§1065.1139. Aging cycle generation. — Inbound Citations

(6) Perform accelerated bench aging of aftertreatment devices to represent normal engine operation over the useful life using the service accumulation hours determined in paragraph (c)(5) of this section. Design your bench aging to represent 10,000 hours of in-use engine operation for every 1,000 hours of accelerated bench aging. Use the accelerated bench-aging procedure in 40 CFR 1065.1131 through 1065.1145 or get our advance approval to use a different procedure that adequately that accounts for thermal and chemical degradation. For example, this might involve testing consistent with the analogous procedures that apply for light-duty vehicles under 40 CFR part 86, subpart S.

Sections 1065.1131 through 1065.1145 specify procedures for aging compression-ignition engine aftertreatment systems in an accelerated fashion to produce an aged aftertreatment system for durability demonstration. Determine the target number of hours that represents useful life for an engine family as described in the standard setting part. The method described is a procedure for translating field data that represents a given application into an accelerated aging cycle for that specific application, as well as methods for carrying out aging using that cycle. The procedure is intended to be representative of field aging, includes exposure to elements of both thermal and chemical aging, and is designed to achieve an acceleration of aging that is ten times a dynamometer or field test (1,000 hours of accelerated aging is equivalent to 10,000 hours of standard aging).

(3) Derive the thermal reactivity coefficient, Ea,D, for each zone of the SCR, based on the guidance provided in paragraphs (d)(1) and (2) of this section. The zone that yields the lowest Ea,D shall be used for calculating the target cumulative thermal load, as outlined in § 1065.1139.

(b) There are two methods for using field data to develop aging cycles, as described in § 1065.1139(b)(1) and (2). Method selection depends on the type of field data available. Method 1 directly uses field data to generate aging modes, while Method 2 uses field data to weight appropriate regulatory duty cycles that are used for emissions certification.

(1) When using Method 1, direct field data use, as described in § 1065.1139(b)(1), record data for exhaust flow rate and at least one representative inlet temperature for each major aftertreatment system catalyst component, such as a diesel oxidation catalyst (DOC), diesel particulate filter (DPF), or selective catalytic reduction (SCR) catalyst. If a given catalyst component has multiple substrates installed directly in sequence, it is sufficient to record only the inlet temperature for the first catalyst substrate in the sequence. It is not necessary to record separate temperatures for substrates that are “zone-coated” with multiple catalyst functions. Record a representative outlet temperature for any major catalyst component that is used to elevate the temperature of downstream components. This could be the inlet of the next major component if that would be representative. We recommend that you record engine fuel rate to assist in the determination of sulfur exposure rates, but you may use other data for this purpose.

(b) There are two methods for using field data to develop aging cycles, as described in § 1065.1139(b)(1) and (2). Method selection depends on the type of field data available. Method 1 directly uses field data to generate aging modes, while Method 2 uses field data to weight appropriate regulatory duty cycles that are used for emissions certification.

(2) When using Method 2, weighting of certification cycles, as described § 1065.1139(b)(2), record data for engine speed and engine load. Record sufficient ECM load parameters to determine a torque value that can be compared directly to engine torque as measured in the laboratory. You may optionally use ECM fuel rate measurements to determine load, but only if the same measurements can also be performed during laboratory testing on certification test cycles using sensors with comparable response characteristics. For example, you could use ECM fuel consumption rates for both field data and during laboratory tests.

(i) Optionally, as an alternative to the parameters required in this paragraph (b)(2), you may use a system exhaust temperature measurement to represent load. This requires one recorded temperature that represents the aftertreatment system. We recommend that you use a temperature recorded at the outlet of the first major catalyst component. If you choose to use this option, you must use the same temperature sensor for both field and laboratory measurements. Do not compare measurements between on-engine production temperature sensors with laboratory temperature sensors.

(ii) Optionally, as an alternative to the parameters required in this paragraph (b)(2), you may use exhaust flow and temperature measurements recorded in the field to support Method 2 calculations. Only one recorded temperature that represents the aftertreatment system is needed in this case. We recommend that you use a temperature recorded at the outlet of the first major catalyst component. Do not compare measurements between on-engine production temperature sensors with laboratory temperature sensors.

(iv) If you are unable to reach the target deactivation by following paragraphs (e)(6)(i) through (iii) of this section, use good engineering judgment to increase the number of regenerations to meet the criteria in paragraph (e)(5) of this section. Note that this will increase the total regeneration hours, therefore you must decrease the number of normal operation hours and re-calculate mode durations for the normal operation modes.

(iv) If you are unable to reach the target deactivation by following paragraphs (e)(6)(i) through (iii) of this section, use good engineering judgment to increase the number of regenerations to meet the criteria in paragraph (e)(5) of this section. Note that this will increase the total regeneration hours, therefore you must decrease the number of normal operation hours and re-calculate mode durations for the normal operation modes.

(iv) If you are unable to reach the target deactivation by following paragraphs (e)(6)(i) through (iii) of this section, use good engineering judgment to increase the number of regenerations to meet the criteria in paragraph (e)(5) of this section. Note that this will increase the total regeneration hours, therefore you must decrease the number of normal operation hours and re-calculate mode durations for the normal operation modes.

(v) If you are not able to achieve the target Dt,field using the steps in paragraphs (e)(6)(i) through (iv) of this section without exceeding catalyst temperature limits, use good engineering judgement to reduce the acceleration factor from 10 to a lower number. If you reduce the acceleration factor you must re-calculate the number of hours determine in paragraph (a) of this section and re-run the process in this paragraph (e). Note that if you reduce the acceleration factor you must use the same lower acceleration factor in the chemical exposure calculations in paragraph (h) of this section, instead of 10.

(b) Use good engineering judgment to modify the engine to increase oil consumption rates to levels required for accelerated aging. These increased oil consumption levels must be sufficient to reach the bulk pathway exposure targets determined in § 1065.1139(h). A combination of engine modifications and careful operating mode selection will be used to reach the final bulk pathway oil exposure target on a cycle average. You must modify the engine in a fashion that will increase oil consumption in a manner such that the oil consumption is still generally representative of oil passing the piston rings into the cylinder. Use good engineering judgment to break in the modified engine to stabilize oil consumption rates. We recommend the following methods of modification (in order of preference):

(1) Install the second compression ring inverted (upside down) on one or more of the cylinders of the bench aging engine. This is most effective on rings that feature a sloped design to promote oil control when normally installed.

(2) If the approach in paragraph (b)(1) of this section is insufficient to reach the targets, modify the oil control rings in one or more cylinders to reduce the spring tension on the oil control ring. It should be noted that this is likely to be an iterative process until the correct modification has been determined.

(3) If the approach in paragraph (b)(2) of this section is insufficient to reach the targets, modify the oil control rings in one or more cylinders to create small notches or gaps (usually no more than 2 per cylinder) in the top portion of the oil control rings that contact the cylinder liner (care must be taken to avoid compromising the structural integrity of the ring itself).

(e) Incorporate a means of introducing lubricating oil into the burner fuel to enable the volatile pathway of oil exposure. You must introduce sufficient oil to reach the volatile pathway oil exposure targets determined in § 1065.1139(h). You must measure the rate of volatile pathway oil introduction on a continuous basis.