PROJECT NAME

METHOD STATEMENT FOR

INSTALLATION OF AIR HANDLING UNITS & FRESH AIR HANDLING UNITS

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PROJECT NAME

METHOD STATEMENT FOR

INSTALLATIONOF AIR HANDLING UNITS& FRESH AIR HANDLING

UNITS

PROJECT NAME
METHOD STATEMENT FOR
INSTALLATION OF AIR HANDLING UNITS & FRESH AIR HANDLING UNITS

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REVISION RECORD

This cover page is a record of all revisions of the document identified above by number and title. All
previous cover pages are hereby superseded and are to be destroyed.

Rev. No.

Date

By

Chkd.

Approval
s

Description and Page Numbers of

Revisions

PROJECT NAME
METHOD STATEMENT FOR
INSTALLATION OF AIR HANDLING UNITS & FRESH AIR HANDLING UNITS

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CONTENTS

1.0 1.0 PURPOSE

2.0 2.0 SCOPE
3.0 3.0 REFERENCES
4.0 4.0 DEFINITIONS
5.0 5.0 RESPONSIBILITIES
6.0 6.0 EQUIPMENTS
7.0 7.0 PROCEDURE
8.0 8.0 ATTACHMENTS

1.0 PURPOSE
This method statement is applicable for the Supply & Installation Air Handling
Units & Fresh Air Handling Units for the project as mentioned in the
Specifications & Approved Shop Drawings.

2.0 SCOPE

PROJECT NAME
METHOD STATEMENT FOR
INSTALLATION OF AIR HANDLING UNITS & FRESH AIR HANDLING UNITS

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This method Statement shall cover the Supply & Installation AHU & FAHU in
line with project requirements as indicated in the Approved Shop Drawings,
specifications & manufacturers instructions.

3.0 REFERENCE
3.1 Latest Approved shop drawings intended for HVAC.
3.2 Specification:.
3.3ISO 9001:2008.
3.4Project Quality Plan
3.5Project HSE Plan
3.6Material Approval Request references:Air Handling Units & Fresh Air Handling Units

4.0 DEFINITIONS
Main Contractor :
MEP Contractor :
PQP
: Project Quality Plan
PSP
: Project Safety Plan
QCP
: Quality Control Procedure
HSE
: Health, Safety and Environment
MS
: Method Statement
ITP
: Inspection Test Plan
QA/QC
: Quality Assurance / Quality Control Engineer.
ITR
: Inspection and Test Request
MVR
: Material Verification Request
MAR
: Material Approval Request
AHU
: Air Handling Unit
FAHU
: Fresh Air Handling Unit

5.0 RESPONSIBILITIES:
Responsibilities for ensuring that the steps in this procedure shall be carried
out are specified at relevant steps in the procedure:
Project Manager
Construction manager
QA/QC Engineer
Site Engineer
HSE officer
SK
5.1 Project Manager
The work progress shall be carried out as per planned program and all the
equipments required to execute the works shall be available and in good
condition as per project planned.
Specific attention is paid to all safety measures and quality control in

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METHOD STATEMENT FOR
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coordination with Safety Engineer and QA/QC Engineer and in line with PSP
and PQP.
5.2 Construction Manager
Construction Manager is responsible to supervise and control the work on
site.
Coordinating with QA/QC Engineers, Site Team & Foremen for all activities on
site.
Control and sign all ITRs before issuing to Consultant approval.
5.3 Site Engineer
The method of statement to the system shall be implemented according to
the project specifications and approved shop drawings.
Provision of all necessary information and distribution of responsibilities to
his Construction team.
The work progress shall be monitored in accordance with the planned work
program and he will provide reports to his superiors.
The constant coordination with the Safety Engineer to ensure that the works
are carried out in safe working atmosphere.
The constant coordination with the QA/QC Engineer for any works to be
carried out and initiate for the Inspection for the finished works.
He will ensure the implementation of any request that might be raised by the
Consultant.
Efficient daily progress shall be obtained for all the equipment and
manpower.
He will engage in the work and check the same against the daily report
received from the Foremen.
The passage of all the revised information to the Foremen and ensure that
its being carried out properly.
5.4 QA/QC Engineer (MEP):
The monitoring of executions of works at site and should be as per the
approved shop drawings and project specifications.
Ensure ITRs and MVRs are being raised for activities in timely manner and
inspected by the Consultant.
He will follow and carries out all the relevant tests as per project
specifications.
Obtain the required clearance prior to Consultants inspections.
Should acquire any necessary civil works clearances and coordination.
QA/QC Engineer will assist the Consultant Engineer/ Inspector during Inspection.
Check & ensure work is completed prior to offer consultant for inspection.
Coordination with site construction team.
He will assist the Consultant Engineer/ Inspector during the inspection.
Ensure all works have been completed prior to raise inspection to the

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consultant.
5.5

Site Foreman

The carrying-out of work and the proper distribution of all the available
resources in coordination with the Site Engineer on a daily basis.
Daily reports of the works are achieved and coordinated for the future
planning with the Site Engineer.
Incorporate all the QA/QC and Safety requirements as requested by the
concerned Engineer.
Meeting with any type of unforeseen incident or requirement and reporting
the same to the Site Engineer immediately.
5.6 Safety Officer
The implementation of all safety measures in accordance with the HSE plan
and that the whole work force is aware of its proper implementation.
The implementation of safety measures is adequate to maintain a safe
working environment on the work activity.
Inspection of all the site activities and training personnel in accident
prevention and its proper reporting to the Construction Manager and the
Project Manager.
The site is maintained in a clean and tidy manner.
Ensure only trained persons shall operate the power tools.
Ensure all concerned personals shall use PPE and all other items as required.
Ensure adequate lighting is provided in the working area at night time.
Ensure high risk elevated areas are provided are barricade, tape, safety nets
and provided with ladders.
Ensure service area/inspection area openings are provided with barricade,
tape, and safety nets.
Ensure safe access to site work at all times.
5.7 Store Keeper (SK)
Responsible for overall Store operations in making sure to store the material
delivery to the site and keep it in suitable area that will keep the material in
safe from rusty and damage.
One who will acknowledge the receiving of materials at site in coordination with
QA/QC & concerned Engineer.

6.0

EQUIPMENTS
Following tools shall be arranged before starting the job.
a. Tool Box.
b. Measuring Tape.
c. Hack Saw Blade
d. Spirit Level

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e. Electric Drill Machine

f.

Step Ladders

g. Threading Machine
h. Solvent Cement
i.

Electric welding machine. (if required)

j.

Torque Wrench

k. Pipe Cutting Machine

l.

Grinding Machine

m. Pressure Gauge
n. Hammer
o. Water Level Marker
p. Mobile Scaffolds
q. Staging Platforms

7.0

PROCEDURE
Work Sequence/Procedure

7.1

General Requirements
All the materials received at site shall be as per the approved technical
material submittal and to be inspected upon receipt & approved by the
engineer prior in proceeding with the installation through MVR. Any
discrepancies, damages etc., should be reported to the supplier for

rectification or replacement& to be removed from site immediately.

All construction/inspection/testing works shall be carried out in
accordance with the specifications & to be done by qualified Mechanical
Engineers and shall be checked and approved by MEP Subcontractor

Construction Manager along with QA/QC Engineer.

Contractor has to clarify the procedure for material delivery to the site
through consultant Engineer at site.
7.2

Material Transport/ Delivery

AHU & FAHU units are normally shipped & despatch for goods condition
and carefully loaded in containers with crating / boxing. Hence, in case
of transit damage, supplier must be informed immediately.
Special care must be taken to ensure that units are offloaded from
containers. Rough handling can result in damage to aluminium
framework and double skin panels. It is possible to lift the sections by

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METHOD STATEMENT FOR
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slings or by forklift.
All the received units shall be checked & inspected to ensure that it is
complying with the approved material submittals prior to site storage.

7.3

Storage on Site Store

To ensure that deterioration of the AHU & FAHU does not occur during
storage, it is recommended to store the equipment in sheltered conditions

that are protected from weather elements and accidental damage.

AHUs & FAHUs shall be protected with plastic/ tarpaulin or shall not be

removed from the shipping package unless otherwise instructed to do so.

All packages for the equipment reaching the site shall be identified as per
package list.

7.4 Sequence of Installation for the AHU & FAHU

7.4.1 Safety

All site safety rules & regulations shall be complied with.

Supervisors will deliver tool box talks, relevant to these activities to all
operatives involved in the installation and shall be recorded.

All operatives will be equipped with minimum personnel protective

equipment; hard hat, coveralls, safety boots, safety glasses.

The persons using cleaning fluid and solvent cement have to wear hand
gloves.

Ensure only qualified personnel shall install, test & commissioned the
equipment.

During Testing & Commissioning, (which will be done on later stage) display
warning sign boards necessarily provided and barricade the area whenever
necessary.

Only competent, experienced & trained personnel shall perform all the
required activities stated in this method statement.

Ensure that all operatives fully understand the method of these activities.

7.4.2 Pre- Installation Procedure

Before commencement of installation activity, the supervisor must ensure that:
Delivered AHUs & FAHUs shall have been inspected & approved via MVR by the
consultant prior to installation at site.
All Installations & Pressure Testing of Pipe/ Duct works have been completed & approved
by the consultant.
Relevant documents or certificates shall be presented at the time of inspection if required

PROJECT NAME
METHOD STATEMENT FOR
INSTALLATION OF AIR HANDLING UNITS & FRESH AIR HANDLING UNITS

7.4.3

by the Consultant.
Permission to start or Civil Clearances prior to installation has been given by the main
contractor.
All relevant Shop drawings for the installation of the equipment shall be available &
approved by the consultant. No installation shall be done without Approved Shop
Drawings.
Installation activities shall only commence when all associated works by the Civil such as
clearing of work place, water proofing, etc. have been verified & completed.
Safe access shall be provided by the Main Contractor thru Work Permit in coordination
with the Safety in charge at site.
Inspect the relevant area for any possible clashes with other services.
Check for other services, making sure that there is no interference between each service &
adequate access to work and for future maintenance can be maintained.

Installation Procedure for AHU & FAHU

7.4.4

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Ensure that adequate access exists for connecting all supplies, disposal of condensate/
overflows, inspection & maintenance and for replacement of renewal parts such as filters,
belts, bearings etc.
Installation of units must be in accordance to the project specifications, approved shop
drawings, details, good engineering practice.
Structural base with rubber pad for the units must be level & rigid.
Make sure that the base is high enough from the floor to allow the installation of
condensate drain with necessary trap for easy flow.

Assembly
Between the sides of the sections that shall be connected, it must be inserted a continuous
foam gasket for airtight seal.
Push the sections towards one another, making sure that they are lined up with one another.
Consequently the sections must be locked together by stainless steel bolts located in
factory predrilled assembly holes into the corner brackets on the inside of the frame. Make
sure that they are firmly in position.
Necessary steel bolts & foam gaskets are supplied in a bag, normally located within the fan
section.
The required anti vibration material to be installed below the unit & the required slope of
equipment of condensate drain to be considered.
Check the height of foundation to achieve the unit condensate drain based on the ESP.
It must be noted that during installation and assembly, there is a possibility of
misalignment if individual sections are not carefully handled. Do not use excessive force to
align because it may deform the aluminium structural framework.
If in any case that it is not possible to access the inside of the casing, the connection can be
made either by opening an inspection door or by removing a wall panel.
Free movement of all dampers must be checked.
Manually operated dampers can be adjusted to obtain the required airflow by loosening the
Bakelite knob and then turning the control lever. Bakelite knob must be tightened after
setting up at the desired location on locking quadrant.
Motorized dampers are supplied with the linkage rod for connection to the actuator. It must

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be ensured that the actuator motors are rigidly fixed to the structural framework of the unit
and not to the double skinned panels. Care must be taken to ensure that the actuator does
not attempt to push the damper beyond fully open or fully closed positions.
Check the quality of filters is in accordance with the drawings.
Panel Filters with flat or corrugated media are normally fitted within the unit prior to
shipping.
Bag Filters along with pre-filters (if any) each housed within a special holding steel frame
with necessary locking spring to ensure proper sealing. A bank of such special frames
(quantity depends on the type of air flow) is assembled within peripheral aluminium
framework of each Bag Filter Section. Entire assembly along with Pre-filter must be locked
with four springs to ensure no leakage of air.
Automating roll filters have two headers, one houses the clean spool, while the other dirty
spool, which is driven by a geared motor and chain drive actuated by differential pressure.
Normally filter media are supplied loose for site installation. Filter media roll is mounted
on the clean spool header, taken along the guide channel through working section and
locked to the dirty spool. Switch must be installed and connected to the control panel.
Absolute filters are housed in a special purpose made of aluminium frame with corner
brackets & locking devices for each cell. While assembly special care must be taken to
ensure that each filter cell is properly seated within the assembly frame and perfectly
sealed against the neoprene foam gasket with no possibility of leakage.
Heat Exchanger Coils are leak tested & checked prior to assembly. Fins are checked for
proper condition prior to shipping. During installation they might be slightly bent and hence
they must be checked and combed out if necessary. Do not remove plastic protective covers
from the header connections until the system is ready for hook up. System lay-out should
take into consideration of possible coil withdrawal. All connecting pipework must be
properly insulated.
Water Coils system design, pipe connections and valve arrangement must be checked. Flow
& return connections are clearly identified on the unit panels and pipe work must be
connected accordingly, preferably through flexible couplings to avoid transmission of any
vibration from the piping to coil. Excessive tightening torque might damage the coils. Pipe
work must be supported independently to the coil or to the unit.
Plugged drains & vents are provided for each coil and their use must be limited to the
respective coil. They must not be used for draining or venting the other part of the system.
Sufficient antifreeze chemicals must be added to the circulating water in cooling coils, when
there is a possibility of being exposed to temperatures below 2C.
It is recommended that the water flow is switch off when fan is switched off.
Condensate Drains: All chilled water coils must be individually trapped and connected to
drain with adequate pitch for easy flow. Depending on the ambient temperature and plant
location, it is recommended to insulate the condensate drain pipework.
Supply & Return Fan Assemblies:
Units are supplied with neoprene or spring isolators on which fan & motor assembly is
suspended, are locked prior to shipping to avoid damage during transit. Once unit is in
position and fan outlet is connected to ductwork, spring isolators mounts must be
released.
Flexible connection to be used between units and supply/ return/ Fresh Air Duct.
Check the type & voltage of motor. If information is available, cable entry holes through

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the double skinned panels can be factory drilled. Ensure that no holes drilled and no
connections are made through the access door. It is recommended to use flexible
armoured conduit between the panel and motor terminal box. All conduiting/ wiring
must be carried out in accordance to project specifications & local standards.
Check the type of start (direct on line/ star delta) meets with the local regulations.
Provide starter/ controls/ overload protecting devices/ interlocks as required.
Ductwork must be connected and insulated in accordance with the project specification
& approved drawings. It is also recommended to protect all lining and attenuation
materials with smooth perforated metallic sheets to avoid migration of fibres into
occupied areas/ blockage and subsequent replacement of filters frequently.
Belt Tension: The belts must be correctly tensioned to ensure good contact with the
pulley. If insufficiently tensioned, the belts may slip and if excessively tensioned, the
motor may be over loaded.
Heat Pipe Installations:
During installation, lift heat pipe assemblies by holding the casing and not headers or
connections. Larger coils may have specific provision for eyebolts or similar lifting
arrangements.
When lifting the heat pipes, it may be necessary to drill the casing flanges in order to
fit eye bolts etc. for lifting. It is imperative that these holes are drilled in the side
plates of the casing rather than in the endplates.
In order to prevent any possible damage to the tubes of the heat pipes, all lifting must
be via the side plates. The side plates have turned-in flanges for stiffness.
Horse shoe heat pipes are shipped with transit plates bolted between the side plates.
These plates are intended to maintain the separation between the two legs of the heat
pipe and to stiffen/ brace the assembly. The transit plates should be left in the casing
until the final assembly procedure whereby cooling coil is inserted between the heat
pipe legs.
Casework should be securely fixed prior to pipework flanges being made upon
combined heat pipe/ cooling coils.
Water flow is into the bottom connection and return from the top, thus assisting in
venting of the system.
The coils are handed and should be connected in counter flow. The water flow
connection is at the leaving airside of the coil, and thusly the return flows to the
entering air side of the coil.
When making screwed connections for the coil, hold the header connection with
grips. The copper coil tubes may be bent or fractured if excessive strain is put on the
headers.
Maintain a minimum of 100mm gap between the leaving face of the cooling coil and
the entering face of the heat pipes reheat sections.
Ensure that the external fins shall be of aluminium with minimum thickness 0.15mm
and shall be of continuous plate type.
Check that the casing shall be of galvanized sheet steel with a minimum thickness of
1.2mm. The casing shall incorporate tube plates and top and bottom plates around
both the pre-cool & reheat pipe blocks.
Run Around Coil Heat Recovery
The air leakage rate between fresh air & return air streams on thermal wheels can go

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METHOD STATEMENT FOR
INSTALLATION OF AIR HANDLING UNITS & FRESH AIR HANDLING UNITS

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8.2.
8.3.
8.4.
8.5.
8.6.

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up to 5% maximum under normal condition.

To avoid air contamination, the pressures on the fresh air side shall be higher than
on the return air side.
Heat recovery system shall be protected against any freezing risk.
Support positions should be determined to provide a distributed support for the unit
base and should not obstruct access panels or air way connections.
Access for maintenance and inspection for the RAC Coil is generally from the side
of the units.
Once assembled in position, sufficient free space must be available adjacent to the
unit for future inspection, maintenance, component service, repair, & connection of
service.
Control System (Integration with BMS)
Units are available with factory engineered controls as a plug and play package.
Therefore, the units are provided with components including control components
(sensors and actuators) controller and power wiring.
Electrical connections may become untightened during transport. All electrical
connections should be checked and re-tightened prior to installation/
commissioning.
All electrical connections shall be made according to the wiring diagrams provided
on the components or in supplied documents.
All the low voltage end devices are factory installed on the unit and wired back to a
central terminal strip where connections to BMS controller can be easily made on
site.
The central connection module will need to be sited so that there is adequate access
to the control panel for commissioning and maintenance purposes. The minimum
clearance is 1 meter wide and 2 meters high.
Main connections are normally made through the bottom of the control panel. All
the cables should be suitably arranged so as not to put excessive strain on the
terminals. They should be fitted with suitable glands to prevent water ingress.
Fire Signal (optional): The AHU unit maybe interfaced to a fire alarm shut down by
connecting a normally closed contact to the designated terminals. If this is not
required the fire contacts are replaced by a link. Remote firemans override switches
can be connected to allow operation of the extract fan after a fire alarm has been
actuated. Where a mixing box is fitted, the exhaust air damper will be driven to the
fully open position while the mixed air and fresh air dampers are driven closed.
Override contacts can be connected to the designated terminals.

ATTACHMENTS
Quality Control Procedure
Inspection & Test Plan
Installation Check Sheet for AHU
Installation Check Sheet for FAHU
Risk Assessment