Down Pipe Temperature Drop CES Application Engineering - AE Training Vishaul Ravi

Information Security Protect Information - Competitors desire to know what we are doing Discuss only with other team members who have a “Valid Right and Need to Know” Information shared should be clearly stated as Cummins Confidential and the vehicle OEM should use same “Need to Know” criteria for distribution within their company 9/21/2018 Cummins Confidential

Scope This presentation provides The installation and test procedure for ensuring the downpipe temperature loss for the following MR and HD applications MR Applications QSB 6.7 (>174 hp) QSL 9 (all ratings) HD Applications QSG 12 QSX 15 (all ratings) 9/21/2018 Cummins Confidential

Objectives After completing this course you will be able to: Understand the reasons for performing Aftertreatment temperature drop testing and why it is important Recognize the Aftertreatment locations for temperature drop measurement Realize the available test methods and tools, and acceptable requirement limits for completion of the testing 9/21/2018 Cummins Confidential

What is ‘Downpipe temperature Drop’? Down Pipe Temp Drop: The temperature loss within the OEM Down Pipe, which is the tubing from Turbo outlet to the aftertreatment Inlet 9/21/2018 Cummins Confidential

Why Interested in Temperature Drop? Hot exhaust gas is required to reach the Aftertreatment system for particulate and NOx emissions to be efficiently reduced For DOC and DPF systems, higher temps are required to: Meet Regeneration and SCR conditioning temperatures Increase catalyst performance Minimizes active regeneration requirements. For SCR systems Minimized DEF Deposits Increases SCR Efficiency Meeting temp drop ensures performance at low ambient temperatures 9/21/2018 Cummins Confidential

What is Exhaust System Cleaning (Regeneration)? Thermal regeneration of filters involves the oxidation of solid particulates to gaseous products, preferably to CO2. Depending on the after treatment design and the engine operating conditions (exhaust gas temperatures), the oxidation of the carbon in diesel soot can be made possible in a few different ways as described in the next few slides Are references to an external website allowed? 9/21/2018 Cummins Confidential

Types of Exhaust System Cleaning (Regeneration) Passive regeneration No change in engine operation. Occurs when temps are high enough to naturally regenerate Active regeneration (In Mission) Active regeneration happens during the normal operation of the machine. Based on the inputs to the DPF, the Aftertreatment control system will initiate regeneration. No observable engine changes but addition fuel is added to raise exhaust temperatures. 9/21/2018 Cummins Confidential

Types of Exhaust System Cleaning (Regeneration) Contd... Active Regeneration (Out of mission) Non-Mission regeneration is initiated by the operator when system is unable to go into In-Mission Regeneration. Operator flips switch to initiate regeneration. Engine must be in Idle state Engine will stop regeneration and act normally if operator begins using equipment. DPF Lamp 9/21/2018 Cummins Confidential

SCR Exhaust System Cleaning What is it? A proactive (exhaust heat management) approach to ensure that the DEF/urea introduction into the SCR system is proactively managed to provide the optimum product performance, efficiency, and reliability. Uses the same heat management process via in-cylinder diesel dosing with VGT assist to periodically elevate the exhaust temperature.

Temperature Drop Considerations Temperature Drop is affected by: Tubing length Tubing diameter Tubing elbows Tubing insulation Equipment configuration Proximity to cooling devices such as fan air flow Temperature Drop can be reduced by: Use of insulated or double-wall tubing Insulation thickness and quality 9/21/2018 Cummins Confidential

Temperature Measurement Locations A = Turbo Out Temp (Thermocouple) (Non-ECM parameter) B = OEM installed thermocouple installed in the downpipe before the DOC (Non- ECM parameter) Down Pipe DOC Down Pipe Temp Drop = A - B OEM ancillary tube Decomposition Reactor Tube OEM ancillary tube SCR Tailpipe Measurement Locations: A – Turbo Outlet Temp B – DOC Inlet Temp 9/21/2018 Cummins Confidential

Temperature Measurement Locations A – Turbo Outlet Temp B – DOC/DPF Inlet Temp Can you identify these locations on the two configurations shown? A B DOC Only System DOC + DPF System A B A B 9/21/2018 Cummins Confidential

Test Procedure (Mid-Range example) 9/21/2018 Cummins Confidential

Test Conditions Test must be carried out between 10 to 40oC (50 to 104 oF) ambient conditions The test must be run for a minimum of 40 mins for both MR and HD systems Test may be conducted in a chassis dynamometer or outside. Cooling fan should be locked On. Air-condition should be switched off. Test during a non-mission regeneration: HC dosing OFF (11.2013 correction per AEB24.62 Attach. B and AEB27.10 Attach. E) for Heavy Duty. Non-mission SCR conditioning with HC dosing OFF for Mid-Range. The regen must be run for a minimum of 40 mins (MR and HD) 9/21/2018 Cummins Confidential

Test Preparation Instrumentation: Two external thermocouples for Turbo Out and Ambient Air Temperatures capable of logging at a sample rate of 1 Hz Calterm logging parameters at sample rate of 1 Hz: Turbine Outlet Temperature – Non-ECM Parameter (A) DOC/DPF inlet temperature – Non-ECM Parameter (B) Exhaust flow rate Engine RPM 9/21/2018 Cummins Confidential

Take Note Use Caution: During Regeneration (Exhaust System Cleaning) and SCR Exhaust System Cleaning, the exhaust gas temperatures could reach 975C (1787F), and surface temperatures could exceed 700C (1292F) To prepare for a non-mission regeneration: Select appropriate vehicle location (surface and surrounding acceptable for high temperatures) Park equipment securely Set up a safe exhaust area Ensure exhaust surfaces are clear Expect engine speed changes (engine speed may reach 950-1050 rpm, depending upon equipment) 9/21/2018 Cummins Confidential

Starting a Non-Mission SCR Conditioning with HC Dosing Off Example Only: QSB 6.7. Refer to AEB 27.10 for up to date list of Calterm Parameters 1. Verify no active fault codes exist in Calterm 6. Verify EXM_NonMission_Regen_Active = 1 2. Verify Permit_Switch = 1 a. If EXM_NonMission_Regen_Active ≠ 1, THEN Verify EXM_NonMissionRegen_En =1, if Permit_Switch≠ 1, Set O_AIM_PermitSwEnbl = 1 b.if EXM_NonMissionRegen_En ≠1, O_AIM_PermitSwVal =1 3. Verify C_SFR_DeSOxTimedRegen_Enbl = 1 THEN SET   H_EXM_AcceleratorPedalEnCond =1 4. Turn off HC Dosing H_EXM_VehicleSpeedEnCond =1 Override O_OCR_fg_HC_Inj_Enbl = 1 H_EXM_EPD_EndCond = 1 Override O_OCR_fg_HC_Inj_Val = 0 H_EXM_ClutchEnCond = 1 H_EXM_ServiceBrakeEnCond = 1 5. Initiate Non-mission SCR conditioning H_EXM_OOGearEnCond =1 Set C_SFR_tmh_SinceDeSOxRegenThd = 0 H_EXM_CtrlPTO_EnCond = 1 Set C_SFR_tmh_SinceAnyRegenThd = 0 H_EXM_EngineWarmEnCond = 1 Set C_SFR_tmh_DeSOxRegenThd = 0 H_EXM_AirHandlingSysEnCond = 1 Set C_SFR_tmh_DeSOxNMTrig_Max = 0 H_EXM_DL_RTD_IngibitRegen = 0 Override O_AIM_NMRegen_SW_Enbl = 1 V_ATP_Permit_Switch = 1 Override O_AIM_NMRegen_Sw_Val = 1 9/21/2018 Cummins Confidential

Data Logs and Test Conclusion Verify that SCR Conditioning has initiated Combustion_Control_Path_Owner = 66 Wait for all the temperatures to stabilize. Experience shows a minimum of 40 mins run time is required. Log data for a minimum of 5 minutes after the temperatures have stabilized. Save this data file for analysis. Test can be concluded after the data has been saved by: Changing all Calterm parameters in back to their original values by going to Edit<Revert All in Calterm Window. Wait for PTM_Final_Oper_Mode = 1 and Combustion_Control_Path_Owner = 11 to ensure that SCR conditioning is complete Once SCR conditioning is complete, idle for 5 minutes to allow system to cool before key-off

Data Analysis Compute Average Engine Speed, Exhaust Flow Rate, and Values for Temperatures A, B. Compute Downpipe Temperature Drop and compare to IQA Pass Criteria (shown in the next slide). Calculator Input Information for Data Analysis Average Engine Speed = _____________[rpm] Average Exhaust Flow Rate [g/s] = ___________[g/s] Average Ambient Air Temperature [Deg C], AAT= _____________[Deg C] Average Turbo Out Temperature [Deg C], A= _____________[Deg C] Average Non ECM DOC In Temperature [Deg C], B = ___________ [Deg C] Input the above values in the Down-pipe temperature worksheet and calculator provided as an attachement to determine if the configuration has passed the downpipe temperature drop requirement 9/21/2018 Cummins Confidential

IQA Pass Criteria Engine/Rating Tier 4 Final Max Down Pipe Temp Drop for Std Conditions (AB) Test Ambient Temperature QSB6.7 >174Hp ≤ 20 oC 10 to 40 oC QSL9 – All Ratings QSG12 – All Ratings ≤ 28.2 oC QSX15 – All Ratings

Test Method and Tools To Use AEB 27.10 Attachment E (Heavy Duty), F (Mid-Range) – provides Test Method to measure Down Pipe Temp Drop AEB 24.40 Attachment B (Heavy Duty)– provides Down Pipe Temp Drop worksheet and calculator Example 9/21/2018 Cummins Confidential

Example: Temperature drop test B Ambient Air Temp Mass flow Down Pipe Temp Drop Delta A-B 285.2 262.4 22.8 92.0 23.0 Cummins Confidential

Example: Truck, Temperature drop test Determine the result of the test from the Downpipe temperature drop worksheet and calculator mentioned on slide 24 A B A B Ambient Air Temp Mass flow Down Pipe Temp Drop Delta A-B 285.2 262.4 22.8 92.0 23.0 Temp drop is higher than permissible The Downpipe temperature loss from the Turbine outlet (A) to the DOC inlet (B) must be 20deg Celsius or less Cummins Confidential

Summary – Aftertreatment Temp Drop When performing Aftertreatment Temperature Drop Testing: Review system layout and identify any issues Locate thermocouples correctly on the assembly Use Calterm to monitor key measurements Check that corrected temperature drop values meet requirements You are now familiar with Application Engineering’s role in Aftertreatment Down Pipe Temperature Drop 9/21/2018 Cummins Confidential

Change Control Date Author Description Pages Nov 27, 2012 Vivek Jaryal, Orvin Kendall Original document published All Feb 6, 2013 Vinay Ha Add example exercise 21, 22 5/7/2013 Nathan Solomon, Rebeka Sultana Updated Training Material for T4F 5/10/2013 Nathan Solomon Added Test Results and Changed Presentation based on Review 2/5/2014 Vishaul Ravi Updated the presentation with the new temp drop requirements. No combined system temperature drop moving forward Multiple 9/21/2018 Cummins Confidential