National Environmental Protection Standard of the People s Republic of China 中华人民共和国国家环境保护标准 HJ 438 2008 Durability of Emission Control Systems of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles (Durability Technical Requirements of Emission Control Systems of Compression Ignition and Gas Fuelled Positive Ignition Engines and Vehicles) 车用压燃式 气体燃料点燃式发动机与汽车排放 控制系统耐久性技术要求 How to BUY & immediately GET a full-copy of this standard? 1. www.chinesestandard.net; 2. Search --> Add to Cart --> Checkout (3-steps); 3. No action is required - Full-copy of this standard will be automatically & immediately delivered to your EMAIL address in 0~60 minutes. 4. Support: Sales@ChineseStandard.net. Wayne, Sales manager Issue on: June 24, 2008 Implemented on: July 1, 2008 Issued by: Ministry of Environmental Protection
Announcement of the Ministry of Environmental Protection of the People s Republic of China [2008] No. 25 With a view to implementing the Environmental Protection Law of the People s Republic of China and Law on Prevention of Air Pollution of the People s Republic of China, preventing the environmental pollution caused by pollutant emissions of vehicles, protecting the environment and safeguarding the human health, The Ministry of Environmental Protection hereby approves to issue 3 standards, including Technical Specification for On-board Diagnostic (OBD) System of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles. The name and number of such standards are as follows: I. Technical Specification for On-board Diagnostic (OBD) System of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles HJ 437 2008; II. Durability of Emission Control Systems of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles HJ 438 2008; III. In-service Conformity of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles HJ 439 2008. The above standards shall be implemented as from July 1, 2008 and published by China Environmental Science Press. The contents of such standards are available on the official website of the Ministry of Environmental Protection (bz.mep.gov.cn). Hereby announced! June 24, 2008
Contents Foreword... I 1 Application Scope... 1 2 Normative References... 1 3 Terms and Definitions... 1 4 Type Approval Application... 2 5 General Requirements... 3 Appendix A... 5 (Normative)... 5 Durability Test Specifications for Emission Control System... 5
Foreword This standard was formulated with a view to implementing the Environmental Protection Law of the People s Republic of China and the Law on Prevention of Air Pollution of the People s Republic of China, preventing the environmental pollution caused by pollutant emissions of vehicles, and improving the environmental quality. This standard specifies the durability requirements (including measurement methods) of emission control systems of compression ignition and gas fuelled positive ignition engines of vehicles. It supplements the contents about durability of emission control system in Limits and Measurement Methods for Exhaust Pollutants from Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles (III, IV, V) GB 17691. This standard is modified in relation to the requirements for the durability of heavy-duty vehicles specified in Directive 2005/55/EC of European Union (EU) Relating to the measures to be taken against the emission of gaseous and particulate pollutants from compression-ignition engines for use in vehicles, and the emission of gaseous pollutants from positive-ignition engines fuelled with natural gas or liquefied petroleum gas for use in vehicles as well as the requirements for the durability test procedures of emission control system specified in Directive 2005/78/EC. This standard is issued for the first time. Appendix A of this standard is normative. This national standard is formulated by the Technology and Standards of the Ministry of Environmental Protection. Drafting organizations of this standard: Jinan Vehicle Test Center, Chinese Research Academy of Environmental Science and China Automotive Technology & Research Center This standard was approved by the Ministry of Environmental Protection of the People s Republic of China on June 24, 2008. This standard shall be implemented from July 1, 2008. Ministry of Environmental Protection is responsible for the explanation of this standard. I
Durability of Emission Control Systems of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles 1 Application Scope This standard specifies the durability requirements (including measurement methods) for vehicle adopted with compression ignition engine and that adopted with the spark ignition engine fuelled with natural gas (NG) or liquefied petroleum gas (LPG) as well as emission control system of such engines. This standard is applicable to the type approval of the emission control system of compression ignition (including gas fuelled positive ignition) engines equipped in M 2, M 3, N 1, N 2 and N 3 vehicles with design speed greater than 25km/h as well as M 1 vehicles with total mass greater than 3500kg. Where N 1 and M 2 vehicles adopted with compression ignition (including gas fuelled positive ignition) engines meet the durability requirements of Limits and Measurement Methods for Emissions from Light-duty Vehicles GB 18352.3 2005, this standard may not be implemented. 2 Normative References The following normative documents contain provisions which, through reference in this text, constitute provisions of this standard. For undated references, the effective edition of the normative document applies. GB 17691 Limits and Measurement Methods for Exhaust Pollutants from Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles (III IV V) GB 18352.3 2005 Limits and Measurement Methods for Emissions from Light Duty Vehicles GB/T 15089 2001 Classification of Power-driven Vehicles and Trailers HJ 437 2008 Technical Specification for On-board Diagnostic (OBD) System of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles 3 Terms and Definitions For the purpose of this standard, terms and definitions specified in GB 17691 and Technical Specification for On-board Diagnostic (OBD) System of Compression Ignition and Gas Fuelled Positive Ignition Engines of Vehicles HJ437 2008 applies. 3.1 Useful Life It is the running distance or service time specified in 5.2 of this standard. It is confirmed during the type approval and ensures that the vehicle (engine) is in normal operation and in accordance with relevant limits of gaseous and particulate pollutants and smoke emission. 3.2 Exhaust After-Treatment System It refers to the catalytic converter (oxidation or three-way catalytic converter), particulates collector, deno x system, combined deno x -particulate filter or other emission reduction device installed in the engine exhaust system, excluding the exhaust gas recirculation (EGR) system. 1
3.3 denox System It is an exhaust after-treatment system used to reduce oxynitride (NO x ) like the NO x catalyst, adsorption NO x catalyst and selective catalytic reduction (SCR) system of active and passive lean-burn engine. 3.4 Emission Control System It includes the exhaust after-treatment system, engine electronic control unit (EECU), relevant component of engine exhaust device which receives the input signal or discharges the output signal and communication interface (hardware or software where applicable) between EECU and any other powertrain or vehicle emission control unit. 3.5 Engine-after-treatment System Family The manufacturing enterprise further combines various engine systems into system families according to the exhaust after-treatment system similarity to determine the deterioration factor and inspect the compliance of in-service vehicle/engine. 3.6 The M 3 Vehicles Are Divided Into Grade A, Grade B, Grade I, Grade II and Grade III According to the requirements of GB/T 15089 2001: M 3 vehicles refer to the passenger vehicles with seats more than 9 (including the driver seat) and maximum design gross mass greater than 5000kg. Therein, Grade A: carrying not more than 22 passengers (excluding the driver); standing passengers are permissible. Grade B: carrying not more than 22 passengers (excluding the driver); standing passengers are not permissible. Grade I: carrying more than 22 passengers (excluding the driver); passengers are allowed to stand and walk about. Grade II: carrying more than 22 passengers (excluding the driver); passengers are only allowed to stand in the passage or a standing area not greater than the area of 2 double-entrance seats. Grade III: carrying more than 22 passengers (excluding the driver); standing passengers are not permissible. 4 Type Approval Application 4.1 The type approval shall be applied by vehicle or engine manufacturing enterprise according to the requirements of Chapter 4 of GB 17691. 4.2 Before the durability test, the manufacturing enterprise shall submit the durability test application to the type approval agency; during the application, the enterprise shall make detailed description of the durability test codes with contents as follows: a) Parameter of test source machine; b) Parameter of after-treatment device; 2 c) Test method (vehicle road test or engine pedestal test);
d) Performance stability travel and time of engine after-treatment device; e) Road mileage and distribution of vehicle road durability running test; f) Time and cycle of engine pedestal operation test and relevance analysis of engine durability operation test and road used for vehicle road durability running test (where applicable); g) Category and measurement method (the measurement method of ESC test and ETC test shall be determined according to the requirement of GB 17691) of the measured gaseous pollutant and the mileage interval or time during the durability operation test; h) Maintenance items. 5 General Requirements 5.1 From the Stage IV specified in GB 17691, the new vehicle (or engine) shall ensure that the emission control device of the vehicle (or engine) shall be in normal operation throughout its useful life, and the exhaust of gaseous pollutant shall meet the limits specified in Table 1 and Table 2 of GB 17691. 5.2 As for the operation test for the durability of emission control system of vehicle or engine, the durability test specified in Table 1 shall be carried out according to the requirements of Appendix A under effective supervision of type approval agency, and the deterioration factor (or deterioration correction value) shall be determined. Table 1 Requirement of Durability and Test Category of Vehicle Running mileage/km Useful life (1) Service time/a Minimum permissible test mileage (2) /km M 1 (3) 100000 5 100000 M 2 100000 5 100000 M 3 [I, II, A and B (GVM (4) 7.5t)] 200000 6 125000 M 3 [III and B (GVM>7.5t)] 500000 7 167000 N 1 100000 5 100000 N 2 200000 6 125000 N 3 (GVM 16t) 200000 6 125000 N 3 (GVM>16t) 500000 7 167000 (1) The useful life shall be the running mileage or the actual service time, whichever occurs earlier. (2) The minimum actual road running mileage of vehicle which is permissible (or the road running mileage converted by hours of actual engine pedestal test). (3) Only M 1 vehicles with GVM greater than 3500 are included. (4) The maximum design gross mass of vehicle. 5.3 Deterioration factors specified in Table 2 are only applied in the following conditions: a) During the declaration of type approval, where the actual durability test is not completed, vehicle or engine manufacturing enterprise may temporarily use deterioration factors specified in Table 2 instead of actual deterioration factor. After the durability test, the test data of type approval shall be calibrated by actual deterioration factor. b) Where it is allowed by the environmental protection department of the State Council. 3
Table 2 Alternative Deterioration Factors Type of engine Test cycle CO HC NMHC CH 4 No x PM Compression ignition engine ESC 1.1 1.05 1.05 1.1 ETC 1.1 1.05 1.05 1.1 Gas fuelled positive ignition engine ETC 1.1 1.05 1.05 1.2 1.05 5.4 The vehicle or engine manufacturing enterprise may apply the determined deterioration factor to engines or combinations of engine and after-treatment device which belong to different engine families. In such case, the vehicle or engine manufacturing enterprise must prove to the type approval agency that the basic engine or the combination of engine and after-treatment device is provided with the same technical specification, vehicle installation requirements and exhaust characteristics as that of the engine or combination of engine and after-treatment device adopted with the same deterioration factor. 5.5 Production compliance inspection 5.5.1 According to the requirements of Chapter 10 of GB 17691, from the Stage IV, the measured value of gaseous and particulate pollutants of engine shall be calibrated by the actual deterioration factor (or deterioration correction value). 5.5.2 During the type approval, the vehicle or engine manufacturing enterprise may simultaneously measure the emissions before the exhaust after-treatment system so as to establish an informal deterioration factor for the production line terminal inspection of engine and after-treatment system in the enterprise. 4
Appendix A (Normative) Durability Test Specifications for Emission Control System A.1 General This Appendix specifies the durability operation test methods, including the vehicle road durability test and the engine pedestal durability test. This Appendix specifies the method of durability operation test and the determination method of deterioration factor. This Appendix specifies relevant maintenance items during the durability operation test, including maintenance items related or unrelated to the emission. A.2 Test Engine Selection A.2.1 The type of engine used for durability test shall be determined according to the requirements of Section 9.1 of GB 17691. A.2.2 Different engine families may be combined as an engine-after-treatment system family based on the type of their exhaust after-treatment system. Where the engine manufacturing enterprise want to combine engine combinations with different cylinder quantity and cylinder configuration but the same technical specification and installation mode of exhaust after-treatment system, it shall submit materials to the type approval agency to prove that engines and after-treatment systems within the same family are provided with the same technical specification, vehicle installation requirements and emission characteristics A.2.3 According to the requirements of Section 9.2 of GB 17691, the vehicle (or engine) manufacturing enterprise shall select a representative engine from the engine-after-treatment system family and carry out durability operation test on it according to the method specified in Section A.3. A.2.3.1 If the type approval agency holds that other type can better represent the worst emission level of the engine-after-treatment system family, another engine shall be jointly selected by the type approval agency and the vehicle (or engine) manufacturing enterprise. A.3 Durability Operation Test Method A.3.1 The vehicle (or engine) manufacturing enterprise may carry out vehicle road durability test on vehicle equipped with source machine or carry out engine pedestal durability test on the selected source machine. A.3.1.1 The vehicle (or engine) manufacturing enterprise shall select proper test method (vehicle or engine), running mileage or engine operation time according to engineering experience. The running mileage (or engine operation time) of the durability test may be less than the useful life specified in Table 1 of Section 5.2. However, it shall not be less than the minimum permissible test mileage specified in Table 1 anyway. A.3.1.2 The vehicle (or engine) manufacturing enterprise shall be determine the test time and interval (5 points like the starting point and ending points shall be included at least, and the interval mileage must not be greater than 30000km) for the ESC test and ETC test. 5
A.3.1.3 Where required by the vehicle (or engine) manufacturing enterprise and approved by the type approval agency, only 1 test cycle (ESC or ETC) may be adopted for each measurement point while all test cycles (ESC and ETC) are adopted for the starting and ending point. A.3.1.4 Only 1 durability test method may be as for engines within the same engine-after-treatment system family while different durability test methods may be adopted for engines of different engineafter-treatment system families. A.3.1.5 The vehicle (or engine) manufacturing enterprise shall submit data on the application relationship between the minimum vehicle road durability (test mileage) and engine pedestal test hours, such as the relationship with fuel consumption and engine speed. A.3.1.6 The vehicle (or engine) manufacturing enterprise shall describe the program of vehicle road (or engine pedestal) durability test in detail while submitting the durability test application to the type approval agency. A.3.1.7 Pretreatment of engine-after-treatment system As for each engine-after-treatment system family, the vehicle (or engine) manufacturing enterprise shall determine the time for the engine-after-treatment system to reach stability after being started, and shall provide relevant data and analyzing data if required by the type approval agency. As an alternative method, the vehicle (or engine) manufacturing enterprise may select 125 hours as the time for engine-after-treatment system to reach stability. The durability test shall be carried out after the pretreatment of engine-after-treatment system, and such point shall be regarded as the starting point of the durability test. A.3.2 The type approval agency is authorized to add ESC and ETC test points between measurement points selected by the vehicle (or engine) manufacturing enterprise. The vehicle (or engine) manufacturing enterprise shall modify the durability test method as required and ask for type approval agency s approval. A.3.3 The commercially available fuel (Stage IV/V) shall be adopted as specified in the durability test. A.3.4 The fuel used in the emission test during the durability test shall meet requirement in the GB 17691. A.3.5 The instrument and equipment used in the durability test shall meet the requirements of relevant national standard. A.3.6 The maintenance to the engine during the durability test shall be in accordance with requirements specified in Article A.6. A.3.7 During the durability test, the unplanned maintenance may be carried out to the engine or vehicle, for instance, if a problem is monitored by the OBD system, the problem will activate the failure indicator (MI). A.4 Report A.4.1 The emission testing (ESC and ETC) result of the durability test shall be submitted to the type approval agency. If any invalid emission testing existed, cause analysis and explanation are required, and another group of emission testing (ESC and ETC) shall be carried out in the following 100h. 6
A.4.2 All of the engine emission testing and maintenance record shall be kept. The record, along with emission testing result during the durability test shall be submitted to type approval agency together. A.5 Determination of Deterioration Factor/Correction Value A.5.1 The measurement results of all kinds of emissions at each test point in the ESC and (or) ETC test cycle, their linear regression equation shall be established through least squares method. One more decimal digit shall be remained in the measurement result compared with the relevant emission limits specified in Table 1 and Table 2 of GB 17691. A.5.2 According to the regression equation in Article A.5.1, interpolation method shall be adopted in calculating the emissions interpolation of the useful life ending point (Mi1) and the durability test starting point (Mi0) as specified in the Table 1 and Table 2 of GB 17691. A.5.2.1 For engines with exhaust after-treatment system, the deterioration factor (DF i) of all kinds of pollutants shall be calculated as follows: Mi1 DF i = Mi0 Where Mi0 The emission amount of pollutant i at the durability test starting point, g/(kw h); Mi1 The emission amount of pollutant i at the useful life ending point, g/(kw h). DF i shall be regarded as 1 where it is less than 1. A.5.2.2 For engines without exhaust after-treatment system, the deterioration correction value (DC i ) of all kinds of pollutants shall be calculated as follows: DC i =Mi1 Mi0 Where Mi0 The emission amount of pollutant i at the durability test starting point, g/(kw h); Mi1 The emission amount of pollutant i at the useful life ending point, g/(kw h). DF i shall be regarded as 0 where it is less than 0. A.5.2.3 Where the type approval agency approves, only one type of test cycle (ESC or ETC) shall be used on each test point, while the other kind of test cycle (ESC or ETC) shall only be operated at the starting and ending point of the durability test. If relation similarity exists between the durability test starting point and ending point measurement result in different test cycles, deterioration factor (or deterioration correction value) of one test cycle shall be applied on the other kind of test cycle. A.6 Maintenance A.6.1 Maintenance for normal operation of engine and reactant supply system during the durability test can be divided into emission-relevant maintenance and emission-irrelevant maintenance, further division are planned maintenance and unplanned maintenance, and some emission-relevant maintenance is regarded as emission-relevant critical maintenance. A.6.2 Emission-relevant planned maintenance A.6.2.1 The emission-relevant planned maintenance carried out during the durability test shall be consistent with the maintenance project as required in the user maintenance instructions of the automobiles or engine manufacturing enterprise. 7
A.6.2.2 The mileage (or time) interval of the emission-relevant planned maintenance carried out during the durability test shall be detailed in the user maintenance instructions of the automobiles or engine manufacturing enterprise. During the durability test, maintenance plan can be modified or updated if necessary. If some maintenance towards the engine in the durability test has been carried out, deletion of this maintenance item from the maintenance plan is prohibited after modification and updating and this item shall be supplemented into the user maintenance instructions. A.6.2.3 Any maintenance of the engine related to emission shall ensure that the vehicle maintenance item is consistent with the in-service vehicle compliance requirement. Meanwhile, relevant information shall be submitted to the type approval agency to prove that all emission-relevant planned maintenance items are necessary technically. A.6.2.4 The manufacturing enterprise shall make statement of the adjustment, cleaning and maintenance (if necessary) of the following items: 8 a) Gas recirculation system, including relevant filter, cooler, control valve and pipeline; b) Crankcase ventilation device; c) Oil nozzle (cleaning only); d) Oil ejector; e) Turbocharger; f) Electronic control unit of the engine and relevant sensor and actuator; g) Particulate matter collector (including relevant parts and components); h) Any exhaust after-treatment system. A.6.2.5 The following parts and components maintenance is emission-relevant critical maintenance: a) Any exhaust after-treatment system; b) Electronic control unit of the engine and relevant sensor and actuator; c) Gas recirculation system, including relevant filter, cooler, control valve and pipeline; d) Crankcase ventilation device. A.6.2.6 All of the critical planned maintenance related to emission shall be provided with reasonable possibility in practical situations. The automobiles or engine manufacturing enterprise shall prove the reasonable possibility to the type approval agency before the durability test maintenance. A.6.2.7 The critical planned maintenance item related to emission which is in accordance with any condition required in Articles 6.2.7.1~6.2.7.4 shall be considered as reasonably possible in practical situations. A.6.2.7.1 The manufacturing enterprise shall submit data used for determine relations between emission and vehicle performance, such as: increased emission caused by lack of maintenance, and the automobile performance will deteriorate to unacceptable degree under typical running condition. A.6.2.7.2 The manufacturing enterprise shall submit investigation statistical data (confidence level 80%) about 80% engines has been taken critical maintenance in recommended time interval during actual use.
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