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KENNECOTT UTAH COPPER CORPORATION

STANDARD OPERATING PROCEDURE Operating & Safety Document Approval

Effective Date: 11/29/07 Document Number: SMSOP500-0032 Rev: 00

Page 1 of 15 Plant: Smelter

PRINTED COPIES ARE UNCONTROLLED KUC00011.00

PURPOSE:

The purpose of this procedure is to provide instruction on how to obtain approval for the operation and safety document package. This package consists of an SOP and risk analysis, and, if needed, a JSA and/or safety isolation.

This procedure is part of the Critical Linkages Training and Management System series of standard operating procedures used to identify, produce, analyze, review, revise, and control critical safety documents.

These related procedures are listed in the “Additional SOPs” section of this document on page 2.

SCOPE:

Kennecott Utah Copper – Smelter

RESPONSIBILITY:

Operations: Smelter Standard Operating Procedure Writers

HEALTH & SAFETY:

All KUCC Health and Safety Standards are to be considered when developing a standard operating procedure and supporting documentation. These standards can be found on the KUCC intranet.

In addition, any Federal, State, and/or local government health and safety regulations that apply are to be considered.

ENVIRONMENTAL:

All KUCC environmental standards, practices and policies are to be considered when developing a standard operating procedure and supporting documentation.

In addition, any Federal, State, and/or local government environmental regulations that apply are to be considered.

DEFINITIONS & ABBREVIATIONS:

JSA - Job Safety Analysis






MOC -Management of Change

RA - Risk Analysis

SIE - Safety Isolation (from the Safety Isolation Editor)

SOP - Standard Operating Procedure

TRACK – acronym for: Think through the Task Recognize the Hazards Assess the Risks Control the Hazards Keep Safety First in all Tasks

REFERENCES:

P&IDs: N/A

Equipment Number(s): N/A

Risk Analysis: Risk ID# - N/A

Isolation Procedure: N/A

Job Safety Analysis Number: N/A

Additional SOPs and Documentation:

MOC Users Manual aka Management of Change User and Administrator Guide

SMSOP500-0001, Control and Revision Procedures for SOPs and JSAs

Note: This and the following SOPs are part of the Critical Linkages Training and Management System:

SMSOP500-0004, Operation & Safety Document Development Overview

SMSOP500-0024, Identifying a Task for a Standard Operating Procedure (SOP)

SMSOP500-0025, Update P&IDs for Standard Operating Procedures (SOPs) and Safety Isolations

SMSOP500-0026, Evaluate and Revise a Standard Operating Procedure (SOP)






SMSOP500-0027, Developing a Standard Operating Procedure (SOP)

SMSOP500-0028, Standard Operating Procedure (SOP) Review

SMSOP500-0029, Using the Safety Isolation Editor (SIE)

SMSOP500-0030, Developing a Risk Analysis

SMSOP500-0031, Developing a Job Safety Analysis (JSA)

SMSOP500-0033, Using Documentum

SMSOP500-0034, Using the Safety Isolation Browser






PROCESS OVERVIEW:

A critical safety document package approval consists of approvals of the standard operating procedure (SOP) and risk analysis, and the JSA and/or safety isolation if they are needed because of certain conditions in the SOP. The interrelationships between these four (4) documents are depicted below in Figure 1.

Figure 1: Critical Safety Document Package

Where: -- Standard Operating Procedure

-- Risk Analysis -- Job Safety Analysis

-- Safety Isolation (from the Safety Isolation Editor)

The SOP, risk analysis, and JSA (if included) are all "Supporting Documents" to the MOC, and are attached to the MOC for approval routing.

The safety isolation approvals are documented in the Safety Isolation Editor. Safety isolation approvals are not performed in the MOC, but the attachment of the Isolation Data Sheet to the MOC is strongly recommended for future reference.






Frequency: Use this procedure when all operating and safety documents (SOP, Risk Analysis, and, if needed, JSA and/or Isolation Data Sheet) are ready for final approval and entry into Documentum. The Safety Isolation approval, which is done in the Safety Isolation Editor, is included in this procedure.

Estimated Completion Time: One (1) hour to enter "Supporting Documents" into MOC system.

Introduction:

SOP, risk analysis, and JSA approval authority and routing are automatically determined by the Impact Level subroutine in the MOC program. This program is located in the KUCC intranet. See Figure 2 below for the MOC intranet link.

Figure 2: MOC on the KUCC Intranet

MOC intranet link






For MOC and Impact Levels details see the MOC Users Manual and MOC Impact Levels document links in the KUCC intranet. See Figure 3 below.

Figure 3: MOC Document Links

MOC document links






Safety Isolation approval authority is contained in the Safety Isolation Editor (SIE). Safety isolations list the "Created By," "Walkdown - Completed By," and "Isolation - Approved By", in their respective fields, in the "Edit Safety Isolation" window and the Isolation Data Sheet. See Figures 4 and 5 below.

Figure 4: Edit Safety Isolation Window - Approval Input Fields.

Approval input fields






Figure 5: Isolation Data Sheet Approval Fields

These two (2) programs, the MOC and SIE, constitute the total approval mechanism needed to submit the critical safety document package for entry into Documentum.

The following procedure is an instruction on how to attach the individual critical safety documents (SOP, Risk Analysis, JSA, and Isolation Data Sheet) to an MOC for approval routing.

Approval fields






PROCEDURE:

Walkdowns

1. Obtain hard copies of all the documents in the Critical Safety Document package after SMSOP500-0028, Standard Operating Procedure (SOP) Review was performed. This should include the SOP and Risk Analysis, and the JSA and/or Isolation Data Sheet if applicable.

2. Perform an equipment walkdown to confirm that all the conditions and the "As Found", "Proposed", and "Implemented" procedural and engineering changes, called out in the SOP, Risk Analysis, JSA, and Safety Isolation, are provided for by the equipment and work environment as needed in the SOP PROCEDURE.

Note: It is very important to determine if all conditions are present in the field to provide for the exact execution of the procedure. All safety controls called out in the SOP, Risk Analysis, and JSA that are associated with the equipment and work environment should be in place, or will be brought into place, when the PROCEDURE is performed for the first time.

If the engineering and/or procedural changes needed for correctly performing the SOP and related procedures are not in place, DO NOT proceed with this approval process until they ARE IN PLACE, or will be brought into place, before the commencement of the SOP PROCEDURE.

Note: If engineering changes are needed, consult with the engineering, operations, maintenance, safety, and environmental departments, as needed, on operational, process, equipment, and implementation issues.

Isolation Safety Data Sheet (SIE)

3. Walkdown the safety isolation procedure, if applicable, with the isolation approver and copies of the Isolation Data Sheet and SOP. Check for the accuracy of the isolation procedure in providing instructions to prevent the release of all hazardous energy and material, and in providing safe conditions while performing the task as described in the SOP.

4. When the conditions in Step 3 are met, left click the "Isolation Created" input box in the "Edit Safety Isolation" window, in the SIE, for the isolation previously walked down. Your name should appear in the adjacent data field. See Figure 6 on the next page.






Note: If the isolation was created on a different date that appears in the adjacent date box, use the attached date pull down menu button to change the date.

Note: If a different person than you created the isolation, use the "Created By" personnel pull down menu button to select that person.

Figure 6: Isolation Created

5. Repeat Step 4 for the "Walkdown Complete" and "Isolation Approved" Completion details boxes with the correct dates and personnel that apply to these functions.

6. Enter the "Approval Expires" date or "Expiry (days)," if applicable, or left click the "set to default" bar if a "none" entry is desired.

Note: These expiration date input controls are logically connected.

"Created By" personnel pull down menu button Step 4, Left click "Isolation Created" input box

Created date pull down menu button






7. Left click the "Edit Safety Isolation" window "Save" bar when you're done with the "Completion details." It's located in the lower right hand corner of this window.

8. Left click on the "Reports..." blue print located in the upper left hand corner of the "Edit Safety Isolation" window. A "Select Report" window will now appear. See Figure 7 below.

Figure 7: Select Reports

9. Left click the "Isolation Data Sheet" print in the "Select Report" window. This print will 'blue highlight.'

10. Left click the "Ok" bar at the bottom of the "Select Report' window. The Isolation Data Sheet will now appear.

Step 8, Left click "Reports..."

Step 9, Left click "Isolation Data Sheet"






11. Left click the Export Report icon located on the upper tool bar of the "Report Viewer" window. An "Export Report" window will appear. See Figure 8 below.

Figure 8: Export Report

12. Left click the "File name:" data input field, so the typing cursor appears here, and type in the alpha-numeric document number and title of the isolation procedure, "SMISOXXX-YYYY - (and the SOP title as it appears in the SOP title block)".

Example: An Isolation Data Sheet for standard operating procedure SMSOP551-0917, Seal Lip Cleaning, Pneumapress would get a file name "SMISO551-0917 - Seal Lip Cleaning, Pneumapress".

Step 11, Left click Export Report icon






13. Confirm that the "Adobe Acrobat (*.pfd)" resides in the "Save as type:" data input field of the "Export Report" window.

14. Search for and enter the folder of your choice that will contain this file in the "Save in" data input field of the "Export Report" window.

15. Left click the "Save" bar located in the bottom right hand corner of the "Export Report" window. The "Export Report" window will disappear. Close or minimize all SIE windows.

Attaching Documents to the MOC for Approval Routing

16. Follow MOC procedures to attach the SOP, JSA, and Isolation Data Sheet to the "Supporting Documents" bar shown below. Left click this bar and follow the prompts to guide you thought the attachment process.

"Supporting Documents" attachment bar

Figure 9: Supporting Documents Attachment






17. Follow MOC procedures to attach the Risk Analysis, in Adobe Acrobat (*.pfd) format, to the "Risk Assessment" bar shown below. Left click this bar and follow the prompts to guide you thought the attachment process. See MOC Users Manual aka Management of Change User and Administrator Guide for details.

Figure 10: Risk Assessment Attachment

18. Route the MOC for approval per the MOC Users Manual.

19. When all approvals are met, perform a "Check Off" and "Post Audit" per MOC procedures. Left click these bars and follow the prompts to guide you thought these processes. See Figure 10 above.

20. Route the approved MOC and Supporting Documents to the Document Control department, for entry into Documentum, per MOC procedures.

"Risk Assessment" attachment bar

Document Control acknowledges receipt of documents

"Check Off" & "Post Audit"






21. Check to see if the Document Control received the documents in good order. See Figure 10 on the previous page.

22. Confirm the document package is in Documentum. Inform operations the SOP and supporting documents are approved and ready for implementation.

Note: Congratulations, you've completed Critical Linkages Training and Management System series of standard operating procedures.

REVISION HISTORY:

MOC# Description of Change Prepared By Date

SM05170 New Standard Operating Procedure. Procedure formatted, numbered, and linked with other critical safety documents.

D. Petersen 10/15/07