Document No.

: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

1: Introduction
An Air Handling Unit (AHU) is used to air circulate as part of a ventilating and main cooling system. The basic function
of the AHU is to take in air, cooled it and supply it to the office to maintain the temperature.

2: Purpose
The purpose of this Standard operating procedure (SOP) is to set a procedure, which the technician will follow to
ensure the work is as per the technical and HSE standards.

3: Scope
 Permit to work.
 Isolate power source.
 De-energize, Test and confirm, there is no power source available.
 Ensure earthing is proper.
 All power tools used should be of low voltage If possible, the tools should be double insulated with joint free
cables, PAT tested and tagged.
 Do not wear any jeweler while working with electricity and near rotating equipment.
 Proper access with fall protection (Ladders can be used for short duration, Scaffolds to be used for longer
duration and height. Work at height permit to be obtained if working at higher elevations)
 Manual handling is allowed for load below 20 kg only, for loads above mechanical handling to be employed.
 This load is not permissible at higher elevations.
 Provision for collection and proper disposal of spills to be provided to avoid flooding and damage of assets.
 MSDS of chemicals used should be displayed (if any is used).
 Breathing protection to be used to avoid contaminated / Toxic dust entering in to the body by inhalation
 Hearing protection to be used in plant rooms where noise levels are high
 All other appropriate P.P.E to be worn
 Long hair, long beard and loose clothing is a hazard of entanglement near moving equipment.
 Hand tools to be inspected and tagged
 Do not remove any protection guards
 Hot work is controlled by permit, All necessary precautions like fire watch, fire blankets, flash back arrestor etc.
to be provided, all sparks from cutting or welding activities.
 Portable fire protection systems and adequate signs to be posted.
 Never attempt to reach overhead services without adequate access and proper visibility.
 Tool Box talk to be provided by the respective hard services supervisor or authorized technician briefing the
PPM expectations.
4: Responsibilities
 Site leadership team is responsible in devising the PPM schedule and in ensuring that the team on ground
follow the Annual PPM schedule.
 The Annual PPM schedule includes the Frequency of the PPM based on the asset condition. (FMR register to be
reviewed to validate if the PPM schedule captures the assets requiring regular maintenance)
 Site leadership to ensure system is functioning optimally after the PPM task.
 Site leadership to ensure care and maintenance requirements are followed by maintenance staff during the
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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

PPM.
 Site leadership team to validate the completed PPM tasks and to check in random the completed task to
ensure the service standards as per the OEM recommendations.
5: Safety Precautions
 Prior to any maintenance, shut off the electric power supply and lockout
 Check if there is any restriction or permit requirement in the equipment to open the panel. In that case inform,
your immediate manager
 To avoid hand injuries, always wear gloves
 Check if anything is forgotten before starting the unit again
 Never stop the motor by hand, but let it stop on its own
 Excessive grease can cause overheating
 Request to supervisor for any support.
 Conduct site survey and make sure you are safe before start the works.
 Make sure that there is no unsafe electrical power source

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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

6: Procedure
SI No. Activity Reference Pictures

Prepare all the materials that you will need (Vacuum cleaner,
1
grease pump and grease, tool box and ladders)

Check if the panel corresponds with the AHU in which we are

2
going to work.

3 All the safety operations are done from the panel.

4 Switch off the AHU.

Turn off the main switch and put a safety tag. ( Follow Loto
5
Procedures )

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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

7 Check for absence of power.

8 Lock out at the main switch and put a safety tag.

Take off the protection grill of the motor unit.

Examine drive belts for tension and wear, adjust or replace from
9
site stock.
Check drive pulleys for alignment, adjust as necessary.

Loosen the adjustable tangent.

10 Check the pulley condition, it should not be marked.
Re-install the protective grill after checking/replacing the belts.

Check all pipe works and for sign of leaks and reports. Clean the
11
condensate U trap every 3 months.

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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

The drain pan and drain lines if applicable, should be checked to

12 see that any forming condensate is being properly drained
without restriction. Clean inlets & outlet vent coil.

13 Clean and grease dampers and actuators.

14 Check air intake/outlets for obstructions and clear as necessary.

Check the operation of the inlet and recirculation dampers and

15
lubricate as necessary.

16 Check for any damage of inlet guide vanes and clean it.

17 Check condition of all fixed filters. Change from site stock as

necessary.
Take out the pre filters and the bag filters.

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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

Clean all the surfaces by means of vacuum cleaner, brush and

18
wipe them

Examine all holding down bolts and tighten as necessary.

19 Inspect anti-vibration mountings and report any apparent
defect.

Check that the canvas flexible duct connections are properly

20
secured.

21 Check fan shaft bearings for wear by testing, float and side play.

22 Clean down motors and bases. Tighten the electrical

connections and check the wires. Clean out motor windings
ventilation louvers and internals with compressed air, if
required.
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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

Clean all the parts inside including the wheel impeller and
23 motor.
Clean all AHU internal surfaces, including fan casing.

Re-lubricate bearings as necessary. Add grease through the fan's

24
bearing nipple.

Check all doors access seals and report for any air leakage
25 deterioration.
Check the light and door's seal.

27 Remove lock and safety tag. Turn on the main switch.

Turn on the AUH switch. Put in to Auto mode. Check for full
28
motor running and temperature.

29 Check if the unit starts up and the dampers are fully open.

After half an hour, check for the belt tension again and install
30
the protective grill.

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 Document No.: KHI-IFM-INTT-SOP-01
Standard Operating Procedure
Version: 1.0
Planned Preventive Maintenance for Air Handling Unit
Effective Date: May 2022

Check the amps balancing details and report for any

32 abnormalities.

33 Fill the PPM Check list and take the signatures.

7: Reference Documents
ASSOCIATED CHECKLIST, FORMS OR DRAWING
Checklist Number: KHI-IFM-INTL-F-013
8: Revision & Approval
Revision # Prepared by Revision Detail Date

1 Sarbjit Singh Nil May 2022

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