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?
Top Related