AS-NZS-3584.2-2008.pdf

AS/NZS 3584.2:2008 Australian/New Zealand Standard Diesel engine systems for underground coal mines Part 2: Explosion protected AS/NZS 3584.2:2008 AS/NZS 3584.2:2008 This Joint Australian/New Zealand Standard was prepared by Joint Technical Committee ME-018, Mining Equipment. It was approved on behalf of the Council of Standards Australia on 19 January 2007 and on behalf of the Council of Standards New Zealand on 2 February 2007. This Standard was published on 23 January 2008. The following are represented on Committee ME-018: Australasian Institute of Mining and Metallurgy Australian Chamber of Commerce and Industry Australian Coal Association Bureau of Steel Manufacturers of Australia Chamber of Minerals and Energy of Western Australia Department of Infrastructure, Energy and Resources (Tasmania) Department of Labour, New Zealand Department of Mineral Resources, N.S.W. Department of Minerals and Energy, W.A. Department of Mines and Energy (Qld) Department of Natural Resources and Environment, Vic. Institution of Mining Engineers, Australia Minerals Council of Australia South Australian Chamber of Mines and Energy Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about joint Australian/New Zealand Standards can be found by visiting the Standards Web Shop at www.standards.com.au or Standards New Zealand web site at www.standards.co.nz and looking up the relevant Standard in the on-line catalogue. Alternatively, both organizations publish an annual printed Catalogue with full details of all current Standards. For more frequent listings or notification of revisions, amendments and withdrawals, Standards Australia and Standards New Zealand offer a number of update options. For information about these services, users should contact their respective national Standards organization. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Please address your comments to the Chief Executive of either Standards Australia or Standards New Zealand at the address shown on the back cover. This Standard was issued in draft form for comment as DR 06619. AS/NZS 3584.2:2008 Australian/New Zealand Standard Diesel engine systems for underground coal mines Part 2: Explosion protected COPYRIGHT © Standards Australia/Standards New Zealand All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher. Jointly published by Standards Australia, GPO Box 476, Sydney, NSW 2001 and Standards New Zealand, Private Bag 2439, Wellington 6020 ISBN 0 7337 8516 6 Originated as AS 35841988. Second edition 1991. Jointly revised and redesignated as AS/NZS 3584.2:2003. Second edition 2008. AS/NZS 3584.2:2008 2 PREFACE This Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee ME-018, Mining Equipment, to supersede AS/NZS 3584.2:2003. The objective of this Standard is to promote the safety of explosion-protected diesel engine systems that are used underground in coal mines. This Standard is one of the following series of Standards: AS/NZS 3584 Diesel engine systems for underground coal mines 3584.1 Part 1: Fire protectedHeavy duty 3584.2 Part 2: Explosion protected (this Standard) 3584.3 Part 3: Maintenance This edition allows for the implementation of new technology in diesel engine systems, including the use of dry exhaust systems, limiting the emission of diesel aerosol particulates and generally reducing the emission of pollutants. New measures have been included to provide a greater assurance of safety by preventing the propagation of an internal explosion. Its emphasis is to facilitate the implementation of new technology resulting in the increased operational safety of diesel engine systems. The terms normative and informative have been used in this Standard to define the application of the appendix to which they apply. A normative appendix is an integral part of a Standard, whereas an informative appendix is only for information and guidance. Statements expressed in mandatory terms in notes to tables are deemed to be requirements of this Standard. 3 AS/NZS 3584.2:2008 CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 5 1.2 APPLICATION.5 1.3 REFERENCED DOCUMENTS 6 1.4 DEFINITIONS 7 SECTION 2 DESIGN AND CONSTRUCTION 2.1 ENGINE TYPES. 10 2.2 CONDITION MONITORING. 10 2.3 SURFACE TEMPERATURE 10 2.4 MATERIALS 10 2.5 FLEXIBLE METALLIC PIPES 10 2.6 JOINTS 11 2.7 TRANSMISSION BELTS. 13 2.8 ENGINE BREATHER. 13 2.9 STARTING AIDS . 14 2.10 FUEL SYSTEMS 14 2.11 AIR INLET SYSTEMS. 14 2.12 AIR COMPRESSORS. 14 2.13 COOLING SYSTEMS. 15 2.14 ENGINE SHUTDOWN SYSTEMS 15 2.15 EXHAUST SYSTEMS 17 2.16 ELECTRICAL SYSTEMS 25 SECTION 3 MARKING 3.1 COMPLIANCE PLATE 26 3.2 ENGINE SPECIFICATION PLATE . 27 3.3 WARNING LABELS 28 SECTION 4 TESTING 4.1 TYPE TESTING 30 4.2 MODIFIED COMPONENTS 30 4.3 INSTALLED TESTS BY THE DIESEL ENGINE SYSTEM MANUFACTURER. 31 4.4 ROUTINE COMMISSIONING TESTS BY THE MANUFACTURER 31 4.5 USE OF LOW EMISSION FUEL . 32 4.6 MANAGEMENT SYSTEM 32 SECTION 5 DOCUMENTATION 5.1 DOCUMENTATION TO BE SUPPLIED . 33 5.2 GENERAL ARRANGEMENT DRAWINGS 34 APPENDICES A MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD. 37 B DETERMINING LOAD-SPEED CHARACTERISTICS 38 C DETERMINING CONSTITUENTS OF EXHAUST GAS 42 D DETERMINING GASEOUS EMISSION LEVELS 49 E DETERMINING DURATION, TEMPERATURE AND FLUID USAGE. 57 F TESTING ENGINE PROTECTION SYSTEMS . 61 G TESTING SPARK ARRESTER COMPONENTS. 67 AS/NZS 3584.2:2008 4 H TESTING PARTICULATE FILTER COMPONENTS . 69 I SPECIFICATION FOR MEASURING EQUIPMENT 70 J SPECIFICATION FOR DIESEL FUEL 73 K SMOKE METER CONVERSION CHART. 74 L TESTING SUB-ASSEMBLY COMPONENTS. 76 M HYDROSTATIC TESTING OF INTAKE AND EXHAUST SYSTEMS 84 N IMPACT TESTINGCOATED LIGHT ALLOY PARTS . 86 O THE EFFECTS OF TEMPERATURE AND PRESSURE ON THE SAFETY OF POSITIVE FLAMETRAPS. 88 5 AS/NZS 3584.2:2008 COPYRIGHT STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Australian/New Zealand Standard Diesel engine systems for underground coal mines Part 2: Explosion protected S E C T I O N 1 S C O P E A N D G E N E R A L 1.1 SCOPE This Standard specifies safety requirements for diesel engine systems that are explosion- protected for use in underground coal mines, including use in explosion-risk zones. NOTES: 1 Compliance to this Standard implies a limited time safe operation in atmospheres containing up to 1% methane, including (a) the control of surface temperature, to avert ignition of coal dust that could settle on a hot surface; (b) containment or elimination of flames and sparks that could ignite flammable gases and dust that may be present (such as in underground coal mines); and (c) control of diesel emissions. 2 This Standard also addresses inadvertent short-term exposure to high methane levels and any consequent abnormal combustion. 3 Appendix A gives guidance for demonstrating compliance with this Standard. 1.2 APPLICATION This Standard is intended for the guidance of manufacturers, users, regulatory authorities, testing authorities and associated interests. It has no legal authority in its own right, but it may acquire legal standing in one or more of the following ways: (a) Adoption by a regulatory authority. (b) Reference to compliance with the Standard as a contract requirement. (c) Claim by a manufacturer or manufacturers agent of compliance with the Standard. This Standard nominates the means by which identified hazards may be managed. Alternative technologies or innovations may also provide solutions to the management of these hazards. An alternative technology or innovation may be adopted, provided the alternative meets or exceeds the applicable requirements of this Standard. A formal risk assessment, meeting applicable Standards, shall be required to provide evidence of such compliance. In addition to the requirements of this Standard, there may be other requirements set by the regulatory authority. Users of this Standard should, therefore, make themselves aware of any such requirements where the diesel engine system will be used. AS/NZS 3584.2:2008 6 COPYRIGHT 1.3 REFERENCED DOCUMENTS The following documents are referred to in this Standard: AS 1019 Internal combustion enginesSpark emission control devices 1722 Pipe threads of Whitworth form 1722.1 Part 1: Sealing pipe threads AS 2784 Endless wedge belt and V-belt drives 4024 Safeguarding of machinery 4024.1 Part 1: Safety of machinery (series) 4024.1301 Part 1301: Principles of risk assessment 4024.1501 Part 1501: General principles 4024.1502 Part 1502: Validation 4024.1601 Part 1601: GuardsGeneral requirements for the design and construction of fixed and moveable guards 4024.1604 Part 1604 Emergency stopPrinciples for design 62061 Safety of machineryFunctional safety of safety-related electrical, electronic and programmable electronic control systems AS/NZS 1826 Electrical equipment for explosive gas atmospheres - Special protection - Type of protection s 4871 Electrical equipment for coal mines, for use underground 4871.1 Part 1: General requirements 4871.2 Part 2: Distribution, control and auxiliary equipment 4871.3 Part 3: Substations 4871.4 Part 4 Mains powered electrical mobile machines 4871.5 Part 5: Battery powered electrical mobile machines 4871.6 Part 6: Diesel powered machinery and ancillary equipment 60079 Electrical apparatus for explosive gas atmospheres 60079.0 Part 0: General requirements ISO 9000 Quality management systemsFundamentals and vocabulary ISO 9001 Quality management systemsRequirements ISO 9004 Quality management systemsGuidelines for performance improvements ISO 8178 Reciprocating internal combustion enginesExhaust emission measurement 8178-1 Part 1: Test-bed measurement of gaseous and particulate exhaust emissions 8178-4 Part 4: Test cycles for different engine applications ADR Australian Design Rules 30 Diesel engine exhaust smoke omissions ASTM D1298 Standard Test Method for Density, Relative Density (Specific gravity), or API Gravity of Crude Petroleum and Liquid Petroleum Products by Hydrometer Method HB Standards Australia handbook 18 Conformity assessment 18.28 Guide 28: Guidance on third-party certification scheme for products 7 AS/NZS 3584.2:2008 COPYRIGHT SAE J 244 Measurement of intake air or exhaust gas flow of diesel engines J 255 Diesel engine smoke measurement J 1003 Diesel engine emission measurement procedure, recommended practice 1.4 DEFINITIONS For the purpose of this Standard, the definitions below apply. 1.4.1 Abnormal combustion Unintended or uncontrolled combustion in the engine. NOTES: 1 Abnormal combustion may be caused by induced flammable gas, liquid or vaporized hydrocarbons. 2 Abnormal combustion may cause intake flashbacks, high exhaust temperature or high surface temperatures or catastrophic engine failure, engine overspeed, uncontrollable engine running and/or render the explosion protection system ineffective. 3 Abnormal combustion may not be apparent to an operator except for a marginal change of power and/or emissions. 1.4.2 Catalytic converter Equipment that modifies the constituents of an exhaust gas stream by means of a catalyst. 1.4.3 Designated safe area A place in which there is a minimum possibility of an explosive atmosphere being present in such quantities that would require special precautions while a diesel engine is operated, serviced or maintained. NOTES: 1 The management of fire and explosion hazards is of particular importance to the safety of underground coal mines. 2 It cannot be assumed that areas of a mine that are not classified as being explosion-risk zones are designated safe areas. 3 Legislation, regulations or requirements by the relevant statutory authority may define designated safe areas in greater detail. 4 The statutory authority may require the use of risk-analysis techniques, to identify designated safe areas. Such techniques may require safe areas to be enclosed by barriers, even where the probability of an occurrence is considered to be very low, or where events having a maximum reasonable consequence of a fatality exist. 5 Where a consequence could be catastrophic, the mathematical product of risk and consequence may not be appropriate for the risk assessment decision-making process. 1.4.4 Engine safety shutdown system A protection system that automatically causes an engine to stop in the event of an unsafe condition occurring. 1.4.5 Emergency safety shutdown system A system fitted to stop the diesel engine in the event of the failure of the other systems to stop the engine. 1.4.6 Explosion-protected diesel engine system A diesel engine that is designed, manufactured and maintained so it will not propagate or generate flame or sparks, which could initiate an explosion of the surrounding atmosphere. The diesel engine system includes (a) inlet systems and inlet flametrap; AS/NZS 3584.2:2008 8 COPYRIGHT (b) exhaust systems and exhaust flametrap; (c) combustion chamber; (d) cooling systems; (e) starting systems; (f) shutdown and protection systems; and (g) other ancillary equipment attached to or driven by the engine, including electrical systems that start the engine, or are associated with the engine operation or engine control. NOTE: Equipment driven from the output side of a diesel engine flywheel should not be considered to be part of any explosion-protected diesel engine system. 1.4.7 Explosion-risk zone A place where during the normal course of events there is a possibility that there may be an accumulation of flammable or explosive gas that could create a hazard for the operation, servicing or maintenance of a diesel engine system. NOTE: Legislation for underground coal mines may define certain parts of the mine as explosion- risk zones and may use the term hazardous area to describe an explosion-risk zone. 1.4.8 Fire protection Design features that will prevent the diesel engine system from igniting flammable material or substances. NOTE: Such features are not necessarily intended to prevent the ignition of flammable or explosive gas. 1.4.9 Flametrap A device that prevents the propagation of an explosion of gas from a diesel engine to the outside atmosphere. NOTE: Flametraps may be dry (not relying on water for effectiveness) or wet (relying on the retention or presence of water). 1.4.10 Gland A device for attachment to an electrical enclos