Ingot

Summer 2014BC OperationsPrimary Metal

8 A trip down memory lane

2 Celebrating 60 years

1 9 5 4 - 2 0 1 4BC OPERATIONS

w

Summer 2014Volume 60 / Number 01

IngotTable of contents

PUBLISHERColleen NyceMember of International Associationof Business Communicators

EDITORKatherine VoigtMember of the Canadian Public Relations Society

CONTRIBUTORSDwight Magee, CAPAStephanie HanlonHilary Zornow

DESIGN AND PRODUCTIONNorthern Sentinel, Kitimat, BC

Ingot is published quarterly byRio Tinto Alcan – BC Operations

You can also visit us atwww.riotintoalcaninbc.com

Ingot editor:Phone: 01 250 639 8241Email: katherine.voigt@riotinto.com

The submission deadline for theFall 2014 issue is31 September 2014.

Please note that photographs intended for publication must be at 300 dpi at the size they will be printed. Please set your camera for the highest possible resolution. Hard copy photos submitted via internal mail will be scanned and returned.

Publications mail agreementNo. 40052381

Return undeliverable Canadianaddresses to:Rio Tinto Alcan - BC OperationsCommunications1 Smeltersite RoadP.O. Box 1800Kitimat, BC V8C 2H2Email: katherine.voigt@riotinto.com

Ingot uses 431kg of paper, whichhas a post-consumer recycled percentage of 10 per cent. The paperselection preserves one tree forthe future, saves 1,284 litres ofwastewater fl ow, and conserves 565,461 BTUs energy.

Ingot is printed onFlo Elementalchlorine free paper with a10 per cent post-consumerrecycled fi ber.

3 Briefs Alfred Barrios visits with Rio Tinto Alcan’s employees/Making the grade/Relay for Life

4 The facts about handover

6 Saying goodbye to Line 5

8 A trip down memory lane

10 Building a community

12 Historic milestones

Cover photo

Did you know that on 29 January 2014 the last pot at BC Operations was started? Pot number 49 in Line 3A is the last pot to be put into operation in this, our last full year of operations at the existing smelter.

Shown on the cover is Manuel Matos, who began his career with BC Operations in Line 3, 37 years ago. His last day of work before retiring was the same day the last pot was started.

Another big change? Since the photo was taken half-face respirators were phased out in the Lines earlier this year and full face masks are now mandatory.

Celebrating 60!

For Rio Tinto Alcan media releases,visit www.riotintoalcan.comFor LME updates visit www.lme.co.uk/aluminium.asp

The years 1954 to 2014 have offered six decades of excellence in aluminium production for BC Operations. Throughout this special year, we will be celebrating our accomplishments by honouring the past and

continuing to build our future. Ingot magazine will continue to capture the milestone moments that illustrate our commitment to safe and successful operations, construction and transition for the next 60 years, just as it has for the past 60. We hope you will continue the journey along with us.

In recognition of this unique birthday year, Rio Tinto Alcan will be highlighting the past, present, and future of BC Operations through various community events and special occasions for our employees – past and present. Stay tuned for information on these upcoming opportunities to commemorate our anniversary. See the editor’s note in Blueprint to learn more about how the Ingot and the Blueprint are celebrating the ‘turning of the page’ for our operations through its pages.

1 9 5 4 - 2 0 1 4BC OPERATIONS

w

Summ

er 2014Ingot

3Summer 2014Volume 60 / Number 01

Ingot Rio Tinto Alcan Briefs

Making the gradeOn 5 June, six lucky and hard-working high school graduates from Mount Elizabeth Middle Secondary School were presented with $1,500 scholarships each by general manager of BC Operations, Gaby Poirier on behalf of Rio Tinto Alcan.

Gaby and the BC Operations team are delighted to have been able to contribute to these annual scholarships again in 2014, assisting some of the best and brightest students in the local community achieve their post-secondary goals in a variety of career fields.

Canada DayThis Canada day employees, families, retirees and even our furry friends came out to take part in the annual Canada Day parade.

To kick off celebrations of our 60th year of operations, a special commemorative float was built to pay tribute to the Delta King,

the original floating accommodations during the early construction of the current

smelter.

The float itself could not have been possible without the support of staff and community groups who helped with its construction.

Volunteers from the Kitimat Scouts, Kitimat Gymnastics and students from Mount Elizabeth

Middle Secondary School gave a day out of their weekend to come and help decorate the float.

Left to right: Alfredo Barrios speaking with employees Steve Day and Glenn Lucyk while on a tour of the Garage.

Alfredo Barrios visits BC OpsOn 1 June, Alfredo Barrios, took the reins of Rio Tinto’s aluminium division by becoming the chief executive of Rio Tinto Alcan. Alfredo is pictured here interacting with employees in the Garage while visiting Kitimat Operations for the first time in his new role on 4 July. As part of the transition into his new role, he has been visiting with Rio Tinto Alcan operations worldwide. On 2

July 2014 he made his way to northwest BC to tour both our current operations and the KMP site. Part of his visit was a guided helicopter tour of the entire watershed region and meetings with key stakeholders. Alfredo also took the time to stop and chat with employees while on site. We look forward to working with him as we move forward into this new chapter.

Relaying for lifeThe annual Kitimat Relay for Life was held on Saturday 31 May on a sunny day at the Mount Elizabeth track. Many BC Ops employees participated in their own way by volunteering for a team, donating to the cause, or taking part in the variety of activities during the family event. A gate collection was held by the Rio Tinto Alcan and Unifor Local 2301 teams to fundraise for the event by collecting generous financial donations from employees upon entering the plant gates. This alone yielded $ 3,065.60. A special thank you goes out to all of the employees who contributed in some way to the important cause - great work everyone!

Handover and tagging process4

Summ

er 2014Ingot The facts about handover

As construction ramps up and pieces of the new smelter are completed, many may think that it will be as simple as handing over the keys. But there is much more to this process than one would think.

Cobus Smith

At left: employees from IS&T and the Central Maintenance pilot team met with general manager, Gaby Poirier, and director of operations, Patrice Bergeron, to discuss KMP readiness during a recent employee roadshow session.

Processes and equipment in the new smelter will be significantly different and much more complex, with a focus on operational precision and a greater scope of work procedures. At the end of the day, the goal is that the new smelter operations will be ready to take on a full load and begin producing top quality product. To do this, a strong focus on the Commissioning and Start-Up (C&SU) procedure for sustaining the future operating plant needs to be in place and expertly managed.

A big part of this process is Cobus Smith, the operational readiness director with Rio Tinto Alcan. A civil engineer by trade, Cobus has over 25 years experience working with aluminium smelters. Originally from South Africa, it was there that he began his career and since then has

travelled across the globe to land here at the Kitimat Modernization Project in 2012.

To fully understand the complexity of the task at hand, we must think of the project in systems. There are currently 360 systems and 253 handover systems. “Systems are construction completed activities and handover systems are completed facilities that are able to produce product,” explains Cobus. The initial systems reach practical completion status only after the construction phase to become handover systems for the commissioning stage. Let’s take a look at the process as a whole.

The first phase of the system handover process is the construction stage. In this stage at KMP, Bechtel is the owner of the systems and has full custody and control. What this means is simply that Bechtel’s rules and responsibilities are in effect. Anyone entering the construction zone must follow those rules.

Summ

er 2014Ingot

5

Passion for ‘Zero Harm’ - Allen Veasey facilitates a risk assessment and HAZOP analysis for one of the hundreds of handover systems with the Carbon Pilot Team. From left to right: Allen Veasey, Thomas Hale, Cobus Smith, Frank Halloway, Joe Velho, Rawuel Gomes, Leonard Eyre.

Once the systems meet mechanical completion in the construction phase, it moves on to pre-commissioning. Again, the contractor will have custody and control of that area and it will be known as a ‘blue tag’ area. Everything under pre-commissioning will be marked with a blue tag.

Upon entering that area, there will be a blue sign with an area contact listed. All visitors who do not have the appropriate induction for that area must check in with this person. Any visitors must follow the rules and regulations set out by the contractor. At this stage systems are able to take on a partial load and the contractor is ensuring that the equipment is completed to design before it reaches practical completion and becomes a handover system ready for commissioning and start-up.

Once handover systems are turned over to Rio Tinto Alcan, it is a ‘green tag’ zone. Once again the owner, this time being Rio Tinto Alcan, has full custody and control. This time visitors must adhere to Rio Tinto

Alcan rules and conditions such as new personal protective equipment (PPE) requirements, new personnel responsibilities and new processes. Once again a visitor who has not completed the required training for that area will have to advise the area contact of their arrival prior to entering the zone.

It is here that equipment is expected to be able to take a full load and be able to produce product. However before the equipment or system is started up, the Operational Readiness team, led by Cobus, must give the formal go ahead. Cobus provides a good analogy to explain this. “Take a car for example. The construction and pre-commissioning make sure that the car is built to design, and the commissioning side makes sure that the operators are trained to drive the car safely. The readiness team makes sure that the car is ready to be driven by the driver.”

“We are the glue that brings those two sides together,” jokes Cobus.

Once commissioning is complete it is time to start-up and begin producing product. The entire process ensures that no stone is left unturned and that BC Operations is able to continue producing the highest quality product for our clients for years to come.

““We are the glue that brings those two sides together,” jokes Cobus.

Construction phaseContractor: Bechtel

Verifi cation phase POVpre-commissioning

Bechtel

Commissioningand Start-up Operation

Ramp upOperation

Milestone:Mechanical Completion (MC)

Milestone:Industrial Completion (IC)

Milestone:Practical Completion (PC)

An illustration of the handover process

Idling of Line 56

Summ

er 2014Ingot

Saying goodbyeto Line 5

On 21 May it was announced that during the week of 16 June, aluminium production in Line 5 would be idled in preparation for the transition to the modernized Reduction area under construction by KMP. This brings mixed emotions to the employees directly impacted by the change - excitement for the modernized operations and some hesitation to see familiar work spaces change.

At left: employees involved in the idling process lock out the area.

An important piece in the idling process is actually shutting off power to the line. Pictured here is Doug Howard, a power system operator with Power Operations, shutting off power to Line 5 at building 205.

At right: employees from D shift after the idling of Line 5 is complete.

Summ

er 2014Ingot

7What this means, is that pots in Line 5 will gradually become available for reallocation to improve performance of the other four potlines. Line 5 is the � rst potline to go inactive in this transitioning process, and a lot of factors were considered in coming to that decision. First and foremost, this choice allows for optimal alignment with the Operational Readiness Plan, and the KMP equipment delivery schedule to support the � rst hot metal milestone expected in the spring of 2015.

So on the morning of 17 June 2014, after weeks of preparation, Line 5 was of� cially idled.

Employees on D shift gathered in the basement of Line 5 to witness the � ipping of the switch. Employees were working hard in preparation for that moment to extract as much hot metal as possible in order to shut off the remaining pots. Everyone involved in the process should be pleased of how safe the entire process was handled. With no incidents to be reported, it was a smooth transition and should serve as a benchmark for the idling of the remaining four lines. Alfredo Barrios, Rio Tinto Alcan’s new CEO, sent his regards and thumbs up for the safe implementation of the idling plan.

Going forward, the remaining potlines will stay in operation and any further decisions to idle production capacity will be based on the rate of progress of KMP construction. When the idling of the next line is announced, we are con� dent that it will be accomplished with the same level of safety as was seen with Line 5.

Kelly Loran, a cell operator who has worked in Line 5 for 38 years, had the honour of � ipping the switch on 17 June 2014. Kelly is one of the longest running employees on the Line and is set to retire in about a year’s time.

A trip down memory lane8

Summ

er 2014Ingot A trip downmemory lane

From Joe FeldhoffI immigrated to Canada via Halifax on 3 March 1955. One week later I arrived in Winnipeg by train and lived there with hundreds of fellow immigrants in the immigration building. I was offered a job underground in a gold mine in Bisset, Northern Manitoba. After one year at work in the gold mine and with $1000 savings I traveled west in search of work more suitable to my profession (I was trained and worked for five years in a bank in Cologne, Germany).

The last stop on my long search was the employment office in Vancouver. I was rejected for work at Alcan because I wasn’t part of a union, at the time I didn’t even know what a union was. I decided to go to Kitimat anyway with a friend I had met in the gold mine. We arrived on 5 May 1956. Our lodging was a room on the Delta King. I was happy to start working for Alcan at an excellent wage of $1.57 an hour as I had only $10 left of my savings.

My first job as a potroom spare had me sweeping passage ways in the lines. From there I was moved to line 2A as a crust breaker. The pay was good but the work was tough in dirt, smoke and heat. About four weeks later I was lucky to get a transfer to an office job as a time keeper with a weekly salary of $65. About three months later I was promoted to head timekeeper.

One year later I transferred to office work in the Remelt department. A few years later I became head clerk responsible for liaison with the head office in Montreal for scheduling of production in our furnaces, selection of aluminium shipments by rail, truck or ships and in charge of the office. Years later I transferred to the purchasing department in the main office building where I was in charge of the office staff who supported the suppliers in addition to all customs related work.

For this special 60th anniversary year, we hope to pay tribute to the men and women who got us here. Part of our history are the personal milestones and memories of our employees – past and present. Earlier this year, we asked a number of retirees to submit their most striking memories of early smelter construction and operations. Here are some of the stories that we received.

When the purchasing department moved into the plant my duties changed to include being a tax specialist which required daily contact with government officials. Looking back I can say I was always very busy and enjoyed my work which required me to visit the head office in Montreal many times, and the eastern smelters in Arvida, Shawinigan, Beauharnois and Isle Maligne.

I met my supportive wife Gertrud in Kitimat and we married in 1959. We had four children, two of which, Mario and Markus, still live in Kitimat.

From Allen PritchardMy brother David and I arrived in Canada from England on 8 May 1955. We sailed from Liverpool to Quebec City on the SS Franconia and were probably some of the last immigrants to travel from England to Canada by boat. We journeyed west by car and after staying with a relative in Courtney, BC for a few weeks we flew to Kitimat in August of that same year. We were both new to flying and it proved a rather hair-raising experience sitting among the mailbags while the plane dodged mountain peaks before finally landing at Minette Bay.

A taxi picked us up at the terminal and we drove to town. After crossing the Haisla Bridge I asked the cab driver where the town was. He jerked his head toward a side window at the mass of construction all around, “this is it,” was his terse reply.

We were taken to a camp where Albatross Street is now and housed in a tent with shower facilities. Another large tent served as kitchen and cafeteria. Male staff served the food at the long tables amid the babble of a dozen or more different tongues of the newly arrived immigrants. A week later we were transferred to Town Site Camp which later became a motel. Bears roamed the camp at night and I was sometimes awakened by the clatter of garbage cans as they searched for anything edible.

Introduction to the reduction lines was a startling experience, with the whine and clatter of pneumatically powered machines, showers of sparks and the glow of molten bath. Overhead, huge mobile cranes spanned

Summ

er 2014Ingot

9

Having a horticultural background, I had visions of owning my own nursery in the future and ordered an assortment of tulips, daffodils and hyacinth bulbs from a company in Holland for delivery to Kitimat. In early September I was notified by customs there was a shipment of Dutch bulbs and duty was due before release. With the help of Bernie Rivest and his pick-up we stashed the smaller crates under my bed at the bunkhouse and the rest in the carpenter shop at Anderson Creek (co-owned by Bernie). I had colour pictures of all the bulb varieties and suitable paper bags to start my sales campaign to the staff houses. The ladies were surprised by such an opportunity but not too eager to buy. The company agreed to a purchase and I set to work planting two large beds in front of the Cafeteria/Hudson Bay store as well as in front of the Smeltersite hospital.

In October, the rains came, and the completion of houses was delayed. The people who were already in their homes had other problems and no concern for planting bulbs. By mid-October only 50% of my bulbs had sold and through an agreement with Gordon Robinson from Kitamaat Village the remainder was sold in three weeks turning the village into a spring garden.

I brought bedding plants in from Smithers via CN Rail and articles from Eddie’s nursery in Vancouver, but the business nose-dived after the local super market opened a garden section. I abandoned my dream of my own nursery when all further expansion of the Kitimat project was stopped in 1957 due to changing market conditions. Thirty feet of snow and heavy rains didn’t help.

I took an early retirement in 1976, built a home in Nanoose Bay and we are happily growing our own vegetables and fruit besides travelling by land, sea and air.

the building and the roar of exhaust fans was constant. My brother and I were placed on a demolition crew of five men, including a gang leader, and used jackhammers to remove carbon linings from the reduction cells that were being replaced. We worked eight hour shifts under a foreman named Don Griffin.

After five months on the demolition crew I was transferred to pot-relining working on a crew with a gangleader named Klaus Muller and shift foreman Charlie Dudy. By that time my brother and I had been transferred to Main Camp where we shared a room in a bunkhouse of seven, enjoying additional facilities including having our hair cut by a barber on the Delta King.

I was present for the opening of lines seven and eight and also witnessed the Carbon Plant fire. My brother was on shift at the time and I was worried until I made contact with him. Sadly, one man died in the fire.

I left Kitimat in 1958 to try farming and logging near Prince George and returned at Halloween 1962. My wife Ursula and daughter Monika arrived just before Christmas that year. I retired from Alcan as a millwright January 1, 1993.

From Fred Lippke“I am taking the old fashioned approach to communication,” writes Fred Lippke who shared his story with us on a delicate parchment, “Email, Twitter, Facebook… leave me unimpressed. I rely on my old, trusty Remington portable [typewriter].” In an age where most human interaction occurs through a computer screen, Mr. Lippke’s typewritten letter harkens back to a simpler time as he shares with us a slice of his life in Kitimat.

I arrived in Vancouver from Germany on 9 April 1954. I was impressed with the Kitimat development, particularly the steady work, well-planned community and basic facilities. On 22 June 1954 I was hired on as a potroom spare.

I was assigned to a bunkhouse and started working. I inspected progress in the town-site and utilized my days off to make some extra money. We painted houses at the smeltersite, unloaded cement barges and stacked lumber at the building supply store. In August I became the proud owner of a house on Partridge Street, it was only a hole in the ground but promised to be ready by October.

From the family of Ernie Archer -In memoriumErnie Archer was always prepared to share stories of his lifetime with Alcan, as it was known when he retired. An active member and steady fixture of the local Royal Canadian Legion, Ernie first came to the shores of Kemano from Montreal. Having served time at sea a new adventure in a far off land was nothing new to the young sailor.

Throughout his career with the company Ernie was a warehouseman, purchasing manager and active safety committee member and newsletter editor. He formed many friendships that he often proudly recounted in his recollections of his time at Alcan. Ernie was passionate about community service and volunteered with community events, dressing up as Santa Claus, acting as a Town Crier and was a proud Cub Scout Akela (Leader).

In a tribute to Ernie, his daughter in-law Nancy remembers her father as a “bright, blue eyed spunky sailor who swept an air force gal off her feet…a hardworking man holding down so many jobs his sons only remember him coming and going…the Alcan purchasing manager catching too many Kemano salmon to fill freezers other than his own…the chatty legion barman peering at you through a haze of blue.”

Ernie was known to be kind and generous and readily had a smile and a Werther’s to share, he was compassionate and actively engaged in discussions and causes he held dear. He will be missed at the Kitimat Modernization Community office where he regularly frequented to say hello and reminisce on his days with the company. Our condolences to his family and friends.

How Kitimat started10

Summ

er 2014Ingot Building acommunity

On 30 December 1950, an agreement between the BC Government and the Aluminum Company of Canada was signed, signaling the beginning of what would be the world’s largest smelter at that time and a new town for northern BC.

Summ

er 2014Ingot

11

Kitimat would become British Columbia’s � rst planned community and one whose focus was ful� lling the needs of the people as a suburban utopia and a stable community for workers. This would be achieved by bringing in renowned American architect and town planner Clarence Stein, along with town planners Mayer & Whittlesey of New York. They chose a green space model, which would separate pedestrian and vehicle traf� c and create “peaceful open spaces, removed from intrusion and hazard by the automobile.”

Many companies were involved in the project, but two housing companies were prominent in the early days of construction – Johnson Crooks and Hullah. They would go on to create the � rst homes

on Oriole, Partridge and Pintail streets. These houses were prefabricated and put together on site to keep with the short timeline for town completion. The very � rst neighborhood that would form was “Nechako” followed by “Kildala” and City Centre by 1956. A portion of the Whitesail neighborhood would follow shortly after. The town was quickly taking shape, and by 1953, Kitimat had become the � rst town in British Columbia to be incorporated without any residents. However, as the smelter’s construction neared its completion, people began to arrive and community growth had begun.

Community spiritFrom its early beginnings, community spirit was thriving in Kitimat, as people from all walks of life were calling the new town their home. Service clubs began to form, such as the Kinsmen, Kitimat Rotary, the Elks and Kiwanis. New residents joined the Royal Canadian Legion, the Nechako Toastmasters, and the Kitimat Business and Professional Women’s Club. By 1955, just a year after the smelter began production, the Kitimat Chamber of Commerce was formed and business was booming in the Nechako and City Centres.

Public events such as concerts, dances, garden shows and sporting events were a prime source of entertainment and socializing. The Aluminum Company of Canada was sponsoring a local sports association, and in no time, soccer and hockey became the preferred competitive sports for the town. The formations of the Rod & Gun Club, the curling rink, and the Kitimat Little Symphony soon followed.

Looking aheadFast forward 60 years later, and we are still a thriving community about to embark on a new chapter in our region’s history. As the 60th anniversary of the smelter takes place, and as the Kitimat Modernization Project steams ahead, it is important to re� ect on how we got here.

Historic milestones

Summ

er 2014Ingot HistoricmilestonesAs the Kitimat Modernization Project mega construction project nears its completion during the 60th anniversary year of aluminium smelting in Kitimat, it can be easy to overlook the many milestones achieved in years gone by. Let’s take a moment to retrace our steps in time and have a look at how we got here.

12

30 December 1950 – After many years of discussion, an agreement between the BC Government and the Aluminum Company of Canada is signed.

1951 – Construction begins on the Kitimat townsite, Kemano and the complex smelter and power generation operations.

1953 – The District of Kitimat is incorporated and the Kemano power tunnel is complete.

1954 – Completion of the Kenney Dam in the Watershed region.

15 July1954 – The � rst power is generated in Kemano.

3 August 1954 – The smelter of� cially begins operations with His Royal Highness Prince Philip, the Duke of Edinburgh, inspecting the � rst ingot.

Kemano Powerhouse

Historic milestonesBlueprint Summer 201412

Commemorating the shutdown of Pot lines 7 and 8 at Rio Tinto Alcan -BC Operations 25 August 2010.

Construction fully begins in2012 with the � rst concrete pour on the KMP Potrooms

1 December 2011 - Rio Tinto Alcan announces full Notice to Proceed

The Rio Tinto Alcan - Haisla Legacy Agreement is signed 5 March 2010

2008 - intentions to modernize are announced in Kitimat

2006Alcan announces conditional plans to modernize the existing Kitimat smelter and increase aluminium production.

2007Alcan contracts Bechtel to complete the Kitimat Modernization Project (KMP) feasibility study.

2007Alcan is acquired by Rio Tinto to become Rio Tinto Alcan.

2010 The Haisla Nation and Rio Tinto Alcan signed a historic 30 year Legacy Agreement that was rati� ed by majority members of the Haisla Nation; the � rst of its kind in British Columbia.

2010Closure and dismantling of Pot lines 7 & 8 take place to allow for new KMP construction.

1 December 2011 Rio Tinto Alcan announces full Notice to Proceed (NTP) for the Kitimat Modernization Project.

March 2014 Delta Spirit Lodge arrives at Terminal B at Kitimat Operations, reliving the history of the Delta King’s role in the original smelter construction.

17 June 2014Idling of Line 5 takes place.

Historic milestones

11

To develop the dam, workers had to gain access by building a 97 kilometre road from Vanderhoof. Once the dam area was cleared a 10 metre horseshoe tunnel had to be created in 470 metres of lime canyon wall with the river diverted through it.

During the development of the dam, a main concern was, and remains today, the habitat of the sockeye salmon. The sockeye are one of five species that call the watershed home. A catch of them would be of greater value than any other salmon species and is by far the most profitable. The fear was that a power outage or shortage on the river may indirectly affect one or more phases of the sockeye’s life cycle. Even after scientist observations showed that the risk was minor, over $400,000 was spent on remedial works.

The project was one of the largest hydro power sites in the world and Kemano was designed to deliver over 1,650,000 horsepower to the Kitimat smelter. It was made more difficult by the rugged terrain and unreliable climate that made construction almost inaccessible and very expensive. Construction included underground excavation for a power tunnel, a conduit system and the installation of the conduit equipment. Careful planning ensured that it would not only be completed on schedule

but it would set a few world records along the way. One record being that almost 30 million work hours were used for the total hydroelectric development and about 70 per cent was devoted to underground work.

To transmit energy from Kemano to the Kitimat smelter was not an easy feat as engineers ran into the same issues– rocky terrain and severe climate conditions. The 82 kilometre transmission line was designed to be uniquely heavy to withstand these conditions and provide the shortest route possible. After many helicopter surveys of the area, it was decided that the Kildala Pass was the best route that would allow suitable tower sites and reasonable access. While this passage would still cross a range of mountains and be at risk for landsides and flash flooding, it was just another of the many obstacles to overcome in this remarkable project.

Now here we are 60 years later doing just as our ancestors did; trying to build the best smelter in the world. We have run into obstacles and hard times, just as they had and like they did, we persevered and pushed to the end. Sure the times have changed, but the passion and drive that they had in 1954 still remains true today.

How it all began

Smelter constructionBlueprint Summer 201410

From onemega projectto another

In 1941, the premier of British Columbia was exploring the possibility of developing hydroelectric power in the northwestern region of the province. Exploiting this energy source was a challenge due to the gigantic development, lack of consumer use and a range of other complications. It would need a massive investment and could not be done without the assurance of a large initial power load.After being delayed by the second World War, the government of British Columbia once again considered introducing the aluminium industry to BC and approached the Aluminum Company of Canada.

Plans were made but there were a number of hurdles to get over in the process from building a town from the ground up to building a wharf. However there were certain challenges that stick out which were groundbreaking feats for that time.

The Kenney Dam was essential for the Kemano power development and it would be at the time the largest of its kind in the world. It raised the water some 91 metres and turned the direction of the Nechako River from east to west.

On 3 August 1954 Prince Philip, the Duke of Edinburgh, arrived in Kitimat to inspect the � rst ingot produced by the Aluminum Company of Canada. The day they imagined during 40 years of discussions and hard work had � nally come to life. But it wasn’t an easy road to aluminium production in BC’s northwest – a true wilderness frontier of its day.

How it all began

09

a retired river paddle wheeler built 30 years earlier in Scotland but assembled in San Francisco. The ship was readily available and arrangements were made to quickly tow the ship to Kitimat. Over the next seven years the ship was home to a rotation of thousands of workers until it was shutdown in 1959 and returned to California where the Delta King now serves as a restaurant and hotel in San Diego.

Today, some 60 years later, history is repeating itself with the arrival in Kitimat of the Silja Festival, ceremoniously redubbed the Delta Spirit Lodge, a passenger ferry recently pulled from service in the Baltic region of Europe and brought to Kitimat to house up to 450 of the 2,900 daily workers to be engaged in building the modernized aluminium smelter.

Kitimat is a relatively small town with a population base of just over 8,000 people. And with a booming economy of several potential developments on the horizon, the community is experiencing an alarming zero vacancy rate. In addition to the approximately 1700-bed capacity of the KMP Construction Village, further

accommodations were needed to support project construction and minimize the impact of the influx of workers to the town.

Solutions had to be found quickly and it was suggested that what worked in the past could still work today so Bechtel, the EPCM of KMP, worked with Bridgemans-Haisla LP, a company specializing in floating accommodations.

A team was formed to investigate finding a suitable ship that was to be readily available and could be brought to Kitimat for about a year to finish off the project. The team consisted of Don Ritchie, Workforce Services manager for Bechtel, and Brian Grange and Andrew Purdy both principals of Bridgemans-Haisla LP.

The team inspected several ships in Mexico, the US and Great Britain but settled on a passenger ferry based in Tallinn, Estonia. Don likened the search for a suitable ship to participating in the Amazing Race. “It was an exhausting but incredible experience,” he said. “In two and half days we traveled to five countries on opposite sides of the ocean. We didn’t even have time to unpack because we slept in airports and on planes.”

The Silja Festival aka Delta Spirit Lodge had all of the amenities needed to act as a temporary lodge in Kitimat and could be available within the short timeframe needed. Arrangements were made to lease the ship with over 550 cabins, several restaurants, a gym and extensive entertainment facilities and sail the ship to Kitimat, which will be her new home for just under a year.

The trip from Tallinn began on28 January and after sailing just over

20,000 kilometres across the Atlantic Ocean and through the Panama Canal, the ship finally arrived in Kitimat on 10 March in the early morning.

According to Aivar Moorus, the 25 year veteran sailor and the captain responsible for bringing the 170 metre vessel to Kitimat, 19 crew members made the trip and during that time work began in earnest to prepare the ship for its new role. The ship hadn’t been used for some time so it required a thorough cleaning and cabin retrofit. The crew encountered a winter storm off the coast of France and Spain, which made it very rough for three days, but the ship handled well.

On arrival in Kitimat, it didn’t take long for the Delta Spirit Lodge to fill up with residents. “The contract with Bridgemans-Haisla LP calls for 450 KMP employees to live aboard and we are almost at that number,” said Don. “There are currently about 60 support staff who do everything from producing close to a thousand meals a day to housekeeping and providing security along with the 19 members of the ship’s crew to supervise and maintain the technical aspects of running the ship. Even though the ship is tied up at dock it has to be maintained,” he finishes.  

For a few residents of Kitimat such as Joe Feldhoff, the arrival of the Delta Spirit Lodge has awakened memories from 60 years ago when Joe as a young immigrant from Germany arrived in Kitimat and moved into the original Delta King. At the recent opening of the Delta Spirit Lodge, Joe was front and center as part of the team who cut the ribbon to officially open the lodge. Joe didn’t have to say anything; the sparkle in his eyes said it all.

Joe Feldhoff

The Delta Spirit Lodge berthed atTerminal B to support KMP construction.

Traditional solution in a modern timeBlueprint Summer 201408

For some of those watching, the ship called the Delta King would be their home for the next two to three years while they helped build the massive new aluminium smelter at Kitimat. Bringing the Delta King to Kitimat was a creative solution back then and it proved to be the foundation for a creative solution today.

Construction began in 1950 on the smelter project, a project that was the largest single investment by a private enterprise in Canadian history. The Kitimat Project underwritten by the Aluminum Company of Canada (precursor

to Rio Tinto Alcan) consisted of building a large earthen dam, a 16 kilometre long tunnel blasted and drilled out of solid rock, an 80 kilometre transmission line over some of the most rugged territory in Northern British Columbia and a massive new smelter at Kitimat. These components coupled with building a town where one didn’t exist before meant that overnight some10,000 workers came to the region to help build the foundation of our company’s success in BC.

Housing that many workers was a challenge as scarce land availability and the logistics of running camps created signifi cant challenges. One of the out-of-the-box solutions that proved to be quite successful was to bring a ship to Kitimat and use that as a temporary camp.

Back in the 1950s communication systems were rudimentary so Kitimat contractors sent a team to port cities in Canada and the United States to fi nd a ship that would accommodate up to 400 workers. The team found a suitable vessel in San Francisco in the Delta King,

Memories of a ship from the past are brought back to lightIt was a dreary spring afternoon back in May 1952 when a number of construction workers stood ankle deep in mud and gazed out in the harbour as a tug boat arrived pulling a riverboat paddle wheeler – a rather unusual site for this part of the world.

The Delta King on the Douglas Channel shore during 1950s construction.

Of� cial ribbon cutting ceremony on the new Delta Spirit Lodge. Left to right: Brian Grange, chief councillor Ellis Ross, Brent Hegger, hereditary chief Jasee Sammy Robinson, Gaby Poirier, and Joe Feldhoff.

07

To accommodate the new configurations of the smelter footprint in the post-modernized BC Operations, a new fire truck had to be acquired to provide ease of access in the event of an emergency to the many points of entry in which the existing fire response vehicle will not be able to fit or maneuver through. On 15 May, the shiny new fire engine arrived at Main Gate for its delivery and immediately the formal handover process between KMP and BC Operations began, as did a training session for members of the Plant Protection department in order to familiarize themselves with the new equipment and learn to adapt their fire response techniques to take full advantage of the new features that the truck has to offer. This included spray testing of the new

Ray Nicklas

Fire response training exercise

ground liner and nozzle extensions at the south end of Terminal B, as well as a full run-through of the electrical and mechanical pump features by a Hub Firetrucks representative, who supplied the vehicle.

Ray Nicklas is a long time maintenance employee with Kitimat Operations and was figuratively in the driver’s seat during the parallel handover and commissioning process. As part of the central maintenance pilot team, it was his role to help ensure that the new fire truck systems meet specification and that the vehicle was fully functioning prior to signing off on its acceptance from Bechtel.

successful together,” said Keith. Phil would also like to “leave a legacy so that operations will welcome us back.” They feel that this can be accomplished through high involvement of both operations and key stakeholders, clear lines of communication and listening to what others have to say. Feedback from the workforce, clients and the community are important factors as they try to complete the job.

Where teamwork begins.We asked them what they thought were the reasons that they work so well together. Phil states it’s because they both have such similar values. “We like to build organizations of trust based on respect for people.”

Keith adds that it’s because they have a passion for people, and making sure everyone is treated fairly and equally, that they are able to complete any projects with a degree of success. Ultimately, it is the strong trust and unwavering respect for one another that make them such a winning team.

Fire response –a story of modernization

In one way or another, modernization applies to all aspects of our operations at the Kitimat plant. Plant

Ray, both participant and spectator to the combination tagging process and training session, was pleased with putting his planning work into practice and seeing the results of the pilot team’s lead-up efforts come to realization that day for one of many new machines arriving at the smelter site.

Protection and the systems and equipment it relies on to maintain BC Operations’ security and respond to emergency incidents are a key component.

Winning teamBlueprint Summer 201406Both men have had extensive experience and have worked on over four projects together through their careers - worth over $12 billion combined – in the bauxite, alumina and aluminium industries. After the success of working together on the Yarwun 2 alumina refinery in Australia, it was time to bring them back together one more time in Kitimat. But what was it about Yarwun 2 that made it so successful?

They say it was due to upfront preparation over 18 months prior to project start, which focusses on creating alignment with common goals, team building and precise budget planning. Phil states that strong communication, transparency and a “can do” attitude were also major contributors to the project’s success.

So what are their goals for the Kitimat Modernization Project?A big focus for them will always be safety. “We won’t be a success if we hurt people,” says Phil. Their major goal is to decrease the number of incidents and promote an even stronger focus on safety on the work site.

In addition to safe delivery, Keith states that his goals are to complete everything on time and on budget, and for everyone to go home at the end of the day enjoying their work on the project. They share a strong ‘one team’ vision – “we can only be

Keith Nugent, KMP project director with Rio Tinto, has worked in major construction for years, with 32 at Rio Tinto. He has worked all over the world, including Australia, New Zealand, and Malaysia.

A winning combination Keith Nugent at left, and Phil Newsome at right.

Yarwun 2 alumina refinery, Australia

Phil Newsome, KMP project director with Bechtel, has spent 37 years in engineering and construction and the last 20 years with Bechtel.The next chapter in their careers has just begun on KMP.

The crew at the Anode Bake Furnace stops for a photo to mark the completion of brick installation.

The transition from construction to modernized operations is happening at an incredible pace. The aerial map of the construction area illustrates just how much progress has taken place. At approximately 70% complete at the time of print, KMP is well on its way to delivering the legacy of world-class aluminium smelting technology we have been waiting for.

Recent milestones include the construction completion of the Carbon Control room and completion of Anode Bake Furnace (ABF) refractory brick installation work. At over 3 million bricks in the ABF alone - no small feat!

The daily site population is now at peak with approximately 2,900 people on site per day contributing to construction.

Operations is also now fully engaged in transition and system acceptance work. To date, we have already received some of the new smelter’s equipment, including:

• Pot Tending Assembly (PTA) Simulator

• MV Substation - Cathode sealing

• Temporary crucible cleaner

• Bath Tapping vehicles16

KMP Progress Update 05

Cathode sealing

Blueprint Summer 201404

KMPprogressupdate

The Kitimat Modernization Project - 27 June 2014

1) Potroom A 2) Potroom B 3) Potroom C 4) Potroom D 5) Electrical substation 6) Anode rodding shop 7) Anode handling &

storage 8) Anode bake furnace 9) Cathode sealing shop 10) Pot Tending Assembly

maintenance shop 11) Compressor room

12) Busbar corridor 13) Casthouse C 14) Reduction of� ces 15) Cafeteria /

shower room 16) Alumina silo 17) Lining / Delining

ship 18) Gas treatment

centre east 19) Anode pallet

storage building 20) Anode paste plant

Legend

Legend 1) Potroom A 2) Potroom B 3) Potroom C 4) Potroom D 5) Electrical substation 6) Anode rodding shop 7) Anode handling & storage 8) Anode bake furnace 9) Cathode sealing shop 10) Pot Tending Assembly maintenance shop 11) Compressor room 12) Busbar corridor 13) Casthouse C 14) Reduction offices 15) Cafeteria / shower room 16) Alumina silo 17) Lining / Delining shop 18) Gas treatment centre east 19) Anode pallet storage building 20) Anode paste plant

111

17

2

14

10

13

18

19

67

8

34

5

16

9

12

15

20

The Kitimat Modernization Project - 27 June 2014

11

1

12

4 3 2

5

20

9

17

10

14

13

1519

678

18

03Blueprint summer 2014

Allen Veasey

KMp builds a cureA prize was given to the team for their significant contribution - a trip for four on Via Rail to go to Prince George – but the team in turn thought it best to give it back to the Canadian Cancer Society so it can be used for Kitimat cancer patients to travel to the Prince George clinic for treatments.

Since KMP started supporting this cause in 2009, the Kitimat KMP Builds a Cure team has raised $124,401.

Outstanding efforts everyone! 

A big thank you goes out to all who participated, volunteered, and donated to the KMP Builds a Cure team for the annual Relay for Life fundraiser. KMP’s results are quite impressive. 

This year alone, $43,225 was raised.  

Due to the generosity of the team, KMP Builds a Cure came in first place for the local Relay for Life fundraising efforts and was also recognized as one of the top five fundraisers across Canada. 

The Kitimat Fire Mountain Shooting Range required expanding to accommodate the increase of new users. The clubhouse was relocated from Rio Tinto Alcan property (now sand and salt storage) and redeveloped in 2009/2010 with the assistance of Rio Tinto Alcan, the District of Kitimat, federal funding, local business and volunteers. The site’s popularity has continued to grow and at times had become crowded, producing wait times and potential safety concerns.

The Kitimat Fire Mountain Shooting Club determined expanding was the only option and applied for federal funding which the District of Kitimat (DOK)

committed to match. The grant was not obtained but the DOK stayed committed to the project. The club then sought local and visiting businesses and contractors to make up for the shortfall to complete the expansion project.

These businesses stepped up in a big way: Viking Construction, Western Industrial Contractors (WIC), Lapointe Engineering, Kitimat Iron & Metal Works, Harris Rebar, Glacier Concrete, McElhanney

KMp contractors assist with local recreation infrastructure expansion

Meet … John StaatsA seasoned fisherman and skier, John Staats enjoys making the most of life outdoors. Currently based in Kitimat, John is working on the Kitimat Modernization Project as manager, Health, Safety, and Environment (HSE).

What does your job entail?My primary responsibility is to ensure that safe, environmentally acceptable working methods and practices are implemented across all KMP construction activities conducted by the engineering, procurement, and construction management (EPCM) and contractors.

What’s the best part of your role?The best part of my role is that the only constant is change. Projects present new challenges every day and there’s never a dull moment. And the people! HSE management is an extremely social role and I get to meet people from all over the globe that love sharing their experiences.

Engineering, Stelcon Industries and Local 97 Iron Workers Clyve Thiebold, Richard Norman, and Vince Toth of Coastal Mountain Crane. The iron workers kept coming out until the steel was up.

The expanded facility will accommodate current and future users leaving a first class recreation facility as a legacy of KMP. The Kitimat Fire Mountain Shooting Club wants to thank all businesses and volunteers for their contribution.

BlueprintpuBlisherColleen NyceMember of International Associationof Business Communicators

eDiTOrKatherine VoigtMember of Canadian Public Relations Society

COnTriBuTOrsDwight Magee, CAPA Jason VinesValerie McCainAli Al-HamawandyStephanie HanlonNicolas Waterhouse

Design anD prODuCTiOnNorthern Sentinel, Kitimat, BC

Kitimat Modernization projectBlueprint is published quarterly byrio Tinto alcan – Kitimat Modernization project

You can also visit us atwww.riotintoalcaninbc.com, orwww.kitimatworksmodernization.com

Kitimat Modernization project Blueprint editorTel: 01 250 639 8241email: katherine.voigt@riotinto.com

The submission deadline for the next issue is30 September 2014.

Please note that photographs intended for publication must be at 300 dpi at the size they will be printed. Please set your camera for the highest possible resolution. Hard copy photos submitted via internal mail will be scanned and returned.

Publications mail agreementNo. 40052381

return undeliverable Canadianaddresses to:Rio Tinto Alcan - BC OperationsCommunications1 Smeltersite RoadPO Box 1800, Kitimat BC V8C 2H2Email: katherine.voigt@riotinto.com

Kitimat Modernization project Blueprint uses 431kg of paper, whichhas a post-consumer recycled percentage of 10 per cent. The paperselection preserves one tree forthe future, saves 1,284 litres ofwastewater flow, and conserves565,461 BTUs energy.

Kitimat Modernization project Blueprint is printed onFlo Elemental chlorine free paperwith a 10 per cent post-consumerrecycled fiber.

Issue 11 Summer 2014

COVER PHOTO: The Silja Festival, redubbed the Delta Spirit Lodge, arrives at Terminal B in the early hours of 10 March to join the Kitimat Modernization Project.

Celebrating 60 -a new format for a new era

Briefshead officepays a visit From 13 to 16 May, Hugo Bague, group executive for organisational resources with Rio Tinto’s head office in London, came to visit operations in Kitimat.

During his visit, Hugo toured the smelter operations, the KMP site and visited with our pilot teams at the KMP Centre for Learning @ Roy Wilcox.

Pictured here is Hugo testing out the new simulator designed to train workers on the Pot Tending Assembly (PTA) in the potrooms of the new smelter.

It’s not just another year at BC Operations. We are on the cusp of a new era of aluminium production in BC. It was around this time of year in 1954 that the finishing touches were being put into place in preparation for the start-up of the original Kitimat smelter project. Prince Phillip was on the guest list and completion of the original mega project of its day was in sight for the many construction and operations workers.

Flash forward 60 years and we are in many ways at a point of repeating history for the next generation of aluminium smelting with the Kitimat Modernization Project. Although the first hot metal milestone isn’t expected until the Spring of 2015, much of the transition towards preparing for modernized operations and receiving the new systems will take place in 2014 – not a bad way to celebrate a 60th birthday.

This commemorative year deserves a gesture within the pages of Ingot magazine. Symbolically, we are combining the longstanding publication with its sister KMP publication, Blueprint magazine, for the year to illustrate the handover from current construction to operations. As with aluminium production, Ingot magazine has been with us for 60 years and is turning the page in preparation for another 60 more.

It’s our privilege to share these significant milestones with you through these pages.

Sincerely,

Katherine Voigt EditorIngot and Blueprint magazines

P4 KMP updateP10 Original mega project construction

P6 Delta Spirit Lodge

Issue 11 - Summer 2014Kitimat Modernization Project

1 9 5 4 - 2 0 1 4BC OPERATIONS

PRINTED IN CANADA

PM40052381