In-Use PM testing with Sensors Inc. PPMD Process, Options, Issues

Transcription

1 In-Use PM testing with Sensors Inc. PPMD Process, Options, Issues Riverside, CA, March 24th 2011 Craig Kazmierczak Compliance and Regulatory Affairs Internal Use Only 1

2 Configuration as tested Sensors PPMD, single MPS (130 lbs single MPS, 170 lbs dual MPS) Panasonic Toughbook (minimum screen resolution required) Remote diluter Semtech-DS (78 lbs 35.4 kg) EFM II exhaust flow meter CT software Compliance and Regulatory Affairs Daimler Trucks 2

3 Configuration as tested EFM II PPMD w/ single MPS, non remote diluter mounted on catwalk Compliance and Regulatory Affairs Daimler Trucks 3

4 Configuration as tested Remote diluter Semtech-DS Compliance and Regulatory Affairs Daimler Trucks 4

5 Configuration as tested Ambient Temperature & Humidity sensor Remote diluter setup, inside vehicle installation Compliance and Regulatory Affairs Daimler Trucks 5

6 Periodic Calibration, per CFR Component Requirement Maximum Time Between Checks PPMD Internal flow meter calibration (Done at Sensors Inc.) 185 Days Humidity Sensor Linearization 365 Days EFM II Linearization both with PPMD and with Semtech-DS (Done at Sensors Inc.) 185 Days Semtech DS Linearization check 35 Days completed internally at DDC Note: linearization of upgraded NDUV analyzer is much improved, however CO NDIR linearization continues to be very difficult upgrades needed. Compliance and Regulatory Affairs Daimler Trucks 6

7 Pre-Test Calibration Process Notes Time Crystal cleaning/greasing Crystal burn-in new technique (wipe w/ Q-tip till minimum is left) is much faster and easier than old method (dilute grease) 30 minutes 10 minutes Crystal self check MPS lookup table check/adjust 20 minutes 20 minutes to 1 hour Leak check Sample flow audit/calibration using Mityvac, 45 min using old method 15 minutes 10 minutes Total pre-testing preparation time is about 2 hours Compliance and Regulatory Affairs Daimler Trucks 7

8 Testing Configuration Options PPMD can be operated with other gaseous systems other than Semtech-DS With or without exhaust flow meter and the extra effort, space and equipment Remote diluter or direct exhaust gas feed, PPMD must be mounted outside of vehicle cab for direct exhaust gas feed Smaller alternator vehicles will require generator and AC/DC transformer for equipment power supply (Semtech-DS requires 30 amps average, PPMD requires 20 amps average, together spikes can reach 80 amps) Power line diode to protect against PPMD and Semtech-DS re-boot upon engine start Environmental enclosures for PPMD and Semtech-DS if mounted externally may be necessary Cold weather may require insulation of PPMD crystal head Compliance and Regulatory Affairs Daimler Trucks 8

9 Testing Configuration Options PPMD mounted in environmental case on catwalk Compliance and Regulatory Affairs Daimler Trucks 9

10 Testing Configuration Options APU, idles until required Non remote diluter CQCM head Compliance and Regulatory Affairs Daimler Trucks 10

11 Testing Configuration Options Insulation around CQCM while in environmental case PVC cap to insulate CQCM Compliance and Regulatory Affairs Daimler Trucks 11

12 Installation, 2 hours Select vehicle, check applicability, check faults codes, record vehicle maintenance history, read historical vehicle idle %, record vehicle ID info Locate PPMD and Semtech-DS on vehicle, power up for warm-up Remove exhaust stack, replace with EFM II & remote diluter sample device Install heated emission and remote diluter lines, install PPMD communication cable and Semtech-DS antennae, perform leak checks before locating remote diluter line at EFM II end. (use Mityvac method instead, only 15min) Install periphery equipment, humidity sensor, GPS, J1939 connection, FID bottle (check pressure setting), window blocks, generator, temporary calibration gases Install hardware restraints, zip tie harnesses, minimize/remove driver area/vision intrusions Compliance and Regulatory Affairs Daimler Trucks 12

13 Installation, 2 hours Set PPMD to proportional mode, set maximum exhaust flow rate, set reference crystal (PPMD software not clearly organized) Set Semtech-DS to control PPMD, install correct torque curve (lug curve) in Semtech-DS, turn off idle shut down in vehicle ECM, set FID leak check preference, auto-zero preference, ATS regeneration preference, low FID fuel preference Enter test info in Test Configuration before opening file in Session Manager Compliance and Regulatory Affairs Daimler Trucks 13

14 Calibration, 1 hour (10 min of which is PPMD) Calibrate Semtech-DS simultaneous to the following PPMD checks Zero MPS pressures with compressor off Crystal temperature check Compliance and Regulatory Affairs Daimler Trucks 14

15 Testing Check that once testing/data sampling has started that system is sampling exhaust gases and not atmospheric air, (easy mistake to make, wasting whole day) Check that all J1939 data is registering on Semtech-DS (careful of custom PIDs) Check that EFM II is reading on Semtech-DS (confirms communication between Semtech-DS and PPMD) Check that GPS is reading, (some re-booting scenarios cause GPS communication to fail) Rev up engine and note that MPS proportional control is working Compliance and Regulatory Affairs Daimler Trucks 15

16 Post Testing, 2 hours Make sure there is 5 minutes QCM idle/stabilization time since last NTE event before stopping test Stop test, run post test spans & audits on Semtech-DS Close test files and upload data Post process Semtech-DS data Post process PPMD data (PPMD post processor not clearly organized) Quick graph gaseous & PPMD data looking for invalid test situations Enter data into custom spreadsheets to determine preliminary pass/fail Compliance and Regulatory Affairs Daimler Trucks 16

17 Post Testing, Data Results Compliance and Regulatory Affairs Daimler Trucks 17

18 Post Testing, Data Results Compliance and Regulatory Affairs Daimler Trucks 18

19 Post Testing, Data Results Compliance and Regulatory Affairs Daimler Trucks 19

20 Post Testing, Data Results Compliance and Regulatory Affairs Daimler Trucks 20

21 ft-lb Post Testing, Data Results NTE zone NTE pts TCG curve %maxT Nlo rpm Compliance and Regulatory Affairs Daimler Trucks 21

22 Post Testing, Data Results Standard: from: [search on " E" in A] Consent Decree multiplier [search for "NTE (i)(a)" in A & search for NOx + NMHC 1.3 (using optional (C)) 1.5 (Choose from drop down list) CO 15.5 NMHC 0.14 PM 0.01 Testing margin: from: (h)(2) [search on "(h)(2) of" in A, pg 75] NOx 0.1 (Choose from drop down list) CO NMHC PM 0.01 (0.00 for 2012) (from raw csv data) Relative HuAbsolute HVolume HuLocal Amb Local Ambient Tempe Altitude [search on " Accuracy Margin: from: How" in T or HDIUT Final rule] iscb_rh ihum_abs ihum_vol iscb_lap iscb_lat igps_alt NOx 0.45 (0.15 for 2010) % grains/lb dr% mbar deg C m CO 0.50 (0.25 for 2010) NMHC 0.02 (0.01 for 2010) deg F feet PM (.006 for MA) Threshold: NOx + NMHC [search on "(B)(1) T" in A & " " in Tech ammendment] CO Option A NMHC 0.23 not using Use NOx RH correction? YES PM 0.04 Use NOx Temp correction? NO calculated [search on "(B)(1) T" in A & " " in Tech ammendment] Option B Option (B) T= 98.0 Use NOx RH correction? YES Data valid per T? YES [search on "7.14" in N & search on " " in Tech ammendment] Note: If Absolute Humidity drops below 50 grains, correction is INVALID for early versions of Semtec Compliance and Regulatory Affairs Daimler Trucks 22

23 Post Testing, Data Results, CFR references(some) (h)(2) in Tech ammendment (1) (C) option (d) DFR dated 02/29/08 Guidance Letter CISD HD 05/05/ Table Table Compliance and Regulatory Affairs Daimler Trucks 23 PM Pass Time sec eval time sec minimum time= Sum of pass= Sum of total= Rpass= Result= PASS

24 g/bhp-hr Post Testing, Data Results NTE event PM measurement of minor crack in DPF vs no crack in DPF BSPM BSPM DPF cracked PM threshold through Compliance and Regulatory Affairs Daimler Trucks 24

25 Post Testing, Equipment Removal Cut zip ties, remove hardware restraints Remove periphery devices Remove heated emission and remote diluter lines Remove EFM II Remove PPMD & Semtech-DS Restore vehicle to original configuration Compliance and Regulatory Affairs Daimler Trucks 25

26 Finalize Data for Presentation and Submission Engine ID Vehicle ID Software level Vehicle maintenance, repairs, faults, weight Fuel sample Customer recruiting info, test program status Test issues Test data Compliance and Regulatory Affairs Daimler Trucks 26

27 Data Submission - EPA Enter data into CT User Data.xml file, using CT software Post process, 2 steps, using CT software (creates all files necessary for submission to EPA) Change data file names to unique trackable names Upload using EPA authorized web site Record file names, dates uploaded - tracking Make copy of files on CD for ARB Compliance and Regulatory Affairs Daimler Trucks 27

28 PPMD Performance at DDC 5 tests completed and reported, 2 repeats => 71% success rate No major repairs 663 recorded NTE events gaseous 546 recorded NTE events PM => 82% NTE yield Compliance and Regulatory Affairs Daimler Trucks 28