH SLIPPING. 3

4 CUT STUB SHAFT IN HALF AND TAKE OUT.USING TORCH.

4 SPARKS FROM TORCH AND PINCH POINTS. 4

5 INSTALL NEW STUB AND BOLT TOGETHER. 5 WRENCH SLIPPING. 5

6 REPLACE HANGER BEARING AND FOLLOWBLOCK BEARING IF NEEDED.

6 WRENCH SLIPPING AND NOISE FROM IMPACT. 6

7 REPLACE COVER. 7 PINCH POINTS AND BACK STRAIN. 7

8 REMOVE LOCKS AND RETURN PERMIT. 8 NONE. 8


NONE.

WATCH POSITION OF HANDS AND WEAR PROPER P.P.E.

WEAR P.P.E.

WEAR P.P.E. AND LIFT PROPERLY.

WEAR PROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCHES. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38).

WORK IN PAIRS, STAY ALERT AND WEAR P.P.E.

WEAR PROPER P.P.E. AND USE CORRECT TOOLS.

"STUB" SHAFT ON SCREW CONVEYOR



AFI - M - 033 Written By: COOK / WING



1 LOCKOUT SCREW CONVEYOR AND SIGNPERMIT.


2 REMOVE COVERS. 2 PINCH POINTS AND COVER FALLING. 2

3 REMOVE HANGER BEARING, STUB SHAFTBOLTS, AND BEARING IN ENDS OF SHAFT.(POSSIBLE USING TORCH).

3 SPARKS FROM TORCH AND WRENCH SLIPPING. 3

4 CUT STUB SHAFT AND REMOVE SCREWSECTION USING COM-A-LONG OR CHAIN FALLS.( POSSIBLE USING TORCH).

4 SPARKS FROM TORCH, PINCH POINTS,IMPROPER RIGGING, CHOCKER SLIPPING ANDFAULTY EQUIPMENT.

4

5 INSTALL NEW SCREW AND STUB SHAFT. USECOM-A-LONG TO LIFT SCREW SECTION INTOHOUSING AND BOLT TOGETHER.

5 WRENCH SLIPPING, PINCH POINTS, IMPROPERRIGGING, CHOCKER SLIPPING AND FAULTYEQUIPMENT. SCREW FALLING FROM RIGGINGHOIST WELL.

5

6 REPLACE HANGER BEARING AND PILLOWBLOCK BEARING IF NEEDED.

6 WRENCH SLIPPING AND NOISE FROM IMPACT. 6

7 REPLACE COVERS. 7 PINCH POINTS AND BACK STRAIN. 7

8 CLEAN UP AREA. REMOVE LOCKS AND RETURNPERMIT TO CONTROL ROOM.

8 NONE. 8



WATCH POSITION HANDS, INSPECT RIGGING AND LIFTINGEQUIPMENT, WORK IN PAIRS AND WEAR P.P.E.

INSPECT RIGGING AND LIFTING EQUIPMENT. WORK IN PAIRSAND SOMEONE ON THE GROUND LEVEL TO OPERATE HOIST ANDKEEP PEOPLE OUT OF AREA. WEAR P.P.E.

NONE.

WEAR P.P.E.

LIFT PROPERLY, WORK IN PAIRS AND WEAR P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD AND CONTROL ROOM. REFER TO EMPLOYEESAFETY MANUAL LOCKOUT PROCEDURE SECTION (38).

STAY ALERT AND WEAR P.P.E.

USE PROPER TOOLS AND WEAR PROPER P.P.E.

REPAIR OR REPLACE SCREW CONVEYOR



AFI - M - 034 Written By: WING / DONALDSON



1 LOCKOUT EQUIPMENT (TWO MOTORS ONDRYER). GET A PERMIT.

1 NOT LOCKING OUT BOTH MOTORS ON DRYER ORWRONG EQUIPMENT.

1

2 REMOVE GUARDS AND RIG ACCORDING TOJOB.

2 BACK STRAIN, PINCH POINTS AND FAULTYRIGGING.

2

3 REMOVE ALL BOLTS EXCEPT ONE FROMCOUPLING. HOOK-UP RIGGING.

3 COUPLING HOT CAUSING BURNS AND COUPLINGFALLING.

3

4 REMOVE LAST BOLT AND THEN REMOVECOUPLING.

4 COUPLING HOT CAUSING BURN. 4

5 INSTALL NEW COUPLING AND BOLTS. REMOVERIGGING FROM COUPLING.

5 COUPLING FALLING. 5

6 INSTALL GUARD AND REMOVE RIGGING FROMJOB.



7 NONE. 7

8 8 8


REPLACE FLUID DRIVE COUPLING

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK FIELD SWITCHES AND HAVE CHIEF CHECK CONTROLROOM. SIGN A PERMIT. REFER TO EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURE SECTION (38).

USE PROPER LIFTING PROCEDURES. CHECK RIGGINGEQUIPMENT AND WEAR PROPER P.P.E

BEWARE OF HOT COUPLING, WEAR PROPER P.P.E. AND MAKESURE RIGGING IS SCURE.

BE AWARE OF HOT COUPLING AND WEAR P.P.E.

MAKE SURE RIGGING IS SECURE.

LIFT PROPERLY AND WEAR P.P.E.

NONE.






1 LOCKOUT PIECE OF EQUIPMENT. GET APERMIT.

1 EQUIPMENT STARTING UP. WRONG EQUIPMENTLOCK OUT.

1

2 LOOSEN BASE BOLTS ON EQUIPMENT MOTOR,BREAK COUPLING AND REMOVE GUARDS.

2 WRENCH SLIPPING AND BACK STRAIN. 2

3 ATTACH DIAL INDICATOR TO MOTOR SHAFT. 3 NONE. 3

4 ROLL SHAFT TOP-BOTTOM AND SIDE TO SIDECHECKING INDICATOR.

4 NONE. 4

5 ADJUST WITH BAR. ADD SHIMS IF NECESSARYAND TIGHTEN BASE BOLT.

5 BAR OR WRENCH SLIPPING. 5

6 REMOVE DIAL INDICATOR, RECOUPLECOUPLING AND INSTALL GUARD.

6 WRENCH SLIPPING AND PINCHED FINGERS. 6

7 REMOVE LOCKS AND TURN IN PERMIT. 7 NONE. 7

8 8 8


USE CORRECT TOOLS AND WEAR PROPER P.P.E.

NONE.

ALIGN PUMP MOTORS & GEAR BOXES

WATCH HAND POSITION AND WEAR P.P.E.

NONE.

JOB SAFETY ANALYSIS

USE CORRECT TOOLS, WORK IN PAIRS TO REMOVE GUARD IFNECESSARY AND WEAR PROPER P.P.E.

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCHES AND REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38).

NONE.


NEW WALES OPERATIONS AFI MAINTENANCE JSA REVIEWED: 4/9/2009AFI - M - 036

Written By: CASTRO / WING



1 PLACE BOLT AND RUBBER ON CENTER BAR. 1 CUTS AND SCRATCHES. 1

2 PLACE SCREEN ON BOLTS. 2 CUTS AND SCRATCHES. 2

3 INSTALL RUBBER, BAR AND NUTS (IF BOTTOMSCREEN WELD NUTS).

3 CUTS AND SCRATCHES. NOISE FROM IMPACT. 3

4 4 4

5 5 5

6 6 6

7 7 7

8 8 8



JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

WEAR P.P.E

WEAR P.P.E.

MAKE UP PRIMARY SCREENS

WEAR P.P.E.



Written By: WING



1 LOCKOUT CONVEYOR BELT AND CHECK FIELDSWITCH. GET A PERMIT.

1 LOCKING OUT WRON EQUIPMENT. 1

2 REMOVE SIDE PLATES AND PULL OUT OLDSKIRTING.

2 WRENCH SLIPPPING AND NOISE FROM IMPACT. 2

3 INSTALL NEW RUBBER. 3 PINCH POINTS. 3

4 INSTALL SIDE PLATES, 4 WRENCH SLIPPING AND NOISE FROM IMPACT. 4

5 REMOVE LOCK AND RETURN PERMIT TOCONTROL ROOM.

5 NONE. 5

6 6 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38). SIGN PERMIT.

WEAR PROPER P.P.E.

WEAR PROPER P.P.E.

REPLACE SKIRTS ON CONVEYOR BELTS

WEAR PROPER P.P.E.

NONE.



Written By: WING



1 LOCKOUT CONVEYOR BELT AND CHECK FIELDSWITCH. GET A PERMIT.


2 TAKE OUT BOLTS AND REMOVE IDLERS. MAYUSE TORCH TO BURN BOLTS.

2 SPARKS FROM TORCH, WRENCH SLIPPING,PINCH POINTS AND BACK STRAIN.

2

3 SLIDE NEW IDLER BETWEEN BELT AND TABLE.INSTALL NEW BOLTS.

3 BACK STRAIN AND PICH POINTS. 3

4 CLEAN AREA AND REMOVE OLD IDLER FROMAREA.

4 BACK STRAIN. 4

5 REMOVE LOCK AND TURN IN PERMIT TOCONTROL ROOM.

5 NONE. 5

6 6 6

7 7 7

8 8 8




NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL PROCEDURE SECTION(38). SIGN A PERMIT.



REPLACE IDLERS ON CONVEYOR BELT



Written By: COOK / WING

TOPIC: REPLACE DUST SEAL ONApproved By: ASC


1 LOCKOUT THE FULLER KENYON PUMP ANDCHECK THAT THE VALVE ON THE AIR LINE ISCLOSED. GET A PERMIT AND VERIFY SWITCH.


2 REMOVE THE FRONT COVER, SIDE COVERS,AND GREASE LINES.

2 DROPPING COVER, NOISE FROM IMPACT. 2

3 LOOSEN LOCK HUB AND SLIDE OUT SCREW.REMOVE SEAL.

3 DROPPING SCREW, MASHING HAND, AND BACKSTRAIN.

3

4 REPLACE SLEEVE AND COPPER RING. 4 SCREW ROLLING ON FINGERS. 4

5 REPLACE SCREW AND SEAL. 5 DROPPING SCREW, MASHING HAND, AND BACKSTRAIN.

5

6 REPLACE SCREW AND SEAL,THEN TIGHTENHUB.

6 DROPPING COVERS, NOISE FROM IMPACT. 6

7 REMOVE LOCKS. RETURN PERMIT TOCONTROL ROOM.

7 NONE. 7

8 8 8Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:



JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

WEAR PROPER P.P.E.

USE PROPER LIFTING PROCEDURE AND DON'T JERK SUPPORTSCREW. WEAR PROPER P.P.E.

FULLER KENYON PUMP

SUPPORT SCREW AND WATCH POSITION OF HANDS.

LIFT CORRECTLY AND WEAR PROPER P.P.E.

WERAR PROPER P.P.E.

NONE.



Written By: CASTRO / COOK



1 CHECK WITH CHIEF OR OPERATOR TO OBTAINA PERMIT. CHECK DRAINS AND PLACEPERSONAL LOCKS ON VALVES. GET A PERMITAND VERIFY SWITCH.

1 WRONG VALVES LOCKOUT AND POSSIBLE ACIDIN LINE.

1

2 REMOVE FLANGE COVER. 2 SHARP EDGES. 2

3 REMOVE BOLTS AND MAY REQUIRE A TORCH. 3 ACID IN LINE, WRENCH SLIPPING AND POSSIBLEBURNS FROM TORCH.

3

4 REMOVE LINE. 4 ACID IN LINE AND PIPE FALLING FROMCORROSION FROM OLD BOLTS.

4

5 INSTALL NEW LINE AND REPLACE BOLTS. 5 PINCH POINTS AND WRENCH SLIPPING. 5

6 REPLACE FLANGE COVERS. 6 SHARP EDGES. 6


8 8 8




WEAR PROPER P.P.E.

NONE.

USE PROPER RIGGING AND WEAR PROPER P.P.E.

BE AWARE OF SURROUNDING AND USE PROPER TOOLS FORTHE JOB. WEAR PROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38). CHECK WITH CHIEF OR OPERATOR TO CHECKCORRECT VALVES ARE LOCKOUT. SIGN PERMIT.

WEAR PROPER P.P.E.

BREAK FLANGE AWAY FROM YOU. USE PROPER TOOLS FORTHE SPECIFIC JOB. IF USING TORCH, BARRICADES MAY BEREQUIRES. WEAR PROPER P.P.E.

REPAIR OR REPLACE ACID LINE



Written By: CASTRO / COOK



1 CHECK WITH CHIEF OR OPERATOR TOLOCKOUT PUMPS AND VALVES. GET A PERMIT.VERIFY SWITCH.

1 LOCKING OUT WRONG PUMP AND VALVE. LINECOULD STILL BE FULL OF ACID AND ACID ONGROUND CAUSING SLIPPAGE.

1

2 REMOVE FLANGE COVERS. 2 FLANGE COULD SPRING OPEN AND CUT HAND. 2

3 REMOVE BOLTS AND VALVE. 3 WRENCH SLIPPING, BACK STRAIN, VAVLEFALLING AND ACID IN LINE.

3

4 INSTALL NEW VALVE AND BOLTS. 4 BACK STRAIN AND WRENCH SLIPPING. 4

5 INSTALL FLANGE COVERS. 5 FLANGE COVERS SPRING OPEN. (MAY CUTHAND).

5


7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCHES. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). MAKE SURE DRAIN IS OPEN AND WASH ACID OFF PAD. SIGNPERMIT.

WEAR PROPER P.P.E.

RIG VALVE PROPERLY. USE PROPER BODY POSITION ANDBREAK FLANGE AWAY FROM YOU. WEAR PROPER P.P.E.

REPAIR OR REPLACE VALVES

RIG PROPERLY AND USE PROPER BODY POSITION. WEARPROPER P.P.E.

WEAR PROPER P.P.E.

NONE.



Written By: WING / DONALDSON

TOPIC: REPAIR OR REPLACEApproved By: ASC


1 CHECK WITH CHIEF TO GET A PERMIT.LOCKOUT PUMP, SUCTION VALVE, ANDDISCHARGE VALVE. VERIFY SWITCH'S.

1 LOCKOUT WRONG PUMPS AND VALVES. LINENOT DRAINED. ( DRAIN MIGHT BE PLUG)

1

2 REMOVE COUPLING, BOLTS AND GUARD FROMPUMP.

2 WRENCH SLIPPING AND PINCH POINTS. 2

3 REMOVE PUMP. 3 PUMP FALLING, BACK STRAIN, PINCH POINTSAND ACID IN LINE.

3

4 INSTALL NEW PUMP AND REPLACE BOLTS. 4 PUMP FALLLING AND BACK STRAIN. 4

5 INSTALL COUPLING AND GUARD. 5 PINCH POINTS AND WRENCH SLIPPING. 5


7 7 7

8 8 8




NONE.

USE PROPER RIGGING AND PROPER BODY POSITION. WEARPROPER P.P.E.

WEAR PROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCHES. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). MAKE SURE THE CORRECT VALVES ARE LOCKED ANDCHECK DRAIN VALVE. SIGN PERMIT.

HOLD WRENCH SQUARELY AND WEAR PROPER P.P.E.

USE PROPER RIGGING AND EASE PUMP FROM VOLUTE. USEPROPER BODY POSITION AND WATCH FOR ACID. WEAR PROPERP.P.E.

PUMPS AND COUPLING



Written By: McCULLERS

TOPIC: REPLACE EVAPORATORApproved By: ASC


1 LOCKOUT CIRCULATING PUMP. LOCKOUT ACIDFEED, QUICK FILL AND H2SO4. CHECK WITHCHIEF TO OBTAIN A PERMIT AND VERIFYSWITCH.

1 LOCKING OUT WRONG PUMP AND VAVLES. 1

2 OPEN SIGHT GLASS DOOR FIRST AND THENOPEN THE BOTTOM DOOR.

2 ACID COULD BE LAYING IN BOTTOM. 2

3 INSTALL RIGGING AND REMOVE SPOOL PIECE,EXPANSION JOINT, AND GUARDS (EXPANSIONJOINT AND BELT).

3 DAMAGED OR UNDERRATED RIGGING. AIRHOSE COMING APART AND GUARD FALLING.

3

4 REMOVE BASE BOLT AND RIG PUMP TOCRANE. REMOVE BELTS.

4 SLIPPING AND SOCKET COMING OFF IMPACT.DAMAGED BELT'S OR UNDERRATED CHOKER.

4

5 REMOVE SHEAVES FROM OIL PUMP ANDINSTALL ON NEW PUMP.

5 DROPPING SHEAVES ON GROUND OR FOOT. 5

6 INSTALL NEW PUMP, EXPANSION JOINT,ANDSPOOL PIECE.

6 SLIPPING AND DOUBLE BLOCKING RIG. MASHEDFINGERS, FEET AND BACK STRAIN.

6

7 ALIGN PUMP, PACK PUMP REPLACE BELTS ANDGUARD.

7 BACK STRAIN, MASHED FINGERS AND GUARDFALLING.

7

8 CLOSE DOORS AND HYDRO TEST TO ENSURETHERE ARE NO LEAKS. INSTALL EXPANSIONJOINT GUARD.

8 WRENCH SLIPPING, WATER SPRAYING, GUARDFALLING AND BACK STRAIN.

8

9 REMOVE RIGGING. 9 SLIPPING AND FALLING. 9 KEEP BALANCE AND STAY ALERT.10 REMOVE LOCKS AND RETURN PERMIT. 10 NONE. 10 NONE.




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCHS. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

INSPECT RIGGING AND KNOW THE WEIGHT OF THE PUMP.INSPECT HOSE FOR PINS AND BAD SECTION. STAY ALERT. HOLDTHE GUARD AND WEAR PROPER P.P.E.

CIRCULATING PUMP

OPEN BOTTOM DOOR WITH CAUTION. WEAR PROPER P.P.E.

WASH DOWN AREA. HOLD ONTO SOCKET AND CHECK ALLRIGGING.( REPLACE BELT'S IF NEEDED).

HOOK TO CRANE AND WEAR P.P.E.

KEEP WRENCH FLUSH ON BOLTS. STAY CLEAR OF AREA UNTILAFTER TEST. LIFT PROPERLY AND HOLD ONTO GUARD UNTILBOLTS ARE INSTALLED.

WASH DOWN AREA. STAY ALERT AND WATCH BLOCK KEEP FEETAND HANDS CLEAR OF LOAD. LIFT PROPERLY AND WEAR P.P.E.

LIFT PROPERLY. STAY ALERT SO GUARD DOES NO HANG UPAND FALL. WEAR P.P.E.


NEW WALES OPERATIONS AFI MAINTENANCE JSA REVIEWED: 4/13/2009AFI- M - 044

Written By: WING / WOLFE

TOPIC: REPLACE EVAPORATORApproved By: ASC


1 LOCKOUT PUMP, ACID, QUICK FILL, AND H2SO4LINES. GET A PERMIT.

1 LOCKING OUT WRONG PUMP OR LINES.(POSSIBLE ACID IN LINE).

1

2 INSTALL RIGGING COM-A-LONG AND CHAINFALL.

2 PINCH POINTS AND SLIPPERY. 2

3 REMOVE PACKING. 3 PINCH POINTS. 3

4 REMOVE BOLTS FROM SPOOL IN FRONT OFPUMP.

4 NOISE FROM IMPACT, SPOOL FALLING ON FEET. 4

5 REMOVE IMPELLER. 5 DROPPING IMPELLER ON FEET AND PINCHPOINTS.

5

6 WELD STUDS ON SHAFT SLEEVES. INSTALLPULLER AND PULL SLEEVES.

6 BURNS, FLASH BURN AND PULLER FALLING ONFEET.

6

7 INSTALL NEW SLEEVE AND PACKING. 7 PINCH POINTS. 7

8 INSTALL IMPELLER. 8 PINCH POINTS. 8

9 INSTALL SPOOL. 9 NOISE FROM IMPACT AND PINCH POINTS. 9 WEAR P.P.E. AND WATCH HAND POSITON.

10 CLEAN UP AREA, RETURN TOOLS TO TOOL 10 SLIPPING, FALLING AND PINCH POINTS. 10 WATCH FOR SLIPPERLY SURFACES AND WEAR PROPER P.P.E.ROOM AND REMOVE LOCKS. RETURN PERMIT.



WEAR P.P.E. AND WATCH HAND POSITION.

GET HELP HOLDING PULLER AND SLEEVE WHEN IT COMES OFFSHAFT. WEAR PROPER P.P.E.

WATCH HANDS POSITION AND WEAR P.P.E.

RIG PROPERLY AND WEAR PROPER P.P.E.

WATCH HANDS POSITION, RIG PROPERLY AND WEAR P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCHS. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). WEAR PROPER P.P.E.

WATCH FOR SLIPPERY SURFACES AND WATCH POSITION OFHANDS. WEAR PROPER P.P.E.

WATCH POSITION OF HANDS AND WEAR P.P.E.

CIRCULATING PUMP SHAFT SLEEVE

MOSAIC AREA DATE WRITTEN:

NEW WALES OPERATIONS AFI MAINTENANCE JSA REVIEWED:AFI - M - 039

Written By:

TOPIC: REPLACE DUST SEAL ONApproved By: ASC


1 1 1

2 2 2

3 3 3

4 4 4

5 5 5

6 6 6

7 7 7

8 8 8

Please review this JSA . Sign and date in the appropriate section below:Superintendant & Supervisor Review: Safety Committee Review:DAVE BAKER JACK BLEDSOESTEVE COLE MIKE RANGEL

CORRECTIVE ACTIONS

JOB SAFETY ANALYSIS






1 LOCKOUT CIRCULATING PUMP, SULFURIC ANDPHOSPHORIC ACID QUICK FILL, AND STEAM,GET A PERMIT AND VERIFY SWITCH'S.

1 ACID STILL IN EVAPORATOR AND PUMPSTARTING.

2 OPEN DESIGNATED DOORS THAT PRODUCTIONWANTS . "STARTING AT THE TOP OFEVAPORATOR.

2 WRENCH SLIPPING AND BACK STRAIN. 2

3 CLOSE ALL DOORS. 3 WRENCH SLIPPING AND BACK STRAIN. 3


5

6

7

8




NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. STAY ALERT.WEAR PROPER P.P.E. REFER TO EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURE SECTION (38). SIGN PERMIT.

DO NOT JERK OR WRENCH AND WEAR P.P.E.

DO NOT JERK OR WRENCH AND WEAR P.P.E.

OPEN AND CLOSE EVAPORATOR



AFI - M - 046 Written By: J, WOLFE



1 LOCKOUT CIRCULATING PUMPS ACID FEED,QUICK FILL, H2S04 AND STEAM VALVES. USE ALOCK BOX AND GET A PERMIT.

1 LOCKOUT WRONG PUMP OR LINES. ACID MAYBE IN LINE.

1

2 OPEN DOOR ON TOP OF HEAT EXCHANGERAND LUMP SCREEN DOOR.

2 WRENCH SLIPPING AND STRAINED BACK. 2

3 DROP LADDER THROUGH TOP DOOR. 3 BACK STRAIN. 3

4 INSERT PLUG INTO TOP TUBE, MARKED BYPRODUCTION.

4 ACID FUMES AND GETTING ACID ON SKIN OREYES.

4

5 INSERT PLUG INTO BOTTOM OF TUBE ASMARKED BY PRODUCTION.

5 ACID FUMES, GETTING ACID ON SKIN OR EYES,SLIPPING HAZARD WHILE STANDING ON LUMPSCREEN.

5

6 AFTER WATER TEST, REMOVE TOOLS ANDCLOSE DOORS.

6 STRAIN BACK AND WRENCH SLIPPING. 6

7 REMOVE LOCKS AND RETURN PERMITS. 7 NONE 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. WEAR PROPERP.P.E. AND REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURE SECTION (38).

BE AWARE OF YOUR SURROUNDING.

GET HELP HANDLING LADDER.

PLUG EVAPORATOR TUBES

WEAR PROPER P.P.E.

WATCH FOOTING AND WEAR PROPER P.P.E.

BE AWARE OF SURROUNDING.

NONE.




TOPIC: REPLACE BATCH TANKApproved By: ASC


1 LOCKOUT AGITATOR. HAVE MOTORDISCONNECTED IF NECESSARY. GET APERMIT.


2 BREAK MOTOR COUPLING, REMOVE MOTORBASE FROM GERA BOX AND SET ASIDE WITHRIG.

2 NOISE, WRENCH SLIPPING, BAD RIGGING, ANDFUMES FROM TANK.

2

3 REMOVE BASE BOLTS. RIG TO CRANE ANDRAISE GEAR BOX. INSTALL CLAMP ON SHAFTAND BREAK COUPLING. SET GEAR BOX ONGROUND.

3 NOISE FROM WRENCH. SLIPPING AND BADRIGGING. FUMES FROM TANK. BACK STRAINAND PINCH POINTS.

3

4 REVERSE PROCEDURE TO INSTALL NEW GEARBOX.

4 SAME AS STEPS # 1 AND # 2 ABOVE. 4

5 CLEAN UP AREA, REMOVE LOCKS ANDRETURN PERMIT.

5 NONE. 5

7 7 7

8 8 8




NONE.

JOB SAFETY ANALYSIS

SAME AS STEPS #1 AND # 2 ABOVE.

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION (38).

AGITATOR GEAR BOX (LIGHTNIN)

INSPECT CHOKERS AND WORK IN PAIRS. IF NECESSARY TOINSTALL CLAMP. WEAR PROPER P.P.E.

INSPECT CHOKERS AND WEAR PROPER P.P.E.




TOPIC: REMOVE BATCH TANKApproved By: ASC


1 GET A PERMIT. LOCKOUT GEARBOX. HAVEMOTOR DISCONNECTED.


2 REMOVE BASE BOLTS AND RIG TO CRANE. 2 NOISE FROM IMPACT AND WRENCH SLIPPING.BAD RIGGING AND FUMES FROM BATCH TANK.

2

3 RAISE GEARBOX AND INSTALL CLAMP ONSHAFT AND BREAK COUPLING. SET ONGROUND.

3 NOISE, BAD RIGGING, GEARBOX FALLING,WRENCH SLIPPING, AND FUMES FROM BATCHTANK.

3

4 REVERSE PROCEDURE TO INSTALL NEWGEARBOX.

4 SAME AS STEPS # 1 , # 2, AND # 3 ABOVE. 4


5 NONE. 5

6 6 6

7 7 7

8 8 8



JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. SIGN PERMIT.REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38).

INSPECT CHOKERS AND HAVE RESPIRATOR IN CASE IT ISNEEDED. WEAR PROPER P.P.E.

HAVE RESPIRATOR AND INSPECT LIFTING EQUIPMENT. WEARPROPER P.P.E.

AGITATOR GEARBOX (PHILADELPHIA)

SAME AS STEPS # 1, # 2, AND # 3 ABOVE.

NONE.






1 LOCKOUT EQUIPMENT AND OBTAIN A PERMIT.VERIFY SWITCH'S.

1 LOCKING OUT WRONG EQUIPMENT ANDEQUIPMENT STARTING UP.

1

2 REMOVE GUARDS AND BREAK COUPLING.( IFBELT DRIVEN THEN REMOVE BELTS) REMOVEBASE BOLTS, SUCTIONS AND DISCHARGEPIPING.

2 PINCH POINTS, BACK STRAIN AND SHARPEDGES ON GUARD. WRENCH SLIPPING ANDNOISE FROM IMPACT.

2

3 REMOVE BLOWER AND REINSTALLREPLACEMENT BLOWER.


4 REVERSE STEP # 2 ABOVE. 4 SAME AS STEP # 2 ABOVE. 4

5 CLEAN UP WORK AREA AND REMOVE LOCKS.TURN IN PERMIT.

5 BACK STRAIN. 5

6 6 6

7 7 7

8 8 8



SAME AS STEP # 2 ABOVE.

LIFT PROPERLY.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. SIGN THEPERMIT. REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURE SECTION (38). SIGN PERMIT.

LIFT PROPERLY, USE PROPER TOOLS, WORK IN PAIRS, ANDWEAR PROPER P.P.E.

USE PROPER RIGGING AND LIFTING EQUIPMENT. FORK-LIFT AND/ OR CHAIN COM-A-LONG. WEAR P.P.E.

REPAIR AND REPLACE BOOTS BLOWER






1 GET A PERMIT. ROPE OFF AREA UNDER ANDAROUND WHER YOU ARE WORKING.

1 NONE. 1

2 USE A TORCH TO CUT OR BURN OFF OLDGRATING OR STAIRS.

2 POSSIBLE BURN FROM SLAG AND FALLINGTHROUGH GRATING OR STAIR.

2

3 INSTALL NEW GRATING AND TACK WELD THEGRATING TO STRUCTURE. INSTALL NEW STAIRAND REPLACE BOLTS.

3 POSSIBLE BURN FROM SLAG AND FALLINGTHROUGH STAIRS OR GRATING.

3


4 BACK STRAIN. 4

5 5 5

6 6 6

7 7 7

8 8 8




NONE.

STAY ALERT AND WEAR PROPER P.P.E.

REPLACING STAIRS AND GRATING


JOB SAFETY ANALYSIS

WEAR PROPER P.P.E. AND STAY ALRET.

CORRECTIVE ACTIONS



MM - 022 Written By: REIBSOME / GAINEY



1 CHECK WITH CHIEF OPERATOR AND SPOTBELT. GET A PERMIT.

1 PINCH POINTS AND WRONG BELT LOCKOUT. 1

2 LOCKOUT CONVEYOR BELT. 2 WRONG BELT LOCKOUT. 2

3 ATTACH NEW BELT TO OLD BELT. 3 PINCH POINTS AND SHARP EDGES. 3

4 ROLL NEW BELT ON CONVEYOR. 4 MOVING MACHINERY. 4

5 SPLICE NEW BELT. 5 PINCH POINTS, SHARP EDGES AND BACKSTRAIN.

5

6 REMOVE OLD BELT. 6 PINCH POINTS, BACK STRAIN FROM MOVINGEQUIPMENT. INJURY FROM CUTTING BELT.

6


7 NONE. 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

STAY CLEAR OF BELT.

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT ON BUMPPINGAND JOGGING PROCEDURE SECTION (38.4).

WEAR P.P.E.

REPLACE CONVEYOR BELT

STAN CLEAR OF CONVEYOR.


CUT AWAY FROM YOURSELF, STAND CLEAR OF CONVEYOR,WORK IN PAIRS AND WEAR P.P.E.

NONE.



MM - 023 Written By: CARTER / SCONIERS



1 CHECK WITH CHIEF OPERATOR, THENLOCKOUT FEEDER AND EQUIPMENT AS PERAPM. GET A PERMIT.

1 LOCKOUT WRONG EQUIPMENET. 1

2 REMOVE GUARD AND GEAR BOX. 2 PINCH POINTS, BACK STRAIN AND WRENCHSLIPPING.

2

3 REMOVE FEEDER. 3 PINCH POINTS, BACK STRAIN, AND WRENCHSLIPPING.

3

4 REPLACE FEEDER, GEAR BOX AND GUARDS BYREVERDING STEPS # 3, # 2, AND # 1 ABOVE.

4 SAME AS STEPS # 3, # 2, AND # 1 ABOVE. 4

5 REMOVE LOCKS AND RETURN PERMIT TO THECONTROL ROOM.

5 NONE. 5

6 6 6

7 7 7

8 8 8




SAME AS STEPS # 3, # 2, AND # 1 ABOVE.

REPLACE ROTARY FEEDERS

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38).

WORK IN PAIRS, USE LIGTING EQUIPMENT, SECURE WRENCHAND PULL EVENLY. WEAR P.P.E.

WORK IN PAIRS, USE LIFTING EQUUIPMENT, SECURE WRENCHAND PULL EVENLY. WEAR P.P.E.



MM - 025 Written By: CARTER / REIBSOME

TOPIC: PLOW DRIVE SHAFTApproved By: ASC


1 CLEAR WITH PRODUCTION CHIEF OPERATOR,LOCKOUT PLOW DRIVE, SPINNER SEPARATORAND FEEDER. GET A PERMIT.

1 WRONG EQUIPMENT LOCKOUT. 1

2 REMOVE BELT GUARD AND GEAR BOX. 2 PINCH POINTS, BACK STRAIN, AND WRENCHSLIPPING.

2

3 BREAK SHAFT AND HOUSING LOOSE FROMPLOW. (POSSIBLE USING TORCH)

3 PINCH POINTS, BACK STRAIN AND BURNS FROMROSE BUD.

3

4 LOWER SHAFT AND BEARING ASSEMBLY. 4 PINCH POINTS AND BACK STRAINS. 4

5 INSTALL SHAFT AND BEARING ASSEMBLY BYREVERSING STEPA #4. #3, # 2, AND #1 ABOVE.

5 SAME AS STEPS # 4, # 3, # 2, AND # 1 ABOVE. 5


6 NONE. 6

7 7 7

8 8 8




USE 2 (3/4) TON CHAIN JACKS TO LOWER GEAR BOX. SECUREWRENCH AND PULL EVENLY. WEAR P.P.E.

USE LIFT EQUIPMENT TO LOWER SHAGT ASSEMBLY WITH EYEBOLT CONNECTED TO 1'' ALL THREAD 59' LONG. WEAR P.P.E.

NONE.

SAME AS STEPS # 4, # 3, # 2 AND # 1 ABOVE.

JOB SAFETY ANALYSIS

AND BEARING REPLACEMENT

USE LIFTING EQUIPMENT AND SUPPORT SHAFT ASSEMBLY.WEAR PROPER P.P.E.

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38).



MM - 026 Written By: EVANS/ CONLEY/GAINEY

TOPIC: CHANGE CRUSHER ROLLS REIBSOME / RAYFORD

Approved By: ASC


1 NOTIFY CHIEF OPERATOR AND LOCKOUTEQUIPMENT. GET A PERMIT.


2 UNBOLT AND REMOVE CHUTES IN TWOSECTIONS AT TOP OF CRUSHER.

2 PINCH POINTS AND BACK STRAINS. 2

3 REMOVE BELT GUARDS AND REMOVE INSIDEPANELS AND SLOT SECTIONS.


4 REMOVE ADJUSTMENTS ARMS AND RELEASETENSION SPRINGS.


5 LIFT MOTOR AND REMOVE BELTS. REMOVESHEAVES AND UNBOLT BEARINGS.


6 LIFT OUT CRUSHER ROOS AND LOWER TOGROUND.

6 PINCH POINTS AND SLING SLIPPING. 6

7 REVERSE STEPS # 8, #7, # 6, # 5 , # 4, # 3, # 2ABOVE.

7 PINCH POINTS, BACK STRAIN AND SLINGSLIPPING.

7

8 UNLOCK EQUIPMENT, ADJUST CRUSHER PERMAINTENANCE JSA # 4. ADJUST # 2 PRIMARYOR SECONDARY CRUSHER.

8 PINCH POINTS, WRENCH SLIPPING AND BACKSTRAIN.

8

9 REMOVE LOCKS AND RETURN PERMIT TO 9 NONE. 9 NONE.CONTROL ROOM.



JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38).

WEAR P.P.E.

USE CHAIN FALL FROM MONORAIL TO REMOVE GUARDS ANDWORK IN PAIRS TO LIFT OUT PANELS. WEAR P.P.E.

(NEW SYSTEM #2) PRIMARY & SECONDARY CRUSHER


USE COM-A-LONG AND CHOKER. CHOKE FROM WALL PERLING.KEEP HANDS CLEAR OF PINCH POINTS. USE MONORAIL ANDCHAIN FALL TO REMOVE SHEAVES. WEAR P.P.E.

PULL WRENCH EVENLY AND WEAR P.P.E.

USE 6'' WEB SLING IN CENTER OF ROLL FOR BALANCE ANDWEAR P.P.E.

WEAR P.P.E. AND REVERSE THE STEPS # 8 ------# 2.


NEW WALES OPERATIONS MULTIFOS MAINTENANCE JSA REVIEWED: 4/15/2009MM - 027

Written By: B. EVANS



1 NOTIFY PRODUCTION CHIEF OPERATORLOCKOUT BELT. GET A PERMIT.

1 WRONG BELT LOCKOUT. 1

2 USE TORCH TO BURN BOLTS AND REMOVEIDLERS.

2 SPARKS FROM TORCH, PINCH POINTS, EYEINJURY AND BACK PAIN.

2

3 SLIDE NEW IDLER BETWEEN BELT AND TABLE.SET IDLER IN PLACE AND BOLT DOWN.


4 CLEAN AREA AND REMOVE OLD IDLERS FROMWORK AREA.

4 BACK STRAIN. 4

5 REMOVE LOCKS AND RETURN PERMIT TOCONROL ROOM.

5 NONE. 5

6 6 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


BEND KNEES AND KEEP BACK STRAIGHT WHILE LIFTING. P.P.E.

REPLACE IDLERS ON CONVEYOR BELTS


BEND KNEES AND KEEP BACK STRAIGHT WHILE LIFTING. WEARP.P.E.

NONE.

MOSAIC AREA DATE WRITTEN: 7-01-098


Written By: REIBSOME / DEAN



1 GET WITH CHIEF OPERATOR AND GET APERMIT. LOCATE AIR LINE. SHUT VALVE OFFAND REMOVE AIR LINE FROM VIBRATOR.

1 SHUT OFF WRONG AIR LINE. 1

2 REMOVE FOUR BOLTS IN VIBRATOR ANDREMOVE SAFETY CABLE.

2 PINCH POINTS AND SHARP EDGES ON CABLE. 2

3 INSTALL NEW VIBRATOR. REVERSE STEPS # 2AND # 1.

3 PINCH POINTS AND SHARP EDGES ON CABLE. 3

4 RETURN PERMIT TO CONTROL ROOM. 4 NONE. 4

5 5 5

6 6 6

7 7 7

8 8 8




NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

TRACE LINE AND MAKE SURE CORRECT LINE AND VALVE ARECLOSED.

WEAR P.P.E.

WEAR P.P.E.

CHANGING OUT AIR OPERATED VIBATORS



MM - 009 Written By: RIEBSOME / RAYFORD /

TOPIC: PULL & REPLACE "A", "B" GAINEY

Approved By: ASC


1 CHECK WITH PRODUCTION CHIEF OPERATORAND GET A PERMIT. LOCKOUT ALL EQUIPMENT.


2 LOCK POND WATER LINE. 2 WATER COULD BE IN LINE. WRONG LINELOCKOUT.

2

3 RIG HEADER WITH 4-3/8" X 8" CHOKERS, USE 4-1/2" SHACKLES, AND RIG CHOKERS TOGETHERAND HOOK TO CRANE.

3 WORN OR BROKEN CHOKERS, PINCH POINTS,TRIPPING HAZARDS AND UNBALANCED LOAD.

3

4 GET P.P.E. AND REMOVE BOLTS FROM ALLHEADERS, FLANGES, AND BRACKETS.

4 POSSIBLE LOAD SHIFT AND TAG LINE. 4

5 REPLACE HEADER BY REVERSING STEPS # 4 -#3 AND # 2.

5 SAME POTENTIAL HAZARDS AS # 4 - # 3 - AND #2.

5

6 CLEAN AREA AND RETURN PERMIT TOCONTROL ROOM.

6 NONE. 6

7 7 7

8 8 8




NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK WITH CHIEF AT CONTROL ROOM AND FIELD SWITCH'S.REFER TO EMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURESECTION (38).

MAKE SURE WATER LINE IS DRAINED.

CLEAR WORK AREA INSPECT CHOKERS AND RIGGING. BE SURELOAD IS BALANCED. WEAR PROPER P.P.E.

USE TAG LINE AND CLEAR AREA BEFORE SWINGING LOAD TOGROUND.

WEAR PROPER P.P.E.

& "C" KILN SCRUBBERS, HEADERS & EQUIPMENT

MOSAIC AREA DATE WRITTEN: Dec-02

NEW WALES OPERATIONS MULTIFOS MAINTENANCE JSA REVIEWED: 4/6/2009MM -010

Written By: EVAN / GAINEY

TOPIC: CHANGING SCREENApproved By: ASC


1 CLEAR WITH PRODUCTION CHIEF OPERATOR.LOCK OUT SCREEN BANK, KNIFE GATE ANDBARRICADE HOISTWELL AND TAG, OBTAINCONFINED SPACE PERMIT.

1 POSSIBLE TRIPPING, FALLING, LOCKING OUTWRONG EQUIPMENT AND A DISCONNECTFAILURE.

1

2 PROCEED IN TAKING SCREEN PANELS UPHOIST AND OVER TO SCREEN BANK.

2 POSSIBLE SCEEN SLIP AND FALL TO GROUND.BACK STRAIN, PINCH POINTS, FALLINGPRODUCT AND NOISY AREA.

2

3 REMOVE INSPECTION DOORS. 3 TRIPPING AND FALLING ON STAIRS AND STEPS. 3

4 ENTER SCREEN BANK, REMOVE VIBRATORFOOT AND SIDE RAIL. REMOVE OLD SCREENPANELS.

4 HOT AND DUSTY WORKING AREA. SAFETYGLASSES FOGGING UP AND PINCH POINTS.

4

5 INSTALL SCREEN REVERSE STEPS # 4 - 3 - 2AND # 1.

5 SAME HAZARDS STEPS AS # 4-3-2-1. 5


6 SAME AS # 3 ABOVE. 6

7 7 7

8 8 8




SAME AS # 2 ABOVE.

KEEP GLASSES CLEAN, WORK IN PAIRS, REMOVE OTHERSCREEN PARTS FROM WORKING AREA AND WEAR P.P.E.

WEAR PROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM OR FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). CLEAN WALKWAY AREA , CHECK EQUIPMENT NUMBER TOBE SURE RIGHT EQUIPMENT WAS LOCKED OUT.

POSITION BODY TO AVOID BACK STRAIN, WORK IN PAIRS, ANDWEAR PROPER P.P.E.

REMOVE INSPECTION DOORS FROM WORKING AREA.

PANELS ON # 1 SCREEN SYSTEM



Written By: RAYFORD / REIBSOME

TOPIC: REPLACING BEARINGSApproved By: ASC


1 CHECK WITH CHIEF OPERATOR AND LOCKOUT(61-2116 A OR B) SCRUBBER FAN. GET APERMIT.

1 IMPROPER LOCKOUT PROCEDURE. 1

2 REMOVE GUARD, BOLTS, SHEAVE OIL LINES,AND SIGHT GLASSES,

2 PINCH POINTS, SLIPPAGE AND BACK STAIN. 2

3 REMOVE BOLTS ON BEARING HOUSING. 3 WRENCH SLIPPING. 3

4 JACK BEARING SHAFT UP WITH 1 - 1 1/2 TONCABLE COM-A-LONG AND REMOE BOLTS.REMOVE BEARING HOUSING FROM SHAFT ANDLOOSEN TAPER LOCKS AND REMOVE


5 INSTALL NEW HOUSING AND BEARING. 5 PINCH POINTS AND BACK STRAIN. 5

6 REPLACE BOLTS ON HOUSING. 6 WRENCH SLIPPING. 6

7 REPLACE SHEAVE, OIL LINES, SIGHT GLASSESAND GUARD.

7 PINCH POINTS AND SLIPPING. 7






BEND AT THE KNEES AND WEAR P.P.E.

WEAR P.P.E.

WEAR P.P.E.


WEAR P.P.E. AND BEND AT KNEES.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK WITH CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38).

CLEAN AREA FOR GREASE AND OIL. WORK IN PAIRS AND WEARP.P.E

PLACE WRENCH FIRMLY ON BOLTS.

ON SCRUBBER FANS



Written By: SCONIERS / CARTER

TOPIC: CHANGE OUT ROLLERSApproved By: ASC


1 CHECK WITH CHIEF OPERATOR. LOCKOUTDRAGFLIGHT. OBTAIN CONFINED SPACEPERMIT.


2 REMOVE ACCESS DOOR. 2 PINCH POINT. 2

3 LIFT CHAIN. 3 BACK STRAIN AND PINCH POINTS. 3

4 REMOVE ROLLER. 4 BACK STRAIN, PINCH POINTS AND WRENCHSLIPPING.

4

5 INSTALL ROLLER. REVERSE STEPS # 4, # 3 AND# 2.

5 BACK STRAIN, PINCH POINS, AND WRECHSLIPPING.

5


6 NONE. 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWIITCH'S. REFER TOEMPLOYEE MANUAL SAFETY LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

WEAR P.P.E.

USE COM-A-LONG AND WEAR P.P.E.

IN DRAGFLIGHT

WORK IN PAIRS AND SECURE WRENCH AND PULL EVENLY.WEAR P.P.E.

WORK IN PAIRS, WEAR P.P.E. AND SECURE WRENCH AND PULLEVENLY.

NONE.



Written By: CARTER / SCONIERS



1 CHECK WITH CHIEF OPERATOR THENLOCKOUT MOTOR. GET A PERMIT.

1 LOCKOUT WRONG MOTOR OR EQUIPMENT. 1

2 REMOVE GUARD. 2 PINCH POINTS, BACK STRAIN , WRENCHSLIPPING AND NOISE FROM IMPACT WRENCH.

2

3 REMOVE MOTOR, BELTS AND SHEAVES ORCOUPLING.

3 PINCH POINTS, BACK STRAIN , WRENCHSLIPPING AND NOISE FROM IMPACT WRENCH.

3

4 INSTALL MOTOR BY REVERSING STEPS # 3AND # 2.

4 PINCH POINTS, BACK STRAIN , WRENCHSLIPPING AND NOISE FROM IMPACT WRENCH.

4

5 RETURN TO PRODUCTION AND CLEAN AREA.SIGN AND RETURN PERMIT.

5 NONE. 5

6 6 6

7 7 7

8 8 8




WORK IN PAIRS, LIFT WITH LEGS, SECURE WRENCH AND PULLEVENLY. WEAR PROPER P.P.E.

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. REFR TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.



CHANGE OUT ELECTRIC MOTORS



Written By: CARTER / SCONIERSTOPIC: CHANGING OUT HOT POND WATER

Approved By: ASC


1 CHECK WITH CHIEF OPERATOR. LOCKOUTBOOSTER WATER PUMP AND GET A PERMIT.

1 VERIFY RIGHT PUMP IS LOCKOUT ANDEQUIPMENT.

1

2 REMOVE GUARD AND UNBOLT COUPLING. 2 PINCH POINTS AND WRENCH SLIPPING. 2

3 REMOVE PUMP. 3 PINCH POINTS, WRENCH SLIPPING AND BACKSTRAIN.

3

4 INSTALL PUMP AND REVERSE STEP # 3 AND# 2.

4 PINCH POINTS, WRENCH SLIPPING AND BACKSTRAIN.

4

5 REMOVE LOCKS, CLEAN AREA AND RETURNPERMIT TO CONTROL ROOM.

5 NONE. 5

6 6 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

SECURE WRENCH ON NUT AND PULL EVENLY. WEAR PROPERP.P.E.

SECURE WRENCH ON NUT AND PULL EVENLY. LIFT PROPERLYUSING LEGS AND WORK IN PAIRS. WERA PROPER P.P.E.

HAVE CHIEF TRY START AND STOP SWITCH. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38).

BOOSTER & ONCE-THRU WATER PUMPS

SECURE WRENCH ON NUT AND PULL EVENLY. LIFT PROPERLYUSING LEGS AND WORK IN PAIRS. WERA PROPER P.P.E.

NONE.






1 CHECK WITH CHIEF OPERATOR AND LOCKOUTACID PUMP. INSURE ALL ACID LINES AREDRAINED, CLEARED AND CLEANED. GET APERMIT.

1 VALVES NOT BEING CLOSED, DRAINED ANDACID BURNS.

1

2 GET P.P.E. REMOVE FLANGE COVERS ANDSPOOL PIECES FROM SUCTION ANDDISCHARGE OF PUMP.

2 CUT FROM SHARP EDGES, ACID BURNS, PINCHPOINTS AND WRENCH SLIPPING.

2

3 REMOVE OR DISASSEMBLE PUMP. 3 PINCH POINTS, BACK STRAIN AND WRENCHSLIPPING.

3

4 ASSEMBLE PUMP ASSEMBLY. SPOOL PIECESAND FLANGE COVERS.

4 PINCH POINTS, BACK STRAIN AND WRENCHSLIPPING.

4

5 REMOVE LOCK, CLEAN AREA AND TURN INPERMIT.

5 NONE. 5

6 6 6

7 7 7

8 8 8




WORK IN PAIRS AND SECURE WRENCH AND PULL EVENLY.WEAR PROPER P.P.E.

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN A PERMIT.

SECURE WRENCH AND PULL EVENLY. WEAR PROPER P.P.E.

WORK IN PAIRS AND SECURE WRENCH AND PULL EVENLY.WEAR PROPER P.P.E.

CHANGE OUT & REPAIR ACID PUMPS



Written By: COOK / WING

TOPIC: REPLACE SPINNERApproved By: ASC


1 OBTAIN " TANK ENTRY" PERMIT. LOCKOUTMOTOR, FAN, PLOW DRIVE AND VIBER SCREEN.


2 OPEN DOOR ON SPINNER SEPARATOR ANDREMOVE BELT GUARD AND OIL LINES.


3 REMOVE SHEAVES, BEARINGS AND DRIVESHAFT COVER COLLAR.


4 REMOVE SPINNER BLADES AND SPINNER HUBWITH 1-1/2 TON CHAIN JACK.

4 SHARP EDGES, PINCH POINTS AND BACKSTRAIN.

4

5 REMOVE BOLTS FROM GEAR BOX AND DRIFTGEAR BOX WITH COM-A-LONG.

5 WRENCH SLIPPING, PINCH POINTS AND GEARBOX FALLING.

5

6 REVERSE STEPS # 5 - 4 - 3 - 2. 6 REVERSE STEPS # 5 - 4 - 3 - 2. 6

7 REMOVE LOCKS AND RETURN PERMIT. NOTIFYPRODUCTION.

7 NONE. 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


FIT WRENCH ON BOLTS FIRMLY AND WEAR PROPER P.P.E.

FIT WRENCH ON BOLTS FIRMLY AND WEAR PROPER P.P.E.

SEPARATOR GEAR BOX

WEAR PROPER P.P.E.

STAND CLEAR OF GEAR BOX , WHEN DRIFTING OUT. CHECK ALLLIFTING EQUIPMENT BEFORE LIFTING.

REVERSE STEPS # 5 - 4 - 3 - 2.

NONE.



Written By: REIBSOME / DEAN



1 CHECK WITH CHIEF OPERATOR AND GET HOTWORK PERMIT. LOCKOUT EQUIPMENT IFNECESSARY.

1 HOT PRODUCT FALLING AND LOCKOUT WRONGEQUIPMENT.

1

2 FABRICATE PATCHES AND INSTALL ONCHUTES. POSSIBLE SOME WELDING.

2 FLASH BURN FROM WELDING, HOT AND SLAG.PINCH POINTS AND SHARP EDGES.

2

3 RETURN PERMIT TO CONTROL ROOM ANDCLEAN UP AREA.

3 NONE. 3

4 4 4

5 5 5

6 6 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. (REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38)' SIGN PERMIT.

WEAR PROPER P.P.E.

NONE.

PATCH HOLES IN CHUTES






1 NOTIFY PRODUCTION CHIEF OPERATOR ANDGET PERMIT. RUN ELEVATOR EMPTY.

1 NONE. 1

2 BE SURE ELEVATOR BUCKETS HAVE BEENEMPTIED AND LOCKOUT ELEVATOR. CHECKFIELD SWITCH.

2 WRONG EQUIPMENT LOCKOUT. POSSIBLEMATERIAL STILL IN BUCKETS.

2

3 OPEN DOORS TO ELEVATOR. 3 BACK STRAIN AND PINCH POINTS. 3

4 REMOVE LOCKS AND JOG ELEVATOR INTOPOSITION TO CHANGE BAD BUCKETS.

4 NONE. 4

5 LOCKOUT ELEVATOR. 5 WRONG EQUIPMENT LOCKOUT. POSSIBLEMATERIAL STILL IN BUCKETS.

5

6 USE TORCH TO BURN BOLTS FROM DAMAGEDBUCKETS. REMOVE OLD AND INSTALL NEWBUCKETS.

6 HOT SLAG, PINCH POINTS, AND EYE INJURY. 6

7 REMOVE LOCKS AND NOTIFY PRODUCTIONPERSONAL. RETURN PERMIT TO CONTROLROOM.

7 NONE. 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

REFER TO EMPLOYEE SAFETY BUMPING AND JOGGINGPROCEDURE SECTION (38.4). SIGN PERMIT.


CHANGING ELEVATOR BUCKETS

NONE.

REFER TO EMPLOYEE SAFETY BUMPING AND JOGGINGPROCEDURE SECTION (38.4). SIGN PERMIT.

WEAR PROPER P.P.E.

NONE.



Written By: DEAN / SCONIERS

TOPIC: REPLACE BEARING ONApproved By: ASC


1 CHECK WITH CHIEF OPERATOR. LOCKOUTCONVEYOR AND GET PERMIT. VERIFYCONTROL ROOM AND FIELD SWITCH'S.


2 PICKUP COUNTERWEIGHT WITH COM-A -LONGOR SECURE TAIL PULLEY.


3 REMOVE BEARING AND / OR SHAFTS. 3 PINCH POINTS. 3

4 REPLACE BEARINGS REVERSING STEPS # 3 - 2 -AND # 1 ABOVE.

4 SAME AS STEPS # 3 - 2 - AND # 1 ABOVE. 4


5 NONE. 5

6 6 6

7 7 7

8 8 8




WEAR PROPER P.P.E.

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS



WEAR PROPER P.P.E.

COUNTERWEIGHT, HEAD SHAFT, &/OR TAIL SHAFT




TOPIC: REPLACING HANGING BEARINGApproved By: ASC


1 CHECK WITH CHIEF OPERATOR AND LOCKOUTSCREW. GET PERMIT.


2 REMOVE COVERS AND ENSURE ITS EMPTY. 2 PINCH POINTS AND BACK STRAIN. 2

3 REPLACE HANGING BEARING CONNECTINGSHAFT AND / OR SCREW SECTION.


4 IF BURNING IS NECESSARY. (USING TORCH).BURN OLD BOLTS.

4 BURNS FROM TORCH. 4

5 REPLACE COVERS. 5 PINCH POINTS AND BACK STRAIN. 5

6 CLEAN AREA AND RETURN PERMIT TOPRODUCTION.

6 NONE. 6

7 7 7

8 8 8




WEAR P.P.E. AND WORK IN PAIRS.



JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CONNECTING SHAFTS & / OR SCREW SECTIONS

WEAR PROPER P.P.E.


NONE.



Written By: CARTER



1 CHECK WITH CHIEF OPERATOR AND LOCKOUTFAN. GET PERMIT.

1 LOCKOUT WRONG FAN OR EQUIPMENT. 1

2 UNBOLT AND REMOVE EXPANSION JOINT. 2 PINCH POINTS, BACK STRAIN, SLIPPING ANDFALLING.

2

3 REPLACE EXPANSION JOINTS. 3 PINCH POINTS, BACK STRAIN, SLIPPING ANDFALLING.

3

4 CLEAN AREA AND RETURN PERMIT TOPRODUCTION. REMOVE LOCKS.


5 5 5

6 6 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


WORK IN PAIRS AND WEAR PROPER P.P.E. BUILD SCAFFOLDAND SECURE FOOTING.

WORK IN PAIRS AND WEAR PROPER P.P.E. BUILD SCAFFOLDAND SECURE FOOTING.

CHANGE OUT FAN EXPANSION JOINTS

WEAR P.P.E.



Written By: SOWELL / REIBSOME



1 CHECK WITH CHIEF OPERATOR AND LOCKOUTSCREW. GET A PERMIT.

1 LOCKING OUT WRONG SCREW AND / OREQUIPMENT.

1

2 REMOVE GUARDS AND SCREW HOUSINGDOORS.

2 PINCH POINTS. 2

3 TAKE SCREW HOUSING LOOSE FROMEXPANSION JOINT AND BASE, SLIDEDISCHARGE END NORTH.


4 REMOVE COUPLING AND BEARING FROMSCREW. REMOVE SCREW FROM HOUSING.

4 PINCH POINTS AND BACK STRAIN, POSSIBLECUTS FROM SHARP EDGES.

4

5 INSTALL SCREW BY REVERSING STEPS NO. 4,3, AND 2 ABOVE.

5 PINCH POINTS AND BACK STRAIN, POSSIBLECUTS FROM SHARP EDGES.

5

6 CLEAN AREA AND TURN OVER TOPRODUCTION. SIGN PERMIT.

6 NONE. 6

7 7 7

8 8 8




NONE.

WEAR P.P.E. AND WORK IN PAIRS.

WORK IN PAIRS AND USE (6') PRY BAR TO SLIDE HOUSING. WEARP.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK WITH CONTROL ROOM AND FIELD SWITCH'S. REFER TOWMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

WEAR P.P.E.

WORK IN PAIRS AND USE (6') PRY BAR TO SLIDE HOUSING. WEARP.P.E.

REPLACE VIBRA SCREW



Written By: CARTER / SOWELL

TOPIC: CHANGE OUT HEADSHAFTApproved By: ASC


1 CHECK WITH CHIEF OPERATOR AND LOCKOUTELEVATOR. GET CONFINED SPACE PERMIT.

1 LOCKOUT WRONG ELEVATOR. 1

2 OPEN ELEVATOR AND LIFT COUNTERWEIGHT. 2 PINCH POINTS, BACK STRAIN, OPEN EQUIPMENTAND LOOSE OBJECTS IN ELEVATOR.

2

3 REMOVE GUARDS AND COVERS FROMHEADSHAFT AND DRIVE CHAIN.

3 PINCH POINTS, BACK STRAIN AND SLIPPING. 3

4 SECURE AND BREAK BUCKET CHAIN. BREAKAND REMOVE DRIVE CHAIN. (USING TORCH)

4 PINCH POINTS, BACK STRAIN AND POSSIBLEBURN FROM TORCH OR FIRE FROM TORCH.

4

5 REMOVE BACKSTOP AND BEARING BASEBOLTS. (USING TORCH TO BURN BOLTS).

5 PINCH POINTS, BACK STRAIN AND POSSIBLEBURN FROM TORCH.

5

6 REMOVE HEADSHAFT FROM ELEVATOR. 6 PINCH POINTS, BACK STRAIN AND LOADSHIFTING.

6

7 INSTALL HEADSHAFT REVERSING STEPS # 6, 5,4, 3, AND 2 ABOVE.

7 SAME AS STEPS AS # 6, 5, 4, 3, AND 2 ABOVE. 7

8 CLEAN AREA AND RETURN PERMIT TOPRODUCTION. REMOVE LOCKS.





JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

INSPECT ELEVATOR, BARRICADE AREA, USE TWO 3/4 TON CHAINJACKS TO LIFT COUNTERWEIGHT AND WEAR P.P.E. WORK INPAIRS.

WORK IN PAIRS AND WEAR P.P.E. CATCH OIL, USE OIL DRY IFNECESSARY.

ON ELEVATOR

POST A FIRE WATCH AND WORK IN PAIRS. WEAR PROPER P.P.E.

POST A FIRE WATCH AND WORK IN PAIRS. WEAR PROPER P.P.E.

BEND AT KNEES AND WORK IN PAIRS. WEAR P.P.E.

USE TWO CHOKERS TO LEVEL LOAD AND WORK IN PAIRS. WEARP.P.E.

SAME AS STEPS AS # 6, 5, 4, 3, AND 2 ABOVE.




TOPIC: REPLACE ELEVATOR CHAIN A & BUNSIZED PRODUCTApproved By: ASC


1 CHECK WITH CHIEF OPERATOR. LOCKOUTELEVATOR AND OBTAIN CONFINED SPACEPERMIT. VERIFY START & STOP BUTTON.


2 OPEN ELEVATOR AND LIFT COUNTERWEIGHT. 2 PINCH POINTS, BACK STRAIN, OPEN EQUIPMENTAND LOOSE OBJECTS IN ELEVATOR.

2

3 SECURE CHAIN, (POSSIBLE USING TORCH). 3 PINCH POINTS, BACK STRAIN, BACK STOP NOTHOLDING AND BURNS FROM TORCH.

3

4 BREAK CHAIN, ATTACH NEW CHAIN TO OLDCHAIN. (USE TORCH)

4 BURNING HAZARDS, PINCH POINTS AND BURNSFROM TORCH.

4

5 JOG NEW CHAIN INTO POSITION IN STAGES,SECURE CHAIN DURING REMOVAL OF OLDCHAIN AND CONNECTION OF NEW CHAIN.

5 PINCH POINTS, GETTING CAUGHT IN MOVINGEQUIPMENT, & BACK STRAIN. RUN AWAYELEVATOR, BACK STOP NOT WORKING ANDBURNING HAZARDS.

5

6 MAKE FINAL CONNECTION OF NEW CHAIN. 6 PINCH POINTS, BACK STRAIN, BURNINGHAZARDS, RUN AWAY ELEVATOR AND BACKSTOP NOT WORKING.

6

7 LOWER COUNTERWEIGHT AND CLOSEELEVATOR.



8 PINCH POINTS. 8





WORK IN PAIRS AND WEAR PROPER P.P.E. USE TWO 3/4 TONCHAIN JACKS OR 6' RAILROAD BAR TO SECURE CHAIN. USE ONE3/4 TO CHAIN JACK TO PULL CHAIN TOGETHER FOR



WORK IN PAIRS. STAY CLEAR OF MOVING EQUIPMENT. USE FORKLIFT TO HOLD & PULL OLD CHAIN FROM ELEVATOR. USE TWO 3/4TON CHAIN JACKS OR 6' RAILROAD BAR TO SECURE CHAINDURING CONNECTION & CUTTING. WEAR PROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL BUMPING & JOGGING LOCKOUTPROCEDURE SECTION (38.4). SIGN PERMIT.

INSPECT ELEVATOR, WORK IN PAIRS, USE TWO 3/4 CHAIN JACKSTO LIFT COUNTERWEIGHT AND WEAR PROPER P.P.E.

WORK IN PAIRS, USE TWO 3/4 TON CHAIN JACKS TO HOLD CHAINOR 6' RAILROAD BAR. WEAR PROPER P.P.E.

MIX FEED RECLAIM DRY ROCK & EMERGENCY FEED



Written By: SCONIERS



1 CHECK WITH CHIEF OPERATOR AND LOCKOUTCONVEYOR. GET PERMIT AND FIELD TEST.

1 LOCKOUT WRONG EQUIPMENT OR CONVEYOR. 1

2 LIFT COUNTERWEIGHT OR LOOSEN BELTADJUSTMENTS AND CLAMP OFF BELT.


3 REMOVE GUARDS, CHAIN, AND SPROCKET. 3 PINCH POINTS AND BACK STRAIN. 3

4 REMOVE BEARING BASE BOLTS AND DRIFTHEADSHAFT OUT.

4 PINCH POINTS AND BACK STRAIN. CABLESLIPPING.

4

5 INSTALL BEARING AND DRIFT HEADSHAFT IN. 5 PINCH POINTS AND BACK STRAIN. CABLESLIPPING.

5

6 INSTALL SPROCKET, DRIVE CHAIN ANDGUARDS.


7 REMOVE CLAMP, LOWER COUNTERWEIGHT,AND ADJUST BELT.


8 CLEAN AREA AND TURN OVER TOPRODUCTION. REMOVE LOCK AND SIGNPERMIT.

8 BACK STRAIN. 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


WEAR P.P.E. WORK IN PAIRS AND USE TWO 3/4 CHAIN COM-A-LONG TO LIFT COUNTERWEIGHT.


REPLACE HEADSHAFT ON CONVEYOR

WORK IN PAIRS AND USE TWO 3/4 TON JACK TO DRIFTHEADSHAFT. CONNECT THE TWO LIFTING CABLES TOGETHERPARALLEL TO HEADSHAFT TO KEEP CABLES FROM SLIPPING OFFSHAFT. WEAR P.P.E.

WORK IN PAIRS AND USE TWO 3/4 TON JACK TO DRIFTHEADSHAFT. CONNECT THE TWO LIFTING CABLES TOGETHERPARALLEL TO HEADSHAFT TO KEEP CABLES FROM SLIPPING OFFSHAFT. WEAR P.P.E.



WEAR P.P.E AND WORK IN PAIRS.






1 CHECK WITH CHIEF OPERATOR AND GET APERMIT. LOCKOUT LINES AND VALVES.

1 WRONG LINE OR VALVES LOCKOUT. 1

2 DOUBLE BLOCK AND BLEED. LOOK FORSAFETY SHOWER AND INSPECT.

2 PUMP STARTING, VALVES OPEN, ACID UNDERPRESSURE IN LINE WHILE BEING OPENED, BACKSTRAIN AND PINCH POINTS.

2

3 BARRICADE AREA AS NEEDED IT. 3 GET COVER WITH ACID OR SLIPPING. 3

4 REPLACE ACID LINE. 4 BACK STRAIN AND PINCH POINTS. 4

5 REMOVE LOCKS, CLEAN AREA AND TURN INPERMIT TO PRODUCTION.

5 NONE. 5

6 6 6

7 7 7

8 8 8





NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK WITH OPERATOR MAKE SURE THE CORRECT LINES ANDVALVES ARE LOCK. REFER TO EMPLOYEE SAFETY MANUALLOCKOUT PROCEDURE SECTION (38). SIGN PERMIT.

CHECK CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). CHECK FOR EYEWASH AND SHOWER IN AREA. WORK INPAIRS AND WEAR PROPER P.P.E. HAVE A FRESH WATER HOSEON JOG WHEN NECESSARY AND BREAK LINE AWAY FROM YOU.

WASH UP AREA AND WEAR PROPER P.P.E.

CHANGE OUT OR REPAIR ACID LINES OR VALVES



Written By: LANEY / SHARP



1 LOCK OUT BOTH INNER AND OUTER CAGE MILLDRIVES. GET A PERMIT.

1 PLACE LOCKS ON WRONG MILL DRIVES. 1

2 REMOVE BELT GUARD COVER. 2 PINCH POINTS FOR HANDS AND FINGERS. BACKSTRAIN.

2

3 LOOSEN AND SLIDE MOTOR FORWARD.REMOVE OLD BELTS FROM SHEAVES ANDGUARD.

3 WRENCH SLIPPING AND PINCH POINTS. CUTTINGHAND WHEN REMOVING OLD BELT.

3

4 INSTALL NEW BELTS. 4 PINCH POINTS. 4

5 ADJUST MOTOR TO PROPER BELT TENSION.TIGHTEN BASE BOLTS ON MOTOR.

5 PINCH POINTS. 5

6 REINSTALL GUARD COVER. 6 BACK STRAIN WHEN LIFTING. PINCH POINTS FORHANDS OR FINGERS. SLIPPING.

6

7 REMOVE LOCKS AND TURN IN PERMIT. 7 NONE. 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK WITH CHIEF OR OPERATOR TO TRY CONTROL ROOM ANDFIELD SWITCH. REFER TO EMPLOYEE SAFETY MANUAL LOCKOUTPROCEDURE SECTION (38). SIGN PERMIT.

WATCH FOOTING TO AVOID SLIPPING & HURTING BACK ORHANDS. DO NOT TWIST & BEND WITH KNEES, NOT BACK. STAYAWAY OF PINCH POINTS AND WEAR P.P.E.

STAY AWAY OF PINCH POINTS AND USE LOCK BLADE KNIFE IFTHE BELT GET ALL TANGLE. STAY ALERT OF POSITION OF HANDSAND KNIFE BLADE AT ALL TIMES. WEAR P.P.E.

CHANGE CAGE MILL BELTS

BE AWARE OF WHERE FINGERS AND WEAR P.P.E.

BE AWARE OF WHERE FINGERS AND WEAR P.P.E.

WATCH FOOTING TO AVOID SLIPPING & HURTING BACK ORHANDS. DO NOT TWIST & BEND WITH KNEES, NOT BACK. STAYAWAY OF PINCH POINTS AND WEAR P.P.E.

NONE.




TOPIC: REPLACING BEARINGS ONApproved By: ASC


1 CHECK WITH CHIEF OPERATOR AND LOCKOUTSCRUBBER FAN. VERIFY THE START AND STOPBUTTON. GET A PERMIT.

1 IMPROPER LOCKOUT PROCEDURE OR WRONGEQUIPMENT LOCKOUT.

1

2 REMOVE GUARD, BOLTS, SHEAVES, OIL LINES,SIGHT GLASSES AND GREASE LINES.

2 PINCH POINTS. SLIPPAGE AND BACK STRAIN. 2

3 REMOVE BOLTS ON BEARING HOUSING. 3 WRENCH SLIPPING. 3

4 JACK BEARING SHAFT UP 1 1/2 TON COM-A-LONG AND REMOVE BOLTS. REMOVE BEARINGHOUSING FROM SHAFT AND LOOSEN TAPERLOCKS AND REMOVE BEARINGS.


5 INSTALL NEW HOUSING AND BEARINGS. 5 PINCH POINTS AND BACK STRAIN. 5

6 REPLACE BOLTS ON HOUSING. 6 WRENCH SLIPPING. 6

7 REPLACE OIL LINES, SIGHT GLASSES ANDGUARD.

7 PINCH POINTS AND SLIPPING. 7






BEND AT KNEES AND WEAR P.P.E.

WEAR P.P.E.

WEAR PROPER P.P.E.


BEND AT KNEES AND WEAR PROPER P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


CLEAN AREA FOR GREASE AND OIL. WORK IN PAIRS AND WEARPROPER P.P.E.

PLACE WRENCH FIRMLY ON BOLTS.

EQUIPMENT SCRUBBER FAN



Written By: A. W. MOOSE



1 NOTIFY PRODUCTION CHIEF OPERATOR. 1 NONE. 1

2 CLEAN AREA AROUND ADJUSTMENTS BOLTS. 2 HEAT STRESS, BACK STRAINS AND PINCHPOINTS.

2

3 INSPECT KNOCKER WRENCH FOR BURRS ANDCHEK OTHER TOOLS FOR ANY DAMAGE.

3 KNOCKER WRENCH SPLITTING OR BREAKINGPIECES FROM SLEDGE HAMMER ON IMPACT.

3

4 FACE SHIELDS TO BE WORN BY ALL EMPLOYEEIN AREA.

4 CHIPPED STEEL PARTICLES FROM KNOCKERWRENCH AND / OR HAMMER.

4

5 USE DIAL INDICATORS. DO NOT MOVE IN ANYDIRECTIONS MORE THAN .01 INCHES EACHTIME.

5 NONE. 5

6 NOTIFY PRODUCTION UPON COMPLETION ANDRETURN PERMIT TO CONTROL ROOM.

6 NONE. 6

7 7 7

8 8 8




NONE.

WEAR PROPER P.P.E.

NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

WORK IN PAIRS AND KEEP HAND AWAY FROM ANY PINCHPOINTS.

INSPECT KNOCKER WRENCH AND HAMMER BEFORE AND

DURING USE. TOOLS SHOULD BE GROUND SMOOTH.DO NOTTRIM TOOLS WITH TORCH.

ADJUSTMENT OF KILN TRUNNIONS



Written By: MOOSE / SPURGEON



1 LOCKOUT DUST COLLECTOR FAN AND DAMPERCONTROL. GET A PERMIT.


2 REMOVE BOLT, GREASE LINES, ANDEXPANSION JOINTS.

2 PINCH POINTS. 2

3 HOOK CHAIN FALLS TO PADEYES AND RIG. 3 NONE. 3

4 HOIST DAMPER OUT AND HOIST NEW DAMPERIN PLACE.


5 REPLACE BOLTS. 5 PINCH POINTS. 5

6 UNHOOK RIGGING. 6 PINCH POINTS. 6

7 REPLACE EXPANSION JOINT AND GREASELINES.

7 PINCH POINTS. 7

8 REMOVE LOCKS FROM FAN AND DAMEPER ANDRETURN PERMIT.

8 NONE. 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


WEAR P.P.E.

WEAR P.P.E.

REMOVING KILN DUST COLLECTOR FAN DAMPER

USE TAG LINE AND WEAR P.P.E.

WEAR P.P.E.

NONE.

WEAR P.P.E.

WEAR P.P.E.



Written By: MOOSE / GAINEY

TOPIC: START UP COOLERApproved By: ASC


1 CHECK WITH CHIEF OPERATOR AND HAVEOERATOR STAY ON JOB AND BE IN CONTACTWITH CHIEF OPERATOR. GET A PERMIT.

1 NONE. 1

2 BEWARE OF MOVING PARTS. 2 NONE. 2

3 BACK SPRINGS OFF ALL THE WAY. 3 PINCH POINTS AND BACK STRAINS. 3

4 START UP COOLER. 4 NONE. 4

5 ADJUST SPRINGS TO DESIRED TENSION. 5 PINCH POINTS. 5

6 6 6

7 7 7

8 8 8




NONE

WEAR P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

NONE.

NONE.

WEAR P.P.E.

FOR SPRING ADJUSTMENT



Written By: BRITT / COLGATE

TOPIC: "C" KILN- REPLACING AUX DRIVE UNITApproved By: ASC


1 CHECK WITH CHIEF OPERATOR AND OBTAINPERMIT. LOCKOUT "C" KILN AND AUX. DRIVEMOTOR.

1 EQUIPMENT STARTING UP. 1

2 REMOVE GUARD ON GERABOX COUPLING.REMOVE BOLTS / GRID ON KILN SIDE OFGEARBOX.

2 STORED ENERGY ON COUPLING FROM KILNBEING LOADED, PINCH POINTS AND BACKSTRAIN.

2

3 CHECK WITH CHIEF OPERATOR, REMOVELOCKS AND START KILN BACK UP.

3 COUPLING ROTATION AND CLEAN GREASE OFFCOUPLING.

3

4 REMOVE BAD UNIT / UNITS AND REPLACE BADUNIT / UNITS.

4 HEAT FROM KILN AND RIGGING. 4

5 CHECK WITH CHIEF OPERATOR AND LOCK OUT"C" KILN.


6 INSTALL BOLTS / GRID ON COUPLING ON KILNSIDE OF GEARBOX AND REPLACE GUARDS.


7 CHECK WITH OPERATOR TO REMOVE LOCKSAND START KILN UP. RETURN PERMIT.

7 NONE. 7

8 8 8




USE TWO PEOPLE ON GUARD AND WEAR P.P.E.

NONE.

USE PORTABLE FAN AND TAKE BREAKS AS NEEDED. USEPROPER RIGGING AND WEAR P.P.E.

CHECK CONTROL ROOM AND FIELD SWITCH"S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38).

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK CONTROL ROOM AND FIELD SWITCH"S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

BE EXRTEMELY CAFEFUL REMOVING LAST BOLT / GRID FROMCOUPLING. UES TWO PEOPLE ON GUARD AND WEAR P.P.E.

STAND CLEAR AND BACK UP WHEN STARTING KILN.

(DIESEL, MTR, FLUID DRIVE & GEARBOX)



Written By: BRITT / COLGATE

TOPIC: A & B KILNS REPLACINGApproved By: ASC


1 CHECK WITH CHIEF OPERATOR. GET A PERMITAND LOCKOUT DIESEL DRIVE AT DISCONNECTSWITCH.


2 REMOVE GUARD ON UNIT TO BE REPLACE. 2 PINCH POINTS AND BACK STRAIN. 2

3 REMOVE UNIT TO BE REPLACED AND REPLACEUNIT.

3 RIGGING AND PINCH POINTS. 3

4 REPLACE GUARDS / GUARDS. 4 PINCH POINTS AND BACK STRAIN. 4

5 CHECK WITH CHIEF OPERATOR AND REMOVELOCKS AND START AUX DRIVE UP. RETURNPERMIT.

5 NONE. 5

6 6 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


WORK IN PAIRS TO LIFT GUARD AND WEAR P.P.E.

USE PROPER RIGGING AND WEAR P.P.E.

AUX DRIVE UNITS (DIESEL, FLUID DRIVE & GEARBOX)

WORK IN PAIRS TO LIFT GUARDS AND WEAR P.P.E.

NONE.



Written By: STEWARD / STEVENSON


WORK STEP POTENTIAL HAZARDS1 LOCKOUT BOTH INNER AND OUTER CAGE MILL

DRIVES AND CHECK FIELD SWITCH. SIGNPERMIT.

1 PLACING LOCKS ON WRONG MILL DRIVES. 1

2 REMOVE GUARD, BELTS AND SHEAVES. 2 PINCH POINTS, BACK STRAIN, LOOSE FOOTINGAND POOR CONDITIONS.

2

3 REMOVE PEDESTAL BASE BOLTS ANDSEPARATE CAGES.

3 SLIPPING AND PINCH POINTS. 3

4 SUPPORT CAGE WITH OVERHEAD CHAIN FALLAND BURN OF BOLTS. REMOVE CAGE. (USINGTORCH).

4 BURNS, CAGE FALLING SIDEWAYS WHENLETTING DOWN, PINCH POINTS AND SLIPPING INOPENING.

4

5 REMOVE LOCKNUT AND HUB FROM SHAFT ANDMAY NEED A TORCH.

5 BURNS, HUB FALLING IN OPENING AND BACKSTRAIN.

5

6 REMOVE BEARING BASE BOLTS AND SHAFTFROM PEDESTAL.

6 SHAFT FALLING OR SLIPPING AND PICH POINTS. 6

7 INSTALL NEW SHAFT AND BASE BOLTS 7 SHAFT FALLING OR SLIPPING. 7

8 INSTALL HUB AND LOCKNUT. 8 BACK STRAIN, HITTING HAND WITH HAMMER ANDSLIPPING IN OPENING.

8

9 REPLACE CAGE AND BOLT ON HUB. BURN 9 PINCH POINTS FROM CAGE FALLING OVER AND 9 BE AWARE OF PINCH POINTS. WATCH FOOTIN AND WEAR P.P.E.EXCESS THREAD OFF BOLTS USING TORCH. SLIPPING IN OPENING. BURNS FROM SPARKS.

10 PULL CAGES TOGETHER, ALIGN, INSTALL BASE 10 SLIPPING, TRIPPING AND PINCH POINTS. FOOT 10 WATCH FOOTING AND BEAWARE OF PINCH POINTS. WEAR P.P.E.BOLTS AND TIGHTEN. SLIPPING AND PINCH POINTS.

11 REPLACE DUST SEALS ON HOUSING. 11 FOOT SLIPPING AND PINCH POINTS. 11 HAVE AREA CLEANED, DO NOT DROP SIDE PANELS. BE AWARE OFPINCH POINTS AND WEAR P.P.E.

12 REINSTALL SHEAVES, BELTS AND GUARDS 12 PINCH POINTS AND BACK STRAIN 12 BE AWARE OF PINCH POINTS. LIFT WITH LEGS NOT BACK ANDWEAR P.P.E.

13 REMOVE LOCKS AND SIGN OFF PERMITS. 13 NONE. 13 NONE.




HAVE GOOD FOOTING, LIFT WITH LEGS, NOT BACK AND STAYALERT. WEAR P.P.E.

RIG SHAFT PROPERLY AND BE AWARE OF PINCH POINTS. WEARP.P.E.

RIG SHAFT PROPERLY AND WEAR P.P.E.

STAY CLEAR OF CAGE SO IT CANNOT ROLL ON YOU. WATCHFOOTING AROUND OPENING AND WEAR P.P.E.

USE CHAIN FALL ON HUB AND USE LEGS WHEN LIFTING HUB.WEAR P.P.E.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONSCHECK CONTROL ROOM AND FIELD SWITCH'S. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

HAVE AREA CLEANED, BEND WITH KNEES AND NOT BACK. BEAWARE OF PINCH POINTS AND WEAR P.P.E.

HAVE AREA CLEANED AND BE AWARE OF PINCH POINTS. WEARP.P.E.

CHANGE CAGE MILL SHAFT

F



Written By: STAGG / GARGUS / LEE



1 LOCKOUT OUT BOTH INNER AND OUTER CAGEMILL DRIVES AND CHECK FIELD SWITCH. GET APERMIT.

1 PLACING LOCKS ON WRONG MILL DRIVES. 1

2 REMOVE GUARDS, BELTS AND SHEAVES. 2 PINCH POINTS, BACK STRAIN, LOOSE FOOTINGAND POOR CONDITIONS.

2

3 REMOVE PEDESTAL BASE BOLT AND SEPARATEINNER AND OUTER CAGES USING TWO 1 - 1/2TON CHAIN JACKS.

3 SLIPPING AND PINCH POINTS. 3

4 SUPPORT OLD CAGES WITH OVERHEAD CHAINFALL, BURN OFF OLD BOLTS AND REMOVECAGE.

4 BURNS, CAGE FALLING SIDEWAYS WHENLOWERING IT, PINCH POINTS, AND SLIPPING INOPENING.

4

5 HOOK UP NEW CAGE TO THE CHAIN FALL,REPLACE BOLT, TIGHTEN WITH 3/4'' IMPACT,AND BURN OFF EXCESS THREADS.

5 PINCH POINTS FROM CAGE FALLING OVER,SLIPPING IN OPENING AND BURNS FROMSPARKS.

5

6 PULL INNER AND OUTER CAGES TOGETHERAND ALIGN CAGES. INSTALL BASE BOLTS ANDTIGHTEN.

6 SLIPPING OR TRIPPING AND PINCH POINTS. 6

7 REINSTALL SHEAVES, BELTS AND GUARDS. 7 PINCH POINTS AND BACK STRAIN. 7

8 REMOVE LOCKS AND SIGN OFF PERMIT. 8 NONE. 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS


HAVE AREA CLEANED, BEND WITH KNEES NOT BACK. STAYALERT OF WHERE HANDS ARE. WEAR P.P.E.

HAVE AREA CLEANED AND STAY AWARE OF PINCH POINTS.WEAR P.P.E.

CHANGE CAGE MILL CAGES

STAY CLEAR OF CAGE SO IT CANNOT ROLL ON YOU. WATCHFOOTING AROUND OPENING. WEAR P.P.E.

USE PROPER CHOKERS, WATCH FOOTING AROUND OPENING,AND WEAR PROPER P.P.E.

NONE.

WATCH FOOTING AND BE AWARE OF PINCH POINTS. WEAR P.P.E.

BE AWARE OF PINCH POINTS AND LIFT PROPERLY. WEAR P.P.E.






1 CHECK WITH CHIEF OPERATOR AND SPOTBELT. GET A PERMIT.

1 PINCH POINTS. 1

2 LOCKOUT CONVEYOR USING EMPLOYEESAFETY MANUAL LOCKOUT PROCEDURE ONBUMPING AND JOGGING SECTION (38.4).

2 WRONG BELT OR EQUIPMENT LOCKOUT. 2

3 ATTACH NEW BELT TO OLD BELT AND RUNNEW BELT ON TO CORRECT POSITION. CUTTHE OLD BELT FROM THE BOTTOM.

3 PINCH POINTS, SHARP EDGES, AND MOVINGMACHINERY.

3

4 LOCKOUT BELT AND INSTALL BELT CLAMPS ONNEW BELT. THEN PULL TOGETHER.

4 BELT STARTING. COM-A-LONG BREAKING ANDPINCH POINTS.

4

5 CUT AND SPLICE BELT. 5 SHARP EDGES. 5

6 REMOVE CLAMPS, COM-A-LONG, BOARD ANDCUT OLD BELT.

6 WRENCH SLIPPING, PINCH POINTS AND KNIFESLIPPING.

6

7 REMOVE LOCKS AND OLD BELTS. 7 PINCH POINTS. 7


8 NONE. 8


DAVE BAKER JACK BLEDSOE

STEVE COLE MIKE RANGEL

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

STAY CLEAR OF BELT AND SIGN PERMIT.

CHECK WITH CHIEF AND FIELD VERIFY THE CONTROLS. (ON &OFF SWITCH'S).

WATCH HAND AND BODY POSITION. WEAR PROPER P.P.E.

REPLACE OR REPAIR CONVEYOR BELT

CHECK FIELD SWITCHES. CHECK LIFTING EQUIPMENT ANDWATCH HAND AND BODY POSITION. WEAR PROPER P.P.E.

WEAR P.P.E.

WEAR P.P.E. AND STAY ALER AROUNG FORK-LIFT.

WATCH HAND AND BODY POSITION. USE PROPER TOOL FORCUTTING AND WEAR P.P.E.

WEAR P.P.E.



Written By: D. NEAD



1 OBTAIN SAFE WORK PERMIT. LOCKOUTDIVERTER.

1 LOCKOUT WRONG DIVERTER. 1

2 OPEN DOORS AND VISUAL INSPECT. 2 WRENCH SLIPPING AND PINCH POINTS. BUILD-UP FALLING AND PINCH POINTS.

2

3 REPAIR AS NEEDED. 3 PINCH POINTS. 3

4 CLEAN AREA AND RETURN PERMIT. 4 NONE. 4

5 5 5

6 6 6

7 7 7

8 8 8




NONE.

JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

CHECK WITH CONROL ROOM AND FIELD SWITCH. REFER TOEMPLOYEE SAFETY MANUAL LOCKOUT PROCEDURE SECTION(38). SIGN PERMIT.

SECURE WRENCH, PULL EVENLY AND WEAR PROPER P.P.E.

REPAIR DIVERTER GATES

BEAWARE OF SURROUNDING AND WEAR P.P.E.



Written By: D. NEAD



1 OBTAIN HOT WORK PERMIT FROM CHIEFOPERATOR.

1 FALLING METAL AND SPARKS. 1

2 SET UP TORCH AND WELDER. 2 CHECK HOSE FOR LEAKS , LEADS, AND CUT / ORLOOSE CONNECTIONS.

2

3 MEASURE AND CUT PATCH. USING TORCH. 3 HOT MEATALS AND SPARKS. 3

4 WELD PATCH ON CHUTE. 4 FLASH BURN. 4

5 CLEAN UP AREA AND TURN IN PERMIT. 5 BACK STRAIN. 5

6 6 6

7 7 7

8 8 8




JOB SAFETY ANALYSIS

CORRECTIVE ACTIONS

FIRE WATCH AND BARRICADE TAPE WITH DANGER TAGATTACHED AND PROPERLY LABLE.

TIGHTEN FITTING AND TAPE CUT.

WEAR PROPER P.P.E. AND REMOVE ALL FLAMMABLE MATERIALSFROM AREA.

PATCH CHUTES

WEAR P.P.E.

BEND AT THE KNEES AND WEAR P.P.E.

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