Closely Checked Equipment

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					                                                             P H A S E     I I    N E W S L E T T E R

    Volume 3, Number 3                                                                                                                        April 2005

Pre-operational Inspections
Closely Checked Equipment
Installing new equipment compatible with                     ment are handed over to Alouette. The VPO        operation, in places like the potrooms and
existing infrastructure is near the top of                   team makes sure that installed systems           anode plant for instance, requires special
the list of Phase II challenges. The                         correspond to technical drawings, supplier       precautions, which are stipulated in direc-
38 experts who make up the pre-opera-                        manuals and Alouette specifications. In the      tives drawn up further to risk analysis.
tional inspection (“VPO”) team, including                    words of Lévis Villeneuve, who leads the VPO
people from Alouette, SNC-Lavalin/                           personnel assigned to the smelting sector,       Well-planned start-up
Hatch (SLH) and subcontractors, are                          “All of the mechanical, pneumatic, electric,     Even before construction got under way, a
responsible for ensuring equipment com-                      hydraulic and automatic systems and equip-       group of SLH designers and people from
patibility and smooth operations.                            ment are inspected. Once we’re sure they’re      Alouette evaluated available systems and
                                                             in compliance, we deliver them to the cus-       new technologies in order to make the best
Careful inspections                                          tomer.”                                          choices. Collaboration between SLH and
Pre-operational inspections — the logical,                                                                    Alouette for most of the modernization work
essential sequel to construction work — are                  Eliminating risks                                and equipment programming has been one
carried out before new facilities and equip-                 Analyzing, verifying, assisting, monitoring,     of the keys to the success of Phase II. “This
                                                             approving: these are some of the VPO team        approach has greatly simplified coordina-
                                                             members’ daily duties. Certain sectors of the    tion, allowing us to reach the project objec-
                                                             facility are riskier than others and therefore   tives quickly and optimize the start-up of the
                                                             require a more in-depth analysis. New equip-     new facility,” says Sébastien Schlésak, VPO
                                                             ment installed close to equipment already in     director.

                                                                                                              The site has been divided into four pre-operational
                                                                                                              inspection sectors:
                                                                                                              > carbon
                                                                                                              > smelting
                                                                                                              > casthouse
                                                                                                              > general services and high voltage
                                                                                                              The buildings and equipment in each sector are identi-
                                                                                                              fied as “batches.” At the end of the work, 276 batches
                                                                                                              will be have been inspected and handed over safely to

In this Issue
No Room for Risks                                        2

End of Recruitment Period                                3

Did You Know That… ?                                     3
Work in Progress
Delivery of Final Superstructure                         3

Regional Job Creation                                    4

Legal Deposit - Bibliothèque nationale du Québec, 2005
ISSN : 1710-0801
                                                        L A     P L U M E ,      VOLUME 3, NUMBER 3

       No Room for Risks
      Safety measures apply to every type of            The next step consists in preparing the wheels
      activity on a construction site 12 months a       for transportation. Once again, strict security
                                                                                                            Important safety measures:
      year. When the work winds down and peo-           measures are applied. During this work under
      ple start leaving the site, additional safety     the trailer, the unit has to be raised by special   > Wear a harness and lifeline for
      measures are applied during the “demobi-          lifting equipment. A worker makes sure that            work in high places.
      lization” of subcontractors’ trailers.            the rear wheels are blocked and installs two        > Avoid risks related to falling ice.
                                                        wooden cages or levellers at the other end.
                                                                                                            > Use appropriate protective equipment
      Inside . . .                                      The cages or levellers keep the trailer from
      The demobilization work starts inside the         crashing to the ground in the event of a mal-          (gloves, eyeglasses, etc.).
      trailers. First, workers remove all mobile ele-   function of the lifting equipment.                  > Watch out for electrical risks.
      ments (tables, chairs, air conditioning units),                                                       > Work in positions that adequately
      fasten them down or dispose of them ade-          Always the first time                                  protect your back.
      quately in compliance with environmental          “Routine is a cunning enemy. All of the steps
      standards.                                        in this work require absolute vigilance.            > Eliminate Freon in compliance with
                                                        Workers have to do the job as if each time is          environmental standards.
      . . . and out                                     the first time and scrupulously apply a num-        > Be familiar with all environmental
      Before even thinking about towing a con-          ber of safety rules,” says Clifford Cox, a super-      protection measures.
      struction trailer off the site, workers have to   visor with DE-VI CO, the contractor in charge
                                                                                                            > Make sure that all workers are
      remove any ice from the roof in order to          of demobilizing the Phase II worksite.
      avoid “avalanches” during transportation. The                                                            informed about these measures.
      power is shut off and electricians disconnect
      the wires. The trailers are stripped of their
2     stairs, porches and wooden skirting.

    Clifford Cox, DE-VI CO worksite supervisor.

                                                                                                               Jean-Yves Mercier and Yves Lebel busy demobilizing.
                                                      L A     P L U M E ,       VOLUME 3, NUMBER 3

End of Recruitment Period

On April 1st, the Alouette human resources             tions. They set up a selection process involv-     Did You Know That... ?
team put the finishing touches on the                  ing over ten hours of tests and interviews
Phase II recruitment process.                          per identified candidate. All told, they hired      • At the peak of construction on the site,
                                                       340 new employees!
                                                                                                             there were 235 trailers 12-by-60-ft —
With support from supervisors, superinten-
                                                                                                             enough to fill the 232 trailer spots at
dents and managers in all sectors, these               Congratulations for their excellent work!
skilled recruiters have accomplished a great           Alouette also wishes to thank the population          the summer campground at Clarke
deal. Temporarily located in an office in down-        for its interest in the company.                      City, close to the Alouette
town Sept-Îles since February 2003, they                                                                     facility.
received and processed 8,943 job applica-
                                                     Employees take part in training in the new smelter


Work in Progress
Delivery of Final Superstructure
The final superstructure was delivered on the site last month while La Plume was going to press.
The event was a milestone for all workers, particularly the people at Alco-tek. Installed in its final
position, the 330th superstructure is now an integral part of the potroom decor!

Workers and management personnel
from subcontractor Alco-tek and SLH
pose in front of the final superstructure
delivered to the Alouette site.

Gino Moreau, Mario Maltais, Yvon Kim, Daniel
Yockell, Paul Coulombe, Louis Forest and
Claude Bouchard (all with Alco-tek), Martin
Cartier (SLH), Laurent Rogers (Alco-tek),
Sylvain Laramée (SLH), Aurèle Landry (Alco-
tek), Normand Gauthier (SLH), Louis Gagnon,
René Perron, Normand Wilkins and Jean Blan-
chard (all with Alco-tek).
                                                            L A      P L U M E ,        VOLUME 3, NUMBER 3

    Regional Job Creation

    Phase II has generated substantial spin-                Profitable expertise                                Job-creating contract
    offs for the local economy. Just ask Fabnor!            As soon as Fabnor was awarded the contract,         Aluminum-rod production got under way in
    Thanks to an anode-assembly manufac-                    it had to reassess its operations and hire more     September 2004 and will soon be completed.
    turing contract, the Sept-Îles–based com-               employees. It also refitted its shop in order to    Alouette will maintain its business relation-
    pany has been able to prove its expertise               group together all of its personnel assigned to     ship with Fabnor, which already repairs anode
    and hire new personnel.                                 manufacturing aluminum rods, along with the         rods and potshells. A number of welding
                                                            appropriate equipment. In short, Fabnor had         graduates have found jobs in their field with
    Assembled in Sept-Îles                                  to create an assembly line adapted to the           Fabnor, and other personnel have benefited
    To be able to produce aluminum, each of the             technical specifications. Each week, 312 anode      from on-the-job training. Thanks to Phase II,
    new reduction cells has to be equipped with             assemblies are delivered to the site, at the rate   this small Sept-Îles company has enhanced its
    20 electricity-conducting anode assemblies.             of two shipments per day. According to              know-how and created new jobs for workers
    The assemblies are made up of aluminum                  Fabnor general manager Yves-Marie Côté,             in the region.
    rods attached to steel elements and anodes. A           “The expertise that we’ve developed with the
    total of 7,524 new assemblies had to be built           aluminum plant is useful for us today.”
    for Phase II.

                        Steps in manufacturing anode rods at the Fabnor plant in Sept-Îles.


               A Fabnor employee at work.                               Part of the assembly line.

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