MDEC 2003

S3P2 - 1

Effect of Altitude on Diesel Engine Emissions

Bob Setren

Mine Safety and Health Administration

MDEC – November 4 – 6, 2003

Altitude Topics

MSHA Part 7 Subpart E Approval– Altitude Fuel Deration requirement

Adjustments on NA engines

Altitude Compensators for NA engines

Altitude effects on Turbo-charged engines– Field Tests

– Lab Tests

Regulatory considerations

MDEC 2003

S3P2 - 2

Part 7 Subpart E Approval

ISO 8178 emission tests

Maximum fuel air ratio determined– Cat. A: CO < 3000 ppm; NOX < 2000 ppm

– Cat. B: CO < 2500 ppm; NOX < 2000 ppm

Requires a fuel deration chart– Maximum F/A ratio is not exceeded at altitude

Ventilation rate established

DPM output determined and documented

Naturally Aspirated Engines

Isuzu C240, tested in field and lab

Cat 3306 PCNA tested in lab– Altitude simulator

MDEC 2003

S3P2 - 3

Altitude SimulationCat 3306 PCNA

CAT 3306 PCNA TestsDPM Weighted Averages

0.0 5.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 45.0

1

2

3

TE

ST

DPM (g/hr)

Test 1: DPM weighted avg Baseline ~ 1100 ft.Test 2: DPM weighted avg – no deration – 7000 ftTest 3: DPM wght avg – derated 3%/1K – 7000 ft.

MDEC 2003

S3P2 - 4

CAT 3306 PCNA – CO effectsCO comparisons

0.0

1000.0

2000.0

3000.0

4000.0

5000.0

6000.0

7000.0

8000.0

1 2 3 4 5 6 7 8

TEST MODE

CO

(p

pm

)

MSHA-BASE 1000 Sea Level CO (ppm)

MSHA-7000-SLF 7000 Sea Level CO (ppm)MSHA-7000-DF 7000 Derated CO (ppm)

CAT 3306 PCNA – NO EffectsNO COMPARISONS

0.0

100.0

200.0

300.0

400.0

500.0

600.0

700.0

800.0

1 2 3 4 5 6 7 8

TEST MODE

NO

(p

pm

)

Series1 Series2 Series4

MDEC 2003

S3P2 - 5

CAT 3306 PCNA – NO2 EffectsNO2 COMPARISONS

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

100.0

1 2 3 4 5 6 7 8

TEST MODE

NO

2 (p

pm

)

MSHA-BASE 1000 Sea Level NO2 (ppm)MSHA-7000-SLF 7000 Sea Level NO2 (ppm)MSHA-7000-DF 7000 Derated NO2 (ppm)

CAT 3306 PCNA – CO2 EffectsCO2 COMPARISONS

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

1 2 3 4 5 6 7 8

TEST MODE

CO

2 (%

)

MSHA-BASE MSHA-7000-SLF MSHA-7000-DF

MDEC 2003

S3P2 - 6

Supercharged 3306 PCNA

Supercharged 3306 – CO effects

Altitude Simulation Test of Supercharger Altitude Compensator

0.0

50.0

100.0

150.0

200.0

250.0

300.0

350.0

1 2 3 4 5 6 7 8

Test Mode

CO

(gr

/hr)

Baseline Emissions Supercharged/AfterCooled 8000ft

MDEC 2003

S3P2 - 7

Supercharged 3306 – dpm effects

Altitude Simulation Test of Supercharger Altitude Compensator

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

45.0

50.0

1 2 3 4 5 6 7 8

Test Mode

DP

M (

gr/h

r)

Baseline Emissions Supercharged/AfterCooled 8000ft

Turbo-charged EnginesConfiguration Diversity

Turbo-charged – non wastegated

Turbo-charged – wastegated

After-cooled

Fuel deration – manual

Fuel deration - electronic

Timing – electronic

Combinations of the above

MDEC 2003

S3P2 - 8

Turbo-charged Engine Tests

Mercedes – 904 Field Tests– Wastegated, charged air cooled, timing

changes

Deutz – BF4M1013FC – Field Tests– Wastegated, charged air cooled, fuel deration

Cummins CTAA8.3-C – Laboratory Tests– Non-wastegated, charged air cooled

Mercedes 904 Tests – F/AFue l / A i r Ra t i o c ompa r i son

0.0000

0.0100

0.0200

0.0300

0.0400

0.0500

0.0600

1 2 3 4 5 6 7 8

M ode

Appr oval Reno Santa Fe 1 Santa Fe 2 Santa Fe 3

MDEC 2003

S3P2 - 9

Mercedes 904 Tests – NO Vent NO Ve nt r a t e c ompa r i son

0

2000

4000

6000

8000

10000

12000

1 2 3 4 5 6 7 8

M ode

Appr oval Reno Santa Fe 1 Santa Fe 2 Santa Fe 3

Mercedes 904 Tests – CO VentCO Ve nt R a t e C ompa r i son

0

1000

2000

3000

4000

5000

6000

7000

1 2 3 4 5 6 7 8

M ode

Appr oval Reno Santa Fe 1 Santa Fe 2 Santa Fe 3

MDEC 2003

S3P2 - 10

Cummins CTAA8.3-C – F/A

Cummins CTAA8.3-C Change in FA Ratio with Altitude for 8-mode Test

0.0000

0.0100

0.0200

0.0300

0.0400

0.0500

0.0600

1 2 3 4 5 6 7 8

Mode

FA

Rat

io

Approval Test Lab

1000ft

4000ft

6000ft

8000ft

Cummins F/A Altitude Effects Cummins 8.3-C MaxCO (max restriction) FA Ratio Data for various

Altitudes

0.0000

0.0100

0.0200

0.0300

0.0400

0.0500

0.0600

0 500 1000 1500 2000 2500

RPM

FA

Rat

io

4000ft 6000ft 8000ft Approval Test Lab

MDEC 2003

S3P2 - 11

Cummins CO ResultsCummins 8.3-C MaxCO (max restriction) CO Data for various

Altitudes

0500

10001500200025003000350040004500

0 500 1000 1500 2000 2500

RPM

CO

(pp

m)

4000ft 6000ft 8000ft Approval Test Lab

Off Scale Reading

Cummins – DPM effectsChanges in Weighted Average DPM with Altitude: Cummins 8.3-C

0 5 10 15 20 25 30 35

Approval Test Lab

1000ft

4000ft

6000ft

8000ft

Weighted Average DPM g/hr

MDEC 2003

S3P2 - 12

Cummins – DPM Effects

Changes in DPM with Altitude: Cummins 8.3-C

0

10

20

30

40

50

60

70

80

90

100

1 2 3 4 5 6 7 8

Mode

DP

M g

/hr Approval Test Lab

1000ft

4000ft

6000ft

8000ft

Cummins – Altitude Effect on COCummins CTAA8.3-C Change in CO Vent Rates with Altitude for 8-mode Test

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

1 2 3 4 5 6 7 8

Mode

CO

V

ent

(CF

M)

Approval Test Lab

1000ft

4000ft

6000ft

8000ft

Nameplate = 9000 CFM

MDEC 2003

S3P2 - 13

Cummins – Altitude effects on NO

Cummins CTAA8.3-C Change in NO Vent Rates with Altitude for 8-mode Test

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

1 2 3 4 5 6 7 8

Mode

NO

Ven

t (C

FM

) Approval Test Lab

1000ft

4000ft

6000ft

8000ft

Nameplate = 9000 CFM

Deutz BF4M1013FC – Effect on CO – Vent Rate

CO, Vent Rate

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

1 2 3 4 5 6 7 8

Mode

CO

, CF

M

Deutz Santa Fe 1 Santa Fe 2

MDEC 2003

S3P2 - 14

Deutz Effect on Raw CO

CO, Raw

0

500

1000

1500

2000

2500

3000

1 2 3 4 5 6 7 8

Mode

CO

, pp

m

Deutz Santa Fe 1 Santa Fe 2

Deutz - Effect on NOX Vent Rate

NOX, Vent Rate

0

1000

2000

3000

4000

5000

6000

7000

8000

9000

10000

1 2 3 4 5 6 7 8

Mode

NO

X, C

FM

Deutz Santa Fe 1 Santa Fe 2

MDEC 2003

S3P2 - 15

Future Test Plans – MSHA Lab

Mercedes 904

Cummins

Deutz

Cummins 3.3

Isuzu 4JG1T

CAT 3126

Altitude Deration Requirement

MSHA Position Being DevelopedEngine Manufacturers may be unwilling to make special settings for miningIf F/A increases with altitude, this may be OK provided miners at high altitude mines are afforded the same degree of health protection as those at sea level.Must define same degree of health protection

MDEC 2003

S3P2 - 16

Health Protection of MSHA Approved Engine

Category A produces no more than 3000 ppm of CO and 2000 ppm of NOx in raw exhaust under any condition of operationCategory B produces no more than 2500 ppm of CO and 2000 ppm of NOx in raw exhaust under any condition of operationEstablishes a ventilation rate which dilutes exhaust gas to 5000 ppm CO2; 50 ppm CO; 25 ppm NO; and 5 ppm NO2.Determines dpm output of the engine – limits established for usage.

Summary

Work in Progress

Open for Input

Will Continue to Conduct Tests

MSHA will be working with a committee formed by the Coal Diesel Partnership

Questions?