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METHOD STATEMENT

SUPPLY, DELIVERY, INSTALLATION, TESTING, COMMISSIONING AND


MAINTENANCE OF LIFT SERVICES

FOR

MAHKAMAH BAHARU AMPANG, SELANGOR

BY

SIGMA ELEVATOR (M) SDN BHD (414986-V)


UTC Building & Industrial Systems, Ground Floor, No. 1, Jalan Industri PBP
3, Taman Industri Pusat Bandar Puchong, Selangor Darul Ehsan, Malaysia.
Tel: (+60 3) 2035 5840
Fax: (+60 3) 2035 5501/5502
METHOD STATEMENT FOR LIFT INSTALLATION

Prior to commencement of lift installation works, all the lift shafts and pits have to be
cleared of formworks debris and water. Once these are cleared, scaffoldings shall be
erected from the pit to the soffit of the motor room floor slab for template setting.

1.0a Handling, storage and delivery of materials.

All equipment are shipped to port and delivered to site on trailers. At the site,
hoisting of equipment to storage site is done by the tower crane or mobile crane.
Storage of equipment is preferably in a covered area protected from rain water.
Pellet truck is used to arrange and handle the equipment.

1.0 Template Setting

Steel piano wires are used to plumb down from the highest floor to the lift pit at
various points for installation works. Six (6) lengths of wire are used out of which
two (2) for the entrance, two (2) for car guide rails and two (2) for the
counterweight rails. A reference line or point shall be provided by the Building
Contractor at Ground Floor lift lobby as a datum line so as to ensure the door
entrances in a common are in line for installation of two (2) or more lifts in a
common shaft. After completion of the template setting the guide rail bracket and
landing sill installation can then commence.

2.0 Car and Counterweight Rail Brackets

Rail brackets are fastened to the building by M16 anchor bolts on reinforced
concrete walls or welded to steel support beams by lap joint 3mm fillet welds.
These brackets are normally spaced at 2500 mm apart along the entire height of
the hoist way. Each rail normally has two (2) bracket support points. After the
completion of the bracket installation, the installation of guide rails shall
commence.

3.0 Guide Rail Erection

Car and counterweight rails are erected vertically in the lift shaft by means of a
winch starting from the pit where these rails sit on the buffer channel bases. Guide
rails are not painted. Most guide rails are 5000 mm in length and are joined by fish
plates ( refer to picture attached ) with bolts and nuts at every rail end. These rails have to
reach the soffit of the motor room slab leaving a gap of about 100 mm clear. After
the rails have been installed, their alignment is checked for verticality using a rail
gauge at as many intervals as required from 2 points per rail to the entire rail. The
rail verticality has to be precise to ensure smooth riding comfort in the car upon
commissioning.

4.0 Buffer Channel Bases

Buffer channel bases are fixed to the bottom end of the rails and rail height is
adjusted to 50mm – 70mm by using nuts to ensure the buffer channel bases are
horizontal. Buffer channel bases are mounted onto the pit floor slab by anchor
bolts after the rail alignment. (refer to attached picture)
5.0 Landing Entrance Sills

Prior to the landing sill setting, the reinforced concrete sill supports or sill
supporting angle installation has to be completed. The finished floor level (datum
line) has to be provided at each landing entrance and marked on the wall by the
building Contractor. Setting of the sills is done based on the datum line and the
plumb line. After the completion of the sill setting, all gaps around the sills are to
be grouted with cement whereby its thickness depends on the existing jobsite.

6.0 Landing Door Frames (Jambs)

The frames are assembled and mounted on the landing sills and fastened by
bolts. The entrance width and verticality of the door frames are checked by cross-
checking with the lobby reference line and the finish floor reference line provided
by the main contractor. Once the alignment has been verified, the door frames are
then set in position by welding the frame steel bracing to the anchor bolts or steel
bars protruding from the side of the reinforced concrete walls by tee joint spot fillet
welds 2 – 3 mm thick.

7.0 Landing Door Header

The door header assembly is set in position on top of the door frame with M12
bolts and brackets after its vertical alignment has been checked against the plumb
line. The assembly position is also adjusted to meet the entrance width plumb
lines. Spot welding on the brackets and door header assembly is also done to
prevent movement. Upon completion of the door frame and header assembly at
each entrance opening, cement grouting to all the gaps between the door frames
and structural openings shall be carried out by the building Contractor. The
installation of the landing doors shall commence after the completion of the
grouting works.

8.0 Landing Door Installation and Adjustment

Mechanical adjustment of landing entrance door assembly is almost the same for
all types of door mechanism.
Preliminary arrangement and check is conducted to ensure that the dirt and dust
in the groove for door shoes are removed. Confirm that the door can move
smoothly and door panels are not twisted. Check that the gap between sill and
bottom of the door panel is 5+ 1mm when door is in closed position. Confirm that
the gap between door panels is less than 0.5 mm, otherwise shims are used for
adjustment. The gap between door rail and up thrust roller are adjusted to be 0.1
mm to 0.3 mm, and nuts are tightened. The gap between door panels and door
frames is 4+ 2mm. In case of 2-panel side-opening door, gap between sliding
door panels is also 4+ 2mm. Door panels must move parallel to the door frames.
The link wire rope is adjusted so that the door panels are in line with entrance
jamb when the door is fully open. In case of 2-panel side-opening door, confirm
that the overlap of door panel with jamb is 20+ 2mm when the door is closed.

9.0 Hall Call Button and Position Indicator

Remove the faceplate of the hall button and indicator from the box to avoid
scratched and damage. Set the box at the required level and dimension. Cement
grout around the box to hold it in position.
10.0 Lift Motor Room Equipment

The lift motor room equipment mainly the traction machines, controllers and
diverter pulley sheaves shall be hoisted up into the motor room after taking
possession of the site.

a) Machine Beams

Machine beams are set in position from the template setting below. After
the level of the machine beams has been checked, M16 anchor bolts for
the supporters are tightened and the machine beams are then welded on
to the steel bearing plates by lap joint fillet weld 3mm – 4mm thick on the
supporters leaving a small gap between the motor room floor slab and the
machine beams. ( Refer to picture attached)
b) Machine Bed

Anti-vibration isolator rubber units are fixed to the machine beams before
installing the machine base frame bed in position by rail clips and bolts.

c) Traction Machine Diverter Sheave

Hoist the traction machine by means of a chain block and place it on the
machine bed and adjust its position correctly before fixing it by bolts and
clips.

d) Controller

Set the controller in position using anchor bolts after ascertaining the
correct level.

e) Overspeed Governor

Install the governor as per dimensions shown in layout drawing using the
template as a guide with M12 anchor bolts.

11.0 Counterweight Frame Assembly

After the alignment of guide rails is completed, hoist the counterweight frame into
the lift shaft at the pit area and set it at the required height using supporting beams
or wire ropes with clips.

12.0 Car Frame and Cage Assembly

A certain section of the scaffoldings at the highest stopping floor has to be


removed for preparation of car frame installation. A safety plank made of 2in x 4in
timber must be set first by clamping to both side rails.

Install a chain block at the required height using wire ropes and clips. Set the
bottom car frame in position. Next, install the side car sling to the bottom car
frame. The car platform assembly is hoisted by a chain block or a power winch
and is set on its position on top of the safety plank. Before bolting the car platform
assembly to the car frame, carry out the alignment, centering and leveling of car
frame using the lines plumbed from the template setting. Level difference should
be less than 2 mm for any direction and centering must be within + 1mm from
entrance centre line and car sill must be 30 mm+ 2mm gap from entrance sill. The
crosshead beam is hoisted by a chain block or a power winch up to a little above
the car slings and is then lowered and mounted on the slings. To install the car
cage assembly, the ceiling is hung firmly to the crosshead beam and the
kickplates are assembled, entrance columns and wall panels and tighten. The
ceiling is then placed on the walls. When the car cage assembly work is
completed, set the car door operator motor and then fit in the car operating panels
and other accessories.

a) Preliminary Check

i) The car and entrance sill centre lines should correspond to each
other (+1.0 mm).

ii) Car sill center to entrance column are balanced (Opening Width /
2+0.5 mm).

iii) Car sill and platform are level (+0.5 mm from horizontal).

b) Alignment Check

i) The gap between car and landing sills must be confirmed to be 30


mm +2 mm at all floors. If not, adjust to meet the clearance by
moving the car platform.

ii) The car entrance columns are checked for verticality in both X and
Y directions. If not, adjust it by inserting shims under anti-vibration
rubber units below the car platform. The verticality tolerance
should be +0.5 mm.

13.0 Roping

a) Main Hoisting Ropes

The main ropes are laid down from the motor room with one end attached
to the crosshead beam on the car top and the other end attached to the
counterweight top frame. The ropes are held at both ends by thimble rods
( Refer to picture attached). After the roping is completed, the required sub-weights
are stacked into the counterweight frame.

b) Governor Rope

The governor rope is also laid down from the motor room passing through
the tension sheave in the lift pit. A long manila rope is used to bring up the
governor rope. The governor rope ends are also connected to the rod of
the safety gear device at the car top by wire clips and the U-bolts ( Refer to
picture attached) of the clips must be applied from guide rail side.

14.0 Wiring In Hoistway

Hoistway wiring are run from the pit to the lift motor room. Hoistway wiring is by
0.75 sqmm multi-core cables which are laid down from the motor room to the pit.
Some wires are diverted to the respective floors for connection to hall button,
indicator and door interlock mechanism. Sharp bending and strong twist of cables
must be avoided.
In the motor room, the wires are connected / terminated at the respective terminal
points. Travelling cables are laid down from the motor room to the car cage and
terminated at the respective terminal points. A final check is carried out prior to
the dismantling of scaffoldings, after which the completed lift installation is ready
for testing.

15.0 Labeling & Identification

Main parts are labeled in the motor room such as the motor, lift no. ,ebops,
governor, etc. Hazard labels are also provided in the motor room and car top
highlighting the main hazards present such as high voltage, hoisting beam SWL,
trip hazard, etc. Signage on motor room door is provided others.

16.0 Pre Testing & Commisioning

Prior to T&C (testing and commissioning), several requirements that must be


fulfilled are checked:

a) Power supply to lift motor room switchboard is verified with an AM meter


measured from the DB outgoing and also the incoming on Sigma switchboard.

b) Lighting and exhaust fan in lift motor room.

c) Lift motor room cleanliness, debris and rubbish to be cleared before


commencement of T&C.

d) Lift motor room signage and door with lock provided

e) Lift pit dry and no signs of water seepage. Sufficient water proofing provided.

f) All openings at lift landings grouted and covered properly.


METHOD STATEMENT FOR LIFT TESTING

Procedure on Lift Testing Is Carried Out

EXECUTION

Megger test shall be carried out for all checking of cabling / wiring from lift D.B to LIFT
CONTROL PANEL to LIFT MOTOR before provision of the power supply to lift D.B at
motor room.

TESTING

Upon provision of main supply of 3 PH 4W 415V 50Hz out tester then will check on the
data plate on each motor and governor to ensure that it was supplied correct.

PROCEDURE

1) After the testing team has checked that the main rope tension and bolts, cotter pins,
buffer oil also gear oil were install properly, they will start the slow speed operation.
This operation includes the buffer test and CC test.

2) Alignment and adjustment of the lift components such as counterweight, car cage
upright, static balance, car shoe, load weighing device, governor tension, car door,
adjustment of door speed, check open / close of doors at hall, DC/AC check, safety
circuit, traveling cable check, governor tripping, over balance will be carried out before
the lift is ready for high speed.

3) Finally, after the over balance, acceleration, riding, comfort, levelling brake adjustment
(gap, slip 0.15 – 0.2 mm), operation check of car operating panel fixtures such as car
call buttons, indicators, door closing and opening buttons, emergency call buttons, car
lighting and fan, over load adjustment (full load is put in to check over load) have been
checked the lift is ready for high speed testing.

4) One the items 1 ~ 3 is completed, then, the hall call button testing will be carried out
to ensure it works properly.

5) Finally, final fine tuning, compliance of requirement such as car door lock, Ebops,
lighting and indicator in car cage will be checked and there after JKKP inspection shall
be arranged and carried out once the date is confirmed by the JKKP inspector.
FLOW CHART OF TESTING / ADJUSTMENT

START
Check the data plate of the traction
machine and the governor.
(Check rope tension, double nuts, and
Preparation of Slow
cotter pins, tie down adjustment and
Speed Operation
buffer oil)

Slow Speed Operation Travelling cable length, twisting or


Buffer Test and CC Test deformation, kink, etc.
Main rope length (buffer clearance).

Adjustment of
Counterweight and Main rope tension, counterweight guide,
Related Parts shoe Anti-derailing measures.
Check of the safety mechanism and
tightening.

Safety Link Guide Shoe


Car Balance
(Main rope tension, Tightening Check)

Car
Alignment Car inclination, Running clearance, Car
Center, Car level, Car vibration stopper
(Cab sustainer).

Alignment of Alignment of the tape pulley in the pit


Retiring Cam, and cleaning.
Limit Switch and Load Buffer inclination.
Weighing Device Governor tensioner.

P2
P2

Limit Switch
Slow Down Cam

Car door, relative locations, installed


Adjustment of condition, operating machine, gate
Car Door switch, cam switch, safety shoe
mechanism.

Hall Door Adjustment of the retiring cam, gaps and


Adjustment alignment.

Mounting of When scribing the level line, check the


Inductor Plate running clearance, the level and in the
car.

Alignment
of Door Cam

Application of Power to
the Door Motor Open /
Close

Tentative Adjustment of Check the opened door surface,


Door Speed. alignment of the cam and the coupling
Check Open / Close of roller.
Doors at All Hall Floors

Preparation Adjustment Cleaning of the brake, buffer test, DC/AC


of Door check, Safety Circuit check, travelling
cable, catch test, governor tripping.
Tentative over-balance, load weighing
device

P3
P3

Over balance, acceleration/deceleration,


High Speed riding comfort, leveling
Operation

Gap, slip (0.15 -0.2mm)


Brake
Adjustment

Car call buttons, emergency fixtures


Operation Check
Indicator Check

Load Adjustment over load


Weighing

Hall call, hall lantern, hall indicator


Check of button.
Lantern

Other fine adjustment.


Adjustment of
Touchless
-door & door speed

Check of
Supervisory
Panel &
Bomba

Check of
Group
Supervisory
Control

P4
P4

Inspection/ QA/QC Inspection


Acceptance

Preparation for JKKP Inspection


inspection with
attendance of the
government inspector

End Handover to client


TESTING AND COMMISSIONING FLOW CHART

PRE-TESTING &
COMMISSIONING
REQUIREMENT

CONNECTION & CONFIRMATION OF WIRINGS


AT CONTROL PANEL AND LIFT CAR

LIFT RUNNING AT
SLOW SPEED

CLEANINGWORKS (GUIDE
RAILS, LANDING SILL & ETC)

MECHANICAL SETTING INSTALLATION & SETTING OF


AND ADJUSMENT SAFETY DEVICES

PRE-AUTHORITY
INSPECTION
REQUIREMENTS

INSTALLATION & SETTING OF FIRE &


GENSET HOMING FEATURES

INSTALLATION OF HALL TESTING & COMMISSIONING OF


OPERATING FIXTURES SUPERVISORY PANEL
(FACE PLATE)

READY FOR THE


JKKP INSPECTION