[Code of Federal Regulations]
[Title 30, Volume 1]
[Revised as of July 1, 2002]
From the U.S. Government Printing Office via GPO Access
[CITE: 30CFR7.86]
[Page 30-41]
TITLE 30--MINERAL RESOURCES
CHAPTER I--MINE SAFETY AND HEALTH ADMINISTRATION, DEPARTMENT OF LABOR
PART 7--TESTING BY APPLICANT OR THIRD PARTY--Table of Contents
Subpart E--Diesel Engines Intended for Use in Underground Coal Mines
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
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(viii) For testing category A engines, an apparatus for metering in
1.0 0.1 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, D1319 Remainder.
olefins.
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.
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[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 33]]
(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 34]]
[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 35]]
(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 36]]
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 [le] 1
part per million equivalent carbon (ppmC), and [le] 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 [le] 1ppm C,
[le] 1 ppm CO, [le] 400 ppm CO2, and [le] 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 37]]
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.
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[GRAPHIC] [TIFF OMITTED] TR25OC96.002
[[Page 39]]
[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 40]]
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.F9 deg.F (25 deg.C5 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.C5 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 [mu]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 41]]
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.F5 deg.F (22
deg.C3 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.F5 deg.F (9.5 deg.C3 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 [mu]g and
resolution of 10 [mu]g. For filters less than 70 mm diameter, the
precision and resolution shall be 2 [mu]g and 1 [mu]g, respectively.
(21) All filters shall be neutralized to eliminate the effects of
static electricity prior to weighing.