A detailed AHU ANNUAL preventive maintenance checklist
1. Safety Precautions
- Locate the main power disconnect switch for the AHU.
- Turn off the power supply and secure the switch in the 'off' position.
- Use a lockout/tagout device to prevent accidental re-energization.
- Wear safety goggles to protect eyes from debris.
- Use gloves to safeguard hands from chemicals and sharp objects.
- Don hard hats and steel-toed boots for head and foot protection.
- Obtain the latest SDS for all chemicals involved.
- Read and understand the hazards and safety measures outlined.
- Ensure easy access to SDS during maintenance operations.
- Locate the main power disconnect switch for the AHU.
- Turn off the power supply and secure the switch in the 'off' position.
- Use a lockout/tagout device to prevent accidental re-energization.
- Wear safety goggles to protect eyes from debris.
- Use gloves to safeguard hands from chemicals and sharp objects.
- Don hard hats and steel-toed boots for head and foot protection.
- Obtain the latest SDS for all chemicals involved.
- Read and understand the hazards and safety measures outlined.
- Ensure easy access to SDS during maintenance operations.
- Check all doors and access panels to ensure they are closed.
- Use locks or barriers to restrict unauthorized access.
- Post warning signs indicating restricted areas.
- Walk through the work area to identify any hazards.
- Remove or mark any obstructions present on the floor.
- Clean up any spills immediately to prevent slips.
- Inspect harnesses and lanyards for wear before use.
- Ensure ladders are stable and positioned correctly.
- Use guardrails or safety nets where applicable.
- Open windows or doors to enhance airflow.
- Use exhaust fans if necessary to remove fumes.
- Monitor air quality as needed during maintenance.
- Check that the first aid kit is fully stocked.
- Train personnel on how to use the items in the kit.
- Keep the kit accessible and inform the team of its location.
- Develop a clear evacuation route and procedures.
- Conduct drills to ensure everyone understands the plan.
- Post evacuation maps in visible locations.
- Inspect fire extinguishers for proper signage and accessibility.
- Check gauges to ensure they are fully charged.
- Ensure personnel know how to use the extinguishers.
- Identify and label hazardous materials in the work area.
- Follow local regulations for disposal of hazardous waste.
- Ensure personnel are trained in handling hazardous materials.
- Assign a buddy for each team member working in confined spaces.
- Use radios or hand signals for effective communication.
- Conduct regular check-ins with team members.
- Inspect tools for damage or wear before use.
- Use tools that are appropriate for the specific tasks.
- Report any faulty equipment to the supervisor immediately.
- Fill out incident report forms for any safety issues.
- Review incidents in safety meetings to prevent recurrence.
- Maintain a log of incidents for future analysis.
2. Visual Inspection
- Assess physical integrity of the AHU unit.
- Check for any visible damage or wear.
- Review cleanliness and order of the surrounding area.
- Identify any potential hazards or obstructions.
- Inspect all visible pipe connections and joints.
- Look for puddles or stains around the unit.
- Examine insulation for dampness or mold.
- Check the floor for any signs of water accumulation.
- Ensure all panels are closed and latched properly.
- Check for missing screws or fasteners.
- Inspect hinges for wear or misalignment.
- Confirm that seals are intact and effective.
- Look for tears, fraying, or compressed areas.
- Check for discoloration indicating moisture intrusion.
- Ensure insulation is securely attached.
- Assess insulation thickness and integrity.
- Inspect metal surfaces for rust or pitting.
- Look for flaking paint or protective coatings.
- Check joints and fasteners for signs of corrosion.
- Assess the condition of any exposed metal parts.
- Inspect brackets for bending or cracking.
- Check for loose bolts or fasteners.
- Ensure supports are stable and secure.
- Look for signs of rust or corrosion.
- Listen for rattling, grinding, or humming sounds.
- Check for excessive vibrations that could indicate misalignment.
- Observe operation during peak load conditions.
- Document any irregular sounds for follow-up.
- Inspect for peeling, chipping, or fading paint.
- Check coatings for signs of wear or damage.
- Look for bare metal areas needing protection.
- Evaluate overall aesthetic condition.
- Clear any obstructions near air intake and exhaust.
- Check for accumulated dust or dirt.
- Ensure pathways and access routes are clear.
- Look for any vegetation that may obstruct airflow.
- Verify that all guards are intact and undamaged.
- Check that covers are securely fastened.
- Inspect for any missing safety devices.
- Confirm compliance with safety standards.
- Ensure all signs are legible and displayed prominently.
- Check for any outdated or missing information.
- Verify that safety warnings are clear.
- Assess visibility in both light and dark conditions.
- Inspect for rust, corrosion, or leaks.
- Check for proper drainage and blockages.
- Assess the integrity of the pan structure.
- Ensure the pan is clean and free from debris.
- Check belts for fraying, cracking, or tension issues.
- Inspect pulleys for wear and alignment.
- Look for signs of dust accumulation.
- Ensure all components are properly lubricated.
3. Filter Maintenance
- Turn off AHU before maintenance.
- Remove filters carefully to avoid dust release.
- Clean reusable filters with appropriate methods.
- Replace disposable filters with new units.
- Ensure correct fit in the filter housing.
- Inspect frames for cracks or deformation.
- Check seals for integrity and proper fit.
- Replace damaged frames or seals immediately.
- Ensure no gaps between filter and housing.
- Verify that frames are clean and free of debris.
- Measure existing filter dimensions accurately.
- Note specifications required for replacement.
- Purchase filters that match these specifications.
- Keep records of sizes for future replacements.
- Label filters with size for easy identification.
- Turn off AHU before maintenance.
- Remove filters carefully to avoid dust release.
- Clean reusable filters with appropriate methods.
- Replace disposable filters with new units.
- Ensure correct fit in the filter housing.
- Inspect frames for cracks or deformation.
- Check seals for integrity and proper fit.
- Replace damaged frames or seals immediately.
- Ensure no gaps between filter and housing.
- Verify that frames are clean and free of debris.
- Measure existing filter dimensions accurately.
- Note specifications required for replacement.
- Purchase filters that match these specifications.
- Keep records of sizes for future replacements.
- Label filters with size for easy identification.
- Locate airflow arrows on filter frames.
- Align filters according to the indicated direction.
- Ensure airflow matches system requirements.
- Double-check installation before securing filters.
- Conduct a visual inspection to confirm alignment.
- Use a manometer to measure pressure drop.
- Compare readings against manufacturer specifications.
- Record baseline pressure drop for future reference.
- Replace filters if pressure drop is excessive.
- Regularly schedule monitoring based on usage.
- Identify if pre-filters are installed.
- Remove pre-filters carefully.
- Clean reusable pre-filters or replace if necessary.
- Ensure compatibility with main filters.
- Document any actions taken on pre-filters.
- Inspect seals around access doors.
- Check for wear or damage to gaskets.
- Replace any compromised seals immediately.
- Ensure doors close securely and latch properly.
- Verify no gaps that could allow air bypass.
- Inspect filters for discoloration or odors.
- Wear protective gear when handling contaminated filters.
- Dispose of contaminated filters safely.
- Clean AHU components to prevent future growth.
- Maintain humidity levels to inhibit mold.
- Review manufacturer specifications for filters.
- Ensure filters meet MERV ratings required.
- Verify dimensions and thickness match requirements.
- Consult with HVAC professionals if unsure.
- Keep a list of approved filter types.
- Assess system usage and environmental factors.
- Establish a maintenance schedule accordingly.
- Set reminders for upcoming maintenance tasks.
- Review intervals annually for adjustments.
- Communicate schedule to maintenance team.
- Record filter conditions and maintenance dates.
- Include details of any issues found.
- Log replacement dates and filter types used.
- Maintain a clear history for future reference.
- Use a standardized format for documentation.
4. Fan and Blower Maintenance
- Examine blades, housing, and mounts for cracks or deformities.
- Check for signs of rust or corrosion.
- Ensure all components are securely attached and in good condition.
- Use a laser alignment tool to confirm alignment.
- Monitor vibration levels with a vibration analyzer.
- Adjust or replace components as necessary to reduce vibration.
- Refer to the manufacturer's manual for lubrication intervals.
- Use the recommended lubricant type and amount.
- Check seals and ensure they are intact to prevent leakage.
- Examine blades, housing, and mounts for cracks or deformities.
- Check for signs of rust or corrosion.
- Ensure all components are securely attached and in good condition.
- Use a laser alignment tool to confirm alignment.
- Monitor vibration levels with a vibration analyzer.
- Adjust or replace components as necessary to reduce vibration.
- Refer to the manufacturer's manual for lubrication intervals.
- Use the recommended lubricant type and amount.
- Check seals and ensure they are intact to prevent leakage.
- Remove any debris from the blades and housing.
- Use a soft brush or cloth to clean without damaging surfaces.
- Inspect blades for any physical damage or wear.
- Listen for grinding, rattling, or high-pitched sounds.
- Record any irregularities and investigate potential causes.
- Ensure all components are securely fastened and in good condition.
- Check all bolts and screws for tightness.
- Use appropriate tools to ensure proper torque settings.
- Replace any damaged fasteners as needed.
- Use an anemometer to measure airflow rates.
- Compare readings against design specifications.
- Adjust dampers or other components to optimize airflow.
- Check for fraying, cracking, or signs of wear on belts.
- Ensure belts are properly tensioned according to guidelines.
- Align belts with pulleys to prevent slippage.
- Measure voltage and current using a multimeter.
- Verify readings against manufacturer specifications.
- Monitor for excessive heat or irregular operation.
- Use a vacuum or compressed air to clear dust buildup.
- Wipe down surfaces with a damp cloth as needed.
- Ensure no debris obstructs airflow.
- Inspect all metal parts for discoloration or flaking.
- Treat any corrosion with appropriate rust inhibitors.
- Replace severely corroded parts as necessary.
- Verify that all guards are intact and properly mounted.
- Check that covers are not loose or missing.
- Confirm that safety mechanisms are functioning correctly.
- Analyze past maintenance records for trends.
- Identify any patterns or frequent malfunctions.
- Plan corrective actions based on historical data.
- Check control parameters against specifications.
- Test system responses to control adjustments.
- Adjust settings as needed to maintain optimal performance.
- Record all inspections, repairs, and adjustments.
- Include dates, observations, and any parts replaced.
- Store documentation in an accessible location for future audits.
5. Coil Inspection
- Visually examine coils for dirt, dust, or debris.
- Check for signs of corrosion or rust on coil surfaces.
- Ensure that the coil surface is not obstructed by foreign materials.
- Inspect surrounding areas for leaks or moisture.
- Select a cleaning solution suitable for coil materials.
- Apply the cleaning solution evenly across the coil surfaces.
- Use a soft brush or cloth to gently scrub stubborn stains.
- Rinse thoroughly with water to remove any cleaning residue.
- Inspect inlet and outlet connections for blockages.
- Ensure that drain lines are clear and free of obstructions.
- Verify that water is flowing evenly across the coil surface.
- Test drain pan for proper slope and drainage.
- Visually examine coils for dirt, dust, or debris.
- Check for signs of corrosion or rust on coil surfaces.
- Ensure that the coil surface is not obstructed by foreign materials.
- Inspect surrounding areas for leaks or moisture.
- Select a cleaning solution suitable for coil materials.
- Apply the cleaning solution evenly across the coil surfaces.
- Use a soft brush or cloth to gently scrub stubborn stains.
- Rinse thoroughly with water to remove any cleaning residue.
- Inspect inlet and outlet connections for blockages.
- Ensure that drain lines are clear and free of obstructions.
- Verify that water is flowing evenly across the coil surface.
- Test drain pan for proper slope and drainage.
- Examine fins for bends, breaks, and overall alignment.
- Use a fin comb to straighten damaged fins carefully.
- Replace any fins that are excessively damaged.
- Ensure fins are clean and free from debris.
- Inspect insulation for rips, tears, or moisture damage.
- Check for gaps or areas where insulation is missing.
- Ensure insulation is securely attached to coils.
- Replace any compromised insulation to maintain efficiency.
- Look for oily residues or discoloration near connections.
- Use a refrigerant leak detector for accurate identification.
- Inspect joints and fittings for tightness.
- Document any found leaks for repair scheduling.
- Use a thermocouple or thermometer to measure inlet and outlet temperatures.
- Calculate the temperature differential.
- Compare the differential to manufacturer specifications.
- Document findings for performance tracking.
- Examine supports for rust, corrosion, or structural damage.
- Check that all fasteners are secure and tight.
- Look for signs of sagging or misalignment.
- Ensure the support structure can bear the coil's weight.
- Visually inspect drain pans for dirt and blockages.
- Remove any debris or buildup in drain pans.
- Look for pooling water which indicates drainage issues.
- Ensure drain pans are sloped correctly for water flow.
- Activate the automated cleaning system as per manufacturer instructions.
- Monitor the system for proper operation and effectiveness.
- Check for any error messages or alarms.
- Document the performance of the automated system.
- Record all observations and measurements in a maintenance log.
- Note any repairs needed and prioritize actions.
- Include dates and personnel involved in maintenance.
- Ensure documentation is accessible for future inspections.
6. Ductwork Inspection
- Visually examine all duct sections for visible leaks.
- Use a smoke pencil or similar tool to detect air leaks.
- Check insulation for moisture damage and wear.
- Clean any dirt or debris from the duct surfaces.
- Inspect duct interior for any foreign objects.
- Use a flashlight to illuminate dark areas.
- Ensure that all bends and turns are clear.
- Record any obstructions for further assessment.
- Inspect all joints for tightness and sealing.
- Use duct tape or mastic for any loose connections.
- Check for signs of air leakage around seams.
- Ensure no gaps exist between connected sections.
- Visually examine all duct sections for visible leaks.
- Use a smoke pencil or similar tool to detect air leaks.
- Check insulation for moisture damage and wear.
- Clean any dirt or debris from the duct surfaces.
- Inspect duct interior for any foreign objects.
- Use a flashlight to illuminate dark areas.
- Ensure that all bends and turns are clear.
- Record any obstructions for further assessment.
- Inspect all joints for tightness and sealing.
- Use duct tape or mastic for any loose connections.
- Check for signs of air leakage around seams.
- Ensure no gaps exist between connected sections.
- Inspect all hanger brackets for rust or damage.
- Ensure supports are holding ducts without sagging.
- Tighten any loose hardware as necessary.
- Replace any corroded supports to maintain integrity.
- Look for discoloration or unusual odors inside ducts.
- Use a moisture meter to check humidity levels.
- Document any findings for potential remediation.
- Consider air quality tests if mold is suspected.
- Check for tears, gaps, or water damage in insulation.
- Evaluate insulation thickness and density.
- Replace any damaged insulation to improve efficiency.
- Ensure insulation is securely attached to ducts.
- Check that all dampers open and close smoothly.
- Adjust dampers to ensure balanced airflow.
- Inspect actuator mechanisms for proper function.
- Lubricate moving parts as necessary.
- Look for droppings or nesting materials around ducts.
- Inspect for entry points where animals may enter.
- Consult pest control if infestations are detected.
- Seal any openings to prevent future access.
- Check that access panels are securely fastened.
- Inspect hinges and latches for functionality.
- Replace any missing or damaged panels.
- Ensure panels provide adequate access for maintenance.
- Examine duct surfaces for signs of rust or corrosion.
- Check for peeling paint or protective coatings.
- Clean and repaint any affected areas as needed.
- Document severe deterioration for replacement assessment.
- Use an anemometer to measure airflow rates.
- Test multiple locations to assess balance.
- Adjust ductwork or dampers to correct imbalances.
- Record airflow data for future reference.
- Evaluate the layout for unnecessary bends or turns.
- Identify areas where airflow may be restricted.
- Consider redesign options for enhanced efficiency.
- Document recommendations for future upgrades.
- Keep detailed records of all inspections and results.
- Prioritize repairs based on urgency and impact.
- Share findings with relevant maintenance personnel.
- Schedule follow-up actions for unresolved issues.
7. Controls and Sensors
- Activate each control system and sensor.
- Monitor system response and check for alarms.
- Document any irregularities or failures.
- Ensure all readings are within specified ranges.
- Use a calibrated reference instrument.
- Adjust sensors to match reference readings.
- Record calibration data for future reference.
- Check for drift since last calibration.
- Verify operation of all safety devices.
- Test alarm signals and response times.
- Check for visible damage or wear.
- Ensure compliance with safety standards.
- Activate each control system and sensor.
- Monitor system response and check for alarms.
- Document any irregularities or failures.
- Ensure all readings are within specified ranges.
- Use a calibrated reference instrument.
- Adjust sensors to match reference readings.
- Record calibration data for future reference.
- Check for drift since last calibration.
- Verify operation of all safety devices.
- Test alarm signals and response times.
- Check for visible damage or wear.
- Ensure compliance with safety standards.
- Access the BMS interface and check connectivity.
- Ensure data is accurately displayed.
- Test manual control functions through BMS.
- Document any connectivity issues.
- Review current control logic settings.
- Adjust algorithms based on system performance.
- Test performance after adjustments.
- Ensure settings align with operational goals.
- Perform visual inspection of all wiring.
- Check for signs of corrosion or fraying.
- Tighten loose connections as needed.
- Replace damaged wiring immediately.
- Remove dust and debris from panels.
- Ensure indicator lights are visible.
- Check for accessibility to controls.
- Inspect for damage to panel surfaces.
- Simulate emergency conditions.
- Activate shut-off controls and observe response.
- Confirm that systems stop as intended.
- Document any issues encountered.
- Analyze current operational data.
- Adjust setpoints to optimize efficiency.
- Communicate changes to relevant personnel.
- Ensure all changes are logged.
- Check for available software updates.
- Install updates according to manufacturer instructions.
- Verify functionality after updates.
- Document all updates performed.
- Create a detailed report of issues.
- Include timestamps and affected components.
- Prioritize issues based on severity.
- Schedule follow-up maintenance as necessary.
- Develop a training plan for staff.
- Conduct hands-on training sessions.
- Provide written materials for reference.
- Gather feedback on training effectiveness.
8. Drainage System Maintenance
- Check for visible blockages or debris.
- Use a flashlight to inspect hard-to-see areas.
- Confirm water flows freely through the drain.
- Use a wet-dry vacuum if necessary to clear clogs.
- Remove any standing water from drain pans.
- Use a suitable cleaning solution to scrub surfaces.
- Rinse thoroughly to eliminate residue.
- Inspect for signs of rust or damage after cleaning.
- Manually activate the float switch to test response.
- Check electrical connections for any signs of wear.
- Ensure float moves freely without obstruction.
- Replace any faulty components as needed.
- Check for visible blockages or debris.
- Use a flashlight to inspect hard-to-see areas.
- Confirm water flows freely through the drain.
- Use a wet-dry vacuum if necessary to clear clogs.
- Remove any standing water from drain pans.
- Use a suitable cleaning solution to scrub surfaces.
- Rinse thoroughly to eliminate residue.
- Inspect for signs of rust or damage after cleaning.
- Manually activate the float switch to test response.
- Check electrical connections for any signs of wear.
- Ensure float moves freely without obstruction.
- Replace any faulty components as needed.
9. Electrical Components
- Check all terminal connections for signs of oxidation.
- Ensure wires are securely attached without loose ends.
- Look for frayed or damaged wires.
- Use a multimeter to measure continuity if needed.
- Simulate normal operation and test switch functionality.
- Reset all circuit breakers after testing.
- Ensure that safety switches engage and disengage properly.
- Document any faulty switches or breakers for replacement.
- Measure voltage at the motor terminals using a multimeter.
- Compare readings against manufacturer specifications.
- Check for voltage drops under load conditions.
- Report any discrepancies to maintenance management.
- Check all terminal connections for signs of oxidation.
- Ensure wires are securely attached without loose ends.
- Look for frayed or damaged wires.
- Use a multimeter to measure continuity if needed.
- Simulate normal operation and test switch functionality.
- Reset all circuit breakers after testing.
- Ensure that safety switches engage and disengage properly.
- Document any faulty switches or breakers for replacement.
- Measure voltage at the motor terminals using a multimeter.
- Compare readings against manufacturer specifications.
- Check for voltage drops under load conditions.
- Report any discrepancies to maintenance management.
- Inspect wires for discoloration or melting.
- Feel components for excessive heat during operation.
- Look for burnt odor or smoke signs.
- Identify and address potential overload issues.
- Examine insulation for cracks, breaks, or abrasions.
- Replace any damaged insulation immediately.
- Verify that wires are routed properly to prevent chafing.
- Use appropriate insulating tape or sleeves where needed.
- Disconnect power before testing for safety.
- Use a multimeter to check continuity across connections.
- Look for breaks or shorts in the circuit.
- Repair or replace any faulty components.
- Listen for clicking sounds to confirm operation.
- Check for burnt contacts or signs of wear.
- Test functionality by activating the relay manually.
- Replace any faulty relays or contactors.
- Inspect grounding wires for tightness and stability.
- Clean any corroded connections with a wire brush.
- Use a multimeter to check for proper grounding.
- Document any issues and recommend corrective actions.
- Access the VFD control panel and review settings.
- Verify operational parameters against specifications.
- Test the response to changes in speed settings.
- Document any anomalies for further analysis.
- Remove enclosure covers carefully.
- Use compressed air or a vacuum to clear dust.
- Check for moisture or foreign objects inside.
- Seal any openings to prevent future contamination.
- Test the emergency shut-off buttons or switches.
- Confirm that they are clearly marked and visible.
- Check for any obstructions that could hinder access.
- Document the status of emergency systems.
- Inspect batteries for corrosion or wear.
- Perform a load test on the backup system.
- Check the charging system for functionality.
- Document battery condition and service intervals.
- Take detailed notes on observed problems.
- Include photographs if necessary for clarity.
- Suggest specific corrective actions for each issue.
- Review documentation with the maintenance team.
10. Documentation and Reporting
11. Final Checks
- Collect all tools used during maintenance.
- Inspect the area for any leftover materials.
- Ensure no items are left near moving parts.
- Confirm that the work area is clear and safe.
- Turn on the main power supply.
- Check for any error messages on control panel.
- Observe system startup for unusual sounds.
- Verify that all operational indicators are functional.
- Review maintenance schedule and intervals.
- Select a date that accommodates operational needs.
- Document the scheduled date in the maintenance log.
- Notify relevant personnel about the upcoming maintenance.
- Collect all tools used during maintenance.
- Inspect the area for any leftover materials.
- Ensure no items are left near moving parts.
- Confirm that the work area is clear and safe.
- Turn on the main power supply.
- Check for any error messages on control panel.
- Observe system startup for unusual sounds.
- Verify that all operational indicators are functional.
- Review maintenance schedule and intervals.
- Select a date that accommodates operational needs.
- Document the scheduled date in the maintenance log.
- Notify relevant personnel about the upcoming maintenance.
- Inspect all guards and covers visually.
- Ensure fasteners are tightened and secure.
- Check for any signs of wear or damage.
- Confirm that no parts are missing.
- Listen for abnormal sounds during operation.
- Inspect pipes and ducts for any signs of leaks.
- Check around the unit for any fluid accumulation.
- Ensure all components are functioning quietly.
- Inspect each access panel visually.
- Ensure seals are intact and not damaged.
- Check that panels are securely fastened.
- Document any panels that require attention.
- Review system specifications for temperature ranges.
- Use gauges to measure current temperature and pressure.
- Compare readings with specifications.
- Document any discrepancies for follow-up.
- Check airflow direction and volume at vents.
- Inspect dampers for proper positioning and functionality.
- Adjust dampers as needed for optimal airflow.
- Record airflow measurements for reference.
- Document any issues discovered during maintenance.
- Record parts replaced or repairs performed.
- Update any changes to maintenance procedures.
- Ensure all entries are clear and concise.
- Test each alarm individually.
- Verify that alarms activate in response to simulated conditions.
- Check indicator lights for proper operation.
- Document any alarms that require servicing.
- Prepare a brief overview of changes made.
- Schedule a training session for relevant staff.
- Provide written materials for future reference.
- Encourage questions to clarify new procedures.
- Collect all waste materials and tools.
- Follow local regulations for waste disposal.
- Ensure the area is left in a clean state.
- Document waste disposal actions taken.
- Create a list of parts replaced or repaired.
- Include part numbers and descriptions.
- Update inventory records as necessary.
- Ensure documentation is accessible for future maintenance.
- Test each sensor for accuracy.
- Adjust calibration settings as necessary.
- Verify that controls respond correctly to inputs.
- Document calibration results for future reference.
- Check for debris or equipment blocking vents.
- Ensure pathways are clear for maintenance access.
- Inspect surrounding structures for any encroachments.
- Document any obstructions that need addressing.
- Identify critical issues discovered during maintenance.
- Communicate findings to management or relevant teams.
- Provide recommendations for urgent action.
- Document notifications made for record-keeping.
Use in Manifestly