Lift and Escalator Safety and their Protection IMechE CPD Certificate Course Date: 21 Nov. 2016 1 Introduction Lifts and Escalators Mechanism in HK Lift System Escalator System 2
The (Lifts & Escalators)mechanism governed by the Hong Kong Lift and Escalator Ordinance (i.e. Cap327, 618); Lifts and Escalators (General) Regulation; Lifts and Escalators (Fees) Regulation; Cap 590 Factories and Industrial Undertakings (Goods Lifts) Regulation 3 The relevant COPs for lifts & Escalators Works in Hong Kong Code of Practice on the Design and Construction of Lifts and Escalators - EMSD; Code of Practice for Lift Works and Escalators Works - EMSD; Code of Practice for Energy Efficiency of Lift and Escalator Installations - EMSD 4
The relevant COPs for lifts & Escalators Works in Hong Kong Code of Practice Building Works For Lifts and Escalators - BA Code of Practice for Means of Access for Firefighting and Rescue - BA Code of Practice Fire Resisting Construction - BA Design Manual Barrier Free Access - BA 5 The relevant COPs for lifts & Escalators Works in Hong Kong Code of Practice for Safety at Work (Lift and Escalator) - LD Guide on Safety in Lift Repair & Maintenance - LD 6
The relevant COPs for lifts & Escalators Works in Hong Kong GUIDELINES on Safety of Lift shaft Works (Volume 1 During Construction Stage and before Handing over to lift installation Contractor) - CIC GUIDELINES on Safety of Lift Shaft Works (Volume 2 During lift installation stage until of occupation permit and handing over to developer) - CIC GUIDELINES on Safety of Lift Shaft Works (Volume 3 Throughout the occupation stage of building) - CIC 7 Cap 327 & Cap 618 The Lifts and Escalators Ordinance (Cap. 618) was enacted in April 2012 Put into full operation on 17 December 2012 to replace the repealed Lifts and Escalators (Safety) Ordinance (Cap. 327) which was enacted in the 1960s. 8
Chapter 327 Maintenance and Examination of Lifts and Escalators and Testing of Safety Equipment Section 19 Periodic maintenance of lifts and escalators (Schedule 5 Part 1 & Part 5) The lift or escalator, all machinery and equipment connected therewith and the safety equipment provided therefor to be cleaned, oiled and adjusted by a registered lift contractor or a registered escalator contractor, as the case may be, at intervals not exceeding one month. 9 Chapter 327 Section 20 Periodic examination of lifts (Schedule 5 Part 2) At intervals not exceeding 12 months, cause the lift to be thoroughly examined by a registered lift engineer in order to determine whether the lift and all machinery and equipment connected therewith is in safe working order. Section 21 Periodic examination of escalators (Schedule 5 Part 5) At intervals not exceeding 6 months, cause the escalator to be thoroughly examined by a registered escalator engineer in order to determine whether the escalator and all machinery and equipment connected therewith is in safe working order. 10
Chapter 327 Section 23 Periodic testing of safety equipment of lifts (Schedule 6) (a) (b) (c) (d) At intervals not exceeding 12 months, by the operation of the same without any load in the lifts; At intervals not exceeding 5 years, by the operation of the same with full rated load in the lift; At intervals no exceeding 5 years, by the operation of the overload device of the same with a load in the car of the lift weighing between 90 per cent to 110 per cent of the rated load; and At intervals not exceeding 5 years, by the operation of the brake when the car or platform of the lift is travelling in the downward direction at tis rated speed with a load weighting 125 per cent of the rated load for lifts designed and constructed in accordance with BS 5655: Part 1 and weighing 110 per cent of the rated load for other lifts 11 Chapter 327 Section 24 Periodic testing of safety equipment of escalators At intervals not exceeding 12 months, the owner of every escalator shall, in addition the examination thereof required by section 22, cause the safety equipment provided therefor to be tested by a registered escalator engineer by the operation of the same without any load on the escalator 12
Lifts and Escalators Ordinance (Chapter 618) Come into force and repealed the Cap327 since 17 December 2012 Lifts and Escalators (General) Regulation Lifts and Escalators (Fees) Regulation 13 Features of Cap618 Increasing the penalty levels of offences (i.e. RC from $50,000 to $100,000 & RLE/REE from $0 to $10,000 and the maximum fine is $200,000 and max. imprisonment 12 months) Responsible Persons ( RPs ) who include with owners of a lift/escalator and other person who have the management or control of the lift/escalator Guidebook for Responsible Persons for lifts Guidebook for Responsible Persons for Escalators 14
The ordinance ensures the safety of lift and escalator 1. Equipment compliance: Safety components are required type approved by EMSD 2. Quality control: Installation, maintenance, repair, alteration and demolition of lifts/escalators are undertaken by RCs RCs are required to notify EMSD in respect of undertaking and subcontracting of lift/escalators work (i.e. except installation or demolition works) 15 3. RCs are required to attend to failures of emergency devices of lifts within 4 hours when RCs aware of the failures (Emergency devices include alarm system, emergency lighting, intercommunication system, ventilation fan) Under the Lift and Escalator (General) Regulation section 8 4. If the failure of any emergency device cannot be rectified within 24 hours, RC must within 24 hours notify EMSD in the specified form 16
5. Registration system: RCs and REs are required to renew their registration every 5 years A new registration system for lift/escalator workers (i.e. RWs) REs and RWs are required to carry their registration cards at works Disciplinary actions can be taken registered persons who have committed disciplinary offences 17 6. Public monitoring RP is required to notify EMSD and the RC within 24 hours if incident occur RCs are required to display a notice within 4 hours if lift/escalator is suspended due to the incident Incidents are included as the following: Death or injury involves a lift Failure of main drive system Breakage of suspension rope Failure of brake, overload device, safety equipment Failure of interlocking device for any door (i.e. include with lift-way door or car door) 18
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21 Code of Practice on the Design and Construction of Lifts and Escalators 22
Code of Practice on the Design and Construction of Lifts and Escalators The code is based on EN81-1, EN81-2 and EN- 115-1 The first code is from 1993 edition and revised in 2000, 2010 The code will be effective upon the day section 157 of the Cap 618 23 Code of Practice for Lift Works and Escalator Works 24
Code of Practice for Lift Works and Escalator Works The code give guidance on matters relating to the safety of lifts and escalators; In particular on the works with installation, commissioning, examination, maintenance, repair, alternation or demolition; The code has been consulted the trade on the proposed contents of the works code The code sets out the min. industry standard in satisfying the Ordinance The code had been made reference to the relevant safety standards of the European Standards Institution The Code will be effective upon the day on section 157 of the Cap 618 25 Code of Practice for Lift Works and Escalator Works Section 3 - Overview of Duties: General duties of RPs General duties of RCs General duties of REs General duties of RWs General relationship between registered persons 26
Code of Practice for Lift Works and Escalator Works Section 4 General Requirements: Type approval Change in design and construction Work to be carried by two or more lift workers Relationship of lift works or escalators with building works Fire safety measures in carrying out lift works or escalator works in buildings with occupations Fire resisting construction requirements for lift shaft Work concerning the landing door or car door of a lift Working within a lift shaft Working on the top of a lift car Working in a lift pit Working in machinery spaces or pulley rooms General safety measures for carrying out escalator 27 Code of Practice for Lift Works and Escalator Works Section 5 - Specific Requirements Relating to Lift Works and Escalators Works: 5.1 General 5.2 Matters relating to installation of lifts or escalators 5.3 Examination of lifts or escalators upon completion of installation 5.4 Maintenance of lifts and escalators 5.5 Periodic examination of lifts or escalators 5.6 Major alterations 5.7 Thorough examination following major alterations 5.8 Demolition of lifts or escalators 5.9 Notification for subcontracting of lift works or escalators works 28
Code of Practice for Lift Works and Escalator Works 6 Miscellaneous: Entering information into log-books Maintenance records to be kept by RCs O&M manuals and technical data Handling fault calls and safe release of trapped passengers Reportable incidents Posting of notice relating to incidents Incident investigations 29 Code of Practice for Building Works for Lifts and Escalators 2011 30
Code of Practice for Safety at Work (Lift and Escalator) 31 Guide on Safety in Lift Repair & Maintenance 32
Guidelines on Safety of Lift shaft Works (Volume 1 During Construction Stage and before Handing over to lift installation Contractor) 33 Guidelines on Safety of Lift shaft Works (Volume 2 During Lift Installation Stage Until Issue of Occupation Permit and Handling over To Developer) 34
Guidelines on Safety of Lift shaft Works (Volume 3 Throughout the Occupation Stage of Building) 35 Lift System 36
Principle of Electric Traction Lift System 37 Safety Gear Table 3 Relationship between Governor Tripping Speed, Type of Safety Gear and Rated Speed Maximum Rated Speed Type of Safety Gear 0.63 m/s Instantaneous type, except captive roller type Maximum Governor Tripping Speed 0.8 m/s 0.63 m/s Captive roller 1 m/s instantaneous type 1.0 m/s Instantaneous type 1.5 m/s with buffered 1.0 m/s Progressive type 1.5 m/s Instantaneous Type Exceeding 1.0 m/s Progressive type 1.25V + 0.25/V m/s Progressive Type COP5.11.1 Part 1: The car shall be provided with a safety gear capable of operating in the downward direction and capable of stopping a car carrying the rated load, at the tripping speed of the overspeed governor, even if the suspension devices break, by gripping the guide rails, and of holding the car there 38
Car safety Gear Tests The following tests should be conducted with the car descending, with the brake open and the machine continuing to run till the ropes or become slack: Progressive Type: 1.The safety gear shall operate correctly when engaging at rated speed with the rated load uniformity distribute in the lift car; OR 2.The safety gear shall operate correctly when engaging at levelling or inspection speed with 125%/150% of the rated load uniformity in the lift car Instantaneous Type: The safety gear shall operate correctly when engaging at rated speed with the rated load uniformity distributed 39 Overspeed Governor Tripping speed of the overspeed governor for the car safety gear shall occur at a speed at least equal to 115% of the rated speed and conform to the Table 3; Breaking load of the rope shall be related by a safety factor of a least 8 to the tensile force produced in the rope of the overspeed governor when tripping ; Nominal rope diameter of the safety rope at least 6 mm; Pitch diameter of the overspeed governor pulley and the nominal rope diameter shall be at least 30 The breakage or slackening of the rope shall cause the motor to stop by means of an electrical safety device 40
Case Study For reference only Manufacture Rated Speed m/s Electrical Switch Overspeed Governor Tripped Speed Manufacture Min. Manufacture Max Instantaneous Type (m/s) % (m/s) % (m/s) % (m/s) % Fujitec 1 1.3 130 1.15 115 1.4 140 1.5 150 Hitachi 1 1.25 125 1.15 115 1.31 131 1.5 150 Otis 1 1.28 128 1.15 115 1.38 138 1.5 150 Fujitec 1.25 1.71 137 1.44 115 1.88 150 1.76 141 Mitsubishi 1.25 1.5 120 1.44 115 1.67 134 1.76 141 Fujitec 1.75 2 114 2.01 115 2.33 133 2.33 133 Hitachi 1.75 2.18 125 2.01 115 2.28 130 2.33 133 Fujitec 2 2.23 112 2.30 115 2.48 124 2.63 131 Fujitec 2 2.33 117 2.30 115 2.6 130 2.63 131 Hitachi 2 2.48 124 2.30 115 2.58 129 2.63 131 Hitachi 2.5 3.11 124 2.88 115 3.18 127 3.23 129 Otis 2.5 2.88 115 3.66 146 3.23 129 Safety Gear Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Progressive Type Tripping Tripping speed comply speed comply with max. with min. requirements requirements 1.25V+0.25 115% /V No No No No 41 Brake The brake can sustain the static car in the lower part of its travel at its rated speed, with the 125% of the rated load (passenger/general freight lifts) or 150% of the rated load (vehicle lifts/industrial truck loaded freight lifts) of the rated speed; (test criterion) In these conditions the retardation of the car shall not exceed resulting from operation of the safety gear or stopping on the buffer; If one of the components was not working on the brake drum a sufficient braking effort to slow down the car when containing with rated load; Any solenoid plunger is considered to be a mechanical part, any solenoid coil is not. 42
Suspension Ropes 43 Rope Traction 1. The car shall be maintained at floor level without slip when load to 125%/150%; 2. It shall be ensured that any emergency braking causes the car, whether empty or with rated load, to decelerate with a value not exceeding the setting of the buffer 3. It shall not be possible to raise the empty car when counterweight is resting on the buffer Traction Check: 1. The empty car could be travelling upwards at rated speed; 2. The car can be stopped with 125% of the rated speed when travelling downwards in the lower part of the lift well at rated speed; 3. With the counterweight resting on its fully compressed buffers, it is not be possible to raise the empty car 44
Energy Accumulation Buffers The total possible stroke of the buffers shall be at least equal to twice the gravity stopping distance corresponding to 115% of the rated speed, (i.e. 2 x 0.0674 V 2 meters). In any cases it shall not be less than 65 mm; Buffer shall be designed to cover the stroke defined above under a static load of between 2.5 to 4 times the sum of the mass of the car and it rated load (or the mass of the counterweight); Energy accumulation type buffers with buffered return movement may only be used if the rated speed of the lifts does not exceed 1.6 m/s. 45 Energy Dissipation Type Buffers Energy dissipation type buffers may be used whatever the rated speed of the lift; Total possible stroke of the buffers shall be at least equal to the gravity stopping distance corresponding to 115% of the rated speed, i.e. 0.067V 2 m. Reduced Buffer Stroke When the retardation of the lift at the ends of its travel is monitored: a. 50% of the stroke with the speed not exceed 4 m/s and the stroke does not less than 420 mm; b. 33 1/3% of the stroke with the speed exceeds 4m/s and the stroke shall not less than 540 mm Buffer Tests: a) The car shall be brought into contact with the buffers at rated load at rated speed, or at a speed for which the stroke of the buffers has been calculated (i.e.. 2 x 0.0674 V 2 ) b) The buffers shall recover automatically after operation 46
Final limit Switch Final limit switch shall be set to function as close as possible to the terminal floors, without risk of accident operation; They shall operate before the car (or counterweight if there is one) comes into contact with the buffers. The action of the final limit switches shall be maintained whilst the buffers are compressed 47 Slowdown of the lift in the case of Reduced Stroke Buffers The devices shall check that the slowdown of the lift car is effective before arrival at terminal landings; If the slowdown is not effective these devices shall cause the car speed to be reduced in such a way that, if the car comes into contact with the buffers, the striking speed shall not exceed that for which the buffers were designed 48
Overload Protective Device 4..2.4 Overload Device: Fail safe design; Not be damaged by excessive overloading; Operate in exceed 10% or more Preventing door closing and movement Audible and visual signals Cap 618: Load weight in the car shall be between 90% and 110% of rated load 49 Protection during door operations 4.6 of pt1-cop Automatic power operated horizontally sliding doors: Prevent the door closing shall not exceed 150 N when the door closing in 1/3 travel distance and average closing speed shall not exceed 10 J A sensitive protective device shall automatically initiate re-opening: Effect of the device may be neutralized at last 50 mm of travel In case of make the protective device inoperative after a fixed period of time, the kinetic energy shall not exceed 4J with audible alarm A single beam light ray alone is considered insufficient Re-open button shall be provided on the COP The detection device shall be positioned at a height of between 500 mm to 600 mm above the floor of the lift car. (Barrier Free Access 2008/79(4)) 50
A car door locking device 4.7 of pt1-cop Car door locking device Shall be certify a Type Test Certificate 4.9 of pt1-cop Locking of the car door Every car door shall be mechanically locked by at least 7 mm that it can only be opened by in the unlocking zone; If horizontal distance between the wall of the well and the sill or entrance frame is over 150 mm, the locking shall be proved by electrical safety device. 51 Levelling BS5655-6: 2002 a. AC1 between ±25 mm and ± 40 mm b. AC2 between ±10 mm and ± 20 mm c. ACVV and DCVV between ±10 mm d. VVVF between ±10 mm and ± 5 mm 52
Lift well and Enclosure 1.1 of pt1-cop General Provisions Car and counterweight shall be enclosed in a lift well Comply with fire resisting construction (FRP 2hrs.) When the lift well is required to protect of the building against spread of fire, it shall be totally enclosed and comply with Building (Planning) Regulations If not, the landing door size shall either cover of full height or be minimum height of 3.5 m and enclosure shall be of minimum 2.5 m with minimum horizontal of 0.5 m to moving parts of lift 1.6 of pt1-cop Exclusive Use of the Lift Well The well shall be exclusively for the lift. It shall not contain cables or devices etc., other than for lift and for telecommunication at the lift car; Nor shall it be fitted with any fire sprinklers 53 Escalator 54
Construction of Escalator H θ θ is the inclined angle of escalator (i.e. 30 0 or 35 0 ) H is the height of the escalator 55 The support structure shall be designed in a way that it can support the dead weight of the escalator plus a passenger weight of 5,000 N/m 2 (Load Weight); Load carrying weight = nominal width of step (Z 1 ) x distance between support (l 1 ); Base on passenger weight, the maximum calculated or measured deflection shall not exceed 1/750 of the distance between supports l 1, The deflection value shall be reduced to 1/1000 of l 1 for public service escalator Truss 56
Dimension of escalator Nominal Width (m) Number of carrying passengers 600 1 800 1.5 1000 2 57 Theoretical Capacity Nominal Width (m) Rated Speed (m/s) 0.50 0.65 0.75 0.6 4500 persons/h 5850 persons/h 6750 persons/h 0.8 6750 persons/h 8775 persons/h 10125 persons/h 1.0 9000 persons/h 11700 persons/h 13500 persons/h 58
Safety Device for escalator 59 Safety device Slagging 1. Slagging of steps 2. Slagging of step rollers 3. Slagging of step chain rollers 60
Skirt Panel Safety Device Rise Number of skirting safety device at provided at each of the inclined section 6 m 6 m < Rise 7.5 m 7.5 m < Rise 9 m The number of electrical safety device required for an escalator of rise exceeding 9 m shall be so calculated accordingly 1 2 3 61 Comb Plate Safety Device 62
Comb Comb The comb should be engaged into the comb at least 6mm COP part 4 7.3.1 Less than 4 mm COP Part 4 7.3.2 Comb Plate Less than 4mm Measurement gauge 63 Handrail Entry Inlet Safety Switch To prevent the pinching of fingers, hands or other objects COP Part 4 3.5.3 The dimension shall be not less than 0.10 m and not exceed 0.25 m COP Part 4 3.5.1 64
No Load Downward Stopping Distance Rated Speed Stopping Distance 0.5m/s min 0.20m and max. 1.00m 0.65m/s min 0.30m and max. 1.30m 0.75m/s min 0.40m and max.1.70m 65 Auxiliary Brake Escalator (excluding non-inclined passenger conveyors) shall be equipped with auxiliary brake acting immediately, or via gears or shaft, on the main driving shaft in the condition as the following: 1. The coupling of the operational brake and the driving wheels of the steps, pallet or the belt is not accomplished by shafts or gear wheels; or 2. The operational brake is not an electro-mechanical brake; or 3. The rise exceed 6 m; or 4. They are public service escalators 66
Operation of Auxiliary Brake 1. Before the speed exceeds a value of 1.4 times the rated speed by the operation of the overspeed governor or other speed control devices; 2. By the time the steps and pallet or the belt change from the present direction of motion; or 3. In the event of the failure of the coupling of the operational brake and the driving wheels of the steps, pallet or the belt, in case the coupling is not accomplished by shafts or gear wheels 67 Landing Area At the landings of the escalators a sufficient unrestricted area shall be available to accommodate passengers; The width of the unrestricted area shall at least correspond to the distance between the handrail centerlines; The depth shall be at least 2.50m measured from the end of the balustrade; It is permissible to reduce it to 2.00 m if the width of the unrestricted area is increased to reduce at least double size. And the clear Height shall be at least 2.3 m 2.0 m / 2.5 m 68
Clearance between Balustrade and Adjacent Rail/Wall The maximum clearance between the balustrade exterior paneling and any guard rail/wall erected adjacent to the escalator shall not more than 100 mm. 69 Accident 70
Accident 71 Accident 72
Accident 73 Steps Broken 74