Elevator Germany

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


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


Introduction


• 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


… who is involved?

… who is responsible?

If something goes wrong …


Parties involved in elevator safety

Authority

Inspection co

Owner

Maintenance co.

Authority


Elevators have to be safe!

To guarantee a safe operation of elevators

a professional, statutory inspection scheme

is indispensable all over the world.


Laws / Ordinances / Directives

Legal background:

Codes / Standards


The elevator codes

European Lifts DirectiveEN 81

JIS

ASMEA 17 / B 44


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.


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.


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


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)


- 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


... 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.



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


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


- 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



Conformity marking

Passport for free moving within EC member states


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


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, …




a) For putting new elevators in operation (European law)


b) For existing elevators(National law)

BetrSichV (Operational Safety Directive)


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)


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


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.




How to make a transition to a new national law?

How to overcome the original stipulations?



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.


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


European standard EN 81 part 80

Risk profile to start with


European standard EN 81 part 80

Risk profile with priority levels


Elevator inspection body

Acting as an

in Germany


Choose certainty.

Add value.


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?


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


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)


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


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


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!


Scope of inspection services


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



Periodic inspections = assessment of actual technical stateVisual & functional tests, replacing load test with ADIASYSTEM



• 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


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


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



Type approval of Safety Components and Liftsin compliance to the Lifts Directive

Progressive safety gear Overspeed governor Rope brake



- Type examination of safety components- Door locking devices- Safety gears / rope brakes- Overspeed governors- Buffers - Hydraulic safety valves- Safety devices containing electronic parts


Type examination in compliance to Directive 95/16/EG

type examinationis compulsory



Evaluations after accidents / valuation of operation conditionSupplement measurements & documentation with ADIASYSTEM

Fotos: ThyssenKrupp Aufzüge 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


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


Tools for inspecting elevators

What is the ADIASYSTEM?


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


• 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


Distance gauge

•• distance measurementsdistance measurements

•• speed measurementsspeed measurements

•• time related diagramstime related diagrams(including trigger information)(including trigger information)


Traction test= rope friction in grooves of traction sheave


Traditional load test

125% rated loadin the car


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


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


Calculation(loaded car)

Measurement(empty car)

Safety gear test

TÜV SÜD Industrie Service GmbH TÜV Süddeutschland

Maximum permissible deceleration


The safety gear is the ultimate safety device!

Reliable safety gear testing is imperative!


Worst-case accidents do happen!






Reporting of accidents / incidents is a must!


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.


Deceleration too low!


Buffer test with rated load

V = 2 m/s


Evaluation of speed diagram

Travel quality, 100 Hz, raw mode

Travel quality, 100 Hz, digital low pass filter


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


Releveling test


Unusual pressure peaks (sampling rate: 10 Hz)


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


Gauge or lift door kinetics

Lift door parameters:Kinetic energyClosing speedRemaining closing force


• 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?


Further benefits of PC application


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?


E-mail: Report

TÜV inspector.Manufacturer

OwnerInternet: Report / investigation

Pure electronic communication process

What is eDocX/netDocX?


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


Conclusions


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


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


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

Documents

Elevator Germany