[Title 30 CFR ]
[Code of Federal Regulations (annual edition) - July 1, 2023 Edition]
[From the U.S. Government Publishing Office]
[[Page i]]
Title 30
Mineral Resources
________________________
Parts 1 to 199
Revised as of July 1, 2023
Containing a codification of documents of general
applicability and future effect
As of July 1, 2023
Published by the Office of the Federal Register
National Archives and Records Administration as a
Special Edition of the Federal Register
[[Page ii]]
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[[Page iii]]
Table of Contents
Page
Explanation................................................. v
Title 30:
Chapter I--Mine Safety and Health Administration,
Department of Labor 3
Finding Aids:
Table of CFR Titles and Chapters........................ 765
Alphabetical List of Agencies Appearing in the CFR...... 785
List of CFR Sections Affected........................... 795
[[Page iv]]
----------------------------
Cite this Code: CFR
To cite the regulations in
this volume use title,
part and section number.
Thus, 30 CFR 1.1 refers to
title 30, part 1, section
1.
----------------------------
[[Page v]]
EXPLANATION
The Code of Federal Regulations is a codification of the general and
permanent rules published in the Federal Register by the Executive
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parts covering specific regulatory areas.
Each volume of the Code is revised at least once each calendar year
and issued on a quarterly basis approximately as follows:
Title 1 through Title 16.................................as of January 1
Title 17 through Title 27..................................as of April 1
Title 28 through Title 41...................................as of July 1
Title 42 through Title 50................................as of October 1
The appropriate revision date is printed on the cover of each
volume.
LEGAL STATUS
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OMB CONTROL NUMBERS
The Paperwork Reduction Act of 1980 (Pub. L. 96-511) requires
Federal agencies to display an OMB control number with their information
collection request.
[[Page vi]]
Many agencies have begun publishing numerous OMB control numbers as
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PAST PROVISIONS OF THE CODE
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``[RESERVED]'' TERMINOLOGY
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What is a proper incorporation by reference? The Director of the
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approval is based are:
(a) The incorporation will substantially reduce the volume of
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(b) The matter incorporated is in fact available to the extent
necessary to afford fairness and uniformity in the administrative
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(c) The incorporating document is drafted and submitted for
publication in accordance with 1 CFR part 51.
What if the material incorporated by reference cannot be found? If
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that volume.
[[Page vii]]
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Oliver A. Potts,
Director,
Office of the Federal Register
July 1, 2023
[[Page ix]]
THIS TITLE
Title 30--Mineral Resources is composed of three volumes. The parts
in these volumes are arranged in the following order: parts 1--199,
parts 200--699, and part 700 to end. The contents of these volumes
represent all current regulations codified under this title of the CFR
as of July 1, 2023.
For this volume, Gabrielle E. Burns was Chief Editor. The Code of
Federal Regulations publication program is under the direction of John
Hyrum Martinez, assisted by Stephen J. Frattini.
[[Page 1]]
TITLE 30--MINERAL RESOURCES
(This book contains parts 1 to 199)
--------------------------------------------------------------------
Part
chapter i--Mine Safety and Health Administration, Department
of Labor.................................................. 1
[[Page 3]]
CHAPTER I--MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR
--------------------------------------------------------------------
Editorial Note: Nomenclature changes to chapter I appear at 69 FR
18803, Apr. 9, 2004.
SUBCHAPTER A--OFFICIAL EMBLEM AND OMB CONTROL NUMBERS FOR RECORDKEEPING
AND REPORTING
Part Page
1 Mine Safety and Health Administration;
establishment and use of official emblem 7
3 OMB Control Numbers under the Paperwork
Reduction Act........................... 7
SUBCHAPTER B--TESTING, EVALUATION, AND APPROVAL OF MINING PRODUCTS
5 Fees for testing, evaluation, and approval
of mining products...................... 11
6 Testing and evaluation by independent
laboratories and non-MSHA product safety
standards............................... 12
7 Testing by applicant or third party......... 14
14 Requirements for the approval of flame-
resistant conveyor belts................ 90
15 Requirements for approval of explosives and
sheathed explosive units................ 94
18 Electric motor-driven mine equipment and
accessories............................. 101
19 Electric cap lamps.......................... 143
20 Electric mine lamps other than standard cap
lamps................................... 148
22 Portable methane detectors.................. 153
23 Telephones and signaling devices............ 157
27 Methane-monitoring systems.................. 162
28 Fuses for use with direct current in
providing short-circuit protection for
trailing cables in coal mines........... 170
33 Dust collectors for use in connection with
rock drilling in coal mines............. 175
35 Fire-resistant hydraulic fluids............. 182
[[Page 4]]
36 Approval requirements for permissible mobile
diesel-powered transportation equipment. 189
SUBCHAPTERS C-F [RESERVED]
SUBCHAPTER G--FILING AND OTHER ADMINISTRATIVE REQUIREMENTS
40 Representative of miners.................... 203
41 Notification of legal identity.............. 204
42 National Mine Health and Safety Academy..... 206
43 Procedures for processing hazardous
conditions complaints................... 207
44 Rules of practice for petitions for
modification of mandatory safety
standards............................... 210
45 Independent contractors..................... 222
SUBCHAPTER H--EDUCATION AND TRAINING
46 Training and retraining of miners engaged in
shell dredging or employed at sand,
gravel, surface stone, surface clay,
colloidal phosphate, or surface
limestone mines......................... 224
47 Hazard Communication (HazCom)............... 232
48 Training and retraining of miners........... 240
49 Mine rescue teams........................... 260
SUBCHAPTER I--ACCIDENTS, INJURIES, ILLNESSES, EMPLOYMENT, AND PRODUCTION
IN MINES
50 Notification, investigation, reports and
records of accidents, injuries,
illnesses, employment, and coal
production in mines..................... 274
SUBCHAPTER J [RESERVED]
SUBCHAPTER K--METAL AND NONMETAL MINE SAFETY AND HEALTH
56 Safety and health standards--surface metal
and nonmetal mines...................... 285
57 Safety and health standards--underground
metal and nonmetal mines................ 341
[[Page 5]]
58 Health standards for metal and nonmetal
mines................................... 443
SUBCHAPTER L [RESERVED]
SUBCHAPTER M--UNIFORM MINE HEALTH REGULATIONS
62 Occupational noise exposure................. 444
SUBCHAPTER N [RESERVED]
SUBCHAPTER O--COAL MINE SAFETY AND HEALTH
70 Mandatory health standards--underground coal
mines................................... 452
71 Mandatory health standards--surface coal
mines and surface work areas of
underground coal mines.................. 466
72 Health standards for coal mines............. 480
74 Coal mine dust sampling devices............. 485
75 Mandatory safety standards--underground coal
mines................................... 496
77 Mandatory safety standards, surface coal
mines and surface work areas of
underground coal mines.................. 679
90 Mandatory health standards--coal miners who
have evidence of the development of
pneumoconiosis.......................... 735
SUBCHAPTER P--CIVIL PENALTIES FOR VIOLATIONS OF THE FEDERAL MINE SAFETY
AND HEALTH ACT OF 1977
100 Criteria and procedures for proposed
assessment of civil penalties........... 747
101-103
[Reserved]
SUBCHAPTER Q--PATTERN OF VIOLATIONS
104 Pattern of violations....................... 761
105-199
[Reserved]
[[Page 7]]
SUBCHAPTER A_OFFICIAL EMBLEM AND OMB CONTROL NUMBERS FOR RECORDKEEPING
AND REPORTING
PART 1_MINE SAFETY AND HEALTH ADMINISTRATION; ESTABLISHMENT AND USE OF
OFFICIAL EMBLEM--Table of Contents
Sec.
1.1 Official emblem.
1.2 Description.
1.3 Use of letters and acronym MSHA.
Authority: Sec. 508, Federal Coal Mine Health and Safety Act of
1969; sec. 301 of Title 5, United States Code; secs. 301(a) and 302(a),
Federal Mine Safety and Health Amendments Act of 1977, Pub. L. 95-164,
30 U.S.C. 961 and 951 and 29 U.S.C. 577a, 91 Stat. 1317 and 91 Stat.
1319; sec. 508, Federal Mine Safety and Health Act of 1977, Pub. L. 91-
173 as amended by Pub. L. 95-164, 30 U.S.C. 957, 83 Stat. 803.
Source: 39 FR 23997, June 28, 1974, unless otherwise noted.
Sec. 1.1 Official emblem.
The following emblem is established and shall be used as the
official emblem of the Mine Safety and Health Administration, except
where use of the Departmental Seal is required:
[GRAPHIC] [TIFF OMITTED] TC22OC91.000
[39 FR 23997, June 28, 1974, as amended at 43 FR 12312, Mar. 24, 1978]
Sec. 1.2 Description.
The emblem of the Mine Safety and Health Administration is of
contemporary design with the letters and acronym of the Administration
delineated as MSHA appearing in large letters in the middle of the
emblem. Above the letters and acronym appear the words ``United States
Department of Labor'' and below the letters and acronym appear the words
``Mine Safety and Health Administration.''
[39 FR 23997, June 28, 1974, as amended at 43 FR 12312, Mar. 24, 1978]
Sec. 1.3 Use of letters and acronym MSHA.
The letters and acronym MSHA may be used and substituted for the
words ``Mine Safety and Health Administration'' in correspondence,
rules, regulations, and in certificates of approval, approval plates,
labels, and markings prescribed by the Mine Safety and Health
Administration to designate and denote equipment, devices, and apparatus
approved as ``permissible'' and suitable for use in mines under the
applicable parts of Chapter I of this title, and in such other
documents, publications, and pamphlets, and on signs, clothing and
uniforms, and offices of the Administration and at such times and
locations as may be deemed appropriate by the Assistant Secretary of
Labor for Mine Safety and Health.
[39 FR 23997, June 28, 1974, as amended at 43 FR 12312, Mar. 24, 1978]
PART 3_OMB CONTROL NUMBERS UNDER THE PAPERWORK REDUCTION ACT-
-Table of Contents
Authority: 30 U.S.C. 957; 44 U.S.C. 3501-3520.
Sec. 3.1 OMB control numbers.
The collection of information requirements in MSHA regulation
sections in this chapter have been approved and assigned control numbers
by the Office of Management and Budget (OMB) under the Paperwork
Reduction Act. Regulation sections in this chapter containing paperwork
requirements and their respective OMB control numbers are displayed in
the following table:
Table 1--OMB Control Numbers
------------------------------------------------------------------------
30 CFR Citation OMB Control No.
------------------------------------------------------------------------
Subchapter B--Testing, Evaluation, and Approval of Mining Products
------------------------------------------------------------------------
6.10................................................. 1219-0066
7.3.................................................. 1219-0066
7.4.................................................. 1219-0066
7.6.................................................. 1219-0066
7.7.................................................. 1219-0066
[[Page 8]]
7.23................................................. 1219-0066
7.27................................................. 1219-0066
7.28................................................. 1219-0066
7.29................................................. 1219-0066
7.30................................................. 1219-0066
7.43................................................. 1219-0066
7.46................................................. 1219-0066
7.47................................................. 1219-0066
7.48................................................. 1219-0066
7.49................................................. 1219-0066
7.51................................................. 1219-0066
7.63................................................. 1219-0066
7.69................................................. 1219-0066
7.71................................................. 1219-0066
7.83................................................. 1219-0066
7.90................................................. 1219-0066
7.97................................................. 1219-0066
7.105................................................ 1219-0066
7.108................................................ 1219-0066
7.303................................................ 1219-0066
7.306................................................ 1219-0066
7.309................................................ 1219-0066
7.311................................................ 1219-0066
7.403................................................ 1219-0066
7.407................................................ 1219-0066
7.408................................................ 1219-0066
7.409................................................ 1219-0066
7.411................................................ 1219-0066
15.4................................................. 1219-0066
15.8................................................. 1219-0066
18.6................................................. 1219-0066
18.15................................................ 1219-0066
18.53................................................ 1219-0066, -0116
18.81................................................ 1219-0066
18.82................................................ 1219-0066
18.93................................................ 1219-0066
18.94................................................ 1219-0066
19.3................................................. 1219-0066
19.13................................................ 1219-0066
20.3................................................. 1219-0066
20.14................................................ 1219-0066
22.4................................................. 1219-0066
22.8................................................. 1219-0066
22.11................................................ 1219-0066
23.3................................................. 1219-0066
23.7................................................. 1219-0066
23.10................................................ 1219-0066
23.12................................................ 1219-0066
23.14................................................ 1219-0066
27.4................................................. 1219-0066
27.6................................................. 1219-0066
27.11................................................ 1219-0066
28.10................................................ 1219-0066
28.23................................................ 1219-0066
28.25................................................ 1219-0066
28.30................................................ 1219-0066
28.31................................................ 1219-0066
33.6................................................. 1219-0066
33.12................................................ 1219-0066
35.6................................................. 1219-0066
35.10................................................ 1219-0066
35.12................................................ 1219-0066
36.6................................................. 1219-0066
36.12................................................ 1219-0066
------------------------------------------------------------------------
Subchapter G--Filing and Other Administrative Requirements
------------------------------------------------------------------------
40.3................................................. 1219-0042
40.4................................................. 1219-0042
40.5................................................. 1219-0042
41.20................................................ 1219-0042
43.4................................................. 1219-0014
43.7................................................. 1219-0014
44.9................................................. 1219-0065
44.10................................................ 1219-0065
44.11................................................ 1219-0065
45.3................................................. 1219-0040
45.4................................................. 1219-0040
------------------------------------------------------------------------
Subchapter H--Education and Training
------------------------------------------------------------------------
46.3................................................. 1219-0131
46.5................................................. 1219-0131
46.6................................................. 1219-0131
46.7................................................. 1219-0131
46.8................................................. 1219-0131
46.9................................................. 1219-0131
46.11................................................ 1219-0131
47.31................................................ 1219-0133
47.32................................................ 1219-0133
47.32(a)(4).......................................... 1219-0133
47.41................................................ 1219-0133
47.51................................................ 1219-0133
47.71................................................ 1219-0133
47.73................................................ 1219-0133
48.3................................................. 1219-0009, -0141
48.9................................................. 1219-0009
48.23................................................ 1219-0009
48.29................................................ 1219-0009
49.2................................................. 1219-0078
49.3................................................. 1219-0078
49.4................................................. 1219-0078
49.6................................................. 1219-0078
49.7................................................. 1219-0078
49.8................................................. 1219-0078
49.9................................................. 1219-0078
49.12................................................ 1219-0144
49.16................................................ 1219-0144
49.18................................................ 1219-0144
49.50................................................ 1219-0144
------------------------------------------------------------------------
Subchapter I--Accidents, Injuries, Illnesses, Employment, and Production
in Mines
------------------------------------------------------------------------
50.10................................................ 1219-0007, -0141
50.11................................................ 1219-0007, -0141
50.20................................................ 1219-0007
50.30................................................ 1219-0007
------------------------------------------------------------------------
Subchapter K--Metal and Nonmetal Mine Safety and Health
------------------------------------------------------------------------
56.1000.............................................. 1219-0042
56.3203(a)........................................... 1219-0121
56.5005.............................................. 1219-0048
56.13015............................................. 1219-0089
56.13030............................................. 1219-0089
56.14100............................................. 1219-0089
56.18002............................................. 1219-0089
56.19022............................................. 1219-0034
56.19023............................................. 1219-0034
56.19057............................................. 1219-0049
56.19121............................................. 1219-0034
57.1000.............................................. 1219-0042
57.3203(a)........................................... 1219-0121
57.3461.............................................. 1219-0097
57.5005.............................................. 1219-0048
57.5037.............................................. 1219-0003
57.5040.............................................. 1219-0003
57.5047.............................................. 1219-0039
57.5060.............................................. 1219-0135
[[Page 9]]
57.5065.............................................. 1219-0135
57.5066.............................................. 1219-0135
57.5067.............................................. 1219-0135
57.5070.............................................. 1219-0135
57.5071.............................................. 1219-0135
57.5075.............................................. 1219-0135
57.8520.............................................. 1219-0016
57.8525.............................................. 1219-0016
57.11053............................................. 1219-0046
57.13015............................................. 1219-0089
57.13030............................................. 1219-0089
57.14100............................................. 1219-0089
57.18002............................................. 1219-0089
57.19022............................................. 1219-0034
57.19023............................................. 1219-0034
57.19057............................................. 1219-0049
57.19121............................................. 1219-0034
57.22004(c).......................................... 1219-0103
57.22204............................................. 1219-0030
57.22229............................................. 1219-0103
57.22230............................................. 1219-0103
57.22231............................................. 1219-0103
57.22239............................................. 1219-0103
57.22401............................................. 1219-0096
57.22606............................................. 1219-0095
------------------------------------------------------------------------
Subchapter M--Uniform Mine Health Regulations
------------------------------------------------------------------------
62.110............................................... 1219-0120
62.130............................................... 1219-0120
62.170............................................... 1219-0120
62.171............................................... 1219-0120
62.172............................................... 1219-0120
62.173............................................... 1219-0120
62.174............................................... 1219-0120
62.175............................................... 1219-0120
62.180............................................... 1219-0120
62.190............................................... 1219-0120
------------------------------------------------------------------------
Subchapter O--Coal Mine Safety and Health
------------------------------------------------------------------------
70.201(c)............................................ 1219-0011
70.202(b)............................................ 1219-0011
70.204............................................... 1219-0011
70.209............................................... 1219-0011
70.210............................................... 1219-0011
70.220............................................... 1219-0011
70.220(a)............................................ 1219-0011
71.201(c)............................................ 1219-0011
71.202(b)............................................ 1219-0011
71.204............................................... 1219-0011
71.209............................................... 1219-0011
71.210............................................... 1219-0011
71.220............................................... 1219-0011
71.220(a)............................................ 1219-0011
71.300............................................... 1219-0011
71.301............................................... 1219-0011
71.301(d)............................................ 1219-0011
71.403............................................... 1219-0024
71.404............................................... 1219-0024
72.500............................................... 1219-0124
72.503............................................... 1219-0124
72.510............................................... 1219-0124
72.520............................................... 1219-0124
75.100............................................... 1219-0127
75.153(a)(2)......................................... 1219-0001
75.155............................................... 1219-0127
75.159............................................... 1219-0127
75.160............................................... 1219-0127
75.161............................................... 1219-0127
75.204(a)............................................ 1219-0121
75.215............................................... 1219-0004
75.220............................................... 1219-0004
75.221............................................... 1219-0004
75.222............................................... 1219-0004
75.223............................................... 1219-0004
75.310............................................... 1219-0088
75.312............................................... 1219-0088
75.335............................................... 1219-0142
75.336............................................... 1219-0142
75.337............................................... 1219-0142
75.338............................................... 1219-0142
75.342............................................... 1219-0088
75.350............................................... 1219-0138
75.351............................................... 1219-0088, -0116,
-0138
75.352............................................... 1219-0138
75.360............................................... 1219-0088
75.361............................................... 1219-0088
75.362............................................... 1219-0088
75.363............................................... 1219-0088
75.364............................................... 1219-0088
75.370............................................... 1219-0088
75.371............................................... 1219-0088, -0138
75.372............................................... 1219-0073
75.373............................................... 1219-0073
75.382............................................... 1219-0088
75.512............................................... 1219-0116
75.703............................................... 1219-0116
75.703-3............................................. 1219-0116
75.800............................................... 1219-0116
75.800-4............................................. 1219-0116
75.820............................................... 1210-0116
75.821............................................... 1219-0116
75.900............................................... 1219-0116
75.900-4............................................. 1219-0116
75.1001-1............................................ 1219-0116
75.1100-3............................................ 1219-0054
75.1103-8............................................ 1219-0054
75.1103-11........................................... 1219-0054
75.1200.............................................. 1219-0073
75.1200-1............................................ 1219-0073
75.1201.............................................. 1219-0073
75.1202.............................................. 1219-0073
75.1202-1............................................ 1219-0073
75.1203.............................................. 1219-0073
75.1204.............................................. 1219-0073
75.1204-1............................................ 1219-0073
75.1321.............................................. 1219-0025
75.1327.............................................. 1219-0025
75.1400-2............................................ 1219-0034
75.1400-4............................................ 1219-0034
75.1432.............................................. 1219-0034
75.1433.............................................. 1219-0034
75.1501.............................................. 1219-0054
75.1502.............................................. 1219-0054, -0141
75.1504.............................................. 1219-0141
75.1505.............................................. 1219-0141
75.1702.............................................. 1219-0041
75.1712-4............................................ 1219-0024
75.1712-5............................................ 1219-0024
75.1713-1............................................ 1219-0078
75.1714-3............................................ 1219-0141
75.1714-3(e)......................................... 1219-0044
75.1714-4............................................ 1219-0044
75.1714-5............................................ 1219-0141
75.1714-8............................................ 1219-0141
75.1716.............................................. 1219-0020
75.1716-1............................................ 1219-0020
75.1716-3............................................ 1219-0020
75.1721.............................................. 1219-0073
75.1901.............................................. 1219-0119
[[Page 10]]
75.1904.............................................. 1219-0119
75.1911.............................................. 1219-0119
75.1912.............................................. 1219-0119
75.1914.............................................. 1219-0119
75.1915.............................................. 1219-0119, -0124
77.100............................................... 1219-0127
77.103(a)(2)......................................... 1219-0001
77.105............................................... 1219-0127
77.106............................................... 1219-0127
77.107............................................... 1219-0127
77.107-1............................................. 1219-0127
77.215............................................... 1219-0015
77.215-2............................................. 1219-0015
77.215-3............................................. 1219-0015
77.215-4............................................. 1219-0015
77.216-2............................................. 1219-0015
77.216-3............................................. 1219-0015
77.216-4............................................. 1219-0015
77.216-5............................................. 1219-0015
77.502............................................... 1219-0116
77.800............................................... 1219-0116
77.800-2............................................. 1219-0116
77.900............................................... 1219-0116
77.900-2............................................. 1219-0116
77.1000.............................................. 1219-0026
77.1000-1............................................ 1219-0026
77.1101.............................................. 1219-0051
77.1200.............................................. 1219-0073
77.1201.............................................. 1219-0073
77.1202.............................................. 1219-0073
77.1404.............................................. 1219-0034
77.1432.............................................. 1219-0034
77.1433.............................................. 1219-0034
77.1702.............................................. 1219-0078
77.1713.............................................. 1219-0083
77.1900.............................................. 1219-0019
77.1901.............................................. 1219-0082
77.1906.............................................. 1219-0034
77.1909-1............................................ 1219-0025
90.201(c)............................................ 1219-0011
90.202(b)............................................ 1219-0011
90.204............................................... 1219-0011
90.209............................................... 1219-0011
90.220............................................... 1219-0011
90.300............................................... 1219-0011
90.301............................................... 1219-0011
90.301(d)............................................ 1219-0011
------------------------------------------------------------------------
[73 FR 36790, June 30, 2008]
[[Page 11]]
SUBCHAPTER B_TESTING, EVALUATION, AND APPROVAL OF MINING PRODUCTS
PART 5_FEES FOR TESTING, EVALUATION, AND APPROVAL OF MINING PRODUCTS-
-Table of Contents
Sec.
5.10 Purpose and scope.
5.30 Fee calculation.
5.40 Fee administration.
5.50 Fee revisions.
Authority: 30 U.S.C. 957.
Source: 80 FR 45056, July 29, 2015, unless otherwise noted.
Sec. 5.10 Purpose and scope.
This part establishes a system under which MSHA charges a fee for
services provided. This part includes the management and calculation of
fees for the approval program, which includes: Application processing,
testing and evaluation, approval decisions, post-approval activities,
and termination of approvals.
Sec. 5.30 Fee calculation.
(a) Fee calculation. MSHA charges a fee based on an hourly rate for
Approval and Certification Center (A&CC) approval program activities and
other associated costs, such as travel expenses and part 15 fees. Part
15 fees for services provided to MSHA by other organizations may be set
by those organizations.
(b) Hourly rate calculation. The hourly rate consists of direct and
indirect costs of the A&CC's approval program divided by the number of
direct hours worked on all approval program activities.
(1) Direct costs are compensation and benefit costs for hours worked
on approval program activities.
(2) Indirect costs are a proportionate share of the following A&CC
costs:
(i) Compensation and benefit hours worked in support of all A&CC
activities;
(ii) A&CC building and equipment depreciation costs;
(iii) A&CC utilities, facility and equipment maintenance, and
supplies and materials; and
(iv) Information Technology and other services the Department of
Labor provides to the A&CC.
(c) Fees are charged for--
(1) Application processing (e.g., administrative and technical
review of applications, computer tracking, and status reporting);
(2) Testing and evaluation (e.g., analysis of drawings, technical
evaluation, testing, test set up and test tear down, and internal
quality control activities);
(3) Approval decisions (e.g., consultation on applications, records
control and security, document preparation); and
(4) Two post-approval activities: changes to approvals and post-
approval product audits.
(d) Fees are not charged for--
(1) Technical assistance not related to processing an approval
application;
(2) Technical programs, including development of new technology
programs;
(3) Participation in research conducted by other government agencies
or private organizations; and
(4) Regulatory review activities, including participation in the
development of health and safety standards, regulations, and
legislation.
(e) Fee estimate. Except as provided in paragraphs (e)(1) and (2) of
this section, on completion of an initial administrative review of the
application, the A&CC will prepare a maximum fee estimate for each
application. A&CC will begin the technical evaluation after the
applicant authorizes the fee estimate.
(1) The applicant may pre-authorize an expenditure for services, and
may further choose to pre-authorize either a maximum dollar amount or an
expenditure without a specified maximum amount.
(i) All applications containing a pre-authorization statement will
be put in the queue for the technical evaluation on completion of an
initial administrative review.
[[Page 12]]
(ii) MSHA will concurrently prepare a maximum fee estimate for
applications containing a statement pre-authorizing a maximum dollar
amount, and will provide the applicant with this estimate.
(2) Where MSHA's estimated maximum fee exceeds the pre-authorized
maximum dollar amount, the applicant has the choice of cancelling the
action and paying for all work done up to the time of the cancellation,
or authorizing MSHA's estimate.
(3) Under the Revised Acceptance Modification Program (RAMP), MSHA
expedites applications for acceptance of minor changes to previously
approved, certified, accepted, or evaluated products. The applicant must
pre-authorize a fixed dollar amount, set by MSHA, for processing the
application.
(f) If unforeseen circumstances are discovered during the
evaluation, and MSHA determines that these circumstances would result in
the actual costs exceeding either the pre-authorized expenditure or the
authorized maximum fee estimate, as appropriate, MSHA will prepare a
revised maximum fee estimate for completing the evaluation. The
applicant will have the option of either cancelling the action and
paying for services rendered or authorizing MSHA's revised estimate, in
which case MSHA will continue to test and evaluate the product.
(g) If the actual cost of processing the application is less than
MSHA's maximum fee estimate, MSHA will charge the actual cost.
Sec. 5.40 Fee administration.
Applicants and approval holders will be billed for all fees,
including actual travel expenses, if any, when approval program
activities are completed. Invoices will contain specific payment
instruction, including the address to mail payments and authorized
methods of payment.
Sec. 5.50 Fee revisions.
The hourly rate will remain in effect for at least one year and be
subject to revision at least once every three years.
PART 6_TESTING AND EVALUATION BY INDEPENDENT LABORATORIES AND NON-MSHA
PRODUCT SAFETY STANDARDS--Table of Contents
Sec.
6.1 Purpose and effective date.
6.2 Definitions.
6.10 Use of independent laboratories.
6.20 MSHA acceptance of equivalent non-MSHA product safety standards.
6.30 MSHA listing of equivalent non-MSHA product safety standards.
Authority: 30 U.S.C. 957.
Source: 68 FR 36417, June 17, 2003, unless otherwise noted.
Sec. 6.1 Purpose and effective date.
This part sets out alternate requirements for testing and evaluation
of products MSHA approves for use in gassy underground mines. It permits
manufacturers of certain products who seek MSHA approval to use an
independent laboratory to perform, in whole or part, the necessary
testing and evaluation for approval. It also permits manufacturers to
have their products approved based on non-MSHA product safety standards
once MSHA has determined that the non-MSHA standards are equivalent to
MSHA's applicable product approval requirements or can be modified to
provide at least the same degree of protection as those MSHA
requirements. The provisions of this part may be used by applicants for
product approval under parts 18, 19, 20, 22, 23, 27, 33, 35, and 36.
This rule is effective August 18, 2003.
Sec. 6.2 Definitions.
The following definitions apply in this part.
Applicant. An individual or organization that manufactures or
controls the assembly of a product and applies to MSHA for approval of
that product.
Approval. A written document issued by MSHA which states that a
product has met the applicable requirements of part 18, 19, 20, 22, 23,
27, 33, 35, or 36. The definition is based on the existing definitions
of ``approval'' in the parts specified above. It is expanded to include
``certification'' and ``acceptance'' because these terms also are used
to denote MSHA approval.
[[Page 13]]
Approval holder. An applicant whose application for approval of a
product under part 18, 19, 20, 22, 23, 27, 33, 35 or 36 of this chapter
has been approved by MSHA.
Equivalent non-MSHA product safety standards. A non-MSHA product
safety standard, or group of standards, determined by MSHA to provide at
least the same degree of protection as the applicable MSHA product
approval requirements in parts 14, 18, 19, 20, 22, 23, 27, 33, 35, and
36, or which in modified form provide at least the same degree of
protection.
Independent laboratory. A laboratory that:
(1) has been recognized by a laboratory accrediting organization to
test and evaluate products to a product safety standard, and
(2) is free from commercial, financial, and other pressures that may
influence the results of the testing and evaluation process.
Post-approval product audit. The examination, testing, or both, by
MSHA of approved products selected by MSHA to determine whether those
products meet the applicable product approval requirements and have been
manufactured as approved.
Product safety standard. A document, or group of documents, that
specifies the requirements for the testing and evaluation of a product
for use in explosive gas and dust atmospheres, and, when appropriate,
includes documents addressing the flammability properties of products.
[68 FR 36417, June 17, 2003, as amended at 73 FR 80609, Dec. 31, 2008]
Sec. 6.10 Use of independent laboratories.
(a) MSHA will accept testing and evaluation performed by an
independent laboratory for purposes of MSHA product approval provided
that MSHA receives as part of the application:
(1) Written evidence of the laboratory's independence and current
recognition by a laboratory accrediting organization;
(2) Complete technical explanation of how the product complies with
each requirement in the applicable MSHA product approval requirements;
(3) Identification of components or features of the product that are
critical to the safety of the product; and
(4) All documentation, including drawings and specifications, as
submitted to the independent laboratory by the applicant and as required
by the applicable part under this chapter.
(b) Product testing and evaluation performed by independent
laboratories for purposes of MSHA approval must comply with the
applicable MSHA product approval requirements.
(c) Product testing and evaluation must be conducted or witnessed by
the laboratory's personnel.
(d) After review of the information required under paragraphs (a)(1)
through (a)(4) of this section, MSHA will notify the applicant if
additional information or testing is required. The applicant must
provide this information, arrange any additional or repeat tests and
notify MSHA of the location, date, and time of the test(s). MSHA may
observe any additional testing conducted by an independent laboratory.
Further, MSHA may decide to conduct the additional or repeated tests at
the applicant's expense. The applicant must supply any additional
components necessary for testing and evaluation.
(e) Upon request by MSHA, but not more than once a year, except for
cause, approval holders of products approved based on independent
laboratory testing and evaluation must make such products available for
post-approval audit at a mutually agreeable site at no cost to MSHA.
(f) Once the product is approved, the approval holder must notify
MSHA of all product defects of which they become aware.
Sec. 6.20 MSHA acceptance of equivalent non-MSHA product safety
standards.
(a) MSHA will accept non-MSHA product safety standards, or groups of
standards, as equivalent after determining that they:
(1) Provide at least the same degree of protection as MSHA's product
approval requirements in parts 14, 18, 19, 20, 33, 35 and 36 of this
chapter; or
[[Page 14]]
(2) Can be modified to provide at least the same degree of
protection as those MSHA requirements.
(b) MSHA will publish its intent to review any non-MSHA product
safety standard for equivalency in the Federal Register for the purpose
of soliciting public input.
(c) A listing of all equivalency determinations will be published in
this part 6 and the applicable approval parts. The listing will state
whether MSHA accepts the non-MSHA product safety standards in their
original form, or whether MSHA will require modifications to demonstrate
equivalency. If modifications are required, they will be provided in the
listing. MSHA will notify the public of each equivalency determination
and will publish a summary of the basis for its determination. MSHA will
provide equivalency determination reports to the public upon request to
the Approval and Certification Center.
(d) After MSHA has determined that non-MSHA product safety standards
are equivalent and has notified the public of such determinations,
applicants may seek MSHA product approval based on such non-MSHA product
safety standards.
[68 FR 36417, June 17, 2003, as amended at 73 FR 80609, Dec. 31, 2008]
Sec. 6.30 MSHA listing of equivalent non-MSHA product safety standards.
MSHA evaluated the following non-MSHA product safety standards and
determined that they provide at least the same degree of protection as
current MSHA requirements with or without modifications as indicated:
(a) The International Electrotechnical Commission's (IEC) standards
for Electrical Apparatus for Explosive Gas Atmospheres, Part 0, General
Requirements (IEC 60079-0, Fourth Edition, 2004-01) and Part 1,
Electrical Apparatus for Explosive Gas Atmospheres, Flameproof
Enclosures ``d'' (IEC 60079-1, Fifth Edition, 2003-11) must be modified
in order to provide at least the same degree of protection as MSHA
explosion-proof enclosure requirements included in parts 7 and 18 of
this chapter. Refer to Sec. Sec. 7.10(c)(1) and 18.6(a)(3)(i) for a
list of the required modifications. The IEC standards may be inspected
at the U.S. Department of Labor, Mine Safety and Health Administration,
Electrical Safety Division, Approval and Certification Center, 765
Technology Drive, Triadelphia, WV 26059, and may be purchased from
International Electrical Commission, Central Office 3, rue de
Varemb[eacute], P.O. Box 131, CH-1211 GENEVA 20, Switzerland.
(b) [Reserved]
[71 FR 28583, May 17, 2006, as amended at 73 FR 52210, Sept. 9, 2008]
PART 7_TESTING BY APPLICANT OR THIRD PARTY--Table of Contents
Subpart A_General
Sec.
7.1 Purpose and scope.
7.2 Definitions.
7.3 Application procedures and requirements.
7.4 Product testing.
7.5 Issuance of approval.
7.6 Approval marking and distribution record.
7.7 Quality assurance.
7.8 Post-approval product audit.
7.9 Revocation.
7.10 MSHA acceptance of equivalent non--MSHA product safety standards.
Subpart B_Brattice Cloth and Ventilation Tubing
7.21 Purpose and effective date.
7.22 Definitions.
7.23 Application requirements.
7.24 Technical requirements.
7.25 Critical characteristics.
7.26 Flame test apparatus.
7.27 Test for flame resistance of brattice cloth.
7.28 Test for flame resistance of rigid ventilation tubing.
7.29 Approval marking.
7.30 Post-approval product audit.
7.31 New technology.
Subpart C_Battery Assemblies
7.41 Purpose and effective date.
7.42 Definitions.
7.43 Application requirements.
7.44 Technical requirements.
7.45 Critical characteristics.
7.46 Impact test.
7.47 Deflection temperature test.
7.48 Acid resistance test.
7.49 Approval marking.
7.50 Post-approval product audit.
7.51 Approval checklist.
[[Page 15]]
7.52 New technology.
Subpart D_Multiple-Shot Blasting Units
7.61 Purpose and effective date.
7.62 Definitions.
7.63 Application requirements.
7.64 Technical requirements.
7.65 Critical characteristics.
7.66 Output energy test.
7.67 Construction test.
7.68 Firing line terminals test.
7.69 Approval marking.
7.70 Post-approval product audit.
7.71 Approval checklist.
7.72 New technology.
Subpart E_Diesel Engines Intended for Use in Underground Coal Mines
7.81 Purpose and effective date.
7.82 Definitions.
7.83 Application requirements.
7.84 Technical requirements.
7.85 Critical characteristics.
7.86 Test equipment and specifications.
7.87 Test to determine the maximum fuel-air ratio.
7.88 Test to determine the gaseous ventilation rate.
7.89 Test to determine the particulate index.
7.90 Approval marking.
7.91 Post-approval product audit.
7.92 New technology.
Subpart F_Diesel Power Packages Intended for Use in Areas of Underground
Coal Mines Where Permissible Electric Equipment Is Required
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 J_Electric Motor Assemblies
7.301 Purpose and effective date.
7.302 Definitions.
7.303 Application requirements.
7.304 Technical requirements.
7.305 Critical characteristics.
7.306 Explosion tests.
7.307 Static pressure test.
7.308 Lockwasher equivalency test.
7.309 Approval marking.
7.310 Post-approval product audit.
7.311 Approval checklist.
Appendix I to Subpart J of Part 7
Subpart K_Electric Cables, Signaling Cables, and Cable Splice Kits
7.401 Purpose and effective date.
7.402 Definitions.
7.403 Application requirements.
7.404 Technical requirements.
7.405 Critical characteristics.
7.406 Flame test apparatus.
7.407 Test for flame resistance of electric cables and cable splices.
7.408 Test for flame resistance of signaling cables.
7.409 Approval markings.
7.410 Post-approval product audit.
7.411 New technology.
Subpart L_Refuge Alternatives
7.501 Purpose and scope.
7.502 Definitions.
7.503 Application requirements.
7.504 Refuge alternatives and components; general requirements.
7.505 Structural components.
7.506 Breathable air components.
7.507 Air-monitoring components.
7.508 Harmful gas removal components.
7.509 Approval markings.
7.510 New technology.
Authority: 30 U.S.C. 957.
Source: 53 FR 23500, June 22, 1988, unless otherwise noted.
Subpart A_General
Sec. 7.1 Purpose and scope.
This part sets out requirements for MSHA approval of certain
equipment and materials for use in underground mines whose product
testing and evaluation does not involve subjective analysis. These
requirements apply to products listed in the subparts following this
Subpart A. After the dates specified in the following subparts, requests
for approval of products shall be made in accordance with this Subpart A
and the applicable subpart.
Sec. 7.2 Definitions.
The following definitions apply in this part.
Applicant. An individual or organization that manufactures or
controls the assembly of a product and that applies to MSHA for approval
of that product.
[[Page 16]]
Approval. A document issued by MSHA which states that a product has
met the requirements of this part and which authorizes an approval
marking identifying the product as approved.
Authorized company official. An individual designated by applicant
who has the authority to bind the company.
Critical characteristic. A feature of a product that, if not
manufactured as approved, could have a direct adverse effect on safety
and for which testing or inspection is required prior to shipment to
ensure conformity with the technical requirements under which the
approval was issued.
Equivalent non-MSHA product safety standards. A non-MSHA product
safety standard, or group of standards, that is determined by MSHA to
provide at least the same degree of protection as the applicable MSHA
product technical requirements in the subparts of this part, or can be
modified to provide at least the same degree of protection as those MSHA
requirements.
Extension of approval. A document issued by MSHA which states that
the change to a product previously approved by MSHA under this part
meets the requirements of this part and which authorizes the continued
use of the approval marking after the appropriate extension number has
been added.
Post-approval product audit. Examination, testing, or both, by MSHA
of approved products selected by MSHA to determine whether those
products meet the applicable technical requirements and have been
manufactured as approved.
Technical requirements. The design and performance requirements for
a product, as specified in a subpart of this part.
Test procedures. The methods specified in a subpart of this part
used to determine whether a product meet the performance portion of the
technical requirements.
[53 FR 23500, June 22, 1988; 53 FR 25569, July 7, 1988, as amended at 68
FR 36418, June 17, 2003]
Sec. 7.3 Application procedures and requirements.
(a) Application. Requests for an approval or extension of approval
shall be sent to: U.S. Department of Labor, Mine Safety and Health
Administration, Approval and Certification Center, 765 Technology Drive,
Triadelphia, WV 26059.
(b) Fees. Fees calculated in accordance with part 5 of this title
shall be submitted in accordance with Sec. 5.40.
(c) Original approval. Each application for approval of a product
shall include--
(1) A brief description of the product;
(2) The documentation specified in the appropriate subpart of this
part;
(3) The name, address, and telephone number of the applicant's
representative responsible for answering any questions regarding the
application;
(4) If appropriate, a statement indicating whether, in the
applicant's opinion, testing is required. If testing is not proposed,
the applicant shall explain the reasons for not testing; and
(5) If appropriate, the place and date for product testing.
(d) Subsequent approval of a similar product. Each application for a
product similar to one for which the applicant already holds an approval
shall include--
(1) The approval number for the product which most closely resembles
the new one;
(2) The information specified in paragraph (c) of this section for
the new product, except that any document which is the same as one
listed by MSHA in prior approvals need not be submitted, but shall be
noted in the application;
(3) An explanation of any change from the existing approval; and
(4) A statement as to whether, in the applicant's opinion, the
change requires product testing. If testing is not proposed, the
applicant shall explain the reasons for not testing.
(e) Extension of an approval. Any change in the approved product
from the documentation on file at MSHA that affects the technical
requirements of this part shall be submitted to MSHA for approval prior
to implementing the change. Each application for an extension of
approval shall include--
(1) The MSHA-assigned approval number for the product for which the
extension is sought;
[[Page 17]]
(2) A brief description of the proposed change to the previously
approved product;
(3) Drawings and specifications which show the change in detail;
(4) A statement as to whether, in the applicant's opinion, the
change requires product testing. If testing is not proposed, the
applicant shall explain the reasons for not testing;
(5) The place and date for product testing, if testing will be
conducted; and
(6) The name, address, and telephone number of the applicant's
representative responsible for answering any questions regarding the
application.
(f) Certification statement. (1) Each application for original
approval, subsequent approval, or extension of approval of a product
shall include a certification by the applicant that the product meets
the design portion of the technical requirements, as specified in the
appropriate subpart, and that the applicant will perform the quality
assurance functions specified in Sec. 7.7. For a subsequent approval or
extension of approval, the applicant shall also certify that the
proposed change cited in the application is the only change that affects
the technical requirements.
(2) After completion of the required product testing, the applicant
shall certify that the product has been tested and meets the performance
portion of the technical requirements, as specified in the appropriate
subpart.
(3) All certification statements shall be signed by an authorized
company official.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33722, June 29, 1995;
73 FR 52210, Sept. 9, 2008]
Sec. 7.4 Product testing.
(a) All products submitted for approval under this part shall be
tested using the test procedures specified in the appropriate subpart
unless MSHA determines, upon review of the documentation submitted, that
testing is not required. Applicants shall maintain records of test
results and procedures for three years.
(b) Unless otherwise specified in the subpart, test instruments
shall be calibrated at least as frequently as, and according to, the
instrument manufacturer's specifications, using calibration standards
traceable to those set by the National Bureau of Standards, U.S.
Department of Commerce or other nationally recognized standards and
accurate to at least one significant figure beyond the desired accuracy.
(c) When MSHA elects to observe product testing, the applicant shall
permit an MSHA official to be present at a mutually agreeable date,
time, and place.
(d) MSHA will accept product testing conducted outside the United
States where such acceptance is specifically required by international
agreement.
[53 FR 23500, June 22, 1988; 53 FR 25569, July 7, 1988; 60 FR 33722,
June 29, 1995]
Sec. 7.5 Issuance of approval.
(a) An applicant shall not advertise or otherwise represent a
product as approved until MSHA has issued the applicant an approval.
(b) MSHA will issue an approval or a notice of the reasons for
denying approval after reviewing the application, and the results of
product testing, when applicable. An approval will identify the
documents upon which the approval is based.
Sec. 7.6 Approval marking and distribution record.
(a) Each approved product shall have an approval marking, as
specified in the appropriate subpart of this part.
(b) For an extension of approval, the extension number shall be
added to the original approval number on the approval marking.
(c) Applicants shall maintain records of the initial sale of each
unit having an approval marking. The record retention period shall be at
least the expected shelf life and service life of the product.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33722, June 29, 1995]
Sec. 7.7 Quality assurance.
Applicants granted an approval or an extension of approval under
this part shall--
(a) Inspect or test, or both, the critical characteristics in
accordance with the appropriate subpart of this part;
[[Page 18]]
(b) Unless otherwise specified in the subparts, calibrate
instruments used for the inspection and testing of critical
characteristics at least as frequently as, and according to, the
instrument manufacturer's specifications, using calibration standards
traceable to those set by the National Bureau of Standards, U.S.
Department of Commerce or other nationally recognized standards and use
instruments accurate to at least one significant figure beyond the
desired accuracy.
(c) Control production documentation so that the product is
manufactured as approved;
(d) Immediately report to the MSHA Approval and Certification
Center, any knowledge of a product distributed with critical
characteristics not in accordance with the approval specifications.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33722, June 29, 1995]
Sec. 7.8 Post-approval product audit.
(a) Approved products shall be subject to periodic audits by MSHA
for the purpose of determining conformity with the technical
requirements upon which the approval was based. Any approved product
which is to be audited shall be selected by MSHA and be representative
of those distributed for use in mines. The approval-holder may obtain
any final report resulting from such audit.
(b) No more than once a year except for cause, the approval-holder,
at MSHA's request, shall make an approved product available at no cost
to MSHA for an audit to be conducted at a mutually agreeable site and
time. The approval-holder may observe any tests conducted during this
audit.
(c) An approved product shall be subject to audit for cause at any
time MSHA believes that it is not in compliance with the technical
requirements upon which the approval was based.
Sec. 7.9 Revocation.
(a) MSHA may revoke for cause an approval issued under this part if
the product:
(1) Fails to meet the applicable technical requirements; or
(2) Creates a hazard when used in a mine.
(b) Prior to revoking an approval, the approval-holder shall be
informed in writing of MSHA's intention to revoke approval. The notice
shall:
(1) Explain the specific reasons for the proposed revocation; and
(2) Provide the approval-holder an opportunity to demonstrate or
achieve compliance with the product approval requirements.
(c) Upon request, the approval-holder shall be afforded an
opportunity for a hearing.
(d) If a product poses an imminent hazard to the safety or health of
miners, the approval may be immediately suspended without a written
notice of the agency's intention to revoke. The suspension may continue
until the revocation proceedings are completed.
Sec. 7.10 MSHA acceptance of equivalent non-MSHA product safety standards.
(a) MSHA will accept non-MSHA product safety standards, or groups of
standards, as equivalent after determining that they:
(1) Provide at least the same degree of protection as MSHA's
applicable technical requirements for a product in the subparts of this
part; or
(2) Can be modified to provide at least the same degree of
protection as those MSHA requirements.
(b) MSHA will publish its intent to review any non-MSHA product
safety standard for equivalency in the Federal Register for the purpose
of soliciting public input.
(c) A listing of all equivalency determinations will be published in
this part 7. The listing will state whether MSHA accepts the non-MSHA
product safety standards in their original form, or whether MSHA will
require modifications to demonstrate equivalency. If modifications are
required, they will be provided in the listing. MSHA will notify the
public of each equivalency determination and will publish a summary of
the basis for its determination. MSHA will provide equivalency
determination reports to the public upon request to the Approval and
Certification Center. MSHA has made the following equivalency
determinations applicable to this part 7.
[[Page 19]]
(1) MSHA will accept applications for motors under Subpart J
designed and tested to the International Electrotechnical Commission's
(IEC) standards for Electrical Apparatus for Explosive Gas Atmospheres,
Part 0, General Requirements (IEC 60079-0, Fourth Edition, 2004-01) and
Part 1, Electrical Apparatus for Explosive Gas Atmospheres, Flameproof
Enclosures ``d'' (IEC 60079-1, Fifth Edition, 2003-11) (which are hereby
incorporated by reference and made a part hereof) provided the
modifications to the IEC standards specified in Sec. 7.10(c)(1)(i)
through (ix) are met. The Director of the Federal Register approves this
incorporation by reference in accordance with 5 U.S.C. 552(a) and 1 CFR
part 51. The IEC standards may be inspected at the U.S. Department of
Labor, Mine Safety and Health Administration, Electrical Safety
Division, Approval and Certification Center, 765 Technology Drive,
Triadelphia, WV 26059, or at the National Archives and Records
Administration (NARA). For information on the availability of this
material at NARA, call 202-741-6030, or go to: http://www.archives.gov/
federal_register/code_of_federal_regulations/ibr_locations.html. These
IEC standards may be obtained from International Electrical Commission,
Central Office 3, rue de Varemb[eacute], P.O. Box 131, CH-1211 GENEVA
20, Switzerland.
(i) Enclosures associated with an electric motor assembly shall be
made of metal and not have a compartment exceeding ten (10) feet in
length. External surfaces of enclosures shall not exceed 150 [deg]C (302
[deg]F) in normal operation.
(ii) Enclosures shall be rugged in construction and should meet
existing requirements for minimum bolt size and spacing and for minimum
wall, cover, and flange thicknesses specified in paragraph (g)(19) of
Sec. 7.304 Technical requirements. Enclosure fasteners should be
uniform in size and length, be provided at all corners, and be secured
from loosening by lockwashers or equivalent. An engineering analysis
shall be provided for enclosure designs that deviate from the existing
requirements. The analysis shall show that the proposed enclosure design
meets or exceeds the mechanical strength of a comparable enclosure
designed to 150 psig according to existing requirements, and that
flamepath clearances in excess of existing requirements will not be
produced at an internal pressure of 150 psig. This shall be verified by
explosion testing the enclosure at a minimum of 150 psig.
(iii) Enclosures shall be designed to withstand a minimum pressure
of at least 150 psig without leakage through any welds or castings,
rupture of any part that affects explosion-proof integrity, clearances
exceeding those permitted under existing requirements along flame-
arresting paths, or permanent distortion exceeding 0.040-inch per linear
foot.
(iv) Flamepath clearances, including clearances between fasteners
and the holes through which they pass, shall not exceed those specified
in existing requirements. No intentional gaps in flamepaths are
permitted.
(v) The minimum lengths of the flame arresting paths, based on
enclosure volume, shall conform to those specified in existing
requirements to the nearest metric equivalent value (e.g., 12.5 mm, 19
mm, and 25 mm are considered equivalent to \1/2\ inch, \3/4\ inch and 1
inch respectively for plane and cylindrical joints). The widths of any
grooves for o-rings shall be deducted in measuring the widths of flame-
arresting paths.
(vi) Gaskets shall not be used to form any part of a flame-arresting
path. If o-rings are installed within a flamepath, the location of the
o-rings shall meet existing requirements.
(vii) Cable entries into enclosures shall be of a type that utilizes
either flame-resistant rope packing material or sealing rings
(grommets). If plugs and mating receptacles are mounted to an enclosure
wall, they shall be of explosion-proof construction. Insulated bushings
or studs shall not be installed in the outside walls of enclosures. Lead
entrances utilizing sealing compounds and flexible or rigid metallic
conduit are not permitted.
(viii) Unused lead entrances shall be closed with a metal plug that
is secured by spot welding, brazing, or equivalent.
(ix) Special explosion tests are required for electric motor
assemblies that share leads (electric conductors)
[[Page 20]]
through a common wall with another explosion-proof enclosure, such as a
motor winding compartment and a conduit box. These tests are required to
determine the presence of any pressure piling conditions in either
enclosure when one or more of the insulating barriers, sectionalizing
terminals, or other isolating parts are sequentially removed from the
common wall between the enclosures. Enclosures that exhibit pressures
during these tests that exceed those specified in existing requirements
must be provided with a warning tag. The durable warning tag must
indicate that the insulating barriers, sectionalizing terminals, or
other isolating parts be maintained in order to insure the explosion-
proof integrity for either enclosure sharing a common wall. A warning
tag is not required if the enclosures withstand a static pressure of
twice the maximum value observed in the explosion tests.
(2) [Reserved]
(d) After MSHA has determined that non-MSHA product safety standards
are equivalent and has notified the public of such determinations,
applicants may seek MSHA product approval based on such non-MSHA product
safety standards.
[68 FR 36418, June 17, 2003, as amended at 71 FR 28583, May 17, 2006; 73
FR 52210, Sept. 9, 2008]
Subpart B_Brattice Cloth and Ventilation Tubing
Sec. 7.21 Purpose and effective date.
This subpart establishes the specific requirements for approval of
brattice cloth and ventilation tubing. It is effective August 22, 1988.
Applications for approval or extension of approval submitted after
August 22, 1989, shall meet the requirements of this part.
Sec. 7.22 Definitions.
The following definitions apply in this subpart:
Brattice cloth. A curtain of jute, plastic, or similar material used
to control or direct ventilating air.
Denier. A unit of yarn size indicating the fineness of fiber of
material based on the number of grams in a length of 9,000 meters.
Film. A sheet of flexible material applied to a scrim by pressure,
temperature, adhesion, or other method.
Scrim. A substrate material of plastic or fabric laminated between
or coated with a film.
Ventilation tubing. Rigid or flexible tubing used to convey
ventilating air.
Sec. 7.23 Application requirements.
(a) Brattice cloth. A single application may address two or more
products if the products differ only in: weight of the finished product;
weight or weave of the same fabric or scrim; or thickness or layers of
the same film. Applications shall include the following information:
(1) Trade name.
(2) Product designations (for example, style and code number).
(3) Color.
(4) Type of brattice (for example, plastic or jute).
(5) Weight of finished product.
(6) Film: type, weight, thickness, supplier, supplier's stock number
or designation, and percent of finished product by weight.
(7) Scrim: Type, denier, weight, weave, the supplier, supplier's
stock number or designation, and percent of finished product by weight.
(8) Adhesive: type, supplier, supplier's stock number or
designation, and percent of finished product by weight.
(b) Flexible ventilation tubing. Applications shall include the
product description information in paragraph (a) of this section and
list the type of supporting structure, if applicable; inside diameters;
and configurations.
(c) Rigid ventilation tubing. A single application may address two
or more products if the products differ only in diameters, lengths,
configuration, or average wall thickness. Applications shall include the
following information:
(1) Trade name.
(2) Product designations (for example, style and code numbers).
(3) Color.
(4) Type of ventilation tubing (for example, fiberglass, plastic, or
polyethylene).
(5) Inside diameter, configuration, and average wall thickness.
[[Page 21]]
(6) Suspension system (for example, metal hooks).
(7) Base material: type, supplier, the supplier's stock number, and
percent of finished product by weight.
(8) Resin: type, supplier, the supplier's stock number, and percent
of finished product by weight.
(9) Flame retardant, if added during manufacturing: type, supplier,
the supplier's stock number, and percent of finished product by weight.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33722, June 29, 1995]
Sec. 7.24 Technical requirements.
(a) Brattice cloth shall be flame resistant when tested in
accordance with the flame resistance test in Sec. 7.27.
(b) Flexible ventilation tubing shall be manufactured using an MSHA-
approved brattice cloth. If a supporting structure is used, it shall be
metal or other noncombustible material which will not ignite, burn,
support combustion or release flammable vapors when subjected to fire or
heat.
(c) Rigid ventilation tubing shall be flame resistant when tested in
accordance with the flame resistance test in Sec. 7.28.
Sec. 7.25 Critical characteristics.
A sample of each batch or lot of brattice cloth and ventilation
tubing shall be flame tested or a sample of each batch or lot of the
materials that contribute to the flame-resistance characteristic shall
be inspected or tested to ensure that the finished product will meet the
flame-resistance test.
Sec. 7.26 Flame test apparatus.
The principal parts of the apparatus used to test for flame-
resistance of brattice cloth and ventilation tubing shall be constructed
as follows:
(a) A 16-gauge stainless steel gallery lined on the top, bottom and
both sides with \1/2\ inch thick Marinite or equivalent insulating
material yielding inside dimensions approximately 58 inches long, 41
inches high, and 30 inches wide;
(b) Two \3/8\-inch diameter steel J hooks and a \9/16\-inch diameter
steel rod to support the sample located approximately 2\3/16\-inches
from the front and back ends of the test gallery, 1\1/2\-inches from the
ceiling insulation and centrally located in the gallery along its
length. Samples shall be suspended to preclude folds or wrinkles;
(c) A tapered 16-gauge stainless steel duct section tapering from a
cross sectional area measuring 2 feet 7 inches wide by 3 feet 6 inches
high at the test gallery to a cross-sectional area 1 foot 6 inches
square over a length of 3 feet. The tapered duct section must be tightly
connected to the test gallery;
(d) A 16-gauge stainless steel fan housing, consisting of a 1 foot 6
inches square section 6 inches long followed by a 10 inch long section
which tapers from 1 foot 16 inches square to 12 inches diameter round
and concluding with a 12 inch diameter round collar 3 inches long. A
variable speed fan capable of producing an air velocity of 125 ft./min.
in the test gallery must be secured in the fan housing. The fan housing
must be tightly connected to the tapered duct section;
(e) A methane-fueled impinged jet burner igniting source, measuring
12 inches long from the threaded ends of the first and last jets and 4
inches wide with 12 impinged jets, approximately 1\3/8\-inches long and
spaced alternately along the length of the burner tube. The burner jets
must be canted so that they point toward each other in pairs and the
flame from these pairs impinge upon each other.
Sec. 7.27 Test for flame resistance of brattice cloth.
(a) Test procedures. (1) Prepare 6 samples of brattice cloth 40
inches wide by 48 inches long.
(2) Prior to testing, condition each sample for a minimum of 24
hours at a temperature of 70 10 [deg]F (21 5.5 [deg]C) and a relative humidity of 55 10%.
(3) For each test, suspend the sample in the gallery by wrapping the
brattice cloth around the rod and clamping each end and the center. The
brattice cloth must hang 4 inches from the gallery floor.
(4) Use a front exhaust system to remove smoke escaping from the
gallery. The exhaust system must remain on during all testing, but not
affect the air flow in the gallery.
(5) Set the methane-fueled impinged jet burner to yield a flame
height of 12
[[Page 22]]
inches as measured at the outermost tip of the flame.
(6) Apply the burner to the front lower edge of the brattice cloth
and keep it in contact with the material for 25 seconds or until 1 foot
of material, measured horizontally, is consumed, whichever occurs first.
If the material shrinks during application of the burner flame, move the
burner flame to maintain contact with 1 foot of the material. If melting
material might clog the burner orifices, rotate the burner slightly
during application of the flame.
(7) Test 3 samples in still air and 3 samples with an average of 125
ft./min. of air flowing past the sample.
(8) Record the propagation length and duration of burning for each
of the 6 samples. The duration of burning is the total burning time of
the specimen during the flame test. This includes the burn time of any
material that falls on the floor of the test gallery during the igniting
period. However, the suspended specimen is considered burning only after
the burner is removed. Should the burning time of a suspended specimen
and a specimen on the floor coincide, count the coinciding burning time
only once.
(9) Calculate the average duration of burning for the first 3
samples (still air) and the second 3 samples (125 ft./min. air flow).
(b) Acceptable performance. The brattice cloth shall meet each of
the following criteria:
(1) Flame propagation of less than 4 feet in each of the six tests.
(2) An average duration of burning of less than 1 minute in both
groups of three tests.
(3) A duration of burning not exceeding two minutes in each of the
six tests.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33723, June 29, 1995]
Sec. 7.28 Test for flame resistance of rigid ventilation tubing.
(a) Test procedures. (1) Prepare 6 samples of ventilation tubing 48
inches in length with all flared or thickened ends removed. Any sample
with a cross-sectional dimension greater than 24 inches must be tested
in a 24-inch size.
(2) For each test, suspend the sample in the center of the gallery
by running a wire through the 48-inch length of tubing.
(3) Use a front exhaust system to remove smoke escaping from the
gallery. The exhaust system must remain on during all testing but not
affect the air flow in the gallery.
(4) Set the methane-fueled impinged jet burner to yield a flame
height of 12 inches as measured at the outermost tip of the flame.
(5) Apply the burner to the front lower edge of the tubing so that
two-thirds of the burner is under the tubing and the remaining third is
exposed to allow the flames to curl onto the inside of the tubing. Keep
the burner in contact with the material for 60 seconds. If melting
material might clog the burner orifices, rotate the burner slightly
during application of the flame.
(6) Test 3 samples in still air and 3 samples with an average of 125
ft./min. of air flowing past the sample.
(7) Record the propagation length and duration of burning for each
of the 6 samples. The duration of burn is the total burning time of the
specimen during the flame test. This includes the burning time of any
material that falls on the floor of the test gallery during the igniting
period. However, the suspended specimen is considered burning only after
the burner is removed. Should the burning time of a suspended specimen
and a specimen on the floor coincide, count the coinciding burn time
only once.
(8) Calculate the average duration of burning for the first 3
samples (still air) and the second 3 samples (125 ft./min. air flow).
(b) Acceptable performance. The ventilation tubing shall meet each
of the following criteria:
(1) Flame propagation of less than 4 feet in each of the 6 tests.
(2) An average duration of burning of less than 1 minute in both
groups of 3 tests.
(3) A duration of burning not exceeding 2 minutes in each of the 6
tests.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33723, June 29, 1995]
[[Page 23]]
Sec. 7.29 Approval marking.
(a) Approved brattice cloth shall be legibly and permanently marked
with the assigned MSHA approval number at intervals not exceeding ten
feet. If the nature of the material or method of processing makes such
marking impractical, permanent paint or ink may be used to mark the edge
with an MSHA-assigned color code.
(b) Approved ventilation tubing shall be legibly and permanently
marked on each section with the assigned MSHA approval number.
(c) An approved product shall be marketed only under a brand or
trade name that has been furnished to MSHA.
Sec. 7.30 Post-approval product audit.
Upon request by MSHA but no more than once a year except for cause,
the approval-holder shall supply to MSHA at no cost up to fifty feet of
each approved design of brattice cloth and ventilation tubing for audit.
Sec. 7.31 New technology.
MSHA may approve brattice cloth and ventilation tubing that
incorporates technology for which the requirements of this subpart are
not applicable, if the Agency determines that the product is as safe as
those which meet the requirements of this subpart.
Subpart C_Battery Assemblies
Sec. 7.41 Purpose and effective date.
This subpart establishes the specific requirements for MSHA approval
of battery assemblies intended for incorporation in approved equipment
in underground mines. It is effective August 22, 1988. Applications for
approval or extensions of approval submitted after August 22, 1989,
shall meet the requirements of this part.
Sec. 7.42 Definitions.
The following definitions apply in this subpart:
Battery assembly. A unit or units consisting of cells and their
electrical connections, assembled in a battery box or boxes with covers.
Battery box. The exterior sides, bottom, and connector receptacle
compartment, if any, of a battery assembly, excluding internal
partitions.
Sec. 7.43 Application requirements.
(a) An application for approval of a battery assembly shall contain
sufficient information to document compliance with the technical
requirements of this subpart and include a composite drawing with the
following information:
(1) Overall dimensions of the battery assembly, including the
minimum distance from the underside of the cover to the top of the
terminals and caps.
(2) Composition and thicknesses of the battery box and cover.
(3) Provision for securing covers.
(4) Documentation of flame-resistance of insulating materials and
cables.
(5) Number, type, and rating of the battery cells.
(6) Diagram of battery connections between cells and between battery
boxes, except when connections between battery boxes are a part of the
machine's electrical system.
(7) Total weight of the battery, charged and ready for service.
(8) Documentation of materials and configurations for battery cells,
intercell connectors, filler caps, and battery top:
(i) If nonmetallic cover designs are used with cover support blocks;
or
(ii) If the cover comes into contact with any portion of the cells,
caps, filler material, battery top, or intercell connectors during the
impact test specified by Sec. 7.46.
(b) All drawings shall be titled, dated, numbered, and include the
latest revision number.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33723, June 29, 1995]
Sec. 7.44 Technical requirements.
(a)(1) Battery boxes and covers constructed of AISI 1010 hot rolled
steel shall have the following minimum thicknesses based on the total
weight of a unit of the battery assembly charged and ready for service:
------------------------------------------------------------------------
Weight of battery unit Minimum required thickness
------------------------------------------------------------------------
1,000 lbs. maximum........................ 10 gauge or \1/8\
nominal
1,001 to 2,000 lbs........................ 7 gauge or \3/16\
nominal
2,001 to 4,500 lbs........................ 3 gauge or \1/4\
nominal
[[Page 24]]
Over 4,500 lbs............................ 0 gauge or \5/16\
nominal
------------------------------------------------------------------------
(2) Battery boxes not constructed of AISI 1010 hot rolled steel
shall have at least the tensile strength and impact resistance of
battery boxes for the same weight class, as listed in paragraph (a)(1)
of this section.
(3) Battery box covers constructed of materials with less than the
tensile strength and impact resistance of AISI 1010 hot rolled steel or
constructed of nonmetallic materials shall meet the acceptable
performance criteria for the impact test in Sec. 7.46. Nonmetallic
covers shall be used only in the battery assembly configuration in which
they pass the impact test.
(4) Nonmetallic materials for boxes and covers shall--
(i) Be accepted by MSHA as flame-resistant material under part 18 of
this chapter; and
(ii) Meet the acceptable performance criteria for the deflection
temperature test in Sec. 7.47.
(b) All insulating material shall have a minimum resistance of 100
megohms at 500 volts d.c. and be accepted by MSHA as flame resistant
under part 18 of this chapter.
(c) Battery box and cover insulating material shall meet the
acceptable performance criteria for the acid resistance test in Sec.
7.48.
(d) Covers shall be lined with insulating material permanently
attached to the underside of the cover, unless the cover is constructed
of insulating material.
(e) Covers, including those used over connector receptacle housings,
shall be provided with a means of securing them in a closed position.
(f) Battery boxes shall be provided with vent openings to prevent
the accumulation of flammable or toxic gases or vapors within the
battery assembly. The size and location of openings shall prevent direct
access to cell terminals and other uninsulated current carrying parts.
The total minimum unobstructed cross-sectional area of the ventilation
openings shall be no less than the value determined by the following
formula:
[GRAPHIC] [TIFF OMITTED] TC15NO91.011
N = Number of cells in battery box.
R = Rated 6 hour battery capacity in ampere hours.
M = Total minimum ventilation area in square inches per battery box.
(g) Battery boxes shall have drainage holes to prevent accumulation
of water or electrolyte.
(h) Battery cells shall be insulated from the battery box walls,
partitions and bottom by insulating material, unless such part of the
battery box is constructed of insulating material. Battery box wall
insulating material shall extend to the top of the wall.
(i) Cell terminals shall be burned on, except that bolted connectors
using two or more bolts may be used on end terminals.
(j) Battery connections shall be designed so that total battery
potential is not available between adjacent cells.
(k) Cables within a battery box shall be accepted by MSHA as flame
resistant under part 18 of this chapter or approved under subpart K of
this part. The cables shall be protected against abrasion by insulation,
location, clamping, or other effective means.
(l) When the battery plug and receptacle are not located on or
within the battery box, strain on the battery terminals shall be
prevented by a strain-relief device on the cable. Insulating material
shall be placed between the strain-relief device and cable, unless the
device is constructed of insulating material.
(m) At least a \1/2\-inch air space shall be provided between the
underside of the battery cover and the top of the battery, including the
terminals and connectors.
[53 FR 23500, June 22, 1988, as amended at 57 FR 61220, Dec. 23, 1992]
Sec. 7.45 Critical characteristics
The following critical characteristics shall be inspected or tested
on each battery assembly to which an approval marking is affixed:
(a) Thickness of covers and boxes.
(b) Application and resistance of insulating material.
(c) Size and location of ventilation openings.
[[Page 25]]
(d) Method of cell terminations.
(e) Strain relief devices for cables leaving boxes.
(f) Type, location, and physical protection of cables.
Sec. 7.46 Impact test.
(a) Test procedures. (1) Prepare four covers for testing by
conditioning two covers at -13 [deg]F (-25 [deg]C) and two covers at 122
[deg]F (50 [deg]C) for a period of 48 hours.
(2) Mount the covers on a battery box of the same design with which
the covers are to be approved, including any support blocks, with the
battery cells completely assembled. If used, support blocks must contact
only the filler material or partitions between the individual cells. At
the test temperature range of 65 [deg]F-80 [deg]F (18.3 [deg]C-26.7
[deg]C), apply a dynamic force of 200 ft. lbs. to the following areas
using a hemispherical weight with a 6 maximum radius:
(i) The center of the two largest unsupported areas;
(ii) The areas above at least two support blocks, if used;
(iii) The areas above at least two intercell connectors, one cell,
and one filler cap; and
(iv) Areas on at least two corners. If the design consists of both
inside and outside corners, test one of each.
(3) Record the condition of the covers, supports, intercell
connectors, filler caps, cell covers, and filler material.
(b) Acceptable performance. Impact tests of any of the four covers
shall not result in any of the following:
(1) Bent intercell connectors.
(2) Cracked or broken filler caps, except plastic tabs which extend
from the body of the filler caps.
(3) Cracks in the cell cover, cells, or filler material.
(4) Cracked or bent supports.
(5) Cracked or splintered battery covers.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33723, June 29, 1995]
Sec. 7.47 Deflection temperature test.
(a) Test procedures. (1) Prepare two samples for testing that
measure 5 inches by \1/2\ inch, by the thickness of the material as it
will be used. Prior to testing, condition the samples at 73.4 3.6 [deg]F (23 2 [deg]C) and 50
5% relative humidity for at least 40 hours.
(2) Place a sample on supports which are 4 inches apart and immersed
in a heat transfer medium at a test temperature range of 65 [deg]F-80
[deg]F (18.3 [deg]C-26.7 [deg]C). The heat transfer medium must be a
liquid which will not chemically affect the sample. The testing
apparatus must be constructed so that expansion of any components during
heating of the medium does not result in deflection of the sample.
(3) Place a temperature measuring device with an accuracy of 1% into
the heat transfer medium within \1/8\ inch of, but not touching, the
sample.
(4) Apply a total load, in pounds, numerically equivalent to 11
times the thickness of the sample, in inches, to the sample midway
between the supports using a \1/8\ inch radius, rounded contact. The
total load includes that weight used to apply the load and any force
exerted by the deflection measurement device.
(5) Use a deflection measuring device with an accuracy of .001 inches to measure the deflection of the sample at
the point of loading as the temperature of the medium is increased at a
uniform rate of 3.6 .36 [deg]F/min. (2 0.2 [deg]C/min.). Apply the load to the sample for 5
minutes prior to heating, to allow compensation for creep in the sample
due to the loading.
(6) Record the deflection of the sample due to heating at 180 [deg]F
(82 [deg]C).
(7) Repeat steps 2 through 6 for the other sample.
(b) Acceptable performance. Neither sample shall have a deflection
greater than .010 inch at 180 [deg]F (82 [deg]C).
[53 FR 23500, June 22, 1988; 53 FR 25569, July 7, 1988; 60 FR 33723,
June 29, 1995]
Sec. 7.48 Acid resistance test.
(a) Test procedures. (1) Prepare one sample each of the insulated
surfaces of the battery box and of the cover that measure at least 4
inches by 8 inches, by the thickness of the sample which includes the
insulation plus the battery cover or box material. The insulation
thickness shall be representative of that used on the battery box and
cover. If the insulation material and thickness of material are
identical for
[[Page 26]]
the battery box and cover, only one sample need be prepared and tested.
(2) Prepare a 30 percent solution of sulfuric acid (H2
SO4) by mixing 853 ml of water with 199 ml of sulfuric acid
(H2 SO4) with a specific gravity of 1.84.
Completely cover the samples with the acid solution at the test
temperature range of 65 [deg]F-80 [deg]F (18.3 [deg]C-26.7 [deg]C) and
maintain these conditions for 7 days.
(3) After 7 days, record the condition of the samples.
(b) Acceptable performance. At the end of the test, the insulation
shall not exhibit any blistering, discoloration, cracking, swelling,
tackiness, rubberiness, or loss of bond.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33723, June 29, 1995]
Sec. 7.49 Approval marking.
Each approved battery assembly shall be identified by a legible and
permanent approval plate inscribed with the assigned MSHA approval
number and securely attached to the battery box.
Sec. 7.50 Post-approval product audit.
Upon request by MSHA, but no more than once a year except for cause,
the approval-holder shall make an approved battery assembly available
for audit at no cost to MSHA.
Sec. 7.51 Approval checklist.
Each battery assembly bearing an MSHA approval plate shall be
accompanied by a description of what is necessary to maintain the
battery assembly as approved.
[53 FR 23500, June 22, 1988, as amended at 60 FR 33723, June 29, 1995]
Sec. 7.52 New technology.
MSHA may approve a battery assembly that incorporates technology for
which the requirements of this subpart are not applicable, if the Agency
determines that the battery assembly is as safe as those which meet the
requirements of this subpart.
Subpart D_Multiple-Shot Blasting Units
Source: 54 FR 48210, Nov. 21, 1989, unless otherwise noted.
Sec. 7.61 Purpose and effective date.
This subpart establishes the specific requirements for MSHA approval
of multiple-shot blasting units. It is effective January 22, 1990.
Applications for approval or extensions of approval submitted after
January 22, 1991 shall meet the requirements of this subpart.
Sec. 7.62 Definitions.
The following definitions apply in this subpart:
Blasting circuit. A circuit that includes one or more electric
detonators connected in a single series and the firing cable used to
connect the detonators to the blasting unit.
Blasting unit. An electric device used to initiate electric
detonators.
Normal operation. Operation of the unit according to the
manufacturer's instructions with fully-charged batteries, with electric
components at any value within their specified tolerances, and with
adjustable electric components set to any value within their range.
Sec. 7.63 Application requirements.
(a) Each application for approval of a blasting unit shall include
the following:
(1) An overall assembly drawing showing the physical construction of
the blasting unit.
(2) A schematic diagram of the electric circuit.
(3) A parts list specifying each electric component and its
electrical ratings, including tolerances.
(4) A layout drawing showing the location of each component and
wiring.
(5) The model number or other manufacturer's designation of the
blasting unit.
(b) All drawings shall be titled, numbered, dated, and include the
latest revision number. The drawings may be combined into one or more
composite drawings.
[[Page 27]]
(c) The application shall contain a list of all the drawings
submitted, including drawing titles, numbers, and revisions.
(d) A detailed technical description of the operation and use of the
blasting unit shall be submitted with the application.
[54 FR 48210, Nov. 21, 1989, as amended at 60 FR 33723, June 29, 1995]
Sec. 7.64 Technical requirements.
(a) Energy output. Blasting units shall meet the acceptable
performance criteria of the output energy test in Sec. 7.66.
(b) Maximum blasting circuit resistance. The maximum value of the
resistance of the blasting circuit that can be connected to the firing
line terminals of the blasting unit, without exceeding its capacity,
shall be specified by the applicant. The specified maximum blasting
circuit resistance shall be at least 150 ohms.
(c) Visual indicator. The blasting unit shall provide a visual
indication to the user prior to the operation of the firing switch when
the voltage necessary to produce the required firing current is
attained.
(d) Firing switch. The switch used to initiate the application of
energy to the blasting circuit shall--
(1) Require deliberate action for its operation to prevent
accidental firing; and
(2) Operate only when the voltage necessary to produce the required
firing current is available to the blasting circuit.
(e) Firing line terminals. The terminals used to connect the
blasting circuit to the blasting unit shall--
(1) Provide a secure, low-resistance connection to the blasting
circuit as demonstrated by the firing line terminals test in Sec. 7.68;
(2) Be corrosion-resistant;
(3) Be insulated to protect the user from electrical shock; and
(4) Be separated from each other by an insulated barrier.
(f) Ratings of electric components. No electric component of the
blasting unit, other than batteries, shall be operated at more than 90
percent of any of its electrical ratings in the normal operation of the
blasting unit.
(g) Non-incendive electric contacts. In the normal operation of a
blasting unit, the electric energy discharged by making and breaking
electric contacts shall not be capable of igniting a methane-air
atmosphere, as determined by the following:
(1) The electric current through an electric contact shall not be
greater than that determined from Figure D-1.
(2) The maximum voltage that can be applied across an electric
contact that discharges a capacitor shall not be greater than that
determined from Figure D-2.
(3) The electric current through an electric contact that interrupts
a circuit containing inductive components shall not be greater than that
determined from Figure D-3. Inductive components include inductors,
chokes, relay coils, motors, transformers, and similar electric
components that have an inductance greater than 100 microhenries. No
inductive component in a circuit with making and breaking electric
contacts shall have an inductance value greater than 100 millihenries.
[[Page 28]]
[GRAPHIC] [TIFF OMITTED] TC22OC91.001
[[Page 29]]
[GRAPHIC] [TIFF OMITTED] TC22OC91.002
[[Page 30]]
[GRAPHIC] [TIFF OMITTED] TC22OC91.003
(h) Maximum temperature. In the normal operation of the blasting
unit, the maximum temperature of any electric component shall not exceed
302 [deg]F (150 [deg]C).
(i) Capacitor discharge. The blasting unit shall include an
automatic means
[[Page 31]]
to dissipate any electric charge remaining in any capacitor after the
blasting unit is deenergized and not in use.
(j) Construction. Blasting units shall meet the acceptable
performance criteria of the construction test of Sec. 7.67.
(k) Locking device. The blasting unit shall be equipped with a
locking device to prevent unauthorized use.
(l) Enclosure. The blasting unit enclosure shall be protected
against tampering by--
(1) Sealing the enclosure, except the battery compartment, using
continuous welding, brazing, soldering, or equivalent methods; or
(2) Sealing the electric components, other than batteries, in a
solidified insulating material and assembling the enclosure with tamper-
resistant hardware.
(m) Battery charging. Blasting units that contain rechargeable
batteries shall have the following:
(1) A blocking diode, or equivalent device, in series with the
battery to prevent electric energy in the battery from being available
at the charging connector.
(2) The charging connector recessed into the enclosure.
Sec. 7.65 Critical characteristics.
The following critical characteristics shall be inspected or tested
on each blasting unit to which an approval marking is affixed:
(a) The output current.
(b) The voltage cut-off time.
(c) The components that control voltage and current through each
making and breaking electric contact.
(d) Operation of the visual indicator and the firing switch.
Sec. 7.66 Output energy test.
(a) Test procedures. The blasting unit shall be tested by firing
into each of the following resistive loads, within a tolerance of 1%:
(1) The maximum blasting circuit resistance.
(2) Any resistive load between 3 ohms and the maximum blasting
circuit resistance.
(3) One ohm.
(b) Acceptable performance. (1) The voltage shall be zero at the
firing line terminals 10 milliseconds after operation of the firing
switch.
(2) The electric current from the blasting unit shall be:
(i) Less than 50 milliamperes except during firing of the blasting
unit.
(ii) Available only through the firing line terminals.
(iii) At least an average of 2 amperes during the first 5
milliseconds following operation of the firing switch.
(iv) Not exceed an average of 100 amperes during the first 10
milliseconds following operation of the firing switch.
Sec. 7.67 Construction test.
The construction test is to be performed on the blasting unit
subsequent to the output energy test of Sec. 7.66.
(a) Test procedures. (1) The blasting unit shall be dropped 20 times
from a height of 3 feet onto a horizontal concrete floor. When dropped,
the orientation of the blasting unit shall be varied each time in an
attempt to have a different surface, corner, or edge strike the floor
first for each drop.
(2) After the blasting unit has been drop tested in accordance with
paragraph (a)(1) above, it shall be submerged in 1 foot of water for 1
hour in each of 3 tests. The water temperature shall be maintained
within 5 [deg]F (2.8 [deg]C)
of 40 [deg]F (4.4 [deg]C), 70 [deg]F (21.1 [deg]C) and 100 [deg]F (37.8
[deg]C) during the tests.
(3) Immediately after removing the blasting unit from the water at
each temperature, the unit shall be operated first with the firing line
terminals open circuited, then operated again with the firing line
terminals short circuited, and last, the output energy tested in
accordance with the output energy test of Sec. 7.66.
(b) Acceptable performance. (1) The blasting unit shall meet the
acceptable performance criteria of the output energy test in Sec. 7.66
each time it is performed.
(2) There shall be no damage to the firing line terminals that
exposes an electric conductor.
(3) The visual indicator shall be operational.
(4) The batteries shall not be separated from the blasting unit.
[[Page 32]]
(5) There shall be no water inside the blasting unit enclosure,
except for the battery compartment.
Sec. 7.68 Firing line terminals test.
(a) Test procedures. (1) The contact resistance through each firing
line terminal shall be determined.
(2) A 10-pound pull shall be applied to a No. 18 gauge wire that has
been connected to each firing line terminal according to the
manufacturer's instructions.
(b) Acceptable performance. (1) The contact resistance shall not be
greater than 1 ohm.
(2) The No. 18 gauge wire shall not become disconnected from either
firing line terminal.
Sec. 7.69 Approval marking.
Each approved blasting unit shall be identified as permissible by a
legible and permanent marking securely attached, stamped, or molded to
the outside of the unit. This marking shall include the following:
(a) The assigned MSHA approval number.
(b) The maximum blasting circuit resistance.
(c) A warning that the unit's components must not be disassembled or
removed.
(d) The replacement battery types if the unit has replaceable
batteries.
(e) A warning placed next to the charging connector that the battery
only be charged in a fresh air location if rechargeable batteries are
used.
(f) A warning that the unit is compatible only with detonators that
will--
(1) Fire when an average of 1.5 amperes is applied for 5
milliseconds;
(2) Not misfire when up to an average 100 amperes is applied for 10
milliseconds; and
(3) Not fire when a current of 250 milliamperes or less is applied.
Sec. 7.70 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 blasting unit
available for audit at no cost to MSHA.
Sec. 7.71 Approval checklist.
Each blasting unit bearing an MSHA approval marking shall be
accompanied by a description of what is necessary to maintain the
blasting unit as approved.
[54 FR 48210, Nov. 21, 1989, as amended at 60 FR 33723, June 29, 1995]
Sec. 7.72 New technology.
MSHA may approve a blasting unit that incorporates technology for
which the requirements of this subpart are not applicable if the Agency
determines that the blasting unit is as safe as those which meet the
requirements of this subpart.
Subpart E_Diesel Engines Intended for Use in Underground Coal Mines
Source: 61 FR 55504, Oct. 25, 1996, unless otherwise noted.
Sec. 7.81 Purpose and effective date.
Subpart A general provisions of this part apply to this subpart E.
Subpart E establishes the specific engine performance and exhaust
emission requirements for MSHA approval of diesel engines for use in
areas of underground coal mines where permissible electric equipment is
required and areas where non-permissible electric equipment is allowed.
It is effective November 25, 1996.
Sec. 7.82 Definitions.
In addition to subpart A definitions of this part, the following
definitions apply in this subpart.
Brake Power. The observed power measured at the crankshaft or its
equivalent when the engine is equipped only with standard auxiliaries
necessary for its operation on the test bed.
Category A engines. Diesel engines intended for use in areas of
underground coal mines where permissible electric equipment is required.
Category B engines. Diesel engines intended for use in areas of
underground coal mines where nonpermissible electric equipment is
allowed.
[[Page 33]]
Corrosion-resistant material. Material that has at least the
corrosion-resistant properties of type 304 stainless steel.
Diesel engine. Any compression ignition internal combustion engine
using the basic diesel cycle where combustion results from the spraying
of fuel into air heated by compression.
Exhaust emission. Any substance emitted to the atmosphere from the
exhaust port of the combustion chamber of a diesel engine.
Intermediate speed. Maximum torque speed if it occurs between 60
percent and 75 percent of rated speed. If the maximum torque speed is
less than 60 percent of rated speed, then the intermediate speed shall
be 60 percent of the rated speed. If the maximum torque speed is greater
than 75 percent of the rated speed, then the intermediate speed shall be
75 percent of rated speed.
Low idle speed. The minimum no load speed as specified by the engine
manufacturer.
Maximum torque speed. The speed at which an engine develops maximum
torque.
Operational range. All speed and load (including percent loads)
combinations from the rated speed to the minimum permitted engine speed
at full load as specified by the engine manufacturer.
Particulates. Any material collected on a specified filter medium
after diluting exhaust gases with clean, filtered air at a temperature
of less than or equal to 125 [deg]F (52 [deg]C), as measured at a point
immediately upstream of the primary filter. This is primarily carbon,
condensed hydrocarbons, sulfates, and associated water.
Percent load. The fraction of the maximum available torque at an
engine speed.
Rated horsepower. The nominal brake power output of a diesel engine
as specified by the engine manufacturer with a specified production
tolerance. For laboratory test purposes, the fuel pump calibration for
the rated horsepower must be set between the nominal and the maximum
fuel tolerance specification.
Rated speed. Speed at which the rated power is delivered, as
specified by the engine manufacturer.
Steady-state condition. Diesel engine operating condition which is
at a constant speed and load and at stabilized temperatures and
pressures.
Total oxides of nitrogen. The sum total of the measured parts per
millions (ppm) of nitric oxide (NO) plus the measured ppm of nitrogen
dioxide (NO2).
Sec. 7.83 Application requirements.
(a) An application for approval of a diesel engine shall contain
sufficient information to document compliance with the technical
requirements of this subpart and specify whether the application is for
a category A engine or category B engine.
(b) The application shall include the following engine
specifications--
(1) Model number;
(2) Number of cylinders, cylinder bore diameter, piston stroke,
engine displacement;
(3) Maximum recommended air inlet restriction and exhaust
backpressure;
(4) Rated speed(s), rated horsepower(s) at rated speed(s), maximum
torque speed, maximum rated torque, high idle, minimum permitted engine
speed at full load, low idle;
(5) Fuel consumption at rated horsepower(s) and at the maximum rated
torque;
(6) Fuel injection timing; and
(7) Performance specifications of turbocharger, if applicable.
(c) The application shall include dimensional drawings (including
tolerances) of the following components specifying all details affecting
the technical requirements of this subpart. Composite drawings
specifying the required construction details may be submitted instead of
individual drawings of the following components--
(1) Cylinder head;
(2) Piston;
(3) Inlet valve;
(4) Exhaust valve;
(5) Cam shaft--profile;
(6) Fuel cam shaft, if applicable;
(7) Injector body;
(8) Injector nozzle;
(9) Injection fuel pump;
(10) Governor;
(11) Turbocharger, if applicable;
(12) Aftercooler, if applicable;
(13) Valve guide;
[[Page 34]]
(14) Cylinder head gasket; and
(15) Precombustion chamber, if applicable.
(d) The application shall include a drawing showing the general
arrangement of the engine.
(e) All drawings shall be titled, dated, numbered, and include the
latest revision number.
(f) When all necessary testing has been completed, the following
information shall be submitted:
(1) The gaseous ventilation rate for the rated speed and horsepower.
(2) The particulate index for the rated speed and horsepower.
(3) A fuel deration chart for altitudes for each rated speed and
horsepower.
Sec. 7.84 Technical requirements.
(a) Fuel injection adjustment. The fuel injection system of the
engine shall be constructed so that the quantity of fuel injected can be
controlled at a desired maximum value. This adjustment shall be
changeable only after breaking a seal or by altering the design.
(b) Maximum fuel-air ratio. At the maximum fuel-air ratio determined
by Sec. 7.87 of this part, the concentrations (by volume, dry basis) of
carbon monoxide (CO) and oxides of nitrogen (NOX) in the
undiluted exhaust gas shall not exceed the following:
(1) There shall be no more than 0.30 percent CO and no more than
0.20 percent NOX for category A engines.
(2) There shall be no more than 0.25 percent CO and no more than
0.20 percent NOX for category B engines.
(c) Gaseous emissions ventilation rate. Ventilation rates necessary
to dilute gaseous exhaust emissions to the following values shall be
determined under Sec. 7.88 of this part:
Carbon dioxide......................... -5000 ppm
Carbon monoxide........................ -50 ppm
Nitric oxide........................... -25 ppm
Nitrogen dioxide....................... -5 ppm
A gaseous ventilation rate shall be determined for each requested speed
and horsepower rating as described in Sec. 7.88(b) of this part.
(d) Fuel deration. The fuel rates specified in the fuel deration
chart shall be based on the tests conducted under paragraphs (b) and (c)
of this section and shall ensure that the maximum fuel:air (f/a) ratio
determined under paragraph (b) of this section is not exceeded at the
altitudes specified in the fuel deration chart.
(e) Particulate index. For each rated speed and horsepower
requested, the particulate index necessary to dilute the exhaust
particulate emissions to 1 mg/m\3\ shall be determined under Sec. 7.89
of this part.
Sec. 7.85 Critical characteristics.
The following critical characteristics shall be inspected or tested
on each diesel engine to which an approval marking is affixed--
(a) Fuel rate is set properly; and
(b) Fuel injection pump adjustment is sealed, if applicable.
Sec. 7.86 Test equipment and specifications.
(a) Dynamometer test cell shall be used in determining the maximum
f/a ratio, gaseous ventilation rates, and the particulate index.
(1) The following testing devices shall be provided:
(i) An apparatus for measuring torque that provides an accuracy of
2.0 percent based on the engine's maximum value;
(ii) An apparatus for measuring revolutions per minute (rpm) that
provides an accuracy of 2.0 percent based on the
engine's maximum value;
(iii) An apparatus for measuring temperature that provides an
accuracy of 4 [deg]F (2 [deg]C) of the absolute
value except for the exhaust gas temperature device that provides an
accuracy of 27 [deg]F (15 [deg]C);
(iv) An apparatus for measuring intake and exhaust restriction
pressures that provides an accuracy of 5 percent
of maximum;
(v) An apparatus for measuring atmospheric pressure that provides an
accuracy of 0.5 percent of reading;
(vi) An apparatus for measuring fuel flow that provides an accuracy
of 2 percent based on the engine's maximum value;
(vii) An apparatus for measuring the inlet air flow rate of the
diesel engine that provides an accuracy of 2
percent based on the engine's maximum value; and
(viii) For testing category A engines, an apparatus for metering in
1.0 0.1
[[Page 35]]
percent, by volume, of methane (CH4) into the intake air
system shall be provided.
(2) The test fuel specified in Table E-1 shall be a low volatile
hydrocarbon fuel commercially designated as ``Type 2-D'' grade diesel
fuel. The fuel may contain nonmetallic additives as follows: Cetane
improver, metal deactivator, antioxidant, dehazer, antirust, pour
depressant, dye, dispersant, and biocide.
Table E-1--Diesel Test Fuel Specifications
------------------------------------------------------------------------
Item ASTM Type 2-D
------------------------------------------------------------------------
Cetane number.......................... D613 40-48
Cetane index........................... D976 40-48
Distillation range:
IBP [deg]F......................... D86 340-400
([deg]C)....................... .............. (171.1-204.4)
10 pct. point, [deg]F.............. D86 400-460
([deg]C)....................... .............. (204.4-237.8)
50 pct. point, [deg]F.............. D86 470.540
([deg]C)....................... .............. (243.3-282.2)
90 pct. point, [deg]F.............. D86 560-630
([deg]C)....................... .............. (293.3-332.2)
EP, [deg]F......................... D86 610-690
([deg]C)....................... .............. (321.1-365.6)
Gravity,[deg]API....................... D287 32-37
Total sulfur, pct...................... D2622 0.03-0.05
Hydrocarbon composition:
Aromatics, pct..................... D1319 27 minimum
Paraffins, naphthenes, olefins..... D1319 Remainder
Flashpoint, minimum, [deg]F............ 93 130
([deg]C)........................... .............. (54.4)
Viscosity, centistokes................. 445 2.0-3.2
------------------------------------------------------------------------
(3) The test fuel temperature at the inlet to the diesel engine's
fuel injection pump shall be controlled to the engine manufacturer's
specification.
(4) The engine coolant temperature (if applicable) shall be
maintained at normal operating temperatures as specified by the engine
manufacturer.
(5) The charge air temperature and cooler pressure drop (if
applicable) shall be set to within 7 [deg]F(4
[deg]C) and 0.59 inches Hg (2kPa) respectively, of
the manufacturer's specification.
(b) Gaseous emission sampling system shall be used in determining
the gaseous ventilation rates.
(1) The schematic of the gaseous sampling system shown in Figure E-1
shall be used for testing category A engines. Various configurations of
Figure E-1 may produce equivalent results. The components in Figure E-1
are designated as follows--
(i) Filters--F1, F2, F3, and F4;
(ii) Flowmeters--FL1, FL2, FL3, FL4, FL5, FL6, and FL7;
(iii) Upstream Gauges--G1, G2, and G5;
(iv) Downstream Gauges--G3, G4, and G6;
(v) Pressure Gauges--P1, P2, P3, P4, P5, and P6;
(vi) Regulators--R1, R2, R3, R4, R5, R6, and R7;
(vii) Selector Valves--V1, V2, V3, V4, V6, V7, V8, V15, and V19;
(viii) Heated Selector Valves--V5, V13, V16, and V17;
(ix) Flow Control Valves--V9, V10, V11 and V12;
(x) Heated Flow Control Valves--V14 and V18;
(xi) Pump--Sample Transfer Pump;
(xii) Temperature Sensor--(T1);
(xiii) Dryer--D1 and D2; and
(xiv) Water traps--WT1 and WT2.
(A) Water removal from the sample shall be done by condensation.
(B) The sample gas temperature or dew point shall be monitored
either within the water trap or downstream of the water trap and shall
not exceed 45 [deg]F (7 [deg]C).
(C) Chemical dryers are not permitted.
[[Page 36]]
[GRAPHIC] [TIFF OMITTED] TR25OC96.000
(2) The schematic of the gaseous sampling system shown in Figure E-2
shall be used for testing category B engines. Various configurations of
Figure E-2 may produce equivalent results. The components are designated
as follows--
(i) Filters--F1, F2, F3, and F4;
[[Page 37]]
(ii) Flowmeters--FL1, FL2, FL3, and FL4;
(iii) Upstream Gauges--G1, and G2;
(iv) Downstream Gauges--G3, and G4;
(v) Pressure Gauges--P1, P2, P3, and P4;
(vi) Regulators--R1, R2, R3, and R4;
(vii) Selector Valves--V1, V2, V3, V4, V6, and V7;
(viii) Heated Selector Valves--V5, V8, and V12;
(ix) Flow Control Valves--V9, V10, V11;
(x) Heated Flow Control Valves--V13;
(xi) Pump--Sample Transfer Pump;
(xii) Temperature Sensor--(T1); and
(xiii) Water traps--WT1 and WT2.
(A) Water removal from the sample shall be done by condensation.
(B) The sample gas temperature or dew point shall be monitored
either within the water trap or downstream of the water trap and shall
not exceed 45 [deg]F (7 [deg]C).
(C) Chemical dryers are not permitted.
(3) All components or parts of components that are in contact with
the sample gas or corrosive calibration gases shall be corrosion-
resistant material.
[[Page 38]]
[GRAPHIC] [TIFF OMITTED] TR25OC96.001
(4) All analyzers shall obtain the sample to be analyzed from the
same sample probe.
(5) CO and CO2 measurements shall be made on a dry basis.
[[Page 39]]
(6) Calibration or span gases for the NOX measurement
system shall pass through the NO2 to NO converter.
(7) A stainless steel sample probe shall be straight, closed-end,
multi-holed, and shall be placed inside the exhaust pipe.
(i) The probe length shall be at least 80 percent of the diameter of
the exhaust pipe.
(ii) The inside diameter of the sample probe shall not be greater
than the inside diameter of the sample line.
(iii) The heated sample line shall have a 0.197 inch (5 mm) minimum
and a 0.53 inch (13.5 mm) maximum inside diameter.
(iv) The wall thickness of the probe shall not be greater than 0.040
inch (1 mm).
(v) There shall be a minimum of 3 holes in 3 different radial planes
sized to sample approximately the same flow.
(8) The sample probe shall be located in the exhaust pipe at a
minimum distance of 1.6 feet (0.5 meters) or 3 times the diameter of the
exhaust pipe, whichever is the larger, from the exhaust manifold outlet
flange or the outlet of the turbocharger. The exhaust gas temperature at
the sample probe shall be a minimum of 158 [deg]F (70 [deg]C).
(9) The maximum allowable leakage rate on the vacuum side of the
analyzer pump shall be 0.5 percent of the in-use flow rate for the
portion of the system being checked.
(10) General analyzer specifications. (i) The total measurement
error, including the cross sensitivity to other gases, (paragraphs
(b)(11)(ii), (b)(12)(iii), (b)(13)(iii), and (b)(13)(iv) of this
section), shall not exceed 5 percent of the
reading or 3.5 percent of full scale, whichever is
smaller. For concentrations of less than 100 ppm the measurement error
shall not exceed 4 ppm.
(ii) The repeatability, defined as 2.5 times the standard deviation
of 10 repetitive responses to a given calibration or span gas, must be
no greater than 1 percent of full scale
concentration for each range used above 155 parts per million (ppm) or
parts per million equivalent carbon (ppmC) or 2
percent of each range used below 155 ppm (or ppmC).
(iii) The analyzer peak to peak response to zero and calibration or
span gases over any 10 second period shall not exceed 2 percent of full
scale on all ranges used.
(iv) The analyzer zero drift during a 1-hour period shall be less
than 2 percent of full scale on the lowest range used. The zero-response
is the mean response, including noise, to a zero gas during a 30-second
time interval.
(v) The analyzer span drift during a 1-hour period shall be less
than 2 percent of full scale on the lowest range used. The analyzer span
is defined as the difference between the span response and the zero
response. The span response is the mean response, including noise, to a
span gas during a 30-second time interval.
(11) CO and CO2 analyzer specifications. (i) Measurements
shall be made with nondispersive infrared (NDIR) analyzers.
(ii) For the CO analyzer, the water and CO2 interference
shall be less than 1 percent of full scale for ranges equal to or
greater than 300 ppm (3 ppm for ranges below 300 ppm) when a
CO2 span gas concentration of 80 percent to 100 percent of
full scale of the maximum operating range used during testing is bubbled
through water at room temperature.
(12) For NOX analysis using a chemiluminescence (CL)
analyzer the following parameters shall apply:
(i) From the sample point to the NO2 to NO converter, the
NOX sample shall be maintained between 131 [deg]F (55 [deg]C)
and 392 [deg]F (200 [deg]C).
(ii) The NO2 to NO converter efficiency shall be at least
90 percent.
(iii) The quench interference from CO2 and water vapor
must be less than 3.0 percent.
(13) For NOX analysis using an NDIR analyzer system the
following parameters shall apply:
(i) The system shall include a NO2 to NO converter, a
water trap, and a NDIR analyzer.
(ii) From the sample point to the NO2 to NO converter,
the NOX sample shall be maintained between 131 [deg]F (55
[deg]C) and 392 [deg]F (200 [deg]C).
(iii) The minimum water rejection ratio (maximum water interference)
[[Page 40]]
for the NOX NDIR analyzer shall be 5,000:1.
(iv) The minimum CO2 rejection ratio (maximum
CO2 interference) for the NOX NDIR analyzer shall
be 30,000:1.
(14) When CH4 is measured using a heated flame ionization
detector (HFID) the following shall apply:
(i) The analyzer shall be equipped with a constant temperature oven
that houses the detector and sample-handling components.
(ii) The detector, oven, and sample-handling components shall be
suitable for continuous operation at temperatures of 374 [deg]F (190
[deg]C) 18 [deg]F (10 [deg]C).
(iii) The analyzer fuel shall contain 40 2
percent hydrogen. The balance shall be helium. The mixture shall contain
<=1 part per million equivalent carbon (ppmC), and <=400 ppm CO.
(iv) The burner air shall contain <2 ppmC hydrocarbon.
(v) The percent of oxygen interference shall be less than 5 percent.
(15) An NDIR analyzer for measuring CH4 may be used in
place of the HFID specified in paragraph (b)(14) of this section and
shall conform to the requirements of paragraph (b)(10) of this section.
Methane measurements shall be made on a dry basis.
(16) Calibration gas values shall be traceable to the National
Institute for Standards and Testing (NIST), ``Standard Reference
Materials'' (SRM's). The analytical accuracy of the calibration gas
values shall be within 2.0 percent of NIST gas standards.
(17) Span gas values shall be traceable to NIST SRM's. The
analytical accuracy of the span gas values shall be within 2.0 percent
of NIST gas standards.
(18) Calibration or span gases for the CO and CO2
analyzers shall have purified nitrogen as a diluent. Calibration or span
gases for the CH4 analyzer shall be CH4 with
purified synthetic air or purified nitrogen as diluent.
(19) Calibration or span gases for the NOX analyzer shall
be NO with a maximum NO2 concentration of 5 percent of the NO
content. Purified nitrogen shall be the diluent.
(20) Zero-grade gases for the CO, CO2, CH4 ,
and NOX analyzers shall be either purified synthetic air or
purified nitrogen.
(21) The allowable zero-grade gas (purified synthetic air or
purified nitrogen) impurity concentrations shall not exceed <=1ppm C,
<=1 ppm CO, <=400 ppm CO2, and <=0.1 ppm NO.
(22) The calibration and span gases may also be obtained by means of
a gas divider. The accuracy of the mixing device must be such that the
concentration of the diluted calibration gases are within 2 percent.
(c) Particulate sampling system shall be used in determining the
particulate index. A schematic of a full flow (single dilution)
particulate sampling system for testing under this subpart is shown in
Figures E-3 and E-4.
(1) The dilution system shall meet the following parameters:
(i) Either a positive displacement pump (PDP) or a critical flow
venturi (CFV) shall be used as the pump/mass measurement device shown in
Figure E-3.
(ii) The total volume of the mixture of exhaust and dilution air
shall be measured.
(iii) All parts of the system from the exhaust pipe up to the filter
holder, which are in contact with raw and diluted exhaust gas, shall be
designed to minimize deposition or alteration of the particulate.
(iv) All parts shall be made of electrically conductive materials
that do not react with exhaust gas components.
(v) All parts shall be electrically grounded to prevent
electrostatic effects.
(vi) Systems other than full flow systems may also be used provided
they yield equivalent results where:
(A) A seven sample pair (or larger) correlation study between the
system under consideration and a full flow dilution system shall be run
concurrently.
(B) Correlation testing is to be performed at the same laboratory,
test cell, and on the same engine.
(C) The equivalency criterion is defined as a 5 percent agreement of the sample pair averages.
(2) The mass of particulate in the exhaust shall be collected by
filtration. The exhaust temperature immediately
[[Page 41]]
before the primary particulate filter shall not exceed 125 [deg]F (52.0
[deg]C).
(3) Exhaust system backpressure shall not be artificially lowered by
the PDP, CFV systems or dilution air inlet system. Static exhaust
backpressure measured with the PDP or CFV system operating shall remain
within 0.44 inches Hg (1.5 kPa) of the static
pressure measured without being connected to the PDP or CFV at identical
engine speed and load.
(4) The gas mixture temperature shall be measured at a point
immediately ahead of the pump or mass measurement device.
(i) Using PDP, the gas mixture temperature shall be maintained
within 10 [deg]F (6.0 [deg]C) of the average
operating temperature observed during the test, when no flow
compensation is used.
(ii) Flow compensation can be used provided that the temperature at
the inlet to the PDP does not exceed 122 [deg]F (50 [deg]C).
(iii) Using CFV, the gas mixture temperature shall be maintained
within 20 [deg]F (11 [deg]C) of the average
operating temperature observed during the test, when no flow
compensation is used.
(5) The heat exchanger shall be of sufficient capacity to maintain
the temperature within the limits required above and is optional if
electronic flow compensation is used.
(6) When the temperature at the inlet of either the PDP or CFV
exceeds the limits stated in either paragraphs (c)(4)(i) or (c)(4)(iii)
of this section, an electronic flow compensation system shall be
required for continuous measurement of the flow rate and control of the
proportional sampling in the particulate sampling system.
(7) The flow capacity of the system shall be large enough to
eliminate water condensation.
[[Page 42]]
[GRAPHIC] [TIFF OMITTED] TR25OC96.002
[[Page 43]]
[GRAPHIC] [TIFF OMITTED] TR25OC96.003
(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
[[Page 44]]
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
2 percent of reading.
(12) The dilution air shall have a temperature of 77 [deg]F 9 [deg]F (25 [deg]C 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 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
9 [deg]F (25 [deg]C 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 [micro]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
[[Page 45]]
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 5
[deg]F (22 [deg]C 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 5 [deg]F (9.5 [deg]C 3 [deg]C) and a relative humidity of 45 percent 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 5.0 percent (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 [micro]g and
resolution of 10 [micro]g. For filters less than 70 mm diameter, the
precision and resolution shall be 2 [micro]g and 1 [micro]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 NOX
analyzers to the lowest analyzer range that will be used during this
test.
(3) While running the engine, the following shall apply:
(i) The parameter for the laboratory atmospheric factor,
fa, shall be: 0.98<=fa<=1.02;
(A) The equation is fa = ( 99/Ps) *
((Ta + 273)/298)\0.7\ for a naturally aspirated and
mechanically supercharged engines; or
(B) The equation is fa = (99/Ps)\0.7\*
((Ta + 273)/298)\1.5\ for a turbocharged engine with or
without cooling of the intake air.
Where:
Ps = dry atmospheric pressure (kPa)
Ta = intake air temperature ([deg]C)
(ii) The air inlet restriction shall be set within 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
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 NOX as specified in paragraph (a)(6)of this section.
[[Page 46]]
(iv) The air inlet restriction shall be set within 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 NOX 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 0.1 percent
CH4 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 NOX, dry basis, in the
raw exhaust.
(b) Acceptable performance. The CO and NOX 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, CO2, NOX, and CH4 analyzers
shall be zeroed and spanned at the analyzer range to be used prior to
testing.
(4) Run the engine.
(i) The parameter for fa 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 Sec. Sec. 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 0.1 percent CH4, 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, CO2, NO,
and NO2, and CH4- exhaust (category A engines
only).
(i) Test speeds shall be maintained within 1
percent of rated speed or 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 2 percent of the maximum torque at the test speed.
(7) The concentration of CH4 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.
[[Page 47]]
(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\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
PCCH4--Percent CH4 (intake air)
UCH4--Unburned CH4
PCECH4--Percent Exhaust CH4
(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-PCCH4
Y = (PCAir)(0.289) + (PCCH4)(0.16)
Z = (0.16)(PCCH4) / Y
mCH4 = (A)(Z) / (1-Z)
(v) Exhaust gas flow calculation for category A engines shall be (m
Exh) = (A) + (m fuel) + (m CH4)
(vi) Unburned CH4 (lbs/hr) calculation for category A
engines shall be mUCH4 = (m Exh)(0.0052)(PCECH4)
(vii) Fuel/air ratio for category A engines shall be (f/a) = ((m
fuel) + (m CH4)-(m UCH4)) / (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)
(NO2 wet basis) = (NO2 dry basis)(J)
(CO2 wet basis) = (CO2 dry basis)(J)
(CO wet basis) = (CO dry basis)(10-4)(J)
Where:
J = (f/a)(-1.87) + (1 - (0.00022)(H))
(ix) NO and NO2 correction for humidity and temperature
for category A and category B engines shall be:
(NO corr) = (NO wet basis) / (E)
(NO2 corr) = (NO2 wet basis) / (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 NO2) = (NO2 corr)(0.000720)(m Exh)
(m CO2) = (CO2 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 NO2) = (m NO2)(K)
(cfm CO2) = (m CO2)(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.
[61 FR 55504, Oct. 25, 1996; 62 FR 34640, June 27, 1997]
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.
[[Page 48]]
(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 fa 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 Sec. Sec. 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 0.1 percent CH4, 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 Sec. Sec.
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 percent of rated speed or 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 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.
(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 (PF for the single filter
method; PF,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.
[[Page 49]]
(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)
Pf--Particulate sample mass collected on a filter (mg) at
each test mode as determined in Table E-3.
Kp--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 (Pf part), the equation shall be:
Pfcorr = (Pf)(Kp)
Kp = 1 / (1 + 0.0133 * (H - 10.71))
Where:
Ha = humidity of the intake air, g water per kg dry air
Ha = (6.220 * Ra * pa) /
(pB-pa - Ra *
10-2)
Ra = relative humidity of the intake air, %
pa = saturation vapor pressure of the intake air, kPa
pB = 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
[[Page 50]]
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,
WFE,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
0.005 (absolute value) of the weighting factors
listed in Table E-3.
(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.
[61 FR 55504, Oct. 25, 1996; 62 FR 34640, June 27, 1997]
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.
[[Page 51]]
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
Source: 61 FR 55518, Oct. 25, 1996, unless otherwise noted.
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:
[[Page 52]]
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, 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.
[[Page 53]]
(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
[[Page 54]]
engine oil pressure must be overridden to start the engine, the 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
[[Page 55]]
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\\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\\2\
different planes; cylinders or equivalent.
Maximum clearances; joint in two or more planes,
cylinders or equivalent:
Portion perpendicular to plane............... 0.008\3\
Plane portion................................ 0.006
Maximum fastening \4\ spacing; joints all in one 6
plane \5\.
Maximum fastening spacing; joints, portions of 8
which are in different planes.
Minimum diameter of fastening (without regard to \3/8\
type of joint) \6\.
Minimum thread engagement of fastening \7\....... \3/8\
Maximum diametrical clearance between fastening \1/16\
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.
[[Page 56]]
\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\ If 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
[[Page 57]]
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 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.
[61 FR 55518, Oct. 25, 1996, 62 FR 34640, 34641, June 27, 1997]
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.
[[Page 58]]
(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 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 1.8 percent, by volume,
and the oxygen 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 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
[[Page 59]]
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
200 RPM and twenty at 1000 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 200 RPM, and twenty dynamic tests at 1000 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 200 RPM, and twenty dynamic tests at 1000 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 200 RPM, and twenty dynamic tests at 1000 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 200 RPM, and twenty dynamic tests at 1000 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
[[Page 60]]
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.
[61 FR 55518, Oct. 25, 1996; 62 FR 34641, June 27, 1997]
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 4 [deg]F
(2 [deg]C).
(iii) Operate the engine at rated horsepower and with 0.5 0.1 percent, 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) 10 [deg]F (6 [deg]C) and the intake air
temperature shall be maintained at 70 [deg]F (21 [deg]C) 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 4 [deg]F (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
[[Page 61]]
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 4 [deg]F (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
[[Page 62]]
(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.
(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 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
[[Page 63]]
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.
Subpart J_Electric Motor Assemblies
Source: 57 FR 61193, Dec. 23, 1992, unless otherwise noted.
Sec. 7.301 Purpose and effective date.
This subpart establishes the specific requirements for MSHA approval
of certain explosion-proof electric motor assemblies intended for use in
approved equipment in underground mines. Applications for approval or
extensions of approval submitted after February 22, 1996 shall meet the
requirements of this part. Those motors that incorporate features not
specifically addressed in this subpart will continue to be evaluated
under part 18 of this chapter.
Sec. 7.302 Definitions.
The following definitions apply in this subpart:
Afterburning. The combustion of any flammable mixture that is drawn
into an enclosure after an internal explosion in the enclosure. This
condition is determined through detection of secondary pressure peaks
occurring subsequent to the initial explosion.
Cylindrical joint. A joint comprised of two contiguous, concentric,
cylindrical surfaces.
Explosion-proof enclosure. A metallic enclosure used as a winding
compartment, conduit box, or a combination of both that complies with
the applicable requirements of Sec. 7.304 of this part and is
constructed so that it will withstand the explosion tests of Sec. 7.306
of this part.
Fastening. A bolt, screw, or stud used to secure adjoining parts to
prevent the escape of flame from an explosion-proof enclosure.
Flame-arresting path. Two or more adjoining or adjacent surfaces
between which the escape of flame is prevented.
Internal free volume (of an empty enclosure). The volume remaining
after deducting the volume of any part that is essential in maintaining
the explosion-proof integrity of the enclosure or necessary for
operation of the motor. Essential parts include the parts that
constitute the flame-arresting path and those necessary to secure parts
that constitute a flame-arresting path.
Motor assembly. The winding compartment including a conduit box when
specified. A motor assembly is comprised of one or more explosion-proof
enclosures.
Plane joint. A joint comprised of two adjoining surfaces in parallel
planes.
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.
Stuffing box. An entrance with a recess filled with packing material
for cables extending through a wall of an explosion-proof enclosure.
Threaded joint. A joint consisting of a male- and a female-threaded
member, both of which are the same type and gauge.
Sec. 7.303 Application requirements.
(a) An application for approval of a motor assembly shall include a
composite drawing or drawings with the following information:
(1) Model (type), frame size, and rating of the motor assembly.
(2) Overall dimensions of the motor assembly, including conduit box
if applicable, and internal free volume.
(3) Material and quantity for each of the component parts that form
the explosion-proof enclosure or enclosures.
(4) All dimensions (including tolerances) and specifications
required to
[[Page 64]]
ascertain compliance with the requirements of Sec. 7.304 of this part.
(b) All drawings shall be titled, dated, numbered, and include the
latest revision.
Sec. 7.304 Technical requirements.
(a) Voltage rating of the motor shall not exceed 4160 volts.
(b) The temperature of the external surfaces of the motor assembly
shall not exceed 150 [deg]C (302 [deg]F) when operated at the
manufacturers' specified ratings.
(c) Minimum clearances between uninsulated electrical conductor
surfaces, or between uninsulated conductor surfaces and grounded metal
surfaces, within the enclosure shall meet the requirements of table J-1
of this section.
Table J-1--Minimum Clearances Between Uninsulated Surfaces
------------------------------------------------------------------------
Clearances (inches)
-----------------------
Phase-to-
Phase-to-phase voltage (rms) Phase-to- ground or
phase control
circuit
------------------------------------------------------------------------
0 to 250........................................ 0.25 0.25
251 to 600...................................... 0.28 0.25
601 to 1000..................................... 0.61 0.25
1001 to 2400.................................... 1.4 0.6
2401 to 4160.................................... 3.0 1.4
------------------------------------------------------------------------
(d) Parts whose dimensions can change with the motor operation, such
as ball and roller bearings and oil seals, shall not be used as flame-
arresting paths.
(e) The widths of any grooves, such as grooves for holding oil seals
or o-rings, shall be deducted in measuring the widths of flame-arresting
paths.
(f) An outer bearing cap shall not be considered as forming any part
of a flame-arresting path unless the cap is used as a bearing cartridge.
(g) Requirements for explosion-proof enclosures of motor assemblies.
(1) Enclosures shall be--
(i) Constructed of metal;
(ii) Designed to withstand a minimum internal pressure of 150 pounds
per square inch (gauge);
(iii) Free from blowholes when cast; and
(iv) Explosion proof as determined by the tests set out in Sec.
7.306 of this part.
(2) Welded joints forming an enclosure shall be--
(i) Continuous and gas-tight; and
(ii) Made in accordance with or exceed the American Welding Society
Standard AWS D14.4-77, ``Classification and Application of Welded Joints
for Machinery and Equipment,'' or meet the test requirements set out in
Sec. 7.307 of this part. AWS D14.4-77 is incorporated by reference and
has been approved by the Director of the Federal Register in accordance
with 5 U.S.C. 552(a) and 1 CFR part 51. Copies may be obtained from the
American Welding Society, Inc., 2501 NW 7th Street, Miami, FL 33125.
Copies may be inspected at the U.S. Department of Labor, Mine Safety and
Health Administration, Approval and Certification Center, 765 Technology
Drive, Triadelphia, WV 26059, or at the National Archives and Records
Administration (NARA). For information on the availability of this
material at NARA, call 202-741-6030, or go to: http://www.archives.gov/
federal_register/code_of_federal_regulations/ibr_locations.html.
(3) External rotating parts shall not be constructed of aluminum
alloys containing more than 0.6 percent magnesium. Non-metallic rotating
parts shall be provided with a means to prevent an accumulation of
static electricity.
(4) Threaded covers and mating parts shall be designed with Class 1A
and 1B (coarse, loose fitting) threads. The covers shall be secured
against loosening.
(5) Flat surfaces between fastening holes that form any part of a
flame-arresting path shall be plane to within a maximum deviation of
one-half the maximum clearance specified in paragraph (g)(19) of this
section. All 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.
(6) For a laminated stator frame, it shall be impossible to insert a
0.0015 inch thickness gauge to a depth exceeding \1/8\ inch between
adjacent laminations or between end rings and laminations.
[[Page 65]]
(7) Lockwashers, or equivalent, shall be provided for all
fastenings. Devices other than lockwashers shall meet the requirements
of Sec. 7.308 of this part. Equivalent devices shall only be used in
the configuration in which they were tested.
(8) Fastenings shall be as uniform in size as practicable to
preclude improper installation.
(9) Holes for fastenings in an explosion-proof enclosure shall be
threaded to ensure that all specified bolts or screws will not bottom
even if the washers are omitted.
(10) Holes for fastenings shall not penetrate to the interior of an
explosion-proof enclosure, except holes made through motor casings for
bolts, studs, or screws to hold essential parts, such as pole pieces,
brush rigging, and bearing cartridges. The attachments of such parts
shall be secured against loosening. The threaded holes in these parts
shall be blind unless the fastenings are inserted from the inside, in
which case the fastenings shall not be accessible with the rotor in
place.
(11) For direct current motor assemblies with narrow interpoles, the
distance from the edge of the pole piece to any bolt hole in the frame
shall be at least \1/8\ inch. If the distance is \1/8\ to \1/4\ inch,
the diametrical clearance for the pole bolt shall not exceed \1/64\ inch
for not less than \1/2\ inch through the frame. Furthermore, the pole
piece shall have the same radius as the inner surface of the frame. Pole
pieces may be shimmed as necessary. If used, the total resulting
thickness of the shims shall be specified. The shim assembly shall meet
the same requirements as the pole piece.
(12) Coil-thread inserts, if used in holes for fastenings, shall
meet the following:
(i) The inserts shall have internal screw threads.
(ii) The holes for the inserts shall be drilled and tapped
consistent with the insert manufacturer's specifications.
(iii) The inserts shall be installed consistent with the insert
manufacturer's specifications.
(iv) The insert shall be of sufficient length to ensure the minimum
thread engagement of fastening specified in paragraph (g)(19) of this
section.
(13) A minimum of \1/8\ inch of stock shall be left at the center of
the bottom of each blind hole that could penetrate into the interior of
an explosion-proof enclosure.
(14) Fastenings shall be used only for attaching parts that are
essential in maintaining the explosion-proof integrity of the enclosure,
or necessary for the operation of the motor. They shall not be used for
making electrical connections.
(15) Through holes not in use shall be closed with a metal plug.
Plugs, including eyebolts, in through holes where future access is
desired shall meet the flame-arresting paths, lengths, and clearances of
paragraph (g)(19) of this section and be secured by spot welding or
brazing. The spot weld or braze may be on a plug, clamp, or fastening
(for example see figure J-1). Plugs for holes where future access is not
desired shall be secured all around by a continuous gas-tight weld.
(16) O-rings, if used in a flame-arresting path, shall meet the
following:
(i) When the flame-arresting path is in one plane, the o-ring shall
be located at least one-half the acceptable flame-arresting path length
specified in paragraph (g)(19) of this section from within the outside
edge of the path (see figure J-2).
(ii) When the flame-arresting path is one of the plane-cylindrical
type (step joint), the o-ring shall be located at least \1/2\ inch from
within the outer edge of the plane portion (see figure J-3), or at the
junction of the plane and cylindrical portion of the joint (see figure
J-4), or in the cylindrical portion (see figure J-5).
(17) Mating parts comprising a pressed fit shall result in a minimum
interference of 0.001 inch between the parts. The minimum length of the
pressed fit shall be equal to the minimum thickness requirement of
paragraph (g)(19) of this section for the material in which the fit is
made.
(18) The flame-arresting path of threaded joints shall conform to
the requirements of paragraph (g)(19) of this section.
(19) Explosion-proof enclosures shall meet the requirements set out
in table
[[Page 66]]
J-2 of this section, based on the internal free volume of the empty
enclosure.
Table J-2--Explosion-Proof Requirements Based on Volume
----------------------------------------------------------------------------------------------------------------
Volume of empty enclosure
-----------------------------------------------
Less than 45 45 to 124 cu. More than 124
cu. ins. ins. inclusive cu. ins.
----------------------------------------------------------------------------------------------------------------
Minimum thickness of material for walls \1\..................... \1/8\ eq> eq>
Minimum thickness of material for flanges and covers............ \2\ \1/4\ thn-eq> thn-eq>
Minimum width of joint; all in one plane........................ \1/2\
eq> eq>
Maximum clearance; joint all in one plane....................... 0.002 thn-eq> thn-eq>
Maximum clearances; joint in two or more planes, cylinders or
equivalent: \5\
(a) Portion perpendicular to plane \6\...................... 0.008 eq> eq>
Minimum thread engagement of fastening \10\..................... \1/4\ eq> eq>
Maximum diametrical clearance between fastening body and \1/64\ eq> eq>
Minimum distance from interior of enclosure to the edge of a
fastening hole: \8 13\
Joint--minimum width 1........................... .............. .............. \14\ \7/16\
Joint--less than 1 wide.......................... \1/8\ eq>
----------------------------------------------------------------------------------------------------------------
Cylindrical Joints
----------------------------------------------------------------------------------------------------------------
Shaft centered by ball or roller bearings:
Minimum length of flame-arresting path........................ \1/2\
eq> eq>
Maximum diametrical clearance................................. 0.020
eq> eq>
Maximum diametrical clearance............................... 0.006 in diameter. The
length of the flame-arresting path shall not be reduced when a pushbutton is depressed. Operating rods shall
have a shoulder or head on the portion inside the enclosure. Essential parts riveted or bolted to the inside
portion are acceptable in lieu of a head or shoulder, but cotter pins and similar devices shall not be used.
\16\ 6 with a minimum of 4 fastenings.
\17\ 8 with a minimum of 4 fastenings.
(h) Lead entrances. (1) Each cable, which extends through an outside
wall of the motor assembly, shall pass through a stuffing-box lead
entrance (see figure J-7). All sharp edges shall be removed from
stuffing boxes, packing nuts, and other lead entrance (gland) parts, so
that the cable jacket is not damaged.
(2) When the packing is properly compressed, the gland nut shall
have--
(i) A clearance distance of \1/8\ inch or more, with no maximum, to
travel without interference by parts other than packing; and
(ii) A minimum of three effective threads engaged (see figures J-8,
J-9, and J-10).
(3) Packing nuts (see figure J-7) and stuffing boxes shall be
secured against loosening (see figure J-11).
(4) Compressed packing material shall be in contact with the cable
jacket for a length of not less than \1/2\ inch.
(5) Requirements for lead entrances in which MSHA accepted rope
packing material is specified, are:
(i) Rope packing material shall be acceptable under Sec. 18.37(e)
of this chapter.
(ii) The width of the space for packing material shall not exceed by
more than 50 percent the diameter or width of the uncompressed packing
material (see figure J-12).
(iii) The maximum diametrical clearance, using the specified
tolerances, between the cable and the through holes in the gland parts
adjacent to the packing (stuffing box, packing nut, hose tube, or
bushings) shall not exceed 75 percent of the nominal diameter or width
of the packing material (see figure J-13).
(6) Requirements for lead entrances in which grommet packing made of
compressible material is specified, are:
(i) The grommet packing material shall be accepted by MSHA as flame-
resistant material under Sec. 18.37(f)(1) of this chapter.
(ii) The diametrical clearance between the cable jacket and the
nominal inside diameter of the grommet shall not exceed \1/16\ inch,
based on the nominal specified diameter of the cable (see figure J-14).
(iii) The diametrical clearance between the nominal outside diameter
of the grommet and the inside wall of the stuffing box shall not exceed
\1/16\ inch (see figure J-14).
(i) Combustible gases from insulating material. (1) Insulating
materials that give off flammable or explosive gases when decomposed
electrically shall not be used within explosion-proof enclosures where
the materials are subjected to destructive electrical action.
(2) Parts coated or impregnated with insulating materials shall be
treated to remove any combustible solvent before assembly in an
explosion-proof enclosure.
[57 FR 61193, Dec. 23, 1992, as amended at 73 FR 52210, Sept. 9, 2008]
Sec. 7.305 Critical characteristics.
The following critical characteristics shall be inspected on each
motor assembly to which an approval marking is affixed:
(a) Finish, width, and planarity of surfaces that form any part of a
flame-arresting path.
(b) Clearances between mating parts that form flame-arresting paths.
(c) Thickness of walls, flanges, and covers that are essential in
maintaining the explosion-proof integrity of the enclosure.
(d) Spacing of fastenings.
(e) Length of thread engagement on fastenings and threaded parts
that assure the explosion-proof integrity of the enclosure.
(f) Use of lockwasher or equivalent with all fastenings.
(g) Dimensions which affect compliance with the requirements for
packing gland parts in Sec. 7.304 of this part.
Sec. 7.306 Explosion tests.
(a) The following shall be used for conducting an explosion test:
(1) An explosion test chamber designed and constructed to contain an
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explosive gas mixture to surround and fill the motor assembly being
tested. 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 explosive mixture
surrounding the motor assembly.
(2) A methane gas supply with at least 98 by volume per centum of
combustible hydrocarbons, with the remainder being inert. At least 80
percent by volume of the gas shall be methane.
(3) Coal dust having a minimum of 22 percent dry volatile matter and
a minimum heat constant of 11,000 moist BTU (coal containing natural bed
moisture but not visible surface water) ground to a fineness of minus
200 mesh U.S. Standard sieve series.
(4) An electric spark ignition source with a minimum of 100
millijoules of energy.
(5) A pressure recording system that will indicate the pressure
peaks resulting from the ignition and combustion of explosive gas
mixtures within the enclosure being tested.
(b) General test procedures. (1) Motor assemblies being tested
shall--
(i) Be equipped with unshielded bearings regardless of the type of
bearings specified; and
(ii) Have all parts that do not contribute to the operation or
assure the explosion-proof integrity of the enclosure, such as oil
seals, grease fittings, hose conduit, cable clamps, and outer bearing
caps (which do not house the bearings) removed from the motor assembly.
(2) Each motor assembly shall be placed in the explosion test
chamber and tested as follows:
(i) The motor assembly shall be filled with and surrounded by an
explosive mixture of the natural gas supply and air. The chamber gas
concentrations shall be between 6.0 by volume per centum and the motor
assembly natural gas concentration just before ignition of each test.
Each externally visible flame-arresting path fit shall be observed for
discharge of flames for at least two of the tests, including one with
coal dust added.
(ii) A single spark source is used for all testing. Pressure shall
be measured at each end of the winding compartment simultaneously during
all tests. Quantity and location of test holes shall permit ignition on
each end of the winding compartment and recording of pressure on the
same and opposite ends as the ignition.
(iii) Motor assemblies incorporating a conduit box shall have the
pressure in the conduit box recorded simultaneously with the other
measured pressures during all tests. Quantity and location of test holes
in the conduit box shall permit ignition and recording of pressure as
required in paragraphs (c)(1) and (c)(4)(i) of this section.
(iv) The motor assembly shall be completely purged and recharged
with a fresh explosive gas mixture from the chamber or by injection
after each test. The chamber shall be completely purged and recharged
with a fresh explosive gas mixture as necessary. The oxygen level of the
chamber gas mixture shall be no less than 18 percent by volume for
testing. In the absence of oxygen monitoring equipment, the maximum
number of tests conducted before purging shall be less than or equal to
the chamber volume divided by forty times the volume occupied by the
motor assembly.
(c) Test procedures. (1) Eight tests at 9.4 0.4 percent methane by volume within the winding
compartment shall be conducted, with the rotor stationary during four
tests and rotating at rated speed (rpm) during four tests. The ignition
shall be at one end of the winding compartment for two stationary and
two rotating tests, and then switched to the opposite end for the
remaining four tests. If a nonisolated conduit box is used, then two
additional tests, one stationary and one rotating, shall be conducted
with ignition in the conduit box at a point furthest away from the
opening between the conduit box and the winding compartment.
(2) Four tests at 7.0 0.3 percent methane by
volume within the winding compartment shall be conducted with the rotor
stationary, 2 ignitions at each end.
(3) Four tests at 9.4 0.4 percent methane by
volume plus coal dust shall be conducted. A quantity of coal dust
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equal to 0.05 ounces per cubic foot of internal free volume of the
winding compartment plus the nonisolated conduit box shall be introduced
into each end of the winding compartment and nonisolated conduit box to
coat the interior surface before conducting the first of the four tests.
The coal dust introduced into the conduit box shall be proportional to
its volume. The remaining coal dust shall be equally divided between the
winding compartment ends. For two tests, one stationary and one
rotating, the ignition shall be either in the conduit box or one end of
the connected winding compartment, whichever produced the highest
pressure in the previous tests. The two remaining tests, one stationary
and one rotating, shall be conducted with the ignition in the winding
compartment end furthest away from the conduit box.
(4) For motor assemblies incorporating a conduit box which is
isolated from the winding compartment by an isolating barrier the
following additional tests shall be conducted--
(i) For conduit boxes with an internal free volume greater than 150
cubic inches, two ignition points shall be used, one as close to the
geometric center of the conduit box as practical and the other at the
furthest point away from the isolating barrier between the conduit box
and the winding compartment. Recording of pressure shall be on the same
and opposite sides as the ignition point furthest from the isolating
barrier between the conduit box and the winding compartment. Conduit
boxes with an internal free volume of 150 cubic inches or less shall
have one test hole for ignition located as close to the geometric center
of the conduit box as practical and one for recording of pressure
located on a side of the conduit box.
(ii) The conduit box shall be tested separately. Six tests at 9.4
0.4 percent methane by volume within the conduit
box shall be conducted followed by two tests at 7.0 0.3 percent methane by volume. Then two tests at 9.4
0.4 percent methane by volume with a quantity of
coal dust equal to 0.05 ounces per cubic foot of internal free volume of
the conduit box and meeting the specifications in paragraph (c)(3) of
this section shall be conducted. For conduit boxes with an internal free
volume of more than 150 cubic inches, the number of tests shall be
evenly divided between each ignition point.
(iii) The motor assembly shall be tested following removal of the
isolating barrier or one sectionalizing terminal (as applicable). Six
tests at 9.4 0.4 percent methane by volume in the
winding compartment and conduit box shall be conducted using three
ignition locations. The ignition shall be at one end of the winding
compartment for one stationary and one rotating test; the opposite end
for one stationary and one rotating test; and at the ignition point that
produced the highest pressure on the previous test in paragraph
(c)(4)(ii) of this section in the conduit box for one stationary and one
rotating test. Motor assemblies that use multiple sectionalizing
terminals shall have one test conducted as each additional terminal is
removed. Each of these tests shall use the rotor state and ignition
location that produced the highest pressure in the previous tests.
(d) A motor assembly incorporating a conduit box that is isolated
from the winding compartment that exhibits pressures exceeding 110 psig,
while testing during removal of any or all isolating barriers as
specified in paragraph (c)(4) of this section, shall have a warning
statement on the approval plate. This statement shall warn that the
isolating barrier must be maintained to ensure the explosion-proof
integrity of the motor assembly. A statement is not required when the
motor assembly has withstood a static pressure of twice the maximum
pressure recorded in the explosion tests of paragraph (c)(4) of this
section. The static pressure test shall be conducted on the motor
assembly with all isolating barriers removed, and in accordance with
Sec. 7.307 of this part.
(e) Acceptable performance. Explosion tests of a motor assembly
shall not result in--
(1) Discharge of flames.
(2) Ignition of the explosive mixture surrounding the motor assembly
in the chamber.
(3) Development of afterburning.
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(4) Rupture of any part of the motor assembly or any panel or
divider within the motor assembly.
(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, except as provided in paragraph (d)
of this section unless the motor assembly has withstood a static
pressure of twice the maximum pressure recorded in the explosion tests
of this section following the static pressure test procedures of Sec.
7.307 of this part.
(7) Permanent deformation greater than 0.040 inches per linear foot.
Sec. 7.307 Static pressure test.
(a) Test procedure. (1) The enclosure shall be internally
pressurized to a minimum of 150 psig and the pressure maintained for a
minimum of 10 seconds.
(2) Following the pressure hold, the pressure shall be removed and
the pressurizing agent removed from the enclosure.
(b) Acceptable performance. (1) The enclosure during pressurization
shall not exhibit--
(i) Leakage through welds or casting; or
(ii) Rupture of any part that affects the explosion-proof integrity
of the enclosure.
(2) The enclosure following removal of the pressurizing agent shall
not exhibit--
(i) Visible cracks in welds;
(ii) Permanent deformation exceeding 0.040 inches per linear foot;
or
(iii) Clearances, in excess of those specified in this subpart,
along accessible flame-arresting paths, following any necessary
retightening of fastenings.
Sec. 7.308 Lockwasher equivalency test.
(a) Test procedure. (1) Each test sample shall be an assembly
consisting of a fastening with a locking device. Each standard sample
shall be an assembly consisting of a fastening with a lockwasher.
(2) Five standard samples and five test samples shall be tested.
(3) Each standard and test sample shall use a new fastening of the
same specifications as being used on the motor assembly.
(4) A new tapped hole shall be used for each standard and test
sample. The hole shall be of the same specifications as used on the
motor assembly.
(5) Each standard and test sample shall be inserted in the tapped
hole and continuously and uniformly tightened at a speed not to exceed
30 rpm until the fastening's proof load is achieved. The torquing device
shall not contact the locking device or the threaded portion of the
fastening.
(6) Each standard and test sample shall be engaged and disengaged
for 15 full cycles.
(b) Acceptable performance. The minimum torque value required to
start removal of the fastening from the installed position (minimum
breakway torque) for any cycle of any test sample shall be greater than
or equal to the average breakway torque of each removal cycle of every
standard sample.
Sec. 7.309 Approval marking.
Each approved motor assembly shall be identified by a legible and
permanent approval plate inscribed with the assigned MSHA approval
number and a warning statement as specified in Sec. 7.306(d) of this
part. The plate shall be securely attached to the motor assembly in a
manner that does not impair any explosion-proof characteristics.
Sec. 7.310 Post-approval product audit.
Upon request by MSHA but not more than once a year, except for
cause, the approval holder shall make a motor assembly available for
audit at no cost.
Sec. 7.311 Approval checklist.
Each motor assembly bearing an MSHA approval marking shall be
accompanied by a list of items necessary for maintenance of the motor
assembly as approved.
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Sec. Appendix I to Subpart J of Part 7
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Subpart K_Electric Cables, Signaling Cables, and Cable Splice Kits
Source: 57 FR 61220, Dec. 23, 1992, unless otherwise noted.
Sec. 7.401 Purpose and effective date.
This subpart establishes the flame-resistant requirements for
approval of electric cables, signaling cables and cable splice kit
designs. Applications for approval or extension of approval submitted
after February 22, 1994 shall meet the requirements of this subpart.
Sec. 7.402 Definitions.
The following definitions apply in this subpart.
Component. Any material in a cable splice kit which becomes part of
a splice.
Conductor. A bare or insulated wire or combination of wires not
insulated from one another, suitable for carrying an electric current.
Electric Cable. An assembly of one or more insulated conductors of
electric current under a common or integral jacket. A cable may also
contain one or more uninsulated conductors.
Jacket. A nonmetallic abrasion-resistant outer covering of a cable
or splice.
Power Conductor. An insulated conductor of a cable assembly through
which the primary electric current or power is transmitted.
Signaling Cable. A fiber optic cable, or a cable containing electric
conductors of a cross-sectional area less than 14 AWG used where the
circuit cannot deliver currents which would increase conductor
temperatures beyond that established for the current-carrying capacity
of the conductors.
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Splice. The mechanical joining of one or more severed conductors in
a single length of a cable including the replacement of insulation and
jacket.
Splice Kit. A group of materials and related instructions which
clearly identify all components and detail procedures used in safely
making a flame-resistant splice in an electric cable.