Overview of Laboratory Testing for Engine Certifications

Transcription

1 Overview of Laboratory Testing for Engine Certifications Palak Patel March 26, PEMS Conference and Workshop

2 Objectives To provide overview of CTC (Cummins Technical Center) laboratory engine certification testing process To describe CTC s emissions testing facilities To provide an overview of laboratory emissions measurement equipment 2

3 Agenda CTC Certification Background CTC CVS Test Cell Description 40CFR1065 Test Cell Verifications/Calibrations Test Plan Submission Engine Installation Engine Mapping and Duty Cycle Generation Duty Cycle Descriptions Emission Measurement Review Results Certification Data Packet Submission 3

4 CTC Certification Background Diesel or Natural Gas Engines 4.5 L to 19 L 100 HP to ~700 HP Applications On Highway Non Road Power Generation Marine/Locomotive Regulatory Agencies/Countries EPA/CARB, EU, JMLIT (Japanese Ministry of Land, Infrastructure, Transport and Tourism), KMOE (Korean Ministry of Environment), India, Brazil, China, Mexico, Peru 4

5 CTC CVS Test Cell Description Four vertically integrated transient emissions test cells built in Q Two cells can run engines with ~700 HP max power capability and two with 500 HP max power capability. Minimum capability of engines with 100 HP. Four additional CVS transient emissions test cells were built in All have ~700 HP max power capability. CVS tunnel flow rates range from 1200 to 5700 SCFM for ~700 HP cells and 760 to 3800 SCFM for 500 HP cells Two test cells have the capability to run Natural Gas engines 5

6 CTC CVS Test Cell Description 6

7 40CFR1065 Test Cell Verifications/Calibrations After an engine is planned to be certified, communications with CTC Test Operations personnel initiate test cell verifications and calibrations Tasks include: Linearity verifications for thermocouples, pressures, various flows, various dewpoints, PM balance, emission analyzers, gas divider, engine speed and torque, intake air flow Emission analyzer calibration curves Various flow calibrations intake air flow, diluted exhaust flow Analyzer verifications Interference (CO, CO2), FID Optimization, NOx quench Analyzer bench verifications Sample dryer verification, NMHC cutter penetration, NOx converter efficiency verification Test cell verifications/calibrations temperature and pressure calibrations, propane check, dewpoint calibrations, intake air flow calibration Checklist created to organize all documentation Insert Data Classification 7

8 40CFR1065 Test Cell Verifications/Calibrations Total Number of Records: 98 8

9 Test Plan Submission Typically, after Engineering communicates with Test Operations of upcoming certification, they submit test plan via internal test plan submission program The test plan defines the test sequence and duty cycles depending on the engine application Review of test plan to ensure correct sequence and duty cycles 9

10 Engine Installation Engine installed on CVS dedicated skid Pressure and temperature instrumentation installed at same time Engine installation in test cell per Cummins Application Engineering Bulletins and 40CFR1065 specifications 10

11 Engine Mapping and Duty Cycle Generation Engine map is a data set that consists of a series of paired data points that represent the maximum brake torque versus engine speed measured at the output shaft Engine mapping conducted to determine various speed/torque inputs to cycle generation Idle Maximum test speed (FTP, USNRTC) A, B, C speeds (RMCSET) Intermediate speed (C1 8 mode) nhi, nlo for determination of reference speed (EUNRTC) 11

12 Duty Cycle Descriptions EPA/CARB EU On Highway: FTP, RMCSET Non Road: USNRTC, C1 8 Mode Power Generation (constant speed): D2 5 mode On Highway: ETC, ESC (Euro V and below); WHTC, WHSC (Euro VI) Non Road: EUNRTC, C1 8 Mode Power Generation (constant speed): D2 5 mode Normalized FTP Torque v/s Speed RMCSET Normalized ETC Torque v/s Speed ESC 12

13 Emission Measurement Gaseous Emissions Gaseous analyzers purchased from California Analytical Instruments NOx, NO: HCLD each CO, CO2: NDIR THC, CH4: HFID each N2O (GHG): FTIR FTIR Insert Data Classification 13

14 Emission Measurement Particulate Measurement System designed by Cummins to comply with EPA 2007 regulations Systems manufactured by Analytical Engineering Inc. of Columbus, Indiana. System Features Temperature control of sample train from the outlet of the mixer to the PM filter. Automated filter changers Insert Data Classification 14

15 Emission Measurement Gravimetric PM Dedicated Weigh Room Temperature controlled: 22 +/- 1 C Dewpoint controlled: 9.5 +/- 1 C 47 mm Teflon membrane filter (Teflo) Filters preconditioned before use and post conditioned for at least 1 hour Insert Data Classification 15

16 Review Results After completion of each duty cycle, review of cycle results Review of emissions results to ensure FEL/STD not exceeded In laboratory testing, the FEL can be different from the STD per banking and trading programs Four automated reports produced which include several 40CFR1065 QC checks Emissions Summary Report Test Verification Report Basic Emission Information - Vacuum Side Leak Checks BS Drift Check - Initial HC Contamination Verification Carbon Balance Error - Cold Start Verification Average Conditions over Cycle - Channel Verifications Fuel Information - Aqueous Condensation Verification Cycle Validation Report Cycle Regression - PM Sampling Dilution Ratio Verification Gaseous Emissions Report Detailed Emissions Information Background Emissions Analysis - Proportional Batch Sampling Verification 16

17 Certification Data Packet Submission After completion of certification test, a data packet is created to forward to PCC (Product Certification and Compliance group) Data Packet includes: 1065 Calibration and Verification Records Engine Information AEBs, Installation Pictures Test Cell Log Scanned PDF Test Plan Scanned PDF Test Results As with Verification/Calibrations checklist, a similar spreadsheet outlines the duty cycles conducted during test sequence. Descriptions of cycles Reference cycle report Torque map report Cycle comments Links to four automated reports Particulate summary report 17

18 Certification Data Packet Submission 18

19 Questions? 19