Approval, Exhaust Gas Monitoring, and Safety Requirements for the Use
of Diesel-Powered Equipment in Underground Coal Mines; Final Rule
[[Continued from page 55511]]
[[Page 55512]]
[GRAPHIC] [TIFF OMITTED] TR25OC96.002
[[Page 55513]]
[GRAPHIC] [TIFF OMITTED] TR25OC96.003
BILLING CODE 4510-43-C
[[Page 55514]]
(8) The flow capacity of the PDP or CFV system using single
dilution shall maintain the diluted exhaust at 125 deg.F (52.0 deg. C)
or less immediately before the primary particulate filter.
(9) The flow capacity of the PDP or CFV system using a double
dilution system shall be sufficient to maintain the diluted exhaust in
the dilution tunnel at 375 deg. F (191 deg. C) or less at the sampling
zone.
(10) The secondary dilution system shall provide sufficient
secondary dilution air to maintain the double-diluted exhaust stream at
125 deg. F (52.0 deg. C) or less immediately before the primary
particulate filter.
(11) The gas flow meters or the mass flow measurement
instrumentation shall have a maximum error of the measured value within
<plus-minus>2 percent of reading.
(12) The dilution air shall have a temperature of 77 deg.
F<plus-minus>9 deg. F (25 deg. C<plus-minus>5 deg. C), and be--
(i) Filtered at the air inlet; or
(ii) Sampled to determine background particulate levels, which can
then be subtracted from the values measured in the exhaust stream.
(13) The dilution tunnel shall have the following specifications:
(i) Be small enough in diameter to cause turbulent flow (Reynolds
number greater than 4,000) and of sufficient length to cause complete
mixing of the exhaust and dilution air;
(ii) Be at least 3 inches (75 mm) in diameter; and
(iii) Be configured to direct the engine exhaust downstream at the
point where it is introduced into the dilution tunnel for thorough
mixing.
(14) The exhaust pipe length from the exit of the engine exhaust
manifold or turbocharger outlet to the dilution tunnel shall not exceed
a total length of 32 feet (10 m).
(i) When the exhaust pipe exceeds 12 feet (4 m), then all pipe in
excess of 12 feet (4 m) shall be insulated with a radial thickness of
at least 1.0 inch (25 mm) and the thermal conductivity of the
insulating material shall be no greater than 0.1 W/mK measured at
752 deg. F (400 deg. C).
(ii) To reduce the thermal inertia of the exhaust pipe, the
thickness to diameter ratio shall be 0.015 or less.
(iii) The use of flexible sections shall be limited to the length
to diameter ratio of 12 or less.
(15) The particulate sample probe shall--
(i) Be installed in the dilution tunnel facing upstream, on the
dilution tunnel centerline, and approximately 10 dilution tunnel
diameters downstream of the point where the engine's exhaust enters the
dilution tunnel; and
(ii) Have 0.5 inches (12 mm) minimum inside diameter.
(16) The inlet gas temperature to the particulate sample pump or
mass measurement device shall remain a constant temperature of
<plus-minus>5 deg. F (3.0 deg. C) if flow compensation is not used.
(17) The secondary dilution portion of the double dilution system
shall have:
(i) A particulate transfer tube shall have a 0.5 inch (12 mm)
minimum inside diameter not to exceed 40 inches (1020 mm) in length
measured from the probe tip to the secondary dilution tunnel has:
(A) An inlet with the transfer tube facing upstream in the primary
dilution tunnel, centerline, and approximately 10 dilution tunnel
diameters downstream of the point where the engine's exhaust enters the
dilution tunnel.
(B) An outlet where the transfer tube exits on the centerline of
the secondary tunnel and points downstream.
(ii) A secondary tunnel that has a minimum diameter of 3.0 inches
(75 mm), and of sufficient length to provide a residence time of at
least 0.25 seconds for the double-diluted sample.
(iii) Secondary dilution air supplied at a temperature of 77 deg.F
<plus-minus> 9 deg. F(25 deg. C<plus-minus>5 deg. C).
(iv) A primary filter holder located within 12.0 inches (300 mm) of
the exit of the secondary tunnel.
(18) The particulate sampling filters shall--
(i) Be fluorocarbon-coated glass fiber filters or fluorocarbon-
based (membrane) filters and have a 0.3 <greek-m>m di-octylphthalate
(DOP) collection efficiency of at least 95 percent at a gas face
velocity between 35 and 80 cm/s.;
(ii) Have a minimum diameter of 1.85 inches (47 mm), 1.46 inches
(37 mm) stain diameter;
(iii) Have a minimum filter loading ratio of 0.5mg/1075 mm \2\
stain area for the single filter method.
(iv) Have minimum filter loading such that the sum of all eight (8)
multiple filters is equal to the minimum loading value (mg) for a
single filter multiplied by the square root of eight (8).
(v) Be sampled at the same time by a pair of filters in series (one
primary and one backup filter) so that:
(A) The backup filter holder shall be located no more than 4 inches
(100 mm) downstream of the primary filter holder.
(B) The primary and backup filters shall not be in contact with
each other.
(C) The filters may be weighed separately or as a pair with the
filters placed stain side to stain side.
(D) The single filter method incorporates a bypass system for
passing the sample through the filters at the desired time.
(vi) Have a pressure drop increase between the beginning and end of
the test of no more than 7.4 in Hg (25kPa).
(vii) Filters of identical quality shall be used when performing
correlation tests specified in paragraph (c)(1)(vi) of this section.
(19) Weighing chamber specifications.
(i) The temperature of the chamber (room) in which the particulate
filters are conditioned and weighed shall be maintained to within 72
deg.F<plus-minus>5 deg.F (22 deg.C<plus-minus>3 deg.C) during all
filter conditioning and weighing.
(ii) The humidity of the chamber (room) in which the particulate
filters are conditioned and weighed shall be maintained to a dewpoint
of 49 deg.F<plus-minus>5 deg.F (9.5 deg.C<plus-minus>3 deg.C) and a
relative humidity of 45 percent <plus-minus>8 percent during all filter
conditioning and weighing.
(iii) The chamber (room) environment shall be free of any ambient
contaminants (such as dust) that would settle on the particulate
filters during their stabilization. This shall be determined as
follows:
(A) At least two unused reference filters or reference filter pairs
shall be weighed within four (4) hours of, but preferably at the same
time as the sample filter (pair) weighings.
(B) The reference filters are to be the same size and material as
the sample filters.
(C) If the average weight of reference filters (reference filter
pairs) changes between sample filter weighings by more than
<plus-minus>5.0 percent (<plus-minus>7.5 percent for the filter pair
respectively) of the recommended minimum filter loading in paragraphs
(c)(18)(iii) or (c)(18)(iv) of this section, then all sample filters
shall be discarded and the tests repeated.
(20) The analytical balance used to determine the weights of all
filters shall have a precision (standard deviation) of 20 <greek-m>g
and resolution of 10 <greek-m>g. For filters less than 70 mm diameter,
the precision and resolution shall be 2 <greek-m>g and 1 <greek-m>g,
respectively.
(21) All filters shall be neutralized to eliminate the effects of
static electricity prior to weighing.
Sec. 7.87 Test to determine the maximum fuel-air ratio.
(a) Test procedure.
(1) Couple the diesel engine to the dynamometer and connect the
sampling and measurement devices specified in Sec. 7.86.
(2) Prior to testing, zero and span the CO and NO<INF>X analyzers
to the lowest analyzer range that will be used during this test.
(3) While running the engine, the following shall apply:
[[Page 55515]]
(i) The parameter for the laboratory atmospheric factor, f<INF>a,
shall be: 0.98<ls-thn-eq>f<INF>a<ls-thn-eq>1.02;
(A) The equation is f<INF>a=(99/P<INF>s) * ((T<INF>a+273)/
298)<SUP>0.7 for a naturally aspirated and mechanically supercharged
engines; or
(B) The equation is f<INF>a=(99/P<INF>s)<SUP>0.7*
((T<INF>a+273)/
298) <SUP>1.5 for a turbocharged engine with or without cooling of the
intake air.
Where:
P<INF>s=dry atmospheric pressure (kPa)
T<INF>a=intake air temperature ( deg.C)
(ii) The air inlet restriction shall be set within <plus-minus>10
percent of the recommended maximum air inlet restriction as specified
by the engine manufacturer at the engine operating condition giving
maximum air flow to determine the concentration of CO as specified in
paragraph (a)(6) of this section.
(iii) The exhaust backpressure restriction shall be set within
<plus-minus>10 percent of the maximum exhaust backpressure as specified
by the engine manufacturer at the engine operating condition giving
maximum rated horsepower to determine the concentrations of CO and
NO<INF>X as specified in paragraph (a)(6)of this section.
(iv) The air inlet restriction shall be set within <plus-minus>10
percent of a recommended clean air filter at the engine operating
condition giving maximum air flow as specified by the engine
manufacturer to determine the concentration of NO<INF>X as specified in
paragraph (a)(6) of this section.
(4) The engine shall be at a steady-state condition when the
exhaust gas samples are collected and other test data is measured.
(5) In a category A engine, 1.0<plus-minus>0.1 percent CH<INF>4
shall be injected into the engine's intake air.
(6) Operate the engine at several speed/torque conditions to
determine the concentrations of CO and NO<INF>X, dry basis, in the raw
exhaust.
(b) Acceptable performance. The CO and NO<INF>X concentrations in
the raw exhaust shall not exceed the limits specified in Sec. 7.84(b)
throughout the specified operational range of the engine.
Sec. 7.88 Test to determine the gaseous ventilation rate.
The test shall be performed in the order listed in Table E-2. The
test for determination of the particulate index described in Sec. 7.89
may be done simultaneously with this test.
(a) Test procedure.
(1) Couple the diesel engine to the dynamometer and attach the
sampling and measurement devices specified in Sec. 7.86.
(2) A minimum time of 10 minutes is required for each test mode.
(3) CO, CO<INF>2, NO<INF>X, and CH<INF>4 analyzers shall be zeroed
and spanned at the analyzer range to be used prior to testing.
(4) Run the engine.
(i) The parameter for f<INF>a shall be calculated in accordance
with Sec. 7.87(a)(3).
(ii) The air inlet and exhaust backpressure restrictions on the
engine shall be set as specified in Secs. 7.87(a)(3) (iii) and (iv).
(5) The engine shall be at a steady-state condition before starting
the test modes.
(i) The output from the gas analyzers shall be measured and
recorded with exhaust gas flowing through the analyzers a minimum of
the last three (3) minutes of each mode.
(ii) To evaluate the gaseous emissions, the last 60 seconds of each
mode shall be averaged.
(iii) A 1.0<plus-minus>0.1 percent CH<INF>4, by volume, shall be
injected into the engine's intake air for category A engines.
(iv) The engine speed and torque shall be measured and recorded at
each test mode.
(v) The data required for use in the gaseous ventilation
calculations specified in paragraph (a)(9) of this section shall be
measured and recorded at each test mode.
(6) Operate the engine at each rated speed and horsepower rating
requested by the applicant according to Table E-2 in order to measure
the raw exhaust gas concentration, dry basis, of CO, CO<INF>2, NO, and
NO<INF>2, and CH<INF>4- exhaust (category A engines only).
(i) Test speeds shall be maintained within <plus-minus>1 percent of
rated speed or <plus-minus>3 RPM, which ever is greater, except for low
idle which shall be within the tolerances established by the
manufacturer.
(ii) The specified torque shall be held so that the average over
the period during which the measurements are taken is within
<plus-minus>2 percent of the maximum torque at the test speed.
(7) The concentration of CH<INF>4 in the intake air shall be
measured for category A engines.
Table E-2.--Gaseous Test Modes
Speed Rated speed Intermediate speed Low-
--------------------------------------------------------------------------------------------------------- idle
speed
% Torque 100 75 50 10 100 75 50 -------
0
----------------------------------------------------------------------------------------------------------------
(8) After completion of the test modes, the following shall be
done:
(i) Zero and span the analyzers at the ranges used during the test.
(ii) The gaseous emission test shall be acceptable if the
difference in the zero and span results taken before the test and after
the test are less than 2 percent.
(9) The gaseous ventilation rate for each exhaust gas contaminant
shall be calculated as follows--
(i) The following abbreviations shall apply to both category A and
category B engine calculations as appropriate:
cfm--Cubic feet per min (ft<SUP>3/min)
Exh--Exhaust
A--Air (lbs/hr)
H--Grains of water per lb. of dry intake air
J--Conversion factor
m--Mass flow rate (mass/hr)
TI--Intake air temperature ( deg. F)
PCAir--Percent Air
PCCH<INF>4--Percent CH<INF>4 (intake air)
UCH<INF>4--Unburned CH<INF>4
PCECH<INF>4--Percent Exhaust CH<INF>4
(ii) Exhaust gas flow calculation for category B engines shall be
(m Exh)=(A)+(m fuel).
(iii) Fuel/air ratio for category B engines shall be (f/a)=(m fuel)
/ (A).
(iv) Methane flow through category A engines shall be determined by
the following:
PCAir=100-PCCH<INF>4
Y=(PCAir)(0.289)+(PCCH<INF>4)(0.16)
Z=(0.16)(PCCH<INF>4)<divide>Y
mCH<INF>4=(A)(Z)<divide>(1-Z)
[[Page 55516]]
(v) Exhaust gas flow calculation for category A engines shall be (m
Exh)=(A)+(m fuel)+(m CH<INF>4)
(vi) Unburned CH<INF>4 (lbs/hr) calculation for category A engines
shall be mUCH<INF>4=(m Exh)(0.00552)(PCECH<INF>4)
(vii) Fuel/air ratio for category A engines shall be (f/a)=((m
fuel)+(m CH<INF>4)-(m UCH<INF>4))<divide>(A)
(viii) Conversion from dry to wet basis for both category A and
category B engines shall be:
(NO wet basis)=(NO dry basis)(J)
(NO<INF>2 wet basis)=(NO<INF>2 dry basis)(J)
(CO<INF>2 wet basis)=(CO<INF>2 dry basis)(J)
(CO wet basis)=(CO dry basis)(10<SUP>-4)(J)
Where:
J=(f/a)(-1.87)+(1-(0.00022)(H))
(ix) NO and NO<INF>2 correction for humidity and temperature for
category A and category B engines shall be:
(NO corr)=(NO wet basis)<divide>(E)
(NO<INF>2 corr)=(NO<INF>2 wet basis)<divide>(E)
Where:
E=1.0+(R)(H-75)+(G)(TI-77)
R=(f/a)(0.044)-(0.0038)
G=(f/a)(-0.116)+(0.0053)
(x) The calculations to determine the m of each exhaust gas
contaminant in grams per hour at each test point shall be as follows
for category A and category B engines:
(m NO)=(NO corr)(0.000470)(m Exh)
(m NO<INF>2)=(NO<INF>2 corr)(0.000720)(m Exh)
(m CO<INF>2)=(CO<INF>2 wet basis)(6.89)(m Exh)
(m CO)=(CO wet basis)(4.38)(m Exh)
(xi) The calculations to determine the ventilation rate for each
exhaust gas contaminant at each test point shall be as follows for
category A and category B engines:
(cfm NO)=(m NO)(K)
(cfm NO<INF>2)=(m NO<INF>2)(K)
(cfm CO<INF>2)=(m CO<INF>2)(K)
(cfm CO)=(m CO)(K)
Where:
K=13,913.4 (pollutant grams/mole) (pollutant dilution value specified
in Sec. 7.84(c)).
(b) The gaseous ventilation rate for each requested rated speed and
horsepower shall be the highest ventilation rate calculated in
paragraph (a)(9)(xi) of this section.
(1) Ventilation rates less than 20,000 cfm shall be rounded up to
the next 500 cfm.
Example: 10,432 cfm shall be listed 10,500 cfm.
(2) Ventilation rates greater than 20,000 cfm shall be rounded up
to the next 1,000 cfm.
Example: 26,382 cfm shall be listed 27,000 cfm.
Sec. 7.89 Test to determine the particulate index.
The test shall be performed in the order listed in Table E-3.
(a) Test procedure.
(1) Couple the diesel engine to the dynamometer and connect the
sampling and measurement devices specified in Sec. 7.86.
(2) A minimum time of 10 minutes is required for each measuring
point.
(3) Prior to testing, condition and weigh the particulate filters
as follows:
(i) At least 1 hour before the test, each filter (pair) shall be
placed in a closed, but unsealed, petri dish and placed in a weighing
chamber (room) for stabilization.
(ii) At the end of the stabilization period, each filter (pair)
shall be weighed. The reading is the tare weight.
(iii) The filter (pair) shall then be stored in a closed petri dish
or a filter holder, both of which shall remain in the weighing chamber
(room) until needed for testing.
(iv) The filter (pair) must be re-weighed if not used within 8
hours of its removal from the weighing chamber (room).
(4) Run the engine.
(i) The parameter for f<INF>a shall be calculated in accordance
with Sec. 7.87(a)(3).
(ii) The air inlet and exhaust backpressure restrictions on the
engine shall be set as specified in Secs. 7.87(a)(3) (iii) and (iv).
(iii) The dilution air shall be set to obtain a maximum filter face
temperature of 125 deg. F (52 deg. C) or less at each test mode.
(iv) The total dilution ratio shall not be less than 4.
(5) The engine shall be at a steady state condition before starting
the test modes.
(i) The engine speed and torque shall be measured and recorded at
each test mode.
(ii) The data required for use in the particulate index calculation
specified in paragraph (a)(9) of this section shall be measured and
recorded at each test mode.
(6) A 1.0<plus-minus>0.1 percent CH<INF>4, by volume shall be
injected into the engine's intake air for category A engines.
(7) Operate the engine at each rated speed and horsepower rating
requested by the applicant according to Table E-3 to collect
particulate on the primary filter.
(i) One pair of single filters shall be collected or eight multiple
filter pairs shall be collected.
(ii) Particulate sampling shall be started after the engine has
reached a steady-state condition.
(iii) The sampling time required per mode shall be either a minimum
of 20 seconds for the single filter method or a minimum of 60 seconds
for the multiple filter method.
(iv) The minimum particulate loading specified in Secs. 7.86(c)(18)
(iii) or (iv) shall be done.
Table E-3.--Particulate Test Modes
----------------------------------------------------------------------------------------------------------------
Speed Rated speed Intermediate speed Low-
--------------------------------------------------------------------------------------------------------- idle
speed
% Torque 100 75 50 10 100 75 50 -------
0
----------------------------------------------------------------------------------------------------------------
Weighting factor................................ 0.15 0.15 0.15 0.1 0.1 0.1 0.1 0.15
----------------------------------------------------------------------------------------------------------------
(v) Test speeds shall be maintained within <plus-minus> percent of
rated speed or <plus-minus>3 RPM, which ever is greater, except for low
idle which shall be within the tolerances set by the manufacturer.
(vi) The specified torque shall be held so that the average over
the period during which the measurements are being taken is within
<plus-minus>2 percent of the maximum torque at the test speed.
(vii) The modal weighting factors (WF) given in Table E-3 shall be
applied to the multiple filter method during the calculations as shown
in paragraph (a)(9)(iii)(B) of this section.
(viii) For the single filter method, the modal WF shall be taken
into account during sampling by taking a sample proportional to the
exhaust mass flow for each mode of the cycle.
(8) After completion of the test, condition and weigh the
particulate filters in the weighing chamber (room) as follows:
(i) Condition the filters for at least 1 hour, but not more than 80
hours.
[[Page 55517]]
(ii) At the end of the stabilization period, weigh each filter. The
reading is the gross weight.
(iii) The particulate mass of each filter is its gross weight minus
its tare weight.
(iv) The particulate mass (P<INF>F for the single filter method;
P<INF>F,<INF>i for the multiple filter method) is the sum of the
particulate masses collected on the primary and back-up filters.
(v) The test is void and must be rerun if the sample on the filter
contacts the petri dish or any other surface.
(9) The particulate index for the mass particulate shall be
calculated from the equations listed below--
(i) The following abbreviations shall be:
cfm--Cubic feet per min (ft\3\ min)
PT--Particulate (gr/hr)
m mix--Diluted exhaust gas mass flow rate on wet basis (kg/hr)
m sample--Mass of the diluted exhaust sample passed through the
particulate sampling filters (kg)
P<INF>F--Particulate sample mass collected on a filter (mg) at each
test mode as determined in Table E-3.
K<INF>p--Humidity correction factor for particulate
WF--Weighting factor
i-Subscript denoting an individual mode, i=1, . . . n
PI--Particulate Index (cfm)
(ii) When calculating ambient humidity correction for the
particulate concentration (P<INF>F part), the equation shall be:
P<INF>fcorr=(P<INF>f)(K<INF>p)
K<INF>p=1/(1+0.0133 * (H-10.71))
Where:
H<INF>a=humidity of the intake air, g water per kg dry air
H<INF>a=(6.220 * R<INF>a * p<INF>a)/(p<INF>B-p<INF>a -
R<INF>a *
10<SUP>-2)
R<INF>a=relative humidity of the intake air, %
p<INF>a=saturation vapor pressure of the intake air, kPa
p<INF>B=total barometric pressure, kPa
(iii) When the multiple filter method is used, the following
equations shall be used.
(A) Mass of particulate emitted is calculated as follows:
[GRAPHIC] [TIFF OMITTED] TR25OC96.004
(B) Determination of weighted particulate average is calculated as
follows:
[GRAPHIC] [TIFF OMITTED] TR25OC96.005
(C) Determination of particulate index for the mass particulate
from the average of the test modes shall be calculated as follows:
[GRAPHIC] [TIFF OMITTED] TR25OC96.006
(iv) When the single filter method is used, the following equations
shall be used.
(A) Mass of particulate emitted:
[GRAPHIC] [TIFF OMITTED] TR25OC96.007
Where:
[GRAPHIC] [TIFF OMITTED] TR25OC96.008
[GRAPHIC] [TIFF OMITTED] TR25OC96.009
(B) Determination of particulate index for the mass particulate
from the average of the test modes shall be as follows:
[GRAPHIC] [TIFF OMITTED] TR25OC96.010
(v) When the effective weighting factor, WF<INF>E,<INF>i, for each
mode is calculated for the single filter method, the following shall
apply.
[GRAPHIC] [TIFF OMITTED] TR25OC96.011
(B) The value of the effective weighting factors shall be within
<plus-minus>0.005 (absolute value) of the weighting factors listed in
Table E-3.
[[Page 55518]]
(b) A particulate index for each requested rated speed and
horsepower shall be the value determined in paragraph (a)(9)(iii)(C) of
this section for the multiple filter method or paragraph (a)(9)(iv)(B)
of this section for the single filter method.
(1) Particulate indices less than 20,000 cfm shall be rounded up to
the next 500 cfm. Example: 10,432 cfm shall be listed 10,500 cfm.
(2) Particulate indices greater than 20,000 cfm shall be rounded up
to the nearest thousand 1,000 cfm. Example: 26,382 cfm shall be listed
27,000 cfm.
Sec. 7.90 Approval marking.
Each approved diesel engine shall be identified by a legible and
permanent approval marking inscribed with the assigned MSHA approval
number and securely attached to the diesel engine. The marking shall
also contain the following information:
(a) Ventilation rate.
(b) Rated power.
(c) Rated speed.
(d) High idle.
(e) Maximum altitude before deration.
(f) Engine model number.
Sec. 7.91 Post-approval product audit.
Upon request by MSHA, but no more than once a year except for
cause, the approval holder shall make a diesel engine available for
audit at no cost to MSHA.
Sec. 7.92 New technology.
MSHA may approve a diesel engine that incorporates technology for
which the requirements of this subpart are not applicable if MSHA
determines that the diesel engine is as safe as those which meet the
requirements of this subpart.
Subpart F--Diesel Power Packages Intended for Use in Areas of
Underground Coal Mines Where Permissible Electric Equipment Is Required
Sec.
7.95 Purpose and effective date.
7.96 Definitions.
7.97 Application requirements.
7.98 Technical requirements.
7.99 Critical characteristics.
7.100 Explosion tests.
7.101 Surface temperature tests.
7.102 Exhaust gas cooling efficiency test.
7.103 Safety system control test.
7.104 Internal static pressure test.
7.105 Approval marking.
7.106 Post-approval product audit.
7.107 New technology.
7.108 Power package checklist.
Subpart F-Diesel Power Packages Intended for Use in Areas of
Underground Coal Mines Where Permissible Electric Equipment is
Required
Sec. 7.95 Purpose and effective date.
Part 7, subpart A general provisions apply to subpart F. Subpart F
establishes the specific requirements for MSHA approval of diesel power
packages intended for use in approved equipment in areas of underground
coal mines where electric equipment is required to be permissible. It
is effective November 25, 1996.
Sec. 7.96 Definitions.
In addition to the definitions in subparts A and E of this part,
the following definitions apply in this subpart.
Cylindrical joint. A joint comprised of two contiguous, concentric,
cylindrical surfaces.
Diesel power package. A diesel engine with an intake system,
exhaust system, and a safety shutdown system installed.
Dry exhaust conditioner. An exhaust conditioner that cools the
exhaust gas without direct contact with water.
Exhaust conditioner. An enclosure, containing a cooling system,
through which the exhaust gases pass.
Exhaust system. A system connected to the outlet of the diesel
engine which includes, but is not limited to, the exhaust manifold, the
exhaust pipe, the exhaust conditioner, the exhaust flame arrester, and
any adapters between the exhaust manifold and exhaust flame arrester.
Fastening. A bolt, screw, or stud used to secure adjoining parts to
prevent the escape of flame from the diesel power package.
Flame arrester. A device so constructed that flame or sparks from
the diesel engine cannot propagate an explosion of a flammable mixture
through it.
Flame arresting path (explosion-proof joint). Two or more adjoining
or adjacent surfaces between which the escape of flame is prevented.
Flammable mixture. A mixture of methane or natural gas with normal
air, that will propagate flame or explode when ignited.
Grade. The slope of an incline expressed as a percent.
High idle speed. The maximum no load speed specified by the engine
manufacturer.
Intake system. A system connected to the inlet of the diesel engine
which includes, but is not limited to, the intake manifold, the intake
flame arrester, the emergency intake air shutoff device, the air
cleaner, and all piping and adapters between the intake manifold and
air cleaner.
Plane joint. A joint comprised of two adjoining surfaces in
parallel planes.
Safety shutdown system. A system which, in response to signals from
various safety sensors, recognizes the existence of a potential
hazardous condition and automatically shuts off the fuel supply to the
engine.
Step (rabbet) joint. A joint comprised of two adjoining surfaces
with a change or changes in direction between its inner and outer
edges. A step joint may be composed of a cylindrical portion and a
plane portion or of two or more plane portions.
Threaded joint. A joint consisting of a male- and female-threaded
member, both of which are the same type and gauge.
Wet exhaust conditioner. An exhaust conditioner that cools the
exhaust gas through direct contact with water, commonly called a water
scrubber.
Sec. 7.97 Application requirements.
(a) An application for approval of a diesel power package shall
contain sufficient information to document compliance with the
technical requirements of this subpart and include: drawings,
specifications, and descriptions with dimensions (including tolerances)
demonstrating compliance with the technical requirements of Sec. 7.98.
The specifications and descriptions shall include the materials of
construction and quantity. These shall include the following--
(1) A general arrangement drawing showing the diesel power package
and the location and identification of the intake system, exhaust
system, safety shutdown system sensors, flame arresters, exhaust
conditioner, emergency intake air shutoff device, automatic fuel
shutoff device and the engine.
(2) Diesel engine specifications including the MSHA approval
number, the engine manufacturer, the engine model number, and the rated
speed, rated horsepower, and fuel rate.
(3) A drawing(s) which includes the fan blade material
specifications, the location and identification of all water-cooled
components, coolant lines, radiator, surge tank, temperature sensors,
and orifices; arrows indicating proper flow direction; the height
relationship of water-cooled components to the surge tank; and the
proper procedure for filling the cooling system.
(4) A drawing(s) showing the relative location, identification of
components,
[[Page 55519]]
and design of the safety shutdown system.
(5) Specific component identification, or specific information
including detail drawings that identify the characteristics of the
cooling system and safety shutdown system that ensures compliance with
the technical requirements.
(6) Detail drawings of gaskets used to form flame-arresting paths.
(7) An assembly drawing showing the location and identification of
all intake system components from the air cleaner to the engine head.
(8) An assembly drawing showing the location and identification of
all exhaust system components from the engine head to the exhaust
outlet.
(9) Detail drawings of those intake and exhaust system components
identified in paragraphs (a)(7) and (a)(8) of this section that ensure
compliance with the technical requirements. An exhaust conditioner
assembly drawing shall be provided showing the location, dimensions,
and identification of all internal parts, exhaust inlet and outlet,
sensors, and the exhaust gas path through the exhaust conditioner. If a
wet exhaust conditioner is used, the exhaust conditioner assembly
drawing must also show the location, dimensions, and identification of
the fill port, drain port, low water check port; high or normal
operating water level; minimum allowable low water level; and the
maximum allowable grade that maintains explosion-proof operations.
(10) A power package checklist which shall consist of a list of
specific features that must be checked and tests that must be performed
to determine if a previously approved diesel power package is in
approved condition. Test procedures shall be specified in sufficient
detail to allow the evaluation to be made without reference to other
documents. Illustrations shall be used to fully identify the approved
configuration of the diesel power package.
(11) Information showing that the electrical systems and components
meet the requirements of Sec. 7.98.
(12) A drawing list consisting of a complete list of those drawings
and specifications which show the details of the construction and
design of the diesel power package.
(b) Composite drawings specifying the required construction details
may be submitted instead of the individual drawings in paragraph (a) of
this section.
(c) All documents shall be titled, dated, numbered, and include the
latest revision.
(d) When all testing has been completed, the following information
shall be submitted and become part of the approval documentation:
(1) The settings of any adjustable devices used to meet the
performance requirements of this subpart.
(2) The coolant temperature sensor setting and exhaust gas
temperature sensor setting used to meet the performance requirements of
this subpart.
(3) The minimum allowable low water level and the low water sensor
setting used to meet the performance requirements of this subpart for
systems using a wet exhaust conditioner as the exhaust flame arrester.
(4) The maximum grade on which the wet exhaust conditioner can be
operated retaining the flame arresting characteristics.
(5) A finalized version of the power package checklist.
Sec. 7.98 Technical requirements.
(a) The diesel power package shall use a category A diesel engine
approved under subpart E of this part with the following additional
requirements:
(1) A hydraulic, pneumatic, or other mechanically actuated starting
mechanism. Other means of starting shall be evaluated in accordance
with the provisions of Sec. 7.107.
(2) If an air compressor is provided, the intake air line shall be
connected to the engine intake system between the air cleaner and the
flame arrester. If the air compressor's inlet air line is not connected
to the engine's intake system, it shall have an integral air filter.
(b) The temperature of any external surface of the diesel power
package shall not exceed 302 deg.F (150 deg.C).
(1) Diesel power package designs using water jacketing to meet this
requirement shall be tested in accordance with Sec. 7.101.
(2) Diesel power packages using other techniques will be evaluated
under the provisions of Sec. 7.107.
(3) When using water-jacketed components, provisions shall be made
for positive circulation of coolant, venting of the system to prevent
the accumulation of air pockets, and effective activation of the safety
shutdown system before the temperature of the coolant in the jackets
exceeds the manufacturer's specifications or 212 deg. F (100 deg. C),
whichever is lower.
(c) External rotating parts shall not be constructed of aluminum
alloys containing more than 0.6 percent magnesium.
(d) If nonmetallic rotating parts are used, they shall be provided
with a means to prevent an accumulation of static electricity. Static
conducting materials shall have a total resistance of 1 megohm or less,
measured with an applied potential of 500 volts or more. Static
conducting materials having a total resistance greater than 1 megohm
will be evaluated under the provisions of Sec. 7.107.
(e) All V-belts shall be static conducting and have a resistance
not exceeding 6 megohms, when measured with a direct current potential
of 500 volts or more.
(f) The engine crankcase breather shall not be connected to the air
intake system of the engine. The discharge from the breather shall be
directed away from hot surfaces of the engine and exhaust system.
(g) Electrical components on diesel power packages shall be
certified or approved by MSHA under parts 7, 18, 20, and 27 of this
chapter.
(h) Electrical systems on diesel power packages consisting of
electrical components, interconnecting wiring, and mechanical and
electrical protection shall meet the requirements of parts 7, 18, and
27 of this chapter, as applicable.
(i) The diesel power package shall be equipped with a safety
shutdown system which will automatically shut off the fuel supply and
stop the engine in response to signals from sensors indicating--
(1) The coolant temperature limit specified in paragraph (b) of
this section;
(2) The exhaust gas temperature limit specified in paragraph (s)(4)
of this section;
(3) The minimum allowable low water level, for a wet exhaust
conditioner, as established by tests in Sec. 7.100. Restarting of the
engine shall be prevented until the water level in the wet exhaust
conditioner has been replenished above the minimum allowable low water
level; and
(4) The presence of other safety hazards such as high methane
concentration, actuation of the fire suppression system, etc., if such
sensors are included in the safety shutdown system.
(j) The safety shutdown system shall have the following features:
(1) A means to automatically disable the starting circuit and
prevent engagement of the starting mechanism while the engine is
running, or a starting mechanism constructed of nonsparking materials.
(2) If the design of the safety shutdown system requires that the
lack of engine oil pressure must be overridden to start the engine, the
[[Page 55520]]
override shall not be capable of overriding any of the safety shutdown
sensors specified in paragraph (i) of this section.
(k) The diesel power package shall be explosion-proof as determined
by the tests set out in Sec. 7.100.
(l) Engine joints that directly or indirectly connect the
combustion chamber to the surrounding atmosphere shall be explosion-
proof in accordance with paragraphs (m) through (q) of this section and
Sec. 7.100. This paragraph does not apply to the following:
(1) Pistons to piston rings;
(2) Pistons to cylinder walls;
(3) Piston rings to cylinder walls;
(4) Cylinder head to cylinder block;
(5) Valve stem to valve guide; or
(6) Injector body to cylinder head.
(m) Each segment of the intake system and exhaust system required
to provide explosion-proof features shall be constructed of metal and
designed to withstand a minimum internal pressure equal to four times
the maximum pressure observed in that segment in tests under Sec. 7.100
or a pressure of 150 psig, whichever is less. Castings shall be free
from blowholes.
(n) Welded joints forming the explosion-proof intake and exhaust
systems shall be continuous and gas-tight. At a minimum, they shall be
made in accordance with American Welding Society Standard D14.4-77 or
meet the test requirements of Sec. 7.104 with the internal pressure
equal to four times the maximum pressure observed in tests under
Sec. 7.100 or a pressure of 150 psig, whichever is less.
(o) Flexible connections shall be permitted in segments of the
intake and exhaust systems required to provide explosion-proof
features, provided that failure of the connection activates the safety
shutdown system before the explosion-proof characteristics are lost.
(p) Flame-arresting paths in the intake and exhaust systems shall
be formed either by--
(1) Flanged metal to metal joints meeting the requirements of
paragraph (q) of this section; or
(2) Metal flanges fitted with metal gaskets and meeting the
following requirements:
(i) Flat surfaces between bolt holes that form any part of a flame-
arresting path shall be planed to within a maximum deviation of one-
half the maximum clearance specified in paragraph (q)(7) of this
section. All metal surfaces forming a flame-arresting path shall be
finished during the manufacturing process to not more than 250
microinches.
(ii) A means shall be provided to ensure that fastenings maintain
the tightness of joints. The means provided shall not lose its
effectiveness through repeated assembly and disassembly.
(iii) Fastenings shall be as uniform in size as practicable to
preclude improper assembly.
(iv) Holes for fastenings shall not penetrate to the interior of an
intake or exhaust system and shall be threaded to ensure that all
specified bolts or screws will not bottom even if the washers are
omitted.
(v) Fastenings used for joints of flame-arresting paths on intake
or exhaust systems shall be used only for attaching parts that are
essential in maintaining the explosion-proof integrity. They shall not
be used for attaching brackets or other parts.
(vi) The minimum thickness of material for flanges shall be \1/2\-
inch, except that a final thickness of \7/16\-inch is allowed after
machining rolled plate.
(vii) The maximum fastening spacing shall be 6 inches.
(viii) The minimum diameter of fastenings shall be \3/8\-inch,
except smaller diameter fastenings may be used if the joint first meets
the requirements of the static pressure test in Sec. 7.104, and the
explosion test in Sec. 7.100.
(ix) The minimum thread engagement of fastenings shall be equal to
or greater than the nominal diameter of the fastenings specified, or
the intake or exhaust system must meet the test requirements of the
explosion tests in Sec. 7.100 and the static pressure test in
Sec. 7.104.
(x) The minimum contact surface of gaskets forming flame-arresting
paths shall be \3/8\-inch, and the thickness of the gaskets shall be no
greater than \1/16\-inch. The minimum distance from the interior edge
of a gasket to the edge of a fastening hole shall be \3/8\-inch. The
gaskets shall be positively positioned, and a means shall be provided
to preclude improper installation. When the joint is completely
assembled, it shall be impossible to insert a 0.0015-inch thickness
gauge to a depth exceeding \1/8\-inch between the gasket and mating
flanges. Other gasket designs shall be evaluated in accordance with
Sec. 7.107.
(q) The following construction requirements shall apply to flame-
arresting paths formed without gaskets:
(1) Flat surfaces between fastening holes that form any part of a
flame-arresting path shall be planed to within a maximum deviation of
one-half the maximum clearance specified in paragraph (q)(7) of this
section. All metal surfaces forming a flame-arresting path shall be
finished during the manufacturing process to not more than 250
microinches. A thin film of nonhardening preparation to inhibit rusting
may be applied to these finished metal surfaces, as long as the final
surface can be readily wiped free of any foreign materials.
(2) A means shall be provided to ensure that fastenings maintain
the tightness of joints. The means provided shall not lose its
effectiveness through repeated assembly and disassembly.
(3) Fastenings shall be as uniform in size as practicable to
preclude improper assembly.
(4) Holes for fastenings shall not penetrate to the interior of an
intake or exhaust system and shall be threaded to ensure that all
specified bolts or screws will not bottom even if the washers are
omitted.
(5) Fastenings used for joints of flame-arresting paths on intake
or exhaust systems shall be used only for attaching parts that are
essential in maintaining the explosion-proof integrity. They shall not
be used for attaching brackets or other parts.
(6) The flame-arresting path of threaded joints shall conform to
the requirements of paragraph (q)(7) of this section.
(7) Intake and exhaust systems joints shall meet the specifications
set out in Table F-1.
Table F-1.--Dimensional Requirements for Explosion-Proof Intake and
Exhaust System Joints
------------------------------------------------------------------------
------------------------------------------------------------------------
Minimum thickness of material for flanges........ \1/2\'' <SUP>1
Minimum width of joint; all in one plane......... 1''
Maximum clearance; joint all in one plane........ 0.004''
Minimum width of joint, portions of which are \3/4\'' <SUP>2
different planes; cylinders or equivalent.
Maximum clearances; joint in two or more planes,
cylinders or equivalent:
Portion perpendicular to plane............... 0.008'' <INF>3
Plane portion................................ 0.006''
Maximum fastening <SUP>4 spacing; joints all in one 6''
plane \5\.
Maximum fastening spacing; joints, portions of 8''
which are in different planes.
[[Page 55521]]
Minimum diameter of fastening (without regard to \3/8\''
type of joint) \6\.
Minimum thread engagement of fastening \7\....... \1/16\''
Maximum diametrical clearance between fastening
body and unthreaded holes through which it
passes \8\ \9\ \10\.
Minimum distance from interior of the intake or
exhaust system to the edge of a fastening hole:
\11\
Joint-minimum width 1''...................... \7/16\''\8\ \12\
Shafts centered by ball or roller bearings:
Minimum length of flame-arresting path....... 1''
Maximum diametrical clearance................ 0.030''
Other cylindrical joints:
Minimum length of flame-arresting path....... 1''
Maximum diametrical clearance................ 0.010''
------------------------------------------------------------------------
\1\ \1/16\-inch less is allowable for machining rolled plate.
\2\ If only two planes are involved, neither portion of a joint shall be
less than \1/8\-inch wide, unless the wider portion conforms to the
same requirements as those for a joint that is all in one plane. If
more than two planes are involved (as in labyrinths or tongue-in-
groove joints), the combined lengths of those portions having
prescribed clearances are considered.
\3\ The allowable diametrical clearance is 0.008-inch when the portion
perpendicular to the plane portion is \1/4\-inch or greater in length.
If the perpendicular portion is more than \1/8\-inch but less than \1/
4\-inch wide, the diametrical clearance shall not exceed 0.006-inch.
\4\ Studs, when provided, shall bottom in blind holes, be completely
welded in place, or have the bottom of the hole closed with a plug
secured by weld or braze. Fastenings shall be provided at all corners.
\5\ The requirements as to diametrical clearance around the fastening
and minimum distance from the fastening hole to the inside of the
intake or exhaust system apply to steel dowel pins. In addition, when
such pins are used, the spacing between centers of the fastenings on
either side of the pin shall not exceed 5 inches.
\6\ Fastening diameters smaller than specified may be used if the joint
or assembly meets the test requirements of Sec. 7.104.
\7\ Minimum thread engagement shall be equal to or greater than the
nominal diameter of the fastening specified, or the intake or exhaust
system must meet the test requirements of Sec. 7.104.
\8\ The requirements as to diametrical clearance around the fastening
and minimum distance from the fastening hole to the inside of the
intake or exhaust system apply to steel dowel pins. In addition, when
such pins are used, the spacing between centers of the fastenings on
either side of the pin shall not exceed 5 inches.
\9\ This maximum clearance only applies when the fastening is located
within the flame-arresting path.
\10\ Threaded holes for fastenings shall be machined to remove burrs or
projections that affect planarity of a surface forming a flame-
arresting path.
\11\ Edge of the fastening hole shall include any edge of any machining
done to the fastening hole, such as chamfering.
\12\ f the diametrical clearance for fastenings does not exceed \1/32\-
inch, then the minimum distance shall be \1/4\-inch.
(r) Intake system. (1) The intake system shall include a device
between the air cleaner and intake flame arrester, operable from the
equipment operator's compartment, to shut off the air supply to the
engine for emergency purposes. Upon activation, the device must operate
immediately and the engine shall stop within 15 seconds.
(2) The intake system shall include a flame arrester that will
prevent an explosion within the system from propagating to a
surrounding flammable mixture when tested in accordance with the
explosion tests in Sec. 7.100. The flame arrester shall be located
between the air cleaner and the intake manifold and shall be attached
so that it can be removed for inspection or cleaning. The flame
arrester shall be constructed of corrosion-resistant metal and meet the
following requirements:
(i) Two intake flame arrester designs, the spaced-plate type and
the crimped ribbon type, will be tested in accordance with the
requirements of Sec. 7.100. Variations to these designs or other intake
flame arrester designs will be evaluated under the provisions of
Sec. 7.107.
(ii) In flame arresters of the spaced-plate type, the thickness of
the plates shall be at least 0.125-inch; spacing between the plates
shall not exceed 0.018-inch; and the flame-arresting path formed by the
plates shall be at least 1 inch wide. The unsupported length of the
plates shall be short enough that permanent deformation resulting from
explosion tests shall not exceed 0.002-inch. The plates and flame
arrester housing shall be an integral unit which cannot be
disassembled.
(iii) In flame arresters of the crimped ribbon type, the dimensions
of the core openings shall be such that a plug gauge 0.018-inch in
diameter shall not pass through, and the flame-arresting path core
thickness shall be at least 1 inch. The core and flame arrester housing
shall be an integral unit which cannot be disassembled.
(3) The intake system shall be designed so that improper
installation of the flame arrester is impossible.
(4) The intake system shall include an air cleaner service
indicator. The air cleaner shall be installed so that only filtered air
will enter the flame arrester. The air cleaner shall be sized and the
service indicator set in accordance with the engine manufacturer's
recommendations. Unless the service indicator is explosion-proof, it
shall be located between the air cleaner and flame arrester, and the
service indicator setting shall be reduced to account for the
additional restriction imposed by the flame arrester.
(5) The intake system shall include a connection between the intake
flame arrester and the engine head for temporary attachment of a device
to indicate the total vacuum in the system. This opening shall be
closed by a plug or other suitable device that is sealed or locked in
place except when in use.
(s) Exhaust system. (1) The exhaust system shall include a flame
arrester that will prevent propagation of flame or discharge of glowing
particles to a surrounding flammable mixture. The flame arrester shall
be constructed of corrosion-resistant metal.
(i) If a mechanical flame arrester is used, it shall be positioned
so that only cooled exhaust gas at a maximum temperature of 302 deg. F
(150 deg. C) will be discharged through it.
(ii) If a mechanical flame arrester of the spaced-plate type is
used, it must meet the requirements of paragraph (r)(2)(ii) of this
section and the test requirements of Sec. 7.100. Variations to the
spaced-plate flame arrester design and other mechanical flame arrester
designs shall be evaluated under the provisions of Sec. 7.107. The
flame arrester shall be designed and attached so that it can be removed
for inspection and cleaning.
(2) The exhaust system shall allow a wet exhaust conditioner to be
used as the exhaust flame arrester provided that
[[Page 55522]]
the explosion tests of Sec. 7.100 demonstrate that the wet exhaust
conditioner will arrest flame. When used as a flame arrester, the wet
exhaust conditioner shall be equipped with a sensor to automatically
activate the safety shutdown system at or above the minimum allowable
low water level established by Sec. 7.100. Restarting of the engine
shall be prevented until the water supply in the wet exhaust
conditioner has been replenished above the minimum allowable low water
level. All parts of the wet exhaust conditioner and associated
components that come in contact with contaminated exhaust conditioner
water shall be constructed of corrosion-resistant material. The wet
exhaust conditioner shall include a means for verifying that the safety
shutdown system operates at the proper water level. A means shall be
provided for draining and cleaning the wet exhaust conditioner. The
final exhaust gas temperature at discharge from the wet exhaust
conditioner shall not exceed 170 deg. F (76 deg. C) under test
conditions specified in Sec. 7.102. A sensor shall be provided that
activates the safety shutdown system before the exhaust gas temperature
at discharge from the wet exhaust conditioner exceeds 185 deg. F
(85 deg. C) under test conditions specified in Sec. 7.103(a)(4).
(3) The exhaust system shall be designed so that improper
installation of the flame arrester is impossible.
(4) The exhaust system shall provide a means to cool the exhaust
gas and prevent discharge of glowing particles.
(i) When a wet exhaust conditioner is used to cool the exhaust gas
and prevent the discharge of glowing particles, the temperature of the
exhaust gas at the discharge from the exhaust conditioner shall not
exceed 170 deg. F (76 deg. C) when tested in accordance with the
exhaust gas cooling efficiency test in Sec. 7.102. A sensor shall be
provided that activates the safety shutdown system before the exhaust
gas temperature at discharge from the wet exhaust conditioner exceeds
185 deg. F (85 deg. C) when tested in accordance with the safety system
controls test in Sec. 7.103. All parts of the wet exhaust conditioner
and associated components that come in contact with contaminated
exhaust conditioner water shall be constructed of corrosion-resistant
material.
(ii) When a dry exhaust conditioner is used to cool the exhaust
gas, the temperature of the exhaust gas at discharge from the diesel
power package shall not exceed 302 deg. F (150 deg. C) when tested in
accordance with the exhaust gas cooling efficiency test of Sec. 7.102.
A sensor shall be provided that activates the safety shutdown system
before the exhaust gas exceeds 302 deg. F (150 deg. C) when tested in
accordance with the safety system control test in Sec. 7.103. A means
shall be provided to prevent the discharge of glowing particles, and it
shall be evaluated under the provisions of Sec. 7.107.
(5) Other means for cooling the exhaust gas and preventing the
propagation of flame or discharge of glowing particles shall be
evaluated under the provisions of Sec. 7.107.
(6) There shall be a connection in the exhaust system for temporary
attachment of a device to indicate the total backpressure in the system
and collection of exhaust gas samples. This opening shall be closed by
a plug or other suitable device that is sealed or locked in place
except when in use.
Sec. 7.99 Critical characteristics.
The following critical characteristics shall be inspected or tested
on each diesel power package to which an approval marking is affixed:
(a) Finish, width, planarity, and clearances of surfaces that form
any part of a flame-arresting path.
(b) Thickness of walls and flanges that are essential in
maintaining the explosion-proof integrity of the diesel power package.
(c) Size, spacing, and tightness of fastenings.
(d) The means provided to maintain tightness of fastenings.
(e) Length of thread engagement on fastenings and threaded parts
that ensure the explosion-proof integrity of the diesel power package.
(f) Diesel engine approval marking.
(g) Fuel rate setting to ensure that it is appropriate for the
intended application, or a warning tag shall be affixed to the fuel
system notifying the purchaser of the need to make proper adjustments.
(h) Material and dimensions of gaskets that are essential in
maintaining the explosion-proof integrity of the diesel power package.
(i) Dimensions and assembly of flame arresters.
(j) Materials of construction to ensure that the intake system,
exhaust system, cooling fans, and belts have been fabricated from the
required material.
(k) Proper interconnection of the coolant system components and use
of specified components.
(l) Proper interconnection of the safety shutdown system components
and use of specified components.
(m) All plugs and covers to ensure that they are tightly installed.
(n) The inspections and tests described in the diesel power package
checklist shall be performed and all requirements shall be met.
Sec. 7.100 Explosion tests.
(a) Test procedures. (1) Prepare to test the diesel power package
as follows:
(i) Perform a detailed check of parts against the drawings and
specifications submitted under Sec. 7.97 to determine that the parts
and drawings agree.
(ii) Remove all parts that do not contribute to the operation or
ensure the explosion-proof integrity of the diesel power package such
as the air cleaner and exhaust gas dilution system.
(iii) Fill coolant system fluid and engine oil to the engine
manufacturer's recommended levels.
(iv) Interrupt fuel supply to the injector pump.
(v) Establish a preliminary low water level for systems using the
wet exhaust conditioner as a flame arrester.
(2) Perform static and dynamic tests of the intake system as
follows:
(i) Install the diesel power package in an explosion test chamber
which is large enough to contain the complete diesel power package. The
chamber must be sufficiently darkened and provide viewing capabilities
of the flame-arresting paths to allow observation during testing of any
discharge of flame or ignition of the flammable mixture surrounding the
diesel power package. Couple the diesel power package to an auxiliary
drive mechanism. Attach a pressure measuring device, a temperature
measuring device, and an ignition source to the intake system. The
pressure measuring device shall be capable of indicating the peak
pressure accurate to <plus-minus>1 pound-per-square inch gauge (psig)
at 100 psig static pressure and shall have a frequency response of 40
Hertz or greater. The ignition source shall be an electric spark with a
minimum energy of 100 millijoules. The ignition source shall be located
immediately adjacent to the intake manifold and the pressure and
temperature devices shall be located immediately adjacent to the flame
arrester.
(ii) For systems using the wet exhaust conditioner as an exhaust
flame arrester, fill the exhaust conditioner to the specified high or
normal operating water level.
(iii) Fill the test chamber with a mixture of natural gas and air
or methane and air. If natural gas is used, the content of combustible
hydrocarbons shall total at least 98.0 percent, by volume, with the
remainder being inert. At least 80.0 percent, by volume, of the gas
shall be methane. For all tests, the methane or natural gas
concentration shall be 8.5<plus-minus>1.8 percent, by volume, and the
oxygen
[[Page 55523]]
concentration shall be no less than 18 percent, by volume.
(iv) Using the auxiliary drive mechanism, motor the engine to fill
the intake and exhaust systems with the flammable mixture. The intake
system, exhaust system, and test chamber gas concentration shall not
differ by more than <plus-minus>0.3 percent, by volume, at the time of
ignition.
(v) For static tests, stop the engine, actuate the ignition source,
and observe the peak pressure. The peak pressure shall not exceed 110
psig. If the peak pressure exceeds 110 psig, construction changes shall
be made that result in a reduction of pressure to 110 psig or less, or
the system shall be tested in accordance with the static pressure test
of Sec. 7.104 with the pressure parameter replaced with a static
pressure of twice the highest value recorded.
(vi) If the peak pressure does not exceed 110 psig or if the system
meets the static pressure test requirements of this section and there
is no discharge of visible flames or glowing particles or ignition of
the flammable mixture in the chamber, a total of 20 tests shall be
conducted in accordance with the explosion test specified above.
(vii) For dynamic tests, follow the same procedures for static
tests, except actuate the ignition source while motoring the engine.
Forty dynamic tests shall be conducted at two speeds, twenty at
1800<plus-minus>200 RPM and twenty at 1000<plus-minus>200 RPM. Under
some circumstances, during dynamic testing the flammable mixture may
continue to burn within the diesel power package after ignition. This
condition can be recognized by the presence of a rumbling noise and a
rapid increase in temperature. This can cause the flame-arrester to
reach temperatures which can ignite the surrounding flammable mixture.
Ignition of the flammable mixture in the test chamber under these
circumstances does not constitute failure of the flame arrester.
However; if this condition is observed, the test operator should
immediately stop the engine and allow components to cool to prevent
damage to the components.
(3) Perform static and dynamic tests of the exhaust system as
follows:
(i) Prepare the diesel power package for explosion tests according
to Sec. 7.100(a)(2)(i) as follows:
(A) Install the ignition source immediately adjacent to the exhaust
manifold.
(B) Install pressure measuring devices in each segment as follows:
immediately adjacent to the exhaust conditioner inlet; in the exhaust
conditioner; and immediately adjacent to the flame arrester, if
applicable.
(C) Install a temperature device immediately adjacent to the
exhaust conditioner inlet.
(ii) If the exhaust system is provided with a spaced-plate flame
arrester in addition to an exhaust conditioner, explosion tests of the
exhaust system shall be performed as described for the intake system in
accordance with this section. Water shall not be present in a wet
exhaust conditioner for the tests.
(iii) If the wet exhaust conditioner is used as the exhaust flame
arrester, explosion testing of this type of system shall be performed
as described for the intake system in accordance with this section with
the following modifications:
(A) Twenty static tests, twenty dynamic tests at 1800 <plus-minus>
200 RPM, and twenty dynamic tests at 1000<plus-minus>200 RPM shall be
conducted at 2 inches below the minimum allowable low water level. All
entrances in the wet exhaust conditioner which do not form explosion-
proof joints shall be opened. These openings may include lines which
connect the reserve water supply to the wet exhaust conditioner, insert
flanges, float flanges, and cover plates. These entrances are opened
during this test to verify that they are not flame paths.
(B) Twenty static tests, twenty dynamic tests at 1800<plus-minus>
200 RPM rated speed, and twenty dynamic tests at 1000<plus-minus>200
RPM shall be conducted at 2 inches below the minimum allowable low
water level. All entrances in the wet exhaust conditioner (except the
exhaust conditioner outlet) which do not form explosion-proof joints
shall be closed. These openings are closed to simulate normal
operation.
(C) Twenty static tests, twenty dynamic tests at
1800<plus-minus>200 RPM rated speed, and twenty dynamic tests at
1000<plus-minus>200 RPM shall be conducted at the specified high or
normal operating water level. All entrances in the wet exhaust
conditioner which do not form explosion-proof joints shall be opened.
(D) Twenty static tests, twenty dynamic tests at
1800<plus-minus>200 RPM, and twenty dynamic tests at
1000<plus-minus>200 RPM shall be conducted at the specified high or
normal operating water level. All entrances in the wet exhaust
conditioner (except the exhaust conditioner outlet) which do not form
explosion-proof joints shall be closed.
(iv) After successful completion of the explosion tests of the
exhaust system, the minimum allowable low water level, for a wet
exhaust conditioner used as the exhaust flame arrester, shall be
determined by adding two inches to the lowest water level that passed
the explosion tests.
(v) A determination shall be made of the maximum grade on which the
wet exhaust conditioner can be operated retaining the flame-arresting
characteristics.
(b) Acceptable performance. The explosion tests shall not result in
any of the following--
(1) Discharge of flame or glowing particles.
(2) Visible discharge of gas through gasketed joints.
(3) Ignition of the flammable mixture in the test chamber.
(4) Rupture of any part that affects the explosion-proof integrity.
(5) Clearances, in excess of those specified in this subpart, along
accessible flame-arresting paths, following any necessary retightening
of fastenings.
(6) Pressure exceeding 110 psig, unless the intake system or
exhaust system has withstood a static pressure of twice the highest
value recorded in the explosion tests of this section following the
static pressure test procedures of Sec. 7.104.
(7) Permanent distortion of any planar surface of the diesel power
package exceeding 0.04-inches/linear foot.
(8) Permanent deformation exceeding 0.002-inch between the plates
of spaced-plate flame arrester designs.
Sec. 7.101 Surface temperature tests.
The test for determination of exhaust gas cooling efficiency
described in Sec. 7.102 may be done simultaneously with this test.
(a) Test procedures. (1) Prepare to test the diesel power package
as follows:
(i) Perform a detailed check of parts against the drawings and
specifications submitted to MSHA under compliance with Sec. 7.97 to
determine that the parts and drawings agree.
(ii) Fill the coolant system with a mixture of equal parts of
antifreeze and water, following the procedures specified in the
application, Sec. 7.97(a)(3).
(iii) If a wet exhaust conditioner is used to cool the exhaust gas,
fill the exhaust conditioner to the high or normal operating water
level and have a reserve water supply available, if applicable.
(2) Tests shall be conducted as follows:
(i) The engine shall be set to the rated horsepower specified in
Sec. 7.97(a)(2).
(ii) Install sufficient temperature measuring devices to determine
the location of the highest coolant temperature. The temperature
measuring devices shall be accurate to <plus-minus>4 deg.F
(<plus-minus>2 deg.C).
(iii) Operate the engine at rated horsepower and with
0.5<plus-minus>0.1 percent,
[[Page 55524]]
by volume, of methane in the intake air mixture until all parts of the
engine, exhaust coolant system, and other components reach their
respective equilibrium temperatures. The liquid fuel temperature into
the engine shall be maintained at 100 deg.F (38 deg.C) <plus-minus>10
deg.F (6 deg.C) and the intake air temperature shall be maintained at
70 deg.F (21 deg.C) <plus-minus>5 deg.F (3 deg.C).
(iv) Increase the coolant system temperatures until the highest
coolant temperature is 205 deg.F to 212 deg.F (96 deg.C to 100
deg.C), or to the maximum temperature specified by the applicant, if
lower.
(v) After all coolant system temperatures stabilize, operate the
engine for 1 hour.
(vi) The ambient temperature shall be between 50 deg.F (10 deg.C)
and 104 deg.F (40 deg.C) throughout the tests.
(b) Acceptable performance. The surface temperature of any external
surface of the diesel power package shall not exceed 302 deg.F (150
deg.C) during the test.
Sec. 7.102 Exhaust gas cooling efficiency test.
(a) Test procedures. (1) Follow the procedures specified in
Sec. 7.101(a).
(2) Install a temperature measuring device to measure the exhaust
gas temperature at discharge from the exhaust conditioner. The
temperature measuring device shall be accurate to <plus-minus>4 deg.F
(<plus-minus>2 deg.C).
(3) Determine the exhaust gas temperature at discharge from the
exhaust conditioner before the exhaust gas is diluted with air.
(b) Acceptable performance.
(1) The exhaust gas temperature at discharge from a wet exhaust
conditioner before the exhaust gas is diluted with air shall not exceed
170 deg.F (76 deg.C).
(2) The exhaust gas temperature at discharge from a dry exhaust
conditioner before the gas is diluted with air shall not exceed 302
deg.F (150 deg.C).
Sec. 7.103 Safety system control test.
(a) Test procedures. (1) Prior to testing, perform the tasks
specified in Sec. 7.101(a)(1) and install sufficient temperature
measuring devices to measure the highest coolant temperature and
exhaust gas temperature at discharge from the exhaust conditioner. The
temperature measuring devices shall be accurate to <plus-minus>4 deg.F
(<plus-minus>2 deg.C).
(2) Determine the effectiveness of the coolant system temperature
shutdown sensors which will automatically activate the safety shutdown
system and stop the engine before the coolant temperature in the
cooling jackets exceeds manufacturer's specifications or 212 deg.F
(100 deg.C), whichever is lower, by operating the engine and causing
the coolant in the cooling jackets to exceed the specified temperature.
(3) For systems using a dry exhaust gas conditioner, determine the
effectiveness of the temperature sensor in the exhaust gas stream which
will automatically activate the safety shutdown system and stop the
engine before the cooled exhaust gas temperature exceeds 302 deg.F
(150 deg.C), by operating the engine and causing the cooled exhaust
gas to exceed the specified temperature.
(4) For systems using a wet exhaust conditioner, determine the
effectiveness of the temperature sensor in the exhaust gas stream which
will automatically activate the safety shutdown system and stop the
engine before the cooled exhaust gas temperature exceeds 185 deg.F (85
deg.C), with the engine operating at a high idle speed condition.
Temporarily disable the reserve water supply, if applicable, and any
safety shutdown system control that might interfere with the evaluation
of the operation of the exhaust gas temperature sensor. Prior to
testing, set the water level in the wet exhaust conditioner to a level
just above the minimum allowable low water level. Run the engine until
the exhaust gas temperature sensor activates the safety shutdown system
and stops the engine.
(5) For systems using a wet exhaust conditioner as an exhaust flame
arrester, determine the effectiveness of the low water sensor which
will automatically activate the safety shutdown system and stop the
engine at or above the minimum allowable low water level established
from results of the explosion tests in Sec. 7.100 with the engine
operating at a high idle speed condition. Temporarily disable the
reserve water supply, if applicable, and any safety shutdown system
control that might interfere with the evaluation of the operation of
the low water sensor. Prior to testing, set the water level in the wet
exhaust conditioner to a level just above the minimum allowable low
water level. Run the engine until the low water sensor activates the
safety shutdown system and stops the engine. Measure the low water
level. Attempt to restart the engine.
(6) Determine the effectiveness of the device in the intake system
which is designed to shut off the air supply and stop the engine for
emergency purposes with the engine operating at both a high idle speed
condition and a low idle speed condition. Run the engine and activate
the emergency intake air shutoff device.
(7) Determine the total air inlet restriction of the complete
intake system, including the air cleaner, as measured between the
intake flame arrester and the engine head with the engine operating at
maximum air flow.
(8) Determine the total exhaust backpressure with the engine
operating at rated horsepower as specified in Sec. 7.103(a)(7). If a
wet exhaust conditioner is used, it must be filled to the high or
normal operating water level during this test.
(9) The starting mechanism shall be tested to ensure that
engagement is not possible while the engine is running. Operate the
engine and attempt to engage the starting mechanism.
(10) Where the lack of engine oil pressure must be overridden in
order to start the engine, test the override to ensure that it does not
override any of the safety shutdown sensors specified in Sec. 7.98(i).
After each safety shutdown sensor test specified in paragraphs (a)(2)
through (a)(5) of this section, immediately override the engine oil
pressure and attempt to restart the engine.
(b) Acceptable performance. Tests of the safety system controls
shall result in the following:
(1) The coolant system temperature shutdown sensor shall
automatically activate the safety shutdown system and stop the engine
before the water temperature in the cooling jackets exceeds
manufacturer's specifications or 212 deg.F (100 deg.C), whichever is
lower.
(2) The temperature sensor in the exhaust gas stream of a system
using a dry exhaust conditioner shall automatically activate the safety
shutdown system and stop the engine before the cooled exhaust gas
exceeds 302 deg.F (150 deg.C).
(3) The temperature sensor in the exhaust gas stream of a system
using a wet exhaust conditioner shall automatically activate the safety
shutdown system and stop the engine before the cooled exhaust gas
exceeds 185 deg.F (85 deg.C).
(4) The low water sensor for systems using a wet exhaust
conditioner shall automatically activate the safety shutdown system and
stop the engine at or above the minimum allowable low water level and
prevent restarting of the engine.
(5) The emergency intake air shutoff device shall operate
immediately when activated and stop the engine within 15 seconds.
(6) The total intake air inlet restriction and the total exhaust
backpressure shall not exceed the engine manufacturer's specifications.
[[Page 55525]]
(7) It shall not be possible to engage the starting mechanism while
the engine is running, unless the starting mechanism is constructed of
nonsparking material.
(8) The engine oil pressure override shall not override any of the
shutdown sensors.
Sec. 7.104 Internal static pressure test.
(a) Test procedures. (1) Isolate and seal each segment of the
intake system or exhaust system to allow pressurization.
(2) Internally pressurize each segment of the intake system or
exhaust system to four times the maximum pressure observed in each
segment during the tests of Sec. 7.100, or 150 psig <plus-minus> 5
psig, whichever is less. Maintain the pressure for a minimum of 10
seconds.
(3) Following the pressure hold, the pressure shall be removed and
the pressurizing agent removed from the intake system or exhaust
system.
(b) Acceptable performance. (1) The intake system or exhaust
system, during pressurization, shall not exhibit--
(i) Leakage through welds and gasketed joints; or
(ii) Leakage other than along joints meeting the explosion-proof
requirements of Sec. 7.98(q).
(2) Following removal of the pressurizing agent, the intake system
or exhaust system shall not exhibit any--
(i) Changes in fastening torque;
(ii) Visible cracks in welds;
(iii) Permanent deformation affecting the length or gap of any
flame-arresting paths;
(iv) Stretched or bent fastenings;
(v) Damaged threads of parts affecting the explosion-proof
integrity of the intake system or exhaust system; or
(vi) Permanent distortion of any planar surface of the diesel power
package exceeding 0.04-inches/linear foot.
Sec. 7.105 Approval marking.
Each approved diesel power package shall be identified by a legible
and permanent approval plate inscribed with the assigned MSHA approval
number and securely attached to the diesel power package in a manner
that does not impair any explosion-proof characteristics. The grade
limitation of a wet exhaust conditioner used as an exhaust flame
arrester shall be included on the approval marking.
Sec. 7.106 Post-approval product audit.
Upon request by MSHA, but not more than once a year except for
cause, the approval-holder shall make an approved diesel power package
available for audit at no cost to MSHA.
Sec. 7.107 New technology.
MSHA may approve a diesel power package that incorporates
technology for which the requirements of this subpart are not
applicable if MSHA determines that the diesel power package is as safe
as those which meet the requirements of this subpart.
Sec. 7.108 Power package checklist.
Each diesel power package bearing an MSHA approval plate shall be
accompanied by a power package checklist. The power package checklist
shall consist of a list of specific features that must be checked and
tests that must be performed to determine if a previously approved
diesel power package is in approved condition. Test procedures shall be
specified in sufficient detail to allow evaluation to be made without
reference to other documents. Illustrations shall be used to fully
identify the approved configuration of the diesel power package.
PARTS 31--DIESEL MINE LOCOMOTIVES [REMOVED]
3. Part 31 is removed.
PART 32--MOBILE DIESEL-POWERED EQUIPMENT FOR NONCOAL MINES
[REMOVED]
4. Part 32 is removed.
PART 36--[AMENDED]
5. The authority for part 36 continues as follows:
Authority: 30 U.S.C. 957, 961.
6. The heading of part 36 is revised to read as follows:
PART 36--APPROVAL REQUIREMENTS FOR PERMISSIBLE MOBILE DIESEL-
POWERED TRANSPORTATION EQUIPMENT.
7. Section 36.1 is revised to read as follows:
Sec. 36.1 Purpose.
The regulations in this part set forth the requirements for mobile
diesel-powered transportation equipment to procure their approval and
certification as permissible; procedures for applying for such
certification; and fees.
8. Section 36.2 is revised to read as follows:
Sec. 36.2 Definitions.
The following definitions apply in this part.
Applicant An individual, partnership, company, corporation,
association, or other organization, that designs, manufactures,
assembles, or controls the assembly and that seeks a certificate of
approval or preliminary testing of mobile diesel-powered transportation
equipment as permissible.
Certificate of approval. A formal document issued by MSHA stating
that the complete assembly has met the requirements of this part for
mobile diesel-powered transportation equipment and authorizing the use
and attachment of an official approval plate so indicating.
Component. A piece, part, or fixture of mobile diesel-powered
transportation equipment that is essential to its operation as a
permissible assembly.
Diesel engine. A compression-ignition, internal-combustion engine
that utilizes diesel fuel.
Explosion proof. A component or subassembly that is so constructed
and protected by an enclosure and/or flame arrester (s) that if a
flammable mixture of gas is ignited within the enclosure it will
withstand the resultant pressure without damage to the enclosure and/or
flame arrester(s). Also the enclosure and/or flame arrester(s) shall
prevent the discharge of flame or ignition of any flammable mixture
that surrounds the enclosure.
Flame arrester. A device so constructed that flame or sparks from
the diesel engine cannot propagate an explosion of a flammable mixture
through it.
Flammable mixture. A mixture of gas, such as methane, natural gas,
or similar hydrocarbon gas with normal air, that will propagate flame
or explode violently when initiated by an incendive source.
Fuel-air ratio. The composition of the mixture of fuel and air in
the combustion chamber of the diesel engine expressed as weight-pound
of fuel per pound of air.
MSHA. The United States Department of Labor, Mine Safety and Health
Administration.
Mobile diesel-powered transportation equipment. Equipment that is:
(1) Used for transporting the product being mined or excavated, or
for transporting materials and supplies used in mining or excavating
operations;
(2) Mounted on wheels or crawler treads (tracks); and
(3) Powered by a diesel engine as the prime mover.
Normal operation. When each component and the entire assembly of
the mobile diesel-powered transportation equipment performs the
functions for which they were designed.
Permissible. As applied to mobile diesel-powered transportation
equipment, this means that the
[[Page 55526]]
complete assembly conforms to the requirements of this part, and that a
certificate of approval to that effect has been issued.
Subassembly. A group or combination of components.
9. Section 36.6, paragraphs (b)(2), (b)(3), and (b)(4) are amended
by inserting the phrase ``Except for equipment utilizing part 7,
subpart F power packages,'' at the beginning of the first sentence of
each paragraph.
10. Section 36.9 is amended by revising the third sentence of
paragraph (a) to read as follows:
Sec. 36.9 Conduct of investigations, tests, and demonstrations.
(a) * * * After the issuance of a certificate of approval, MSHA may
conduct such public demonstrations and tests of the approved mobile
diesel-powered transportation equipment as it deems appropriate. * * *
* * * * *
11. Section 36.20, paragraphs (b) is revised and paragraph (c) is
added to read as follows:
Sec. 36.20 Quality of material, workmanship, and design.
* * * * *
(b) The quality of material, workmanship, and design shall conform
to the requirements of Sec. 7.98(q) of this chapter.
(c) Power packages approved under part 7, subpart F of this chapter
are considered to be acceptable for use in equipment submitted for
approval under this part. Sections 36.21 through 36.26 (except
Sec. 36.25(f)) and Secs. 36.43 through 36.48 are not applicable to
equipment utilizing part 7, subpart F power packages, since these
requirements have already been satisfied.
12. Section 36.21 is amended by revising the first sentence to read
as follows:
Sec. 36.21 Engine for equipment considered for certification.
Only equipment powered by a compression-ignition (diesel) engine
and burning diesel fuel will be considered for approval and
certification. ***
13. Section 36.43 is amended by removing the phrase ``in
underground gassy noncoal mines and tunnels'' from the last sentence of
paragraph (a).
14. The note of Sec. 36.48 is revised to read as follows:
Sec. 36.48 Tests of surface temperature of engine and components of
the cooling system.
* * * * *
Note to Sec. 36.48: The engine may be operated under test
conditions prescribed by MSHA while completely surrounded by a
flammable mixture. MSHA reserves the right to apply combustible
materials to any surface for test. Operation under such conditions
shall not ignite the flammable mixture.
PART 70--[AMENDED]
15. The authority citation for part 70 continues to read as
follows:
Authority: 30 U.S.C. 811, 813(h), 957, and 961.
16. Subparts G-S are reserved and a new subpart T is added to part
70 to read as follows:
* * * * *
Subpart T--Diesel Exhaust Gas Monitoring
Sec.
70.1900 Exhaust Gas Monitoring
SUBPART T--DIESEL EXHAUST GAS MONITORING
Sec. 70.1900 Exhaust Gas Monitoring.
(a) During on-shift examinations required by Sec. 75.362, a
certified person as defined by Sec. 75.100 of this chapter and
designated by the operator as trained or experienced in the appropriate
sampling procedures, shall determine the concentration of carbon
monoxide (CO) and nitrogen dioxide (NO<INF>2):
(1) In the return of each working section where diesel equipment is
used, at a location which represents the contribution of all diesel
equipment on such section;
(2) In the area of the section loading point if diesel haulage
equipment is operated on the working section;
(3) At a point inby the last piece of diesel equipment on the
longwall or shortwall face when mining equipment is being installed or
removed; and
(4) In any other area designated by the district manager as
specified in the mine operator's approved ventilation plan where diesel
equipment is operated in a manner which can result in significant
concentrations of diesel exhaust.
(b) Samples of CO and NO<INF>2 shall be--
(1) Collected in a manner that makes the results available
immediately to the person collecting the samples;
(2) Collected and analyzed by appropriate instrumentation which has
been maintained and calibrated in accordance with the manufacturer's
recommendations; and
(3) Collected during periods that are representative of conditions
during normal operations.
(c) Except as provided in Sec. 75.325(j) of this chapter, when
sampling results indicate a concentration of CO and/or NO<INF>2
exceeding an action level of 50 percent of the threshold limit values
(TLV<Register>) adopted by the American Conference of Governmental
Industrial Hygienists, the mine operator shall immediately take
appropriate corrective action to reduce the concentrations of CO and/or
NO<INF>2 to below the applicable action level. The publication,
``Threshold Limit Values for Substance in Workroom Air'' (1972) is
incorporated by reference and may be inspected at MSHA's Office of
Standards, Regulations, and Variances, 4015 Wilson Boulevard,
Arlington, VA 22203; at any Coal Mine Health and Safety District and
Subdistrict Office; and at the Office of the Federal Register, 800
North Capitol Street, NW Suite 700, Washington, DC. This incorporation
by reference was approved by the Director of the Federal Register in
accordance with 5 U.S.C. 552(a) and 1 CFR part 51. In addition, copies
of the document may be purchased from the Secretary-Treasurer, American
Conference of Governmental Industrial Hygienists, Post Office Box 1937,
Cincinnati, OH 45202.
(d) A record shall be made when sampling results exceed the action
level for the applicable TLV<Register> for CO and/or NO<INF>2. The
record shall be made as part of and in the same manner as the records
for hazards required by Sec. 75.363 of this chapter and include the
following:
(1) Location where each sample was collected;
(2) Substance sampled and the measured concentration; and
(3) Corrective action taken to reduce the concentration of CO and/
or NO<INF>2 to or below the applicable action level.
(e) As of November 25, 1997 exhaust gas monitoring shall be
conducted in accordance with the requirements of this section.
PART 75--[AMENDED]
17. The authority citation for part 75 continues to read as
follows:
Authority: 30 U.S.C. 811.
18. New paragraphs (f) through (k) are added to Sec. 75.325 to read
as follows:
Sec. 75.325 Air quantity.
* * * * *
(f) The minimum ventilating air quantity for an individual unit of
diesel-powered equipment being operated shall be at least that
specified on the approval plate for that equipment. Such air quantity
shall be maintained--
(1) In any working place where the equipment is being operated;
(2) At the section loading point during any shift the equipment is
being operated on the working section;
[[Page 55527]]
(3) In any entry where the equipment is being operated outby the
section loading point in areas of the mine developed on or after April
25, 1997;
(4) In any air course with single or multiple entries where the
equipment is being operated outby the section loading point in areas of
the mine developed prior to April 25, 1997; and
(5) At any other location required by the district manager and
specified in the approved ventilation plan.
(g) The minimum ventilating air quantity where multiple units of
diesel-powered equipment are operated on working sections and in areas
where mechanized mining equipment is being installed or removed must be
at least the sum of that specified on the approval plates of all the
diesel-powered equipment on the working section or in the area where
mechanized mining equipment is being installed or removed. The minimum
ventilating air quantity shall be specified in the approved ventilation
plan. For working sections such air quantity must be maintained--
(1) In the last open crosscut of each set of entries or rooms in
each working section;
(2) In the intake, reaching the working face of each longwall; and
(3) At the intake end of any pillar line.
(h) The following equipment may be excluded from the calculations
of ventilating air quantity under paragraph (g) if such equipment
exclusion is approved by the district manager and specified in the
ventilation plan:
(1) Self-propelled equipment meeting the requirements of
Sec. 75.1908(b);
(2) Equipment that discharges its exhaust into intake air that is
coursed directly to a return air course;
(3) Equipment that discharges its exhaust directly into a return
air course; and
(4) Other equipment having duty cycles such that the emissions
would not significantly affect the exposure of miners.
(i) A ventilating air quantity that is less than what is required
by paragraph (g) of this section may be approved by the district
manager in the ventilation plan based upon the results of sampling that
demonstrate that the lesser air quantity will maintain continuous
compliance with applicable TLV<Register>'s.
(j) If during sampling required by Sec. 70.1900(c) of this
subchapter the ventilating air is found to contain concentrations of CO
or NO<INF>2 in excess of the action level specified by Sec. 70.1900(c),
higher action levels may be approved by the district manager based on
the results of sampling that demonstrate that a higher action level
will maintain continuous compliance with applicable TLV<Register>'s.
Action levels other than those specified in Sec. 70.1900(c) shall be
specified in the approved ventilation plan.
(k) As of November 25, 1977 the ventilating air quantity required
where diesel-powered equipment is operated shall meet the requirements
of paragraphs (f) through (j) of this section. Mine operators utilizing
diesel-powered equipment in underground coal mines shall submit to the
appropriate MSHA district manager a revised ventilation plan or
appropriate amendments to the existing plan, in accordance with
Sec. 75.371, which implement the requirements of paragraphs (f) through
(j) of this section.
19. Section 75.342 is amended by revising paragraph (b)(2) and the
introductory text of paragraph (c) to read as follows:
Sec. 75.342 Methane monitors.
* * * * *
(b)(1) * * *
(2) The warning signal device of the methane monitor shall be
visible to a person who can deenergize electric equipment or shut down
diesel-powered equipment on which the monitor is mounted.
(c) The methane monitor shall automatically deenergize electric
equipment or shut down diesel-powered equipment on which it is mounted
when--
* * * * *
20. Section 75.344 is amended by removing paragraph (d) and
redesignating paragraph (e) as new paragraph (d).
21. Section 75.360 is amended by revising paragraph (b)(7) as
follows:
Sec. 75.360 Preshift Examination.
* * * * *
(b) * * *
(7) Areas where trolley wires or trolley feeder wires are to be or
will remain energized during the oncoming shift.
* * * * *
22. Section 75.371 is amended by revising paragraph (r) and adding
new paragraphs (kk), (ll), (mm), (nn), (oo), and (pp) to read as
follows:
Sec. 75.371 Mine ventilation plan; contents.
* * * * *
(r) The minimum quantity of air that will be provided during the
installation and removal of mechanized mining equipment, the location
where this quantity will be provided, and the ventilation controls that
will be used (see Sec. 75.325(d), (g), and (i)).
* * * * *
(kk) Areas designated by the district manager where measurements of
CO and NO<INF>2 concentrations will be made (see Sec. 70.1900(a)(4)).
(ll) Location where the air quantity will be maintained at the
section loading point (see Sec. 75.325(f)(2)).
(mm) Any additional location(s) required by the district manager
where a minimum air quantity must be maintained for an individual unit
of diesel-powered equipment. (see Sec. 75.325(f)(5)).
(nn) The minimum air quantities that will be provided where
multiple units of diesel-powered equipment are operated (see
Sec. 75.325(g) (1)-(3) and (i)).
(oo) The diesel-powered mining equipment excluded from the
calculation under Sec. 75.325(g). (see Sec. 75.325(h)).
(pp) Action levels higher than the 50 percent level specified by
Sec. 70.1900(c). (see Sec. 75.325(j)).
23. Section 75.380 is amended by removing paragraph (f)(3)(i) and
by redesignating paragraphs (f)(3)(ii) through (f)(3)(v) as paragraphs
(f)(3)(i) through (f)(3)(iv).
24. Section 75.400 is revised to read as follows:
Sec. 75.400 Accumulation of combustible materials.
Coal dust, including float coal dust deposited on rock-dusted
surfaces, loose coal, and other combustible materials, shall be cleaned
up and not be permitted to accumulate in active workings, or on diesel-
powered and electric equipment therein.
25. Section 75.1710 is revised to read as follows:
Sec. 75.1710 Canopies or cabs; diesel-powered and electric face
equipment.
In any coal mine where the height of the coalbed permits, an
authorized representative of the Secretary may require that diesel-
powered and electric face equipment, including shuttle cars, be
provided with substantially constructed canopies or cabs to protect the
miners operating such equipment from roof falls and from rib and face
rolls.
26. Section 75.1710-1 is amended by replacing the phrase ``electric
face equipment'' with ``diesel-powered and electric face equipment'' in
the title and in paragraphs (a) and (f).
27. A new subpart T is added to part 75 to read as follows:
Subpart T--Diesel-Powered Equipment
Sec.
75.1900 Definitions.
75.1901 Diesel fuel requirements.
75.1902 Underground diesel fuel storage--general requirements.
[[Page 55528]]
75.1903 Underground diesel fuel storage facilities and areas;
construction and safety precautions.
75.1904 Underground diesel fuel tanks and safety cans.
75.1905 Dispensing of diesel fuel.
75.1905-1 Diesel fuel piping systems.
75.1906 Transport of diesel fuel.
75.1907 Diesel-powered equipment intended for use in underground
coal mines.
75.1908 Nonpermissible diesel-powered equipment-categories.
75.1909 Nonpermissible diesel-powered equipment; design and
performance requirements.
75.1910 Nonpermissible diesel-powered equipment; electrical system
design and performance requirements.
75.1911 Fire suppression systems for diesel-powered equipment and
diesel fuel transportation units.
75.1912 Fire suppression systems for permanent underground diesel
fuel storage facilities.
75.1913 Starting aids.
75.1914 Maintenance of diesel-powered equipment.
75.1915 Training and qualification of persons working on diesel-
powered equipment.
75.1916 Operation of diesel-powered equipment.
Subpart T--Diesel-Powered Equipment
Sec. 75.1900 Definitions.
The following definitions apply in this subpart.
Diesel fuel tank. A closed metal vessel specifically designed for
the storage or transport of diesel fuel.
Diesel fuel transportation unit. A self-propelled or portable
wheeled vehicle used to transport a diesel fuel tank.
Noncombustible material. A material that will continue to serve its
intended function for 1 hour when subjected to a fire test
incorporating an ASTM E119-88 time/temperature heat input, or
equivalent. The publication ASTM E119-88 ``Standard Test Methods for
Fire Tests of Building Construction and Materials'' is incorporated by
reference and may be inspected at any Coal Mine Health and Safety
District and Subdistrict Office; at MSHA's Office of Standards,
Regulations, and Variances, 4105 Wilson Boulevard, Arlington, VA 22203;
or at the Office of the Federal Register, 800 North Capitol Street,
NW., Washington, DC. This incorporation by reference was approved by
the Director of the Federal Register in accordance with 5 U.S.C. 552(a)
and 1 CFR part 51. In addition, copies of the document may be purchased
from the American Society for Testing Materials (ASTM), 1916 Race
Street, Philadelphia, PA 19103.
Permanent underground diesel fuel storage facility. A facility
designed and constructed to remain at one location for the storage or
dispensing of diesel fuel, which does not move as mining progresses.
Safety can. A metal container intended for storage, transport or
dispensing of diesel fuel, with a nominal capacity of 5 gallons, listed
or approved by a nationally recognized independent testing laboratory.
Temporary underground diesel fuel storage area. An area of the mine
provided for the short-term storage of diesel fuel in a fuel
transportation unit, which moves as mining progresses.
Sec. 75.1901 Diesel fuel requirements.
(a) Diesel-powered equipment shall be used underground only with a
diesel fuel having a sulfur content no greater than 0.05 percent and a
flash point of 100 deg. F (38 deg. C) or greater. Upon request, the
mine operator shall provide to an authorized representative of the
Secretary evidence that the diesel fuel purchased for use in diesel-
powered equipment underground meets these requirements.
(b) Flammable liquids shall not be added to diesel fuel used in
diesel-powered equipment underground.
(c) Only diesel fuel additives that have been registered by the
Environmental Protection Agency may be used in diesel-powered equipment
underground.
Sec. 75.1902 Underground diesel fuel storage--general requirements.
(a) All diesel fuel must be stored in:
(1) Diesel fuel tanks in permanent underground diesel fuel storage
facilities;
(2) Diesel fuel tanks on diesel fuel transportation units in
permanent underground diesel fuel storage facilities or in temporary
underground fuel storage areas; or
(3) Safety cans.
(b) The total capacity of stationary diesel fuel tanks in permanent
underground diesel fuel storage facilities must not exceed 1000
gallons.
(c)(1) Only one temporary underground diesel fuel storage area is
permitted for each working section or in each area of the mine where
equipment is being installed or removed.
(2) The temporary underground diesel fuel storage area must be
located--
(i) Within 500 feet of the loading point;
(ii) Within 500 feet of the projected loading point where equipment
is being installed; or
(iii) Within 500 feet of the last loading point where equipment is
being removed.
(3) No more than one diesel fuel transportation unit at a time
shall be parked in the temporary underground diesel fuel storage area.
(d) Permanent underground diesel fuel storage facilities and
temporary underground diesel fuel storage areas must be--
(1) At least 100 feet from shafts, slopes, shops, or explosives
magazines;
(2) At least 25 feet from trolley wires or power cables, or
electric equipment not necessary for the operation of the storage
facilities or areas; and
(3) In a location that is protected from damage by other mobile
equipment.
(e) Permanent underground diesel fuel storage facilities must not
be located within the primary escapeway.
Sec. 75.1903 Underground diesel fuel storage facilities and areas;
construction and safety precautions.
(a) Permanent underground diesel fuel storage facilities must be--
(1) Constructed of noncombustible materials, including floors,
roofs, roof supports, doors, and door frames. Exposed coal within fuel
storage areas must be covered with noncombustible materials. If
bulkheads are used they must be tightly sealed and must be built of or
covered with noncombustible materials;
(2) Provided with either self-closing doors or a means for
automatic enclosure;
(3) Provided with a means for personnel to enter and exit the
facility after closure;
(4) Ventilated with intake air that is coursed into a return air
course or to the surface and that is not used to ventilate working
places, using ventilation controls meeting the requirements of
Sec. 75.333(e);
(5) Equipped with an automatic fire suppression system that meets
the requirements of Sec. 75.1912. Actuation of the automatic fire
suppression system shall initiate the means for automatic enclosure;
(6) Provided with a means of containment capable of holding 150
percent of the maximum capacity of the fuel storage system; and
(7) Provided with a competent concrete floor or equivalent to
prevent fuel spills from saturating the mine floor.
(b) Permanent underground diesel fuel storage facilities and
temporary underground diesel fuel storage areas must be--
(1) Equipped with at least 240 pounds of rock dust and provided
with two portable multipurpose dry chemical type (ABC) fire
extinguishers that are listed or approved by a nationally recognized
independent testing laboratory and have a 10A:60B:C or
[[Page 55529]]
higher rating. Both fire extinguishers must be easily accessible to
personnel, and at least one fire extinguisher must be located outside
of the storage facility or area upwind of the facility, in intake air;
or
(2) Provided with three portable multipurpose dry chemical type
(ABC) fire extinguishers that are listed or approved by a nationally
recognized independent testing laboratory and have a 10A:60B:C or
higher rating. All fire extinguishers must be easily accessible to
personnel, and at least one fire extinguisher must be located outside
of the storage facility or area upwind of the facility, in intake air.
(3) Identified with conspicuous markings designating diesel fuel
storage; and
(4) Maintained to prevent the accumulation of water.
(c) Welding or cutting other than that performed in accordance with
paragraph (d) of this section shall not be performed within 50 feet of
a permanent underground diesel fuel storage facility or a temporary
underground diesel fuel storage area.
(d) When it is necessary to weld, cut, or solder pipelines, tanks,
or other containers that may have contained diesel fuel, these
practices shall be followed:
(1) Cutting or welding shall not be performed on or within
pipelines, tanks, or other containers that have contained diesel fuel
until they have been thoroughly purged and cleaned or inerted and a
vent or opening is provided to allow for sufficient release of any
buildup pressure before heat is applied.
(2) Diesel fuel shall not be allowed to enter pipelines, tanks, or
containers that have been welded, soldered, brazed, or cut until the
metal has cooled to ambient temperature.
Sec. 75.1904 Underground diesel fuel tanks and safety cans.
(a) Diesel fuel tanks used underground shall--
(1) Have steel walls of a minimum \3/16\-inch thickness, or walls
made of other metal of a thickness that provides equivalent strength;
(2) Be protected from corrosion;
(3) Be of seamless construction or have liquid tight welded seams;
(4) Not leak; and
(5) For stationary tanks in permanent underground diesel fuel
storage facilities, be placed on supports constructed of noncombustible
material so that the tanks are at least 12 inches above the floor.
(b) Underground diesel fuel tanks must be provided with--
(1) Devices for emergency venting designed to open at a pressure
not to exceed 2.5 psi according to the following--
(i) Tanks with a capacity greater than 500 gallons must have an
emergency venting device whose area is equivalent to a pipe with a
nominal inside diameter of 5 inches or greater; and
(ii) Tanks with a capacity of 500 gallons or less must have an
emergency venting device whose area is equivalent to a pipe with a
nominal inside diameter of 4 inches or greater.
(2) Tethered or self-closing caps for stationary tanks in permanent
underground diesel fuel storage facilities and self-closing caps for
diesel fuel tanks on diesel fuel transportation units;
(3) Vents to permit the free discharge of liquid, at least as large
as the fill or withdrawal connection, whichever is larger, but not less
than 1\1/4\ inch nominal inside diameter;
(4) Liquid tight connections for all tank openings that are--
(i) Identified by conspicuous markings that specify the function;
and
(ii) Closed when not in use.
(5) Vent pipes that drain toward the tank without sagging and are
higher than the fill pipe opening;
(6) Shutoff valves located as close as practicable to the tank
shell on each connection through which liquid can normally flow; and
(7) An automatic closing, heat-actuated valve on each withdrawal
connection below the liquid level.
(c) When tanks are provided with openings for manual gauging,
liquid tight, tethered or self-closing caps or covers must be provided
and must be kept closed when not open for gauging.
(d) Surfaces of the tank and its associated components must be
protected against damage by collision.
(e) Before being placed in service, tanks and their associated
components must be tested for leakage at a pressure equal to the
working pressure, except tanks and components connected directly to
piping systems, which must be properly designed for the application.
(f) Safety cans must be:
(1) Limited to a nominal capacity of 5 gallons or less;
(2) Equipped with a flexible or rigid tubular nozzle attached to a
valved spout;
(3) Provided with a vent valve designed to open and close
simultaneously and automatically with the opening and closing of the
pouring valve; and
(4) Designed so that they will safely relieve internal pressure
when exposed to fire.
Sec. 75.1905 Dispensing of diesel fuel.
(a) Diesel-powered equipment in underground coal mines may be
refueled only from safety cans, from tanks on diesel fuel
transportation units, or from stationary tanks.
(b) Fuel that is dispensed from other than safety cans must be
dispensed by means of--
(1) Gravity feed with a hose equipped with a nozzle with a self-
closing valve and no latch-open device;
(2) A manual pump with a hose equipped with a nozzle containing a
self-closing valve; or
(3) A powered pump with:
(i) An accessible emergency shutoff switch for each nozzle;
(ii) A hose equipped with a self-closing valve and no latch-open
device; and
(iii) An anti-siphoning device.
(c) Diesel fuel must not be dispensed using compressed gas.
(d) Diesel fuel must not be dispensed to the fuel tank of diesel-
powered equipment while the equipment engine is running.
(e) Powered pumps shall be shut off when fuel is not being
dispensed.
Sec. 75.1905-1 Diesel fuel piping systems.
(a) Diesel fuel piping systems from the surface must be designed
and operated as dry systems, unless an automatic shutdown is
incorporated that prevents accidental loss or spillage of fuel and that
activates an alarm system.
(b) All piping, valves and fittings must be--
(1) Capable of withstanding working pressures and stresses;
(2) Capable of withstanding four times the static pressures;
(3) Compatible with diesel fuel; and
(4) Maintained in a manner that prevents leakage.
(c) Pipelines must have manual shutoff valves installed at the
surface filling point, and at the underground discharge point.
(d) If diesel fuel lines are not buried in the ground sufficiently
to protect them from damage, shutoff valves must be located every 300
feet.
(e) Shutoff valves must be installed at each branch line where the
branch line joins the main line.
(f) An automatic means must be provided to prevent unintentional
transfer of diesel fuel from the surface into the permanent underground
diesel fuel storage facility.
(g) Diesel fuel piping systems from the surface shall only be used
to transport diesel fuel directly to stationary tanks or diesel fuel
transportation units in a permanent underground diesel fuel storage
facility.
[[Page 55530]]
(h) The diesel fuel piping system must not be located in a borehole
with electric power cables.
(i) Diesel fuel piping systems located in entries must not be
located on the same side of the entry as electric cables or power
lines. Where it is necessary for piping systems to cross electric
cables or power lines, guarding must be provided to prevent severed
electrical cables or power lines near broken fuel lines.
(j) Diesel fuel piping systems must be protected and located to
prevent physical damage.
Sec. 75.1906 Transport of diesel fuel.
(a) Diesel fuel shall be transported only by diesel fuel
transportation units or in safety cans.
(b) No more than one safety can shall be transported on a vehicle
at any time. The can must be protected from damage during transport.
All other safety cans must be stored in permanent underground diesel
fuel storage facilities.
(c) Safety cans that leak must be promptly removed from the mine.
(d) Diesel fuel transportation unit tanks and safety cans must be
conspicuously marked as containing diesel fuel.
(e) Diesel fuel transportation units must transport no more than
500 gallons of diesel fuel at a time.
(f) Tanks on diesel fuel transportation units must be permanently
fixed to the unit and have a total capacity of no greater than 500
gallons of diesel fuel.
(g) Non-self-propelled diesel fuel transportation units with
electrical components for dispensing fuel that are connected to a
source of electrical power must be protected by a fire suppression
device that meets the requirements of Secs. 75.1107-3 through 75.1107-6
and Secs. 75.1107-8 and 75.1107-16.
(h) Diesel fuel transportation units and vehicles transporting
safety cans containing diesel fuel must have at least two multipurpose,
dry chemical type (ABC) fire extinguishers, listed or approved by a
nationally recognized independent testing laboratory and having a
10A:60B:C or higher rating, with one fire extinguisher provided on each
side of the vehicle.
(i) Diesel fuel transportation units shall be parked only in
permanent underground diesel fuel storage facilities or temporary
underground diesel fuel storage areas when not in use.
(j) When the distance between a diesel fuel transportation unit and
an energized trolley wire at any location is less than 12 inches, the
requirements of Sec. 75.1003-2 must be followed.
(k) Diesel fuel shall not be transported on or with mantrips or on
conveyor belts.
(l) Diesel fuel shall be stored and handled in accordance with the
requirements of Secs. 75.1902 through 75.1906 of this part as of
November 25, 1997.
Sec. 75.1907 Diesel-powered equipment intended for use in underground
coal mines.
(a) As of November 25, 1996 all diesel-powered equipment used where
permissible electrical equipment is required must be approved under
part 36 of this chapter.
(b) Diesel-powered equipment approved under part 36 of this chapter
must be provided with additional safety features in accordance with the
following time schedule:
(1) As of April 25, 1997 the equipment must have a safety component
system that limits surface temperatures to those specified in subpart F
of part 7 of this title;
(2) As of November 25, 1999 the equipment must have an automatic or
manual fire suppression system that meets the requirements of
Sec. 75.1911 of this part, and at least one portable multipurpose dry
chemical type (ABC) fire extinguisher, listed or approved by a
nationally recognized independent testing laboratory and having a
10A:60B:C or higher rating. The fire extinguisher must be located
within easy reach of the equipment operator and be protected from
damage by collision.
(3) As of November 25, 1999 the equipment must have a brake system
that meets the requirements of Sec. 75.1909 (b)(6), (b)(7), (b)(8),
(c), (d), and (e);
(4) As of November 25, 1997 a particulate index and dilution air
quantity shall be determined for the equipment in accordance with
subpart E of part 7 of this chapter; and
(5) Permissible diesel-powered equipment manufactured on or after
November 25, 1999 and that is used in an underground coal mine shall
incorporate a power package approved in accordance with part 7, subpart
F of this chapter.
(c) As of November 25, 1999 nonpermissible diesel-powered
equipment, except the special category of equipment under
Sec. 75.1908(d), shall meet the requirements of Secs. 75.1909 and
75.1910 of this part.
Sec. 75.1908 Nonpermissible diesel-powered equipment--categories.
(a) Heavy-duty diesel-powered equipment includes--
(1) Equipment that cuts or moves rock or coal;
(2) Equipment that performs drilling or bolting functions;
(3) Equipment that moves longwall components;
(4) Self-propelled diesel fuel transportation units and self-
propelled lube units; or
(5) Machines used to transport portable diesel fuel transportation
units or portable lube units.
(b) Light-duty diesel-powered equipment is any diesel-powered
equipment that does not meet the criteria of paragraph (a).
(c) For the purposes of this subpart, the following equipment is
considered attended:
(1) Any machine or device operated by a miner; or
(2) Any machine or device that is mounted in the direct line of
sight of a job site located within 500 feet of such machine or device,
which job site is occupied by a miner.
(d) Diesel-powered ambulances and fire fighting equipment are a
special category of equipment that may be used underground only in
accordance with the mine fire fighting and evacuation plan under
Sec. 75.1101-23.
Sec. 75.1909 Nonpermissible diesel-powered equipment; design and
performance requirements.
(a) Nonpermissible diesel-powered equipment, except for the special
category of equipment under Sec. 75.1908(d), must be equipped with the
following features:
(1) An engine approved under subpart E of part 7 of this title
equipped with an air filter sized in accordance with the engine
manufacturer's recommendations, and an air filter service indicator set
in accordance with the engine manufacturer's recommendations;
(2) At least one portable multipurpose dry chemical type (ABC) fire
extinguisher listed or approved by a nationally recognized independent
testing laboratory with a 10A:60B:C or higher rating. The fire
extinguisher must be located within easy reach of the equipment
operator and protected from damage;
(3) A fuel system specifically designed for diesel fuel meeting the
following requirements:
(i) A fuel tank and fuel lines that do not leak;
(ii) A fuel tank that is substantially constructed and protected
against damage by collision;
(iii) A vent opening that maintains atmospheric pressure in the
fuel tank, and that is designed to prevent fuel from splashing out of
the vent opening;
(iv) A self-closing filler cap on the fuel tank;
[[Page 55531]]
(v) The fuel tank, filler and vent must be located so that leaks or
spillage during refueling will not contact hot surfaces;
(vi) Fuel line piping must be either steel-wire reinforced;
synthetic elastomer-covered hose suitable for use with diesel fuel that
has been tested and has been determined to be fire-resistant by the
manufacturer; or metal;
(vii) Fuel line piping must be clamped;
(viii) Primary fuel lines must be located so that fuel line leaks
do not contact hot surfaces;
(ix) The fuel lines must be separated from electrical wiring and
protected from damage in ordinary use;
(x) A manual shutoff valve must be installed in the fuel system as
close as practicable to the tank; and
(xi) A water separator and fuel filter(s) must be provided.
(4) A sensor to monitor the temperature and provide a visual
warning of an overheated cylinder head on air-cooled engines;
(5) Guarding to protect fuel, hydraulic, and electric lines when
such lines pass near rotating parts or in the event of shaft failure;
(6) Hydraulic tanks, fillers, vents, and lines located to prevent
spillage or leaks from contacting hot surfaces;
(7) Reflectors or warning lights mounted on the equipment which can
be readily seen in all directions;
(8) A means to direct exhaust gas away from the equipment operator,
persons on board the machine, and combustible machine components;
(9) A means to prevent unintentional free and uncontrolled descent
of personnel-elevating work platforms; and
(10) A means to prevent the spray from ruptured hydraulic or
lubricating oil lines from being ignited by contact with engine exhaust
system component surfaces.
(b) Self-propelled nonpermissible diesel-powered equipment must
have the following features in addition to those in paragraph (a):
(1) A means to ensure that no stored hydraulic energy that will
cause machine articulation is available after the engine is shut down;
(2) A neutral start feature which ensures that engine cranking
torque will not be transmitted through the powertrain and cause machine
movement on vehicles utilizing fluid power transmissions;
(3) For machines with steering wheels, brake pedals, and
accelerator pedals, controls which are of automobile orientation;
(4) An audible warning device conveniently located near the
equipment operator;
(5) Lights provided and maintained on both ends of the equipment.
Equipment normally operated in both directions must be equipped with
headlights for both directions;
(6) Service brakes that act on each wheel of the vehicle and that
are designed such that failure of any single component, except the
brake actuation pedal or other similar actuation device, must not
result in a complete loss of service braking capability;
(7) Service brakes that safely bring the fully loaded vehicle to a
complete stop on the maximum grade on which it is operated; and
(8) No device that traps a column of fluid to hold the brake in the
applied position shall be installed in any brake system, unless the
trapped column of fluid is released when the equipment operator is no
longer in contact with the brake activation device.
(c) Self-propelled nonpermissible heavy-duty diesel-powered
equipment under Sec. 75.1908(a), except rail-mounted equipment, shall
be provided with a supplemental braking system that:
(1) Engages automatically within 5 seconds of the shutdown of the
engine;
(2) Safely brings the equipment when fully loaded to a complete
stop on the maximum grade on which it is operated;
(3) Holds the equipment stationary, despite any contraction of
brake parts, exhaustion of any nonmechanical source of energy, or
leakage;
(4) Releases only by a manual control that does not operate any
other equipment function;
(5) Has a means in the equipment operator's compartment to apply
the brakes manually without the engine operating, and a means to
release and reengage the brakes without the engine operating; and
(6) Has a means to ensure that the supplemental braking system is
released before the equipment can be trammed, and is designed to ensure
the brake is fully released at all times while the equipment is
trammed.
(d) Self-propelled nonpermissible light-duty diesel-powered
equipment under Sec. 75.1908(b), except rail-mounted equipment, must be
provided with a parking brake that holds the fully loaded equipment
stationary on the maximum grade on which it is operated despite any
contraction of the brake parts, exhaustion of any nonmechanical source
of energy, or leakage.
(e) The supplemental and park brake systems required by paragraphs
(c) and (d) must be applied when the equipment operator is not at the
controls of the equipment, except during movement of disabled
equipment.
(f) Self-propelled personnel-elevating work platforms must be
provided with a means to ensure that the parking braking system is
released before the equipment can be trammed, and must be designed to
ensure the brake is fully released at all times while the equipment is
trammed.
(g) Any nonpermissible equipment that discharges its exhaust
directly into a return air course must be provided with a power package
approved under subpart F of part 7 of this title.
(h) Self-propelled nonpermissible heavy-duty diesel-powered
equipment meeting the requirements of Sec. 75.1908(a) must be provided
with an automatic fire suppression system meeting the requirements of
Sec. 75.1911.
(i) Self-propelled nonpermissible light-duty diesel-powered
equipment meeting the requirements of Sec. 75.1908(b) must be provided
with an automatic or manual fire suppression system meeting the
requirements of Sec. 75.1911.
(j) Nonpermissible equipment that is not self-propelled must have
the following features in addition to those listed in paragraph (a):
(1) A means to prevent inadvertent movement of the equipment when
parked;
(2) Safety chains or other suitable secondary connections on
equipment that is being towed; and
(3) An automatic fire suppression system meeting the requirements
of Sec. 75.1911.
Sec. 75.1910 Nonpermissible diesel-powered equipment; electrical
system design and performance requirements.
Electrical circuits and components associated with or connected to
electrical systems on nonpermissible diesel-powered equipment utilizing
storage batteries and integral charging systems, except for the special
category of equipment under Sec. 75.1908(d), must conform to the
following requirements:
(a) Overload and short circuit protection must be provided for
electric circuits and components in accordance with Secs. 75.518 and
75.518-1 of this part;
(b) Each electric conductor from the battery to the starting motor
must be protected against short circuit by fuses or other circuit-
interrupting devices placed as near as practicable to the battery
terminals;
(c) Each branch circuit conductor connected to the main circuit
between the battery and charging generator must be protected against
short circuit by fuses or other automatic circuit-interrupting devices;
(d) The electrical system shall be equipped with a circuit-
interrupting
[[Page 55532]]
device by means of which all power conductors can be deenergized. The
device must be located as close as practicable to the battery terminals
and be designed to operate within its electrical rating without damage.
The device shall not automatically reset after being actuated. All
magnetic circuit-interrupting devices must be mounted in a manner to
preclude their closing by force of gravity;
(e) Each motor and charging generator must be protected by an
automatic overcurrent device. One protective device will be acceptable
when two motors of the same rating operate simultaneously and perform
virtually the same duty;
(f) Each ungrounded conductor must have insulation compatible with
the impressed voltage. Insulation materials must be resistant to
deterioration from engine heat and oil. Electric conductors must meet
the applicable requirements of Secs. 75.513 and 75.513-1, except
electric conductors for starting motors, which must only meet the
requirements of Sec. 75.513;
(g) All wiring must have adequate mechanical protection to prevent
damage to the cable that might result in short circuits;
(h) Sharp edges and corners must be removed at all points where
there is a possibility of damaging wires, cables, or conduits by
cutting or abrasion. The insulation of the cables within a battery box
must be protected against abrasion;
(i) When insulated wires other than cables pass through metal
frames, the holes must be substantially bushed with insulated bushings.
Cables must enter metal frames of motors, splice boxes, and electric
components only through proper fittings. All electrical connections and
splices must be mechanically and electrically efficient, and suitable
connectors shall be used. All electrical connectors or splices in
insulated wire must be reinsulated at least to the same degree of
protection as the remainder of the wire;
(j) The battery must be secured to prevent movement, and must be
protected from external damage by position. Batteries that are not
protected from external damage by position must be enclosed in a
battery box. Flame-resistant insulation treated to resist chemical
reaction to electrolyte must be provided on battery connections to
prevent battery terminals from contacting conducting surfaces;
(k) A battery box, including the cover, must be constructed of
steel with a minimum thickness of \1/8\ inch, or of a material other
than steel that provides equivalent strength;
(l) Battery-box covers must be lined with a flame-resistant
insulating material permanently attached to the underside of the cover,
unless equivalent protection is provided. Battery-box covers must be
provided with a means for securing them in closed position. At least
\1/2\ inch of air space must be provided between the underside of the
cover and the top of the battery, including terminals;
(m) Battery boxes must be provided with ventilation openings to
prevent the accumulation of flammable or toxic gases or vapors within
the battery box. The size and locations of openings for ventilation
must prevent direct access to battery terminals;
(n) The battery must be insulated from the battery-box walls and
supported on insulating materials. Insulating materials that may be
subject to chemical reaction with electrolyte must be treated to resist
such action; and
(o) Drainage holes must be provided in the bottom of each battery
box.
Sec. 75.1911 Fire suppression systems for diesel-powered equipment
and fuel transportation units.
(a) The fire suppression system required by Secs. 75.1907 and
75.1909 shall be a multipurpose dry chemical type (ABC) fire
suppression system listed or approved by a nationally recognized
independent testing laboratory and appropriate for installation on
diesel-powered equipment and fuel transportation units.
(1) The system shall be installed in accordance with the
manufacturer's specifications and the limitations of the listing or
approval.
(2) The system shall be installed in a protected location or
guarded to minimize physical damage from routine vehicle operations.
(3) Suppressant agent distribution tubing or piping shall be
secured and protected against damage, including pinching, crimping,
stretching, abrasion, and corrosion.
(4) Discharge nozzles shall be positioned and aimed for maximum
fire suppression effectiveness. Nozzles shall also be protected against
the entrance of foreign materials such as mud, coal dust, or rock dust.
(b) The fire suppression system shall provide fire suppression and,
if automatic, fire detection for the engine including the starter,
transmission, hydraulic pumps and tanks, fuel tanks, exposed brake
units, air compressors and battery areas on diesel-powered equipment
and electric panels or controls used on fuel transportation units and
other areas as necessary.
(c) If automatic, the fire suppression system shall include audible
and visual alarms to warn of fires or system faults.
(d) The fire suppression system shall provide for automatic engine
shutdown. If the fire suppression system is automatic, engine shutdown
and discharge of suppressant agent may be delayed for a maximum of 15
seconds after the fire is detected by the system.
(e) The fire suppression system shall be operable by at least two
manual actuators. One actuator shall be located on each side of the
equipment. If the equipment is provided with an operator's compartment,
one of the manual actuators shall be located in the compartment within
reach of the operator.
(f) The fire suppression system shall remain operative in the event
of engine shutdown, equipment electrical system failure, or failure of
any other equipment system.
(g) The electrical components of each fire suppression system
installed on equipment used where permissible electric equipment is
required shall be permissible or intrinsically safe and such components
shall be maintained in permissible or intrinsically safe condition.
(h) Electrically operated detection and actuation circuits shall be
monitored and provided with status indicators showing power and circuit
continuity. If the system is not electrically operated, a means shall
be provided to indicate the functional readiness status of the
detection system.
(i) Each fire suppression system shall be tested and maintained in
accordance with the manufacturer's recommended inspection and
maintenance program and as required by the nationally recognized
independent testing laboratory listing or approval, and be visually
inspected at least once each week by a person trained to make such
inspections.
(j) Recordkeeping Persons performing inspections and tests of fire
suppression systems under paragraph (i) shall record when a fire
suppression system does not meet the installation or maintenance
requirements of this section.
(1) The record shall include the equipment on which the fire
suppression system did not meet the installation or maintenance
requirements of this section, the defect found, and the corrective
action taken.
(2) Records are to be kept manually in a secure manner not
susceptible to alteration or recorded electronically in a secured
computer system that is not susceptible to alteration.
(3) Records shall be maintained at a surface location at the mine
for one year
[[Page 55533]]
and made available for inspection by an authorized representative of
the Secretary and miners' representatives.
(k) All miners normally assigned to the active workings of the mine
shall be instructed about the hazards inherent to the operation of the
fire suppression systems and, where appropriate, the safeguards
available for each system.
(l) For purposes of Sec. 75.380(f), a fire suppression system
installed on diesel-powered equipment and meeting the requirements of
this section is equivalent to a fire suppression system meeting the
requirements of Secs. 75.1107-3 through 75.1107-16.
Sec. 75.1912 Fire suppression systems for permanent underground diesel
fuel storage facilities.
(a) The fire suppression system required by Sec. 75.1903 shall be
an automatic multipurpose dry chemical type (ABC) fire suppression
system listed or approved as an engineered dry chemical extinguishing
system by a nationally recognized independent testing laboratory and
appropriate for installation at a permanent underground diesel fuel
storage facility.
(1) Alternate types of fire suppression systems shall be approved
in accordance with Sec. 75.1107-13 of this part.
(2) The system shall be installed in accordance with the
manufacturer's specifications and the limitations of the listing or
approval.
(3) The system shall be installed in a protected location or
guarded to prevent physical damage from routine operations.
(4) Suppressant agent distribution tubing or piping shall be
secured and protected against damage, including pinching, crimping,
stretching, abrasion, and corrosion.
(5) Discharge nozzles shall be positioned and aimed for maximum
fire suppression effectiveness in the protected areas. Nozzles must
also be protected against the entrance of foreign materials such as
mud, coal dust, and rock dust.
(b) The fire suppression system shall provide automatic fire
detection and automatic fire suppression for all areas within the
facility.
(c) Audible and visual alarms to warn of fire or system faults
shall be provided at the protected area and at a surface location which
is continually monitored by a person when personnel are underground. In
the event of a fire, personnel shall be warned in accordance with the
provisions set forth in Sec. 75.1101-23.
(d) The fire suppression system shall deenergize all power to the
diesel fuel storage facility when actuated except that required for
automatic enclosure and alarms.
(e) Fire suppression systems shall include two manual actuators
located as follows:
(1) At least one within the fuel storage facility; and
(2) At least one a safe distance away from the storage facility and
located in intake air, upwind of the storage facility.
(f) The fire suppression system shall remain operational in the
event of electrical system failure.
(g) Electrically operated detection and actuation circuits shall be
monitored and provided with status indicators showing power and circuit
continuity. If the system is not electrically operated, a means shall
be provided to indicate the functional readiness status of the
detection system.
(h) Each fire suppression system shall be tested and maintained in
accordance with the manufacturer's recommended inspection and
maintenance program and as required by the nationally recognized
independent testing laboratory listing or approval, and be visually
inspected at least once each week by a person trained to make such
inspections.
(i) Recordkeeping. Persons performing inspections and tests of fire
suppression systems under paragraph (h) shall record when a fire
suppression system does not meet the installation or maintenance
requirements of this section.
(1) The record shall include the facility whose fire suppression
system did not meet the installation or maintenance requirements of
this section, the defect found, and the corrective action taken.
(2) Records are to be kept manually in a secure manner not
susceptible to alteration or recorded electronically in a secured
computer system that is not susceptible to alteration.
(3) Records shall be maintained at a surface location at the mine
for one year and made available for inspection by an authorized
representative of the Secretary and miners' representatives.
(j) All miners normally assigned to the active workings of the mine
shall be instructed about the hazards inherent to the operation of the
fire suppression systems and, where appropriate, the safeguards
available for each system.
Sec. 75.1913 Starting aids.
(a) Volatile fuel starting aids shall be used in accordance with
recommendations provided by the starting aid manufacturer, the engine
manufacturer, and the machine manufacturer.
(b) Containers of volatile fuel starting aids shall be
conspicuously marked to indicate the contents. When not in use,
containers of volatile fuel starting aids shall be stored in metal
enclosures that are used only for storage of starting aids. Such metal
enclosures must be conspicuously marked, secured, and protected from
damage.
(c) Volatile fuel starting aids shall not be:
(1) Taken into or used in areas where permissible equipment is
required;
(2) Used in the presence of open flames or burning flame safety
lamps, or when welding or cutting is taking place; or
(3) Used in any area where 1.0 percent or greater concentration of
methane is present.
(d) Compressed oxygen or compressed flammable gases shall not be
connected to diesel air-start systems.
Sec. 75.1914 Maintenance of diesel-powered equipment.
(a) Diesel-powered equipment shall be maintained in approved and
safe condition or removed from service.
(b) Maintenance and repairs of approved features and those features
required by Secs. 75.1909 and 75.1910 on diesel-powered equipment shall
be made only by a person qualified under Sec. 75.1915.
(c) The water scrubber system on diesel-powered equipment shall be
drained and flushed, by a person who is trained to perform this task,
at least once on each shift in which the equipment is operated.
(d) The intake air filter on diesel-powered equipment shall be
replaced or serviced, by a person who is trained to perform this task,
when the intake air pressure drop device so indicates or when the
engine manufacturer's maximum allowable air pressure drop level is
exceeded.
(e) Mobile diesel-powered equipment that is to be used during a
shift shall be visually examined by the equipment operator before being
placed in operation. Equipment defects affecting safety shall be
reported promptly to the mine operator.
(f) All diesel-powered equipment shall be examined and tested
weekly by a person qualified under Sec. 75.1915.
(1) Examinations and tests shall be conducted in accordance with
approved checklists and manufacturers' maintenance manuals.
(2) Persons performing weekly examinations and tests of diesel-
powered equipment under this paragraph shall make a record when the
equipment is not in approved or safe condition. The record shall
include the
[[Page 55534]]
equipment that is not in approved or safe condition, the defect found,
and the corrective action taken.
(g) Undiluted exhaust emissions of diesel engines in diesel-powered
equipment approved under part 36 and heavy-duty nonpermissible diesel-
powered equipment as defined in Sec. 75.1908(a) in use in underground
coal mines shall be tested and evaluated weekly by a person who is
trained to perform this task. The mine operator shall develop and
implement written standard operating procedures for such testing and
evaluation that specify the following:
(1) The method of achieving a repeatable loaded engine operating
condition for each type of equipment;
(2) Sampling and analytical methods (including calibration of
instrumentation) that are capable of accurately detecting carbon
monoxide in the expected concentrations;
(3) The method of evaluation and interpretation of the results;
(4) The concentration or changes in concentration of carbon
monoxide that will indicate a change in engine performance. Carbon
monoxide concentration shall not exceed 2500 parts per million; and
(5) The maintenance of records necessary to track engine
performance.
(h) Recordkeeping. Records required by paragraphs (f)(2) and (g)(5)
shall be--
(1) Recorded in a secure book that is not susceptible to
alteration, or recorded electronically in a computer system that is
secure and not susceptible to alteration; and
(2) Retained at a surface location at the mine for at least 1 year
and made available for inspection by an authorized representative of
the Secretary and by miners' representatives.
(i) Diesel-powered equipment must be maintained in accordance with
this part as of November 25, 1997.
Sec. 75.1915 Training and qualification of persons working on diesel-
powered equipment.
(a) To be qualified to perform maintenance, repairs, examinations
and tests on diesel-powered equipment, as required by Sec. 75.1914, a
person must successfully complete a training and qualification program
that meets the requirements of this section. A person qualified to
perform these tasks shall be retrained as necessary to maintain the
ability to perform all assigned diesel-powered equipment maintenance,
repairs, examinations and tests.
(b) A training and qualification program under this section must:
(1) Be presented by a competent instructor;
(2) Be sufficient to prepare or update a person's ability to
perform all assigned tasks with respect to diesel-powered equipment
maintenance, repairs, examinations and tests;
(3) Address, at a minimum, the following:
(i) The requirements of subpart T of this part;
(ii) Use of appropriate power package or machine checklists to
conduct tests to ensure that diesel-powered equipment is in approved
and safe condition, with acceptable emission levels;
(iii) Proper maintenance of approved features and the correct use
of the appropriate maintenance manuals, including machine adjustments,
service, and assembly;
(iv) Diesel-powered equipment fire suppression system tests and
maintenance;
(v) Fire and ignition sources and their control or elimination,
including cleaning of the equipment;
(vi) Safe fueling procedures and maintenance of the fuel system of
the equipment; and
(vii) Intake air system maintenance and tests.
(4) Include an examination that requires demonstration of the
ability to perform all assigned tasks with respect to diesel-powered
equipment maintenance, repairs, examinations and tests; and
(5) Be in writing. The written program shall include a description
of the course content, materials, and teaching methods for initial
training and retraining.
(c) Recordkeeping. The operator shall maintain a copy of the
training and qualification program required by this section and a
record of the names of all persons qualified under the program.
(1) The record of the names of qualified persons shall be made in a
manner that is not susceptible to alteration, or recorded
electronically in a computer system that is secure and not susceptible
to alteration.
(2) The training and qualification program and record of qualified
persons are to be kept at surface location of the mine and made
available for inspection by an authorized representative of the
Secretary and by miners' representatives.
Sec. 75.1916 Operation of diesel-powered equipment.
(a) Diesel-powered equipment shall be operated at a speed that is
consistent with the type of equipment being operated, roadway
conditions, grades, clearances, visibility, and other traffic.
(b) Operators of mobile diesel-powered equipment shall maintain
full control of the equipment while it is in motion.
(c) Standardized traffic rules, including speed limits, signals and
warning signs, shall be established at each mine and followed.
(d) Except as required in normal mining operations, mobile diesel-
powered equipment shall not be idled.
(e) Diesel-powered equipment shall not be operated unattended.
[FR Doc. 96-26838 Filed 10-24-96; 8:45 am]
BILLING CODE 4510-43-P
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