WORK METHOD STATEMENT - AHU INSTALLATION

Job/ Activity/Task: AHU Installation Ref: MS/SAEPL/HVAC/WMS/004

Codes/Standards applicable:
HVAC PROJECT NAME: MORGAN STANELY – PARIVARTAN
Project Location: Goregaon, Mumbai Area / Floor: 9th to 14th Floor
Risk assessment reference:
Prepared by: Mr. Himanshu Niveriya Reviewed by: Mr. Amod Mande
Designation: Project Manager Designation: Project Head
Date: 28/03/2023
Activity Carried by: - M/s Safe Air Engineers Pvt
Ltd Engineer available at site: -
• Mr. Tushar Gaikwad
• Mr. Nilesh Handure
• Mr. Nandukumar Mallshette
HSE Officers Available at Site : -
• Mr. Hannan Khan
• Mr. Mahesh Nikale
• Mr. Sharad Pawshe
SCOPE OF WORK:

• SITC of AHU’s as per BOQ and Technical Specification 2.1 MS/AC/801/C

REFERENCE DOCUMENTS:

• Material Approval Submittal.

• Approved Shop Drawing.
• Technical Specification of AHU 2.1 to 2.18 TS Page No. 20 – 28

ORGANIZATION AND RESPONSIBILITES:

Sr. NO. Designation Job Responsibilities

1 Project Manager 1. It is the Project Manager duty to ensure that all necessary safety
and protective equipment are provided along with properly trained
and
qualified personnel. Moreover, to ensure that all survey works are
carried out in accordance with this method statement.
2 Quality Engineer 1. It is the Quality Engineer’s responsibility to ensure that all
surveying equipment is being calibrated.
2. Ensure that all inspections and tests are carried out as per
Project requirements and that all are recorded.
3. Maintaining all quality records relevant to verification of records.
3 Site Engineer & Site 1. It is the Site Engineer / Site Supervisor’s duty to organize the
Supervisor work force in a safe manner and to ensure that safety and
protective equipment are being properly utilized.
2. He must also ensure that the method statement procedure is
followed
and notify the HAC Q.C / EHAF International for inspection.
4 Safety Engineer 1. The Safety Engineer is responsible for devising and implementing
programmers and plans to safeguard, health and safety of all
employees, and to prevent loss or damage to the existing assets and
 projects.
2. He is responsible for the implementing of the safety programs.
3. Provide support to site safety officers advising them on safe
working methods and assisting with training of personnel.
4. Carryout regular site safety audits and reports and correct unsafe
work practices and potential hazards.
5. Investigate and report all accidents near misses and
recommend prevention measures.
6. Ensure maintenances of good hygienic standards and availability
of safety equipment and first aid treatment.
7. Present monthly safety reports and required documents.
5 Safety Officer 1. The day-to-day activities of maintaining safety on project site, they
must: Understand and comply with requirements of the safety
manual.
2. Cooperate with the safety engineer to create and maintain
safe working conditions.
3. Assist the site engineers and foremen to organize the work area so
that the men can perform their duties with maximum efficiency and
minimize risk to themselves or to equipment.
4. Inspect equipment and tools before use to ensure correct storage
and properly utilization. Maintain record of all injuries and
damages on site, submit reports as required.

RISK ASSESSMENT:

Activity Sub Activities Identified Hazard and Controls

(Break the job Assessment (What you are going to do to make this step as
down into steps) (What can cause a high safe as
degree of harm?) possible, include equipment to be used where
appropriate)
Installatio 1.Mobilization Lack of awareness 1. Awareness about the basic precaution
n of new of manpower/ during movement which should to be taken by workers and
AHU. Site survey of on site/work leads foreseen hazards present on the site is
work location to personnel imparting by HSE induction training.
injury. 2. Job specific training.
3. Controlled entry of only trained workers
at the site by means of gate pass issued
only to those who have been imparted
HSE induction training.
4. Adequate supervisor should available at
site on regular basis.
5. TBT should be attended by all person daily
basis and record should be maintain.
6. Applicable PPEs like safety Helmet, Safety
shoes, safety goggles. Reflective jacket
should be available to workers.
Installatio 2. Mobilization Of Fall of Person due All scaffolding equipment and tools should be
n of new scaffolding to use of defective in perfect & sound condition.
AHU. material. material 2. Ensure all material is checked at gate as
Slip, trip, cut hazards per checklist before using on site.
3. Ensure only approved & valid equipment and
tools is used for the scaffolding.
4. Ensure rejected & damaged material is
immediately disposed off / send out of the
site on same date.
5. Use of hand gloves (Cut-1) while handling of
scaffolding & other height work material.
6. All access should be clean & clear from
obstruction.
7. Maintain good housekeeping in working
place.
8. All sharp edge should be
covered

Installatio 3. Stacking of Sliding or toppling 1. Ensure ground level should be well

n of new Scaffolding material of materials while compacted before stacked of material.
AHU. put on soft 2. Use of wooden sleeper below the material.
material/ uneven 3. Material stacked area should be proper
surface, fall of barricaded with caution signage.
material due to 4. Do not stack the material adjacent to
uneven surface excavation pit or any loose place.
5. Stacking height should not be more than
shoulder height (1.2m).
6. Appropriate gap shall be maintained while
stacking of material to ensure that no body
part is trapped/ stuck while work is in
progress.
7. Check the line & level of stack and all
elements are stacked on wooden
planks/wooden blocks.
8. Barricade the stack area & put the visual
control signage.
9. Adjacent stacks shall be spaced apart and not
touching each other.
Installatio 4.Shifting the Slip, trip, hazards 1. Ensure all access is clean & free from
n of new scaffolding material personal injury due obstruction.
AHU. from stack area to to lifting excess 2. Provide the appropriate PPEs (Safety
work location. weight Helmet, Safety Jacket, Safety Shoe, Hand
Gloves cut level-1, Safety Goggle).
3. Work should be done under expert
supervision.
4. Provide the shoulder pad for all workers who
are involved in manual shifting activity.
5. Separate work permit should be taken from
authorized person.
6. All slippery area should be covered with
sand.
7. Ensure no any person lift above 16kg
load.
8. Provide the shoulder pad for worker.
9. Material handling training should be
conducted before commencement of work.
 10.Platforms are properly tied throughout the
vertical height of scaffold as it progresses.
11. Temporary railing by rope or pipe is
carried out on the scaffolding platform
Where persons are working.
12. Scaffolding is used for the purpose
(General, Light & Very light) to which they
have been erected. They are not overloaded
under any circumstances.
13. Personnel working on scaffolds are
instructed not remove or alter an existing
scaffold.
14. Any person on top of scaffolding ensures at
first that the scaffolding is properly secured by
bracings and is safe.
15. Mobile scaffold towers should never be
moved while people are still on the
platform.
16. Mobile scaffold towers to be properly
braced.
17. Ensure proper brakes are provided for
mobile scaffolds.
18. Ensure brakes of mobile scaffolds are
applied & jacks grounded before using it.
19. Material for scaffold erection to be shifted
manually under close supervision.
20. Red & Green Tag to be
used.

Installatio 6. Working on 1. Collapsing of 1. Always use safety harness with double

n of new scaffolding scaffolding land yard and shock absorber.
AHU. 2. Personnel injury 2. Always use all required PPE (like Safety
shoes, fluorescent jacket, and helmet etc.)
3. Only HSE inducted person allow to carry out
the activity.
4. Scaffold trained person allowed to carry
the work on scaffoldings.
5. Height work permit to be taken before
starting the height work (above 1.2meter)
activity.
6. No mobile use while working at height.
7. Proper illumination to be maintained (if
work is extended/ night work)
8. The fall area below & around the scaffold to
be properly barricaded.
9. Housekeeping to be maintained all time till
completion of the task.
Installatio 1. New AHU 1. Muscle strains, 1. Before starting the work, all person should
n of new material Pulls and be attending the TBT (Tool box talk) on daily
AHU. loading/unloading respective motion Basis.
lifting (max height- injuries. 2. Deployement of experienced personnel.
2mtr, weight- 01 2. Fooot or 3. Workers need to maintain Gap/Distance from
Ton) shifting & leg injuries. moving materials to placing them under
positioing of 3.Finger or required area.
different size of hand 4. It is recommended that workers use either
required tools & injuries. rock bars or hand lifting rope to minimize the
different size of 4.Cut injury potential for injuries to hands.
Electrical due to sharp 5. Proper techniques of stretching, lifting,
panels,cables GI edge. bending, moving, rolling.
sheet 5. Slip, trip, and 6. Manually single person should not lift more
channel,valuve,cab fall of person due that !6kg, trolley/hand lifter shall be provided.
l e drum. Etc. to obstacles in 7. Materialshall be properly stacked and to
access/egress. be tied if required to avoid fall/loss of
-Manually 6. Fall of materials control.
-Hand pallet due to failure lifting 8. For material handling by using crane rigging
trolley/hand - acceries. plan shall be prepared and sign off from signal
trolley 7. Loss of man & driver to be taken.
-By crane(for heavy control of 9. SLI must be available in crane.
loaded material) materials. 10. All safety features must be inspected before
8.Crane start of use of crane daily, TCL-crane
2. Shifting of tools failure. guideline shall be followed.
& materials from 9.Hand trolley 11. All lifting tools and tackles should be
ground floor to failure due to inspected visually and as per approved
roof,Materials overload. 10.Failure checklist before use.
mannualy of lifting Ensure lifting items should not be damage and
accessories. respective TPI certificate available at site.
11.Suspended load. 13.Ensure working area should be barricaded.
14. Authorised supervisor should be available on
regular basis during activity. Even work should
not be progress without supervisor.
15. Ensure information should be shared with
TCL team before one week for major activity.
12. Ensure involved workman should be worn
proper PPEs like gloves (cut resistance) safety
shoes, reflective jacket, safety goggles.
Installatio 3. Hanging of chain Physical hazard 1. Proper supervisions should be ensured in
n of new block in AHU -Head injuries. the lifting area.
AHU. structure -Eye injuries. 2. Use of mandatory PPEs for all workmen.
-Fall of person. 3. Deploy trained person for the job.
-Fall of material 4. Do not lift over 16kg per person.
(chain block 5. Provide adequate manpower.
while working) 6. Provide tagline on all hand tools.
3. -Ergonomic 7. Chain block TPI should be ensured.
hazard 8. Chain block safety latch should be in
working.
9. Use of FBI with DLSA and ensure
anchoring height.
10. Maintain good body posture. If not
possible, take periodically rest.
Installatio Lifting & shifting of -Physical hazard 1. Use of mandatory PPEs. Deploy trained
n of new AHU by using chain -Properly damage person for the job.
AHU. block -Slip & Trip 2. Excess overweight material beyond the
-Crushing?cut injuries. 75% capacity of chain block shall not be
-Hit of objects allowed.
-Roll over materials 3. Lifting materials shall be properly
tightened with D- shackles, I-bolt & Web
sling belt. All these should be certified &
tested by third party.
4. Guide rope should be used while lifting
materials.
5. Proper manual handling techniques
should be followed.
6. Use of proper hand trolley for shifting of
materials.
7. Access free from obstruction should
be ensured.
8. Additional person should be engaged as
per the size of the objects.
9. Proper rest & job rotation should be
followed & maintained.
10. Proper staking methods should be
maintained.
11. Enough space between materials
should be maintained.
12. Sharp edges & protruding parts be
covered with the required materials.
13. Adequate illumination should be
maintained.
14. Required stopper/chokers should be
ensured for the rolling materials.
15. Ensure maintain safe distance while
stacking of unloading materials.
16. Skilled persons are only allowed to
person the activity.
17. Use of ladder to climb on the AHU.
RESOURCES:

- Equipment & Machinery:

- Mechanical Hand Tool

- Fork Lifter
- Material Handling trolley
- Chain Pully

- Tools Required:

- Standard Mechanical Toolbox kit.

- Standard electrical toolbox kit
- Pipefitter toolbox with complete hand tools
- Measuring tape
- Digital Multi meter
- Cleaning Brush
- PPE (Hand gloves, face masks, safety goggles)
- Safety harness (for high-level work)
- Trouble Light
- Mobile Scaffolding & Ladders
MOBILIZATION:
 Preparation and Planning

1. Precautions, manpower, and equipment are available before the commencement of work.
2. The Site Team shall make sure that access roads are always clear from any obstruction
and the site is always accessible.

 Site clearance

1. Before commencing the work, the area shall be cleared of all debris,
materials, or other obstructions.
2. The Site Team with the assistance of the Safety Officers shall coordinate logistics
and materials movement through the site following the direction on site.
3. The Work Permits and Operator Certificates shall be compiled and files for
reference by authorized personnel.
 Pre-construction Safety Meetings

1. The meeting shall be scheduled prior to the beginning of the work and before any
Subcontractor starts on the project.
2. Safety awareness meetings will be conducted every working day morning/every other
day to brief the workforce on safety prevention measures. The equipment check for
safety shall be recorded/ documented during the daily Safety Awareness Meeting.
3. Traffic safety will be discussed to emphasize these meetings.
4. Each worker will be instructed to follow specific safety requirements related to his
trade. They will be required to follow installed safety signs, observe barricades and
use PPEs.
5. The Safety personnel will perform hazard risk analysis by identifying all steps, hazards
identified in those steps, with a focus on the relationship between the work task, the
tools, and the work environment. After identifying uncontrolled hazards; the Contractor
will take steps to eliminate or reduce them to an acceptable risk level.
6. General Contractual Safety, Health, and Environmental requirements.
7. Roles of the contractor, subcontractors, authorized representatives, and all project workers.
8. Accident reporting requirements.
9. Specific details of the work to be performed along with the use of personal protective
equipment.
10. Emergency procedure.
 Operating Procedures

A site investigation has to be carried out to develop safety precautions and measures prior to
the commencement of the work. After such investigation, relevant signboards will be displayed
and
barricades will be installed where and as necessary, such as but not limited to the following:

1. Relevant information, advanced signs, warning, and mandatory signs will be placed as
required.
2. After completion of the work, safety cones and barricades have to be removed accordingly.
METHODOLOGY:

The installation AHU will be according to the recommendation from the manufacturer’s Method
Statement.

 OFFLOADING:

1. Special care must be taken to ensure that units are offloaded from the containers.

2. Rough handling can result in damage to the aluminium framework and double-skin panels.

3. It is possible to lift the sections by slings or by forklift. Slings, preferable nylon, must be
placed around the structural base frame.

4. In the case in which the lifting tube is utilized, it must be inserted into the specific hole,
then the sling, which is equipped with a particular loop, must be connected to the tube.
After that, the section can be lifted.

5. Note: It is strongly recommended that offloading and installation operations will be carried
out by specialists with the necessary equipment and proper tools.

6. Special care must be taken to ensure that units are offloaded from the containers.

7. Rough handling can result in damage to the aluminium framework and double-skin panels.

8. It is possible to lift the sections by slings or by forklift. Slings, preferable nylon, must be
placed around the structural base frame.

9. In the case in which the lifting tube is utilized, it must be inserted into the specific hole,
then the sling, which is equipped with a particular loop, must be connected to the tube.
After that, the section can be lifted.

10. Note: It is strongly recommended that offloading and installation operations will be carried
out by specialists with the necessary equipment and proper tools.

 INSTALLATION:

1. Prior to installation, it must be ensured that adequate access exists for connecting all supplies,
disposal of condensate/overflows, inspection, maintenance, and replacement of renewal parts
such as filters, belts, bearings, etc.

2. Installation of units must be in ·accordance with good engineering practice. Structural base
units must be level and rigid. Further, it must be ensured that the base is high enough from
the floor to allow the installation of a condensate drain with the necessary trap for easy flow.
General Installation of Floor Mounted AHU

1. The AHU shall be supported on concrete bases using neoprene pads.

2. AHU shall be installed level & plumb.

3. Arrange installation of units to provide access space around AHU for service and maintenance
(coil removal). Floor mounted AHUs with internal isolation shall be supported with internal
supplies, disposal of condensate/overflows, inspection, maintenance, and replacement of
renewal parts such as filters, belts, bearings, etc.

 ASSEMBLY:

1. Units are normally designed to make the best use of containers (shipping) volume in two or
more sections depending on the design of units. However, all the sections are externally marked
and their sequence of assembly can be easily identified from the enclosed drawings. Once all
the sections are located, they can be easily aligned and locked together.

2. First of all, between the sides of the sections that shall be connected, it must be inserted with a
continuous foam gasket for an airtight seal, Push the sections towards one another, making sure
that they are lined up with one another as shown below.

 SETTING UP OF COMPONENTS:

• DUCT CONNECTION

When duct flanges are connected to damper frames, it must be ensured that the fixing bolts are
of the correct length and do not obstruct the movement of the damper lever/linkages.

• DAMPERS

All dampers must be checked for free movement prior to proceeding further.

1. Manually operated dampers can be adjusted to obtain the required airflow, by loosening
the bakelite knob and then turning the control lever. The Bakelite knob must be
tightened after setting up at the desired location on the locking quadrant.

2. Motorized dampers are supplied with the linkage rod for connection to the actuator. It
must 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 at-
 tempt to push the damper beyond fully open or fully closed positions.

• FILTERS

1. Check the type and quality of filters are in accordance with the drawing.

2. Panel Filters: flat or corrugated media are normally fitted within the unit prior to shipping.

3. Bag Filters: pre-filters (if any) are normally shipped in closed carton boxes, as supplied by the
filter manufacturer, to avoid any collection of dust and loss of efficiency prior to commissioning.
Each bag filter is housed within a special holding frame with the necessary locking spring to
ensure proper sealing. A bank of such special frames (quantity depends on the type and airflow)
is assembled within the peripheral aluminium framework of each bag filter section. The entire
assembly along with the pre-filter must be locked with four springs to ensure no leakage of air.

4. Automating roll filters have two headers, one house the clean spool, while the other dirty spool,
which is driven by a geared motor and chain drive actuated by differential pressure (D.P.)
switch. Normally filter media and D.P. switch are supplied loose for site installation. For
assembly, the filter media roll is mounted on the clean spool header, taken along the guide
channel through the working section, and locked to the dirty (driving) spool. D.P. switch must be
installed and connected to the control panel.

5. Automating roll filters have two headers, one house the clean spool, while the other dirty spool,
which is driven by a geared motor and chain drive actuated by differential pressure (D.P.)
switch. Normally filter media and D.P. switch are supplied loose for site installation. For
assembly, the filter media roll is mounted on the clean spool header, taken along the guide
channel through the working section, and locked to the dirty (driving) spool. D.P. switch must be
installed and connected to the control panel.

6. Absolute Filters are shipped in sealed carton boxes, as supplied by the filter manufacturer. They
are housed in a special purpose made of an aluminium frame with corner brackets and 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 air leakage.

7. Other types of filters such as actuated carbon, inertial (sand) filters, if installed, will be
supplied with the manufacturer’s instructions along with the units.

• HEAT EXCHANGER COILS

All coils are leak tested and checked prior to assembly. Fins are checked for proper
condition prior to shipping. However, during handling and 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 layout should take into consideration of possible coil withdrawal. All connecting
pipework must be properly insulated.

1. Water Coils: system design, pipe connections, and valve arrangement must be in
accordance with good engineering practice. Flow and return connections are clearly
identified on the unit panels and pipework must be connected accordingly, preferably
through flexible couplings to avoid transmission of any vibration from the piping to coil.
The piping shall be free of any strain and shall not exert any load on AHUs and FAHUs (Fresh
Air Handling Units).
 Excessive tightening torque might damage the coils. Pipework must be supported
independently to the coil and/or the unit. Use a pipe wrench to restrain the pipe connections
of the heat exchanger when tightening the external pipe connections.

2. Plugged drain: Plugged drain and 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 anti-freeze chemicals must be added to the circulating water in
cooling coils when there is a possibility of being exposed to temperatures below 2°c. It is
recommended that the water flow is shut off when the fan is switched off.
Normally each heating coil should be provided with its own circulation pump. This ensures
even circulation of the water in the air heater, regardless of the position of the control
valve, and provides the following important benefit:
Appreciably less risk of freezing, due to the fact that the water velocity in the coil is always
sufficiently high.

3. Condensate Drains: All chilled water coils must be individually trapped and connected to
the drain with an adequate pitch for easy flow. It is recommended to install a trap.
Depending on the ambient temperature and plant location, it is recommended to insulate
the condensate drain pipework.

• SUPPLY AND RETURN AIR FAN ASSEMBLIES

1. Anti-vibration mounts, on which fan & motor assembly is suspended, are locked Prior to
shipping to avoid damage during transit.
2. Once the unit is in position and the fan outlet is connected to ductwork, Anti-vibration
mounts must be released.
3. Check the type and voltage of the motor. If information is made available, cable entry holes
through the double-skinned panels can be factory drilled. However, it is a simple operation
to carry out the same on-site, but ensure that no holes drilled and no connections are made
through the access door. It is recommended to use a flexible armoured conduit between the
panel and motor terminal box. All conduits/wiring must be carried out in accordance with
local standards.
4. Check the type of start (direct online/star delta) that meets with the local electrical
regulations. Provide starter/controls/overload protecting devices/interlocks as required.
5. Manufacturer instructions, which are supplied along with the motor, must be carefully studied
and followed. Ductwork must be connected and insulated in accordance with good engineering
practice. Depending on specified noise levels, attenuators are to be selected and installed as
per the recommendations of acoustic specialists. It is 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

1. 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 and
fan bearings may be over-loaded.
2. When correctly tensioned, the belt deflection L will be 15 mm per meter of distance between
centres when a force P1 ( N ) is applied and P < P1 < 1.5 P, where the force P is dependent
on the belt type. The deflection should be measured preferable by means of a tensiometer.
• ELECTRICAL CONNECTIONS

Electrical power connection shall be done as per the approved drawing.

The cable shall be installed, terminated, and tested as per the approved method statement.
Note: Separate Method Statement for Electrical Connections, Cable Laying Terminations,
 Isolators, etc. will be submitted under Electrical Discipline.

• TESTING

1. Leak test: After installation and completion of valve package connection. Fill the unit with
water and test connections for leaks. Repair leak and retest until no leak exist.
2. Fan operational test: After completion of electrical connection and energizing, start unit to
confirm proper motor rotation and unit operation, remove malfunctioning unit, replace with
the new unit, and retest.
3. Test and adjust control and safeties: Replace damaged and malfunctioning control and equipment.

QUALITY ASSURANCE:

• Quality Assurance Requirements

1. The contractor shall provide the required documents for the Consultant’s approval
prior to initiating the execution of this activity as per project specifications.
2. The quality control requirement shall include related quality procedures QCP, ITP’s and
other related documents as applicable. Refer to Inspection Test Plan.
3. Applicable codes and standards for materials are project specifications.

• Quality Assurance Process

The contractor shall notify the engineer prior to the start of the activity and Comments from
the site Instruction will be complied with the satisfaction of the consultant.

• Follow-up and Evaluation

1. Follow-up on quality performance shall be carried out through an in-house monitoring

system such as progress reporting to the planning department, daily, weekly and monthly
reports generated by the planning department to closely monitor site performance in
general and reflect on quality performance in specific.
2. All the above shall be conducted in close coordination with the quality department to
monitor any deviations from the normal quality requirement and induce corrective actions
whenever required to eliminate non-conformance or quality deviations.
3. All remedial actions to be taken, if any, shall take into account the official schedule which is
to be used as a guideline for performance and most importantly under the close supervision of
the quality control department
Note :
If required for a specific work, detailed method of control for any additional hazards will be provided
separately.

Accepted by: