Appendix 1 RAMS 818-U225

Form & Checklist Doc.No CHVI-540318 Version 1.
0
Effective since 12-Jun-2023 Replaces
Template CQV Method Statement - Risk Assessment Page 1 of 18
/Project BACHTERA, Project, MC4a, Lonza, Visp, Switzerland
(Job No. issued only by

LOTOTO-Office)
Document Approvers Name (Print Name) Signature Date (DD.MMM.YYYY)
Document Author
Žarko Šaravanja
(CQV Engineer)
Approved by Safety
Borislav Vulic
Representative (Lonza)
Approved by CQV Manager

Cormac Kelly
(Lonza)
Document Revision 0 Issue

BACHTERA I12_212055-CQV-MSRA-003 20/Jun/2023
No.: No.: 0 Date:
Page 1 of 18.
Form & Checklist Doc.No CHVI-540318 Version 1.0
1.0 Method Statement

1.1 Purpose of Task
This is an Appendix to a RAMS for a system 818-U225. The risk assessment is the same, the methodology is updated. The goal of this activity is the
replacement of valve U225VH134 on system 818-U225.
1.2 P&ID Mark Ups Associated With Task

 LV2-105323 Blatt 225 Hot Water (MHWS) Generation, P&ID, Status D, Version D
 LV1-105323 Blatt 280 Potable Water Warm (WTW) Generation, P&ID, Status D, Version D
1.3 Task overview
Replacement of valve U225VH134 on system 818-U225.
1.4 Pre-Requisites
1. All operatives involved to have appropriate task specific PPE.
2. Part of system on which the valve will be replaced is depressurised.
3. System 818-U225 Hot Water (MHWS) Generation with LOTOTOs.
1.5 Methodology
Track the completed activities by ticking the completed steps to ensure correct execution.
Verify LOTOTO is in place.

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- LOTOTO is required to the 818-U225 Hot Water (MHWS) Generation:

o Valves closed and locked: U225VH133, U225VH108, U225VH107, U225VH106, U225VH103, U225VH101, U225VH136
- Ensure that the part of the system that would be a subject to the change is depressurised. Drain the part of the system on valve U280VH128.
- Construction team to perform activities of replacement of the valve.
- After finishing of replacement activities, UNLOTOTO is required to the 818-U225 Hot Water (MHWS) Generation:
o Valves unlocked: U225VH133, U225VH108, U225VH107, U225VH106, U225VH103, U225VH101, U225VH136
- Refill the system.
1.6 Safety relevant steps:

 Personnel are wearing the required PPE.
 Radios will be issued prior to works commencing, and a radio check carried out to ensure communication is confirmed between all parties prior to
works commencing.
 LOTOTO has been completed with valves locked closed and relevant blinds tagged
 All Safety signage is in place
 Area is barriered off as required
 Relevant permits are in place and signed off for livening and commissioning activities to be performed.

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1.7 Name of Other Parties/Contractors involved in Task
Team Name Company Contact Number
Lonza Safety Representative Borislav Vulić LONZA +381 65 890 70 41
Lonza CQV Representative Brian O’Mahony LONZA +41 79 801 65 61
CQV Engineer Žarko Šaravanja CQV Systems +385 99 3039053
Mechanical Supervisor N/A N/A N/A
Mechanical Fitter N/A N/A N/A
Electrical Supervisor N/A N/A N/A
E&IC Engineer N/A N/A N/A
Lonza Operator N/A N/A N/A
Lonza Safety Manager Philipp Amacker Lonza +41 79 563 61 99

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2.0 Risk Assessment

2.1 Instructions
1. Break the job down into steps - Be as specific as possible. Write each job step in a new row of column A (Activity). It’s a good idea to leave an extra row
between steps in case you need them later. Add additional rows to the table as needed,
2. Determine the hazards associated with each job step and write them in column B (Hazards). Use the examples of hazards provided below to trigger your
thinking about different types of hazards and energy sources. In the next column state who could be harmed and how that may occur (C).
3. Considering the hazards involved without any control measures being in place, determine the worst credible severity of an incident that could result from
this job step. Use the severity table provided. Write the severity number in column D (Severity).
4. Considering the hazards involved without any control measures being in place, determine the likelihood that an incident will result from this job step. Use
the likelihood table provided. Write the likelihood number in column E (Likelihood).
5. Multiply the severity number by the likelihood number and enter the product in column F (Initial Risk). Colour section F in the corresponding table Colours
for Low, Medium and High to highlight the level and make it simple to see and understand.
6. Repeat steps 2-5 for each of the job steps identified.
7. List any control measures that will be taken to ensure that step is done safely in column G (Control Measures). Use the control measure examples and
hierarchy provided to trigger your thinking about different types of controls and their effectiveness at reducing risk. Controls toward the top of the table
tend to be more effective at minimizing the likelihood of an event than the controls toward the bottom of the table. The Severity of an accident usually
remains the same. It is only the likelihood score that will change following controls.
8. Once all controls are described follow the same process in 2- 5 to complete the severity, likelihood and Residual risk that potentially remains after
mitigation. Sections H, I & J. Colour section J in the corresponding table colours for Low, Medium and High to highlight the level and make it simple to
see and understand.

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9. Consider the risk rating against the thresholds provided in the Overall Risk Ratings.
9.1. Very low and low risk ratings of 1-4. This level is generally considered acceptable provided that all control measures are applied.
9.2. Medium risk ratings of 5 -12. Additional control measures should be considered to determine whether it is practical to further reduce the risk further.
If additional control measures may be required, write them in the Control Measures column on the same line or a new line below. Rescore the
Severity, Likelihood, and Risk taking into consideration this additional corrective action.
9.3. High and Very High-risk ratings of 15-25. Additional control measures must be considered to determine whether it is practical to further reduce the
risk. If additional control measures will be implemented, write them in the Control Measures column on the same line or a new line below. Rescore
the Severity, Likelihood, and Risk taking into consideration this additional corrective action.

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2.2 Risk Measurement
The main tool used for assessing risk in this system is a 5 x 5 matrix. The sides are labelled Severity x Likelihood as shown below.
Severity (S) Likelihood (L) Severity (S)
1 2 3 4 5 1 = Very Unlikely 1 = Minor injury, No lost time or No Delays/Disruption to services
2 4 6 8 10 2 = Unlikely 2 = First aid injury, less than 3 days absence Minor Disruption to service
Likelihood (L)
3 6 9 12 15 3 = Likely 3 = Minor injury, more than 3 days absence or Minor Delays to service
4 8 12 16 20 4 = Very Likely 4 = Major injury, long term absence or Major Delays to service
5 10 15 20 25 5 = Certain 5 = Fatality or Total loss of Service
Low (L) Risk (Green)

If the multiple of Likelihood x Severity is in the range of 1-4 the risk is considered low and provided the correct processes are followed no further control
measures are considered necessary.
Medium (M) Risk (Orange)

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Page 7 of 18.
If the multiple of Likelihood x Severity is in the range of 5-14 the risk is considered medium and further control measures will be in place to reduce the risk.
After the control measures are put in place, the risk will be re-assessed in order to determine the impact of the risk with the control measures in place. A
decision will be taken as to whether the risk is now acceptable before work is allowed to proceed.
High (H) Risk (Red)

If the multiple and the Severity are in the range of 15-20 the risk is considered high no work will take place until control measures are in place to reduce the
risk. After mitigations are considered, if the residual risk still remains high, work will not commence.
Initial Risk Rating Residual Risk Rating
Who might be
Activity Hazard Risk Risk
harmed and how?
No. S L Action to Mitigate Risk- Controls S L
(A) (B) H,M,L H,M,L
(C)
(D) (E) (G) (H) (I)
(F) (J)
- Appropriate PPE worn.

1. Slips tripps and Personnel working in
Safety 2 2 4 - Walkdown the are to identify risks as well as communicate with other 2 1 2
walkdown: falls the area workers in the area and check the whole scope of activity
- Written approval for work before the start

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Page 8 of 18.

Who might be
harmed and how?
(A) (B) H,M,L H,M,L
(C)
(D) (E) (G) (H) (I)
(F) (J)
General Manual Person performing Review access and movement of equipment/materials to required
commissioning handling / work positions.
activities musculo–skeletal Use mechanical handling devices if sensible/possible.
Perform movements using ‘good lifting technique’
injuries
2. Manual 3 3 9 3 1 3
Handling :
Lifting, pushing,
carrying or
reaching with
lifting
equipment,
materials etc.
Personnel working in Opening process under LOTOTO.

3. Pipe filling Water Leaks the area are exposed 2 3 6 System leak check verified prior to system livening 2 2 4
to water leaks Complementary PPE
-Walkie talkies
Personnel working in
Low pressure
4. System live the area open a valve 4 3 12 4 1 4
system leaks LOTOTO the valves as per the LOTOTO plan.
mistakenly

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Page 9 of 18.

Who might be
harmed and how?
(A) (B) H,M,L H,M,L
(C)
(D) (E) (G) (H) (I)
(F) (J)
General Impact / manual Person performing Review access and movement of equipment/materials to required positions.
commissioning handling / work Provide temporary protection/padding if appropriate.
activities musculo–skeletal
injuries Use mechanical handling devices if sensible/possible.
5. 3 3 9 3 1 3
Perform movements using ‘good lifting technique’
Limited working
space Site standard PPE
General Cuts and Person performing Avoid materials and components with sharp edges, corners etc where
commissioning abrasions work reasonably practicable.
activities
Wear appropriate gloves in accordance with site procedures.
6. Sharp edges on 3 3 9 3 1 3
pipework,
equipment,
strainers, flexible
hoses, gaskets
etc.

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Page 10 of 18.

Who might be
harmed and how?
(A) (B) H,M,L H,M,L
(C)
(D) (E) (G) (H) (I)
(F) (J)
General Pinching / Person performing Use suitable tools for prying apart flanges.
commissioning crushing of hands work
activities / fingers Take care not to insert fingers into trap zone.
Wear appropriate gloves in accordance with site procedures.
7. Pipework 3 3 9 Trained competent personnel 3 2 6

assembly,
insertion of
gaskets, spades,
strainers.
bursting discs etc.
General Incorrect use Person using tool Tools should only be used by competent persons.
commissioning causes physical
activities injury Ensure tools are in good condition prior to use.
8. 3 2 6 3 1 3
Use appropriate PPE.
Use of tools

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Page 11 of 18.

Who might be
harmed and how?
(A) (B) H,M,L H,M,L
(C)
(D) (E) (G) (H) (I)
(F) (J)
General Inadequate Person performing Task lighting to be used if required

commissioning background and work
activities task lighting :
9. 3 3 9 3 2 6
slips, trips and
falls, physical
Available lighting injury from task
Measures to reduce the extent of damage:

- Use of proven sealing material
- Openings must always be adequately covered with blind caps and
clamps
Injury due to
- Check the pressures to confirm the line is drained before removing the
Removal of fitting Hot/caustic/ escaping acid/
spool piece
10 caustic/hot/gaseous
pieces / filters or gaseous/acid/ 4 2 8 Organizational measures: 4 1 4
media
spool pieces water leakages - Check the current condition of the system and the operator interface
Possible Reasons:
(DeltaV) and visual inspection (Manometer on filters and vessels)
Piping not emptied
before starting.
- Any work to be done must be reported at the IBN planning meeting.
- Use of trained personnel
- Use of appropriate PPE

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Page 12 of 18.

Who might be
harmed and how?
(A) (B) H,M,L H,M,L
(C)
(D) (E) (G) (H) (I)
(F) (J)
Measures to reduce the extent of damage:

- Use of proven sealing material
Scalding/caustic/ - Openings must always be adequately covered with blind caps and
acid/gasd injury Clamps
Hot/caustic/ due to escaping -
Leaking fittings acid/water media 4 2 8 Organizational measures: 4 1 4
leakages Possible Reasons: - Check the current condition of the system and the operator interface
Connecting are not (DeltaV) and visual inspection (Manometer on filters and vessels)
11 tight before restarting.
- Any work to be done must be reported at the IBN planning meeting.
- Use of trained personnel
- Use of appropriate PPE

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Page 13 of 18.
2.3 PPE Requirements
Task Specific PPE Required
Hand
Overalls / Boots / Face
Protection / Safety Hearing
Protective Protective Shield / Respirator Hi-Vis Hard Hat Harness
Safety Glasses Protection
Clothing Footwear Mask
Gloves
☐ ☐ ☒ ☒ ☐ ☐ ☐ ☒ ☒ ☐

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Page 14 of 18.
3.0 Work Permit and Training Requirements

It is essential to highlight ALL Permits and specific training requirements and certification required by personnel to do the work. The specific team members
must be named.
What permits are required for the works? (TICK þ)
Permit Required
Lonza General Permit to Work ☒

Energized Electrical Work Permit ☐
LOTOTO Permit ☒
Confined Space Work Permit ☐

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Page 15 of 18.
Other ☐

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Page 16 of 18.
Training
Outline additional training requirements for the task, e.g. MEWP / Harness / Abrasive Wheels / Cartridge Tools / Confined Space Entry etc.
Training
Operative Name Training/Certificate Required Received
(Tick þ)
☐
☐
☐
☐
☐
☐
4.0 Emergency Arrangements
USE THE LONZA EMERGENCY PHONE NUMBER: +41 27 948 71 12. REGARDLESS OF SEVERITY, ALL ACCIDENTS ARE TO BE
REPORTED TO LONZA HSE IMMEDIATELY.

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Page 17 of 18.
5.0 Signoff Sheet

I have read and understood the contents of this CQV-Method Statement - Risk Assessment. Anything I did not understand has been explained to me to my
satisfaction. I agree to follow the CQV Method Statement Risk Assessment and understand that any instructions are provided for my safety and the safety
of others.
Print Name Company Signature Date (DD-MMM-YYYY)

No.: No.: 0 Date:
Page 18 of 18.

Appendix 1 RAMS 818-U225

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Appendix 1 RAMS 818-U225

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Form & Checklist Doc.No CHVI-540318 Version 1.

/Project BACHTERA, Project, MC4a, Lonza, Visp, Switzerland

(Job No. issued only by

Document Approvers Name (Print Name) Signature Date (DD.MMM.YYYY)

Approved by CQV Manager

Document Revision 0 Issue

1.0 Method Statement

1.2 P&ID Mark Ups Associated With Task

1.3 Task overview

Replacement of valve U225VH134 on system 818-U225.

Document Revision 0 Issue

- LOTOTO is required to the 818-U225 Hot Water (MHWS) Generation:

1.6 Safety relevant steps:

Document Revision 0 Issue

1.7 Name of Other Parties/Contractors involved in Task

Team Name Company Contact Number

Lonza Safety Representative Borislav Vulić LONZA +381 65 890 70 41

Lonza CQV Representative Brian O’Mahony LONZA +41 79 801 65 61

CQV Engineer Žarko Šaravanja CQV Systems +385 99 3039053

Mechanical Supervisor N/A N/A N/A

Mechanical Fitter N/A N/A N/A

Electrical Supervisor N/A N/A N/A

E&IC Engineer N/A N/A N/A

Lonza Operator N/A N/A N/A

Lonza Safety Manager Philipp Amacker Lonza +41 79 563 61 99

Document Revision 0 Issue

2.0 Risk Assessment

Document Revision 0 Issue

Document Revision 0 Issue

2.2 Risk Measurement

Severity (S) Likelihood (L) Severity (S)

1 2 3 4 5 1 = Very Unlikely 1 = Minor injury, No lost time or No Delays/Disruption to services

5 10 15 20 25 5 = Certain 5 = Fatality or Total loss of Service

Low (L) Risk (Green)

Medium (M) Risk (Orange)

Document Revision 0 Issue

High (H) Risk (Red)

- Appropriate PPE worn.

Document Revision 0 Issue

Initial Risk Rating Residual Risk Rating

Personnel working in Opening process under LOTOTO.

Document Revision 0 Issue

Initial Risk Rating Residual Risk Rating

Document Revision 0 Issue

Initial Risk Rating Residual Risk Rating

Wear appropriate gloves in accordance with site procedures.

7. Pipework 3 3 9 Trained competent personnel 3 2 6

Document Revision 0 Issue

Initial Risk Rating Residual Risk Rating

General Inadequate Person performing Task lighting to be used if required

Measures to reduce the extent of damage:

Document Revision 0 Issue

Initial Risk Rating Residual Risk Rating

Measures to reduce the extent of damage:

Document Revision 0 Issue

2.3 PPE Requirements

Task Specific PPE Required

Document Revision 0 Issue

3.0 Work Permit and Training Requirements

What permits are required for the works? (TICK þ)

Lonza General Permit to Work ☒

Document Revision 0 Issue

Document Revision 0 Issue

Document Revision 0 Issue