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IC 8838 
 
 Bureau of Mines Information Circular/1981 
 
 Polychlorinated Biphenyls: 
 Regulations and Substitutes 
 
 A Compliance Manual 
 
 for the U.S. Mining Industry 
 
 By R. A. Westin, R. P. Barruss, B. Woodcock, 
 and R. L. King 
 
 UNITED STATES DEPARTMENT OF THE INTERIOR 
 
Information Circular 8838 
 
 Polychlorinated Biphenyls: 
 Regulations and Substitutes 
 
 A Compliance Manual 
 
 for the U.S. Mining Industry 
 
 By R. A. Westin, R. P. Barruss, B. Woodcock, 
 and R. L. King 
 
 UNITED STATES DEPARTMENT OF THE INTERIOR 
 James G. Watt, Secretary 
 
 BUREAU OF MINES 
 
# 
 
 
 This publication has been cataloged as follows 
 
 Polychlorinated biphenyls: Regulations and substitutes. 
 
 (Information circular - Bureau of Mines ; 8838) 
 
 Includes bibliographical references. 
 
 Supt. Docs no.: I 28.27:8838. 
 
 1. Polychlorinated biphenyls— Handbooks, manuals, etc. 2. Elec- 
 tricity in mining— Handbooks, manuals, etc. I. Westin, Robert A. II. 
 Series: United States. Bureau of Mines. Information circular ; 8838. 
 
 TN295.U4 [T55.3.H3] 622s [363. 1'79] 80-607190 
 
CONTENTS 
 
 Page 
 
 Abstract 1 
 
 Introduction. 1 
 
 Background 3 
 
 PCB's used in the U.S. mining industry 4 
 
 General requirements 6 
 
 Recordkeeping (40 CFR 761.45) 6 
 
 Marking (40 CFR 761.20) 7 
 
 Containers for PCB's (40 CFR 761.42) 8 
 
 Storage (40 CFR 761.42) 9 
 
 Spill cleanup [40 CFR 761.10(d)] 9 
 
 Other information 10 
 
 Other regulations 10 
 
 Decontamination (40 CFR 761.43) 11 
 
 Transportation [40 CFR 761.42, 761.20(b)] 11 
 
 Disposal (40 CFR 761.10) 12 
 
 Askarel transformers 12 
 
 Uses of askarel transformers in mining 13 
 
 Machine mounted 13 
 
 Underground 14 
 
 Surface 15 
 
 Number of askarel transformers used in U.S. mines 15 
 
 How to identify an askarel-filled transformer 17 
 
 EPA requirements for PCB (askarel) transformers 18 
 
 Precautions for continued use. 20 
 
 Significance of water 20 
 
 Decision guide 21 
 
 Dikes 24 
 
 Berms 27 
 
 Fences and vehicle barriers 28 
 
 Curbs and doorway dikes 29 
 
 Emergency foam packs 29 
 
 Special problems 29 
 
 Mobile mining machinery 30 
 
 Relocation of transformers 31 
 
 Retrof illing 31 
 
 Non-PCB replacement transformers 32 
 
 Characteristics of non-PCB replacement transformers 33 
 
 Oil-filled transformers 33 
 
 Silicone transformer liquid 34 
 
 High-fire-point transformer liquids 34 
 
 Open air-cooled transformers 35 
 
 Sealed gas-filled transformers 36 
 
 Cast coil transformers.... 37 
 
 Mining machinery transformers 37 
 
 Relative costs of non-PCB replacement transformers 38 
 
 Summary — considerations in choosing an alternative to PCB 
 
 transformers 39 
 
 PCB-contaminated transformers ♦ 40 
 
11 
 
 CONTENTS— Continued 
 
 Page 
 
 PCB capacitors 42 
 
 Uses of PCB capacitors in the mining industry 42 
 
 How ~tp identify PCB capacitors 42 
 
 Requirements for PCB capacitors 43 
 
 Precautions for continued use 45 
 
 Substitutes for PCB capacitors 45 
 
 Underground mining machinery 46 
 
 Use 46 
 
 Identification 46 
 
 EPA requirements 47 
 
 Recommended precautions for continued use 48 
 
 Emergency spill response 49 
 
 Non-PCB replacement equipment 49 
 
 Electromagnets 49 
 
 Use 49 
 
 Identification 50 
 
 EPA requirements 50 
 
 Recommended precautions for continued use 51 
 
 Emergency spill response 52 
 
 Non-PCB electromagnets 52 
 
 Heat-transfer fluids 53 
 
 Use 53 
 
 EPA requirements 53 
 
 Recommended precautions for continued use 55 
 
 Emergency spill response 55 
 
 Non-PCB heat-transfer fluids 56 
 
 Hydraulic fluids 56 
 
 Use 56 
 
 Identification 56 
 
 EPA requirements 56 
 
 Non-PCB hydraulic fluids 57 
 
 Waste oil 57 
 
 EPA requirements 57 
 
 Recommendations 57 
 
 Appendix A. — Outline of PCB spill response guide 58 
 
 Appendix B. — Water-only drainage system 59 
 
 ILLUSTRATIONS 
 
 1. Toxic Substances Control Act 5 
 
 2. Typical transformer and switch gear on concrete mounting pad with 
 
 steel dike installed 24 
 
 3. Shop preparation of 6- by 3.5-inch angle-steel dike edge, including 
 
 mitre-cut and ground ends and holes to be drilled 25 
 
 4. Corner joints — 2- by 2-inch steel angle 25 
 
 5. View of corner joint, top view detail of corner joint, and section 
 
 through dike 26 
 
ILLUSTRATIONS— Continued 
 
 iii 
 
 Page 
 
 6. Side view and pictorial view from top of the water-only drainage 
 
 system 26 
 
 7. Schematic diagram of basic parts and dimensions of an extended 
 
 mounting pad 27 
 
 8. Vehicle barrier suitable for protection of an askarel transformer 
 
 located in a parking lot or next to a street 28 
 
 B-l. Copper plumbing pipe with cap and fitting 59 
 
 B-2. Valve face 59 
 
 B-3. Bottom view of valve face 60 
 
 B-4. Two pieces brazed on valve face 60 
 
 B-5. Rectangular piece of copper for "guard plate" 60 
 
 B-6. Brazing of "guard plate" to main body of valve 61 
 
 B-7. "Valve rest" 61 
 
 B-8. Bearing support holes and hole-locating jig 62 
 
 B-9. Silicone rubber for "flapper valve" 63 
 
 B-10. "Flapper valve" as made by method (a) 63 
 
 B-ll. Mold half for pattern of "flapper valve" 64 
 
 B-12. Hinge support for flapper valve 64 
 
 B-13. Pipe flange 65 
 
 B-14. Fitting of drain valve and flange into inside of dike 65 
 
 B-15. Screen covering valve system..... 66 
 
 TABLES 
 
 1. Manufacturers and trade names of PCB's 3 
 
 2. Summary of askarel transformer data gathered during visits to 
 
 mines 16 
 
 3. Extrapolated estimates of numbers of askarel transformers in 
 
 various mining segments 17 
 
 4. Cost comparisons of oil-filled versus other transformer designs 
 
 intended for hazardous locations 39 
 
 5. Quantity of PCB's in mining machinery 46 
 
4 
 
POLYCHLORINATED BIPHENYLS: REGULATIONS AND SUBSTITUTES 
 
 A Compliance Manual for the U.S. Mining Industry 
 
 by 
 R. A. Westin, 1 R. P. Barruss, 2 B. Woodcock, 3 and R. L. King* 
 
 ABSTRACT 
 
 Polychlorinated biphenyls (PCB's) have been widely utilized as fire- 
 resistant dielectric coolants in electrical equipment used in mining 
 applications, including transformers, capacitors, electric motors, and elec- 
 tromagnets. In addition, PCB's have been used in hydraulic fluids and heat- 
 transfer fluids and are present in many oil-filled transformers. The 
 U.S. Environmental Protection Agency (EPA) recently banned the manufacture of 
 PCB's and equipment using PCB's, and imposed strict requirements on the con- 
 tinued use and disposal of existing PCB equipment. This manual discusses the 
 EPA requirements, suggests ways to decrease the risks resulting from continued 
 use of PCB equipment, and surveys the non-PCB equipment that is available as 
 replacements for the PCB electrical equipment presently used in mines. 
 
 INTRODUCTION 
 
 The U.S. Environmental Protection Agency (EPA) recently banned the manu- 
 facture of new equipment containing polychlorinated biphenyls (PCB's) and 
 established stringent requirements on the continued use and disposal of exist- 
 ing equipment containing PCB's. These regulations apply to all PCB's in the 
 United States, Puerto Rico, Virgin Islands, and U.S. Pacific territories. All 
 PCB's are regulated, including those in use in equipment in surface and under- 
 ground mines. 
 
 PCB's have been the basis for fire-resistant askarel liquids used in 
 transformers and capacitors and have been used in various other applications 
 in the mining industry. A contract (J01 77046) was awarded by the U.S. Depart- 
 ment of Interior, Bureau of Mines, to Versar, Inc., Springfield, Va., to study 
 (1) how to comply with EPA regulations and (2) how to select replacements for 
 equipment that contains PCB's. The information in this manual addresses these 
 issues. 
 
 1 Senior chemical engineer, Versar, Inc., Springfield, Va. 
 2 Senior mechanical engineer, Versar, Inc., Springfield, Va. 
 %echanical engineer, Versar, Inc., Springfield, Va. 
 
 ^Technical project officer, Pittsburgh Research Center, Bureau of Mines, 
 Pittsburgh, Pa. 
 
A necessary supplement to this manual is a copy of the EPA regulations on 
 PCB's. Reprints of the PCB Ban Regulation (published in the May 31, 1979, 
 Federal Register) are available from EPA, along with a list of the EPA- 
 approved PCB Disposal Facilities. Additional background information on the 
 regulation is also available in the EPA Support Document to the PCB Ban Regu- 
 lation. Te, obtain copies of all of these reports, call (toll-free, 
 800-424-9065, or in Washington, D.C., local 554-1404) or write the Office of 
 Industry Assistance, Office of Toxic Substances TS-799, U.S. Environmental 
 Protection Agency, 401 M St., S.W., Washington, D.C. 20460. 
 
 Note for potash and phosphate mines and mills : On May 9, 1980, the EPA 
 
 proposed the following regulations: " except for small PCB capacitors and 
 
 except for facilities manufacturing anhydrous liquid ammonia, the use or stor- 
 age of PCB items, as defined in sec. 761.2 (x), at facilities manufacturing, 
 processing, or storing bulk, unpackaged fertilizer or agricultural pesticides 
 is prohibited" (Federal Register, page 30993). This regulation has not yet 
 been promulgated, nor is it known whether it will affect the use of PCB's in 
 potash and phosphate mines or mills. For advice as to whether this will 
 affect the continued use of PCB's at your installation, call (toll-free, 
 800-424-9065, or in Washington, D.C, local 554-1404) or write the Office of 
 Industry Assistance, Office of Toxic Substances TS-799, U.S. Environmental 
 Protection Agency, 401 M St., S.W., Washington, D.C. 20460. 
 
 Other available information : This report does not go into much detail 
 about the health and environmental effects of PCB's or the chemicals now being 
 used as substitutes for PCB's. The following reports cover these technical 
 areas; the NIOSH Criteria Document is particularly recommended for its discus- 
 sion of health issues if you are going to service PCB equipment or clean up 
 PCB spills. 
 
 National Institute for Occupational Safety and Health. Criteria for a 
 Recommended Standard. . .Occupational Exposure to Polychlorinated Biphenyls 
 (PCB's). Pub. 77-225, September 1977; available from U.S. Government 
 Printing Office, Washington, D.C. 
 
 U.S. Environmental Protection Agency. Assessment of the Use of Selected 
 Replacement Fluids for PCB's in Electrical Equipment. Rept. EPA 560/6- 
 77-008, March 1979; available from National Technical Information Service, 
 Springfield, Va. , PB 296 377. 
 
 Interdepartmental Task Force in Polychlorinated Biphenyls. Polychlorinated 
 Biphenyls and the Environment. 1972; available from National Technical 
 Information Service, Springfield, Va. , Rept. NTIC COM-72-10419. 
 
 Versar, Inc. PCB's in the United States: Industrial Use and Environmental 
 Distribution. Feb. 25, 1976; available from National Technical Information 
 Service, Springfield, Va., PB 252 012. 
 
Background 
 
 Polychlorinated biphenyls (PCB's) are a class of chemicals that have been 
 used since 1930 as the basis for nonflammable dielectric liquids in electrical 
 equipment such as transformers and capacitors and as a component of some heat- 
 resistant, heat-transfer, and hydraulic fluids. PCB's were manufactured in 
 the United States from 1930 through 1977, primarily by Monsanto Industrial 
 Chemicals Co., 5 which marketed various mixtures of PCB's under the trade name 
 Aroclor. Mixtures of PCB's and other chemicals were marketed by Monsanto and 
 by other companies under a variety of trademarks for different applications as 
 described later in this report. PCB's have also been manufactured in Europe 
 and Japan, as listed in table 1. 
 
 TABLE 1. - Manufacturers and trade names of PCB's 
 
 Manufacturer 
 
 Bayer 
 
 Caf faro 
 
 Caf faro 
 
 Caf faro 
 
 Chemko 
 
 Geneva Industries.. 
 
 Kanegaf uchi , 
 
 Monsanto 
 
 Monsanto 
 
 Monsanto 
 
 Prodelec. . « 
 
 Prodelec ., 
 
 Sovol , 
 
 Country 
 
 Germany 
 
 Italy 
 
 Italy , 
 
 Italy 
 
 Czechoslovakia 
 
 United States 
 
 Japan 
 
 United Kingdom and United 
 
 States. 
 United Kingdom and Japan. . 
 United Kingdom and Europe. 
 
 France 
 
 France 
 
 U.S.S.R 
 
 Trade name 
 
 Clophen. 
 
 Fenclor . 
 
 DK. 
 
 Inclor. 
 
 None. 
 
 Not Known. 
 
 Kennechlor. 
 
 Aroclor. 
 
 Santotherm FR. 
 
 Pryoclor. 
 
 Phenoclor. 
 
 Pyralene. 
 
 None. 
 
 PCB's were identified as a serious and widespread environmental pollutant 
 in 1968, leading Monsanto to voluntarily limit the sales of PCB's to "totally 
 enclosed" capacitor and transformer applications after 1972. Limitations on 
 the presence of PCB's in food were established by the U.S. Food and Drug 
 Administration (FDA) in 1973. In 1977, the EPA banned the discharge of PCB's 
 into the water effluents from PCB manufacturers, capacitor manufacturers, and 
 transformer manufacturers. A review of the uses and environmental distribu- 
 tion of PCB's in 1975 indicated that more than half the 1.5 billion pounds of 
 PCB's that had ever been manufactured in the United States were still in use 
 in electrical equipment and that only about 10 percent of the total PCB's had 
 entered the environment. Even this relatively low environmental load of PCB's 
 was sufficient to cause the PCB concentration in some freshwater fish to 
 exceed the limits set by the FDA. The resulting ban on the sale of contami- 
 nated fish essentially ended commercial fishing on the Hudson River, in much 
 of the Great Lakes, and in a number of other freshwater lakes and rivers. 
 
 5 Use of brand names is for identification purposes only and does not imply 
 endorsement by the Bureau of Mines. 
 
The environmental and health problems associated with exposure to PCB's 
 result from the same properties that make these chemicals useful in industrial 
 and electrical applications: PCB's are very stable chemically, are soluble in 
 organic solvents, and are almost insoluble in water. PCB's that are released 
 to the environment do not degrade, but accumulate preferentially in the fat of 
 micro-organisms and bioaccumulate in the food chain. As a result, the concen- 
 tration of PCB's in fish may be 1 million times higher than in the water that 
 the fish lives in. Many organic compounds that are insoluble in water are 
 excreted by birds and mammals by being converted to water-soluble compounds by 
 powerful enzymes in the liver. High concentrations of water-insoluble chemi- 
 cals in the body will cause the liver to increase the production of these 
 enzymes. Unfortunately, PCB's are immune to attack by these enzymes and so 
 are not excreted but instead build up in the body, causing the liver to con- 
 tinue its increased production of the enzymes. Although the enzymes do not 
 react with the PCB's, they will react with various hormones, and the increase 
 in enzyme levels in the body activated by PCB concentration results in 
 decreased levels of these hormones, which causes decreased shell thickness in 
 bird eggs and reproductive problems in mammals. PCB's do not appear to be a 
 direct cause of cancer, but the enzyme changes caused by exposure to PCB's may 
 make the body more susceptible to the effects of low levels of direct carcin- 
 ogens found in cigaret smoke and in other manmade environmental pollutants. 
 Ingestion of relatively large quantities of PCB's (on the order of 1 gram) can 
 cause liver damage, skin problems, and other acute health effects. 
 
 In 1976, the U.S. Congress passed the Toxic Substances Control Act, which 
 gave the EPA wide authority to control the production and use of chemicals in 
 the United States. Section 6(e) of this act mandated a complete ban on the 
 manufacture, processing, distribution in commerce, and use of PCB's and 
 required the EPA to establish requirements for the marking and disposal of 
 PCB's in use (fig. 1). The act also allowed the EPA to authorize the contin- 
 ued use of PCB's after July 1, 1979, if the agency found that such use did not 
 present undue risk to human health or the environment. The EPA promulgated 
 the required Disposal and Marking Regulations for PCB's on February 17, 1978, 
 and on May 31, 1979, promulgated the PCB Ban Regulations, which authorize cer- 
 tain continued uses of PCB's and specify the conditions that must be met by 
 those who continue to use PCB's. 
 
 PCB's Used in the U.S. Mining Industry 
 
 The EPA regulations on the marking, processing, use, and disposal of 
 PCB's will affect the following equipment and activities in the mining 
 industry: 
 
 1. Askarel transformers: Marking, maintenance, disposal, spill 
 cleanup, recordkeeping, storage for disposal. 
 
 2. Oil-filled transformers: Disposal of oil. 
 
 3. Capacitors: Marking, disposal, spill cleanup, recordkeeping, 
 storage for disposal. 
 
Section 6(e), Toxic Substances Control Act 
 
 PUBLIC LAW 94-469— OCT. 11, 1976 
 
 90 STAT. 2025 
 
 "Totally enclosed 
 manner." 
 
 (e) Polychlorinated Biphenyls. — (1) Within six months after Rules, 
 the effective date of this Act the Administrator shall promulgate 
 rules to — 
 
 (A) prescribe methods for the disposal of polychlorinated 
 biphenyls, and 
 
 (B) require polychlorinated biphenyls to be marked with clear 
 and adequate warnings, and instructions with respect to their 
 processing, distribution in commerce, use. or disposal or with 
 respect to any combination of such activities. 
 
 Requirements prescribed by rules under this paragraph shall be con- 
 sistent with the requirements of paragraphs (2) and ('A). 
 
 (2) (A) Except as provided under subparagraph (B), effective one 
 year after the effective date of this Act no person may manufacture, 
 process, or distribute in commerce or use any polychlorinated biphenyl 
 in any manner other than in a totally enclosed manner. 
 
 (B) The Administrator may by rule authorize the manufacture, 
 processing, distribution in commerce or use (or any combination of 
 such activities) of any polychlorinated biphenyl in a maimer other than 
 in a totally enclosed manner if the Administrator rinds that such manu- 
 facture, processing, distribution in commerce, or use (or combination 
 of such activities) will not present an unreasonable risk of injury to 
 health or the environment. 
 
 (C) For the purposes of this paragraph, the term "totally enclosed 
 manner" means any manner which will ensure that any exposure of 
 human beings or the environment to a polychlorinated biphenyl will 
 be insignificant as determined by the Administrator by rule. 
 
 (3) (A) Except as provided in subparagraphs (B) and (C) — 
 
 (i) no person may manufacture any polychlorinated biphenyl 
 after two years after the effective date of this Act, and 
 
 (ii) no person may process or distribute in commerce any poly- 
 chlorinated biphenyl after two and one-half years after such date. 
 
 (B) Any person may petition the Administrator for an exemption Petition for 
 from the requirements of subparagraph (A), and the Administrator exemption, 
 may grant bv rule such an exemption if the Administrator finds 
 
 that— 
 
 (i) an unreasonable risk of injury to health or environment 
 
 would not result, and 
 
 (ii) good faith efforts have been made to develop a chemical 
 
 substance which does not present an unreasonable risk of injury 
 
 to health or the environment and which may be substituted for 
 
 such polychlorinated biphenyl. 
 An exemption granted under this subparagraph shall be subject to Terms and 
 such terms and conditions as the Administrator may prescribe and conditions, 
 shall be in effect for such period ( but not more than one year from 
 the date it is granted) as the Administrator may prescribe. 
 
 (C) Subparagraph (A) shall not apply to the distribution in com- 
 merce of any polychlorinated biphenyl if such polychlorinated 
 biphenyl was sold for purposes other than resale before two and one 
 half vears after the date of enactment of this Act. 
 
 (4) Any rule under paragraph (1), (2)(B), or (3)(B) shall be 
 promulgated in accordance with paragraphs (2), (3), and (i) of sub- 
 section (c). 
 
 (5) This subsection does not limit the authority of the Adminis- 
 trator, under any other provision of this Act or any other Federal law. 
 to take action respecting any polychlorinated biphenyl. 
 
 FIGURE 1. - Toxic Substances Control Act. 
 
4. Electric motors (PCB-filled as used on Joy Manufacturing model CU43 
 and 9CM continuous miners and 14BU10 loaders): Continued use, maintenance, 
 disposal, spill cleanup. 
 
 5. Separator electromagnets (PCB-filled): Marking, maintenance, 
 disposal,^spill cleanup. 
 
 6. Hydraulic and heat-transfer systems (that ever contained a PCB-based 
 fluid): Marking, maintenance, use, disposal, spill cleanup. 
 
 7. Waste oil: Disposal, use. 
 
 8. Transportation of any PCB's or PCB equipment. 
 
 9. Storage of any PCB's or PCB equipment. 
 
 10. Recordkeeping: Required if you have any PCB transformers, more than 
 45 kg (99.4 lb) of PCB's in containers, or more than 49 large PCB capacitors. 
 
 GENERAL REQUIREMENTS 
 
 It was the intent of Congress to ban the use of PCB's and thereby prevent 
 the entry of PCB's into the environment. To continue use of PCB's in those 
 applications authorized by the EPA, the requirements specified by the regula- 
 tions must be met. EPA has the authority to enforce these requirements by 
 performing compliance inspections wherever PCB's are used, including in mines. 
 Violations of the regulations can result in fines of up to $25,000 per viola- 
 tion per day. Willful violation of the regulations can result in additional 
 criminal action against the responsible people, with a possible penalty of a 
 $25,000 fine and 1 year in jail. 
 
 EPA is serious about keeping PCB's out of the environment. Continued use 
 or handling PCB's or PCB equipment after July 1, 1979, under the authoriza- 
 tions granted by the EPA, requires compliance with the following general 
 requirements and the specific requirements that apply to specific kinds of PCB 
 equipment. 
 
 Recordkeeping (40 CFR 761.45) 
 
 Special recordkeeping requirements are specified in Annex VI of the PCB 
 regulations. Maintenance of these perpetual PCB inventory records is required 
 for each facility that has in use or in storage — 
 
 45 kg (99.4 lb) of PCB's or PCB contaminated material in containers; 
 
 One or more PCB transformers; 
 
 50 or more large (3 lb liquid) PCB capacitors. 
 
 In addition, an annual report must be prepared by July 1 of each year, 
 summarizing the changes in PCB use during the previous year. EPA will use 
 
these records when it performs compliance inspections, and will consider the 
 lack of records or discrepancies in the records as evidence of lack of intent 
 to comply with the regulations. The records will have to be kept until 
 5 years after the last PCB's have been removed from the facility. 
 
 The EPA regulations are very specific as to the kinds of information that 
 must be kept. Any capacitor that contains 3 lb of PCB's must be considered to 
 be a "large capacitor" for purposes of labeling, disposal, and recordkeeping. 
 To estimate the weight of PCB's in a capacitor, assume that 20 percent of the 
 volume of the can is filled with PCB's weighing 11.4 lb per gal: 
 
 Capacitor can volume (cu in) x 0.01 = lb PCB 
 
 A "large capacitor" would be any capacitor having a total volume 
 exceeding 300 cu in. 
 
 Marking (40 CFR 761.20) 
 
 The EPA requires that special 6-inch-square yellow labels (described in 
 Annex V of the regulations) be applied to practically everything that has more 
 than 50 ppm PCB's except small capacitors (less than 3 lb PCB's) and oil- 
 filled transformers (below 500 ppm PCB's). Labels must be applied to equip- 
 ment that contains PCB's, including transformers, large capacitors operating 
 above 2,000 volts, contaminated hydraulic and heat-transfer systems, electro- 
 magnets, electric motors, cans and drums used to store PCB's and contaminated 
 material, storage areas, and trucks carrying PCB transformers or more than 45 
 kg (99.4 lb) of PCB's or PCB-contaminated material. The only exception to 
 applying the label directly to the item applies to large capacitors mounted on 
 the top of a power pole or behind a fence at a substation; a single label may 
 be applied to the pole or fence if records are adequate to identify which of 
 the capacitors contains PCB's. Large PCB capacitors operating below 2,000 
 volts do not have to have a label until they are removed from service, but it 
 would be a good idea to label them now to identify them as PCB items. It is 
 advisable to keep 10 or 20 extra labels on hand to be applied to drums used to 
 store used transformer oil, clean up spill material, contaminated rags, etc. 
 
 Pressure-sensitive labels meeting EPA requirements may be purchased from 
 a number of companies, including — 
 
 Label Master W.H. Brady Company 
 
 6001 North Clark St. 727 West Glendale Ave. 
 
 Chicago, 111. 60660 Milwaukee, Wis. 53209 
 
 312-973-5100 414-332-8100 
 
 5 This list is for reference only, and does not imply endorsement by the 
 Bureau of Mines or the U.S. Environmental Protection Agency. 
 
Containers for PCB's (40 CFR 761.42) 
 
 Containers used to store liquid PCB's must comply with one of the 
 following requirements: 
 
 (1) 49 CFR 178.80 — specification 5 without removable head. 
 
 (2) 49 x CFR 178.82 — specification 5B without removable head. 
 
 (3) 49 CFR 178.116— specification 17E. 
 
 Any container that meets the requirements described in these specifica- 
 tions will be marked with D0T-5-, D0T-5B-, or D0T-17E-. There may be addi- 
 tional markings, but they do not affect the suitability of the containers. 
 
 If the liquid PCB's are to be stored in containers larger than permitted 
 in the above specifications, the following requirements must be met: 
 
 1. The containers must be designed, constructed, and operated in compli- 
 ance with Occupational Safety and Health Standards, 29 CFR 1910.106. The 
 specification for flammable and combustible liquids is included in Sec- 
 tion 1910, Title 29 of the Code of Federal Regulations. To obtain a copy, 
 call (202-783-3238) or write the U.S. Government Printing Office, Washington, 
 D.C. 20402. 
 
 2. Either (a) the container shall be kept in a storage area that meets 
 the requirements described or (b) a Spill Prevention, Control, and Counter- 
 measures Plan (SPCC), as described in 40 CFR 112, must be prepared and imple- 
 mented. (Amendment of SPCC plans by the Regional Administrator, 40 CFR 112.4, 
 does not apply. The following report describes in detail how to prepare a sat- 
 isfactory SPCC plan for PCB's; to obtain a copy, call (415-961-9043) or write 
 the Electric Power Research Reports Center, Box 50490, Palo Alto, Calif. 
 94303. Electric Power Research Reports Center. Disposal of Polychlorinated 
 Biphenyls (PCB's) and PCB-Contaminated Materials. V. 2. Suggested Procedure 
 for Development of PCB Spill Prevention Control and Countermeasure Plans. 
 
 V. 3. Example Preparation of a Utility PCB Spill Prevention Control and 
 Countermeasure Plan. Palo Alto, Calif., 1980. 
 
 Any container used to store rags, contaminated soil, or other nonliquid 
 PCB's must comply with one of the following: 
 
 (a) 49 CFR 178. 80— specif ication 5. 
 
 (b) 49 CFR 178.82— specification 5B. 
 
 (c) 49 CFR 178.115— specification 17C. 
 
 (d) Any container larger than the 55-gal size given in the above 
 specification shall provide as much protection against leaking and be of the 
 same strength and durability as the containers described. 
 
 Containers that meet either a, b, or c above will be labeled either 
 D0T-5-, D0T-5B-, or D0T-17C-. 
 
With the exception of the specifications from the Occupational Safety and 
 Health Standards, all of the above specifications are included in Title 49 of 
 the Code of Federal Regulations, Transportation (parts 100-199). To obtain a 
 copy, call (202-783-3238) or write the U.S. Government Printing Office, Wash- 
 ington, D.C. 20402. 
 
 Storage (40 CFR 761.42 ) 
 
 The basic requirement is that PCB ' s be stored in special storage areas in 
 buildings that are located above the 100-year flood water elevation and that 
 the storage areas be diked and have impervious floors with no drains. PCB's 
 put into storage before January 1, 1983, must be removed and disposed of by 
 January 1, 1984. PCB's put into storage after January 1, 1983, may not remain 
 in storage for more than 1 year. The items in storage must be checked every 
 30 days to insure that they are not leaking PCB's. 
 
 Temporary storage outside the special storage areas is allowed for cer- 
 tain nonleaking equipment and containers for a period of 30 days. Nonleaking 
 large capacitors and drained askarel transformers may be stored adjacent to 
 the special area until January 1, 1983. The regulations also specify the 
 types of drums and tanks that can be used to store PCB liquids and contami- 
 nated solids. 
 
 The storage requirements are complicated and probably expensive. Most of 
 the problems can be avoided by disposal of any PCB's within 30 days after they 
 are removed from service. However, there are no incinerators presently 
 approved for PCB liquids, so askarel removed from transformers and other con- 
 taminated liquids must be stored in compliance with these regulations until 
 EPA approves an incineration facility. 
 
 Spill Cleanup [40 CFR 761.10(d)] 
 
 EPA regulations require that all material contaminated with PCB's in con- 
 centrations above 50 ppm by weight (for example, 1 lb of PCB's in 10 tons of 
 dirt or other material be picked up, drummed, and disposed of in specially 
 approved facilities. This is potentially the most expensive provision of the 
 regulations. The cost of cleaning up PCB spills onto dirt or major machinery 
 can be high. The cost of cleaning up a PCB spill that has entered the water 
 can be horrendous. The potential cost of spill cleanup will justify work per- 
 formed now to limit the extent of PCB spills and may justify replacing PCB 
 equipment if there is much risk of PCB's entering water from failed equipment. 
 
 Immediate response to PCB spills should be based on three major 
 principles: 
 
 (1) Minimize human exposure to PCB's: Disconnect the power from electri- 
 cal equipment to stop the boil-off of PCB's; provide workers with protective 
 gloves and clothing and, if necessary, breathing apparatus. 
 
10 
 
 (2) Prevent PCB's from entering water: Soak up spilled PCB's with straw, 
 rags, sawdust, dirt, or anything else that is available; throw up temporary 
 dikes to minimize the spread of spilled liquid. 
 
 (3) After the spill is under control, contact experts to decide on 
 cleanup and disposal procedures. The PCB labels that are required on all PCB 
 equipment give the toll-free number of the U.S. Coast Guard National Response 
 Center (800-424-8802). Personnel at this number will give the names and tele- 
 phone numbers of EPA personnel at the appropriate regional office who in turn 
 will be able to give guidance in the cleanup procedure. In the event of a 
 major spill into water, the Coast Guard will send personnel to supervise and 
 aid in assessment and cleanup. 
 
 You might want to consider distributing a short emergency response guide 
 within your own organization to mine superintendents, maintenance supervisors, 
 electrical foreman, etc. A suggested outline is included in appendix A. 
 
 Other Information 
 
 Emergency response: U.S. Coast Guard National Response Center, telephone 
 800-424-8802 (toll-free). 
 
 Supplementary information on cleanup procedures and Federal requirements: 
 U.S. Environmental Protection Agency, Control Action Division, Washington, 
 D.C., telephone 202-755-8033. 
 
 Information on foam plastic and concrete emergency dikes is available in 
 the following publication: 
 
 U.S. Environmental Protection Agency. Control of Hazardous Chemical Spills 
 by Physical Barriers. Rept. EPA R2-73-185, 1973; available from National 
 Technical Information Service, Springfield, Va., PB 221 493 030A. 
 
 Information on protective clothing availability is available in the fol- 
 lowing publication: 
 
 U.S. Coast Guard. A Survey of Personnel Protective Equipment and Respira- 
 tory Apparatus for Use by Coast Guard Personnel in Response to Discharges 
 of Hazardous Chemicals. Available from National Technical Information Ser- 
 vice, Springfield, Va., ADA 010 110. 
 
 Other Regulations 
 
 PCB spills into water are also regulated under the Clean Water Act. 
 Rules proposed by the EPA under this act in the February 16, 1979, Federal 
 Register list 299 regulated hazardous materials, including PCB's. Under these 
 rules, any spill of PCB's in excess of 10 lb constitutes a "discharge" if the 
 spill threatens to reach "the waters of the United States." Waters of the 
 United States do not, at this time, include ground waters, so spills of PCB's 
 in dry areas such as in some Western States do not constitute discharges as 
 far as the Clean Water Act is concerned unless there is a chance the dis- 
 charged fluid can find its way to a stream, river, swamp, or other body of 
 
11 
 
 surface water. The proposed regulations require that any discharge of more 
 than 10 lb of PCB's into water must be reported within 24 hours to the U.S. 
 Government in accordance with procedures specified by the Department of Trans- 
 portation in 33 CFR 153.203. (The proposed regulations also specify separate 
 fines for spills of PCB's into the water.) 
 
 Decontamination (40 CFR 761.43) 
 
 The EPA regulations authorize decontamination of containers, such as 
 steel drums that have been in contact with PCB's by triple rinsing with clean 
 solvent. The volume of solvent used for each rinse must be at least 10 per- 
 cent of the volume of the container. Movable equipment used in storage areas 
 may be decontaminated by swabbing surfaces that have been in contact with 
 PCB's with a suitable solvent. This same procedure could probably be used to 
 decontaminate other machinery such as drag lines contaminated with PCB's. 
 
 The preferred solvents for cleaning up PCB's are kerosene and light fuel 
 oil. The workers should be issued protective gloves and other necessary pro- 
 tective clothing as may be required by the conditions. Protective breathing 
 apparatus may be necessary in some instances. Used solvents and other contam- 
 inated materials must be stored in containers that have been marked. This 
 contaminated material must be stored and disposed of in approved facilities. 
 
 Contaminated gloves and other protective clothing should be discarded 
 into the drums with the other PCB-contaminated solid material. Any PCB's that 
 get onto workers' skin should be removed using waterless hand cleaner and 
 paper towels, the paper towels then being disposed of as required for PCB's. 
 
 Transportation [40 CFR 761.42, 761.20(b)] 
 
 PCB's are not considered a hazardous material under the regulations of 
 the U.S. Department of Transportation (DOT). Therefore, no special type of 
 vehicle or placarding is required. However, EPA is planning to promulgate a 
 comprehensive manifesting system for hazardous chemicals under the authority 
 of the Resource Conservation and Recovery Act. PCB's will be covered under 
 these requirements. 
 
 Containers used to hold PCB's and contaminated material must meet the 
 requirements specified by the EPA. Vehicles used to transport PCB's (includ- 
 ing common carrier trucks and railroad cars) are required to have a PCB label 
 applied to the outside of the vehicle if they are carrying PCB containers that 
 contain (1) more than 45 kg (99.4 lb) of liquid having more than 50 ppm on 
 PCB's or (2) one or more PCB transformers. 
 
 It is not required that askarel transformers be drained before thay are 
 transported. However, the cooling fins on transformers are fragile, and most 
 of the PCB spills that have resulted in major expensive cleanup efforts have 
 been caused by damage to askarel transformers during transportation. If an 
 askarel transformer is drained before it is moved, there will be a greater 
 
12 
 
 chance of damaging the coils; on the other hand, the cost of cleaning up a 
 spill from a transformer after a truck accident or a loading mishap can be 
 extremely high. 
 
 Disposal (40 CFR 761.10) 
 
 Special disposal requirements apply to all PCB equipment and to all mate- 
 rials contaminated with more than 50 ppm PCB's except for small capacitors 
 that contain less than 3 lb of PCB's. These small capacitors may be disposed 
 of in municipal landfills in which the organic wastes are expected to adsorb 
 and immobilize the PCB's after the capacitor casing rusts through. Solid 
 spill materials contaminated with more than 50 ppm PCB's must be disposed of 
 in an approved PCB landfill or special PCB incinerator. Disposal requirements 
 for PCB equipment follow. 
 
 You cannot contract away your responsibility for proper disposal of 
 PCB's. If there is ever a problem and PCB's are traced to you, it is still 
 your responsibility. The EPA regulations establish special and stringent 
 requirements for chemical waste landfills and incinerators used to dispose of 
 PCB's. To obtain a list of approved facilities, call (toll-free, 
 800-424-9065, or in Washington, D.C., local 554-1404) or write the Office of 
 Industry Assistance, Office of Toxic Substances TS-799, U.S. Environmental 
 Protection Agency, 401 M St., S.W., Washington, D.C. 20460. Contact the dis- 
 posal facility for prices and special instructions before sending PCB's. 
 
 EPA has not yet approved any incinerators for commercial disposal of 
 PCB's, so all materials required to be disposed of by incineration must be 
 stored in accordance with the regulations until EPA approves an incinerator. 
 
 ASKAREL TRANSFORMERS 
 
 The term askarel is defined by the 1978 National Electrical Code as "a 
 generic term for a group of nonflammable synthetic chlorinated hydrocarbons 
 used as electrical insulating media. Askarels of various compositional types 
 are used. Under arcing conditions the gases produced, while consisting pre- 
 dominantly of noncombustible hydrogen chloride, can include varying amounts of 
 combustible gases depending upon the askarel type." In fact, all of the types 
 of askarel sold prior to 1979 contained 60 to 100 percent PCB's, the balance 
 of the mixture usually being trichlorobenzene. The unique advantages of PCB- 
 based askarel used as a coolant liquid in transformers have been its chemical 
 inertness and nonf lammability . 
 
 Approximately 2 percent of the pad-mounted transformers in use in the 
 United States contain PCB-based askarel coolant liquid. Askarel transformers 
 have been used where fires might endanger human life and property. PCB's have 
 the advantage of nonf lammability , in contrast to mineral oil, the other major 
 liquid coolant used in transformers. Gaseous coolants are also nonflammable, 
 but gas-cooled (dry-type) transformers have certain disadvantages when com- 
 pared with liquid-cooled transformers. Dry-type transformers are generally 
 more expensive than the liquid-cooled units, and they usually have increased 
 operating noise levels and a lower capacity to withstand temporary overheating 
 
13 
 
 caused by surges of power in the electrical circuit. Alternative liquid cool- 
 ants are available, but none has all the advantages of PCB's. 
 
 Uses of Askarel Transformers in Mining 
 
 The advantages of askarel transformers in mining are the same as in any 
 application: Askarel fluids are nonflammable. Askarel transformers are, of 
 course, no longer being produced, but the ones that are in service will be 
 permitted to remain in service for their occupational lifetimes, which in many 
 instances could be 30 to 40 years or maybe longer. As will be pointed out 
 below, none of the alternatives to askarels are direct replacements for 
 askarel-cooled transformers. Transformers cooled with gases, for instance, 
 present very little fire hazard, but they are voltage limited because of the 
 inherent characteristics of gases, and gases simply do not have the heat 
 capacity of liquids. Liquid-cooled transformers are therefore better where 
 transformers are likely to be occasionally run at a higher than design load- 
 ing. The alternative "high-fire-point transformer liquids" are all more 
 expensive than askarel and do not have the same fire resistance. Oil-cooled 
 transformers, the mainstay of the transformer industry, are the least costly 
 of all transformers available, but in applications requiring fire safety, they 
 must be installed in fire-resistant vaults that can cost several times as much 
 as the basic transformer. 
 
 Askarel-f illed transformers are used in all phases of mining: Under- 
 ground, in surface installations, and onboard large mobile surface machinery. 
 Transformers used in mining range in size from 10 to 8,500 kva and contain up 
 to 3,415 gal of askarel. 
 
 Machine Mounted 
 
 The major manufacturers of large surface mining equipment installed aska- 
 rel transformers on a small portion of their equipment. This was generally 
 done at the request of the company purchasing the machinery, though Page Engi- 
 neering used askarel transformers on all of its walking draglines. 
 
 Bucyrus-Erie used to provide askarel transformers on electrically powered 
 draglines, loading shovels, and blast-hole drills. Usually the customer was 
 being required by its insurance carrier to use a nonflammable transformer 
 fluid. Askarel transformers, when requested, were mounted inside the machin- 
 ery in steel rooms that had originally been designed for oil transformers. 
 These rooms usually had an opening in the floor that would duct the trans- 
 former fluid to the ground to reduce the fire hazard in the event of a trans- 
 former rupture; the rooms also contained openings to provide adequate 
 ventilation. These transformers were 100-to 250-kva single-phase units. It 
 is estimated that askarel transformers were installed on 5 to 6 machines out 
 of roughly 400 that were built by Bucyrus-Erie over the past 15 years. 7 
 Bucyrus-Erie quit suppling askarel transformers around the first part of 1977, 
 and currently use only mineral oil transformers, but they are investigating 
 the use of silicone filled units. 
 
 7 Telephone conversation with Dick Matusak, Bucyrus-Erie, August 5, 1977. 
 
14 
 
 Marion Power Shovels also supplied askarel transformers in the 100-kva 
 range on its shovels and draglines at customer request. Askarel-f illed trans- 
 formers were mounted on only a small percentage of the 1,000 electrically 
 powered machines that Marion has built. As in the case of Bucyrus-Erie, 
 askarel-f illed transformers were mounted inside the machine in the fire- 
 resistant rooms that had been designed to meet specifications for oil-filled 
 transformers. Marion quit supplying askarel filled transformers during 1975. 8 
 
 In contrast with the preceding two companies, Page Engineering, supported 
 by its insurance company, used askarel-f illed transformers on all the walking 
 draglines it built before 1977. Each dragline contains a bank of three 
 single-phase transformers in the 100- to 333-kva range. These transformers 
 are mounted in cages on steel platforms about 8 ft above the main deck of the 
 dragline. A major rupture of one of these transformers would result in PCB's 
 leaking onto the ground underneath the dragline. An estimated 25 of these 
 machines have been built over the past 10 years. 
 
 In addition to the above equipment, an undetermined number of blast-hole 
 drills built by Robbins Drill Division of Joy Manufacturing used three single- 
 phase, askarel-f illed transformers. 
 
 Equipment that uses askarel transformers is used by a relatively small 
 number of mines. In some cases, the mining company was required by its insur- 
 ance carrier to order askarel transformers; thus most or all of the equipment 
 at these particular mines contains askarel transformers. In addition, it is 
 not unusual for a company to order its large equipment from a single supplier. 
 If the supplier were Page, all the draglines at that mine would have askarel 
 transformers on board. 
 
 Underground 
 
 According to information obtained from Electric Service Co., a trans- 
 former service company, from comments made during a telephone survey of load 
 center manufacturers and from information obtained during the mine visits, 
 there are few askarel-f illed transformers in use underground in coal mines. 
 All load centers used dry type transformers that have been designed to with- 
 stand the environment in the mines. When questioned about potential diffi- 
 culties with dust or dampness in the mines, manufacturers replied that these 
 conditions do not cause major problems. The few askarel transformers that are 
 in use in underground coal mines are gradually being taken out and replaced 
 with dry type transformers. 
 
 The relative scarcity of askarel transformers in underground coal mines 
 is not duplicated in underground metal/nonmetal mines, where the use of aska- 
 rel transformers is widespread. During visits to three underground mines, 
 askarel transformers were found in numerous locations in the underground dis- 
 tribution system, covering all applications from main underground substations 
 to small units on lighting circuits. The mountings for these transformers 
 ranged from concrete pads level with a damp mine floor to diked, elevated 
 
 a Telephone conversation with Joseph Ivy, Marion Power Shovels, August 8, 1977. 
 ^Telephone conversation with Frank Oslakovic, Page Engineering Co., August 10, 
 1977. 
 
15 
 
 concrete pads. At two of the mines visited, a major askarel leak would easily 
 find its way into the mine water. This water was being pumped to the surface 
 where it was being used in ore processing operations and was subsequently 
 impounded. A major askarel leak in these cases could cause widespread 
 contamination and would be extremely costly to clean up. 
 
 Failure of an askarel transformer accompanied by an internal electrical 
 arc can vaporize a considerable quantity of PCB's that will then be released 
 through the pressure relief valve. The National Electrical Code requires that 
 askarel transformers located in buildings be vented to the outside because of 
 the potential health problems that could result from worker exposure to high 
 concentrations of PCB vapors. No such venting is possible with those askarel 
 transformers used underground, the mines presumably accepting the increased 
 risk of toxicity as a tradeoff for reduced f lammability. 
 
 The extent of askarel transformer use varies from mine to mine. At one 
 mine only the main underground substations used askarel transformers, and the 
 remaining transformers were either oil filled or dry type. At a second mine 
 all the underground transformers were askarel filled as a matter of company 
 policy. 
 
 Surface 
 
 The use of askarel transformers at the surface facilities of underground 
 mines, both coal and metal /no nmetal, and at the ore processing facilities at 
 strip mines, is also common. Askarel transformers are used any place where 
 such use is required by the National Electrical Code, generally any indoor 
 location where the transformer is not mounted in a fire-resistant enclosure. 
 The transformers that were observed ranged in size from 50 kva single-phase 
 units, which contained roughly 40 gal of askarel and fed an auxiliary power 
 circuit, to 8,500 kva three-phase units that contained 3,415 gal of askarel 
 and served an electrolytic zinc plant. The only environmental problem 
 associated with the present siting of these transformers is that in most cases 
 a major askarel lead would almost certainly find its way through numerous 
 floor drains into the water system of the surface facility. 
 
 Number of Askarel Transformers Used in U.S. Mines 
 
 The information in tables 2 and 3 refers specifically to askarel 
 transformers. Although reference will be made to both askarel transformers 
 and to PCB transformers, the terms are not synonymous. "Askarel transformers" 
 contain askarel, while "PCB transformers" includes askarel transformers plus 
 any other type of transformer that for whatever reason (usually inadvertent 
 contamination) contains more than 500 ppm (0.05 percent) PCB's. This 
 distinction and the problems it imposes are discussed in greater detail later 
 in this publication. 
 
 The 2 percent of all transformers cooled with askarels amounts to between 
 135,000 and 140,000 transformers nationwide. The estimate of the number of 
 askarel transformers in service in mines was based on data gathered in 20 mine 
 
16 
 
 visits. Table 2 summarized the results of visits in terms of stationary 
 transformers, machine-mounted transformers, and surface and underground 
 transformers. 
 
 TABLE 2. - Summary of askarel transformer data gathered during visits to mines 
 
 ~~-\ 
 
 Production, 
 million tons ore 
 per year 
 
 Number of askarel transformers 
 
 Mines 
 
 Machine mounted 1 
 
 Total 
 
 Surface metal/nonmetal: 
 
 1 
 
 2.8 
 31.4 
 20.0 
 
 7.7 
 
 10.2 
 
 3.3 
 
 NA 
 1.6 
 
 NA 
 
 8.1 
 3.2 
 1.7 
 1.6 
 New 
 4.0 
 1.9 
 
 6 
 
 
 
 15 
 
 
 NA 
 
 NA 
 12 
 ( 2 ) 
 
 
 
 
 
 
 
 
 1 
 
 6 
 
 2 
 
 44 
 
 3 
 
 Surface coal: 
 
 1 
 
 65 
 15 
 
 2 
 
 1 
 
 3 
 
 Underground metal/nonmetal: 
 1 
 
 NA 
 24 
 
 2 
 
 25 
 
 3 
 
 Underground coal. 
 
 NA 
 
 3 
 
 
 6 
 
 12 
 2 
 1 
 
 NA Not available. 
 
 Underground transformers for all underground mines. 
 
 -Nearly all. 
 
 %o data available fr 
 
 om mines 
 
 5-11. 
 
 Overall estimates of the number of askarel transformers in use by the 
 various portions of the mining industry have been based on these data and 
 other information obtained over the period of this study. These numbers are 
 shown in table 3. 'For the coal industry, the estimates were made by directly 
 extrapolating the number of transformers at the mines surveyed, based on the 
 tonnage produced at those mines compared with the tonnage produced by the 
 entire industry. For the metal/nonmetal industry, the extrapolation was done 
 based on a comparison of the electrical consumption of the entire industry. 
 The estimate of the number of transformers includes all mining, crushing, 
 grinding, washing, drying, and benef iciation operations for each segment of 
 the mining industry. It is likely that these estimates constitute an upper 
 bound on the number of askarel transformers actually in service because visits 
 were made to those mines known to be using askarel transformers. 
 
17 
 
 TABLE 3. - Extrapolated estimates of numbers of askarel 
 transformers in various mining segments 
 
 Industry segment 
 
 Number of askarel 
 transformers 
 
 
 1,600 
 
 
 1,300 
 400 
 
 
 100 
 
 
 
 Total 
 
 3,400 
 
 
 
 How To Identify an Askarel-Filled Transformer 
 
 The following methods can be used to determine whether or not a 
 transformer is cooled by askarel (PCB): 
 
 (a) Nameplate data — Most transformers will have intact nameplates con- 
 taining details on the size of the unit and the weight and volume (usually in 
 pounds and gallons) of the coolant. In almost all cases where askarel cool- 
 ants are used, the nameplate will contain the manufacturer's trade name for 
 askarel. The following trade names for transformer askarel are the ones most 
 likely to be encountered: 
 
 Manufacturers * Trade Name 
 
 Allis-Chalmers Chlorextol 
 
 American Corp Asbestol 
 
 Electro Engineering Works NA 
 
 Envirotech Buell NA 
 
 ESCO Manufacturing Co Askarel 2 
 
 Ferranti-Packard Ltd Askarel 2 
 
 General Electric Co Pyranol 
 
 H. K. Porter NA 
 
 Helena Corp NA 
 
 Hevi-Duty Electric Askarel 2 
 
 ITE Circuit Breaker Co Nonflammable liquid 
 
 Kuhlman Electric Saf-T-Kuhl 
 
 Maloney Electric NA 
 
 Niagara Transformer Corp Askarel 2 EEC-18 
 
 Power Zone Transformer EEC-18 
 
 R. C. Uptegraff NA 
 
 Research-Cottrell Askarel 2 
 
 Standard Transformer Corp NA 
 
 Van Tran Electric NA 
 
 Wagner Electric No-Flamol 
 
 Westinghouse Inerteen 
 
 ? Nepolin 
 
 ? Dykanol 
 
 NA Not available. 
 
 ^This list is not necessarily complete. PCB's have been used since 
 
 1929, and many companies have gone out of business. 
 ^Generic name used for nonflammable insulating liquids in trans- 
 formers and capacitors. 
 
(b) If the nameplate does not show one of the above tradenames for aska- 
 rel and if it is not plainly written on the nameplate that the unit is oil 
 cooled, then a determination can be made on the basis of the fluid density by 
 dividing the weight of the cooling fluid by the number of gallons. Fluids 
 weighing less than 8 lb/gal are definitely askarel. Fluids of intermediate 
 density should be chemically tested unless the manufacturer of the unit can 
 identify thev coolant. 
 
 (c) If no nameplate data are available (sometimes nameplates become lost 
 or obscured over the years and cannot be read), then a sample of fluid should 
 be withdrawn and tested to establish its density. A simple test consists of 
 using a small amount of water into which a single drop of the fluid 'in ques- 
 tion can be dropped. The amount of water needed should be kept very small 
 because if the fluid does turn out to be askarel, the test water will have to 
 be disposed of in the approved manner. The test is this: If the drop of 
 fluid sinks in the water, it is askarel; if it doesn't, it isn't. 
 
 (d) In many instances where transformers are listed as containing oil, 
 they may in fact contain small, but significant, amounts of PCB. This small 
 content of PCB is the result of the past common practice of topping off oil- 
 filled transformers (after samples have been withdrawn for testing of electri- 
 cal properties) with spare askarel fluid instead of with transformer oil 
 (mineral oil). There is no easy way to test such PCB-contaminated oil; a 
 small sample must be extracted and properly packed and sent to a testing labo- 
 ratory equipped to measure the PCB content of the fluid. If the oil is found 
 to contain more than 500 ppm PCB, the transformer will have to be treated as 
 if it is an askarel transformer in order to be in full compliance with Federal 
 regulations. 
 
 Oil-filled transformers may be assumed to be "PCB-contaminated trans- 
 formers" unless it is known that the oil contains more than 500 ppm PCB's. 
 
 EPA Requirements for PCB (Askarel) Transformers 
 
 Definition : PCB transformers are those liquid-filled transformers in 
 
 which the liquid contains more than 500 ppm PCB's. (Note: PCB transformers 
 
 mounted on railroad locomotives and multiple-unit electric commuter cars are 
 covered by different requirements.) 
 
 Manufacture, import, and sale of new PCB transformers : Banned 
 
 Use : Continued use of nonleaking PCB transformers is authorized 
 indefinitely. 
 
 Diking : Not required, but you are responsible for cleaning up all 
 spilled PCB's. 
 
 Marking : A large (6-inch-square) label must be applied to each PCB aska- 
 rel transformer. 
 
19 
 
 Recordkeeping : The central PCB records must contain the identity and 
 location of each PCB askarel transformer; the weight of PCB's contained in 
 each unit; the date each transformer is removed from service, placed into 
 storage, and shipped for disposal; the storage location and disposal location 
 for each transformer removed from service; and the name and address of the 
 purchaser of each PCB transformer that is resold. 
 
 Resale of used nonleaking PCB transformers by user : Authorized. 
 
 Servicing : Authorized provided the coils are not removed and there is no 
 change in ownership of any PCB's. 10 
 
 Rebuilding : Banned (coils may not be removed from the tank). 
 
 Retrof illing (substitution of other liquid for PCB's): Authorized if 
 there is no change of ownership of PCB's. 11 The transformer must still be 
 considered a PCB transformer as long as the concentration of PCB's in the 
 liquid is above 500 ppm by weight (1 lb PCB's in 2,000 lb of liquid). A 
 retrofilled transformer may no longer meet the definition of an askarel trans- 
 former established by the National Electrical Code and may therefore have dif- 
 ferent code restrictions on its use. 
 
 Processing of used PCB askarel for reuse : Authorized provided there is 
 no change in ownership of the liquid. 12 
 
 Sale of new or reclaimed PCB askarel: Banned. 
 
 13 
 
 Storage of new or reclaimed askarel : Must be in special storage areas 
 meeting the EPA requirements. 
 
 Disposal : Drain liquid PCB askarel into approved containers. Fill 
 transformer with kerosene or fuel oil, allow to stand for at least 18 hours, 
 and drain into approved containers. Seal up drained transformer and dispose 
 of in an approved chemical waste landfill. Dispose of liquids in an approved 
 chemical waste incinerator (at present, store until an approved incinerator 
 becomes available). Storage beyond 30 days to be in special area. 
 
 Scrap recovery of failed PCB transformers : Banned. 
 
 Spill cleanup : All material contaminated with more than 50 ppm PCB's 
 must be picked up and disposed of in facilities approved by the EPA. 
 
 10 Unless the seller of PCB's has applied to the EPA for an exemption from the 
 ban on "distribution in commerce" of PCB's and EPA has granted the 
 exemption. Change of ownership for purposes of approval disposal is 
 allowed. 
 
 ^See footnote 10. 
 
 12 See footnote 10. 
 
 13 See footnote 10. 
 
20 
 
 Precautions for Continued Use 
 
 As pointed out above, there are about 3,400 PCB askarel transformers 
 presently in use in the U.S. mining industry. The EPA regulations will allow 
 these transformers to remain in service until they fail, provided the special 
 PCB label is applied to each unit and the required records are kept. However, 
 the EPA regulations require special disposal of any material that is contami- 
 nated by PCB's spilled or vented from any transformer, whether caused by acci- 
 dental damage to the transformer or by electrical failure of the unit. The 
 resulting cleanup costs can be very high if large quantities of soil are con- 
 taminated or, particularly, if PCB's enter any sewer, stream, or other water. 
 In addition to the costs incurred in cleaning up spilled PCB's, the owner of a 
 failed transformer may be subject to stiff fines for improper disposal of 
 PCB's if it is not possible to recover all the lost fluid. 
 
 The risk of large, uncontrolled PCB spills can be minimized by analyzing 
 the possible risks associated with each PCB askarel transformer and by taking 
 steps to contain the uncontrolled spread and loss of PCB's from the unit. 
 This section describes a number of methods that can be used to secure trans- 
 formers against spills, including: 
 
 Dikes 
 
 Berms 
 
 Curbs 
 
 Plugging of water drains 
 
 Transformer retrofilling 
 
 Transformer relocation 
 
 Fences and vehicle barriers 
 
 Emergency foam packs 
 
 Special problem transformers 
 
 Significance of Water 
 
 When PCB's leak into the environment from transformers or from any 
 source, the already widespread PCB pollution problem becomes aggravated. 
 Recovery or cleanup of spilled PCB's is usually expensive, partly because the 
 disposal costs are high and partly because special effort must sometimes be 
 expended, as in cases where PCB's spill into water. 
 
 When PCB's spill onto land (that is, onto soil or dirt) the cleanup pro- 
 cedure consists primarily of removing the contaminated soil and disposing of 
 it in an EPA-approved chemical waste landfill. This can be expensive. The 
 amount of soil that has been removed following spills has been tens of thou- 
 sands of barrels, which after transport and burial costs, can easily run to 
 costs of more than $100,000. 
 
 Spills into water, however, are vastly more complex and therefore more 
 expensive. Even spills into nonf lowing lakes or swamps, as opposed to rivers 
 or streams, result in extreme cleanup costs because of the dredging operations 
 that are invariably necessary and because of the greater volume of waste mate- 
 rial (for example, earth and sediment) that must be handled, packaged, 
 shipped, and buried. In rivers where the moving water can both aggravate the 
 
21 
 
 cleanup operation as well as spread the PCB's that are stirred up from the 
 bottom sediments during the dredging operations, cleanup costs can be high 
 and, at the same time, substantial environmental pollution can still result. 
 In one instance in Washington State, an askarel transformer containing about 
 250 gal of fluid was accidentally dropped on a dock and leaked into a river. 
 After all the cleanup operations, it was calculated that only about 7 percent 
 of the askarel was recovered, and the cost was close to half a million 
 dollars. 
 
 Cleanup of spills that occur on land can be especially costly if the 
 spill threatens to contaminate groundwater that is used for drinking. Vast 
 amounts of soil may have to be removed to approved chemical waste landfill 
 facilities, and costly tests must be performed to insure that the contamina- 
 tion has been contained. 
 
 Thus the presence of water near a leaking transformer is an important 
 consideration in deciding how to best manage a PCB askarel transformer. 
 
 Decision Guide 
 
 In general, the objective in the securing of PCB transformers is to 
 insure that any large leak of fluid will be contained within a specified area 
 away from access to water of any kind (including sewage water and drainage 
 systems that connect to either sewage systems or to any type of water body 
 including groundwater). It is expected that in most instances (at least 3 out 
 of 4 times) it will be feasible to either build a dike around the transformer 
 and switch gear assembly or to effectively dike the entrance ways to the shel- 
 ter or rooms that contain the units. 
 
 In all instances, the inspector or engineer who makes the decision on how 
 to deal best with a given transformer should be on the lookout for all possi- 
 ble methods by which fluid can escape into the environment. For outdoor 
 transformers, sheltered or unsheltered, the proximity of soil and access to 
 water by way of floor drains, ditches, or whatever method, should be noticed 
 and taken into consideration in establishing both the priority and the type of 
 confinement for a given transformer. For indoor and underground transformers, 
 drains should be pinpointed and should be plugged and sealed. Otherwise, 
 efforts should be taken to insure that spilled fluid will be restricted from 
 access to the water. 
 
 For all transformers, spill confinement measures should include assurance 
 that transformer mounting pads are not cracked or broken, that adjacent walls 
 that may become part of proposed spill-confinement system (especially walls 
 made of porous materials such as cinderblock) are well sealed near the floor, 
 that the interface between the walls and floor (this is called the wall-floor 
 interface) is sealed, that there are no holes in the floor such as conduit 
 access holes through which fluid can drain, and that there are sufficient bar- 
 riers and/or fences to protect the unit from damage from vehicles (automobiles 
 and lift-type trucks) and from damage by people who may be moving or working 
 in the area. 
 
22 
 
 It is not felt that it will be necessary to use the following decision 
 guide in order to effectively analyze all transformer settings for spill 
 potential and optimum spill confinement measures. It is likely that whoever 
 uses this guide will, by doing so, quickly learn to see the points that need 
 to be considered without having to refer to the guide. 
 
 Decision Guide Questions and Considerations 
 
 1. If the PCB askarel is located on the surface inside a building or 
 outside, is there any way that fluid leaked from the unit could find its way 
 to either a water drain (such as a sewer or a gutter leading to a sewer) or 
 directly to water (for instance, by running downhill and into a stream or 
 swamp or river)? 
 
 If so, such units should be given priority in spill prevention mea- 
 sures. If not, the unit should still be secured against leaks, though the 
 urgency is not as great as that of units located with access to water. 
 
 2. If the transformer is located below ground, or even simply below 
 grade, in a location from which groundwater must be continually pumped, is 
 there any way that fluid leaked from the unit could find its way into the 
 water? 
 
 Since groundwater is usually pumped out of mines, PCB contamination 
 could easily be spread to larger volumes of water and soil, and if the water 
 is used in ore processing, it could also contaminate the ore and processing 
 plant. Transformers in such situations should be given priority in spill pre- 
 vention measures. 
 
 3. In some instances PCB transformers are located in rooms or in alcoves 
 that appear to be secure against the loss of fluids to either water or soil; 
 if this is the case, are there curbs or diking either around the transformers 
 or across the entrance ways to the transformer rooms so that the units are 
 completely secure against uncontrolled loss of fluid? 
 
 4. In cases where transformers are situated in rooms with porous cinder- 
 block walls, are those walls sealed with either grout type sealers or with a 
 heavy type of paint that is not soluble in chlorinated hydrocarbon solvents 
 such as PCB and trichlorobenzene? 
 
 5. If the transformer is otherwise secured against leaks, is the mount- 
 ing pad or the floor of the transformer room free of cracks? Cracks that look 
 like they would not prevent the loss of fluid should be grouted and painted 
 with solvent resistant paint that will serve the dual purpose of sealing 
 smaller cracks not grouted and of sealing the pad against water absorption 
 that in cold places can cause freeze fracturing of the concrete. 
 
 6. Is the transformer in a location where vehicular traffic might be a 
 hazard? For instance, is it located near to a driveway or next to a parking 
 lot? If so, a vehicle barrier might be useful, expecially if the unit is 
 located where a body of water might be threatened by a loss of fluid. 
 
23 
 
 7. Is the transformer located near machinery that might throw projec- 
 tiles with sufficient energy to damage the unit? Is the transformer located 
 in a place where forklift vehicles might accidently run into it or snag the 
 heat exchanger or some other part? If so, fences or vehicle barriers might be 
 necessary to provide protection, unless it is reasonably feasible to either 
 relocate the transformer to a safer place or to replace it with a non-PCB 
 transformer. 
 
 8. Is the unit mounted on unwelded steel plates (as might be the case 
 if the unit is platform mounted), mounted on a second story, mounted in a 
 mobile machine, or mounted on some other type of surface that might be 
 extremely difficult to seal against fluid loss? Such a unit could be tempo- 
 rarily removed while the mounting surface is sealed. If the transformer does 
 not present an immediated threat to water or to personnel and would not pose 
 any great difficulties in a cleanup should a spill occur, then no securing 
 measures need be taken. 
 
 9. If the unit is pad mounted, is there room for installation of a dike 
 on the edge of the mounting pad? If not, and if some kind of spill protection 
 is needed, either the pad could be extended and a curb installed as part of 
 the extension or a berm of asphalt, concrete, or clay could be built around 
 the unit. 
 
 10. If the unit is mounted near a wall that will be part of the spill 
 containment barrier, is the wall of nonporous material such as concrete or 
 sealed cinderblock and is the wall-floor interface tight against fluid loss? 
 
 11. If the transformer is in a special room, alcove, or vault, is this 
 area used as storage space, for example, for brooms and other building mainte- 
 nance materials? If so, and if there is no other better storage place for the 
 stored materials, it might be best to put a dike around the transformer itself 
 rather than to secure the room as a whole to prevent additional cleanup 
 expense from contaminating extra material. 
 
 12. If the transformer is in a special room, alcove, or vault, are there 
 also drains in the room that cannot be sealed and removed from service because 
 they are needed to remove water from other systems sharing the room with the 
 transformer (for example, an air-conditioning system)? If so, the transformer 
 rather than the whole room will have to be diked against the possibility of a 
 fluid leak. 
 
 13. If the room is used for nontransformer-related activities, is the 
 unit sufficiently protected against the potential for mechanical damage? 
 
 14. If the unit is located outside and is already adequately diked 
 against the possibility of fluid loss, is there an allowance for the removal 
 of rainwater by a properly designed water-only drainage system? The design of 
 a water-only drainage system that can be built from exiting plumbing hardware 
 is included as appendix B of this report. 
 
24 
 
 15. Is the unit old or does it appear to be old? If so, this may be a 
 consideration in whether or not to replace the unit. There are commercial 
 transformer service companies that are experienced in the testing of trans- 
 formers to find out whether or not they are in condition to continue in 
 service. 
 
 16. Is^there any evidence of an active leak from the transformer? If 
 so, and if it is due to corrosion or a broken or cracked weldment, the unit 
 should probably be replaced. Otherwise, arrangements should be made to repair 
 the unit, especially if it is located near water or a path to water and if 
 there are no immediate plans to secure the unit against fluid loss. (NOTE: 
 Approximately 10 percent of pad-mounted askarel transformers show some evi- 
 dence of leaking.) If the unit has to be replaced, is its setting suitable 
 for the installation of an oil-filled transformer? That is, does the setting 
 satisfy the NEC requirements for the installation of oil-filled transformers 
 (indoor or outdoor)? If not, the new transformer will either have to be of a 
 fire-safe design, or an oil-filled transformer will have to be installed in a 
 different location. 
 
 Dikes 
 
 A dike is the most effective, aesthetically appealing technique for con- 
 taining a potential spill. It is also among the least costly of spill preven- 
 tion measures, expecially when compared with the alternatives of retrofilling 
 and relocation discussed below. 
 
 A suggested steel dike system shown in figures 2 through 5 consists of 
 steel angles (measuring 3.5 by 6 inches) that are bolted to the periphery of 
 the mounting pad. The seal between the dike and the pad consists of a gasket 
 of 3/8-inch-thick closed cell neoprene foam rubber. The corners of the dike 
 are bolted together by means of 2- by 2-inch steel angles. 
 
 Concrete pad 
 
 6-inch-high angle steel with 3.5 foot 
 base and 5/16-inch wall thickness 
 
 Corner joint of 
 2- by 2- by 1/4-inch 
 angle steel 
 
 FIGURE 2. 
 
 Typical transformer and switch gear on con- 
 crete mounting pad with steel dike installed. 
 
 An alternative to this 
 steel dike system is a con- 
 crete, curb-type dike. How- 
 ever, the concrete dike may 
 be more costly to install 
 and, since it would have to 
 be at least 5 inches wide to 
 be sufficiently durable, 
 would require more room on 
 the periphery of a trans- 
 former pad than the steel 
 dike. In cases where the 
 mounting pad is small, this 
 can be an important consid- 
 eration. Also, the curb- 
 type dike would slightly 
 inhibit the accessibility of 
 the transformer for mainte- 
 nance operation, moreso than 
 the steel dike. 
 
25 
 
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27 
 
 Dikes can be installed in both indoor and outdoor locations. In outdoor 
 locations, however, especially in parts of the country where rainfall is 
 excessive, provision must be made for water drainage in order to minimize the 
 corrosion hazard to the transformer-related switch gear and casings. A water- 
 only drainage valve, along with the parts specifications, is shown in fig- 
 ure 6. It will permit the passage of 3 gal/hr of water (when submerged 3 
 inches deep), but will close if the level of askarel approaches the level of 
 the drain opening. 
 
 Clean this surface and coat with 
 epoxy joining compound immediately 
 before pouring cement 
 
 3/4" to 1" re-bar 
 
 (A) 
 
 Soil 
 
 
 t 
 
 6" 
 
 1 
 
 
 i 
 
 L 
 
 _ Q _ 0_ _ 
 
 Mounting pad 
 _) 
 
 Pad extension 
 as cast 
 
 
 FIGURE 7. - Schematic diagram of basic parts and dimen- 
 sions of an extended mounting pad: A, exca- 
 vation and re-bar location; B, cross section 
 of extended pad. 
 
 Curb-type dikes can 
 most easily be installed in 
 those instances where the 
 mounting must be enlarged 
 because of insufficient room 
 even for the steel dike. 
 Figure 7 shows the typical 
 requirements for the 
 enlargements of a mounting 
 and the installation of a 
 curb dike. 
 
 Berms 
 
 A berm is simply a 
 mound of earth or asphalt 
 surrounding an outdoor 
 transformer. A berm, espe- 
 cially an earthen one, would 
 take up much more room than 
 a steel dike, and if porous 
 enough to allow the drainage 
 of rainwater, would also be 
 too porous to give maximum 
 protection against high 
 cleanup costs in the event 
 of a PCB spill. On the 
 other hand, it would be dif- 
 ficult to install an effec- 
 tive water-only drainage 
 system in a berm if the berm 
 were adequately waterproofed 
 with a lining of bentonite 
 or some other impermeable 
 clay. 
 
 Asphalt berms con- 
 structed on asphalt or con- 
 crete surfaces that surround 
 a given transformer mounting 
 
28 
 
 might be a low-cost alternative to dikes, but they can restrict accessibility 
 of the transformer and are not as aesthetically appealing as a dike. 
 
 In cases where there is a moderate problem of water accessibility to a 
 potentially leaking transformer, and where the transformer is in a location 
 where vehicular damage is a possibility, such as near a parking lot or street 
 or driveway, a berra could provide both security against leaks and protection 
 from vehicles. 
 
 Fences and Vehicle Barriers 
 
 It is probable that a small number of PCB transformers will be found in 
 locations where the threat of damage from moving vehicles should. be taken into 
 consideration (for instance, in locations where forklift type vehicles are 
 commonly used, either indoors or outdoors, and next to parking lots and close 
 to driveways). 
 
 In some cases, chain-link fences will provide adequate protection against 
 lightweight freight vehicles, but usually where vehicle damage to transformers 
 is possible, heavier protection such as that depicted schematically in fig- 
 ure 8 is advisable. The simple pipe-type barriers can be installed with 
 
 1.5 feet if surrounded by 
 concrete or asphalt pavement 
 
 5-inch-diameter steel pipe, 
 1/4-inch wall, concrete filled 
 
 FIGURE 8. 
 
 3 feet if set in concrete 
 but surrounded by sod 
 
 Vehicle barrier suitable for protection of an askarel transformer located in a park- 
 ing lot or next to a street. 
 
29 
 
 relatively little effort and cost, and in many instances, one pipe of suffi- 
 cient diameter will provide adequate protection. 
 
 Curbs and Doorway Dikes 
 
 Transformers, PCB or otherwise, are often mounted in special transformer 
 rooms. Whether the room is inside a larger building or is a free-standing 
 structure, the least costly method of securing the transformers against PCB 
 loss is often to install a dike or concrete curb at entrances. The only cases 
 where an entrance sill may not provide adequate protection would be where 
 there is a drain in the room with the transformer that cannot be plugged (say, 
 because the room is shared with an air-conditioning unit that must be provided 
 a drain for the runoff of condensation), or where the floor or walls will not 
 provide a tight sealing barrier against fluids. Walls of special enclosures 
 are often made of unpainted cinderblock built onto concrete mounting pads. In 
 this case, both the walls and the interface between the wall and floor must be 
 sealed with a material that is only minimally soluble in chlorinated hydrocar- 
 bons (PCB's and triclorobenzene). This can be done by grouting with cement or 
 other inorganic material and then painting. 
 
 Emergency Foam Packs 
 
 Possibly the most cost effective means of spill control — but not of 
 prevention — is with the use of emergency foam packs. These are back-mounted 
 units capable of dispensing up to 70 cu ft of urethane foam that can be used 
 to form a fluid barrier very rapidly. However, there are certain disadvan- 
 tages to these units, including the need to keep at least one person in train- 
 ing and on call in the event of a spill. Also, the urethane foam will not 
 adhere well to wet surfaces nor will it provide a good fluid barrier if 
 located on porous or sandy soil. On concrete or asphalt, urethane should make 
 an effective instant dike. The problems with wet surfaces have been studied, 
 and some solutions have been found. For additional information the interested 
 reader is referred to the following publication: 
 
 U.S. Environmental Protection Agency. Control of Chemical Spill by Physical 
 Barriers. Pub. EPA-R2-73-185, March 1973; available from National Techni- 
 cal Information Service, Springfield, Va., PB 221 493 OBA. 
 
 Special Problems 
 
 Instances will probably arise where no set of preestablished procedures 
 will apply to a special-problem transformer. For instance, sometimes in order 
 to conserve floor space, indoor-mounted transformers are mounted on raised 
 platforms 10 or 12 ft or more above the floor, often on a platform of steel 
 plates that are not welded together to form a liquid-tight seal. This is com- 
 mon in draglines. In such a case, there is no way to dike and to seal the 
 platform against fluid loss without temporarily raising the transformer and 
 then welding the platform plates together. But the effort in temporary 
 removal of an askarel transformer is not much less than the work required to 
 relocate the unit either on the floor (on concrete, diked) or outside the 
 
30 
 
 building. A similar effort could replace the unit with a different fire-safe 
 transformer or with an oil-filled transformer mounted outside. In other 
 words, the amount of effort to secure a transformer against fluid loss to 
 adjacent work areas and to the environment at large might be more than is jus- 
 tified by the probability of a major leak. It might be more effective in the 
 long run, if water or vast amounts of porous soil are not threatened by a pos- 
 sible leak, to leave the PCB unit in service without precautions; if water is 
 a problem, it "might be best to replace the unit rather than to secure it 
 against leaks. 
 
 Most transformers can be readily secured against fluid loss, but protec- 
 tion of those that are resistant to easy solution will have to be decided by 
 comparing cost of securing the unit against fluid loss or removing it to a 
 better location versus the potentially high cleanup costs should a leak 
 occur. 
 
 Mobile Mining Machinery 
 
 Transformers are used on electrically powered draglines, shovels, and 
 blasthole drills to reduce the incoming high voltage to the levels required by 
 the drive motors. In most instances, mobile mining machines have been 
 designed to safely use oil-filled transformers. However, several mining com- 
 panies have asked that machines be delivered with askarel transformers, and 
 the manufacturers have complied. 
 
 There appears to be no general method for securing onboard askarel trans- 
 formers against loss of fluid. In some instances there is sufficient room to 
 allow the installation of transformer dikes; in some cases, however, the sim- 
 ple installation of a dike would not be sufficient; for instance, the mounting 
 surfaces often consist of a floor made of steel plates that are butted up 
 against each other without being welded or sealed. Welding of mounting sur- 
 faces under transformers would require the temporary removal of the trans- 
 former, an undertaking that would be almost as costly and time consuming as 
 replacement of the units with nonaskarel units. 
 
 Most mobile mining machinery that contains PCB transformers is used in 
 surface applications. The loss of PCB fluid from an onboard transformer 
 might be difficult to clean up if it runs into the complex portions of the 
 machinery, but the loss of fluid to the ground would probably be unaggravated 
 by the presence of water in most instances. The cleanup procedure would con- 
 sist of decontaminating the machine and the containers and of disposal of 
 earth and soil. 
 
 If anything general can be said about the precautions that can be taken 
 with respect to askarel transformers on mining machines, it is that the indi- 
 vidual mining companies will probably have to use some subjective measures to 
 determine whether the cost of securing their mobile-mounted askarel trans- 
 formers against leaks is likely to be less than the cost of fines, penalties, 
 and cleanup costs in the event of a transformer failure. 
 
31 
 
 Relocation of Transformers 
 
 It has been noted in many transformer surveys, at mines as well as in 
 other industries and operations, that not all askarel transformers are located 
 in places where electrical codes or safety considerations require their use. 
 In such cases, especially where a fluid loss from an askarel or PCB trans- 
 former could reach water or otherwise cause local or environmental damage, the 
 simplest and securest solution is to replace the PCB transformer with an oil- 
 filled unit and to relocate the original transformer in a site known to be 
 secure from leaks. It might be feasible in a small number of cases to simply 
 exchange two transformers, location for locations, and to totally eliminate 
 any other PCB securing measure. 
 
 Retrof illing 
 
 Retrofilling is the replacement of the PCB askarel fluid in a transformer 
 with non-PCB fluid. Askarel transformers located in places where fire hazard 
 is a consideration can be retrofilled with silicone fluid or with the new 
 high-fire-point hydrocarbon fluids that are available. However, retrofilling 
 is expensive and a single retrofill does not usually reduce the concentration 
 of PCB's to below 500 ppm. 
 
 Typical commercial costs for field retrofilling of askarel transformers 
 are $30 per gal of capacity of the transformer, and this does not include the 
 cost for storage of the PCB fluid removed or of the solvent fluids used to 
 flush the transformer at the time of retrofill. (PCB storage is necessary 
 until approved PCB incineration facilities become available; cost of disposal 
 is expected to be high because it must include the cost of shipment by an 
 approved method; the actual cost of incineration will probably be on the order 
 of several dollars per gallon of PCB's.) Retrofilled transformers must be 
 marked and handled as PCB transformers unless the concentration of PCB's has 
 been reduced to below 500 ppm. A transformer must be retrof illled a^t least 
 3 times to get the concentration of PCB's to less than 500 ppm. Successive 
 retrofills should be at least 18 months apart. 
 
 The major advantage of retrofilling is achieved only if the concentration 
 of PCB's is reduced to below 500 ppm by repeated replacement of the liquid. 
 Once the concentration of PCB's has been reduced to this level, the trans- 
 former may be considered a PCB-contaminated transformer and may therefore be 
 rebuilt if it fails. If a PCB askarel transformer is in a critical applica- 
 tion and the time saving achieved by rebuilding rather than replacing the unit 
 when it fails offsets the cost of multiple retrofilling, this procedure might 
 be justified. However, once the unit is filled with oil, silicone, or high- 
 fire-point transformer liquid, the risk of fire is increased, and although the 
 total amount of PCB-filled units in the unit is decreased, the same cleanup 
 requirements exist as for PCB-filled units if the concentration of PCB's is 
 above 50 ppm. 
 
 The technology for reducing residual PCB levels in retrofilled trans- 
 formers is rapidly being developed, and the supplier of the liquid should be 
 
32 
 
 contacted to determine the cost and feasibility of achieving the 50 ppm level 
 of PCB's in retrofilled transformers. The companies most active in this field 
 are — 
 
 For Hydrocarbon fluids: RTE Corp. 
 
 Fluids Division 
 1900 East North St. 
 Waukesha, Wis. 53186 
 414-547-1251 
 
 For silicone fluids: Dow Corning Corp. 
 
 Midland, Mich. 48640 
 517-496-4000 
 
 Non-PCB Replacement Transformers 
 
 New PCB askarel transformers have not been manufactured in the United 
 States since 1978, and EPA regulations prohibit the manufacture of additional 
 new PCB units or the rebuilding of existing units. Therefore, it will be 
 necessary to replace every existing PCB askarel transformer, either when it 
 fails or because there is too great a risk of uncontrolled PCB spills and no 
 adequate way to dike or protect the transformer. 
 
 There are a number of alternatives to the use of PCB askarel trans- 
 formers, but each type is characterized by different tradeoffs of fire safety, 
 overload capacity, and initial price. Most existing large non-PCB trans- 
 formers are filled with transformer oil, which is a refined petroleum oil with 
 viscosity and flammability characteristics comparable to those of SAE 10 motor 
 oil. Oil-cooled transformers are the least costly units available for instal- 
 lations where the potential fire hazard presented by the oil is not a problem. 
 Askarel-f illed transformers have almost all the advantages of oil-cooled 
 transformers, plus they are the most fire safe of any kind of liquid-filled 
 transformer. (The disadvantages of askarel compared with oil, aside from the 
 obvious ones of the recently recognized toxic and environmental hazard, are 
 such minor considerations as the higher solvency strength of askarel on the 
 insulation components of transformer windings, plus slightly lower dielectric 
 strength than oil, and a tendency for the askarel to form corrosive HC1 under 
 conditions of internal arcing or even during corona discharge; the latter 
 effect results in a more stringent maintenance program for askarel trans- 
 formers than for oil transformers.) 
 
 The alternatives to askarel transformers are listed, described, and com- 
 pared below. No one of the alternatives has all of the advantages of askarel 
 transformers, all cost slightly to significantly more than askarel trans- 
 formers, but none present the environmental hazard with PCB's. Some 
 alternatives have special advantages possessed by neither oil nor askarel 
 transformers. The attributes of the different types of non-PCB alternatives 
 are given below; they are compared on an installed cost basis, and a simple 
 decision guide is supplied at the end of this section. 
 
33 
 
 Characteristics of Non-PCB Replacement Transformers 
 
 Oil-Filled Transformers 
 
 The major disadvantage to mineral oil is its f lammability. Transformer 
 mineral oil has a flash point of 145° C, and if an arc occurs within the 
 transformer, the breakdown products will be hydrogen and methane, which are 
 also flammable. Detailed records of such failures are maintained by the 
 electrical industry. Fire underwriters do not approve of the use of oils and 
 other flammable liquids for indoor applications; where oil-filled transformers 
 are not specifically prohibited as onsite replacements for askarel-f illed 
 units, the National Electrical Code imposes certain restrictions upon their 
 mode of installation. 
 
 If safety were not a consideration, there would be no reason why 
 oil-filled transformers could not be used in all applications. Askarel-f illed 
 transformers cost about 1.3 times as much as oil-filled units of the same 
 capacity, and thus most users prefer the oil type where possible. The 
 oil-filled transformers are the same size as the askarel units, and they are 
 considerably lighter in weight. In addition, mineral oil has somewhat better 
 heat-transfer characteristics than does askarel, and an electrical arc in 
 mineral oil results in breakdown products that are noncorrosive. 
 
 Oil-filled transformers can be used in these applications only if they 
 are suitably isolated from flammable structures or if these structures are 
 suitably safeguarded against fires. Where transformers are located outside 
 the building or mine they service, however, the low-voltage power must be 
 brought into the building via cables or insulated buses, incurring additional 
 energy losses due to Joule heating in the additional low-voltage transmission 
 lines. 
 
 The National Electrical Code specifies the vault requirements for 
 oil-filled transformers in indoor locations. Building a fire-resistant vault 
 can double the installed cost of the transformer. 
 
 There are apparently no Federal regulations that prohibit the use of oil- 
 filled transformers in underground mines. Although some mines have removed 
 all oil-filled transformers from underground installations because of the fire 
 hazard associated with the possible loss of hundreds of gallons of hot oil, 
 other mines have used oil-filled units underground for years with no problems. 
 Adequate safety underground can be achieved by installing an oil-filled trans- 
 former in a vault that is equipped with automatic dampers on the ventilation 
 openings and automatic fire supression systems that would flood the vault with 
 carbon dioxide or Halon 1301 gas in the event of a fire. An extensive discus- 
 sion of the fire protection recommended for use with underground oil-filled 
 transformers is included in the following report: 
 
34 
 
 Buckley, J. L. , B. G. Vincent, and R. G. Zalosh (Factory Mutual Research). 
 Improved Fire Protection for Stationary Underground Equipment. BuMines 
 Open File Report 27-78, May 1976, 163 pp.; available from National Techni- 
 cal Information Service, Springfield, Va., PB 280 136/AS. 
 
 Silicone Transformer Liquid 
 
 All liquid-filled transformers have better sustained overload capacity 
 and short-term, high overload capacity than do dry type transformers. The 
 greater heat capacity of liquids compared with air and other coolant gases 
 used in transformers is the reason for this greater overload capability. The 
 fire-resistant alternatives to askarels are mainly silicones and high- 
 fire-point hydrocarbons of the paraffinic variety. A discussion on high- 
 fire-point hydrocarbons follows. 
 
 Silicone-f illed transformers are filled with low-viscosity polydimethyl 
 siloxane liquid. Silicone fluids are nontoxic, have low flammability (though 
 not quite as low as PCB's), and low solvency strength (which means that trans- 
 formers filled with silicone can be expected to have very long service lives). 
 The disadvantages of silicones are (a) even though the material is referred to 
 as "low viscosity," silicone is more viscous than either oil or askarel, which 
 means that silicone-filled transformers must be slightly larger than trans- 
 formers of equivalent power capacity filled with askarel or oil; (b) on a vol- 
 ume basis, silicone fluids cost about twice as much as askarel; (c) when 
 silicone does burn, it releases clouds of amorphous silica that may create 
 visibility problems; and (d) when used as a retrofill fluid, the poorer heat- 
 transfer characteristics of silicone relative to askarel require the derating 
 of the transformer by about 15 percent if the unit is likely to be run contin- 
 uously at close to its original rated temperature. 
 
 Silicone-filled transformers are not recommended for use in underground 
 coal mines because silicone vapors will gradually deactivate methane detec- 
 tors. Silicone liquids are also powerful defoamers, so large spills of trans- 
 former silicone liquid onto ore that will be treated by floatation or into the 
 water of a floatation plant may disrupt the operation of the process. 
 
 High-Fire-Point Transformer Liquids 
 
 The 1978 edition of the National Electrical Code has a new specification 
 for high-fire-point liquid insulated transformers that reads: "Transformers, 
 insulated with a nonpropagating liquid approved for the purpose, having a fire 
 point not less than 300° C shall be permitted to be installed indoors or out- 
 doors. Such transformers installed indoors and rated over 35,000 volts shall 
 be installed in a vault." 
 
 High-fire-point fluids for transformers are essentially of three varie- 
 ties: (1) Natural, that is, derived from natural hydrocarbon fluids by refin- 
 ing out everything but certain molecular species, uaually the long-chain 
 paraffinic molecules; (2) synthetic hydrocarbon, that is, built up out of 
 
35 
 
 simpler molecular species into long-chain paraffinic molecules; and (3) sili- 
 cones. The hydrocarbon products are roughly the same, just derived by differ- 
 ent processes. 
 
 Factory Mutual has published the following installation and protection 
 guidelines for transformers that contain high-fire-point liquids: 
 
 Factory Mutual Engineering Corp. Less Flammable Transformer Fluids. Data 
 Sheet 5-4S/14-8S, October 1979; available from Factory Mutual Engineering 
 Corp., 1151 Boston-Providence Turnpike, Norwood, Mass. 02062, telephone 
 617-762-4300. 
 
 The minimum allowable distances between the edges of the diked area and the 
 adjacent walls and the minimum allowable ceiling height are specified based on 
 the size of the diked area and the rate of heat release from a pool fire of 
 each specific transformer liquid. Factory Mutual has measured heat release 
 rates from the various liquids that are commercially available, and this 
 information is included in the Data Sheet. 
 
 There are a number of questions not yet satisfactorily answered concern- 
 ing the use of the high-fire-point transformer liquids. The most important 
 question concerns the realism of the test conditions. It has been suggested 
 that catastrophic arcing followed by case rupture is a relatively unusual mode 
 of transformer failure and that a more frequent problem is prolonged minor 
 arcing that generates flammable gases from the breakdown of transformer fluid. 
 The flammability of unused liquids may not be a reliable indication of their 
 relative safety under actual transformer operating conditions. 
 
 The fire point of the synthetic hydrocarbon high-fire-point fluid is 
 about 310° C; for the refined high-fire-point hydrocarbon it is about 312° C; 
 and for silicone it is 360° C. The high-fire-point of the paraffinic hydro- 
 carbon fluids is a result of the relatively high molecular weight of the 
 hydrocarbon material. The inherent disadvantage of the high molecular weight 
 is higher viscosity and thus lower heat-transfer capability than either ordi- 
 nary mineral oil or askarel. The major advantages of the high-fire-point flu- 
 ids are their low price relative to silicone and askarel and their inherent 
 biodegradability. 
 
 Open Air-Cooled Transformers 
 
 Transformers can be built without the use of a liquid cooling medium. 
 One type of dry transformer that is quite successful under limited conditions 
 is the open air-cooled transformer. In this design, the required cooling is 
 provided by air that passes through the transformer as a result of either 
 thermal convection or forced fan circulation. In those sizes where air-cooled 
 transformers are available, they are about equal in price to askarel-f illed 
 transformers of the same kva rating. However, the following limitations gov- 
 ern the successful use of open air-cooled transformers and prevent them from 
 being considered for many applications using askarel-f illed transformers. 
 
36 
 
 Heat Capacity : The power drawn from a transformer usually varies over a 
 fairly wide range. The rating of a transformer is basically governed by the 
 power it can handle continuously without overheating. If a liquid-filled 
 transformer is operated at overload conditions for a short period of time, the 
 liquid will act as a heat sink, absorbing the excess heat produced in the 
 transformer without a rapid increase in temperature. The result of this ther- 
 mal inertia is that liquid-filled transformers can operate at outputs of up to 
 200 percentr of rated capacity for a period of 1 to 2 hours without being 
 damaged. 
 
 An air-cooled, dry-type transformer does not have this heat sink availa- 
 ble and is limited to operating at a maximum service rating near its contin- 
 uous rating. Where the current drawn on the transformer does not vary greatly 
 during the day, this limitation is no problem. However, in most cases the 
 variation in load would require that a dry transformer be sized 20 to 30 per- 
 cent greater in capacity than a liquid-filled transformer for the same 
 application. 
 
 Dielectric Strength : The liquid coolant in a liquid-filled transformer 
 also provides a significant level of electrical insulation between the various 
 current-carrying components within the transformer. Air has a much lower 
 dielectric strength, and open air-cooled transformers are limited to a maximum 
 voltage of 25 to 40 kv. The problem of electrical insulation is even more 
 severe if the open air-cooled transformer only operates intermittently. When 
 the transformer is operating, the heat generated within the windings keeps 
 their insulation dry and maintains a high dielectric strength. However, when 
 the transformer is not operating, the coils cool to ambient temperatures and 
 the insulation can absorb moisture from the air, which reduces its dielectric 
 strength. Therefore, an open air-cooled transformer must be carefully dried 
 before being put into service after each time it has been allowed to cool. 
 
 One final problem with dry air-cooled transformers is due to the tendency 
 of dust to be attracted from the air to the coils by electrostatic attraction. 
 This dust can build up in the coils, which blocks the flow of air and causes 
 overheating, or the dust can form conductive paths that short circuit the 
 transformer. 
 
 Dry, open air-cooled transformers are generally limited to dry, clean 
 locations where the load requirements are fairly even and constant, and where 
 the maximum voltage does not exceed 30 kv. 
 
 Sealed Gas-Filled Transformers 
 
 A dry transformer can be provided complete protection from environmental 
 effects by sealing it is a pressure-tight container and using an inert gas as 
 the coolant. Gas-filled sealed transformers have the same overload limita- 
 tions as dry air-cooled units, but better control of the insulating media 
 raises the maximum achievable voltage to levels available with liquid-filled 
 units. 
 
37 
 
 Several different gases have been used as the coolant in sealed gas- 
 filled transformers. The commonly used gas in the United States is hexafluor- 
 oethane (C 2 Fe). Although chlorof luorocarbons are regulated by the EPA, the 
 use of this gas in transformers will probably not be affected by the regula- 
 tions. Nitrogen and sulfur hexafluoride have also been used successfully as 
 transformer coolants in certain applications. 
 
 Because the inert gas increases in pressure when heated, a gas-filled 
 transformer must be enclosed in a heavy pressure vessel housing. The pressure 
 vessel increases both the size and weight of the gas-filled transformer com- 
 pared with that of open air-cooled units. The price of the sealed gas-filled 
 units is also considerably higher than that of open air-cooled units. Because 
 of the poorer heat-transfer characteristics of the gas compared with liquids, 
 the gas-filled transformers are designed to operate at 150° C coil temperature 
 rise and have insulation systems limited to 220° C. Hot spots in the coils 
 can approach 220° C; accordingly, there is no allowance for even short-term 
 operation at loads higher than rated capacity. Therefore, the gas-filled 
 transformers must often be specified in a larger size than the liquid-filled 
 transformers to allow for the expected heavy load peaks of power consumption. 
 
 Cast Coil Transformers 
 
 The third class of dry transformer is the cast coil type. Cast coil 
 transformers have had their primary windings or both their primary windings 
 and their secondary windings totally encapsulated in vacuum-degassed epoxy 
 resin. This type of construction decreases the noise level in comparison to 
 other dry type transformers, and because of the thermal capacity of the encap- 
 sulating epoxy, the overload capacity approaches that of liquid transformers 
 while the fire safety advantage is about the same as that of other dry 
 transformers. 
 
 Cast coil transformers are generally more compact, lighter, and more 
 shock resistant than either liquid-cooled or the other dry-type units. The 
 exceptional thermal performance (comparable with that of liquid transformers 
 in terms of running temperatures and overload capability) is achieved by 
 reducing resistance losses in the coil conductors. This significantly 
 increases manufacturing costs and initial price, but it results in decreased 
 electrical operating costs and is a factor in the probably longer life of 
 these units. 
 
 This technology is better developed in Europe than in the United States. 
 Although the cast coil transformers are among the most expensive in terms of 
 initial cost, they are gaining increased usage where reliability, small size, 
 and fire safety are important consideration. 
 
 Mining Machinery Transformers 
 
 Draglines, shovels, and blasthole drills that are electrically powered 
 use transformers to reduce the incoming high voltage to the levels used by the 
 drive motors. In some instances, the machinery was originally designed for 
 oil-filled transformers. When askarel transformers were specified by the 
 buyer, they were installed in the fire-resistant vaults that had been designed 
 
38 
 
 for oil-filled transformers. In some cases where these customer-ordered aska- 
 rel units fail, they can be directly replaced with oil-cooled transformers 
 with little, if any, increase in fire hazard. In the event that an insurance 
 carrier requires fire safety in addition to an onboard vault, there is likely 
 to be no great difficulty in installing a silicone or high-fire-point, 
 hydrocarbon-cooled transformer. 
 
 In those instances where an item of mobile machinery was actually 
 designed with askarel transformers in mind, the installation of oil-filled 
 transformers might not be possible because of the lack of fire safety precau- 
 tions, such as fireproof vaults. Gas-cooled transformers might be adequate 
 replacements for askarel transformers, except that gas-cooled units are gener- 
 ally slightly larger in physical dimensions then comparable kva liquid-cooled 
 units. Silicone and high-fire-point hydrocarbon transformers might satisfy 
 most safety requirements at slightly higher cost than the original askarel 
 units. 
 
 Several other alternatives to the use of askarel transformers on mobile 
 machinery were observed during the mine visits. On one dragline, there were 
 several oil-filled transformers, each in a steel room with appropriate vents. 
 Each room was equipped with a fire detection system that would set off an 
 alarm in the operator's cabin if a fire occurred and would also activate a 
 Halon 1301A fire suppression system. A second dragline, still under construc- 
 tion, had two large three-phase oil-filled transformers mounted on platforms 
 on the exterior of the machine, thereby minimizing the damage that a trans- 
 former fire could cause. A third possible alternative was under consideration 
 for a transformer on a blasthole drill. This transformer was mounted on the 
 rear of the machine and, in the event of a fire, could have posed a consider- 
 able threat to the operator. Mine personnel were planning to remove the 
 transformer from the drill and mount it nearby on skids so that the trans- 
 former posed less of a hazard but could still be moved as required. Though 
 this particular transformer was oil filled, this same procedure could be done 
 any time an askarel transformer needed to be replaced on any type of machinery 
 with a slight increase in electrical resistance losses. 
 
 Relative Costs of Non-PCB Replacement Transformers 
 
 The National Electrical Code allows only the smallest of oil-cooled 
 transformers to be used indoors without a vault. The cost of a vault can 
 increase the installation cost of an oil-filled transformer in place of an 
 askarel unit by 90 to 133 percent of the base cost of the transformer, thereby 
 eliminating the use of oil-filled transformers for askarel units where no 
 vault already exists. At voltages in excess of 35 kv, the code requires that 
 all types of transformers be installed in vaults if they are located in build- 
 ings. However, as far as the mining industry is concerned, it is unlikely 
 that many transformers will be installed in indoor locations handling more 
 than 35 kv. Therefore, the cost of vault construction will be considered here 
 in connection with oil-cooled transformers only. 
 
39 
 
 Table 4 summarized the relative basic costs and installed costs of vari- 
 ous types of transformers. Askarel transformers are included for the sake 
 of comparison. 
 
 TABLE 4. - Cost comparisons of oil-filled versus other transformer 
 designs intended for hazardous locations, percent 
 
 (1,000 kva, 15 kv transformer) 
 
 Type 
 
 First cost 
 
 Vault 
 
 Catch 
 Basin 
 
 Vent 
 
 Total 
 Installed cost 
 
 Oil 
 
 Askarel (1976) 
 
 High-fire-point hydrocarbon 
 
 liquid 
 
 High-fire-point silicone 
 
 liquid 
 
 Dry open coil air-cooled.... 
 
 Dry gas-filled 
 
 Dry cast coil 
 
 100 
 140 
 
 120 
 
 140 
 
 150-170 
 200 
 150-170 
 
 90-133 
 
 
 
 
 
 
 
 
 
 NAP 
 10 
 
 110 
 
 110 
 
 
 
 
 
 190-233 
 150 
 
 120-130 
 
 150 
 
 150-170 
 200 
 150-200 
 
 ^atch basin is not required by law or regulation but is required as a 
 condition for insurance coverage by certain industrial insurers. 
 
 Sources: Westinghouse Electric Corp. 
 p. 18 (updated). 
 
 Is There Another Way? Sharon, Pa. 
 
 Deaken, R. F. J., and P. D. Smith (Polygon Industries Ltd.). Epoxy 
 Insulation — A New Generation of Dry Type Transformers. Pres. at 
 64th Ann. Meeting, Canadian Pulp and Paper Assoc, Montreal, Quebec, 
 Canada, Jan. 31, 1978. 
 
 Summary — Considerations in Choosing an Alternative to PCB Transformers 
 
 The following considerations apply to all situations in which trans- 
 formers are used in mining; that is, aboveground, underground, indoor, or on 
 mobile machines. 
 
 Oil-Cooled Transformers : There are surprisingly large numbers of trans- 
 former installations, in mining and in other industries, where askarel trans- 
 formers have been installed in places where the prevailing electrical code as 
 well as common sense would have allowed the installation of oil-filled trans- 
 formers. If such an askarel transformer must be replaced, either because it 
 has failed or because in its present location it is too costly or virtually 
 impossible to secure against fluid loss (and therefore presents a potential 
 extreme cleanup threat), the first choice to be considered is an oil-filled 
 unit. If the use of an oil-filled transformer presents no particular fire 
 hazard, and if no additional fire precautions are needed such as a vault, 
 then the oil-filled unit will be the most cost effective and the easiest 
 replacement. 
 
40 
 
 Silicone and High-Fire-Point Transformers : Because the coolant fluids in 
 silicone and high-fire-point type transformers are of a higher viscosity than 
 either askarel or ordinary transformer mineral oil, their heat-transfer char- 
 acteristics are not quite as good. Thus replacement transformers of these 
 types are likely to be slightly larger than the askarel units they replace. 
 They will probably not be as heavy as the equivalent askarel units, however, 
 because of the extremely high density of the askarel coolant. Silicone. and 
 high-fire-point, hydrocarbon-cooled transformers find their best applications 
 as replacements for askarel transformers in places where fire vaults for oil- 
 filled units would either be too expensive to install or would be impractical 
 to install because of space limitation. Being liquid filled, they have the 
 advantage of having high sustained overload capacity, the same as askarel and 
 oil-filled transformers. 
 
 Dry Type Transformers : Dry, open air type transformers are usually 
 larger than liquid-cooled units because of the allowance that must be made for 
 air movement. And assuming that the unit is used in an environment where dust 
 is not a consideration, open air-cooled transformers can operate with less 
 maintenance than any of the liquid type transformers. Open air-cooled trans- 
 formers have two drawbacks as far as mining is concerned: They have only 
 short-term overload capability because they contain no liquid to act as a heat 
 sink, and they -tend to generate much more noise than liquid-filled trans- 
 formers, which can be irritating to people who have to work nearby. 
 
 Sealed gas-cooled transformers have all the same characteristics of open 
 transformers, except they are totally sealed against the hazards of environ- 
 mental dust and corrosive gases and fumes. Since they are sealed, their cases 
 have to be of heavy-gage construction to contain the pressure of the gas 
 inside when the unit is operating at high temperatures. Thus they tend to be 
 heavy as well as large in comparison with liquid units of equivalent rating. 
 Their chief advantage is their almost total freedom from maintenance, which 
 makes them suitable for applications where maintenance is impractical. Their 
 disadvantages include high initial cost, high operating noise, and poor sus- 
 tained overload capacity. 
 
 Cast coil transformers have advantages of both liquid and dry trans- 
 formers. They require virtually no maintenance, they produce noise levels 
 that are intermediate between liquid and other dry units, and because of 
 their designed-in high efficiency plus the amount of material used to encase 
 the windings, they can sustain high overloads almost as well as liquid-filled 
 transformers. Their main disadvantage is high initial cost. 
 
 PCB-CONTAMINATED TRANSFORMERS 
 
 About 98 percent of the liquid-filled transformers in use in the United 
 States (probably including the majority of those used in mining applications) 
 are filled with transformer oil. Analysis of oil taken from several hundred 
 transformers owned by electrical utilities has indicated that as many as 
 38 percent of all of the oil-filled transformers may be contaminated with 
 PCB's in concentrations exceeding 50 ppm (that is, 0.1 lb PCB ' s per ton of 
 oil). The contamination of transformer oil with PCB's may have occurred 
 
41 
 
 either in transformer manufacturing plants where both PCB's and oil were used 
 to fill transformers, or in routine field servicing that involved filtering 
 the liquid by use of equipment that was used for both oil- and askarel-filled 
 units. In a few cases, PCB's may have been used to top off oil-filled 
 transformers. 
 
 PCB's are completely soluble in transformer oil, and there is no easy way 
 to determine whether low levels of PCB's are present in any particular lot of 
 oil at concentrations above 50 ppm. The only feasible method for analyzing 
 for low levels of PCB's in oil involves the use of a gas chromatagraph with an 
 electron capture detector. A number of qualified analytical laboratories will 
 perform this analysis for prices ranging from $60 to $100 per sample depending 
 on the number of samples submitted at one time. 
 
 The EPA regulations on PCB's define "PCB-contaminated transformers" as 
 any oil-filled transformer in which the oil is contaminated with PCB's in con- 
 centrations above 50 ppm, or as any oil-filled transformer in which the oil 
 has not been tested and found to contain less than 50 ppm PCB's. In other 
 words, all oil-filled transformers must be considered to be contaminated with 
 PCB's unless tests must have been performed and the oil found to not contain 
 PCB's. 
 
 Transformer oil known to be contaminated with more than 500 ppm PCB's is 
 classified as a PCB askarel; both the oil and the transformer that it is in 
 are considered to be PCB askarel items and are covered by the regulations. 
 Transformer oil that contains 50 to 499 ppm PCB's or that has not been tested 
 is considered to be PCB contaminated. EPA regulations apply to the disposal 
 or reuse of contaminated oil, but there are no regulations on the continues 
 use, maintenance, rebuilding, or disposal of the transformers. 
 
 Transformer oil that is known by test to contain less than 50 ppm PCB's 
 is not covered by the EPA PCB regulation. 
 
 Disposal of transformer oil from PCB-contaminated transformers: By 
 incineration in an approved PCB incinerator; li+ by burial in an approved PCB 
 chemical waste landfill; by burning as an auxiliary fuel in a large power 
 boiler that meets specific operational requirements (see regulations for 
 details). 
 
 Reuse of oil from PCB-contaminated transformers: Reclamation and reuse 
 of oil is allowed by the owner of the oil. 
 
 Resale of used or reclaimed oil from PCB-contaminated transformers: 
 Banned. 
 
 Storage of out-of-service PCB-contaminated transformers or oil from such 
 units: Must be in a facility meeting the requirements of SPCC plan. 
 
 1H As of January 1981 EPA has not approved any incinerators for commercial 
 disposal of PCB's. See General Requirements, subsection on Disposal. 
 
42 
 
 Spill cleanup : All material contaminated with more than 50 ppm PCB's 
 must be picked up and disposed of as PCB's. In general, the oil spill regula- 
 tions will apply and will be more stringent for low-level contamination of 
 land and water by oil. 
 
 PCB CAPACITORS 
 
 Most AC power capacitors manufactured in the United States between 1935 
 and 1977 used PCB's as a dielectric liquid. The EPA regulations banned the 
 sale of PCB capacitors after July 1, 1979, unless the seller has obtained an 
 exemption from the regulations from the EPA. However, non-PCB capacitors have 
 been developed for almost all of the applications where PCB units were pre- 
 viously used. The liquids used to replace the PCB's in these new designs are 
 more flammable than PCB's, but the manufacturers have developed various 
 pressure-sensitive and heat-sensitive circuit breakers that prevent the capac- 
 itor from rupturing if it fails electrically. 
 
 The EPA regulations will allow existing capacitors to remain in service 
 but impose certain marking, recordkeeping, storage, disposal, and spill 
 cleanup requirements. 
 
 4Jses of PCB Capacitors in the Mining Industry 
 
 Electronics : Small PCB capacitors were used in the power circuits of 
 some microwave ovens and television sets. 
 
 Motor Start Capacitors : Used in series with the secondary windings of 
 larger single-phase motors such as those used in room air conditioners and 
 submersible well pumps. 
 
 Ballast Capacitors : Used in the ballasts of fluorescent lights and high- 
 intensity mercury are arc and sodium arc lamps. 
 
 Power Factor Capacitors : Usually located in substations, although often 
 found on distribution poles. 
 
 Surge Capacitors : Used with circuit breakers in large electric motors 
 and on load centers. 
 
 How To Identify PCB Capacitors 
 
 Liquid dielectric type AC capacitors are sealed metal cans with two or 
 more terminals. The non-PCB capacitors that have been built since July 1, 
 1978, have all been marked "No PCB's." All other capacitors of this type must 
 be assumed to contain PCB's unless you know, based on manufacturer's litera- 
 ture or label information, that a specific capacitor does not contain PCB's. 
 
 The following is a list of the manufacturers known to have produced PCB 
 capacitors since 1971. PCB capacitors manufactured prior to 1971 may not 
 appear on this list if the manufacturer stopped using PCB's or went out of 
 business. 
 
43 
 
 Manufacturers Trade name of liquid 
 
 Aerovox Hyvol 
 
 Axel Electronics NA 
 
 Capacitor Specialists NA 
 
 Cornell Dubilier Dykanol 
 
 Electrical Utilities Corp Eucarel 
 
 Electromagnetic Filter Co NA 
 
 General Electric Pyranol 
 
 Jard Corp Clorphen 
 
 McGraw Edison Elemex 
 
 P. R. Mallory and Co Aroclor B 
 
 R. F. Interonics NA 
 
 Sangamo Electric Co Diaclor 
 
 Sprague Electric Co Clorinol 
 
 Tobe Deutschmann Laboratories NA 
 
 Universal Manufacturing Corp Askarel 
 
 Westinghouse Inerteen 
 
 York Electronics ? 
 
 NA Not available. 
 
 Requirements for PCB Capacitors 
 
 PCB capacitors may continue in use indefinitely, with no special diking 
 provisions required. The PCB regulations define three types of PCB capaci- 
 tors, and different requirements apply to each type: 
 
 Types of PCB Capacitors : 
 
 Small: Contain less than 3 lb PCB's (exempted from all 
 requirements ) . 
 
 Large High Voltage: Contain more than 3 lb PCB's and operate at 
 voltages above 2,000 v (basically distribution system power 
 factor capacitors). 
 
 Large Low Voltage: Contain more than 3 lb PCB's and operate at 
 voltages below 2,000 v. 
 
 Note: In general, "large" capacitors are those having a can volume 
 greater than 300 cu in. 
 
 Use : No restrictions on continued use of existing PCB capacitors. 
 
 Marking : 
 
 Large High Voltage: A PCB label must be applied to each capacitor 
 in use and in storage. 
 
 Large Low Voltage: A PCB label must be applied to each capacitor 
 when it is removed from service. It would probably simplify the 
 
44 
 
 job of keeping track of the large PCB capacitors if the large 
 low-voltage capacitors in service had the label applied, but this 
 is not required. 
 
 Small: No marking requirements. 
 
 Recordkeeping : Required, except for those facilities having fewer than 
 50 large capacitors and no other PCB transformers. The records for capacitors 
 must include the following information: The total number of PCB large high- 
 voltage and low-voltage capacitors in the facility; the date each large PCB 
 capacitor is removed from service, is placed into storage for disposal, and is 
 placed into transport for disposal; for large capacitors removed from service, 
 the location of the initial disposal or storage facility and the name of the 
 owner or operator of the facility; for PCB capacitors in storage in contain- 
 ers, the total weight of capacitor in each container. An annual report must 
 be prepared summarizing this information as of July 1 of each year. All 
 records must be retained for 5 years after the facility ceases using or stor- 
 ing PCB's. 
 
 Storage for Disposal : Requirements apply to storage of large PCB capaci- 
 tors only. In general, capacitors must be placed in drums and stored in spe- 
 cial PCB storage" areas. However, nonleaking large capacitors may be stored on 
 pallets next to an approved storage area until January 1, 1983, provided that 
 (1) the storage area has immediately available unfilled storage space that 
 could accommodate at least 10 percent of the capacitors stored outside the 
 area (in case a capacitor should start to leak, it could be immediately moved 
 into the storage area) and (2) the capacitors on pallets are inspected 
 weekly. 
 
 Disposal : 
 
 Large PCB Capacitors: In an approved PCB landfill until March 1, 
 1981, capacitors must be shipped in steel drums that meet DOT 
 requirements, and void spaces must be filled with sawdust, dirt, 
 or other absorbent material. The use of PCB landfills for dis- 
 posal of capacitors may be allowed after March 1, 1981, if no 
 suitable approved incinerators are available. Check with EPA 
 after March 1, 1981, to determine disposal requirements (toll- 
 free, 800-424-9065). 
 
 Small PCB Capacitors: No special disposal requirements. May be 
 disposed of as any other trash. 
 
 Spill cleanup: It is uncommon, but not unknown, for a capacitor to 
 leak when it fails. Because of the high temperatures and pres- 
 sures caused by an electrical arc occurring inside a capacitor, 
 PCB vapors may be vented under pressure and spray over a consider- 
 able area. The regulations require that all material contaminated 
 with over 50 ppm PCB's be picked up and disposed of in an approved 
 PCB landfill, and that contaminated surfaces of equipment be 
 decontaminated. Rupture of a capacitor in an underground or 
 
45 
 
 indoors application could result in high concentrations of PCB's 
 in the air, which would present a serious health hazard to any 
 workers in the area. 
 
 Precautions for Continued Use 
 
 Capacitors seldom rupture when they fail, and there is little likelihood 
 that a major PCB spill will result from the failure of any PCB capacitor pres- 
 ently in service. Even a large power factor capacitor rated at 200 kvar will 
 contain only about 40 lb of PCB's, and most of this is adsorbed in the paper 
 or other solid dielectric material. Therefore, the maximum amount that could 
 leak out would probably not exceed 8 lb of PCB's. In the infrequent occasion 
 of a rupture of a capacitor, PCB's will probably be sprayed out as a fine 
 mist. This will contaminate nearby objects and materials, and the contami- 
 nated material will have to be picked up and disposed of as PCB's. 
 
 The only significant risk that could result from continued use of PCB 
 capacitors would be human exposure to PCB vapors if a capacitor failed in a 
 building or underground installation. Most capacitors used in these environ- 
 ments are used as surge protection on distribution transformer primary termi- 
 nals and on motor contactors. In most cases, system electrical safety can be 
 improved by removing the capacitors and installing properly sized surge 
 arrestors. This system modification is discussed in more detail in the fol- 
 lowing section. 
 
 Substitutes for PCB Capacitors 
 
 PCB's are no longer being used in capacitors, and the EPA regulations ban 
 the sale of PCB capacitors after July 1, 1979, unless the seller has applied 
 for and been granted an exemption from these ban requirements. Capacitors 
 using non-PCB dielectric liquids are available for most applications. 
 Although the replacement liquids do not have the fire resistance of PCB's, the 
 manufacturers are improving the rupture resistance of non-PCB ballast capaci- 
 tors by building thermal and pressure-sensitive circuit breakers into the 
 capacitors. Most large high-voltage power factor capacitors are located out- 
 doors at substations, and there is little risk of major fire damage even if a 
 leak should occur and the liquid burn. 
 
 The capacitors used in buildings and in underground mines on the primary 
 terminals of distribution transformers and associated with motor contactors 
 can present a potential fire problem if non-PCB capacitors are used. These 
 capacitors are used to limit the rate of voltage rise and to protect the cir- 
 cuit breaker from flash over resulting from chopping when a motor is discon- 
 nected. However, recent research has shown that capacitors used in these 
 applications may actually degrade the electrical system performance. 
 
 The presence of too much load side capacitance can result in prestrike 
 when a motor contactor is closed; the capacitor should be installed on the 
 motor terminals rather than adjacent to the contactor as is usual practice — 
 the inductance of the cable will help reduce the tendency of prestrike. In 
 addition, the charging requirements of excess capacitance can trip out the 
 
46 
 
 ground fault detector in some cases. In most cases, improved system safety 
 can be achieved by removing the capacitors and installing low sparkover dis- 
 tribution class surge arrestors that are coordinated with the insulation char- 
 acteristics of the associated motor and transformer. The factors that must be 
 considered in making this system change are discussed in detail in the follow- 
 ing report: 
 
 Morley, L. A., and others (Pennsylvania State University). Coal Mine Elec- 
 trical System Evaluation. Volumes I through VII. BuMines Open File 
 Rept. 61-78 (set), 1977, 1,015 pp. Available for reference at BuMines 
 facilities in Denver, Colo., Twin Cities, Minn., Bruceton and Pittsburgh, 
 Pa., and Spokane, Wash.; U.S. Dept. of Energy facilities in Carbondale, 
 111., and Morgantown, W. Va.; National Mine Health and Safety Academy, 
 Beckley, W. Va.; and National Library of Natural Resources, U.S. Dept. of 
 the Interior, Washington, D.C.; available from National Technical Informa- 
 tion Service, Springfield, Va., PB 283 489/AS (set); contract G01 55003. 
 
 UNDERGROUND MINING MACHINERY 
 
 Use 
 
 In the late 1960's and early 1970' s PCB's were used in some electric 
 motors manufactured by Reliance Electric for Joy Manufacturing Co. Joy used 
 these motors in the following applications: 
 
 CU43 continuous miners — cutting-head motors, pump motor 
 
 9CM continuous miners — cutting-head motors, pump motor 
 
 14BU10 loaders — traction motors 
 
 Liquid-filled motors were used because they were smaller and lighter than 
 air-cooled motors. A PCB mixture was chosen as the liquid because it was non- 
 flammable, provided adequate lubrication, and possessed the best overall com- 
 bination of electrical properties, chemical stability, and cost. The amount 
 of PCB's used in each of the various kinds of motors is summarized in 
 table 5. 
 
 TABLE 5. - Quantity of PCB's in mining machinery 
 
 Machine 
 
 Weight of fluid 
 per motor 
 
 Weight of fluid 
 per machine 
 
 
 kg 
 
 lb 
 
 kg 
 
 lb 
 
 
 20.9 
 26.1 
 20.9 
 
 46.0 
 57.5 
 46.0 
 
 62.7 
 78.3 
 41.8 
 
 138.0 
 
 172.5 
 
 92.0 
 
 Identification 
 
 All of the CU43's, 9CM's, and 14BU10's originally sold by Joy used PCB- 
 filled motors. Some of the traction motors on the loaders have been converted 
 to air cooling and are no longer affected by the PCB regulation. If one of 
 
47 
 
 the loaders was purchased used, and there is some doubt about whether the 
 motors still contain PCB's, the air-cooled motors can easily be identified 
 because they have no fill-plug or pressure-relief valve. 
 
 Some of the continuous miner motors have been converted to silicone cool- 
 ing. The shop that performed the conversion should be contacted for informa- 
 tion about the possibility of the motors being contaminated with small amounts 
 of PCB's. If the repair shop does not have any information, the following 
 guides should be followed; 
 
 1. If the motor was disassembled, degreased, and rewound , there is 
 little or no chance that any PCB's remain; thus the motor would not be covered 
 by EPA regulations. 
 
 2. If the motor was not rewound but was only drained, flushed, and 
 refilled with silicone, there were probably still enough PCB's trapped in the 
 motor windings to contaminate the silicone. In this case, the motor is cov- 
 ered by the regulations and should still be treated as though it were filled 
 with PCB's. The procedures and recommendations in this chapter should be 
 followed. 
 
 EPA Requirements 
 
 All three types of equipment may be used until January 1, 1982, under the 
 following conditions: 
 
 1. PCB's may be added to any of the motors until January 1, 1982. 
 
 2. PCB-filled motors on the loaders must be rebuilt as non-PCB motors 
 the next time the motor is rebuilt. 
 
 3. PCB-filled motors on the continuous miners may not be rebuilt after 
 January 1, 1980. 
 
 4. Any PCB's that will be used to service PCB-filled motors must be 
 stored in accordance with the requirements previously listed. 
 
 5. PCB motors must be disposed of in an approved chemical waste land- 
 fill. Disposal must take place before January 1, 1984. The regulations per- 
 mit used machinery to be bought and sold. 
 
 The EPA regulations require that labels be applied to anything that con- 
 tains PCB's. In connection with the PCB-filled motors, the following things 
 must be labeled immediately: 
 
 1. Each PCB-filled motor. 
 
 2. Each mining machine that still has a PCB-filled motor. 
 
 3. Each can of PCB's that is on hand for servicing or being stored for 
 disposal. 
 
48 
 
 4. Each area that is being used to store PCB's or PCB-filled motors. 
 The labels should be placed where they can be easily seen. 
 
 Recordkeeping : None required by the regulations. 
 
 Servicing 
 
 PCB's may be added to mining machinery motors until January 1, 1982. 
 After this date, further use of the machinery is prohibited and any PCB's in 
 stock must be disposed of properly. 
 
 The motors on the continuous miners may be rebuilt until January 1, 1980. 
 
 After that date the machinery may still be used (until January 1, 1982); if a 
 
 motor fails and no spare motor is available, the machine must be retired and 
 the motors must be disposed of properly. 
 
 Disposal 
 
 The regulations require that the motors be drained of as much liquid as 
 possible, and the liquid must be shipped to an incinerator that has been 
 approved by the EPA for disposal of PCB's. The drained motor must be disposed 
 of by burial in""an approved chemical waste landfill. To obtain information on 
 the location of approved incinerators and landfills call (toll-free, 
 800-424-9065, or in Washington, D.C., local 554-1404) or write the Office of 
 Industry Assistance, Office of Toxic Substances TS-799, U.S. Environmental 
 Protection Agency, 401 M St., S.W., Washington, D.C. 20460. 
 
 The motor and the liquid must be disposed of before January 1, 1984. If 
 the motor or the liquid will be kept for more than 30 days after the motor is 
 removed from service, storage must be in an area that meets the requirements 
 described above. 
 
 Recommended Precautions for Continued Use 
 
 The following precautions should be taken when using PCB fluids in mining 
 machinery motors: 
 
 1. A pan filled with floor-dry, sawdust, or some other absorbent mate- 
 rial should be placed under a motor before it is topped off. 
 
 2. Drips and spills should be avoided or promptly cleaned up when top- 
 ping off a motor. 
 
 3. Motors should not be overfilled as this has, in some instances, 
 resulted in leaks. 
 
 4. Any leaking motor or any motor that is using a greater than normal 
 amount of fluid should be immediately removed from service until the cause of 
 the loss of fluid is located and eliminated. 
 
49 
 
 5. If a continuous miner is going to be used much past January 1, 1980, 
 Joy Manufacturing Co. should be contacted as soon as possible to make arrange- 
 ments to have the motor rebuilt before the January 1, 1980, deadline on 
 rebuilding. 
 
 Emergency Spill Response 
 
 If PCB's leak or spray out of a mining machinery motor, the procedure 
 described in appendix A should be followed. In addition, if the spill happens 
 underground the following precautions should be taken: 
 
 1. If water is being sprayed on the mine face near the machine, the 
 water should be shut off immediately. 
 
 2. If mine dewatering is being performed in the area of the spill, it 
 should, if possible, be stopped immediately. (If the dewatering system 
 becomes contaminated with PCB's, it will have to be thoroughly cleaned or pos- 
 sibly sent to a chemical waste landfill. ) 
 
 Non-PCB Replacement Equipment 
 
 Loaders 
 
 The traction motors on the loaders can be rebuilt as air-cooled motors. 
 Joy Manufacturing will do this for approximately $3,100 per motor. This is 
 roughly what it would cost for rebuilding the motor for continued PCB-cooled 
 operation. The EPA regulations do not permit the motors to be used after 
 January 1, 1982, and also do not permit Joy to perform the conversion to air- 
 cooling after January 1, 1982. For further information on having the conver- 
 sion performed, contact the nearest Joy sales representative or service 
 facility. 
 
 Continuous Miners 
 
 There is no suitable replacement for the PCB-filled motors on the contin- 
 uous miners. The motors cannot be rebuilt for air-cooled operation because 
 there is not enough room in the machinery frame. Some of these motors have 
 been refilled with a silicone fluid. The use of silicone fluids has not been 
 approved by MSHA because silicone vapors will deactivate methane detectors, 
 and is not recommended by Joy because the silicones will burn. Therefore, 
 silicone fluid cannot be considered an acceptable replacement for PCB's in 
 these motors. The only acceptable alternative is to purchase another miner 
 before the January 1, 1982, deadline. 
 
 ELECTROMAGNETS 
 
 Use 
 
 Most separator electromagnets are filled with mineral oil, but PCB's have 
 been used in magnets mounted in locations where there is an increased danger 
 of fire. These PCB-filled magnets have been used primarily indoors near coal 
 crushers and over conveyors at the head of a mine, though they may be found in 
 other locations. 
 
50 
 
 Identification 
 
 There are no markings on a magnet that tell whether it is filled with 
 mineral oil or PCB's; PCB's were simply substituted for mineral oil at the 
 request of the purchaser. The simplest way to determine what a magnet is 
 filled with is to check company records. If records are not available, the 
 serial number of the magnet should be obtained from the nameplate and the 
 manufacturer should be contacted. Three manufacturers used PCB's in some of 
 their magnets: 
 
 Dings Co. 
 
 4780 West Electric Ave. 
 
 Milwaukee, Wis. 53246 
 
 414-672-7830 
 
 Eriez Magnets 
 95 Magnet Drive 
 Erie, Pa. 16512 
 814-833-9881 
 
 Stearns Magnetics, Inc. 
 6001 South General Ave. 
 Cudahy, Wis. 53110 
 414-769-8000 
 
 EPA Requirements 
 
 PCB-filled electromagnets are considered to be totally enclosed uses of 
 PCB's and are subject to the same requirements as PCB transformers, except for 
 the recordkeeping requirement. 
 
 Marking 
 
 Any electromagnet that contains PCB's or liquid contaminated with over 
 50 ppm PCB's must be labeled. 
 
 Recordkeeping : None required by the regulation. 
 
 Servicing 
 
 Minor servicing of PCB-filled electromagnets is permitted until July 1, 
 1984, but rebuilding or any other type of servicing that requires removing the 
 coil is prohibited. The following requirements must be followed when servic- 
 ing a PCB-filled electromagnet: 
 
 1. PCB's removed from the magnet must be either returned to the magnet, 
 used in some other permitted application, or disposed of properly. The PCB 
 material may not be sold. 
 
 2. Any PCB's that may be used to service or repair a PCB electromagnet 
 must be stored in an area that meets the requirements previously described. 
 
51 
 
 Disposal 
 
 The regulations require that the PCB magnet be drained of as much liquid 
 as possible, and the liquid must be sent to an incinerator that has been 
 approved by the EPA for disposal of PCB's. The drained magnet must be buried 
 in an approved chemical waste landfill. To obtain information on approved 
 incinerators and landfills, call (toll-free, 800-424-9065, or in Washington, 
 D.C., local 554-1404) or write the Office of Industry Assistance, Office of 
 Toxic Substances TS-799, U.S. Environmental Protection Agency, 401 M St., 
 S.W., Washington, D.C. 20460. 
 
 Before the liquid is drained from the magnet, the ground or floor under- 
 neath should be covered with a sheet of plastic and a layer of floor-dry, saw- 
 dust, or other absorbent material. If the magnet does not have a drain plug, 
 a hole should be drilled or cut in one corner of the top of the magnet and the 
 fluid should be siphoned into a barrel or drum that meets the requirements 
 described above and that is acceptable to the incineration facility that will 
 be receiving the fluid. Some incinerator operators may require that small 
 drums of liquid be packed inside of larger barrels of sawdust to provide more 
 protection against spills, so the incinerator facility should be contacted to 
 determine its requirements. After the magnet has been thoroughly drained, the 
 siphoning hose should be placed inside the magnet case and the hole should be 
 plugged to prevent any small amounts of PCB's that remain in the magnet from 
 leaking out when the magnet is sent to the landfill. If any PCB's dripped 
 onto the layer of floor-dry, the contaminated material and, if necessary, the 
 plastic must also be sent to the landfill. 
 
 For additional information on transportation of PCB's see General 
 Requirements. 
 
 Recommended Precautions for Continued Use 
 
 Precautions should be taken to reduce the possibility of spills and leaks 
 when using a PCB-filled electromagnet. These steps include: 
 
 1. Inspecting the magnet at least once a month for minor leaks, with 
 particular attention being paid to the welds, where cracks may develop if the 
 magnet is frequently turned on and off. 
 
 2. If the magnet is being moved, extra care should be taken to insure 
 that the casing is not damaged. 
 
 The EPA regulations allow continued use of PCB-filled separator magnets 
 over coal conveyors because it is assumed that any PCB's that leak out of the 
 magnet will be destroyed when the coal is burned. However, the use of PCB 
 magnets over coal that will be washed or otherwise subjected to water-based 
 physical cleaning processes risks a major PCB contamination incident. Washing 
 coal that has been contaminated with spilled PCB's will result in PCB contami- 
 nation of the wash water, exposure of workers to PCB's vaporized from the 
 recycled water, and stream pollution when the water is discharged from the 
 plant. A major spill of PCB's into the water of a coal cleaning plant, 
 
52 
 
 whether directly or due to contamination of the feed coal, would have to be 
 considered an environmental disaster that would be extremely expensive, if not 
 impossible, to clean up. The consequences of a possible PCB spill should be 
 carefully considered when deciding whether to allow a PCB separator to remain 
 in service. 
 
 Emergency Spill Response 
 
 If a PCB-filled magnet develops a leak, the spill response plan in appen- 
 dix A should be followed. In addition, the following steps should be taken: 
 
 1. The conveyor should be stopped immediately to limit the amount of 
 coal that becomes contaminated. 
 
 2. The magnet should be removed from over the conveyor, and a pan of 
 sawdust or floor-dry should be placed on the conveyor under the leak. 
 
 3. Any visibly contaminated coal should be removed from the conveyor and 
 placed in a drum for disposal. 
 
 4. See General Requirements for decontamination procedures. 
 
 Non-PCB Electromagnets 
 
 Several alternatives to the use of PCB-filled electromagnets are availa- 
 ble. Oil-filled magnets can be used if there is a location where the 
 increased fire risk would not pose a significant threat. 
 
 The magnet manufacturers also sell silicone-filled magnets for use where 
 a fluid with fire-resistant properties is required. A silicone-filled elec- 
 tromagnet costs 40 to 50 percent more than a comparable oil-filled unit. The 
 use of silicone fluids underground is not recommended because silicone vapors 
 will deactivate methane detectors. Although the silicone fluid is nontoxic, 
 major spills onto coal (or ore) prior to wet flotation processing may disrupt 
 the process because silicone is a powerful antifoaming agent. 
 
 Other high-fire-point hydrocarbon transformer liquids might also be con- 
 sidered. These have about the same fire-point characteristics as silicone, 
 but they release more heat than silicone if they do ignite. 
 
 Repeated refilling of existing PCB separator magnets with transformer 
 oil, silicone, or high-fire-point transformer liquid will gradually reduce the 
 residual levels of PCB's. If the concentration of PCB's is reduced to below 
 50 ppm, the magnet would be allowed to be rebuilt or sold for scrap when it 
 fails. (The regulations allow these alternatives for transformers containing 
 less than 500 ppm PCB's. Rebuilding or scrapping a magnet having PCB's pres- 
 ent in the fluid in concentrations between 50 and 500 ppm would require the 
 owner to apply to the EPA for an exemption based on the precedent established 
 for transformers.) 
 
53 
 
 Dry-type separator magnets are also available. Eriez sells an air-cooled 
 magnet that has been approved by Underwriters Laboratory for use in dirty, 
 dusty environments. This type of magnet costs 20 to 25 percent more than a 
 comparable oil-filled unit. 
 
 HEAT -TRANSFER FLUIDS 
 
 Use 
 
 Because of their fire resistance and stability, PCB's were used as the 
 major component of several high-temperature heat-transfer fluids. These 
 fluids were manufactured from 1930 through 1972 by Monsanto. From 1972 
 through 1974 Geneva Industries of Houston, Tex., manufactured one type of 
 PCB-based heat-transfer fluid. Monsanto quit selling PCB-based heat-transfer 
 fluids during 1971-72, but it was several years before all the fluid was in 
 the hands of the final consumer. Most purchasers of heat-transfer fluids were 
 advised by Monsanto to drain their systems and refill them with a different 
 fluid. Recent tests on a number of heat-transfer systems have found PCB's 
 present at levels high enough to be regulated by the EPA even in systems that 
 have been drained and flushed. 
 
 PCB-based heat-transfer fluids manufactured by Monsanto are shown as 
 follows: 
 
 Therminol FR-0; 
 Therminol FR-LO; 
 Therminol FR-1; 
 Therminol FR-2; 
 Therminol FR-3. 
 
 EPA Requirements 
 
 Use : Heat-transfer systems containing fluid contaminated with more than 
 50 ppm PCB's may be used until July 1, 1984, provided that: 
 
 1. Every heat-transfer system that ever contained PCB-based fluid had to 
 be tested by October 1, 1979, to determine the concentration of PCB's 
 remaining in the fluid. 
 
 2. If the concentration of PCB's exceeds 50 ppm: 
 
 (a) The system must be drained and refilled with fluid free of 
 PCB's within 6 months. The PCB-contaminated fluid must be 
 properly stored and disposed of in an approved PCB incinerator. 
 
 (b) The testing and refilling procedure must be repeated annually 
 until the concentration of PCB's is found to be less than 
 
 50 ppm at least 3 months after the most recent replacement of 
 fluid. 
 
 (c) Records of the testing and refilling must be maintained for at 
 least 5 years after the concentration of PCB's is reduced to 
 50 ppm. 
 
54 
 
 Marking 
 
 Any heat-transfer system that contains a fluid with over 50 ppm of PCB's 
 must be marked immediately. The label should be placed where it can be easily 
 seen. Names and addresses of label printers are listed under General 
 Requirements. 
 
 Recordkeeping 
 
 All records resulting from any test conducted to determine the PCB con- 
 tent of the fluid in a heat-transfer system must be kept for at least 5 years 
 after the system is determined to have a concentration of PCB's in the fluid 
 of less than 50 ppm. 
 
 Servicing 
 
 Any type of servicing may be done on contaminated heat-transfer systems. 
 The only restriction is that fluid containing 50 ppm or more of PCB's may not 
 be used to refill or top off a system. This includes fluid that has been 
 removed from a system during servicing. 
 
 Fluid containing over 50 ppm of PCB's may be processed in some manner to 
 reduce the level below 50 ppm, and then the fluid may be used in a heat- 
 transfer system. This processing may be done by the owner of the system or by 
 someone who has received authorization from the EPA to perform this type of 
 servicing. 
 
 Any fluid removed from a system that contains any level of PCB's must 
 either be processed or disposed of in an approved incinerator. Some land- 
 fills may accept liquids with less than 50 ppm PCB's for disposal. Fluid 
 contaminated with any detectable amounts of PCB's may not be used for road 
 oiling, as an herbicide carrier, or in any other similar application. 
 
 Disposal 
 
 When a PCB-contaminated (above 50 ppm PCB's in the fluid) heat-transfer 
 system is taken out of service and will no longer be used, the fluid and the 
 system must be disposed of separately. The fluid must be sent to an approved 
 PCB incinerator. The drained heat-transfer system must then be disposed of by 
 burial in an approved chemical waste landfill. 
 
 Once the system is drained, it must be carefully disassembled for ship- 
 ment (unless it is possible to ship the system whole). Plastic and floor-dry 
 should be placed under each joint before it is taken apart. The landfill and 
 the shipping company should be contacted for instructions on packaging por- 
 tions of the system that are too large to fit in 55- or 110-gal drums. All 
 containers that hold contaminated liquids and parts of the system must be 
 labeled. If any of the material is going to be stored for more than 30 days 
 before it is shipped to the disposal site, it must be stored in an area that 
 meets the requirements described in General Requirements. 
 
55 
 
 Disposal of scrapped PCB heat-transfer systems in a chemical waste land- 
 fill will be expensive. Present costs are about $8 per cu ft plus transporta- 
 tion, and the owner of the machine also loses the scrap value of the metal. 
 It may be cheaper to decontaminate the system using a solvent such as fuel 
 oil, even though the contaminated solvent would require disposal in an 
 approved incinerator. 
 
 Recommended Precautions for Continued Use 
 
 The following precautions are recommended when using a heat-transfer sys- 
 tem that is contaminated with PCB's: 
 
 1. If a major leak in the system could reach the ground or any water 
 drain, the system should be diked. 
 
 2. Any drains or cracks in the floor near the system should be plugged 
 or patched. 
 
 3. If there are minor leaks in the system and it is impractical or 
 impossible to repair them, a pan of floor-dry or sawdust should be used to 
 catch the leakage. The pans should be emptied periodically. Contaminated 
 floor-dry and sawdust should be accumulated in a drum. This drum must be 
 marked, stored in an area that meets the requirements previously described, 
 and disposed of in an approved chemical waste landfill. 
 
 4. The system should be checked at least once a month for leaks. 
 
 5. When servicing is necessary, pans of floor-dry or a layer of plastic 
 and then a layer of floor-dry should be placed under all joints that will be 
 disassembled or that could leak as a result of being stressed while working on 
 a different part of the system. 
 
 6. When a pump, piping, or other component of a system is removed, the 
 ends or other openings should be plugged with rags, or the other component 
 should be supported on a rack, pallet, wooden slats, or in some other manner 
 such that plastic or pans and floor-dry can be placed under all openings that 
 may leak PCBs. 
 
 Emergency Spill Response 
 
 In the event of a leak from a heat-transfer system, the spill response 
 plan in appendix A should be followed. In addition, the following steps 
 should be taken: 
 
 1. The heat should be shut off. 
 
 2. Any pumps in the system should be shut off. 
 
 3. If the leak is in a high-pressure portion of the system, the pressure 
 should be relieved as rapidly as possible. 
 
56 
 
 4. The system should be drained below the level of the leak as rapidly 
 as possible. 
 
 Non-PCB Heat-Transfer Fluids 
 
 When Monsanto discontinued the sale of PCB-based heat-transfer fluids in 
 1972, it made available a number of substitute fluids for high-temperature, 
 low-pressure heat-transfer systems. Suitable fluids are also available from a 
 number of other manufacturers. These fluids are mostly of the chemical type 
 of alkylated aromatics and aromatic ethers. 
 
 The non-PCB fluids have two disadvantages compared with the PCB-based 
 materials: (1) The non-PCB fluids are flammable, and (2) they will oxidize 
 upon prolonged exposure to air at high temperatures. As a result, conversion 
 to non-PCB fluids requires that the expansion reservoir be sealed and blan- 
 keted with an inert gas such as nitrogen to protect the fluid from oxidation. 
 Direct-fired systems must be protected against a major fire resulting from a 
 break in the fired tubes by installing a remotely controlled steam, Halon, or 
 carbon dioxide quench system in the combustion chamber. Information required 
 to design specific applications is available from insurance underwriters and 
 from the National Fire Protection Association, 470 Atlantic Avenue, Boston, 
 Mass. 02210, telephone 617-482-8755. 
 
 HYDRAULIC FLUIDS 
 
 Use 
 
 PCB's were used as the basis of a number of fire-resistant hydraulic flu- 
 ids sold prior to 1972. These fluids were used primarily in die casting 
 machines and in various hot metal equipment in steel mills. This study did 
 not identify any use of PCB-based hydraulic fluid in mining machinery or in 
 mine-related operations. However, it is possible that PCB-based fluid may 
 have been used to some extent in the raining industry, and the EPA regulations 
 apply to all systems that ever used PCB-based fluid, including mine 
 applications. 
 
 Identification 
 
 The only known supplier of PCB-based hydraulic fluid was Monsanto, which 
 marketed a number of different types prior to 1972, under the following trade 
 names: Pydraul A-200, Pydraul AC, Pydraul AC-28, Pydraul F-9, Pydraul 135, 
 Pydraul 150, Pydraul 230, Pydraul 280, Pydraul 312, Pydraul 540, 
 Pydraul 540-A, and Pydraul 625. 
 
 EPA Requirements 
 
 Any system that ever contained a PCB-base hydraulic fluid must be tested 
 by October 1, 1979, to determine the concentration of PCB's remaining in the 
 system. Requirements for recordkeeping, marking, flushing, and periodic test- 
 ing of contaminated hydraulic systems are the same as for contaminated heat- 
 transfer systems. Disposal of drained hydraulic sytems is not regulated if 
 
57 
 
 the liquid contains less than 1,000 ppm PCB ' s ; flushing prior to disposal is 
 required if the fluid contains over 1,000 ppm PCB's. Disposal of fluid con- 
 taminated with over 50 ppm PCB's must be in an approved PCB incinerator. 
 
 Non-PCB Hydraulic Fluids 
 
 Most systems that used PCB-based fluids have been converted to fluids 
 based on phosphate esters or to water-glycol mixtures. Performance has been 
 satisfactory, although neither of these substitute materials has the fire 
 resistance or oxidation resistance of PCB's. 
 
 Analysis of phosphate-ester-based hydraulic fluids for residual PCB's 
 will cost more than will similar tests on hydrocarbon-based fluids because the 
 phosphate interferes with the equipment that is usually used to perform this 
 analysis. There should be no special problems if you tell the analytical lab 
 what type fluid is presently in the system. 
 
 WASTE OIL 
 
 Over 1 billion gal of used oil per year is collected for use as road oil 
 or is reclaimed for use as lubricating oil. The used oil that is re-refined 
 for use as lubricating oil often contains industrial oil such as used trans- 
 former oil and hydraulic fluid that is contaminated with low levels of PCB's. 
 As a result, much of the re-refined motor oil contains low levels of PCB's, 
 and dissipative uses of even segregated motor oil can release PCB's into the 
 environment. 
 
 EPA Requirements 
 
 The use of waste oil containing any detectible levels of PCB's as road 
 oil, insecticide carrier, or other dissipative use is forbidden. The regula- 
 tions do not define the analytical method to be used to check for PCB's, but 
 the commonly used gas chromatagraph can easily detect PCB's at concentrations 
 of 1 or 2 ppm in used oil. 
 
 Recommendations 
 
 The major impact of this ban on the use of PCB-contaminated waste oil 
 will be on the oiling of mining roads. Alternatives to discontinuing road 
 oiling included the use of carefully segregated used virgin motor oil, testing 
 each batch of oil for the presence of PCB's (at a cost of $50 to $70 per 
 batch), the use of synthetic soil stabilization chemicals, or the use of water 
 for dust control. A synthetic material that may perform satisfactorily is 
 Coherex, manufactured by Witco Chemical Corp. The manufacturer should be con- 
 tacted for additional information and recommendations. 
 
 Proper disposal of used oil will be required to prevent the release of 
 low levels of PCB's into the environment. Used oil may be used as a fuel or 
 re-refined without special handling provided that the oil contains less than 
 50 ppm PCB's. 
 
58 
 
 APPENDIX A. --OUTLINE OF PCB SPILL RESPONSE GUIDE 
 
 EMERGENCY SPILL RESPONSE GUIDE FOR POLYCHLORINATED BIPHENYLS 
 
 (PCB's, Askarel, Pyranol, Inerteen, etc.) 
 
 What are PCB's: PCB's are a nonflammable oil used as a coolant and electrical 
 insulating fluid in some transformers, capacitors, and sepa- 
 rator magnets and in electric motors on certain Joy continu- 
 ous miners and loaders. 
 
 Hazards: PCB's are a toxic environmental pollutant. Do not breathe 
 vapors or get on skin. Do not allow spilled PCB's to get 
 into drains, sewers, or other water. 
 
 First Aid: Skin contact: Wash off with waterless hand cleaner using 
 paper towers. Store contaminated towels for special dis- 
 posal. Eye exposure: Flush with water. Vapor exposure: 
 Get medical aid. 
 
 Spill Response 
 
 Spill from live electrical equipment: Disconnect power, call chief 
 electrician (telephone ) 
 
 Then try to plug leaks with rags, stick, or other material. 
 
 All spills: 
 
 Call (environmental engineer, mine superintendent, etc.) (telephone ) 
 
 Protective Use plastic gloves to prevent contact with skin. Contami- 
 clothing: nated gloves, clothing, shoes, etc., should be put into 55- 
 gal drum for disposal as PCB's. Tools may be decontaminated 
 by washing with solvent; dispose of solvent, rags, etc., as 
 PCB's. 
 
 Control spill: Dike major spills with dirt or other material. Soak up 
 
 spilled PCB's with rags, straw, or other material. Do not 
 let PCB's run into drains or water. 
 
 Final cleaning: Check with (mine environmental engineer), at (telephone ) 
 for detailed instructions. 
 
 Disposal of PCB- Solids — load into 55-gal drums; label with PCB label; ship to 
 Contaminated EPA-approved PCB chemical waste landfill. Liquids — drain 
 Material and into 55-gal drums; flush equipment with solvent such as kero- 
 Equipment: sene or fuel oil to remove as much residual PCB as possible; 
 drain solvent into drums; apply PCB label and store in secure 
 roofed area meeting EPA requirements until an approved incin- 
 eration facility becomes available for the disposal of PCB's. 
 
FIGURE B-l 
 
 BRAZE 
 
 Copper plumbing pipe with cap and fitting. 
 
 59 
 
 APPENDIX B.— WATER-ONLY DRAINAGE SYSTEM 1 
 
 The drainage system 
 described below is designed 
 so that water can freely 
 flow out of the diked area, 
 while askarel (PCB) fluid 
 that is denser than water 
 will cause a silicone rubber 
 "flapper valve" to float up 
 into a position covering the 
 drain hole. Figure 6 shows 
 the complete water-only drainage system in side and top views, but without the 
 filter screen system that covers the valve and keeps leaves and other particu- 
 late matter from clogging the valve. 
 
 The fabrication and installation sequences of the valve are as follows: 
 
 1. Cut a 4-inch-long, straight, undented section of 1/2-inch (ID) copper 
 plumbing pipe. 
 
 2. Place a copper cap on one end and a copper fitting having a 1/2-inch 
 male pipe thread on the other end and then braze (do not solder) the three 
 pieces together to thoroughly seal the joints (fig. B-l). Brazing is neces- 
 sary to allow for the additional high-temperature brazing processes that are 
 necessary for adequate strength of the finished valve. 
 
 3. From a piece of 1/8-inch-thick copper flat stock, cut a strip that is 
 2-5/8 inches long and 5/8 inch wide. This will be the "valve face." Braze it 
 onto the part above in this manner (as shown in fig. B-2) . 
 
 VIEW A-A' 
 
 2 5/8" 
 A'. 
 
 FILL WITH BRONZE FOR 
 ^ENTIRE LENGTH, BOTH SIDES 
 
 VALVE FACE 
 
 FIGURE B-2. - Valve face. 
 
 i This appendix is reprinted with permission from the Naval Facilities Engi- 
 neering Command and Versar, Inc. Any questions regarding the information 
 in this appendix should be referred to Versar, Inc., 6621 Electronic Drive, 
 Springfield, Va., 22151. It originally appeared in the following report: 
 Versar, Inc. Guide for the Management of Askarel Transformers. Rept. to 
 Naval Facilities Engineering Command, Alexandria, Va., March 1979, pp. 41- 
 49; contract NOOO-25-78-C-0020. 
 
60 
 
 4. Drill a 3/16-inch hole as shown and then cut away excess metal around 
 the hold and gently grind the entire surface of the valve face on fine emery 
 paper backed by a flat surface to remove any unevenness of the face 
 
 (fig. B-3). 
 
 5. From 1/8-inch-thick copper flat stock, cut two pieces measuring 
 
 3/8 inch by 5/8 inch and braze them onto the valve face in the position shown 
 in figure B-4. 
 
 6. From 1/8-inch, flat copper stock, cut a rectangular piece measuring 
 2 inches by 6-3/8 inches. Bend it to the shape shown in figure B-5 to make 
 the "guard plate." 
 
 DRILL 3/16" 
 
 8/16" 
 
 J5v 
 
 1/4" 
 
 BOTTOM VIEW OF VALVE FACE 
 
 FIGURE B-3. - Bottom view of valve face. 
 
 VIEW A-A' 
 
 A<^ 
 
 3/8"He^ 
 
 A' f 
 
 BRAZE 
 
 BRAZE 
 
 5/8" 
 
 FIGURE B-4. - Two pieces brazed on valve face. 
 
 BEND LINE 
 
 ■4" 
 
 2" 2 1/4" 
 
 *k LJ 
 
 e-^90 
 
 GRIND OFF EXCESS METAL AT 
 THE ENDS, TO THE DIMENSIONS 
 SHOWN 
 
 FIGURE B-5. - Rectangular piece of copper for "guard plate." 
 
61 
 
 7. Braze the "guard plate" to the main body of the valve as shown in 
 figure B-6. 
 
 8. From 1/8-inch flat copper stock, cut a rectangular piece — the "valve 
 rest" — measuring 5/8 inch by 3-3/8 inches, and braze it onto the valve in this 
 position (see note 1 in fig'. B-7) . 
 
 DRILL AND TAPE 1/4-20(2) 
 
 3/8" 
 
 BRAZE 
 
 BRAZE 
 
 SIDEVIEW 
 
 3/8" 
 
 3/8" 3/8" 
 
 FRONT VIEW 
 
 O 
 
 DRILL AND TAP 
 
 1/4-20(2) 
 
 BOTTOM VIEW 
 FIGURE B-6. - Brazing of "guard plate" to main body of valve. 
 
 THE "GUARD 
 PLATE" CAN 
 BE BENT 
 SLIGHTLY TO 
 MEET THE 
 VALVE REST 
 FOR BRAZING 
 
 A. 
 
 1/8"+- 1/8" 
 
 VALVE REST 
 ^BRAZE 
 
 (NOTE #2: THE REASON THE "VALVE REST" SHOULD 
 BE ROUGHENED IS TO LESSEN THE 
 CHANCES THAT THE SILICONE "FLAPPER 
 VALVE" WILL STICK TO THIS SURFACE, 
 BECAUSE THEN THE FLAPPER WILL NOT 
 FLOAT PROPERLY IF IT SHOULD EVER 
 COME TO BE SURROUNDED WITH PCBs 
 FROM THE TRANSFORMER.) 
 
 BRAZE 
 
 (NOTE #1: USE A COARSE WIRE 
 
 BRUSH TO ROUGHEN THE 
 UPPER SURFACE OF THE VALVE 
 REST BEFORE BRAZING INTO 
 PLACE.) 
 
 FIGURE B-7. 
 
 'Valve rest. 
 
62 
 
 VALVE FACE — 
 
 0.1900" +- 0.025" 
 VALVE REST — * 
 
 DRILL 1/8" 
 
 + 3/16"-+ 1/16" 
 
 HOLE-LOCATING 
 JIG: 
 
 t — i 
 
 3/8" D 
 + 0.050" 
 -0.00" 
 
 fct 
 
 FIGURE B-8. - Bearing support holes and hole-locating jig. 
 
 9. Drill a 1/8-inch hole through each of the two (bearing supports) in 
 the location shown in figure B-8. (It might be useful to make an alineraent 
 jig to facilitate the finding of the center for this hole; a schematic of the 
 type of jig that might be useful is shown. ) 
 
 10. After all the brazing processes are finished, the copper will have a 
 coating copper oxide scale. Remove the scale with a rotary wire brush, but be 
 careful not to mar the smooth valve face. Use fine emery paper and light fin- 
 ger pressure to remove scale from the valve face. If there are large irregu- 
 larities on the valve face, remove them with a fine flat file or use fine 
 emery paper backed with a solid flat surface. 
 
 The flapper valve must have these dimensions (see fig. B-9) . 
 
 There are several ways to make these 
 probably being: 
 
 'flapper valves," the two easiest 
 
 (a) On a smooth flat surface, pour out a 5/8-inch-wide, or wider, 
 
 strip of the uncured silicone rubber; make it at least 5/16 inch 
 thick. Locate the Teflon tube so that it is perpendicular to 
 the strip and 5/32 inch (±0.020 inch) off the flat surface. 
 When the rubber has cured, use a razor blade to cut the flapper 
 valve into the required dimensions. The critical dimensions and 
 characteristics are — 
 
63 
 
 1/8" 
 
 3" 
 
 1 
 
 •V 
 
 5/32" 
 
 05/16" 
 
 *T ^ 
 
 f- 
 
 #14 TEFLON TUBE 
 
 (WALL THICKNESS = 0.016" 
 
 ID = 0.064" TO 0.074") 
 
 FIGURE B-9. - Silicone rubber for "flapper valve." 
 
 J 1* 
 
 90 
 
 ^ 
 
 i 
 
 5/32"-+0.020" 
 
 k-5/32" -+ 1/32" 
 
 FIGURE B-10. - "Flapper valve" as made by method (a). 
 
 (1) One surface of the flapper must be very smooth in order to 
 seal the drain hole tightly when PCB's are present in the 
 diked area. 
 
 (2) The location of the Teflon tube must be accurate in both 
 alinement with the rest of the flapper and at height from the 
 faces of the flapper. 
 
 If these two conditions are not met, the flapper may bind 
 during operation when it is supposed to float in PCB's and/or 
 it may not properly cover the drain hole (see fig. B-10). 
 
 (b) The second method is to make a metal or plastic pattern of the 
 flapper valve. The pattern can be used to make a reusable mold 
 out of plastic or metal. Since the flapper valve is symmetric, 
 the two mold halves can be identical in shape. (However, one of 
 the mold halves should have a roughened face so that one side of 
 the flapper valve will also be rough; the roughness will be on 
 the side of the flapper valve that is away from the drain hole, 
 and the purpose of the roughness is to minimize sticking of the 
 flapper valve to the "valve rest" during the period of years 
 that it may lie in the open position. ) 
 
 Each mold half should look like that shown in figure B-ll. 
 
 Use parting compound on the mold halves and do so sparingly on 
 the face that is to be smooth. 
 
64 
 
 A LENGTH OF #14 TEFLON TUBE 
 CAN BE LAID ACROSS THIS TROUGH 
 BEFORE THE MOLD HALVES ARE 
 CLOSED; IN ORDER TO MAKE SURE 
 THE TUBE REMAINS STRAIGHT, CAST 
 THE SILICONE RUBBER AROUND IT 
 WHILE THE 1/16-INCH BRASS HINGE 
 SCREW IS INSIDE THE TUBE. 
 
 FIGURE B-ll. - Mold half for pattern of "flapper valve." 
 
 After casting, cut away the excess rubber (the flash) and (after 
 removing the brass hinge screw) cut the Teflon tube to the 
 proper length — that is, approximately 1/32 inch or 0.030 inch 
 excess tubing on each side of the flapper valve. 
 
 12. The flapper is attached to the valve body by means of a brass hinge 
 screw and four Teflon washers measuring 0.020 inch in thickness and with an 
 inside diameter of 1/16 inch and an outside diameter of 1/4 to 3/8 inch. The 
 hinge screw must have the dimensions shown in the diagram below, and the Tef- 
 lon washers must be placed as shown. The nut should be run down tight against 
 the end of the threaded portion of the hinge screw to provide adequate tight- 
 ness of the nut and screw. The final assembly should allow the flapper valve 
 lots of free play (fig. B-12). 
 
 13. The filter screen is not to be attached until after the entire valve 
 assembly is in place in the dike. Installation of the valve assembly on the 
 dike should follow this sequence: 
 
 (a) A 1/2-inch galvanized pipe flange should be cut in the manner 
 shown in figure B-13 so that it can be fitted low on the inside 
 of the steel dike. 
 
 (b) The drain valve is screwed into the flange tightly, and then the 
 combination of flange and valve is fitted and put into position 
 on the inside of the dike, as shown in figure B-14. 
 
 NUT 
 TEFLON WASHER (4) 
 
 FLAPPER VALVE 
 
 1/16" D BRASS 
 
 1 
 
 f 
 
 (UNTHREADED) 
 
 HINGE SUPPORT 
 
 FIGURE B-12. - Hinge support for flapper valve. 
 
65 
 
 .*»" 
 
 1/8" MIN 
 A 
 
 T 
 
 FIGURE B-13. - Pipe flange. 
 
 IF THERE IS INTEFERENCE AT 
 
 THIS POINT, DO NOT BEND THE 
 
 VALVE REST; EITHER MAKE THE 
 
 VALVE LONGER, OR GRIND 
 
 METAL OF THE DIKE. 
 
 
 ~ FLANGE MUST BE 
 > FLUSH WITH DIKE 
 
 GUARD PLATE SHOULD /* 
 REST ON MOUNTING PAD 
 
 FIGURE B-14. - Fitting of drain valve and flange into inside of dike. 
 
 (c) Remove the flange from the valve and then, after the bolt holes 
 are drilled in the dike, locate and drill the center drain hole 
 in the dike, using the flange to locate the position of the 
 center hole. (Drill a hole of about 3/4-inch diameter, or at 
 least drill a smaller hole that will be positioned so as to 
 allow all water to drain from the valve.) 
 
 (d) Screw the valve back into the flange tightly and, sealing the 
 face of the flange with silicone rubber caulking compound or 
 some other weatherproof sealant, screw the flange and valve 
 assembly tightly into place on the dike. 
 
 (e) Additional sealant on the tops of the flange screws and around 
 the edge of the flange will help assure a liquid-tight seal. 
 
66 
 
 CRIMP THE SCREEN DOWN 
 TIGHTLY ALONG ALL SURFACES 
 OF THE DIKE AND MOUNTING 
 PAD. 
 
 FIGURE B- 1 5. - Screen covering valve system. 
 
 (f) Using brass or stainless steel screen with holes not larger than 
 1/16 inch on an edge, fabricate the filter screen so that it is 
 bolted into place by the screws that mount into the "guard- 
 plate," and so that it completely covers the valve system all 
 the way down to the concrete and to the bottom and side of the 
 dike. The arrangement for the screen should appear something on 
 the order of that shown in figure B-15. 
 
 The hold-down screws should be 1/4-20, hex-head copper, brass, 
 or stainless steel. Washers of the same material should be used 
 under the screws and on top of the screen in order to keep the 
 screen from binding and wrapping up on the screws when they are 
 tightened. Bolt holes can be made in the screen by either a 
 punch or by piercing with an ice pick-like tool having a shank 
 diameter of about 1/2 inch or slightly larger. It is imperative 
 that all sides of the valve system be protected by the screen, 
 because the movement of leaves and other particulate matter into 
 the valve area can keep the valve from functioning properly. 
 
 a93 
 
 PC -23 
 
 <?U.S GOVERNMENT PRINTING OFFICE: 1981-703-002/25 
 
 INT.-BU.OF MINES,PGH.,PA. 25251 
 


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