Elevator Maintenance + Repair Harry Vyas Director Elevators Unit
The NYC Department of Buildings is a registered Provider with The American Institute of Architects Continuing Education Systems (AIA/ CES). Credit earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of Completion for both members and non-AIA members are available upon request. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or constructed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.
Copyright Materials This presentation is protected by US and International Copyright laws. Reproduction, distribution, display and use of the presentation without written permission of the speaker is prohibited. ©NYC Department of Buildings
Course Description New York City is a vertical city with more than 60,000 elevator stocks that make 30 million trips each day. Elevators are designed to transport people in more than 28,000 buildings across New York’s dense urban environment. Maintaining and repairing vertical transportation systems are essential in providing safe and reliable service to riders and building operations. A lack of maintenance and repairs may cause elevator failure, reduce the lifespan of equipment, entrapment and injury. This course will examine the NYC Building Code and ASME A 17.1 requirements for the maintenance of elevators and escalators. It will also discuss best practices for maintenance and repairs; including engineering controls and accident prevention.
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Learning Objectives At the end of this program, participants will have learned: •
Participants will examine NYC Building Codes requirements administrative section 28-304.7 and ASME A 17.1 SECTION 8.6 for elevators and escalators in order to be able to identify specific regulations for elevator maintenance and repairs.
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Participants will examine the Maintenance Control Program and be able to keep a “Maintenance Log” that is reflective of manufacturers and code requirements.
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Participants will review best practices for the maintenance and repairs of elevator and escalators in order to educate on the potential risks while working on equipment.
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Participants will analyze various design and engineering control methods to enhance public safety during maintenance and repair.
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The Elevators Unit’s Mission The Elevators Unit ensures the operational safety, reliable service and lawful use of elevators, escalators, amusement rides and other related devices throughout New York City by performing inspections and testing. The Unit enhances compliant development and safety awareness through the Department’s various outreach programs. The Unit supports development by permitting new technologies under pilot programs.
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Elevator Safety •
The public
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Elevator personnel
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Authorized personnel
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Emergency responders
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Device Types •
Elevators
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Escalators
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Man lifts
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Conveyors
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Personnel hoists
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Wheelchair lifts
2013 BUILD SAFE | LIVE SAFE CONFERENCE
Codes and Standards •
NYC Building Code 2008 (Appendix K, Chapter 30)
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ASME A 17.1/2003 and ANSI/ASSE A10.4 (Personnel Hoist)
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ASME A 17.3/2002 (Existing Elevators and Escalators, as modified by Chapter K3)
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Maintenance and Repair Contract NYC Administrative code 28-304.7 – Required contract •
Owner of New and existing passenger elevators shall have contract with an approved agency to perform elevator repair work and maintenance as defined by ASME A 17.1- Section 8.6.
•
The name, address and telephone number of approved agency under contract shall be maintained at each premises, on the elevator mainline disconnect switch and in a location readily accessible to employees of the department, building maintenance and custodian staff at the premises.
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Elevator Maintenance and Repair •
Maintenance Control Program
•
Maintenance Records
•
Repair
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Maintenance, Repairs and Replacement Shall confirm following code requirements: •
Code at the time of the installation
• Code requirements at the time of any alteration/modernization • ASME A 17.3-2002 as modified by NYC Building Code Appendix K • ASME A 17.1b-2003, Section 8.6
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Maintenance Control Program MCP shall be in compliance with ASME A 17.1b-2003 Section 8.6.1.2: •
Examination, maintenance and tests at schedule interval
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Equipment age, condition, and accumulated wear
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Design and inherent quality of the equipment
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Usage, Environmental condition
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Improved technology
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Cleaning, lubricating, adjusting applicable components at regular intervals
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Repair or replace all worn or defective component where necessary to maintain installation as per codes and manufacturer requirements
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Available at site to elevator personnel
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As required by Manufacturer manual 2013 BUILD SAFE | LIVE SAFE CONFERENCE
MCP Examples
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MCP Examples
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MCP Examples
• MCP Example
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MCP Examples: MRL Elevator (Traction)
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Maintenance Records Maintenance records shall be in compliance with ASME A 17.1b-2003 Section 8.6.1.4: • Description of maintenance task performed and dates • Description and dates of examinations, tests, adjustments, repairs and replacements • Description and dates of call backs (trouble calls), including corrective action taken • Written record of the findings on the fire fighter service • Available at the site for elevator personal
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Maintenance Log Examples
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Maintenance Log Examples
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Maintenance Log Examples
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Maintenance Log Examples
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Maintenance Log Examples
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Maintenance Log Example
• Maintenance Log Example
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Maintenance Log Examples
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Elevator Application •
New installations
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Alterations (change in speed, capacity, rise, structural and location)
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Replacement and modification (replacement/ modification of controller, machine, governor, safety etc.)
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Elevator use for construction use (new or amendment on existing application)
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Removal
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Dismantle
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Electrical permit must be filed for electrical work performed on device
Note: An acceptance test is required for all types of elevator applications (except applications filed under EBN/PPN), and Department inspectors shall perform the necessary test and inspection, as per the scope of work.
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Types of Inspections Department of Buildings Inspectors: • Acceptance Tests - Permitted Application (new and modernized devices) • Complaint Inspections (through NYC 311 call center) • Incidents / Accidents and Emergency Response (24/7) • Periodic Inspections • Violation Re-Inspections
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Enforcement •
ECB violations
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PVT/DOB violations
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Aggravated I and II
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Criminal court summons (under major offenders program)
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Work without permit violation
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Approved Agency Inspections On behalf of the building owner: •
Category One – 1 Year Test (Performed between January 1st and December 31st annually)
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Category Three – 3 Year Test (water hydraulic)
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Category Five – 5 Year Test
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All above inspections and tests shall be performed, witnessed by approved agencies not affiliated with each other
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Affirmation of correction inspection (Cat. 1 defects and PVT violation)
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Maintenances Issues Rouge on ropes – lack of maintenance
Hoist Cables 2013 BUILD SAFE | LIVE SAFE CONFERENCE 30
Maintenances Issues Undersized Ropes
Hoist cables 2013 BUILD SAFE | LIVE SAFE CONFERENCE 31
Maintenances Issues Severe rust condition on safety cable drum
Safety Rope 2013 BUILD SAFE | LIVE SAFE CONFERENCE 32
Maintenances Issues Damaged ropes
Hoist Cables 2013 BUILD SAFE | LIVE SAFE CONFERENCE 33
Maintenances Issues Oil leak on machine
Hoist Machine 2013 BUILD SAFE | LIVE SAFE CONFERENCE 34
Maintenances Issues Lack of oil change
Hoist Machine 2013 BUILD SAFE | LIVE SAFE CONFERENCE 35
Maintenances Issues
Electrical
Jumped fuses
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Maintenances Issues
Electrical
Exposed wiring
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Maintenances Issues
Electrical
Exposed wiring
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Maintenances Issues
House keeping
Dirty pit creating a fire hazard
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Maintenances Issues
Safety
Governor switch blocked
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Maintenances Issues
Safety
Loose bolts
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Maintenances Issues
Safety
Brake sleeve defective
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Hoist Applications New Installations •
ELV-1 Elevator application
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Electrical permit must be filed for electrical work
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Construction application must be filed at the borough office for ties to the building structure and for back structure installation
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Hoist Inspection Requirements •
Acceptance Inspection and Test – Department of Buildings
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Audit Inspection – Department of Buildings
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Hoist Removal – Department of Buildings
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Cathead/Tower Raise – Approved agency Inspectors (Requires 3 days’ notification)
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90 Day Inspection – Approved agency Inspectors (Requires Full Load Test)
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Inspections required as per Code and manufactures manual
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Required maintenance log at the site 2013 BUILD SAFE | LIVE SAFE CONFERENCE
Hoist Maintenance Issue
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Hoist Maintenance Issue
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Advantages of Maintenance as Per MCP •
Enhance safety
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Improve service reliability
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Increase life span of equipment
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Enhance efficiency of vertical system transportation
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Avoid costly repairs
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Avoid violations and penalties 2013 BUILD SAFE | LIVE SAFE CONFERENCE
Elevator Safety •
Worker safety
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Fall protection
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Electrical safety
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Proper use of jumpers
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Lockout and tag out
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Use of caution tape when elevators are serviced – Code requirement
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Questions?
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Elevator Maintenance + Repair Eric Munz, CSP NEII®
NYC Deptartment of Buildings Best Practices and Engineering Controls for Public Safety and Mechanics During Elevator/Escalator Repairs in Occupied Buildings
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Course Description This course will cover essential best practices and engineering controls designed to prevent injury to the general public and elevator mechanics during the repair of vertical transportation equipment including elevators and escalators.
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Safety Tip
1 new text msg: Adhere to Safety Rules; Save Lives. Don’t just be compliant; be committed.
A few over-the-counter drugs like antihistamines, cough syrups, and cold medications can create drowsiness. During allergy season, take notice of the side affects and adjust use accordingly.
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Agenda Public Safety Factors Car Control Jumper Management Caution Tape Deep Pit Protection Barricades Mechanic Safety Practices Access/Egress MR LOTO/Electrical Safety Jumpers Mechanical Safety Hoistway Access Procedure Fall Protection Safety Culture, Creation & Maintenance
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Elevator Safety – General Public CAR CONTROL • Maintained while on “inspection” mode, removing the unit from the bank • Electrical and mechanical energy is isolated during repair tasks • “Safety Chain” includes: door lock, inspection switch, stop switch
De-Energize
Inspection Control
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Elevator Safety – General Public JUMPER MANAGEMENT • The controller is programmed to prevent unwanted movement of the car, jumpers defeat these circuits • Robust management practices must be applied • Personal accountability for jumpers must start with the Mechanic
Controlled Jumper
Uncontrolled jumper
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Elevator Safety – General Public Jumper Best Practices •
Jumpers must not be used as a diagnostic tool.
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Temporary bridging devices must never be used to short out hall door contacts.
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Exceptions must have a written JHA approved by supervision.
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Never jump-out door and gate contacts at the same time.
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Ensure that elevator is on inspection prior to placing jumpers on door, gate, or safety circuits.
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When passenger(s) are trapped inside a stalled car, mechanic must never jump car gate and move the car from the machine room unless they have communication either directly with the passenger(s) or with a second mechanic. In these types of situations it is preferable to move the elevator using TOCI. 2013 BUILD SAFE | LIVE SAFE CONFERENCE 57
Elevator Safety – General Public CAUTION TAPE (NYC) • The code specifies 3” yellow caution safety tape installed at 18” and 54” on the inside car door threshold when working on the elevator • The tape needs to be utilized when the elevator is removed from normal service and a Mechanic is not working in front of the entrance of the actual device • Prevents unintended public entrance • Lights out/Doors open communicates that the car is out of service
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Elevator Safety – General Public DEEP PIT PROTECTION • Pits designed with bottom landing access points represent a challenge for public protection • Falls of any height can cause injury • Deep pit depths can be as great as 20’ • Substantial barricades offer a higher level or protection and OSHA compliance
Substantial Barricade
Standard Barricade
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Elevator Safety – Elevator Mechanic Serious Injury Risk Areas Machine 4%
Controller 2% Machine/Sheave 15% Top of Car 7%
Machine Room/ Entrance 10%
Car/False Car 4% Hoistway 17% Truss 2%
Landing 4%
Hoistway Opening 4%
Landing Floor Plate 2%
Counterweight 2%
Pit Entrance 7% Pit 11%
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Elevator Safety – Elevator Mechanic ACCESS/EGRESS MACHINE ROOM • Presents hazard to the mechanic • Must commonly access rooftops, staircases and mechanical spaces not designed for public access
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Elevator Safety – Elevator Mechanic ELECTRICAL HAZARDS • If electricity is required for the task, the mechanic must work safely around it. • Increase distance from the hazard • Temporarily guard the hazard • Permanently guard the hazard
Temporary Electrical Guarding
Exposed Electrical
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Elevator Safety – Elevator Mechanic JUMPER MANAGEMENT • •
• • •
Jumpers must not be used as a diagnostic tool Temporary bridging devices must never be used to short out hall door contacts. Exceptions must have a written JHA approved by supervision. Never jump-out door and gate contacts at the same time. Ensure that elevator is on inspection prior to placing jumpers on door, gate, or safety circuits.
Controlled Jumper
Uncontrolled Jumpers
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Elevator Safety – Elevator Mechanic MECHANICAL HAZARDS • Elevator companies maintain equipment that is owned by another party • Retrofitting of permanent guards is an owner decision • Use of temporary guarding is a best practice
Guarded
Not Guarded
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Elevator Safety – Elevator Mechanic HOISTWAY ACCESS • Serious injuries occur when control of the car is lost • Specialized tooling and processes to validate the safety circuits is a best practice
Specialized Tools
Improvised Control
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Elevator Safety – Elevator Mechanic FALL PROTECTION • Elevator mechanics can be exposed to great falls • Guardrails eliminate the hazard
Guardrails
Fall Protection
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Escalator Safety – General Public BARRICADES • Separate public from the hazards of fall and electricity
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Escalator Safety – Elevator Mechanic CONTROL OF ENERGY • Redundant control of truss (steps removed) • LOTO/Electrical
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Safety Culture Development Minimum Operational Requirements •
Comply with Federal, State and City regulations
Develop a Culture of Safety • •
Develop a Safety Management System Proactively manage safety through Employee training & communication Proper safety equipment & tools Create an environment where mechanics champion safety Empower mechanics to own safety Support the safest work, not the fastest Vehicle Management/Driver Accountability Invest in the safety program
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Standardize Processes When practical, document a standard work process • • •
Develops efficiencies Improves safety for all Reduces re-work and unproductive time
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Establish the Rules
ALWAYS use fall protection when a fall hazard exists.
ALWAYS lock and tag out equipment when power is not required.
ALWAYS follow the operation authorized procedures for false cars/running platforms.
ALWAYS use certified & inspected hoisting & rigging equipment.
ALWAYS establish and maintain control of the unit prior to accessing. ALWAYS follow proper jumper procedures.
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Establish the Rules
ALWAYS control live electricity and rotating equipment when working within close proximity. NEVER ride escalator when steps are removed.
NEVER ride the car top with the elevator in normal operation.
NEVER work above or below others when working in the hoistway.
ALWAYS secure the step chain from movement.
ALWAYS use barriers and redundant controls (LOTO) when unattended
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Educate Mechanics on the Process Classroom and hands-on training reinforces the learning process Improves accountability and compliance Frequent training/communication Elevator Field Employees’ Safety Handbook
Engaged Training
Safety Handbook
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Job Hazard Analysis (JHA) An important accident prevention tool used by mechanics is the Job Hazard Analysis Process, or JHA. This process allows mechanics to analyze each job step, identify hazards they may encounter, and document ways accidents can be prevented by mitigating these hazards. A written JHA should be used at the start of each day, and when starting each new major task. 2013 BUILD SAFE | LIVE SAFE CONFERENCE
Jobsite Inspections Although NEII® companies continue to drastically reduce the number of injuries, serious injuries still occur. As a result, some members have developed special observation programs to assess the level of understanding of mechanics of the key hazard areas while performing typical procedures. This assessment focuses on preventing the leading causes of serious and fatal injuries.
1. 2. 3. 4.
Fall Protection Control of the hazardous Energy Control of the Elevator High Risk Practices a. Scaffolding b. False Cars / Running Platforms c. Hoisting & Rigging d. Jumpers
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Program Recognition & Enforcement Mature programs • • • • •
Motivate employees to “do the right thing” Reinforces compliance to rules Formally document history Verbal warning to termination options Automatic suspensions for violations, even first time
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This concludes The American Institute of Architects Continuing Education Systems Course
NYC Department of Buildings
AIA Point of Contact: Allison Ginsburg
[email protected] 212-566-4415
Elevator Maintenance + Repair Harry Vyas Director, Elevators Unit
Eric Munz, CSP NEII®
