Effective Date : Jan-2013

Document No : Mech – MS003

METHOD STATEMENT FOR
Revision No : 0
HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 1 of 9
Approved By :

PROJECT

METHOD STATEMENT FOR

HVAC SYSTEM
SERVICE AND MAINTENANCE WORKS
****

(Electromechanical)

AMENDMENTS

REV. PAGE APPROVED BY EFFECTIVE

DESCRIPTION OF AMENDMENT
NO NUMBER (SIGNATURE) DATE

DESCRIPTION TITLE SIGNATURE DATE

Prepared by M. SENTHIL KUMAR

Reviewed by M. MOHAMED HIDHAYATHULLA

Approved by M. SAMEER AHAMED

 Effective Date : Jan-2013
Document No : Mech – MS003
METHOD STATEMENT FOR
Revision No : 0
HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 2 of 9
Approved By :

PROJECT
CONTENTS

1. Activity

2. Introduction

3. Terminology

4. Significant hazards indentified and Control measures

5. Roles & Responsibilities.

6. Sequence of Activities

7. Requirements

7.1. Plans / records and job instructions (documentations)

7.2. Trainings

7.3. On site risk assessment

7.4. PPEs (Personal Protective Equipments)

7.5. Equipment and Tools required

7.6. Additional requirements

8. Emergency Procedures

9. References

10. Attachments
 Effective Date : Jan-2013
Document No : Mech – MS003
METHOD STATEMENT FOR
Revision No : 0
HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 3 of 9
Approved By :

PROJECT

1. Activity

This Method statement illustrates all necessary procedure to be adopted during Service and Maintenance works on
HVAC system,

2. Introduction

 HVAC System Service and Maintenance works shall be carried out as per below procedure.

3. Terminology

 AHU – Air Handling Unit.

 CU – Condensing Unit.
 EH – Electric Heater.
 EF – Extract Fans.
 MFD – Motorized Fire Damper.
 MD – Motorized Damper.
 VCD – Volume Control Damper.
 AD – Access Doors.
 GA – General Arrangement.
 SLD – Single Line Diagram.

4. Significant hazards identified and Control Measures

4.1. Hazards

 Fall of Materials.
 Slip / Trip / Fall – Same level.
 Fall of Person from Height.
 Tools.
 Manual Handling.
 High Pressure.
 Flying Particles.
 Pinch Points.
 Electrical Hazard.
 Fire Hazard.
 Effective Date : Jan-2013
Document No : Mech – MS003
METHOD STATEMENT FOR
Revision No : 0
HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 4 of 9
Approved By :

PROJECT
4.2. Control Measures

 Fall of Materials:-
o Unwanted Materials shall be cleared from roof Area.
o Proper storage of Materials and tools shall be carried out.

 Slip / Trip / Fall - same level (At work spot):-

o Work spot shall be kept free from loose materials
o Proper storage of Materials and tools shall be carried out.

 Fall from height:-

o Employees shall be strictly instructed to use A- Type ladder only.
o Top 2 rungs of A-Type ladder shall be covered.
o Ladder shall be hold by an employee.
o Safety shoes shall be checked for cleanliness while climbing ladder.
o Ladder shall be inspected prior to work start.
o Full body harness shall be worn and hooked up.

 Tools:-
o Hand / Portable tools shall be inspected prior to work starts.
o Skilled personnel shall be deployed.
o Correct tools for the job shall be ensured.
o Helmet, Safety Shoes, Hand gloves shall be worn.

 Manual handling (shifting / manual lifting):-

o Manual handling techniques shall be communicated.
o Wear PPEs and any additional safety requirements.
o Come close to the load to be lifted & attain a firm stable position.
o Keep head up, arms close to body.
o Bend at hips & knees to get down to the load.
o High level lifting should be preferred to stages.
o Don’t twist the body to change direction.

 High Pressure (gas filling / flushing):-

o Calibrated pressure gauges shall be made available.
o Skilled personnel shall be deployed for filling / flushing the gas.
o Pressure to be maintained shall be communicated to the concern technician by competent person as per
specification.
o MSDS shall be referred and followed.
 Effective Date : Jan-2013
Document No : Mech – MS003
METHOD STATEMENT FOR
Revision No : 0
HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 5 of 9
Approved By :

PROJECT
o Prior inspection by competent person shall be done.

 Flying particles (usage of air compressor / vacuuming of CU compressor):-

o Air compressor hoses shall be inspected for any damages prior to work start.
o Whip arrestor shall be provided in hose joints.
o Goggles shall be worn by all employees engaged.

 Pinch Points:-
o Utmost care shall be taken while shifting equipments.
o Hand gloves shall be worn.
o Communication from one person to lead the team.
o Wooden strip shall be provided below the compressor as and when required to avoid pinch point hazard.

 Electricity Hazard:-
o Power Supply to be isolated by Competent person
o TBT shall be conducted for all employees involved in the activity.
o All power supply shall be routed through appropriate circuit breakers which shall be ensured
by competent person (LOTO system shall be followed).
o Helmet, hand gloves, safety shoes, coverall and jacket shall be worn

 Fire Hazard:-
o Waste that have generated shall be discarded through approved agency.
o Portable Fire Extinguisher to be made available near work spot.
o Slip resistant safety shoes, helmet, jacket, coverall and Hand gloves shall be worn.

5. Roles and Responsibilities

 Competent Person
o Ensuring the safe work environment to employees.
o Plan the required resources such as Manpower, Material, and Machineries... well in advance
and ensure the same prior to the commencement.
o Ensuring necessary approved documents at site.
o Ensuring by physical verification about the controls at work spots are in place.
o Verifying the percentage compliance as per risk assessment.
o Ensuring the emergency preparedness.
o Ensures availability of the necessary resources
o Internal checks about the acceptable criteria upon completion.
o Getting O/E Witness Inspection Clearance.
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Document No : Mech – MS003
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AND MAINTENANCE WORKS Page No : Page 6 of 9
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PROJECT
o Conducting TBT based on risk assessment.
o Ensuring the proper usage of recourses by direct supervision
o Implementing the control measures as per risk assessment and also as mentioned in the
permit.
o Close monitoring till completion of work.
o Ensuring the acceptable criteria up on completion of each task.
o Closing the work permit after restoration of work spot.
o Ensuring Proper housekeeping

 Workmen
o Wearing appropriate PPEs.
o Understanding and following the instructions given by line staff.
o No horseplay and shortcuts.
o Follow safety instruction as stated in the LAP / PTW system.

6. Sequence of activities

o Obtain the LAP.

o Barricade the work area.

Maintenance of HVAC unit

o Switch off the running HVAC unit power supply.

o LOTO system to be followed and communicated to all parties.
o Switch ON the Stand-by unit and put into service.
o Compressor terminal box will be covered by plastic cover to prevent water penetration.
o Start water service for condensing unit which is in switch-off condition.
o Check the compressor oil level.
o Clean the AHU pre-filter.
o Check belt tightness and motor bed tightness.
o If required adjust motor bed.
o If required clean the AHU indoor coil.
o Remove all plastic from compressor terminal box which have been provided earlier.
o Switch-on the unit and check gas pressure and other parameters.
o If required top-up gas for compressor which has less gas.
o Repeat the above procedure for remaining other units.
o After completion of work HVAC System all Units will be changed in Auto Mode.
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Document No : Mech – MS003
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HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 7 of 9
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PROJECT
o After completion of work area will be cleaned and unwanted materials will be removed from
work side.
Compressor servicing and Reinstallation

o Electrical works related with HVAC System will be carried out by relevant Electrical Engineer /
Supervisor of HVAC Subcontractor.
o Main Power Supply of AHU & Condensing Unit to be Isolated from HVAC Control Panel & CU
Isolator which is Faulty
o LOTO system to be followed and communicated to all parties.
o Disconnect the Suction and Discharge Refrigerant lines from the particular Compressor which
is faulty.
o Existing Faulty Compressor to be disconnected and returned to unit manufacturer for
overhauling.
o New Compressor or overhauled compressor to be installed.
o The refrigerant lines to be flushed with Nitrogen Gas.
o Connect the Suction and Discharge Refrigerant lines to new compressor
o Leak test to be conducted after connecting of New Compressor and Refrigerating pipes.
o New Filter Drier Core to be fixed.
o System to be vacuumed.
o Compressor Oil to be changed.
o Refrigerant to be charged in the system.
o Replace the contactor if defected and fix New Contactor.
o Condensing unit to be put in to service.
o Check the unit parameters

Fire Pump Room Split Air-Conditioner

o Switch off the Split Air- conditioner and isolate the power supply.
o LOTO system to be followed and communicated to all parties.
o Service the Split Air-conditioner
o Check Refrigerant charge, terminal tightness, contactor and rectify if fault
o After completion of work split Air-conditioner switched on the power supply
o After completion of work area will be cleaned and unwanted materials will be removed from
work side.
o For all the above works safety precaution will be taken care.
 Effective Date : Jan-2013
Document No : Mech – MS003
METHOD STATEMENT FOR
Revision No : 0
HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 8 of 9
Approved By :

PROJECT

7. Requirements

7.1 Plan, records and job instruction(documents)

 LAP
 Calibration Certificate
 HVAC Layout
 HVAC Control panel wiring diagram
 AHU,CU – Maintenance Manual

7.2 Training

 Tool Box Talk.

 Training on portable power tools usage.
 Manual handling method.

7.3 On site risk assessment

 Risk assessment is attached with this and the same shall be reviewed at site specifically
prior to work starts to ensure the existing controls are adequate.

7.4 PPEs

 Safety helmets, safety shoe, goggles, gloves and coverall, safety harness

7.5 Equipments and tools required

Equipment / tools
 Electrical tool box, Fitter/ Duct man tool box , Ratchet spanner set , Torque wrench , A
type ladder , Portable drilling machine , Portable cutoff machine , Vacuum Pump ,
Nitrogen Cylinder.

Interface activities
 Electromechanical works

7.6 Additional requirements

 First aid facilities shall be made available.

8. Emergency procedures
 Effective Date : Jan-2013
Document No : Mech – MS003
METHOD STATEMENT FOR
Revision No : 0
HVAC SYSTEM SERVICE
AND MAINTENANCE WORKS Page No : Page 9 of 9
Approved By :

PROJECT

 In case of major Injuries

o Do not panic. Call ambulance and notify emergency team at site.
o Do not move the injured unless he is in danger.
o If danger exists, he shall be assessed by a trained and qualified first aider before moving. Use a
stretcher
o Do not crowd around the victim. Do not give anything to eat or drink. Ensure adequate air and
lighting.
o Only trained and qualified first aider shall treat the victim and ensure that his airway is kept
clear.
o Victim shall be transported to hospital in an ambulance.
o Preserve the accident scene for further investigation.

 In case of fire
o Follow Transco’s approved emergency procedure as per HSE Plan.
o Never try to extinguish a fire if you are not a trained fire fighter.
o Sound the alarm and notify the emergency controller at site.

 Emergency contact person

o Competent person

9. References

 Transco Specification
 ETA HSE Plan
 ADEHMS – Rev.2
 HVAC Layout
 HVAC Control Panel wiring diagram
 AHU , CU – Maintenance Manual

10. Attachments

 Refer attached Risk assessment