A

Alcoa Inc

Intalco Works

National Emission Standards for Hazardous Air 

Pollutants for Primary Aluminum Reduction 

Plants

Anode Bake Oven

Startup, Shutdown, and Malfunction Plan

Issued: Oct. 8, 1999

Current Rev. Date: July 15, 2005
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: i of 13

Controlled Document

Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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ssmp_Bakes_current.doc

Table of Contents

Introduction ................................................................................................................... 1

SSM Plan Requirements ............................................................................................. 2

Start-Up/Re-Start Baking Furnaces ............................................................................. 4

Shut-Down of Baking Furnaces ................................................................................... 5

Malfunction and Corrective Action Plans ................................................................... 7

Malfunction and Corrective Action Plan Procedure Documentation ............................ 7

High Flow of Process Gas ........................................................................................... 8

Visible Emissions - Dusting Stack(s) ......................................................................... 10

Loss of Parametric Monitoring Signals ...................................................................... 11

Catastrophic Failure of Emission Control Equipment ................................................ 12

Revision Summary...................................................................................................... 13

Appendices.................................................................................................................. 14

Startup, Shutdown, Malfunction / Operating Limit Exceedance Report: Potlines and 

Bake Ovens................................................................................................................. a

PMACT Event Flow Chart............................................................................................ b
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 1 of 13

Controlled Document

Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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Introduction

This document represents the Startup, Shutdown, and Malfunction Plan (SSMP) for the 

Alcoa Intalco Works Primary Aluminum Smelter’s Anode Bake Oven as required under 

Title 40 CFR 63.6(e).

40 CFR §63.6(e) requires that Intalco develop a Startup, Shutdown, and Malfunction 

Plan that describes the procedures to follow, and corrective actions to take, during 

events when the Anode Bake Oven, associated emission control equipment, or 

monitoring equipment experience a start-up, shutdown, or malfunction. The term 

“malfunction” is defined at 40 CFR §63.2 as “any sudden, infrequent, and not 

reasonably preventable failure of air pollution control equipment, process equipment, or 

a process to operate in a normal or usual manner. Failures that are caused in part by 

poor maintenance or careless operation are not malfunctions.”

The purpose of the startup, shutdown, and malfunction plan is to:

• Ensure that, at all times, the owner or operator operates and maintains each 

affected source, including associated air pollution control and monitoring equipment, 

in a manner which satisfies the general duty to minimize emissions established by 

paragraph (e)(1)(i) of 40 CFR Part 63‚ Section 6.

• Ensure that owners or operators are prepared to correct malfunctions as soon as 

practicable after their occurrence in order to minimize excess emissions of 

hazardous air pollutants; and 

• Reduce the reporting burden associated with periods of startup, shutdown, and 

malfunction (including corrective action taken to restore malfunctioning process and 

air pollution control equipment to its normal or usual manner of operation). 

Notes regarding document control:

• The plan will be made available to the permitting authority upon request. 

• All revisions to this plan are to be retained for five (5) years from their date of issue.

• The Environmental Department Manager must approve any changes to this SSM 

plan.

The Corrective Action Plans described in this document must be initiated within one 

hour of first becoming aware that a parametric value was not achieved. Each parametric 

exceedance in excess of the six allowed during a semiannual reporting period is a 

violation. 
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 2 of 13

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Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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SSM Plan Requirements

The following is a summary of this SSM plan’s requirements, as required by federal 

regulations. It is important that each individual be familiar with the requirements to 

ensure the SSM program’s success. 

1. Keep records of each SSM event as required and report if an action taken during an 

SSM event is not consistent with the procedures in the SSM plan.

2. Maintain all SSM records for at least five years (2 of which must be onsite).

3. Maintain records documenting the occurrence and duration of each startup, 

shutdown, or malfunction (refer to this plan for details).

4. Document maintenance performed on the air pollution control equipment.

5. Document actions taken during periods of SSM, including corrective actions to 

restore air pollution control equipment to normal operating conditions. 

6. Notify the Environmental Department as soon as possible after taking any actions 

that deviate from the SSM plan. On day shift, notify the Environmental Department 

immediately; during the night shift, notify the Environmental Department on the 

following working day. Include an explanation of the event:

− The exact timing of the event

− The name of the person who decided not to follow SSM requirements

− Reasons for not following the SSM plan

− Whether parametric monitoring exceedances occurred during the event

7. Maintain documentation necessary to show conformance with the SSM plan during 

an SSM event.

8. Maintain documentation of each period of continuous monitoring system (CMS) 

malfunction or inoperative periods (including out of control periods, calibration 

periods, downtime, etc.).

9. Document all required measurements to demonstrate compliance with a relevant 

standard, including but not limited to all 24 hr average readings of CMS data.

10.Maintain documentation of all results of performance tests, CMS performance 

evaluations, and visible emission observations.

11.Document all CMS calibration checks performed.

12.Document all adjustments and maintenance on CMS, including routine maintenance 

performed.

13.Submit summary report, including relevant data from production and maintenance, 

by the 7th day of each quarter to the Environmental Department for preparation of 

quarterly reports. Keep all SSM plan-required data in the Emission Control 

Supervisor’s office—send only copies or relevant reports and/or summaries to the 

Environmental Department.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 3 of 13

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14.Notify the Environmental Department as soon as possible if the SSM plan fails to 

address or inadequately addresses an event that meets the characteristics of a 

malfunction but is not included in the SSM plan. The Environmental Department will 

revise the plan within 45 days to address the issues.

− If this occurs on day shift, notify the Environmental Department immediately. 

− If this occurs during the night shift, notify the Environmental Department on the 

following working day. 

15.Document dates and times the CMS is out of control or inoperative:

− Specific periods of excess emissions and parametric exceedances (start and end 

times) during SSM events, and otherwise if applicable

− The nature and cause of any exceedance

− Corrective actions taken

− Preventative measures taken

− Adjustments made to the measurement instrument, total process operating time, 

or paste plant control equipment
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 4 of 13

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Start-Up/Re-Start Baking Furnaces

In the event that a start-up or re-start of an anode baking furnace(s) served by this fume 

control system (device) creates or leads to a situation that causes operation outside of 

appropriate parametric ranges for process gas flow or alumina flow the following StartUp plan must be initiated within one hour of first becoming aware of the situation.

A start-up or re-start is defined as the process of initiating heating to an Anode Baking 

furnace in which all sections of that furnace(s) have previously been at ambient 

temperature. The start-up or re-start begins when the heating begins. The start-up or restart concludes when fires begin to move to additional sections of the furnace(s). 

1) The Operator(s) is to assure that prior to start-up or re-start that fresh ore flow 

(alumina) and air flow has been established in the Bake Oven Control Device 

(Baghouse 7), and that the parametric limits stated in this plan are being met. 

2) The start-up or re-start concludes when fire(s) begin to move

3) Records of the start-up are to be retained for five (5) years. Should an exceedance

occur, it is to be entered into the semi-annual reporting period log kept by the 

Environmental Department and be reported in the monthly air operating report 

submitted for the month in question.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 5 of 13

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Shut-Down of Baking Furnaces

In the event that a shut-down of a baking furnace(s) creates or leads to a situation that 

causes operation outside of appropriate parametric ranges for process gas flow or 

alumina flow the following Shut-Down plan must be initiated within one hour of first 

becoming aware of the situation. Two types of furnace shutdown conditions could occur 

on site and both are addressed below:

Long Term

A long term shutdown is defined as the process of allowing a complete anode baking 

furnace(s) to cool to ambient temperature. The shutdown begins when heating fuel has 

been intentionally discontinued for the purpose of a shut down or 24 hours after a 

sustained unintentional loss of heating fuel. The shutdown concludes 72 hours after 

use of heating fuel has been discontinued. 

1) After 72 hours of cooling time, the evolution of fumes from the furnace(s) will have 

ceased and the control device (Baghouse 7) may be shut down.

2) Records of the shut-down are to be retained for five (5) years. Should an 

exceedance occur, it is to be entered into the semi-annual reporting period log kept 

by the Environmental Department and be reported in the monthly air operating report 

submitted for the month in question.

Short Term

A short term shutdown is utilized when short term routine maintenance, repair, and/or 

replacement activities to the system are required to ensure continued safe and proper 

operation of bake furnace and associated emission control equipment. These types of 

routine maintenance, repair, and/or replacement activities are typically completed in 

less than one shift and can not be safely completed without a shut down of the emission 

control system. 

In order to minimize emissions during the above mentioned routine maintenance, repair, 

and/or replacement activities the facility will perform the following steps:

1. All natural gas (fuel) to the anode baking furnaces will be shut off prior to any 

work being performed:

2. All emission control systems will continue to operate following shut down of 

natural gas for a minimum of three hours to allow for purging of the ductwork 

and continued emission control during the three hour period. 
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 6 of 13

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3. Following that purge/cool down period bake furnace operating personnel will 

shutdown the emission control system and begin the required routine 

maintenance, repair, and/or replacement activities needed to ensure safe and 

proper operation of the entire system.

4. All such work performed in 3. above will be performed in an expedited 

manner and the emission control system will be re-started as soon as 

possible following repairs. 

5. All work performed will be documented and records of the shut-down are to 

be retained for five (5) years. Should an exceedance occur, it is to be 

entered into the semi-annual reporting period log kept by the Environmental 

Department and be reported in the monthly air operating report submitted for 

the month in question.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 7 of 13

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Controlled documents are maintained electronically as described in Document Control. Printed versions 

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Malfunction and Corrective Action Plans

This section describes scrubber malfunctions and corrective action to take in the event 

of a malfunction, including the following malfunction scenarios:

• High Air Flow (Process Gas)

• Loss of Alumina Feed

• Visible Emissions - Dusting Stack(s)

• Loss of Parametric Monitoring Signals

• Catastrophic Failure of Emission Control Equipment

In the event of a malfunction, the applicable malfunction plan must be initiated within 

one hour of the malfunction being detected. The procedures in this section describe the 

steps to take to determine the cause, remedy the problem, and document the event.

Malfunction and Corrective Action Plan Procedure Documentation

Records to verify conformance with the scrubber malfunction procedures are:

• SSM Exceedance Report

• Emission Control System Continuous Parameter Monitoring Records
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 8 of 13

Controlled Document

Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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High Flow of Process Gas

In the unlikely event of high flow of process gas (a.k.a.- high air flow) through this fume 

control system (device) the following malfunction and corrective action plan must be 

initiated within one hour of first becoming aware of a malfunction. 

High gas flow rates will reduce gas residence time in the dry alumina scrubber and may 

therefore have a slight impact on POM removal efficiency, but the gas flow rate is 

already limited by fan capacity. Examples of this would be a condition that impacts the 

control device so that an annubar flowmeter parametric is generated above the 

acceptable limits (see table 4.2 below).

Table 4.2. Bake Oven Operating Limits

Monitored 

Parameter

Type of 

Limit

Operating Limit

Air Flow High 116,000 scfm

Ore Flow Low

5 Hours with No 

Fresh Ore Flow

1) The operator is to confirm the system status. The operator is to log the time that the 

condition was first noticed or reported and also log the time at which he/she first 

began to respond to check the system status.

2) Following this initial response, the operator or proxy is to notify appropriate 

maintenance personnel and/or initiate a maintenance work order, or restart the unit 

in events such as momentary loss of power.

3) Personnel responding to the malfunction are to make repair(s), equipment 

replacement(s) or process change(s) to remedy the situation in a safe and efficient 

manner. 

4) The system operator or proxy will be responsible for logging the duration of the 

malfunction and the cause. Maintenance personnel will be responsible for making 

appropriate entries into any maintenance logs.

5) Records of the start-up are to be retained for five (5) years. Should an exceedance

occur, it is to be entered into the semi-annual reporting period log kept by the 

Environmental Department and be reported in the monthly air operating report 

submitted for the month in question.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 9 of 13

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Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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ssmp_Bakes_current.doc

Loss of Alumina Feed

In the event of loss of alumina through this fume control system (device) the following 

malfunction and corrective action plan must be initiated within one hour of first 

becoming aware of a malfunction.

Examples of low flow conditions include, but are not limited to; unexpected failure to 

provide fresh alumina through the fresh alumina feed duct or one of its components and 

reductions in alumina flow due to unplanned Control Device (Baghouse 7) compartment 

outages that result in simultaneous multiple compartment downtime within this control 

device that generates loss of fresh alumina parametric that is below acceptable limits 

(see table 4.2 Ore Flow).

Table 4.2. Bake Oven Operating Limits

Monitored 

Parameter

Type of 

Limit

Operating Limit

Air Flow High 116,000 scfm

Ore Flow Low

5 Hours with No 

Fresh Ore Flow

1) The operator is to confirm the system status, noting which Control Device 

(Baghouse 7) compartments are in a no feed or reduced feed condition. The 

operator is to log the time that the condition was first noticed or reported and also log 

the time at which he/she first began to respond to check the system status.

2) Following this initial response, the operator or proxy is to notify appropriate 

maintenance personnel and/or initiate a maintenance work order, or restart the 

unit(s) in events such as momentary loss of power.

3) Personnel responding to the malfunction are to make repair(s), equipment 

replacement(s) or process change(s) to remedy the situation in a safe and efficient 

manner.

4) The system operator or proxy will be responsible for logging the duration of the 

malfunction and the cause. Maintenance personnel will be responsible for making 

appropriate entries into any maintenance logs.

5) Records of the start-up are to be retained for five (5) years. Should an exceedance

occur, it is to be entered into the semi-annual reporting period log kept by the 

Environmental Department and be reported in the monthly air operating report 

submitted for the month in question.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 10 of 13

Controlled Document

Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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Visible Emissions - Dusting Stack(s)

In the event of visible emissions, dusting stack(s), for this anode bake oven control 

device (Baghouse 7). The following malfunction and corrective action plan must be 

initiated within one hour of first becoming aware of a malfunction.

Examples of visible emissions or dusting stack(s) include, but are not limited to; 

continuous visible emissions noted by the Operator from any stack in the anode bake 

oven control device (Baghouse 7).

1) The operator is to confirm any report of a dusting stack(s) from any source including, 

but not limited to the daily visual checks made by the Operator. The operator is to 

log the time that the condition was first noticed or reported and also log the time at 

which he/she made confirmation of the report.

2) Following this initial response, the operator or proxy is to make arrangements to 

have the appropriate compartment(s) shut down to make repairs.

3) Personnel responding to the malfunction are to make repair(s) to remedy the 

situation in a safe and efficient manner.

4) The system operator or proxy will be responsible for logging the event in the visible 

emission log. Maintenance personnel will be responsible for making appropriate 

entries into any maintenance logs.

5) Records of the start-up are to be retained for five (5) years. Should an exceedance

occur, it is to be entered into the semi-annual reporting period log kept by the 

Environmental Department and be reported in the monthly air operating report 

submitted for the month in question.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 11 of 13

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Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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Loss of Parametric Monitoring Signals 

In the event of loss of fresh alumina feed, or air flow, signal(s) for this Anode Bake Oven 

Control system (device) the following malfunction and corrective action plan must be 

initiated within one hour of first becoming aware of a malfunction.

Examples of a loss of signal include, but are not limited to; unexpected failure of the 

programmable logic controller, PLC, or loss of an annubar flowmeter device that

monitors the airflow parametric.

1) The operator is to confirm the system status, noting if the PLC is off line or which 

Control Device (Baghouse 7) compartments have suffered signal loss. The operator 

is to log the time that the condition was first noticed or reported and also log the time 

at which he/she first began to respond to check the system status.

2) Following this initial response, the operator or proxy is to notify appropriate 

maintenance personnel and/or initiate a maintenance work order, or restart the PLC 

in an event such as momentary loss of power.

3) Personnel responding to the malfunction are to make repair(s), equipment 

replacement(s) or process change(s) to remedy the situation in a safe and efficient 

manner.

4) The system operator or proxy will be responsible for logging the duration of the 

malfunction and the cause. Maintenance personnel will be responsible for making 

appropriate entries into any maintenance logs.

5) Records of the start-up are to be retained for five (5) years. Should an exceedance

occur, it is to be entered into the semi-annual reporting period log kept by the 

Environmental Department and be reported in the monthly air operating report 

submitted for the month in question.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 12 of 13

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Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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Catastrophic Failure of Emission Control Equipment

In the event of catastrophic failure of emission control equipment or components in this 

fume control system (device) the following malfunction and corrective action plan must

be initiated within one hour of first becoming aware of a malfunction.

Examples of catastrophic failure include, but are not limited to; collapse of a control 

device (Baghouse 7) unit or inlet duct, a direct lightning strike, an earthquake or a 

system fire that results in uncontrolled emissions.

1) As soon as the situation has become stable and hazards have been cleared, the 

operator or proxy is to confirm the system status, noting which Control Device 

(Baghouse 7) compartments are either off line or otherwise impaired. The operator 

is to log the time that the condition was first noticed or reported and also log the time 

at which he/she first began to respond to check the system status.

2) Following this initial response, the operator or proxy is to notify appropriate 

maintenance, engineering and support personnel.

3) Personnel responding to the malfunction are to make repair(s), equipment 

replacement(s) or process change(s) to remedy the situation in a safe and efficient 

manner. In certain situations, location management may need to evaluate 

discontinuing the operation of baking furnace capacity. Such decisions may initiate 

appropriate Shut Down plans.

4) The system operator or proxy will be responsible for logging the duration of the 

malfunction. Maintenance personnel will be responsible for making appropriate 

entries into any maintenance logs.

5) Records of the start-up are to be retained for five (5) years. Should an exceedance

occur, it is to be entered into the semi-annual reporting period log kept by the 

Environmental Department and be reported in the monthly air operating report 

submitted for the month in question.
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 13 of 13

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of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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Revision Summary

Note: 40 CFR Part 63‚ Section 850‚ Paragraph (c) states that Ecology may review this plan upon request.

Approval must be obtained by Ecology before any significant changes implemented. 40 CFR 

63.6(e)(3)(viii) requires all changes be reported in Semi-annual Excess Emissions Report.

Revision 

Date

Nature of Revision Document Review Participants

Oct. 8, 1999 Rev. 0: Original Issuance D. Ringwald

June 1, 2005 REV 1

Previous SSM Plan was separated into 

two documents: SSM Plan Potlines and 

this SSM Plan for Anode Bake Ovens. No 

parametric content changed. The 

following formatting, editing, and 

clarifications were made:

• Deleted reference to lower air flow 

parametrics referenced in Start Up

and Shut Down which were not 

applicable given the high air flow rate 

limit. 

• Added Controlled Document 

Elements.

• Added Example “Sample Start up, 

Shut down, Malfunction Exceedance 

Report”

• Revised PMACT Event Flowchart to 

clarify Emission Control’s 

responsibilities versus Environmental 

Department.

• Revised Introduction.

• Transferred all Potline information to a 

new “Potlines Startup, Shutdown, and 

Malfunction Plan.

• Added Summary of SSM Plan 

Requirements. 

Jim Schon, Dave Ringwald, Brad 

Oxford, Kathryn Mitchell (Anvil)

(Reported to Ecology in 2005 First Semi 

Annual Excess Emissions Report).

July 15, 2005 REV 2

Added “Short Term” shut down condition 

to “Shut Down of Baking Furnace” Section 

on page 5 of 13.

• Department of Ecology July 13, 

2005 email from Judy Schwieters to 

Jim Schon.

• Jim Schon, Mike Rousseau, Barry 

Hullett, Patrick Pollock; Roger 

Nordlund, David Ringwald, Kathryn 

Mitchell, Bradford Oxford, Matt 

Loya; Larry Bouma; Ray Chapman; 

Charles Knauft, Iv, Ron Mann
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 2

Rev. Date: 07.15.05

Page: 14 of 13

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Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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Appendices

Sample Start up, Shut down, Malfunction Exceedance Report

PMACT Event Flow Chart
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 1

Rev. Date: 06.01.05

Page: a of Appendix

Controlled Document

Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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Startup, Shutdown, Malfunction / Operating Limit Exceedance Report: 

Potlines and Bake Ovens

Control Device:

_______________________

Date/Time of SSM Event / Exceedance was detected:

Describe Cause of SSM Event / Exceedance (if known):

Time Corrective Action Started:

Describe Corrective Action:

Was the SSM Plan Followed? (Circle one): Yes / No

Reported by:

(Name) (Badge #)

This form is to be forwarded to your supervisor as soon as practicable. An email alert to your 

supervisor is also requested

Air Flow 

Fresh Ore Flow 

Water Flow 

Abnormal Visible Emission 

Loss of Parametric Monitoring Signals 

Catastrophic Failure of Emission Control Equipment 

Cold Weather Shutdown 
Alcoa Intalco Works

Anode Bake Oven Startup/Shutdown/Malfunction Plan 

Department: Environmental

Approval: Jim Schon

Issue Date: 10.8.99

Rev. No.: 1

Rev. Date: 06.01.05

Page: b of Appendix

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of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

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PMACT Event Flow Chart

Notify 

Environmental Staff

Day shift, notify immediately

Night shift, notify on the following 

working day.

Make 

Internal / External

Notifications

Submit

Internal / External

Reports

Archive 

Reports and Documentation

 for 

5 years

Yes

SSMP 

Event

VIOLATION

SSM 

Procedures 

initiated within 

1 hour?

Yes

Yes

No

SSM Plans 

Followed ?

No VIOLATION

Yes
Controlled documents are maintained electronically as described in Document Control. Printed versions 

of documents are controlled up to 24 hours from the following print date/time: Last printed 11/01/2011

4:25 PM

ssmp_Bakes_current.doc

End of SSM

O:\InfoShare\Controlled_Documents\Environmental\E-3 Air\Programs\PMACT\Startup 

Shutdown Malfunction Plans\ssmp_Bakes_current.doc