Elevator cylinder replacement - cylinder hole issues & information

In the elevator universe one of the most intrusive and problematic equipment replacements is the elevator’s hydraulic cylinder.   Replacement can be from cylinder failure during annual testing or deterioration over time.  Replacement can also be a due to code requirements or taking a proactive approach to avoid a extended shut down period waiting for a cylinder to be manufacturered.  This post is to show you some of the issues we run into when replacing a hydraulic cylinder.

City of Chicago building owners - A reminder to building that are in the City of Chicago and have older elevator systems they need to replace their elevator cylinder if it was installed with a single bottom cylinder.  The common year we use is 1972 to make an assumption that the elevator has a single bottom cylinder.  Elevator cylinder manufacturers where making double bottom cylinders in the 1960’s and some elevator manufacturers where making single bottom cylinders into the 1980’s.  It is up to the building owner to show burden of proof.  All single bottom elevator cylinders should have been replaced by 1/1/13.

[General information on cylinder replacement]

No in ground casing – The picture below is from a cylinder we removed and there was no casing.  Cylinder casing is supposed to be installed to hold the integrity of the drilled hole.  For older installations or economically concerned contractors casing may not have been installed.  When there is no casing you would typically need to ream the hole and install casing.   The picture below we had to hire a well driller to clean the hole and install casing.  A project we are completing this week there was no casing but the clay held the hole and when we removed the debris we got a clear hole. Each cylinder hole is different.

[This cylinder hole that has no casing]

[You can closer that there is no casing and the hole is filled with clay - A well driller needed to be called to put casing down]

  

Off set holes – We were at some buildings this week that their cylinders where all replaced, there were two that where more intriguing than the others because they were significantly off set.  You can take a look and see the cylinder is favoring one side of the elevator hoistway.  The cylinder in a perfect scenario would be in the middle.  The reason they are offset could be that the original hole was drilled prior to the building going up and the GC did not mark the elevator pit correctly, or more likely that there was an obstacle in the way that required to redrill next to the original spot.

[This cylinder is favoring the right hand side of the elevator pit]

Well diggers – If at all possible you do not want to hear the words “Well Drillers” if you are a building owner.  That means the cylinder hole will need a specialized company to come and install casing.  While expensive and takes time it is very difficult work and requires specialized tooling and a specific skill set.

Odds of a smooth cylinder installation - We have run into crooked holes, water in holes, collapsed holes, sand, two pit floors, double lined crooked casing[PVC will not fit down the hole], the casing coming up with the cylinder, and almost every other cylinder hole issue that can happen.  When you pull up the cylinder you never know what you are going to get.  What I tell building owners is that 8 out of 10 cylinders go smooth, 1 out of 10 has minor issues that would require a cylinder bag or another additional minor expense and 1 out of 10 goes horribly wrong and requires a well driller.

When prospecting for a company to replace your elevator cylinder make sure you do research.  Make sure they are equipped to do the work, they have the expertise to do the work and they have a good reference list.  Some elevator companies are good at some things and not others.  We work on low to mid rise buildings and do 20-30 cylinder replacements a year.  We would not do a great job on working on a 75 story building.  A company who works on 75 story building’s may not be great replacing cylinders.  

If you have an questions or would like information from Colley Elevator you can go to www.colleyelevator.com, email Craigz@colleyelevator.com or call 630-766-7230.

Elevator phase monitors/phase protection

I recently was at a building that had a two phase monitors, a very old mercury switch phase monitor and a newer solid state phase monitor. I thought it was a pretty cool picture to show a older device that provided phase protection next to a newer device that provides phase protection.

                          [new phase monitor on the left old mercury switch on the right]

Phase monitors are also required on all traction elevators in the State of Illinois[with exception of City of Chicago] – Starting 1/1/15. 

            Traction elevators – State of Illinois – Phase monitors required 1/1/15

            Traction elevators – City of Chicago – Strongly encouraged

            Hydraulic elevators – Everywhere – Strongly encouraged

The National Electrical Code (NEC) specifies that elevators driven by poly-phase

AC motors must be prevented from starting when there is a phase reversal or phase failure condition present. The reversal of three phase voltage can lead to a sudden change in direction, which could lead to a disastrous hazard when the transportation of people is involved. A phase failure could lead to a sudden or uncontrolled stop, which is another possible hazardous condition

14% of all motor failures can be attributed to single phasing

30% of motor failures can be attributed to electrical over loading

The electrical code suggests all elevator systems should have a phase monitor device which would shut an elevator down if the following conditions occur

1.    Phase reversal

2.    Phase loss

3.    Under voltage

Phase monitors can be found in elevator motor drives[traction elevators], solid state starters[hydraulic elevators] or purchased as a component

                     [Motor drive with phase protection - Traction elevators - Magnatek]

                             [Siemens soft start with phase protection - Hydraulic elevators]

[This is a stand alone phase monitor - Traction or hydraulic elevators - Diversified Electronics]

In summary, basic but critical voltage and phase monitoring for applications involving transporting people or heavy equipment such as escalators or elevators is not only imperative, but mandated by the NEC[on new installations]. A simple monitor doesn't cost a fortune, but should something go wrong, failure to provide one can be quite costly in liability claims.

Information used from – Carlo Gavazzi automation components – www.gavazzionline.com

If you have an questions or would like information from Colley Elevator you can go to www.colleyelevator.com, email Craigz@colleyelevator.com or call 630-766-7230.

Elevator pit ladder alteration variances

There have been some clarifications on the pit ladder variance process in the last few weeks.

1.    Submit a variance request to the AHJ[I.E. Forest Park or Oak Park]. 

2.    The AHJ may rule on it internally or submit it to the Elevator Inspection firm that is currently contracted with for clarification and a judgement.

3.    If accepted by the AHJ[I.E. Forest Park or Oak Park] the elevator company will then send it to the State of Illinois Fire Marshall for their records.

Variances will not be given to buildings that can put pit ladders in or make modifications that are reasonable.  Variances will be given to buildings that will have a significant financial burden or the general impossibility of achieving the clearances a code compliant pit ladder requires.

 [Above - This ladder a good candidate for a variance as you move the elevator items rail to get the ladder closer to the hatch door]

  [Above - This ladder a good candidate for a variance as it would be very expensive to move the hydraulic pipe and the wiring trough to install a code compliant pit ladder]

Please note - If a building has to spend $500.00 to $2,000 to install or modify the elevator pit ladder to bring it into compliance and is basing the want for a variance based on only the price it will most likely get denied a variance.

[This ladder needs to be extended, traction tape installed and the trough cut out by the bottom run - Not a good candidate for a variance because it is manageable to be compliant]

If you have an questions or would like information from Colley Elevator you can go to www.colleyelevator.com, email Craigz@colleyelevator.com or call 630-766-7230.

Elevators and extreme cold – hydraulic elevators

In the Chicago land area we have had some very cold days which have caused some buildings to have issues with their elevator system.  I would like to take time to remind building owners that it is their responsibility to keep a heated machine room.  When the elevator machine or elevator shaft gets cold it turns the hydraulic fluid thicker or more viscous.  This means it takes more energy than usual to move the hydraulic fluid from the power unit to the cylinder and move the elevator up and down.  The elevator's valve is set up for normal room temperature not extreme cold or heat. If the oil is too cold or too hot it will affect the elevators ability to level.  When an elevator service technician goes to the building after we get a call on a -3 degree day we get to the building and find that the elevator is not leveling.  We can run the car to heat up the oil and then the elevator will begin leveling and operating properly.  This is not a permanent solution as the next day after a evening of elevator inactivity and the oil gets cold the same issues will arise.

The following items should be addressed

1.    Elevator technician should notify the building of the situation and the importance of keeping the elevator room warm.

2.    If the hoistway walls have exposure to the elements keep the elevator at the lowest landing so more oil is in the elevator room then in the cylinder.

3.    Get heat to the machine room

a.    Portable heater for temporary heat

b.    Hydraulic tank heater[can cost $500.00 to $1,000.00] - The heating element goes into the hydraulic tank and will maintain an constant temperature.  There will need to be a 110vac outlet available adjacent to the elevator machine to plug into.

                      [Nylube tank heater - www.nylube.com]

Older elevator hydraulic systems with older valves will have an especially hard time with the cold weather so it is very important that the elevator hoist way and machine room is properly heated to avoid any issues with leveling or shut downs.  The elevator technician can keep coming back to the building to run the elevator to warm it up, however, it is expensive for the building owner and frustrating[for the building and elevator tech] so working towards a permanent solution for the building should be the goal.

If you have an questions or would like information from Colley Elevator you can go to www.colleyelevator.com, email Craigz@colleyelevator.com or call 630-766-7230.

Elevator maintenance

In the last few weeks we have gone to a number of buildings who have maintenance contracts with elevator companies and found

1.    The maintenance contractor does not show up

2.    There are no maintenance records

3.    Testing is over due

4.    No maintenance is being performed

5.    Building management or ownership have no idea what is going on with the elevator

As a building owner you pay your elevator contractor every month, every quarter or whatever interval they bill you.  As a building owner you should know what you are getting for the payments.  While typically everything should be ok at a building if the elevator contractor misses a monthly or quarterly visit.  We visited a building who was paying for “monthly” inspections and found this.

[This elevator pit filled with 30" of water which looks like it has been there for some time]

You depend on the elevator contractor to not only inspect the elevator equipment but to let you know about these conditions.  While the elevator contractor does not pump water out of elevator pits, we are the only personnel that should be reviewing the elevator pit so it is up to the elevator company to let the building owner know about these conditions. 

Larger OEM or multi national firms and independent companies such as Colley Elevator have much different product offerings.  Recently I have spoken to people at different OEM’s and they let me know about the expectations of the companies they work for

1.    4 minute maintenance stops each quarter

2.    15 minute maintenance stops each quarter

3.    500 elevators on a maintenance routes[team maintenance w/2 mechanics]

Take away - The take away from this is to make sure you know what you are getting from the elevator maintenance agreement you have.  Is the elevator contractor supposed to be there once a month, once a quarter, twice a year, etc.  There isn't much you can do on an elevator if you are only given 4 to 15 minutes each quarter.  Talk to your elevator contractor, find out what you are getting, if you don’t like what you hear.  Call a responsible independent elevator contractor.

If you have an questions or would like information from Colley Elevator you can go to www.colleyelevator.com, email Craigz@colleyelevator.com or call 630-766-7230.

State of Illinois elevator mandates due 1/1/15

In the State of Illinois there are 6 items that are mandated to be installed or have a certain criteria by 1/1/15.

1.    Car illumination – car lighting & emergency lighting

2.    Emergency operation & signaling – emergency lights & alarm bell

3.    Phase reversal and failure protection – only traction elevators – recommended on hydraulic elevators

4.    Reopening devices

5.    Pit stop switch

6.    Pit ladders in accordance with ASME A17.1-2007

The first 5 items are required but very manageable and affordable.  In most circumstances the 6^th item, pit ladder, may be there but will need to be modified or replaced as it doesn’t meet the ASME A17.1-2007 criteria which includes.

-        Pit ladder must extend 48” above lowest level hall sill[bottom of entrance]

-       Ladder rungs, cleats or steps shall be 16” wide however can be 9” if there are obstructions in the pit that prevent a 16” ladder to be installed

-       Ladder rung or steps shall be spaced 12” on center and shall have a rung at the height of the door sill

-       Ladder run or steps shall have knurling, dimpling or be coated with skid resistant material

-       A clear distance of not less than 4 ½”[from center line] front to back from nearest object

-       Side rails shall have a distance of not less than 4 ½” from their nearest permanent object.

-       Ladder shall be rated for 300lbs

-       Retractable ladders need to have an electric contact that opens safety circuit when ladder is in usable position

-       Elevator car door unlocking device shall be accessible from top rung of ladder 72” vertically and 39” horizontally

-       Ladder to be made out of noncombustible material – no wood ladders

 [A17.1 2007 code information]

[graphic lays out some of the distance requirements]

We maintain approximately 1,000 elevators and of most of the ladders in buildings we maintain do not comply 100% with the new requirements.  The process of making all elevator pit ladders code compliant will be very difficult as the elevator pit is a confined space and there may be piping or other objects in the way.

Pit ladder example #1

Information on pit ladder #1 - This particular ladder has a light in the middle of the rungs which needs to be moved, there is not enough space for the rungs to be 4 1/2" from the center line of the rung to the wall[only 1 1/2"] and this ladder only extends 42"[needs to be 48"] above the sill.  This ladder has been installed for over 25 years and complied for 25+ years.  Now it will need to be replaced with a retractable ladder and have the light moved out of the as there is not enough room between the elevator and the hoist way wall to have a rigid or stationary pit ladder.

Pit ladder example #2

Information on pit ladder #2 - As you can see there are many items in the way of making this code compliant.  There is an oil line, light bulb, wiring trough and limited space between the car and the wall.  This building will have a very challenging time making a pit ladder comply with the new requirements.

Retractable ladders 

When there is not enough clearance from the wall to the car there is an option for a retractable ladder.  This is a more expensive option that can enable your elevator pit ladder to comply with the new code requirements. 

[http://www.smartelevatortech.com/RetractaLadder.htm]

If you haven't heard from the elevator company who services your elevator yet, get in touch with them to make sure they are working on a plan of action and pricing for you. Pit ladder modifications do not need permits, new pit ladders will need permits and final inspections.

If you have an questions or would like information from Colley Elevator you can go to www.colleyelevator.com, email Craigz@colleyelevator.com or call 630-766-7230.

Elevator pit ladder variance

We are coming up on the elevator pit ladder requirement that will cause many buildings significant challenges.  

For buildings that have existing pit ladders or do not have room to install a functional pit ladder there will be an opportunity to apply for a variance.  There will be two schools of thought depending on which inspection firm is inspecting your elevator pit ladders.

1^st school of thought – If the existing pit ladder is reasonably safe and we can show it reasonably complies with the new requirements a variance can be applied for by sending the compliance criteria to the elevator inspector for review, they will send it back to the elevator company and we can send it to the municipality. 

2^nd school of thought – If the new or existing pit ladder cannot meet the new compliance criteria based on that there are permanent structures in the way[i.e. oil lines, elevator rails] you can apply for a variance by sending information to the municipality, the municipality may deal with it on the local level or send it to the elevator inspection firm and they will rule accordingly.  Variances will only be given by the elevator inspector only if you can provide proof that a pit ladder cannot be installed without deconstructing permanent structures.  This does not allow a monetary exception in the event a retractable pit ladder can be installed or other reasonable accommodations can be made to install a pit ladder.   

Depending on which elevator inspection firm is completing the elevator inspections you will get a different result.  If you are in Town A and have Elevator Inspector A whom subscribes to the 1^st school of thought you will get a different outcome than Town B who has Elevator Inspector B who subscribes to the 2^nd school of thought.

Example – The pit ladder below will never comply with all the requirements of the new criteria and there is no way to make it comply with all of the requirements[as the elevator guide rails are near the front of the elevator shaft].  The wiring trough in the way would be a reason for a variance with the 1st school of thought not the 2nd school of thought as the wiring trough can be moved. This pit ladder would be a good candidate for a variance.

How to apply for a pit ladder variance – Work with your elevator company to take the measurements required to submit for a variance.  The elevator company should do most of the leg work on this as they will have the information the decision making bodies will need.

Do not forget that all elevators will also need

1.    Car illumination – car lighting & emergency lighting

2.    Emergency operation & signaling – emergency lights & alarm bell

3.    Phase reversal and failure protection – only traction elevators – recommended on hydraulic elevators

4.    Reopening devices – Safe edges are acceptable

5.    Pit stop switch

If you have an questions or would like information from Colley Elevator you can go to www.colleyelevator.com, email Craigz@colleyelevator.com or call 630-766-7230.