BS 4 Tata

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BS IV Information and CQ Preparation

Central Quality Lucknow

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Contents • General Information and Timelines

• SCR (Selective Catalytic Reduction) Technology

• SCR Components

• Application guidelines

• Test Reports

• AUS 32 Quality Requirements

• MOM with Cummins

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SCR System Components

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• Catalyst• Catalyst Mounting (EGP)• Diffuser• Intumescent Mat• Sleeve• Muffler Body

• Doser• Sensors• Filters

SCR System Components

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Application Guidelines Dosing Units

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Application Guidelines Nozzle –

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Application Guidelines Sensors –

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Application Guidelines-System level

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System level Tests Conducted on SCR System by Cummins

TEST DESCRIPTION RESULTTorque Peak Abuse 1) Test combines the most abusive aspects from the Torque Peak Endurance (TPE) test CES

98140 and the Hot Box Test (HBT) CES 98132. 2) The TPA test examines the impact of high oil, coolant, fuel, and air temperatures on an engine and its components at 15% overfuel from maximum torque peak steady-state conditions.

No impact seen on aftertreatment components after Torque Peak Abuse Test

Thermal Cycle Test 1) The thermal cycle test was developed to evaluate the thermal and mechanical fatigue resistance of components.2) The cycle includes both a thermal abuse condition and a mechanical abuse condition which occur over the duration of a six minute cycle. 3) Within this time frame, the cycle transitions from idle to a steady-state abuse power condition and then transitions back to idle for the duration of the cycle.

No impact seen on aftertreatment components after Thermal Cycle Test

Peak Power Overfuel 1) The PPO test was developed as a hurdle test to evaluate the durability and reliability of components. 2)It is a steady state test run at 1800 RPM engine speed with 120% of the set torque curve fuel rate, at 1800 RPM.

No impact seen on aftertreatment components after PPO Test

High Speed Mechanical Test 1) The purpose of the HSM test is to evaluate the effects of high engine speeds on engine durability and wear. 2) The HSM is a steady state endurance type test. The test is run for 1000 hours.

No impact seen on aftertreatment components after HSM Test

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Tests of Nozzle EquipmentTEST DETAILS RESULT

Shaker Test 1) 2 vertically mounted nozzles2) Test based on vehicle vibration profile with 10 x actual vehicle vertical amplitude for 20 hours

PASS

Thermal Robustness 1) Nozzle capable of exhaust gas temperatures of >600°C with and without urea flow. PASS

Low Temperature Test 1) Withstand material freezing without incident PASS

Salt Spray Test 1) Accelerated salt spray chamber test to evaluate material resistance to user environment

PASS

Flow Test 1) Nozzle to flow maximum doser flow rate within design tolerances of +/-0.005 ml/s PASS

Nozzle Orientation Test 1) Steady state emissions with different angles of rotation in nozzle boss per limits as defined in AEB 21.60

Emissions within limits for different orientation of nozzle boss.

Nozzle Thermal shock Validation 1) To determine if the nozzle cracks due to shock from a sudden shift from a cold state to a hot state. 2) The nozzle operates under conditions which could be extremely cold and suddenly hot. Due to these conditions which could affect the mechanical properties of the nozzle, it is likely that the nozzle could crack due to this sudden change in temperature.3) A Decomposition pipe with a nozzle attached was used. It was attached to engine exhaust outlet and then chilled to freezing temperatures. The engine was started causing the temperature in the exhaust tube to reach 45 C in less than 3 minutes.

No crack seen after each thermal shock experiments.

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Tests of Dosing UnitTEST DETAILS RESUL

T

Temperature to failure

1Unless otherwise specified, the start temperature shall be 10 °C below the maximum operating temperature -40 deg to +85 deg. with subsequent 5 °C increments.2) The duration at each temperature shall be a minimum of 1 hour. If EUTs with large thermal mass require longer than an hour to stabilize at temperature, the dwell time shall be increased appropriately.3) The EUT shall be configured in operational modes such that the sensitivity of parameter or function under evaluation is maximized. The operational mode(s) shall be defined by the product design team or included in the individual product specification.

PASS

Temperature cycling durability test

1) Temperature limits shall be -40 deg to +85 deg.2) The profile shall be as shown in Figure 1: Temperature Profile 3) The duration shall be a minimum of 285 cycles (approximately 1000 hours). If EUTs with large thermal mass require longer than an hour to stabilize at temperature, the dwell time at the extremes shall be increased appropriately.

PASS

Resonant search 1)Subject the unit to an acceleration of 39m/s2 (4g) with the frequency being swept through 10 to 2000 Hz at a maximum rate of 1 octave per minute.2)During the test examine for resonance of any part of the unit, where a resonance point is defined by an amplification factor Q greater than or equal to 5.3)Dwell the vibration frequency for 5 minutes at each resonance point.

PASS

Thermal Shock 1) Temperature limits shall be -40 deg to +85 deg.2) The profile shall be as shown in Figure 1: Temperature Profile 3) The duration shall be a minimum of 100 cycles (approximately 200 hours). If EUTs with large thermal mass require longer than an hour to stabilize at temperature, the dwell time at the extremes shall be increased appropriately.

PASS

Mechanical shocks 1) The shock profile shall be as shown in Figure 6: Mechanical Shock Waveform.2) The waveform shall be applied a minimum of 3 times for each direction.3) The profile shall be applied in both directions for each of three orthogonal axes.4) Testing shall be conducted at ambient temperature conditions.

PASS

Drop test 1) The drop height shall be 1 meter.2) The surface shall be solid concrete such as a poured sla2)3) A minimum of one drop per EUT side shall be performed.

PASS

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Besides these detailed test reports of thermistor and NOx sensors are also available.

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AUS 32-Quality Requirements as per DIN 70070

1. Storage temperature below 30 deg is recommended to maintain shelf life.

2. Sun light protection

3. Well closed containments

4. Prolonged storage above 30 deg will lead to ammonia formation and reduced shelf life.

STORAGE CONDITIONS

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• FIRE/EXPLOSION HAZARD

1. Non combustible.

2. Not considered to be a significant fire risk

3. Expansion or decomposition on heating may lead to violent rupture of containers

4. Decomposes on heating and may produce toxic fumes of carbon monoxide

5. May emit acrid smoke.

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• PROCEDURE FOR HANDLING

1. Limit all unnecessary personal contact

2. Use in a well-ventilated area

3. Keep containers securely sealed when not in use

4. Always wash hands with soap and water after handling

5. Keep away from heat and direct sunlight

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MOM with Cummins Valvoline Team in Lucknow

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S. No.Points Discussed during TML visit along with CES and VCL team on 21/11/09.

Status of MOM points as on Dec 18,2009 (as per Discussion with CES)

PDC (Rev)

1CES/VCL to have joint plant visit to Lucknow to create awareness/storage/dispensing/see the plant –  mid Dec 09

Done

2CES/ VCL to share detailed plans (production/ service) - mid dec 09

Detailed Training for service & Prod training will be carried out at the end of J an 2010 by CESTraining will be carried out in 2 Levels1) Diagnostic Trng2)Assy Line Operator TrngThis include Training to service persons also

End of J an 10

3CES to visit TML Lucknow for understanding end-of-line testing to cater for BS-IV requirements. Check with chassis passing limit for emissions

CES to provide 50 Engines Data for Engine Performance (emission) to TML on the basis of which the passing limits of Emission can be set

TBG

5CES/VCL to get in touch with TML –Mktg to understand volume requirements –  30Nov 09

6 Component level test to be shared by CES – DVP for each Project to be sharedDecision on the level of Part Level Component Sharing to be taken after internal Discussion with Suppliers by CES

23-Dec-09

7 Electronics

ECU flashing strategy – CES to come back on the requirement issue for Flasing of Software in Nox ECU & has to provide the same in case it is required

23-Dec-09

INSITE Pro available with TML includes all features pertaining to BS-IV -  

CES confirms the same

TML/CIL/CES electronic team to check electronic compatibility In terms of alternator /other electrical items for performance – e.g. spikes, electronic noise -  

AS per CES Nox Sensor is protected till 14V -36Vspikes & Dosing Unit from 9-32 V , Still CES to confirm the same & also revert back on the Low & High Current value of sustainence of the System

Closure 20 Jan 10

CONT.

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S. No.Points Discussed during TML visit along with CES and VCL team on 21/11/09.

Status of MOM points as on Dec 18,2009 (as per Discussion with CES)

PDC (Rev)

8

CES to provide guidelines for checking in emergencies in case of line failure/ warranty of system and troubleshooting manual.  ( e.g. plan for spare parts, establish accountability , back-up plan in case of line rejects, etc) – 27Dec 09

CES to carry out Training in 2 Levels1) Diagnostic Trng2)Assy Line Operator TrngCES to share the DO & DON’T Check Sheet for Assembly

End of J an 10

9CES to discuss with Fleetguard on serviceability of air-oil separator (e.g. I s it use and throw spin-on filter) – 23 Nov 09

As per CES THE Filter is disposable one & is to be replaced after every 60000KM

Closed

10CES to suggest testing equipment options to verify tail-pipe Nox limits: TML to provide current testing facility. CES to confirm on capability – 25 Nov 09

CES recommnended the Horiba Testing Equipment Detailed discussion of the same has done with planning Closed

11CES to check what precautions needs to be taken in case of water buried EGP due to heavy water logging – 27 Nov 09

As per CES Shell is protected for rust & Protecion. No solution available for the Reaction with VO5(Venedium Penta Oxide) .CES to take up this issue with ERC Pune & Tests to be conducted for VO5 reaction with Water & results to be analysed

Dec last Wk (Disc)

Closue-20 Feb 10

12CES to check for AUS32 consumption trials with TCL Appl Engg – 7 Dec 09

As per CES Testing for BS IV SCR System on Vehicle is already planned with ERC . The data for Urea consumption can be obtained from the same as the testing goes on

13CES to explore requirements for preventive and service maintenance: mid-Dec’09:

As per CES Urea tank to be Cleaned with DeIonised Water for Adulterated Urea Solution Apart from this no Preventive maintenance for any part is required as such

Closed

14

CES to give guidelines for installation process, storage , cleanliness requirements for SCR parts to be defined for production and service – after visit to TML – Lucknow (closure of point - tentatively 3rd week of Dec’09):

As per CES No Special requirement for Handling EGP is there .But EGP Handling trolley/Assy Fixture recommendation is sought from them

TBG

15CES to provide AUS32 tank maintenance guidelines  for cleanliness levels to production and field -

Discussed with Planning with Volvoline during their visit on 17 Dec 09 WIP

16VCL to provide details to TML to support procurement of dispensing Systems, Refracto meters & Quality Checking kits 7 Dec 09

Discussed with Planning with Volvoline during their visit on 17 Dec 09

WIP

17VCL to check for Legal and regulatory Requirements with State Pollution Boards mid Dec 09

18VCL to check for explosive certificate requirements at TML plant states mid Dec 09

19VCL to check for disposal Methodology and GuideLines for AUS 32 which has expired its shelf Life-2nd Dec 09

20VCL to provide TML guidelines for Handling/Storage of AUS32 for production and service

21Cummins/VCL to get in touch with STU co-ordinator – TML Lucknow for AUS32 requirements (educate STU. Govt officials) –

VCL to revert back on these Issues 21 Dec 09

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Thank You