Elevator Germany

International Seminar for Elevator Safety System
The German / European Elevator Safety System and Policy

Alfons Petry Seoul, 02 May 2006
TV SD 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
Introduction
Influences on the safety of an elevator
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
If something goes wrong
who is involved? who is responsible?
Parties involved in elevator safety
Authority Authority
Inspection co
Maintenance co.
Owner
Elevators have to be safe!
To guarantee a safe operation of elevators a professional, statutory inspection scheme is indispensable all over the world.
Legal background: Laws / Ordinances / Directives Codes / Standards
The elevator codes
JIS ASME A 17 / B 44 European Lifts Directive EN 81
Comparing National Elevator Safety Codes
Europe Lifts Directive
USA A17.1 / 2
Prescriptive code
Performance driven
Both codes may have similar safety requirements.

Specifies general essential safety requirements only.
Requirements are described in very specific details.
Comparing National Elevator Safety Codes
Europe Lifts Directive
USA A17.1 / 2
Prescriptive code
Performance driven
Example: Requirement to meet the safety gear test

There is a permissible range of deceleration of 0.2 to 1 g for a car with rated load.
There is a table give with permissible sliding distances for a car with rated load.
Key figures indicating the dominance of Europe
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
Applicable legal provisions in Germany

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

http://europa.eu.int
b) For existing elevators (National law) BetrSichV (Operational Safety Directive)
Fundamental issues of the Directive 95/16/EG

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)
... 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
Essential requirements
Global Approach
Conformity Assessment (8 modules)
Harmonized standards = Presumption of conformity
Product evaluation
Approved quality assurance system
Free circulation /
CE marking
Conformity Assessment Procedure

Manufacturer Notified body
Design Phase
Production Phase
Internal control of production Conformity to type EC type examimation Production QA (ISO29002) Product QA (ISO 29003)
Manufacturer
Product verification Unit verification Full quality assurance (ISO 29001)
European Lift Directive 95/16/EG
Modules for conformity assessment procedures

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)
Conformity marking
Passport for free moving within EC member states
Harmonized standards EN 81, part 1: EN 81, part 2: EN 81, part 21:

Safety rules for the construction and installation of lifts Electric lifts for the transport of persons and goods Safety rules for the construction and installation of lifts Hydraulic lifts for the transport of persons and goods 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) European Lifts Directive
b) For existing elevators (National law)
BetrSichV (Operational Safety Directive)

German Codes
for decades
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) Operational Safety Directive (BetrSichV) (for existing installations)
early 1990s
from 1999
from 2003
Operational Safety Directive
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
The employer is responsible for the Directives 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 existing older elevators is aware of any deviation in safety compared to the latest state-of-art. The owner is encouraged to upgrade.
SNEL (Safety Norm for Existing Lifts)
EN 81 Part 80:
Rules for the improvement of safety of existing passenger and goods passenger 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
Acting as an
Elevator inspection body

in Germany
Choose certainty. Add value.
What is the TV SD group?
A state authorized German inspection and certification body with a history of about 140 years in the segments Industry
Mobility
People
TV SD group
Today, a globally active group with

10,000 employees > 1 billion /a
EU + Switzerland Barcelona Dresden Frankfurt Glasgow Hamburg Hanover Kolding London Madrid Milan Mannheim Munich Paris Portsmouth Strasskirchen Stuttgart Turin Vienna
Asia-Pacific Bangkok Beijing Guangzhou Hong Kong Manila Mumbai Tokyo Wuxi Cairo Shanghai Seoul Singapore Taipei Osaka
Eastern Europe Bratislava Budapest Ljubljana Moscow Posen Prague Istanbul
America Boston Detroit Minneapolis Monterrey/Mexico San Diego San Ramon
Approval as an inspection body in Germany a) Notified Body

for putting new elevators in operation in compliance to European Lifts Directive
b) Accredited Certification Body

for existing elevators in compliance with BetrSichV (Operational Safety Directive)
Both kinds of accreditation are executed by the German National Accreditation Body (ZLS)
Lifts Directive 95/16/EG
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)
Assessment and Accreditation
State Authority
Enforcement of directives
Accreditation Body
Verification and approval of inspection companies Providing inspection services for owners and elevator industry State authorized surveillance performance of the industry and inspection body services
Inspection Company
Market Surveillance
Further issues of being an inspection body Beneficial for the authority Hardly accepted by the market The accreditation must secure an equal level of competency, professionalism, safety, ... Important!
Monopoly
Competition
Registry of elevators Registry of manufacturers Qualification of service personnel

not applicable in Germany / EU
Scope of inspection services
Services of TV SD Acceptance test (unit verification) = initially

Commissioning tests after installation of new elevators (EU Directive) replacing load tests with ADIASYSTEM
Testing, Inspection and Certification

Services of TV SD Periodic inspections = assessment of actual technical state Visual & functional tests, replacing load test with ADIASYSTEM

Inspection criteria
Review for compliance with code requirement regarding structural faults / faulty design Overall visual examinations Functional tests (electrically / mechanically) Testing of all safety features Overload tests (with alternative methods)
Inspection frequency in Germany
Acceptance inspection before putting in service Annual periodic inspection scheme every 2 years full scope of inspections including load test or alternative method
(together with mechanic of maintenance company)
every other year (intermediate inspection), visual and functional tests only
Number of elevator inspection per expert
2-3
initial acceptance inspections per day

(inspection report > 30 pages)
5-6 10 1000
periodic inspections per day

(full scope)
intermediate periodic inspections per day

(visual / functional test only)
inspections per inspector per year
Services of TV SD Type approval of Safety Components and Lifts in compliance to the Lifts Directive
Progressive safety gear
Overspeed governor
Rope brake

Type examination in compliance to Directive 95/16/EG

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 is compulsory
Services of TV SD Evaluations after accidents / valuation of operation condition Supplement measurements & documentation with ADIASYSTEM

Fotos: ThyssenKrupp Aufzge GmbH
Economic considerations
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
Preventive Safety Inspection of Elevators

Additional scope of work Additional requirements
PC-based documentation Analysis of test results Quantitative measurement

time
Savings to economy Protection of investment Trend analysis Scientific evaluation Reliability Code requirement Yes-or-no decision Safety
Know-how & expertise Thorough test and examination Visual inspection Functional check
Tools for inspecting elevators
What is the ADIASYSTEM?
Facts about 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 TV inspectors daily. > 1,000,000 applications.
How ADIASYSTEM works
PC + electronic sensors
accurate measurement
Travel Gauge
Distance Speed
Rope forces:
On-line
Force Gauge
Traction test Balance test
Trigger
Comm
On-line or data logging On-line
Batterie Status Neustart
Acceleration:
Laden
Safety test
Data Logger
Ein/Aus
Extern
Vibrations Pressure
Pressure Gauge
On-line or data logging

Force Gauge Door Gauge
Masses Door features
Distance gauge
distance measurements speed measurements time related diagrams (including trigger information)
Traction test
= rope friction in grooves of traction sheave
Traditional load test
125% rated load in the car
Traction test with ADIASYSTEM
Fcar n
+ Force
F Force
car
Traction test
traction sheave
cable to PC rope rope hook dial gauge
safety string
belt
spring balance
pipe
Bau SD Industrie Innovative Systeme TV und Betrieb / Service GmbH
hoistway ceiling
Data logger
Safety gear test

= Does a free falling lift car come to a full stop with defined deceleration criteria?
Buffer test Travel quality analysis

Safety gear test
Measurement (empty car)
Calculation (loaded car)
Maximum permissible deceleration
TV Sddeutschland TV SD Industrie Service GmbH
The safety gear is the ultimate safety device!
Reliable safety gear testing is imperative!
Worst-case accidents do happen!
Conclusion on digression:
Reporting of accidents / incidents is a must! Analysis / evaluation by independent body

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
Hydraulic pressure gauge
Re-levelling test
Elevator car with 100% rated load must be capable to re-level in upper landing
Evaluation of pressure-time behaviour

Releveling test
Unusual pressure peaks (sampling rate: 10 Hz)
Force and mass gauge
Testing power operated doors (DIN EN 12445) force up to 2,000 N Determination of mass (mass of lift car or counterweight) mass up to 4,000 kg Voltage time recording
Gauge or lift door kinetics
Lift door parameters: Kinetic energy Closing speed Remaining closing force
What are the benefits? 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)
Further benefits of PC application
What is eDocX/netDocX? Pure electronic communication process
E-mail: Inspection schedule, as well as. all elevator data + previous E-reports
TV inspector
ITAS / SAP Time scheduling

What is eDocX/netDocX? Pure electronic communication process
Manufacturer TV inspector.
E-mail: Report Internet: Report / investigation Owner
netDocX the virtual log book Many key customers use our added value by electronic document flow!
www.netinform.de
Customer
Safe internet access
eDocX TV Certificates
2 million Added value for customer: lower administrative costs access always and anytime reliable documentation Benefits for TV: 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
Conclusions
Effects on the elevator industry Innovations and new elevator technologies MRL elevators 2 cars in 1 hoistway electronic controllers and transducers new materials, ... More stringent requirements regarding - documentation (ISO 9000) - liability - additional customer requests Manufacturers own product content is decreasing More subcontractors, also for installation The core competence of the industry is getting slimmer
Effects on elevator inspectors Innovations and new elevator technologies will modify the inspections objectives: Inspectors need more advanced expertise Pure visual and functional testing is inadequate Contemporary inspection tools are required to enhance technical know-how and skills provide electronic fingerprint findings: - traceable results cannot be falsified - prevent doing a personal favor increasing competitiveness demonstrate code compliance
Enhanced benefits for all partners Consequences of a contemporary code Specifies general safety requirements only Risk analysis in case of deviations Future requirements include Strict safety aspects + quality issues! Traceable electronic documentation Fully electronic business processes to - reduce administrative efforts / costs - increase customer loyalty / satisfaction Evidence to lower product liability
A modern elevator inspection will become more important


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International Seminar for Elevator Safety System

The German / European Elevator Safety System and Policy

TV SD Industrie Service GmbH

TV SD Industrie Service GmbH

TV SD Industrie Service GmbH

Influences on the safety of an elevator

If something goes wrong

who is involved? who is responsible?

TV SD Industrie Service GmbH

Parties involved in elevator safety

Elevators have to be safe!

TV SD Industrie Service GmbH

Legal background: Laws / Ordinances / Directives Codes / Standards

TV SD Industrie Service GmbH

The elevator codes

JIS ASME A 17 / B 44 European Lifts Directive EN 81

TV SD Industrie Service GmbH

Comparing National Elevator Safety Codes

Europe Lifts Directive

Both codes may have similar safety requirements.

Requirements are described in very specific details.

Comparing National Elevator Safety Codes

Europe Lifts Directive

Example: Requirement to meet the safety gear test

Key figures indicating the dominance of Europe

3,900,000 elevators installed in Europe

650,000 elevators installed in Germany

Applicable legal provisions in Germany

European Lifts Directive

European Lifts Directive

Fundamental issues of the Directive 95/16/EG

TV SD Industrie Service GmbH

European Lifts Directive

The New and Global Approach

Harmonized standards = Presumption of conformity

Approved quality assurance system

Conformity Assessment Procedure

Product verification Unit verification Full quality assurance (ISO 29001)

TV SD Industrie Service GmbH

European Lift Directive 95/16/EG

Modules for conformity assessment procedures

TV SD Industrie Service GmbH

European Lifts Directive

Passport for free moving within EC member states

TV SD Industrie Service GmbH

European Lifts Directive

Harmonized standards EN 81, part 1: EN 81, part 2: EN 81, part 21:

TV SD Industrie Service GmbH

Applicable legal provisions in Germany

b) For existing elevators (National law)

BetrSichV (Operational Safety Directive)

Operational Safety Directive

Simplification and summing-up of different directives on health & safety, covering

Justification for the changes

Operational Safety Directive

The employer is responsible for the Directives application

The employer has to make a risk analysis:

The Directive just specifies protective aims.

Applicable legal provisions in Germany

TV SD Industrie Service GmbH

Operational Safety Directive

TV SD Industrie Service GmbH

SNEL (Safety Norm for Existing Lifts)