elevator germany
TRANSCRIPT
TÜV SÜD Industrie Service GmbH
International International Seminar for Elevator Safety SystemSeminar for Elevator Safety System
The German / European Elevator Safety System and PolicyThe German / European Elevator Safety System and Policy
Alfons Petry
Seoul, 02 May 2006
TÜV SÜD Industrie Service GmbH
Contents of presentation
• Introduction
• Legal background- applicable German / European laws & directives- elevator safety codes & standards
• Elevator inspection bodies- scope of services- inspection tools- … many other items on the agenda
• Conclusions
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Introduction
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• Hundreds of parts of different manufacturers
• Local fabrication on site – not in factory with QA
• Competition for cheapest market prices
• Qualification of elevator companies / mechanics
• Outsourcing of activities to subcontractors
• Maintenance service
• Carelessness or negligence of elevator owners
Influences on the safety of an elevator
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… who is involved?
… who is responsible?
If something goes wrong …
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Parties involved in elevator safety
Authority
Inspection co
Owner
Maintenance co.
Authority
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Elevators have to be safe!
To guarantee a safe operation of elevators
a professional, statutory inspection scheme
is indispensable all over the world.
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Laws / Ordinances / Directives
Legal background:
Codes / Standards
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The elevator codes
European Lifts DirectiveEN 81
JIS
ASMEA 17 / B 44
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Comparing National Elevator Safety Codes
Both codes may have similar safety requirements.
Performance driven Prescriptive code
USAUSAA17.1 / 2A17.1 / 2
EuropeEuropeLifts Lifts DirectiveDirective
Specifies general essential Requirements are describedsafety requirements only. in very specific details.
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Comparing National Elevator Safety Codes
Example: Requirement to meet the safety gear test
Performance driven Prescriptive code
USAUSAA17.1 / 2A17.1 / 2
EuropeEuropeLifts Lifts DirectiveDirective
There is a permissible range There is a table give withof deceleration of 0.2 to 1 g permissible sliding distances
for a car with rated load. for a car with rated load.
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3,900,000 elevators installed in Europe
650,000 elevators installed in Germany
400,000 elevator inspections / year by our company group in Europe
Single European Market is largest in the world
Key figures indicating the dominance of Europe
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Applicable legal provisions in Germany
a) For putting new elevators in operation(European law)
European Lifts Directivehttp://europa.eu.int
b) For existing elevators (National law)
BetrSichV (Operational Safety Directive)
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- Abolish barriers to free trade in Europe
- Applicable to new installations only
- Member States are responsible for the health and safety of their people
- Only defines general essential safety requirements
- Harmonized standards must retain a non-binding status
- Risk assessment (ISO/TC 14798)
Fundamental issues of the Directive 95/16/EG
European Lifts Directive
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... in compliance with the New & Global Approach:
Products must be submitted to a
Conformity Assessment Procedure
• There are several ways to demonstrate conformity either directly to essential requirements or to harmonized standards.
• The manufacturer has the choice to select one of the different procedures available.
• Passing the conformity assessment procedures is a prerequisite for being allowed affixing the CE marking.
European Lifts Directive
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The New and Global Approach
New Approach Global Approach
Free circulation / CE marking
Conformity Assessment(8 modules)Essential requirements
Productevaluation
Approved quality
assurancesystem
Harmonized standards= Presumption of conformity
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Conformity Assessment Procedure
Internal control of production
Design Phase Production Phase
Unit verification
Full quality assurance (ISO 29001)
Manufacturer
Conformity to type
Production QA (ISO29002)
Product QA (ISO 29003)
Product verification
EC type examimation
Notified body
Manufacturer
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- EC type examination of safety components (module B)
- Conformity to type with random checking (module C / XI)
- Product quality assurance for lifts (module E / VIII)
- Full quality assurance (module H / annex IX)
- EC type examination of model lifts (module B / V)- Final inspection (module F / VI)- Product quality assurance for lifts (module E / XII)- Production quality assurance (module D / XIV)
- Unit verification (module G / X)- Full quality assurance (module H / annex XIII)
European Lift Directive 95/16/EG
Modules for conformity assessment procedures
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European Lifts Directive
Conformity marking
Passport for free moving within EC member states
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Harmonized standardsEN 81, part 1: Safety rules for the construction and installation of lifts
Electric lifts for the transport of persons and goods
EN 81, part 2: Safety rules for the construction and installation of liftsHydraulic lifts for the transport of persons and goods
European Lifts Directive
EN 81, part 21: New passenger and goods lifts in existing buildings
EN 81, part 80: Existing lifts - Rules for the improvement of safety of existing lifts …
…. Standards on fire protection, sound protection, EMC, accident prevention, …
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Applicable legal provisions in Germany
a) For putting new elevators in operation (European law)
European Lifts Directive
b) For existing elevators(National law)
BetrSichV (Operational Safety Directive)
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German Codes
from 1999
Law on Trade & Occupation (§24 GewO)
National Elevator Safety Code (TRA)
Machinery Directive (89/382/EWG)
Equipment Safety Law (GSG)
European Lifts Directive (95/16/EC) (for new installations)
early 1990s
for decades
from 2003 Operational Safety Directive (BetrSichV) (for existing installations)
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Simplification and summing-up of different directives on health & safety, covering• working tools & appliances• organisation of occupational health & safety • equipment & machinery requiring statutory inspection (9 directives)
Justification for the changes• uniform law on operational plant safety • essential safety requirements, as in European Directives
Further requirements• maintaining the same level of safety• high standards for accreditation of authorized inspection bodies• market surveillance
Operational Safety Directive
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The employer is responsible for the Directive’s application (setting up of a labor protection management system).
The employer has to make a risk analysis:
1) To identify and classify all devices and installations
2) To rate and quantify the endangering effects
3) To define safety measures complying with the state-of-the-art
4) To verify the effectiveness of the measures
The Directive just specifies protective aims.
Operational Safety Directive
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Applicable legal provisions in Germany
How to make a transition to a new national law?
How to overcome the original stipulations?
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Operational Safety Directive
In principle, the applicable code is based on the valid code when putting the elevator into operation.
When new codes and standards are published the owner cannot be forced to upgrade the elevator.
The BetrSichV demands that the owner of existingolder elevators is aware of any deviation in safetycompared to the latest state-of-art.
The owner is encouraged to upgrade.
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EN 81 Part 80: Rules for the improvement of safety ofexisting passenger and goods passenger lifts
SNEL (Safety Norm for Existing Lifts)
50% of existing elevators in Europe are more than 20 years old, having different safety standards
Users are expecting a uniform safety level at no risk
Standard defines 74 risks / risk potentials• Guideline and checklist to identify risks• Evaluate the risk potential (frequency and seriousness)• Define priority classes of risk profiles
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European standard EN 81 part 80
Risk profile to start with
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European standard EN 81 part 80
Risk profile with priority levels
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Elevator inspection body
Acting as an
in Germany
TÜV SÜD Industrie Service GmbH
Choose certainty.
Add value.
TÜV SÜD Industrie Service GmbH
A state authorized German inspection and certification body with a history of about 140 years in the segments
Industry
Mobility
People
What is the TÜV SÜD group?
TÜV SÜD Industrie Service GmbH
Today, a globally active group with
10,000 employees
> 1 billion €/aEU + Switzerland
BarcelonaDresden FrankfurtGlasgow HamburgHanoverKoldingLondon Madrid MilanMannheimMunichParisPortsmouthStrasskirchen StuttgartTurinVienna
Eastern Europe
Bratislava BudapestLjubljanaMoscow PosenPrague
Istanbul
Asia-Pacific
Bangkok CairoBeijing ShanghaiGuangzhou SeoulHong Kong SingaporeManila Taipei Mumbai Osaka Tokyo Wuxi
America
BostonDetroitMinneapolisMonterrey/Mexico San DiegoSan Ramon
TÜV SÜD group
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Approval as an inspection body in Germany
a) Notified Bodyfor putting new elevators in operationin compliance to European Lifts Directive
b) Accredited Certification Bodyfor existing elevators in compliance with BetrSichV (Operational Safety Directive)
Both kinds of accreditation are executed by the German National Accreditation Body (ZLS)
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Minimum Criteria on Notification of Inspection Bodies
• Competent, non-disciriminatory, transparent, neutral, independent• Professional integrity and technical competence• Personal requirements: education, experience and capabilities• Technical expert opinion regardless of external influence• Inspector's salary independent from number or result of inspection• Insurance coverage for third-party liability• Adequate quality assurance system• Official recognition by authority having jurisdiction• Collect and analyze findings for exchange of information (training)
Lifts Directive 95/16/EG
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Accreditation Body
Assessment and Accreditation
Inspection Company
Enforcement of directivesState Authority
Verification and approval of inspection companies
Providing inspection servicesfor owners and elevator industry
Market Surveillance State authorized surveillance performance of the industry andinspection body services
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Competition
Registry of elevators
The accreditation must secure an equal level of competency, professionalism, safety, ...
Monopoly
Registry of manufacturersQualification of service personnel
not applicable in Germany / EU
Beneficial for the authorityHardly accepted by the market
Further issues of being an inspection body
Important!
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Scope of inspection services
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Testing, Inspection and Certification
Acceptance test (unit verification) = initiallyCommissioning tests after installation of new elevators (EU Directive)replacing load tests with ADIASYSTEM
Services of TÜV SÜD
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Testing, Inspection and Certification
Periodic inspections = assessment of actual technical stateVisual & functional tests, replacing load test with ADIASYSTEM
Services of TÜV SÜD
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• Review for compliance with code requirementregarding structural faults / faulty design
• Overall visual examinations
• Functional tests (electrically / mechanically)
• Testing of all safety features
• Overload tests (with alternative methods)
Inspection criteria
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Acceptance inspection before putting in service
Annual periodic inspection scheme
• every 2 years full scope of inspectionsincluding load test or alternative method(together with mechanic of maintenance company)
• every other year (intermediate inspection),visual and functional tests only
Inspection frequency in Germany
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2 - 3 initial acceptance inspections per day(inspection report > 30 pages)
5 - 6 periodic inspections per day(full scope)
10 intermediate periodic inspections per day(visual / functional test only)
1000 inspections per inspector per year
Number of elevator inspection per expert
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Testing, Inspection and Certification
Type approval of Safety Components and Liftsin compliance to the Lifts Directive
Progressive safety gear Overspeed governor Rope brake
Services of TÜV SÜD
TÜV SÜD Industrie Service GmbH
- Type examination of safety components- Door locking devices- Safety gears / rope brakes- Overspeed governors- Buffers - Hydraulic safety valves- Safety devices containing electronic parts
European Lifts Directive
Type examination in compliance to Directive 95/16/EG
type examinationis compulsory
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Testing, Inspection and Certification
Evaluations after accidents / valuation of operation conditionSupplement measurements & documentation with ADIASYSTEM
Fotos: ThyssenKrupp Aufzüge GmbH
Services of TÜV SÜD
TÜV SÜD Industrie Service GmbH
Professional inspection services help to
• protect significant investment values
• extend the service time / life time of the elevator
• reduce liability obligations
• cut expenses for avoidable tests
• save budgeting of unnecessary replacements
• prevent costs for accidents and incidents
Economic considerations
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PC-based documentation
Analysis of test results
Quantitative measurement
Know-how & expertise
Thorough test and examination
Visual inspection
Functional check
Savings to economyProtection of investment
Trend analysisScientific evaluation
Reliability
Code requirement Yes-or-no decision
Safety
time
Preventive Safety Inspection of Elevators
Additional scope of work Additional requirements
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Tools for inspecting elevators
What is the ADIASYSTEM?
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Goal: PC-driven measurements to replace statutory load tests
Today:Universal expert system for inspecting elevators;for 15 years state-of-the-art
References:> 600 TÜV inspectors daily. > 1,000,000 applications.
Facts about ADIASYSTEM
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• Distance• Speed
PC + electronic sensors accurate measurement
Travel Gauge
On-line Force Gauge
Acceleration:
•Safety test• Vibrations
Rope forces:
•Traction test• Balance test
• Pressure
Data Logger
On-line ordata logging
Batterie
Status Neustart
Laden
Ein/AusExtern
Trigger Comm
Pressure Gauge
On-line
How ADIASYSTEM works
On-line ordata logging
• Masses• Door featuresDoor Gauge
Force Gauge
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Distance gauge
•• distance measurementsdistance measurements
•• speed measurementsspeed measurements
•• time related diagramstime related diagrams(including trigger information)(including trigger information)
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Traction test= rope friction in grooves of traction sheave
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Traditional load test
125% rated loadin the car
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F =F
n car + Force
F =F
n carForce
Traction test with ADIASYSTEM
TÜV SÜD Industrie Service GmbH Bau und Betrieb / Innovative Systeme
Traction test
rope
safety string belt
hoistway ceilingpipe
dial gauge
spring balance
rope hook
cable to PCtraction sheave
TÜV SÜD Industrie Service GmbH
Safety gear testSafety gear test= Does a free falling lift car = Does a free falling lift car come to a full stop withcome to a full stop withdefined deceleration criteria?defined deceleration criteria?
Buffer testBuffer test
Travel quality analysisTravel quality analysis
……
Data logger
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Calculation(loaded car)
Measurement(empty car)
Safety gear test
TÜV SÜD Industrie Service GmbH TÜV Süddeutschland
Maximum permissible deceleration
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The safety gear is the ultimate safety device!
Reliable safety gear testing is imperative!
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Worst-case accidents do happen!
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Worst-case accidents do happen!
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Worst-case accidents do happen!
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Reporting of accidents / incidents is a must!
Worst-case accidents do happen!
Analysis / evaluation by independent body
Conclusion on digression:
In Germany all inspection bodies have to submit report (CEOC form) to a National organization.
Scarcely any reports are made public!
No comparison among European countries is existing.
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Deceleration too low!
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Buffer test with rated load
V = 2 m/s
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Evaluation of speed diagram
Travel quality, 100 Hz, raw mode
Travel quality, 100 Hz, digital low pass filter
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ReRe--levellinglevelling testtest
Elevator car with Elevator car with 100% rated load 100% rated load must be capable to must be capable to rere--level in upper landinglevel in upper landing
Evaluation of Evaluation of pressurepressure--timetimebehaviourbehaviour
Hydraulic pressure gauge
TÜV SÜD Industrie Service GmbH TÜV Süddeutschland
Releveling test
TÜV SÜD Industrie Service GmbH TÜV Süddeutschland
Unusual pressure peaks (sampling rate: 10 Hz)
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Testing power operateddoors (DIN EN 12445)force up to 2,000 NDetermination of mass(mass of lift caror counterweight)mass up to 4,000 kgVoltage time recording…
Force and mass gauge
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Gauge or lift door kinetics
Lift door parameters:Kinetic energyClosing speedRemaining closing force
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• ADIASYSTEM provides contemporary, quantitative assessment to improve the safety
• Non-destructive testing / less wear
• Exact documentation of measuring results an electronic fingerprint, incl. reliability and quality issues
• Advice for optimising the economic life and minimising the total operation costs
• Significant cost savings(no costs for providing test weights)
What are the benefits?
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Further benefits of PC application
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Pure electronic communication process
TÜV inspector
E-mail: Inspection schedule, as well as.
all elevator data + previous E-reports
ITAS / SAPTime scheduling
What is eDocX/netDocX?
TÜV SÜD Industrie Service GmbH
E-mail: Report
TÜV inspector.Manufacturer
OwnerInternet: Report / investigation
Pure electronic communication process
What is eDocX/netDocX?
TÜV SÜD Industrie Service GmbH
netDocX – the virtual log book
Many key customers use our added value by electronic document flow!
Added value for customer:– lower administrative costs– access always and anytime – reliable documentation
Benefits for TÜV:– customer loyalty (USP)– close linkage of business processes– statistical assessment of findings
Virtual log book (netDocX)File storage and management of inspection certificates for our customers via safe internet access
eDocX
CustomerSafe internet access
TÜV Certificates2 million
www.netinform.de
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Conclusions
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Innovations and new elevator technologies MRL elevators2 cars in 1 hoistwayelectronic controllers and transducersnew materials, ...
More stringent requirements regarding- documentation (ISO 9000)- liability- additional customer requests
Manufacturer’s own product content is decreasingMore subcontractors, also for installationThe core competence of the industry is getting slimmer
Effects on the elevator industry
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Innovations and new elevator technologies will modify the inspection’s objectives:
· Inspectors need more advanced expertise
· Pure visual and functional testing is inadequate
· Contemporary inspection tools are required to …enhance technical know-how and skillsprovide electronic fingerprint findings:
- traceable results cannot be falsified- prevent doing a personal favor
increasing competitivenessdemonstrate code compliance
Effects on elevator inspectors
TÜV SÜD Industrie Service GmbH
Consequences of a contemporary codeSpecifies general safety requirements onlyRisk analysis in case of deviations
Future requirements include Strict safety aspects + quality issues!Traceable electronic documentationFully electronic business processes to - reduce administrative efforts / costs - increase customer loyalty / satisfactionEvidence to lower product liability
Enhanced benefits for all partners
A modern elevator inspection will become more important