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1 1 California Air Resources Board California Air Resources Board Engine Certification Workshop - - Engine Certification Workshop Durability and Deterioration Factors Durability and Deterioration Factors March 24, 2010 March 24, 2010 2 2

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California Air Resources Board California Air Resources Board

Engine Certification Workshop Engine Certification Workshop -

  • Durability and Deterioration Factors

Durability and Deterioration Factors

March 24, 2010 March 24, 2010

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Applicable Categories Applicable Categories

  • On

On-

  • Road CA

Road CA-

  • Medium

Medium-

  • Duty Engines (MDE)

Duty Engines (MDE)

  • On

On-

  • Road Heavy

Road Heavy-

  • Duty Otto

Duty Otto-

  • Cycle Engines (HDOE)

Cycle Engines (HDOE)

  • On

On-

  • Road Heavy

Road Heavy-

  • Duty Diesel Engines (HDDE)

Duty Diesel Engines (HDDE)

  • Off

Off-

  • Road Compression

Road Compression-

  • Ignition Engines

Ignition Engines (OFCI (OFCI--

  • -Tier 4i / Tier 4

Tier 4i / Tier 4)

)

  • Others (HD Hybrids & Special Cases)

Others (HD Hybrids & Special Cases)

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Workshop Agenda Workshop Agenda

  • New Emissions Standards

New Emissions Standards

  • Use of New Emission Control Technologies

Use of New Emission Control Technologies

  • Engine Durability Program / Generating New DFs

Engine Durability Program / Generating New DFs

  • Certification Issues

Certification Issues

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New Emissions Standards New Emissions Standards

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  • HDOE (CFR Part 86)

HDOE (CFR Part 86) – – Otto FTP Transient Otto FTP Transient

  • HDDE (CFR Part 86 and Part 1065)

HDDE (CFR Part 86 and Part 1065) – – Diesel FTP Transient Diesel FTP Transient – – SET (ramp SET (ramp-

  • modal cycle: RMC)

modal cycle: RMC)

  • OFCI (CFR Part 89 and Part 1039)

OFCI (CFR Part 89 and Part 1039) – – Non Non-

  • road Transient (NRTC)

road Transient (NRTC) – – Steady Steady-

  • State (C1 / D2 / etc.)

State (C1 / D2 / etc.)

New Engine Emissions Standards New Engine Emissions Standards

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New Emission Control New Emission Control Technologies Technologies

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  • Exhaust Gas Recirculation (EGR)

Exhaust Gas Recirculation (EGR)

  • Diesel Particulate Filter (DPF)

Diesel Particulate Filter (DPF)

  • Selective Catalytic Reduction (SCR)

Selective Catalytic Reduction (SCR)

New Emission Control New Emission Control Technologies Technologies

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  • Durability of EGR System

Durability of EGR System

  • Valves

Valves

  • By

By-

  • pass controls

pass controls

  • Coolers

Coolers

  • Others

Others

  • Maintenance Intervals

Maintenance Intervals

  • Deterioration Effects

Deterioration Effects

EGR EGR

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  • Infrequent Regeneration and Emissions

Infrequent Regeneration and Emissions Adjustment Factors ( Adjustment Factors (UAFs/DAFs UAFs/DAFs) )

  • Ash Cleaning Event

Ash Cleaning Event

  • Operator Commanded Regeneration (OCR) for

Operator Commanded Regeneration (OCR) for DPF is allowed under safe harbor provisions DPF is allowed under safe harbor provisions

  • See (CHC

See (CHC-

  • 2006

2006-

  • 007

007-

  • 1)

1)

DPF DPF

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SCR SCR

  • SCR system deterioration:

SCR system deterioration:

  • Linear vs. non

Linear vs. non-

  • linear deterioration

linear deterioration

  • Interaction w/ upstream and downstream ATD (OC,

Interaction w/ upstream and downstream ATD (OC, DPF, etc) and engine DPF, etc) and engine

  • Control sensors durability

Control sensors durability

  • Toxics

Toxics

  • Copper

Copper-

  • based catalyst

based catalyst

  • Vanadium catalyst

Vanadium catalyst

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Applicable Regulations Applicable Regulations

  • Exhaust and Evaporative Emissions Compliance

Exhaust and Evaporative Emissions Compliance CCR 1956.8 CCR 1956.8

  • 40 CFR Part 86 xxx

40 CFR Part 86 xxx-

  • 026

026

  • Compliance to FUL

Compliance to FUL

  • Same as before

Same as before On On-

  • Road CA

Road CA-

  • Medium

Medium-

  • Duty Engines and

Duty Engines and Heavy Heavy-

  • Duty Otto

Duty Otto-

  • Cycle Engines

Cycle Engines

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Applicable Regulations Applicable Regulations

  • Exhaust and Evaporative Emissions Compliance

Exhaust and Evaporative Emissions Compliance CCR 1956.8 CCR 1956.8

  • 40 CFR Part 86xxx

40 CFR Part 86xxx-

  • 026 and Part 1039

026 and Part 1039-

  • 240

240

  • Compliance to FUL

Compliance to FUL On On-

  • Road Heavy

Road Heavy-

  • Duty Diesel and

Duty Diesel and Off Off-

  • Road Compression

Road Compression-

  • Ignition Engines

Ignition Engines

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Certification Requirements Certification Requirements

  • Engine Durability to Defined Useful Life via

Engine Durability to Defined Useful Life via service accumulation cycle + hours service accumulation cycle + hours

  • Emissions Compliance to Defined Useful Life via

Emissions Compliance to Defined Useful Life via emissions deterioration factors for emissions deterioration factors for

  • Exhaust

Exhaust

  • Evaporative, as applicable

Evaporative, as applicable

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Performance and Emissions Performance and Emissions Demonstration Demonstration

  • Engine Durability Requirements

Engine Durability Requirements

  • Test Protocol and Test Procedures

Test Protocol and Test Procedures

  • Durability Service Accumulation Cycle

Durability Service Accumulation Cycle

  • DF Calculations (~100% UL)

DF Calculations (~100% UL)

  • Scheduled Maintenance and Emissions Testing

Scheduled Maintenance and Emissions Testing

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Service Accumulation Duration Service Accumulation Duration

  • CA

CA-

  • MDE

MDE FUL = 120k miles FUL = 120k miles

  • On

On-

  • Road HDOE

Road HDOE FUL = 110k miles FUL = 110k miles

  • On

On-

  • Road HDDE

Road HDDE LH/MH/HH 50% FUL LH/MH/HH 50% FUL

  • OFCI

OFCI 50% of FUL 50% of FUL

  • Optional DF for HHDDE/OFCI:35% FUL +

Optional DF for HHDDE/OFCI:35% FUL +

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One service accumulation cycle producing 2DFs: One service accumulation cycle producing 2DFs:

  • HDDE Category (2007+)

HDDE Category (2007+) 1.

  • 1. DF1 = FTP Transient Cycle

DF1 = FTP Transient Cycle 2.

  • 2. DF2 = ramp

DF2 = ramp-

  • modal cycle (RMC)

modal cycle (RMC)

  • OFCI Category (Tier4i / Tier4)

OFCI Category (Tier4i / Tier4) 1.

  • 1. DF1 = Non

DF1 = Non-

  • Road Transient Cycle (NRTC)

Road Transient Cycle (NRTC) 2.

  • 2. DF2 = Steady State

DF2 = Steady State

2 DFs to be Generated 2 DFs to be Generated

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Emissions Test Points / Intervals Emissions Test Points / Intervals

  • Minimum of three, equally spaced test

Minimum of three, equally spaced test points, throughout service accumulation points, throughout service accumulation period (recommend every 250 hours) period (recommend every 250 hours)

  • FTP / NRTC: test sample point = 1 cold start

FTP / NRTC: test sample point = 1 cold start + 3 hot starts + 3 hot starts

  • RMC / C1 / D2: test sample point = 3 hot

RMC / C1 / D2: test sample point = 3 hot starts starts

  • Equal sampling at each test sample point

Equal sampling at each test sample point

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Service Accumulation Cycle Service Accumulation Cycle

  • Service accumulation hours

Service accumulation hours

  • Transient segments required

Transient segments required

  • Real

Real-

  • life or in

life or in-

  • use engine cycle

use engine cycle

  • Emissions testing hours excluded from

Emissions testing hours excluded from total cycle total cycle

  • Recommend agency pre

Recommend agency pre-

  • approval

approval

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Deterioration Factors Deterioration Factors

  • Separate Factors for Each Pollutant

Separate Factors for Each Pollutant

  • Useful Life Projected Values

Useful Life Projected Values

  • Applied to EDE to Show FUL Compliance

Applied to EDE to Show FUL Compliance

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DF Calculation DF Calculation

  • Must include all data collected

Must include all data collected

  • Engines with after

Engines with after-

  • treatment: Multiplicative

treatment: Multiplicative

– – xxHC xxHC, NOx, CO, HCHO , NOx, CO, HCHO – – PM additive PM additive

  • Engines with no after

Engines with no after-

  • treatment: Additive

treatment: Additive

  • Will consider alternatives

Will consider alternatives

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DF Calculation (continued) DF Calculation (continued)

  • Individual pollutant with separate DF

Individual pollutant with separate DF

  • DF for composite

DF for composite xxHC+NOx xxHC+NOx standard standard

  • May use least

May use least-

  • square linear regression

square linear regression method method

  • May propose other calculation methodology

May propose other calculation methodology

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Agency Pre Agency Pre-

  • Approval for Special

Approval for Special Cycles / Procedures Cycles / Procedures

  • Special pre

Special pre-

  • conditioning procedures

conditioning procedures

  • Special emission test procedures

Special emission test procedures

  • Any deviation from established protocols

Any deviation from established protocols

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Durability Engine Durability Engine Allowable Maintenance Allowable Maintenance

  • On

On-

  • Road HDD, HDO, and MDE engines

Road HDD, HDO, and MDE engines

  • Applicability: 40CFR Part86xxx

Applicability: 40CFR Part86xxx-

  • 025

025

  • Highly recommend discussing maintenance

Highly recommend discussing maintenance schedule with agency schedule with agency

  • May require before and after emissions tests

May require before and after emissions tests

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Durability Engine Durability Engine Allowable Maintenance Allowable Maintenance

(continued) (continued)

  • OFCI for all Tier 4i and Tier 4 engines

OFCI for all Tier 4i and Tier 4 engines

  • Applicability: 40CFR Part 1039.125

Applicability: 40CFR Part 1039.125

  • Highly recommend discussing maintenance

Highly recommend discussing maintenance schedule with agency schedule with agency

  • May require before and after emissions tests

May require before and after emissions tests

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Certification Issues Certification Issues

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Certification Issues / Items Certification Issues / Items

  • Unscheduled maintenance

Unscheduled maintenance

  • DF engine

DF engine “ “failures failures” ”

  • DPF ash

DPF ash-

  • cleaning event

cleaning event

  • DF carryover / carry

DF carryover / carry-

  • across

across

  • Future DF protocol

Future DF protocol

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Durability Engine Durability Engine Unscheduled Maintenance Unscheduled Maintenance

Recommend seeking Agency pre Recommend seeking Agency pre-

  • approval,

approval, Example: Example:

  • Cleaning, replace, or repair of :

Cleaning, replace, or repair of :

  • EGR (system), injectors, turbocharger, after

EGR (system), injectors, turbocharger, after-

  • coolers, and by

coolers, and by-

  • pass controls

pass controls

  • After

After-

  • treatment device replacement

treatment device replacement

  • Calibration changes

Calibration changes

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What to do with DF Engine/Part What to do with DF Engine/Part Failure Failure

1.

  • 1. Do NOT replace, repair, clean, or

Do NOT replace, repair, clean, or modify the DF engine or engine modify the DF engine or engine part(s part(s) )

2.

  • 2. Identify and diagnose failure and

Identify and diagnose failure and impact of failed impact of failed part(s part(s) )

3.

  • 3. Contact agency for guidance

Contact agency for guidance

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What to do with DF Engine/Part What to do with DF Engine/Part Failure (continued) Failure (continued)

4.

  • 4. Seek approval from agency for any

Seek approval from agency for any maintenance of the DF engine maintenance of the DF engine

5.

  • 5. Agency will consider appropriate

Agency will consider appropriate action for the DF engine action for the DF engine

6.

  • 6. Must provide engineering report of

Must provide engineering report of failure in application failure in application

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Collection of DPF Ash Cleaning Collection of DPF Ash Cleaning and Resultant Emission Data and Resultant Emission Data

  • If an ash cleaning is required within the

If an ash cleaning is required within the FUL, this event must be demonstrated FUL, this event must be demonstrated

  • Emissions testing before and after the

Emissions testing before and after the ash cleaning event ash cleaning event

  • Emission data will be used to validate the

Emission data will be used to validate the cleaning procedure cleaning procedure

  • Collected data may be part of the DFs

Collected data may be part of the DFs

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DFs: Carry DFs: Carry-

  • Over & Carry

Over & Carry-

  • Across

Across

  • Allowed for comparable engines

Allowed for comparable engines

  • Carry

Carry-

  • over to a different model year
  • ver to a different model year

(minor changes w/o emissions impact) (minor changes w/o emissions impact)

  • Carry

Carry-

  • across between engine families

across between engine families

– – Worksheet to be completed Worksheet to be completed – – Worksheet available on ARB website Worksheet available on ARB website

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Sample C/O and C/A Worksheet Sample C/O and C/A Worksheet

Type of NOx Sensor 37 Maximum Exposure Temperature on Oxygen Sensor 36 Type of Oxygen Sensor 35 Catalyst surface area/Max. Power 34 Reducing agent/fuel consumption ratio (Volumetric) per 1000 Hours of Operation 33 Displacement 5 Cylinder Head Configuration 4 Number of Cylinders 3 Engine Type 2 Tested Family Engine Family 1 DF Carry-across comparison parameters

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DFs: Carry DFs: Carry-

  • Over & Carry

Over & Carry-

  • Across

Across (on (on-

  • road to off

road to off-

  • road)

road)

Comparing these follow items: Comparing these follow items:

  • Engine hardware/software

Engine hardware/software

  • In

In-

  • use characteristics

use characteristics

  • Durability cycle

Durability cycle

  • Emissions test cycles

Emissions test cycles

  • Engine duty

Engine duty-

  • cycle, engine

cycle, engine-

  • load and

load and performance, and control calibrations performance, and control calibrations

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ARB May Consider Accepting ARB May Consider Accepting Alternative DF Protocol Alternative DF Protocol

  • Case by case approval

Case by case approval

  • Rapid Alternative Durability Process (RADP)

Rapid Alternative Durability Process (RADP)

  • Real

Real-

  • world, In

world, In-

  • use validations

use validations

  • Engine

Engine-

  • out vs. tailpipe
  • ut vs. tailpipe-
  • out
  • ut
  • Rapid aging (bench aging protocol)

Rapid aging (bench aging protocol)

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Other Items of Interest Other Items of Interest

  • AECD sensors table (available on ARB website)

AECD sensors table (available on ARB website)

  • Engine emissions label durability and

Engine emissions label durability and alternative protocol to demonstrate label alternative protocol to demonstrate label durableness durableness

  • Provide physical labels for testing

Provide physical labels for testing

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Sample Sensors Table Sample Sensors Table

ARB staff comment AECD Justificati

  • n

AECD Type Impa cts

  • n

Emis sions Failu re Cons eque nce Defau lt Mode / thres hold value Failur e Indic ation Failur e Detec tion sens

  • r

still worki ng? (yes / no) Sens

  • r /

Actua tor Value : Low (unit) Sens

  • r -

Actua tor Value : High (unit) Sense d Param eter Range : High / Low (Units) Senso r or Actua tor Name / Abbre vation li n e n u m b er

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Other Items of Interest Other Items of Interest (continued) (continued)

  • California Warranty

California Warranty

  • HD

HD-

  • ZEV and HD

ZEV and HD-

  • Hybrid rulemaking process

Hybrid rulemaking process

  • HD Hybrid DF protocol

HD Hybrid DF protocol

  • OBD aged

OBD aged-

  • part considerations

part considerations

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Compression Compression-

  • Ignition and

Ignition and Heavy Heavy-

  • Duty Certification

Duty Certification

Manager: Kim Pryor Manager: Kim Pryor

(626) 575 (626) 575-

  • 6640 kpryor@arb.ca.gov

6640 kpryor@arb.ca.gov

Paul Adnani Paul Adnani Tom Chang Tom Chang Zachary Evans Zachary Evans Tsatsu Nukunya Tsatsu Nukunya James Pang James Pang Babak Pazokifard Babak Pazokifard Michael Pham Michael Pham

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Questions and Answers Questions and Answers

Q ??? / A !!! Q ??? / A !!!