EPA-650/4-75-024-d
Environmental Monitoring Series
GUIDELINES
FOR QUALITY ASSURANCE PROGRAMS
FOR MOBILE SOURCE EMISSIONS
MEASUREMENT SYSTEMS:
PHASE II, HEAVY-DUTY DIESEL ENGINES -
TEST PROCEDURES
^
LU
o
lental Protection Agency
U.S. Environr
Office of Research and Development
Washington, D. C. 20460
-------
GUIDELINE DISTRIBUTION RECORD
EPA-650/4-75-024-d "Guidelines for Quality Assurance Programs for
Mobile Source Emissions Measurement Systems: Phase II, Heavy-Duty
Diesel Engines - Test Procedures"
The series of documents, "Guidelines for Quality Assurance Programs for
Mobile Source Emissions Measurement Systems," have been prepared and issued in a
revisable document-controlled format so that any future revisions or additions
may be distributed to the Guideline users. Individual copy numbers have
been assigned to each volume of the series. These numbers appear on this record
sheet and on the title page of each document. The user of these documents must
complete the "Distribution Record Card" and return it in the pre-addressed
envelope to the address shown below so that automatic distribution for future
revisions may be made directly to the user. Also, notice of any reassignment
of the documents by number and title to other individuals (by name, address,
and copy number) should be sent to the same address.
U.S. Environmental Protection Agency
Office of Mobile Source Air Pollution Control
2565 Plymouth Road
Ann Arbor, Michigan 48105
ATTN: Quality Assurance COPY Nc
(cut along dotted line)
DISTRIBUTION RECORD CARD
Guideline
User Date
Last Name First Middle Initial
Title
Address
to Send
Future Street
i-i • • »J I* I CC I*
Revisions
and
Additions
City State Zip Code
If address is a firm (fill in)
Firm
I have received copy No. of EPA-650/4-75-024-d "Guidelines for Quality
Assurance Programs for Mobile Source Emissions Measurement Systems:
Phase II, Heavy-Duty Diesel Engines - Test Procedures"
Please send me any revisions and additions of this volume.
-------
EPA-650/4-75-024-d
GUIDELINES
FOR QUALITY ASSURANCE PROGRAMS
FOR MOBILE SOURCE EMISSIONS
MEASUREMENT SYSTEMS:
PHASE II, HEAVY-DUTY DIESEL ENGINES -
TEST PROCEDURES
by
Harold Wimette, Rod Pilkington, and Tom Kelly £ P .}
Olson Laboratories , Inc.
421 East Cerritos Avenue
Anaheim , California 92805
Contract No. 68-02-1740
ROAP No. 26BGC
Program Element No. 1HA327
EPA Project Officers:
R. C. Rhodes
Quality Assurance and Environmental Monitoring Laboratory
Research Triangle Park, North Carolina 27711
and
C. Don Paulsell
Office of Program Management
Ann Arbor, Michigan 48105
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Mobile Source Air Pollution Control
and
Office of Research and Development
Washington, D. C. 20460
June 1975
-------
EPA REVIEW NOTICE
This volume has been prepared by Olson Laboratories, Incorporated
consistent with the Environmental Protection Agency Quality Assurance
principles and concepts and with the Environmental Protection Agency Mobile
Source Testing Practices at Ann Arbor, Michigan.
The guidelines and procedures are generally applicable to mobile
source testing operations and are intended for use by those engaged in such
measurement programs
It is requested that recipients and users of this document submit any
comments and suggestions to the Project Officers.
Mention of trade names or commercial products does not constitute
Environmental Protection Agency endorsement or recommendation for use.
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environ-
mental Protection Agency, have been grouped into series. These broad
categories were established to facilitate further development and applica-
tion of environmental technology. Elimination of traditional grouping was
consciously planned to foster technology transfer and maximum interface
in related fields. These series are:
i . ENVIRONMENTAL HEALTH EFFECTS RESEARCH
2. ENVIRONMENTAL PROTECTION TECHNOLOGY
3. ECOLOGICAL RESEARCH
4. ENVIRONMENTAL MONITORING
5. SOCIOECONOMIC ENVIRONMENTAL STUDIES
6. SCIENTIFIC AND TECHNICAL ASSESSMENT REPORTS
9. MISCELLANEOUS
This report has been assigned to the ENVIRONMENTAL MONITORING
sc-rirs. This series describes research conducted to develop new or
improved methods and instrumentation for the identification and quanti-
fication of environmental pollutants at the lowest conceivably significant
concentrations. It also includes studies to determine the ambient concen-
Iralions o! pollutants in the environment and/or the variance of pollutants
as a lunclion of time or meteorological factors.
This document is available to the public for sale through the National
Technical Information Service, Springfield, Virginia 22161.
Publication No. EPA-650/4-75-024-d
11
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INTRODUCTION
The test procedures contained in this volume are a documen-
tation of the 1975 heavy-duty diesel emission measurement test require-
ments presently in use at the Ann Arbor facility of the Environmental
Protection Agency. These test procedures comply with Federal Regula-
tions as stated in the Federal Register, (Subparts I and J), Section 3,
Volume I, for the listing of applicable Federal Registers.
Section 5, Volume I, outlines the development of an Operations
manual which may be used as a guideline for a Quality Assurance program.
A typical format of a test procedures manual is described and offers a
guide for implementing and interpreting the test procedures contained in
Volume II. A user may accept the manual in its presented form, or may
modify the format to suit specific contractual obligations, or delete
certain procedures which may not be performed at that facility. The
user will be required to make revisions as needed to assure that the
manual complies with Federal Regulations. Revisions may be implemented
manually, by computer updates or by magnetic card storage.
For ease of use, the test procedures are separated into nine
distinct sections, numbered 100-900. The table of contents shows the
major heading of each section and the test procedures contained in each.
To differentiate between the light-duty and heavy-duty testing which are
both included in this contract, the test procedures are numbered to
correspond to Light Duty, 101-149, 201-249, etc. and Heavy Duty, 150-
199, 250-299, etc. Heavy-duty diesel procedures modified for use with
heavy-duty gasoline engines are suffixed with a -G, e.g.TP-750-G.
Certain procedures developed for Phase I (Light-Duty Gasoline Vehicles)
are equally applicable to Phase II (Heavy-Duty Diesel Engines) and have
been included in this volume, utilizing the original Test Procedure
reference number allocated for Phase I.
To assist in defining the overall scope of the heavy-duty
testing program, the tables from Section 3, Volume I, briefly outlining
the test procedures, specifications, and quality provisions are included
in the introduction to the test procedures manual.
This document details test procedures for heavy-duty diesel
engines, and a supplement will cover test procedures for heavy-duty
gasoline engines (Phase IV). The test procedures for light-duty diesel
engines (Phase III) will appear as a supplement to the light-duty gaso-
line vehicle procedures detailed in Phase I, Volume II.
iii
-------
TABLE OF CONTENTS
INTRODUCTION
TEST PROCEDURE SUMMARY vii
Effective
Date(s)
Section
100 GAS BLENDING, FUEL ANALYSIS AND INVENTORY
101 Preparation of Binary Gas Mixture ....
102 Calibration of Gas Mixtures
200 CALIBRATION
203 Gas Analyzer Calibration Curve Generation
204 Chart Recorder Calibration
205 Temperature Recorder Calibration
206 Barometric Pressure Calibration and Correlation . . .
250 Engine Dynamometer Calibration
251 Calibration of the Smokemeter Neutral Density Filters
300 VERIFICATION
304 CO /HO Interference Check.
400 CORRELATION
401 Analyzer Cross Check.
600 DAILY OPERATION . . .
601 Log Book Entries. . .
602 Drift/Noise/Gain/Tune
700 EMISSION TESTING
750 Receipt, Build-up and Installation of the Diesel
Test Engine
751 Smoke Measurement Test-Heavy Duty Diesel Engine .
752 Measurement of Intake Air Flow of Diesel Engine .
753 Diesel Engine Emission Measurement Procedure,
CO, NO, and O,
754 Diesel Engine Emission Measurement Procedure -
Hydrocarbons
755 Fuel Flow Measurement Flo-Tron LMF Meter. . . .
756 Fuel Flow Measurement-CO Instrument Model 402.
x
800 DATA VALIDATION
850 Data Validation-Heavy Duty Diesel Emissions
900 PROGRAM PLANNING AND QUALITY AUDIT.
-------
FEDERAL EMISSION TEST PROCEDURE - SMOKE AND GASEOUS EMISSIONS
1 fc> 1'LURt t>. tAiK
B. tniiina-Dyno 'Theckout
C. Engine test cycle
D. Saoke •eaaurattent MM)
C. Intake air Masur*»ant
r. NaasuMBMnt of fual flow
cycla
H. McaiuresMnt of HC, CO
MO and 0 in dteeal
1. bata collection and
BHIEI' i'LE' kllllON
The cnqiaa in opvratbd at iJU arm
iuad conditions to rheuk for |.rop«[
deter*!"* thai en'jint speed, torque
and fuel flov Mtct Mfr. specifications.
Engine i» operated At maximm rated
equilibrium
The war* enqine it run through three
•ml UiWlnq modes.
In ordsr to determine omissions on
• stass basis, the a*.a» of intaAe
air suit be Masured as * function
cycl«.
In ordat to dcurmint th« tout ••••
of the •xh*«Mt, tha •>•• of taml
mutt bt *«*«ur«d ptr unit limm,
IU» EH - lUki Air * fUl* rtwl.
brak»-«iMci(tc •mi«»ioni of hydro-
carbon", c*rfcon •onPKld* «rtd oaid«i of
nLtroqcn wtMft *n tnqiix i» of>«r>t«d
through a cycl* which cooal't* of thr«»
ol two »pMd* -ahlch «p«n tlw typU:»X
op«ratin9 ranq« of di*»«l •nqirwft.
Mtaaur^Mnt* •< • »ad« of th* «xh*u«t
concentratioriB during th* Laat Kinutt
r«qulr*10°r at
pwp inltt
torque and Ui« te»t *pead. Harnup for 10
»in. or ftquU. TaP at rated speed and
•nd MX. hp. Operate 10 »in. each mod*. (Sate
C. Preconditioning.) KPN and torque chanqea
b« **t during l*»t win. of vod.*. Fwl-typa
1-D or 3-D.
SAE J177 Sect. 2.1, 2.2, 3.3.1
SAE J21S Sect. J,l, 2.2, 1 and 7
r*ro and «pan at start, node No. 7. end of
lait S mm. each Kxto. Puel flow during
Idle and 2 percent *ay be RU-'asurcd.
lyter rrepona* integrated [or la>t 00
•econda of each node. Correct no for huii-
idlty- Heiqhtinq fautor Idle 0.2* other
«od«i O.OS,
SPK'rriCATIUNS EAE (rft ENC. PRAtT.
EPA testing.
Listen lor internal noifoa,
sut-h •• piston slap, knocks, tap
6 Month*.
A P accuracy of 0.5 percent of idl.
percent of idle flow.
H percent of observed reading.
±2 percent, wveUy check*. 2 Hr.
Detector and oven teap. cont. t/'i ,
•••pi* line 150-JOO"f 12°C of sit
point.
Stt J177
DUALITY I'WJVISIONS
.n.^U.™ ch.,Krf
recuruvj and ctit-cXed
by .Lit* vaicdation.
fuul Hot* metera.
Final «c{uipnent
a tart.
checked by data
validation
Transducer* cali-
brated againct mano-
nctar bafore and
after te»t.
Data cheeked by
validation - fuai
teap and «aae flow.
Flp>««ter calibrated
with dvad weight
tester.
than 10 nin. occurs
repeat teat from
•ode 1. Tine, rpn,
torque checked by
ture. H2O, CO, intfr-
vdlldation.
D..t. vai.dation
TEST INVALID
spec :. used.
Spec, not achieved
by engine or dyno.
Engine not fully
start of teat.
trvaeent drift.
test.
Failure to record
fuel flow during
any pode. Flov-
Mter valtunction
detected.
of 10 minutes, rpn,
torque or tin* out
of tolerance.
ow temp. cont.
CORRECTIVE MT10K
^«Uic.U«.
Repeat test
Repeat test
(•orr.ct probl** «nd
Repeat t«»t
node 1 .
aa required. After
si>ec. condition.
TRAINING nH
SKILL Lf.YlL
mance .
Aa above in B
AB «bov*- with sotoke-
tr-Voing.
installation of LTE
and nanometers.
Instruction in opera-
tion of fuel flow
ticm of dyno controls.
Mint, and Minor ad).
readinq, data
inspection, and
operation aa
required.
H-
H-
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100
-------
Section 100
GAS BLENDING, FUEL ANALYSIS AND INVENTORY
-------
EPA TEST PROCEDURE
Number
TP-101
Page i of
-IO.
SUBJECT
PREPARATION OF GRAVIMETRIC BINARY GAS MIXTURES
Reference
C. D. PAULSELL DRAFT 8/1/73
Data Form No.
101-01, 02
Responsible Organization
CHEMICAL ANALYSIS
Computer Program
CYLBLEND
Test Witness
QUALITY ASSURANCE REVIEW/REQUESTOR
Performance Interval
AS REQUESTED
Type of Test Report
GAS BLEND DATA SHEET
Supersedes
NEW
Report Distribution
QUAL. ASSUR., CORK. & MAINT. , INST. SERV.
Superseded by
REMARKS/COMMENTS
&Rl6iNAt RElitAsE APPROVALS
Office
Section
Signature
Date
PROGRAM MGNT
QUALITY ASSURANCE
LAB. BRANCH
CHIEF
LAB. BRANCH
SUPP. OPERATIONS CHIE
REVISIONS
Change
Letter
Description of Change
Approval
Date
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
1 kO 1 I l\N^V»b \J VJIXk
PROCEDURE NO.
TP-101
pAftF 2 .OFIO
1.0 PURPOSE
This procedure outlines the equipment, blending process, and calculations
necessary to generate binar-y gravimetric gas mixtures to be used as pri-
mary standards. The gravimetric technique is considered to be the most accu-
rate method for the quantification of gases. Since the final data re-
ported for emission measurement is in mass units it is of great impor-
tance that the primary standards be determined by mass rather than
pressure or volumetric relationships.
2.0 TEST ARTICLE DESCRIPTION
Binary mixtures are prepared from pure components or blending mixtures of
propane (C^Hg), carbon monoxide (CO), carbon dioxide (CO2) and nitric
oxide (NO). Dilution of these gases is done with pure nitrogen or air.
3.0 REFERENCES
3.1 Procedure For Making Gravimetric Binary Gas Mixtures. EPA,
C.D. Paulsell, 8/1/73.
3.2 Matheson Gas Data Book
3.3 "The Present State of The Art In The Preparation of Gaseous Standards",
Scientific Gas Products, Inc.
3.4 "Handbook of Compressed Gases", Compressed Gas Assoc., Inc. Rein-
hold Publishing Corp., New York, N.Y.
4.0 REQUIRED EQUIPMENT
4.1 Cylinders:
4.2 Valves:
4.3 Balance:
4.4 Weights:
Marison 1CC3AA1800 Carbon Steel
5.25" O.D. x 13.75" Length Volume -
223 Cubic Inches
Stainless Steel NOX Cylinders
3.75" O.D. x 13.0" Length
Volume - 110 Cubic inches
Brass, Sherwood Selpac B
G-5 3540 F9 CGA350
Stainless Steel Superior
CGA 660SS
Voland Model 1115 CDN
lOKg Capacity
1 Mg Accuracy
2 sets (1 gram to 1 kilogram)
Calibration traceable to NBS
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE3_OF iP__
4.5 Blending manifold with pressure gauges to cover 0-30,
0-300, and 0-2000 PSIA and (1) vacuum gauge 0-5 PSIA
4.6 Vacuum Pump: 150 liter/min maximum capacity
Ultimate pressure 1 millitorr Hg absolute.
4.7 Pure Gases
o Zero grade Air: 220-300 cubic feet
2000-r2600 P.S.I.G.
Max. THC 0.1 PPMC
02 19-23% Analyzed
o Zero grade Nitrogen: 220-300 cubic feet
2200-2600 P.S.I.G.
Max. THC 0.1 PPMC
o 0_ free nitrogen for NO blend
o Propane - Instrument Grade 99.5% minimum
o Carbon Dioxide - Coleman - 99.8% minimum
o Carbon Monoxide - Ultra high purity - 99-. 8%
THC 1 PPMC
o Nitric Oxide, C.P. Grade, 99.0% Min.
5.0 PRECAUTIONS
5.1 Gas blending should be attempted only by qualified personnel famil-
iar with the chemistry of gases and blending equipment operations.
Equipment damage, serious injury, or loss of life could occur from
deviations from prescribed practices.
5.2 Personnel should be familiar with safe handling of compressed gases
5.3 Avoid sudden surges of gases when blending or transferring. Always
"Bleed" gas slowly from one cylinder to another in order to minimize
temperature changes.
5.4 Special precautions should be taken when blending combustible gases
such as propane and CO with air. Only very low concentrations
should be attempted i.e., less than 1000 PPM.
5.5 Attach only the diluent being used to the blending manifold (air
or nitrogen).
5.6 All traces of combustible material such as oil, grease, and solvents
shall be removed from the gauges, fittings, valves and tubing contained
in the blending manifold. All manifold parts should be specified,
"cleaned for oxygen service," when ordered.
8
-------
REVISIONS'
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
1 hW 1 1 l»>^^*» IX Wl\ t
PROCEDURE NO.
TP-101
PAttF ,4 OF 10
5.7 Cylinder valves should be inserted with teflon lubricant only.
5.8 Never drop cylinder or weights onto balance pans or release quickly.
6.0 VISUAL INSPECTION
6.1 Cylinders:
o Check for valve or cylinder damage, especially the threads on
the valve.
o Check the cylinder for dirt or other contamination
6.2 Blending Manifold:
o Check all tubing and the cylinder connections for loose or
damaged fittings.
o Check gauges for proper atmospheric reading.
6.3 Balance:
o Check for any visual damage.
o Check weights for damage or contamination.
7.0 PREPARATION
7.1 Weights:
Remove all weights from the balance pans and case, dust them care-
fully and wipe any smears from the weights with a lint free cloth.
Do not touch with hands.
The weights should be kept in their box when not in use and should
only be handled with the transfer tool provided.
7.2 Balance:
Turn the vernier chain mechanism to zero and release the pans of
the balance. Check the action of the pan arrest pads and adjust
if necessary to achieve smooth operation. When the pans are stable,
the indicator should read null. If it does not, adjust the zero
knob to bring the needle to the null position. Arrest and release
the pans several times to assure that the balance stabilizes in the
null position. The balance point for the loaded pans should be
within ±10 mg.
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
The weights are now ready to be cross checked on the balance to
assure accurate determination under loaded conditions. Place the
weights in the center of the pans as indicated below and note any
deviations.
Left Pan
0
1
1, 2
2, 3
2, 3, 5
2, 3, 5, 10
10, 20
20, 30, 2
20, 30, 50
0
20, 30, 50, 100
100, 200
200, 300
200, 300, 500
0
Right Pan
0
Vernier
3
5
10
20
30
50, 1, Vernier
100
0
200
300
500
1000
0
7.3 Cylinders:
New cylinders or cylinders which have been recently revalved should
be checked for leaks by pressurizing to 1800 PSIG with nitrogen.
Some leaks are not apparent until the cylinder has reached its maxi-
mum pressure distortion. Check for leaks with "Snoop" or other de-
vice which will not leave a residue on the cylinder. Check valve
stem, relief device and cylinder threads. Note results in cylinder
log. Correct leaks if possible. If valve is leaking at the cy-
linder threads, the valve must be removed and reinserted. Do not
attempt to tighten valve.
Cylinders which have previously been used for mixtures should be
flushed with the diluent (air or nitrogen) as follows:
o Vent cylinder contents slowly in the hood being certain the
hood blower is operating.
o Evacuate to 1.0 PSIA.
o Fill to 15 PSIG (30 PSIA) with diluent to be used.
o Vent the contents and evacuate. Repeat this purge to final
evacuation 0.2 PSIA.
o Confirm that cylinder pressure is less than 0.2 PSIA.
o Close cylinder valve firmly and proceed to the blending
procedure.
10
-------
REVISIONS^
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE.
.OF
10
7.4 Blending Manifold:
With all vents closed on the manifold, pressurize all gauges to
25 PSIA and close off the manifold. Check all gauges for corre-
lation and observe the readings for indicating leakage. Find and
correct any leakage. This is especially important in preparation
of NO blends. Small oxygen leaks will oxidize the NO to N02 and
this can occur at manifold pressures above atmospheric. Leakage
of the NO gas should be avoided because of its toxicity and
transfer should be performed in a hood or well ventilated area.
11
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TF<;T PROCEDURE
I to I r i\vx v»u wi\t
PROCEDURE NO.
TP-101
PAftF7 OF 10
8.0 TEST PROCEDURE
The preparation of gravimetric gas mixtures basically involves two
procedures, blending and weighing. Blends are made according to the
information contained on Form No. 101-01. This form must accompany
the work order and be completed by the requestor. Refer to Reference
3.1 for calculation procedures. Test data is entered on Form No.
101-02.
Test Sequence Test Description Data Output
Parent Blend Made From Pure Component
101 Evacuate and purge with diluent (N2 or Air, None
whichever will be used in the mixture) twice and
then evacuate the cylinder to 0.2 PSIA. Close
the cylinder valve and remove the vacuum line.
102 Wipe cylinder to remove the dust and place on Record
the left pan of the balance. cylinder
number
103 Place a similar type cylinder on the right pan
to compensate for buoyancy. This same cylinder Log Book
must be used for all subsequent weight deter- Entry
minations. Record cylinder number in blending
log book.
104 Add weights to right pan until null indicator None
shows a deflection. This will indicate that the
null is within 1 gram of the weight. NOTE: If
the blending cylinder should weigh less than the
tare cylinder a weight must be added to the left
pan. Do not remove this weight until all weigh-
ings have been completed.
105 Close balance door and obtain final null with Cylinder
vernier chain. Record sum of wts. on right bal- Weight
ance and null vernier indicator weight. Secure Grams
and release pans to assure zero null.
106 Attach the cylinder to the minor component regu-
lators. (This line should be equipped with a
flow control valve.) Purge the line with the
minor component up to the empty cylinder valve.
12
-------
REVISIONS^
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURE
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE_L_OF _10_
Test Sequence
107
108
109
110
111
112
Test Description
Set the regulator on the minor component to
the pressure indicated under column shown
PjL PSIG on form 101-01. If pressure is less
than atmospheric the blending manifold must
be used and cylinder is filled using the
pressure indicated under PSIA.
With the flow control valve closed, open the
cylinder valve. Bleed in the desired amount
of pure component. If above atmospheric allow
the cylinder to attain equilibrium with the
regulated pressure.
Close the cylinder valve, and shut off minor
component. NOTE: To achieve 0.1% accuracy
always add at least 5 grams of minor
components. Reweigh the cylinder as in
Sequence 102-105.
The cylinder is now ready for the addition of
diluent. The cylinder is attached to the gauge
manifold and the lines are purged with diluent
up to the CGA fitting. When the 0-2000 PSIA
gauge reaches a pressure higher than that of the
cylinder (200 PSI), open the cylinder valve and
fill it by regulating the diluent in 100 PSIA
increment. Close the cylinder valve when the
pressure gauge needle moves past the desired final
pressure. The final pressure should be approxi-
mately 3% final pressure higher than desired to
makeup for the pressure loss due to the cylinder
cooling.
Shut off the diluent source and bleed the mani-
fold before disconnecting the cylinder. Reweigh
the cylinder as in sequence 102-105 after the
cylinder has reached ambient temperature.
Record the three weights and submit the data for
computation of mass ratio, concentration, and
final pressure.
Data Output
Weight
after
adding
minor
component
None
Weight
after add-
ing Major
Comp.Grams
Initial
Minor
Final
13
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE_LOF
Test Sequence
113
114
Test Description
The parent blend should be mixed thermally for
1/2 hour by directing a heat lamp from a
distance of 18-24 inches at the bottom of the
cylinder which has been tilted 45° with the
horizontal.
If a dilution of the parent mixture is to be
made, the same procedure is used except that the
parent blend can be added to the empty cylinder
by using a well purged regulator to obtain the
approximate pressure needed to achieve the final
concentration desired.
Data Output
14
-------
REVISIONS:
PREPARATION OF GRAVIMETRIC BINARY
GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-101
PAGE_LiLOF 10
9.0 DATA INPUT
Form 101-02 requires the following:
Blending Date
Components
Operators Initials
Cylinder Numbers
Cylinder weights (3) Initial, Minor, Final
Comments
10.0 DATA ANALYSIS
10.1 Submit data for analysis by "CYLBLEND" computer program.
11.0 DATA OUTPUT
11.1 Computer print out showing calculated mass ratio concentration.
Forward with complete job request to requestor.
11.2 Compare specified value with calculated value. Check final cylinder
pressure.
11.3 Check computer entries against original data form.
11.4 If cylinder was previously used, check to see that it has been
deleted from the inventory list.
12.0 ACCEPTANCE CRITERIA
12.1 Calculated values should agree with specified within +5%. If not
determine cause and if final concentration is acceptable, correct
and report the errors or failures.
13.0 QUALITY PROVISIONS
13.1 See Section 7.2 balance check.
13.2 NBS certified weights are used to check the working weights at
six month intervals.
13.3 Gases used for blending are checked for purity when received from
supplier.
15
-------
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6rlhM^
MA^JSosi
CYL. SERIAL MO.
USED
j
FORM lot-01
-------
GRAVIMETRIC GAS BLENDS
INPUT DATA SHEET"
BLENDING
DATE
—
-
COM
MINOR
'I
)NENTS
MAJOR
BLEr
I Nil
201
COMPONENT SYMBOLS
C3H8 - PROPANE (99.5%.MIN.)
MINORS
CO
CO?
NO
CH4
- CARBON MONOXIDE
- CARBON DIOXIDE
- NITRIC OXIDE
- METHANE
it
n
ii
n
MAJORS
AIR - ZERO GRADE AIR
N - ULTRA PURE NITROGEN
*
0
n
«._
i«i
_j
£0
I
i
:
1
CYLINDE
[JEW
BLEND
f
-
-
-
R
NUMBERS
PAPIflT
BLEND
i?
-
-
CYLINDER WEIGHTS (GRAMS)
INITIAL
(EMPTY)
21
AFTER
ADDING
MINOR
?.i
•
AFTER
ADDING
MAJOR
37
-
-
•
...
-
-
COMMENTS:
I't-
I
35
45
SO
70
to
NOTE5:
TWO SPECIAL PARENT CYLINDER NUMBERS ARC RECOGNIZED.
" -PURE " INDICATES A PARENT BLEND HAS BEEi'I MADE FROM PURE COMPONENTS,
n
-VENT
II
MTS COMMAND:
INDICATES THAT THE CYLINDER REFERENCED HAS BEEM VENTED AND
IS TO BE DELETED FROM THE FILE OF CYLINDERS.
[SPRINT
$ RUN SAQF: CYLBLEND. [SCARDS = *SOURCE*] [SPRINT = *SINK*]
DATA SETS MUST BE SEPARATED BY A SINGLE $ ENDFILE CARD.
TOTAL RUN TERMINATES ON TWO $ ENDFILE CARDS.
Form 101-02
-------
TP-101
Attachment No. 1
EPA STANDARDS INVENTORY
Propane in Air
3
5
10
15
25
50
75
100
150
200
275
350
500
1000
ppm *
ppm
ppm *
ppm
ppm
ppm *
ppm
ppm *
ppm
ppm
ppm
ppm
ppm *
ppm
Methane in Air
3 ppm
10 ppm
25 ppm
50 ppm
75 ppm
100 ppm
300 ppm
1000 ppm
20000 ppm P/N-
GRAVIMETRIC GAS
CO in N2
5 ppm
10 ppm
25 ppm
50 ppm*
100 ppm*
150 ppm
200 ppm
250 ppm
500 ppm*
750 ppm
1000 ppm*
1250 ppm
1500 ppm
2000 ppm
2500 ppm
3000 ppm
4000 ppm
0.5%
1.0%
1.5% P
2.5%
5.0%
7.5%
10.0%
BLENDS
CO2 in N2
0.2%
0.4%
0.6%
0.8%
1.0%*
1.5%
2.0%
2.5%
3.0%
4.0%
5.0%
7.0%
9.0%
11.0%
13.0%
15.0%*
NO in N7
25
50
75
100
250
500
750
1000
1500
2000
5000
20000
ppm
ppm *
ppm
ppm *
ppm *
ppm *
ppm
ppm *
ppm
ppm
ppm
ppm
Propane in N,
100
200
400
600
800
1000
2000
3000
4000
6000
8000
10000
15000
20000
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm
ppm P
ppm
ppm
NOTE: The concentrations shown here
are the nominal values (+0,-10%)
which are to be generated,
inventoried, and maintained as
gravimetric standards.
SYHBOLS: P = Parent Blend
* = NBS Standard
Revision Date
18
-------
GAS HLLNl) ANALYSIS
TP-101
Attachment No. 2
DATE: 05-11-7H
MEASURED DATA:
CYLINDER NO.
PARENT
J NO.
G-11865
G-11832
G-11K32
CALCULATED'DATA:
CYLINDER NO.
-VENT
-VENT
MINOR COMPONENT: CO
MAJOR CCiMPONhMT: N2
MEASURED CYLINDER WEIGHTS:
EMPTY
(GRAMS)
79.095
AFFb-^
8S.832
AKTER MAJOR
KHH*O««'0"0»
(GRA^S)
430.388
MINOR
COVP.
nnnnn»»»
'A-'S CO )
f>. J-\7
MAJOR
COMP.
344.556
MASS BLEND
RATIO CONC.
) (HHM)
0.0191777 19181.750
CYL.
PRESS.
(PbIA)
1230.
G-11B65
G-11H32
G-11832
COMMENTS DATA:
CYLINDER NO.
CJ-11H6S USED FO^ Cf4 / C3HH
*»«CYLIMOER NOT FOUND.
G-11832 ERROR IN PREVIOUS MASSES
G-11632 99.5V: PURE SCOTT B-354
PROCESSED: 08:45.00 VAY 14, 1974
19
-------
»»« GRAVlMtTrtlC GAS WLtNO ANALYSIS «»»
TP-101
Attachment No. 3
DATE: os-ii-74 MINOR COMPONENT:* co
BLENDER: JK MAJOR COMPONENT: N2
MEASURED DATA:
CYLINDER NO.
PARENT
CYLINDKR NO.
MEASURED CYLINOEP WEIGHTS:
EMPTY AFTER MINOR AFTER MAJOR
F-01363
F-01364
F-01366
F-01367
F-01369
F-01370'
F-01372
F-01374
-PURE
G-11864
G-11S64
G-11832
-PURE
-PURE
-PURE
-PURE
(GRAMS)
111.534
145.703
127.413
117.401
10.785
74.364
63.287
98.023
(GRAMS)
llb.M04
215.915
196.903
196.591
20.449
93.592
90.777
136.893
(GRAMS)
543.439
512.363
402.777
402.762
388.788
458.242
444.509
474.774
«««MQRE THAN H DATA CARDS.
CALCULATED DATA:
CYLINDER NO.
MINOR
COMP.
F-01363
F-01364
r-01366
F-01367
F-01369
F-01370
F-01372
F-01374
(GRAMS CO )
4.270
70.212
69.440
79.190
9.724
19.228
27.490
33.870
MAJOR
COMP.
«»»««•««»»
(GRAMS N2 ]
427.635
296.448
205.874
206.171
3ort.339
364.650
353.732
337.881
MASS
RATIO
«•» ««• -a- »«•«••»
1
0.009H864
0.0031751
0.0041*43
0.0053221
0.0257206
0.0500889
0.0721102
0.1031716
BLEND
CONC .
•»*•» •»«»•» «•«•
(PPM)
9888.500
3175. 7b«
4185.219
5323.184
25725.941
50099.020
72124.563
103191.375
CYL.
PRtSS.
(PSIA)
1512.
964.
999.
1323.
1344.
1334.
1319.
COMMENTS DATA:
CYLINDER NO.
F-01363
F-01364
F-01366
F-01367
F-01369
F-01370
F-01372
F-01374
SCOTT &5fl2
SCOTT 8582
SCOTT B5H2
SCOTT o5«2
SCOTT
PROCESSED: 0^:45.00 MAY 14. 1974
20
-------
MASS RATIO WAJO* DILU7ANT COMCt.MHAT ION PRESSURE HLENOlMi DATE
«« w tt iKXJO -:HK» tttttttt-iltttia «•«•<><> •«• « iE-02
1 ,3Q4^E-02
9.r /9SE-03
9. 7052E-03
6.6281E-03
3.6106E-03
1 .4404E-02
1.2420E-02
1 .8923E-U3
1.8520E-03
7.0924E-04
6.5849E-04
.CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
CO
C02
C02
,C02
C02
C02
C02
C02
C02
C02
C(12
C02
C02
C02
C02
C02
C02
C02
C02
C3H8
C3nc
C3H5
C3Ho
C3"!b
C3hd
N2
M2
N2
N2
N'2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
M2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
AI«
Al^
AIR
Ale?
AI^
AIR
21
103191.375
72124 .5o3
50099. t.i20
25725.941
19181.750
167U1.809
16638.902
165b4.137
16207. S51
98Hd.500
5323.184
4185.219
3175.788
2815.347
2413.045
1836.925
1410.503
1227.580
999.817
901.215
705. 4B2
522.192
462.176
256.333
192.006
126.660
104.014
90.H79
50.31?
29.644
9.186
15.682
1 3.h62
1 1 ,t^91
8.635
6.768
5.019
3.753
3.045
2.453
1.968
1 .6d3
1.075
1.025
0.834
0.631
0.620
0.423
0.230
9472.020
81 r>l .9^8
1230.997
1212. bb3
464. 1 Hb
430.960
1319.
1334.
1344.
1323.
1230.
1 494 .
1505.
1534.
152b.
1512.
999.
964.
1283.
1595.
1547.
1512.
1565.
1516.
1424.
1443.
153d.
1447.
1365.
1526.
1369.
1475.
1388.
132d.
.1366.
1023.
105**.
1799.
1524.
1460.
1590.
1567.
156b.
1400.
1480.
1537.
1539.
1490.
1279.
1120.
1076.
1092.
1584 .
1118.
1543.
74d.
1435.
1035.
1639.
1023.
1247.
TP-101
05-11-74
05-1 1-74
05-11-74
05-11-74
05-1 1-74
12-10-73
01-16-74
01-16-74
01-16-74
05-11-74
05-11-74
05-11-74
05-11-74
08-25-73
04-13-73
04-13-73
04-13-73
04-13-73
04-13-73
11-01-73
04-13-73
11-01-73
11-05-73
03-02-73
OR-25-73
08-25-73
11-01-73
08-25-73
1 1-01-73
08-25-73
08-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
09-25-73
02-22-74
02-22-74
02-21-7<+
09-25-73
02-21-74
02-21-74
03-02-73
03-02-73
03-02-73
08-2b-73
10-J1-73
03-02-73
Attachment No. 4
-------
G- 11 836
G-118P7
-1-89470
M-89459
H-89466
H-89457
H-89480
G-11835
G-11857
H-89472
G-11852
G-11826
H-89458.
1.1 36 Of- 04
6.7034E-OS
3.717«»P>OS
2.2940E-05
1.3414E-05
9.bie7E-06
4.6B32E-06
F- 04 C3H*
S.()bt>4F-04 C3Hr
4*. 12Q3£-04 C3nH
2.H330E-04 ,
407.10?
770.
C3nri
C3Hd
C3HM
C3bd
C3rtb
C3hb
C3hb
C3Hb
C3H6
AJW
AI*
AIR
1.6650E-04 C3h8 N2
107.778
99.^0H
74.332
62.01H
lb.010
8.777
3.064
105.791
74U.
1014.
03-0^-73
03-0^-/J
03-0if-73
101^>»
1060.
1011.
1010.
104if.
1432.
1486.
03-02-73
10-01-73
10-01-73
11-29-73
10-01-73
10-01-73
10-01-73
1194. 08-28-73
PROCESSED: OK:45.05 MAY 14, 1974
22
TP-101
Attachment No.
-------
EPA TEST PROCEDURE
Number
TP-102
Page 1 of
9
SUBJECT
Calibration of Gas Mixtures (Gas Analysis)
Reference
FR 85.075-23(a) (4)
Responsible Organization
Correlation & Maintenance
Test Witness /Review
Requestor, Quality Assurance
Type of Test Report
Computer Print Out
Report Distribution
Purchasing, Correlation & Maintenance
REMARKS/ COMMENTS
1. Analysis of calibration
Data Form No.
102-m
Computer Program
CYLANAL
Performance Interval
See Below
Supersedes
New
Superseded by
gases are performed when the gases
are received from a vendor, when requested by a contractor
or manufacturer for correlation and traceability reasons
and when an in-house gas is suspect for any reason.
ORI61NAL REiEAsE APPROVALS
Office
Administration
Lab. Branch
Section
Prpcurement
Support Oper. Supv.
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
23
-------
REVISIONS:
CALIBRATION OF GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-102
PAfiF 2 OF 9
1.0 PURPOSE
To determine gas mixture concentrations by comparing them to known standards
used as calibration gases, working gases and, in some cases, zero gases for
the EPA laboratory, contractors, manufacturers.
2.0 TEST ARTICLE DESCRIPTION
A gas blend or mixture blend of two or more gases under pressure in a cylinder
or other suitable container.
3.0 REFERENCES
3.1 Analytical instrument manuals
3.2 "Handbook of Compressed Gases", Compressed Gas Associaton, Inc.,
N.Y., N.Y., Reinhold Publishing Corp., Inc., 1966.
4.0 REQUIRED EQUIPMENT
4.1 Primary gas standards, verified, gravimetric, or NBS cylinders. Verified
standards must be traceable to the EPA gravimetric standards by not more
than one generation. Zero gas, air or nitrogen as required.
4.2 Analytical instruments with the following minimum specifications:
Sensitivity: Full scale for the concentration to be determined.
Reproducibility: 1% of full scale, for successive identical samples.
Stability: Electronic stability of +1% per 24 hours.
Response: 90% of scale in 0.5 seconds.
Dectector Type: CO, CO2 - NDIR: HC - FID, NO - CHE MI.
4.3 Sample handling system, manual or automatic, designed for a minimum hook
up of 2 span gases, one zero gas and the gas to be analyzed. The system
need not be equipped with a sample pump unless required but should have
line filters, flow meters and pressure gauges. The materials of con-
struction of the equipment prior to the instrument sample inlet should
be of teflon, stainless steel and viton. Use best judgment for the in-
strument exhaust plumbing and equipment.
4.4 Pressure regulators, dual stage, outlet pressure to be regulated between
0-80 PSIG, inlet pressure rated at 4000 PSI with a gauge 0-3000 PSI.
The regulator should be equipped with a purge port and safety relief
port. Regulators used for nitrogen oxide or any other corrosive gas
should be of stainless steel construction only, the other gases require
brass with teflon or viton seals.
25
-------
REVISIONS:
CALIBRATION
TEST
OF GAS MIXTURES
PROCEDURE
PROCEDURE NO.
TP-102
OAftF 3 OF 9
NOTE; Some regulators use a Buna N or other rubber type material for
construction of the diaphragm. These should never be used for gas
analysis for hydrocarbon or the zero gases.
4.5 Recorder to match the output of the analytical instrument.
4.6 Digital volt meter with the capability of reading the output to at least
one significant figure (preferably two).
5.0 PRECAUTIONS
5.1 Check work order for adequate information of the sample to be analyzed
such as I.D. number, nominal concentration, sample pressure, components
to be analyzed and type of analysis.
5.2 Check the sample container for proper identification. Check high pressure
cylinder for date of last pressure test. If longer than 5 years the
cylinder should be returned to the vendor.
5.3 Be sure that the analytical system and the regulator purge lines are
properly vented to a hood or other air removal system.
5.4 Excessively high flow rates or long analysis times should be avoided as
this could use a large amount of span or sample gas.
6.0 VISUAL INSPECTION
6.1 Examine sample container for damage.
6.2 Check the container number against the work order for agreement.
6.3 Check the analytical system for loose lines, dirty filters or missing
parts.
7.0 TEST ARTICLE PREPARATION
7.1 Attach a suitable pressure regulation device to the sample container.
7.2 Secure the container and check all fittings for leaks using liquid
detector such as "Snoop".
7.3 Purge regulator and sample line through the venting system.
7.4 Turn on instrument and allow to reach temperature and electronic
stability. Time will depend on instruments and previous history of use.
7.5 Select two span gases, one should indicate a value above the maximum con-
centration of the sample being evaluated and one below the minimal con-
centration of the sample. Neither span gas should exhibit values closer
than ±10 percent of full scale of the sample concentration.
26
-------
REVISIONS:
CALIBRATION OF GAS MIXTURES
TEST PROCEDURE
PROCEDURE NO.
TP-102
8.0 TEST PROCEDURE
Test Sequence
101
102
103
104
105
106
107
108
109
Test Description
Zero instrument using the same flow, pressure
and range as will be used for the span and
sample gases.
NOTE: Pressure should be measured closely
as possible to the detector inlet.
Span instrument using the highest concentra-
tion standard at 95% of scale
Switch to zero gas. If instrument does not
repeat zero, adjust and repeat 102.
Repeat zero and span.
Introduce second span gas and record deflection
Repeat twice.
Introduce sample gas at same flow and pressure
as zero and span. Repeat twice. Reading should
agree within ±0.2% of full scale.
Introduce zero gas and both span gases. Previous
readings should agree within 0.2% of full scale.
If not repeat procedure.
Record data on form #102-01.
If the sample gas deflection does not fall
between the two points the gas may not be within
the required tolerances. Select another set of
standards, repeat #106 and 107 and document results.
Data Output
0 ± 0.1
Reading
95.0 ± 0.2
0 ± 0.1
Average
Deflection
None
27
-------
REVISIONS:
CALIBRATION OF GAS MIXTURES
TPST pporpnu&p
PROCEDURE NO.
TP-102
PAGE-5—OF .2
9.0 DATA INPUT
Form No. 102-01 requires the following information:
o Data
o Analyzer train no.
o Mixture components
o Analyzer vendor
o Sample flow rate and pressure
o FID pressure, air & fuel
o Operators initials
o Cylinder number analyzed
o Nominal concentration
o Analyzer setup data
Low end concentration - meter deflection
High end concentration - meter deflection
Meter deflection of gas analyzed
o Comments: Reference for standard gases used and zero gases.
10.0 DATA ANALYSIS
10.1 Determine if low point and high point concentrations are adequate to
determine the sample concentration. Reliability of the data is a function
of the separation of the two standards and the closeness to one of the
two standards.
10.2 Determine that the deflection for the sample gas is between (or close to)
the deflections for the bracketing standards.
10.3 Confirm that operating parameters are within normal or recommended
specifications.
10.4 Check the calculated concentrations for apparent agreement with deflection
10.5 Note comments for possible conflicts or indication of problems.
28
-------
REVISIONS^
CALIBRATION OF GAS MIXTURES
TFST PROrFHUPF
PROCEDURE NO.
TP-102
PAGE_£_OF _L_
11.0 DATA OUTPUT
11.2 Data entered into cylinder inventory file.
11.3 Data sent to person or company by division representative requesting
the analysis.
12.0 ACCEPTANCE CRITERIA
12.1 Instrument technician must determine that repetition of the zero gas
is within ±0.1 deflection and that the span is within ±0.2 deflections.
12.2 Deflection for the sample gas must be between the deflections for the
two standards.
12.3 The sample gas concentration determined must meet the blending specifi-
cations requested from vendor.
13.0 QUALITY PROVISIONS
13.1 Repetition of span and zero readings
13.2 Repetition of sample readings
13.3 Repetition of span and zero after sample analysis
13.4 Data verification (10.0)
13.5 Acceptance criteria (12.0)
29
-------
GAS BLEND ANALYSIS DATA
DATE
-—
—
•
•
• .
^
.
fct
•
MIXTURE
COMP
GAS
|
•
BAL'
ANALYZER
VENDOR
SAMPLE
FLOW RATE
SCFH
"H20
FID
PRESSURE
AIR
|
FUEL
(
• •
* H-
.u •— •
x. z:
3 HI
1
>o
"I
70
sol
sol
«l
*ol
10
' •
CYLINDER NO.
ANALYZED
1
NOMINAL
CONCENTRATION
(3)
ANALYZER
LOW END
CONC. (1)
SETUP
•1ETER
DEFL.
DATA (NOTE)
HIGH END
cone. (2)
METER
DEFL.
-
•
•
^
(3)
METER
DEFL.
<
>-
COMMENTS:
i
I
h
10
•'
u
JO
5$
JOI
751
ta
NOTE: Use verified, gravimetric, or NBS cylinders for analyzer setup values.
Form 102-01
-------
200
-------
Section 200
CALIBRATION
33
-------
EPA TEST
PROCEDURE NU"
iber
TP-201 Paqe i of 7
SUBJECT
CVS CALIBRATION PROCEDURE FOR POSITIVE DISPLACEMENT PUMP
Reference Federal Register, Vol. 38, N
Appendix III, 85.075-20
Responsible Organization
Correlation and Maintenance
Test Witness
Corr. and
o. 124, June 28, 1973, Data ?°rm No-
201-01
Computer Program
SAQF : CALIBCVS
Performance Interval
Maint. Technician/Quality Assurance See Remarks
Type of Test Report
Computer Print-Out
Supersedes
New
Report Distribution Superseded by
Quality Assurance, Test Operations, Correlation & Maint.
REMARKS/ COMMENTS
1.0 CVS must be calibrated every 0, 50, 100, 200, 400, 800, etc., hours
of use or after major breakdown, cleaning and modification. The CVS
will also be calibrated as required to meet specific contract
requirements .
|
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt.
Lab. Branch
Lab. Branch
Section
Quality Assurance
Test Oner. Chief
Facilities Suooort Chi
Signature
ff
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
35
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
1 kO 1 I IVVXVtf k \J Wl\C
PROCEDURE NO.
TP-201
PAHP2 OF 7
1.0 PURPOSE
To measure the various parameters which must be assessed to establish
the flow rate of the constant volume sampler pump. All the parameters
related to the pump are simultaneously measured with the parameters
related to a flowmeter which is connected in series with the pump.
The calculated flow rate (ft3/rev. @ pump inlet absolute pressure
and temperature) can then be plotted versus a function that is the
value of specific combinations of pump parameters.
2.0 TEST ARTICLE DESCRIPTION
A constant volume sampler which meets requirements stated in Federal
Register 85.075-20.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 124, June 28, 1973, 85.075-20,-
Appendix III
3.2 EPA, Ann Arbor, Preventive Maintenance Guidelines - Section I
4.0 REQUIRED EQUIPMENT
The following equipment is required to perform the CVS calibration:
4.1 LFE - Laminar Flow Element (calibrated by manufacturer)
4.2 Micromanometer (see 7.3 for calibration check)
4.3 Thermometer
4.4 Timing mechanism
4.5 U-tube Manometers
4.6 Temperature Indicator with "J-Type" thermocouples (see procedure #TP205
for calibration)
4.7 A variable flow restrictor with appropriate piping to connect
CVS pump and LFE.
5.0 PRECAUTIONS
5.1 special care should be taken in the initial set-up of the
calibration equipment. Leaks in the system or faulty calibration
equipment will void the calibration.
37
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TF^T PROCEDURE
1 tw 1 • I\VX V* k L/ wIVE.
PROCEDURE NO.
TP-201
PAftF 3 OF 7
5.2 The variable flow restrictor valve should be. placed in the "open
position" at the start of the calibration. CAUTION: never completely
close the valve while the pump is in operation; the motor may be damaged.
5.3 Temperature stability during the calibration is absolutely necessary.
Air handling equipment must be shut off to avoid the normal 4°F oscil-
lations. Gradual temperature increases (2°F are acceptable as long
as they occur over a period of several minutes.
5.4 Thermocouples must be checked for accuracy using a laboratory grade
thermome te r.
6.0 VISUAL INSPECTION
6.1 Check LFE to CVS pump connections for loose fittings
6.2 Check manometers for level placement.
6.3 Check thermocouple connections for tightness.
7.0 TEST ARTICLE PREPARATION
7.1 Connect system as shown in Figure below.
EPI
HDP
u
CVS Calibration Configuration
Variable Flow
/Rcstrictor
Surge
Control
Valve
Figure 7-1
38
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
DAftF4 HP 7
7.2 Connect the LFE and variable flow restrictor to the CVS. Carefully
seal all connections to eliminate any leakage between the LFE
and CVS pump. NOTE; Refer to previous LFE inlet AP, a major drop
may indicate a leak in connection.
7.3 Position the micromanometer and level the base using the adjustable
feet provided. Set the vertical and the vernier scales on zero
and check the meniscus to assure that it is between the hairline
reference marks. If not, adjust the fluid at the rear of the
case until the meniscus is zeroed. Connect the LFE to the micromanometer
and U-tube manometer with leaktight flexible tubing. (See Figure 7-1.)
7.4 Attach the thermometer to the filter of the LFE so that the temperature
of the air entering the LFE is indicated.
7.5 Check that the zero level of the U-tube manometers and adjust
their scales accordingly.
7.6 Check that the CVS timer starts and stops when the counter power button
is pushed.
7.7 Connect the thermocouples to the CVS at the pump inlet and outlet
as shown in 7.1. The fittings normally used for sampling, temperature,
or sample dump connections may be used for thermocouples.
7.8 Start the CVS pump and open the U-tube manometer surge control
valve 1/4 turn. Check the fluid column surge; adjust the valve
to insure the fluid will not oversurge (most surge control valves
have been replaced by a 20 gauge hypodermic capillary fitting.)
when switched from vacuum to pressure. NOTE; Two manometers
may be used to measure these differentials simultaneously.
7.9 With the CVS pump running (20 minute warmup), adjust the micromanometer
to the null position by cranking the vernier down. Operate the
revolution counter and timer to insure proper operation.
7.9.1 Check the revolution counter by measuring revolutions
of the pump using a strobotac and comparing the total
revs, indicated on the counter for a 3-minute period.
39
-------
REVISIONS'
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
PAGE_L-OF _2__
8.0 TEST PROCEDURES
The following data will be collected and recorded in order to calculate the
CVS calibration curve.
Parameter
Barmetric Pressure
(Corrected)
Ambient Temperature
Air Temperature into LFE
Pressure depression upstream
of LFE
Pressure drop across LFE
meeting matrix
Air temperature at CVS
pump inlet
Pressure depression at CVS
pump inlet
Specific Gravity of
Manometer fluid
Pressure differential at
CVS pump outlet
Air temperature at CVS
pump outlet
Pump revolutions during
test period
Elapsed time for test
period
Symbol Units
B
TA
ETI
EPI
EDP
PTI
"Hg
OF
OF
'H2°
"H2°
oF
PPI "Fluid
Sp.Gr. "Fluid
PPO "Fluid
PTO
N
Revs.
Sees.
Tolerance
(accuracy of
data collected)
+.01 "Hg
±.5 °F
±.1 °F
±.05 "H20
±.005 "H20
+ .5 °F
±.05 "Fluid
+.05 "Fluid
±.05 "Fluid
±.5 °F
±0
±.05 Sees.
40
-------
REVISIONS:
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
PAGE_L_OF 7
Test Sequence
101
102
103
104
105
106
107
108
109
110
110A
111
112
113
114
115
116
117
Test Description
Set variable restrictor valve in the wide
open position and run CVS pump for 20 minutes
Start counter and timer
Read air temperature at CVS outlet
Read pressure depression at CVS pump inlet
Read pressure differential at CVS pump outlet
Read ambient temperature
Read barometric pressure (corrected)
Read air temperature at CVS inlet
Read pressure depression upstream of LFE
Read air temperature in LFE
ReadAP across the LFE matrix
Read pump revolutions for test period
Record elapsed time for test period
Reset the restrictor valve to a more re-
stricted condition. A change of about 4"H 0
is adequate to yield a minimum of six data points
Allow system to stabilize for a minimum of
3 minutes
Repeat steps 102 through 114 until sufficient
data points have been established
Adjust temperature controller and temperature
recorder on the CVS to indicate the proper
inlet temperature. Disconnect the micromanometer
and recheck zero setting
Disassemble the calibration setup and recon-
nect all pipes and fittings as used in NORMAL
CVS operation. Check sample flow rates and
other indicators for normal operation
Data Output
-0-
PTO, °F
PPI, "Fluid
PPO, "Fluid
V "Hg
PTI, °F
EDP, "Ho
ETI, °F
EDP, "H2
N, Revs.
t, sees.
-0-
-0-
41
-------
REVISIONS^
CVS CALIBRATION PROCEDURES FOR
POSITIVE DISPLACEMENT PUMP
TEST PROCEDURE
PROCEDURE NO.
TP-201
PAftF 7 ftp 7
9.0 DATA INPUT
9.1 Complete data form 201-01
9.2 Submit data sheet for analysis.
10.0 DATA ANALYSIS
10.1 Analyze data using SAQF:CALIBCVS
10.1.1 These are linear fits of VQ vs. X0 and RPM vsAP.
11.0 DATA OUTPUT
11.1 Printed computer output
11.2 CVS coefficients for storage in Instrument Data File.
12.0 ACCEPTANCE CRITERIA
12.1 Verify new curve against previous curve and tracer gas readings
previously obtained.
12.2 All V0 measured values must lie within ±0.50% of the calculated Vo
values. All RPM measured speeds must be within +0.25% of the
calculated RPM values.
12.3 Check and verify that the Vo vs XQ intercept is approximately
350 ft3/rev and the RPM vs AP intercept is related to the
synchronous speed of the blower motor.
13.0 QUALITY PROVISIONS
13.1 An excessive shift from old curve to new curve may constitute an
invalid test, therefore an investigation of cause should be
implemented.
13.2 Corrective action must be implemented if malfunctions are found and
the procedure must be repeated.
42
-------
CVS CAt.iliUATlON DATA SIIIiET
VS UNIT
-
LAMINAR
EL 'MliNT
KO.
:ALI BRAT ION
DATE
-
-
X)TNTS
^ MAMOHI'TER FLU ID — >
LAMINAR
F.LEHE1
Sl'.T.R.
n
•.-
CVS
SP.GR.
PI
:
T
to
H
M
3
EFFECTIVE
TEST //
V
CVS
•XDOR
PUMP
RANGE
(CFM)
CVS
ELAPSED
HOURS
10
30
SSI
701
rs
so
f
:
'
Afir
BAR1
f »M
'
'
•
1
1
1
T
T
f>T~\
-
-' ~
LA
TIN
--
*
*
-
JtlNAR F
ELF.MEN
PIN
A
,OW
L'
AP
|
-
T
IN
-1
1
•
•
P1N
1
35
cvs r
T
OUT
UMP
POUT
•f;
-
.0!
'
-'
"
RJiV
jCOilMTS'
•
-
-
TIME
^T:;I
-
J5
•
|
-
-
-
-
-
tol 45
-
70
-
-
71
..
80
•:
'
*NOTE: Indicate manometer units
and fluid specific gravity
on card one.
LNITS: IN - Inches
CM = Centimeters
MM - Millimeters
Form "Cl-01
-------
cvs FLO- C
TP-201
Attachment No.
* CvS-O^C «
«•»•»•>»•»«•«•«* »•»»
CVS
PUMP
Y72291*
AMI
300 CFM
DATE: 07-13-74
EFFECT I V*" TEST «:
CVS F.LAPSF.O HOU*St 1080.9
MANOMFTEP SPECIFICATIONS:
M_F»-'ENT: IN. or
CVS PU^P: IN. OF
1.00 SPECIFIC
1.75 SPECIFIC
GRAVITY FLUID
GRAVITY FLUID
MEASURED DATA:
CVS PUMP
«• «» a «• •»«•»*«
8ARO T
29.21 «2.0
29.21
29.21
29.21
29.21
29.21
29.20
83.0
83.0
83.0
83.0
83. C
83.0
•»«•««••»
T
(IN)
83.4
83.5
A3. 5
^3.6
M3.8
84.0
•8- •»*••»«•«•
P
(IN)
4.H5
4
4
4
4
4
4
.75
.65
.55
.50
.45
.35
«•«••»«•*»
DELTA
P
7
7
7
7
7
7
.510
.414
.303
,?21
.HH
.046
«•» «•«•»«
T
HO.O
rtl .0
ei .0
SI .0
bO.O
fO.O
80.0
• •»«••»«••»•» -a
P
(IN) (
17.70
19
21
23
25
27
29
.30
.30
.35
.10
.40
.00
n» •»«••»«
T
;OUT)
o.o
0.0
0.0
0.0
0.0
0.0
0.0
r «••»«••»•»•
P
(OUT)
1 c- . 4 0
1 r) • o n
1^.70
1H . 35
1 2 . 1 o
17.75
1 7 . S5
REV TIME
COUNTS (SFCS)
6?^9. 257.30
61rs7. 253.30
6516. P67.20
6278. 257.60
613*. 252.20
6213. 255.70
61^5. 252.40
CALCULATED DATA:
X
.00026?
.000270
.000276
.000282
.000288
.000295
.000300
CF/REV
ACTUAL
0.2902
0.2901
0.2897
0.?P66
0.2877
O.?ft72
0.2870
CF/REV
CALC
0.2903
O.Ph9r
0.2*91
0.2*85
0. ?87Q
O.HH72
0.2^66
CALC/ACT
l.OOOJ
0.9->-wij
0.99^1
0.9997
l.OOOH
0.9937
0.99MO
SCFM
376.0
37?. 0
367.3
362.0
357.9
3b2.7
348.9
PU^P
DIFF
4.78
H.9 1974
44
-------
NUIT
EPA TEST PROCEDURE
SUBJECT
DYNAMOMETER CALIBRATION
iber
Tp-202 Paae i of 9
Reference Federal Register, Vol. 38, No. 124, June 28, 1973 Data Form No .
Aopendix II. 85 .075-1 5 (rt)
Responsible Organization
Correlation and Maintenance
?n:>-i
Computer Program
DYNAHP
Test Witness /Review Performance Interval
Corr. & Maint. Technician, Quality Assurance Monthly
Type of Test Report
Computer Print-Out
Supersedes
New
Report Distribution Superseded by
Quality Assurance, Test Operations, Support Services, file
REMARKS/ COMMENTS
NOTE: This procedure is in the revision phase by EPA, Ann Arbor. The
final version will reflect new changes.
ORIGINAL RELEASE APPROVALS
Office Section
Program Mgmt Quality Assurance
Lab Operations Chief
Lab Operations Support Services Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
45
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-202
PAftP 2 r>F 9
1.0 PURPOSE
The purpose of the dynamometer calibration procedure is to insure that
the indicated speed and the indicated absorbed power (torque) are correct
and to determine the frictional loss characteristics of the dynamometer.
2.0 TEST ARTICLE DESCRIPTION
2.1 A direct drive chassis dynamometer, having the capabilities described in
Federal Register 85.075-15.
2.2 Speed and torque (hp @ SOmph) meters and controls
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 124, June 28, 1973 - Appendix II
3.2 EPA, Ann Arbor, Preventive Maintenance Guidelines, Section III.
3.3 SAE XJ1094 "Constant Volume Sampler System for Exhaust Emission
Measurement," Section 3.7
4.0 REQUIRED EQUIPMENT
4.1 Test vehicle
4.2 Stroboscopic tachometer or electronic RPM counter (see manufacturer's
manual for calibration procedure)
4.3 Adjustable DC power supply, upper value of at least 8 volts DC
4.4 Weight stand, Clayton
4.5 Weights, 35 pounds and 10 pounds
4.6 Tachometer generator assembly, Clayton
4.7 Varian 614A, strip chart recorder (see procedure #204 for calibration
procedure)
4.8 Stopwatch or electric timer (±.1 sec.)
5.0 PRECAUTIONS
5.1 Inflate the rear tires to 45 psi to protect against blow-outs and to
equalize the contact (especially important with front-wheel drive
and radials)
5.2 Align vehicle on dynamometer. (Drive vehicle on to the dyno, with
vehicle perpendicular to the rolls, insuring that the front wheels
are centered to prevent the rear wheels from sliding off the rolls.)
47
-------
REVISIONS'
DYNAMOMETER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-202
PAftF 3 OF 9
5.3 Operate vehicle cooling fan within 12 inches of vehicle radiator.
5.4 Vent vehicle exhaust.
6.0 VISUAL INSPECTION
6.1 Check equipment set-up, (see sec. 7.0 and 8.0 for set-up
instructions.
7.0 TEST ARTICLE PREPARATION
NOTE: Prior to calibration assure that the dynamometer is wanned up in
accordance with procedure #TP-604
7.1 Speed Meter Calibration
7.1.1 Adjust mechanical zero of the speed meter with rolls stopped.
7.1.2 Place range switch to "LO" position.
7.1.3 Record dynamometer Serial Number.
7.1.4 Place vehicle on dynamometer and tie it down.
7.1.5 Engage flywheels for 4,000 pounds inertia.
7.1.6 Check index on the end of front roll for visibility.
7.1.7 Precondition the dynamometer by operating vehicle at 30 mph
for 15 minutes.
7.1.8 Warm up strobotac and calibrate strobotac according to manu-
facturer's specifications.
7.2 Power Meter Calibration
7.2.1 All calibration steps take place with dynamometer rolls in
stationary position.
7.2.2 Disconnect tachometer leads from torque bridge terminals.
7.2.3 Attach variable voltage power supply to the torque bridge
terminals.
7.2.4 Adjust meter to zero with power supply off.
48
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGE.
.OF
7.3 Determination of Actual Power Absorption
7.3.1
7.3.2
7.3.3
7.3.4
7.3.5
7.3.6
Inspect the dynamometer and service according to manufacturer's
recommended procedure.
Install tachometer generator on the dynamometer frame. Line
up the tach generator pulley with the shaft adaptor pulley
on the front roll. Insure that the center to center pulley
distance is the same as the factory installed tach generator.
Attach front roll tachometer generator electrical leads to
Varian chart recorder.
Drive vehicle on dynamometer and attach vehicle restraint
system.
Disengage roll brakes.
Adjust recorder zero.
49
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-202
PAftF 5 OF 9
8.0 TEST PROCEDURE
The dynamometer calibration is actually separated into three separate
procedures. Therefore, the steps listed below are listed in three
sections. Section I pertains to speed meter calibration; Section II
covers power meter calibration and Section III outlines the determination
of actual power absorption.
Test Sequence
101
102
103
104
105
106
Test Sequence
201
SECTION I. SPEED METER CALIBRATION
Test Description
Operate vehicle at front roll speed of 1,800 rpm
Set strobe tach at 1,800 rpm flash rate and aim
at the front roll index mark. Adjust vehicle speed
to hold the mark steady at 1,800 rpm.
When the front roll is steady at 1,800 check the
speed meter display. ECE-50 with DD-VIF will
indicate 46.3 mph if speed meter is calibrated
correctly.
If the meter indicates other than 46.3 mph, adjust
the speed meter calibration pot in the readout
instrument assembly, until speed meter indicates
correct speed.
Repeat steps 101 through 103. If readings will not
repeat within ±0.5 mph without readjustment a malfunc-
tion must be reported. Necessary maintenance should
be performed before continuing with calibration.
Reduce roll speed to 900 rpm and hold steady. The
speed indicated on the meter should be 23.15 (±0.5)
mph. Any nonlinearity will be reported and cor-
rected. (Perform necessary maintenance before
continuing procedure.)
When calibration is complete, attach calibration
sticker to the back of speed meter.
SECTION II. POWER METER CALIBRATION (TORQUE)
Test Description
Turn on power supply and adjust voltage to display
46.3 mph on the speed meter.
Data Output
Data Output
50
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGE«JLOF 9
Test Sequence
202
203
Test Description
Install the weight stand (Arbor) on the Torque
Arm. Tighten the attaching bolt.
Level the torque arm by turning ball joints in or
out of the load cell.
Data Output
204 Place (one) 35 Ib. weight and (one) 10 Ib.
weight totaling 50 Ibs. on the weight
stand (Arbor wt. stand = 5 Ibs.). Torque/
Power meter should show 50 ft. Ibs. of torque.
If meter does not show proper value, adjust
the meter using the Torque Meter Calibration
pot.
205 Repeat Step 204 substituting weights:
(1) 10 Ib. weight = 15 ft. Ibs. torque and
the weight stand itself 5 Ibs = 5 ft. Ibs.
torque on meter. The nonadjusted torque
readings should agree within ±1 ft. Ib. of
torque. If meter does not agree within limits
without readjustment, a malfunction should be
reported.
206 After completing the calibration with no mal-
functions, a calibration sticker should be
placed on the meter.
SECTION III. ACTUAL POWER ABSORPTION CALIBRATION
50 ft. Ibs.
15 ft. Ibs.
5 ft. Ibs.
Test Sequence
301
302
303
Test Description
Accelerate vehicle to 60 mph and hold steady.
Calibrate the chart recorder at 60 mph full
scale.
Check the calibration of chart at 55, 50, and
45 mph. Insure that 55 and 45 mph points are
easily identified.
Bring the vehicle to a complete stop and
re-zero the recorder.
Data Output
55 = divis.
45 = divis.
51
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGE-L.OF .!_
Test Sequence
304
305
306
307
308
309
310
311
312
313
314
Test Description
Data Output
Measure the recorder chart speed with a stop-
watch or other timing mechanism. This should
be repeated at least 3 times for an accurate
measurement of the distance the paper travels
in one (1) minute.
NOTE: Alternate method of measuring elapsed
time: Direct measurement of time
elapsed between 55 mph and 45 mph can
be accomplished by starting electronic
timer at 55 mph and stopping at 45 mph.
This method will eliminate interpolation
of chart method.
Chart Speed
(inches/mins)
Set dynamometer inertia at 1,500 Ibs.
that rolls are stationary.)
(Insure
Time sees.,
IHP
Accelerate vehicle to 50 mph and hold steady.
Set the Hp (torque) to lowest obtainable
value.
Increase speed to 60 mph and use a winch or
alternate means to pull vehicle off the front
drive roll. Release accelerator and allow
vehicle to decel (caution: insure rear
wheels are completely clear of drive roll).
Measure and record the elapsed time it takes
the front roll to slow from 55 mph to 45 mph.
Loosen the winch and allow vehicle's rear
wheels to contact the front roll. Match the
front roll speed and vehicle speed as closely
as possible to prevent tire damage.
Repeat Steps 307-309 so that two measurements Elapsed Time
are taken at even 500 Ib. increments of inertia IHP
starting at 1,500 Ibs. and ending with 5,500 Ibs.
Stop vehicle and check recorder zero.
Operate vehicle at 50 mph and set Hp at 8.0
indicated Hp.
Repeat Steps 307-309 so that two readings are Elapsed Time
taken at each inertia setting, at 8.0 indicated
Hp.
Repeat Step 311.
52
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-202
PAGE_§__ OF 9
Test Sequence
315
316
317
Test Description
At a steady 50 mph reset Hp to 14.0 indicated
horsepower.
Repeat Steps 307-309 in order that two readings
are taken at each inertia at 14.0 indicated
horsepower.
Remove vehicle from dyno and restore all equip-
ment to normal operating conditions.
Data Output
Elapsed Time
53
-------
REVISIONS:
DYNAMOMETER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-202
PAGE ? OF 9
9.0 DATA INPUT
9.1 Complete form No. 202-01. Submit the form and recorder charts to the
Data Branch for analysis
9.2 Transfer information to data cards for computer input.
10.0 DATA ANALYSIS
10.1 If a chart speed of 6 inches/minute or faster, elapsed time measurements
for coastdowns are made from the chart. To make this measurement, the
distance between the point the trace crosses the 55 mph speed and the
point the trace crosses the 45 mph speed is measured to the nearest
0.01 inch. This distance is then divided by the chart speed.
10.2 A manual curve plot of actual power versus indicated absorber power
(pHp vs pind^ ^s ma<^e f°r each inertia setting.
10.3 Final analysis is made by computer program DYNAHP.
11.0 DATA OUTPUT
11.1 Computer print-out of inertia weight (1,500 to 5,500 Ibs.) and
indicated horspower per Federal Register requirements shown in
paragraph 85.075-15(d).
12.0 ACCEPTANCE CRITERIA
12.1 New calibration curve should be within ±1/2 horsepower
of previous calibration (SAE XJ 1094)
12.2 Compare graph plots of calibration results with the computer output
to insure the data is accurate.
13.0 QUALITY PROVISIONS
13.1 If any malfunctions are reported for speed meter or torque meters,
insure the proper corrective maintenance is performed and a
repeat calibration has been accomplished.
13.2 If calibration does not agree with 12.1 above, reject calibration.
13.3 Perform necessary corrective maintenance or action and repeat the
calibration.
54
-------
DYNAMOMETER CALIBRATION
DYNO
DATE
NO.
>IO DY YR
TtiTl-lT
si
CARD
NO,
2
3
4
5
6
a 7
8
9
10
11
12
13
14
15
16
17
18
19
IND
HP
•
1C
1^
/Jo
4JO
4
- -
4
8
• <
;<
i
R
e
8
•
8
_4
J
8
0
.-.
0
>
0
0
0
0
p
p
I
p
0
,
3
0
1 DYNAMOMETER
1 »l
INERTIA
WT.
•-
-
-
-
-
-.
1
2
2
3
3
4
5
5
1
2
2
3
3
4
4
5
5
7
0
5
0
5
5
0
5
7
0
5
0
5
0
5
0
5
5
0
0
0
0
0
0
0
0
5
0
0
0
0
0
0
3
3
0
0
0
0
0
0
0
0
0
0
0
6
0
0
0
0
0
0
30
TIME;
SEC.
-
-
-
-
-
-
-
-
-|
H
• 4
— <
-
...
-
-
-
INFO:
25
30| 35
-
-
—
40
20
21
22
23
24
25
26
27
28
IND
HP
_
~
1
1
1
1
1
1
1
1
I
4,
4
4
/
4J
^
4
4'
— <
4
4
0
0
0
0
0
-
0
f--
0
3
0
11
sol
JERTIA
WT.
...
-
•
1 7
2 0
2 5
30
35
40
45
5f
4
' 's\
5
0
f~\
\^i
"
:_
ol
0
0
0
0
0
0
0
0
0
0
0
0
10
55l .
TI>iE;
SEC.
...
-
-
— i
-i
-
-
--
-
"1
to) 65
•
-
-
-
--
—
--
—
70
.
-
-
_.
—I
PROGRAM:
-
__IL____
DYNAI1P
FORM 202-01
-------
18.8 HP IrtOO *PM =
03 02-0<*-74
PROCESSED: 17:05.4:4 FE6 4, 1*74 -
MPH
WT.
1750.
2000.
2250.
2500.
3750.
3000.
3bOO.
4000.
4500.
5000.
5500.
5500.
ACT.
HP
7.7
8.3
8.8
9.4
9.9
10.3
11. Z
12.0
1?.7
13.4
13.9
14.4
I NO.
HP
4.9
4.9
5.2
5.7
b.2
6.5
7.0
8.0
d.2
fi.9
fc.9
9.3
-'ITH
a/C
5.5
5.6
6.0
6.5
7.1
7.4
7.9
9.1
9.3
10.1
10.1
10.5
TP-202
Attachment No.
NOTE: LAST 5500 VALUE IS KO* *"TS ABOVE 5751*
T VALUES FO'->
03 02-04-74 18.8 HP 1800
= 46.3 MPH
*'T
1750.
2CUO.
2500.
3000.
3500.
4000.
4500.
5000.
b500.
1750.
2000.
2500.
3(30(1.
J500.
4000.
4500.
SOOn.
5500.
1750.
2000.
25'JO.
3000.
3500.
4000.
4500.
5000.
5500.
• T
16.00
17.00
20.80
25.00
27.70
32.70
35.10
38.10
40. bO
9. JO
9.90
12.40
15.00
17.00
2G.OG
21. 70
24.40
25.t>0
5.70
6.4U
8.00
9.70
10.90
13.00
14.20
16.00
16.90
1*0. HP
4.0
4.0
4.0
4.0
4.U
4.0
4.0
4.0
<*.<)
8.0
8.0
H.O
8.0
8.U
o.O
b.O
8.0
b.u
l^.o
14.0
14.0
14.0
14.0
14.0
14.0
1<*.U
14.0
ACT. HP
t>.t>
7.1
7.3
7.3
7.7
/.4
7.6
o.O
«.2
11.4
12.3
12.2
IS. I
!<;.:>
12.1
12. b
12.4
13.0
18.6
19.0
lv.0
18.8
19.5
18.7
1^.2
1^.0
19.8
4. (I
3.9
3.9
3.9
<*.0
3.9
3.9
8.2
s.2
H.I
8.1
14.0
13.9
13.9
13.9
14.0
13.9
13.9
14.0
14.0
56
-------
EPA TEST
PROCEDURE Nur
nber
Tp-203 Page * of 6
SUBJECT
GAS ANALYZER CALIBRATION CURVE GENERATION
Reference FEDERAL REGISTER, VOL. 38 NO
Oct. 31. 1973 - 85.075-23
Responsible Organization
CORRELATION/MAINTENANCE
Test Witness /Review
QUALITY ASSURANCE
. 209, Data Form No.
203-01
Computer Program
S AQF : CURVEALL
Performance Interval
See Comments
Type of Test Report Supersedes
COMPUTER PRINT-OUT (DEFLECTION VS CONCENTRATION) New
Report Distribution QUALITY ASSURANCE,
CORRELATION AND MAINTENANCE
TEST OPERATIONS, Superseded by
REMARKS/ COMMENTS
1.0 Calibration should be performed every 30 days, after any maintenance
requiring re-alignment or when called for specifically by contract
requirement .
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Support Services Chief
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
57
-------
REVISIONS:
ANALYZER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-203
PAGE_2_OF_6
1.0 PURPOSE
Measurement of exhaust components requires that the deflections obtained
during the analysis be converted to concentrations as accurately as
possible. This document describes the procedure to be used to construct
calibration curves for the instruments which measure hydrocarbons,
oxides of nitrogen, carbon dioxide and carbon monoxide.
2.0 TEST ARTICLE DESCRIPTION
The instruments being calibrated are mounted in a console with provisions
for: analysis of the exhaust sample; recording the instrument outputs; and
suitable gas supplies for spanning and zeroing the instruments.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, No. 209, Oct. 31, 1973 - 85.075-23
3.2 SAE XJ1094, "Constant Volume Sampler System for Exhaust Emission
Measurement," Section 4. (Proposed)
3.3 Operators Manuals for In Use Analyzers
4.0 REQUIRED EQUIPMENT
4.1 Exhaust gas analysis console, equipped with the following instruments:
4.1.1 Hydrocarbons by flame ionization
Beckman Model 400 or equivalent
4.1.2 Carbon monoixde by non-dispersive infrared (NDIR)
Bendix Model 8501B or equivalent
4.1.3 Carbon dioxide by non-dispersive infrared (NDIR)
MSA Model 202 or Beckman Model 315B or equivalent
4.1.4 Oxides of nitrogen by chemiluminescence
Teco Model 10A or equivalent
4.1.5 Flow controls for selecting and monitoring the gases
4.2 Zero gas meeting the requirements specified in FR 85.075-23 (a)(2).
4.3 Calibration (standard) gas mixtures traceable to NBS and/or EPA
primary standards.
4.4 Chart recorders capable of 0-100 deflections with accuracy of
±1 percent, and a readability of ±1 percent.
59
-------
REVISIONS:
ANALYZER CALIBRATION
TEST
PROCEDURE
PROCEDURE NO.
TP-203
PAA*3 OF 6
4.5 Read-out device in percent of scale.
o Computer interface
o DVM
o Meter
5.0 PRECAUTIONS
5.1 Safety - Reference safety manual "Safe Handling of Compressed Gases."
5.2 Meter chart reading, D.V.M. or other output devices should have a
valid calibration tag.
5.3 Check that the proper set of standards are used for the particular
range being calibrated as specified by Quality Assurance.
6.0 VISUAL INSPECTION
6.1 Verify that the instrument serial number is correct for the sample
train.
6.2 Check instrument gain settings against those in the instrument
log book.
6.3 Check instrument response time and noise level.
7.0 TEST ARTICLE PREPARATION
7.1 Check calibration gas mixture for proper cylinder and regulation
pressures.
7.2 Special checks; Converter efficiency test procedure No. 303.
7.3 Adjust analyzers to optimum performance.
7.3.1 Reference analyzer operation manuals
60
-------
REVISIONS:
ANALYZER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-203
PAGE_1_OF 6
8.0 TEST PROCEDURE
The calibration curve is constructed from the data collected as a result of
performing the following sequence of steps:
Test Sequence
101
102
103
104
105
106
107
108
109
110
Test Description
Zero the instrument using zero gas flowing at the
same rate used for span and sample. The HC instru-
ment must be zeroed with air, others with nitrogen
or air.
Select desired range, introduce calibration gas with
highest concentration for that range. Adjust output
to reading obtained in previously monthly calibration
or determine theoretical percent of scale (TPS) by
Data Output
ZERO DEFL.
RANGE
Cylinder Cone.
X100
TPS
Range Cone.
TPS should never be greater than 99 percent.
Introduce zero gas. If not zero, adjust.
Introduce highest span gas
Repeat 103
When steps 103 and 104 can be repeated without
adjustment, go on to 107. If not within a
reasonable period of time, follow instrument
diagnostic and maintenance procedures. Ref. 3.3.
Introduce each successively lower span gas until
zero is repeated.
Introduce each successively higher span gas
until highest reading is obtained.
Repeat steps 107 and 108 until all readings agree
within ±0.25%. If not possible, perform instrument
diagnostic and maintenance procedures. Ref. 3.3.
Record average of all readings except zero on data
form # 203-01
ZERO DEFL.
CONCENTRATION/
DEFLECTION
CONG & DEFL.
CONC & DEFL.
DEFLECTIONS
61
-------
REVISIONS:
ANALYZER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-203
Test Sequence
111
Test Description
Record the following information on the data sheet
date, analyzer, train no., gas analyzer, range no.,
full scale concentration, analyzer vendor, NDIR
cell length, units, flow rate set point, FID pres-
sures, gain setting, recorder type used, operators
initials, also cylinder numbers, and concentrations.
Data Output
SEE
DATA SHEET
62
-------
REVISIONS:
ANALYZER CALIBRATION
TEST PROCFDURF
PROCEDURE NO.
rpr> On*^
PAftF.,6_r>F .6.,_
9.0 DATA INPUT
9.1 Complete form # 203-01.
9.2 Submit the form to the Data Branch for processing.
10.0 DATA ANALYSIS
10.1 Process data using "SAQF: CURVEALL"
11.0 DATA OUTPUT
11.1 Computer print of "Curveall Super Version" Recorder Deflection vs.
Concentration.
12.0 ACCEPTANCE CRITERIA
12.1 Check for linearity of NOx and HC curves.
12.2 Insure that all calibration points fit within ±2% of the point value.
12.3 Insure that no major curve shift was indicated from last calibration.
13.0 QUALITY PROVISIONS
13.1 If data does not follow "Acceptance Criteria", reject calibration and
institute corrective action.
13.2 If data is acceptable and curve update is desired, check the
appropriate space on the Curveall Verification sheet and return
it to the Data Branch.
13.3 If data was unacceptable, upon completion of required corrective
action, institute recalibration.
63
-------
ANALYZER CALIBRATION
CURVE GENERATION DATA
DATE
-
-
~
•
u
.
J°-
t.|
o
LU
M
00 >-
°l
O
2
Ul
cr:
•
15
JO
FULL
SCALE
CONC.
ANALYZER
VENDOR
»| 301
is
NDIR
CELL
LENGTI
(0
00
I ,
«— *
T
FLO
RATE
SCFH
<••
SET
POINT
n i loH
1
1
Ifl
FID
PR
AIR
,_j
5S
:SSURE,S
FUEL 1 SAMP
L
to
<
i_
GAIN
SET-
ZERO
i
"I
L_
INGS
SPA,
70
j
y
i
a
r^ uj
Q ZJ
O UJ
t_) Q.
UJ >-
rs i —
75
1
i
'
'
5
31
- <
C^ h-l
a. z:
o «—
'
to
COh-tEflTS:
CYLINDER
, NUMBER
CYLINDER
,3 cone.
<
*
<
j
•
METE
:,DEFL
-i .
• i
i ^
_..,.
SYMBOLS AND
R GAS
CEL
REC
RAf
HC,
(
1
1
C
I
f
PROGRAM: SAQF:CURVEALL. C
ABBREVIATIONS
ES •• C3H8, CO, C02, NOX, CH4
L LENGTH UNITS - IN, CM
ORDER TYPE - TI (Texas Instr.), HW (Honeywell), LN (Leeds & Northrup),
)VM (Digital Voltmeter), MIS (Other).
GE NO. DESIGNATIONS
CO, NOX (PPM) CO, C02 (X)
11 - 0 - 10 01-0-1.0%
12-0-25 02 - 0 - 2.5%
13-0-50 03 - 0 - 5.0%
)4 - 0 - 100 04 - 0 - 10.0%
15-0-250 05 - 0 - 15.0%
16 - 0 - 500 HFXANE NDIR
17 - 0 - 1000
>8 - 0 - 2500 01 - 0 - 1000 PPM HEX
19 - 0 - 5000- 02 - 0 - 10000 PPM HEX
10-30-73
FORM 203-01
-------
CALIBRATION DATE
ANALYZER TRAIN
GAS ANALYZED
RANGE NUMBER
FULL SCALE COS'C.
ANALYZER VENDOR
NOIK CELL LENGTH
SAMPLE FLOWRATE
MONITOR SET POINT
FID AIP. PKF.SSURE
F!0 fUEL PRESSURE
FIO SAKP PRESSURE
ZE«0 GAIN
SPAN GAIN
RECORDER TYPE
OPEKATOR'S INIT.
COMMENTS
05-20-75
16
CO
09
5000.0
'BECKMAN
0.0
0.0 SCFH
13.0 "H20
0.0 PSI
0.0 PSI
0.0 PSI
0 .0
0.0
OVM
RR
0-5000 PPM CO
11
111
1111
11
11
11
11
11
11
11
1111111111
1111111111
EOUftTIOM:
Ui
CO = X / ( A + B»X »
COEFFICIEMTS:
« « 0- tt tto-oobocouu
(X)
26.90
40.^0
56.lt)
71.60
83.90
95.30
(H>lH»to
976.172
1576. 6r,9
23V6.86S
32«3 . 272
4170.984
5182.027
& «• « U o o a o u «
(Y)
974.712
15M4.002
23B1 .u«2
3302. S10
4156.727
5184.863
U CO 0 -OO 0 (K>
-0.15
0.47
-0 . 64
0.59
-0.29
0.06
AVERAGE PERCENT OF POINT DEVIATION: 0.37
*«»PROCESSED: 15:43 MAY 20, 1975
"o^LOGGED ON LINF: 389
„-.„„,.,_„ ™ — RECORDER DEELEC11QN :_C.QJ4CEN.1RATIQN CO
0.0 0.0
0.5 14.78
1.0 29.69
1.5 '.'..73
3.0 59.91
2.5 75.23
3.0 90.67
3.5 106.25
4.0 121.97
4,5 137. ai
5.0 Ib3.79
5.5 169. 9U
6.0 1Mb. 14
6.5 202.51
7.0 219.01
7.5 235.64
6.0 252.^0
8.5 269.29
9.0 286.31
9.5 303.45
10.0 320.73
10.5 338.12
11.0 355.65
11.5 373.30
12.0 391.07
12. 'b 40B.97
13.0 426.99
13.5 445.14
14.0 463.41
14.5 461.80
15.0 500.30
15.5 516.93
lb.0 537.68
lt>. 5 556.55
17.0 575.54
17.5 594.64
16.0 613.66
16.5 633.20
19.0 652.65
19.5 672.21
20.0 691.89
20.5 711.69
21.0 731.59
21.5 751.61
22.0 771.73
22.5 791.97
23.0 812.32
23.5 832.73
24.0 M53.34
24.5 b 7 4.01
2S<0 894.79
25.5 915.68
26-0 936.67
26.5 957.76
27.0 978.96
27.5 1000.26
28.0 1021.67
28.5 1043.18
29.0 1064.78
29.5 10rf6.SO
30.0 1108.31
30.5 1130.22
31.0 1152.23
31.5 1174.34
32.0 1196.54
32«5 1218.85
'33*0 1241.25
33.5 1263.75
34.0 12fi6.35
34,5 1309.04
35.0 1331.83
35.5 1354.72
36*0 1377.70
36.5 1400.77
37.0 1423.94
37.5 1447.21
38.0 1470.57
36.5 1494.02
39.0 1517.57
39,5 1541.21
40.0 1564.95
40,5 1588.78
41.0 1612.70
41.5 1636.72
42.0 1660.83
42*5 1665.04
•O.O 1709.34
43.5 1733.73
44.0 1758.22
44.5 1782.81
45.0 1807.49
45.5 1832.27
4b.O 1857.15
46.5 1682.12
47.0 1907.19
47.5 1932.35
46.0 1957.62
48.5 1982.99
49.0 2008.45
49.5 203^.02
1
50.0 2059.69
50.5 2085.46
51.0 2111.34
51.5 2137.32
52.0 2163.41
52.5 2189.60
53.0 2215.90
53.5 2242.32
54.0 2268.84
54.5 2295.47
55.0 2322.22
55.5 2349.09
56.0 2376.07
56.5 2403.17
57.0 2430.39
57. S 2457.74
58.0 2485.21
58.5 2512.80
59.0 2540.52
59.5 2568.38
60.0 2596.36
60.5 2624.49
61.0 2652.75
61.5 2681.15
62.0 2709.69
62.5 273B.37
63.0 2767.21
63.5 2796.20
64.0 2825.34
64.5 2854.64
65.0 2384.09
65.5 2913.71
66.0 2943.50
66.5 2973.46
67.0 3003.59
67.5 3033.91
68.0 3064.40
68.5 3095.07
69.0 3125.94
69.5 3157.00
•
70.0 3188.26
70.5 3219.73
71. U 3251.40
71.5 3283.28
72.0 ' 3315.33
72.5 3347.70
73.0 3360.24
73.5 3413.02
74.0 3446.04
74. S 3479.31
75.0 3512.82
75.5 3546.59
76.0 3580.62
76.5 3614.92
77.0 3649.49
77.5 3684.35
78.0 3719.49
78.5 3754.93
79.0 3790.68
79.5 3826.73
80.0 3863.10
80.5 3899.80
81.0 3936.84
81.5 3974.22
82.0 4011.96
82.5 4050.05
83.0 4088.52
83.5 4127.37
84.0 4166.61
84.5 4206.25
85.0 4246.30
85.5 4286.78
86.0 4327.69
86.5 4369.05
87.0 4410.87
87.5 4453.15
88.0 4495.93
88.5 4539.19
89.0 4582.97
89.5 4627.28
90.0 4672.12
90.5 4717.52
91.0 4763.49
91.5 4610.04
92.0 4657.20
92.5 4904.98
93.0 4953.40
93.5 5002.47
94.0 5052.23
94.5 5102.67
95.0 5153.83
95.5 5205.73
96.0 5258.39
96.5 5311.84
97.0 5366.09
97.5 5421.17
93.0 5477.10
98.5 5533.92
99.0 5591.65
99.5 5650.32
_1
-------
EPA TEST PROCEDURE
Number
TP-204
Page
of
SUBJECT
CHART RECORDER/MAINTENANCE
Reference
MANUFACTURER'S SERVICE MANUALS
Data Form No.
INSTR. LOGBOOK
Responsible Organization
INSTRUMENT SERVICES
Test Witness/Review
INSTRUMENT SERVICES LEADER/QUALITY ASSURANCE
Type of Test Report
CALIBRATION STICKER AND LOG BOOK ENTRY
Report Distribution
QUALITY ASSURANCE, INSTRUMENT SERVICES
Computer Program
NONE
Performance Interval
MINIMUM: 90 DAYS
Supersedes
New ...„ .
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Support Services Chief_
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
67
-------
REVISIONS:
CHART RECORDER CALIBRATION/MAINTENANCE
TEST PROCEDURE
PROCEDURE NO.
TP-204
2 3
1.0 PURPOSE
To perform periodic recalibration and maintenance after periods of use
or questionable performance. Recalibration will assure accurate instrument
output and prolong the useful life of the instrument.
2.0 TEST ARTICLE DESCRIPTION
2.1 Chart recorder, two channel model capable of measuring two variables
on the same chart. The recorder is a continuous balance potentiometer
which responds to a d-c signal representing the value of the measured
quantity.
2.2 Typical chart recorders used may be:
o Honeywell 194 Electronik
o Varian G-14A-2
o Varian G-1110
o Hewlett-Packard 680
o Texas Instruments 4525-2, 7822-2 (4 pen)
o Texas Instruments 2596-2 (2 pen)
3.0 REFERENCES
Each recorder listed in 2.2 has a manual showing theory/operation, maintenance
and calibration procedures. These manuals are available and should be
reviewed by the instrument technicians.
4.0 REQUIRED EQUIPMENT
The list of equipment in this section represents an example of the articles
needed to perform a valid calibration. It should be noted that manufacturers
of specific equipment may list requirements for their own calibration items.
4.1 Example of calibration equipment
o Calibrated precision voltage source.
Example: Honeywell Model 2746 portable potentiometer, 0-200
microvolt to 0-500 millivolt ranges.
o Test leads (preferably with banana plugs)
o Calibration screwdrivers (1/8" and 1/4" bits)
5.0 PRECAUTIONS
5.1 Calibration and adjustment of recorders should be accomplished by
Instrument Service Technicians only.
5.2 Safety precautions should be observed in using electrical equipment.
69
-------
REVISIONS:
CHART RECORDER CALIBRATION/MAINTENANCE
TCCT pporpniipp
1 tO 1 rl%VXV«C L/wl\C
PROCEDURE NO.
TP-204
PAftf 3 OF 3
6.0 VISUAL INSPECTION
6.1 Inspect slidewires for signs of wear.
6.2 Inspect RECORDER for disconnected leads and/or broken wires.
7.0 TEST ARTICLE PREPARATION
7.1 Set up calibration equipment as specified in applicable service manual.
8.0 TEST PROCEDURE
Each manufacturer of chart recorders outlines specific calibration procedures
common to their product. Therefore, the test procedures for chart recorder
calibration should be taken from the manufacturer's text. It is also
suggested that routine maintenance should be accomplished prior to the
calibration of each recorder.
9.0 DATA INPUT
9.1 The date of calibration, type of instrument, serial number, and work
performed is recorded in instrument calibration log book (see
attachment).
10.0 DATA ANALYSIS
10.1 Observed readings and calibration input should be compared.
11.0 DATA OUTPUT
11.1 Calibration sticker showing the date of calibration and the date the
next calibration is due is attached to the recorder. Calibration
data sheet shall be filed in the instrument file and logged in the
record book.
12.0 ACCEPTANCE CRITERIA
12.1 Recorder must function within ±1 percent accuracy and repeatability
following calibration.
13.0 QUALITY PROVISIONS
13.1 Check to assure calibration has been completed at proper time intervals.
13.2 Assure that calibration sticker has been placed on recorder.
70
-------
TP-204 ATTACHMENT No, 1
INSTRUMENT SERVICES LOG BOOK
HATS
1—7
76C*''
940757
8-29-74
10-il-74
rf-z?-74
1-11-7$
IMI? fft-bj
72-7-14
,'Z -9 - 74
-P-75
4AM
TO
7T
-------
EPA TEST
PROCEDURE Number TP-205
Page _ X of 4
SUBJECT
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
Reference
MANUFACTURER'S SERVICE MANUAL
Responsible Organization
INSTRUMENT SERVICES
Test Witness /Review
INSTRUMENT SERVICES LEADER, QUALITY ASSURANCE
Type of Test Report
LOG BOOK ENTRY AND CALIBRATION STICKER
Report Distribution
QUALITY ASSURANCE, INSTRUMENT SERVICES
Data Form No.
LOG BOOK
Computer Program
NONE
Performance Interval
MINIMUM: 90 DAYS
Supersedes
NEW
Superseded by
REMARKS/ COMMENTS
Office
Program Mgmt
Lab Branch
Lab Branch
Change
Letter
ORIGINAL RELEASE APPROVALS
Section Signature
Quality Assurance
Chief
Support Services Chief
Date
REVISIONS
Description of Change Approval
Date
73
-------
REVISIONS^
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
TEST
PROCEDURE
PROCEDURE NO.
TP-205
PAftP2 OF 4
1.0 PURPOSE
To perform periodic re-calibration and maintenance after periods of use
and/or questionable performance. Re-calibration of temperature
recorders will assure accurate instrument output and prolong the
instrument's useful life.
2.0 TEST ARTICLE DESCRIPTION
Temperature recorders vary in make, however, the operating principles
are generally the same. A temperature probe (normally iron-constantan
thermocouple) senses the temperature and produces an unknown voltage
which is in turn subtracted from a known voltage. The difference
in voltages is amplified and displayed by the recorder
2.1 Temperature recorders vary in application, ranging from one
channel to as many as 24 channels for measuring independent
variables.
The following recorders are representative of the types used
in emission monitoring,
o Esterline Corp., 24-channel, Model E1124E
o Honeywell, 24-channel, Model Elect. 19
o Honeywell, multi-channel, Model Elect 15
o Rustrax, single-channel, Model 2133
3.0 REFERENCES
Each recorder listed in 2.1 has a manual showing theory/operation,
maintenance and calibration procedures. Manuals of this nature
must be made available to the instrument technicians.
4.0 REQUIRED EQUIPMENT
The list of equipment in this section represents an example of
the articles needed to perform a valid calibration. It should
be noted that manufacturers of specific equipment may list require-
ments for their own calibration items.
75
-------
REVISIONS:
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
TEST PROCEDURE
PROCEDURE NO.
TP-205
PAGEj OF _
-------
REVISIONS:
TEMPERATURE RECORDER CALIBRATION/MAINTENANCE
TEST
PROCEDURE
PROCEDURE NO.
TP-205
PAftF 4 OF 4
10.0 DATA ANALYSIS
10.1 Compare observed temperature readings with the reference standard.
11.0 DATA OUTPUT
11.1 Calibration sticker showing the date of calibration and the
date the next due calibration is attached to the recorder.
11.2 Information regarding the results of the calibration shall be
filed with the instrument records.
12.0 ACCEPTANCE CRITERIA
12.1 Temperature recorder must indicate ambient temperature within
±2 degrees of the true value.
12.2 Temperature indicated must be within 1 percent of full scale at
all points.
13.0 QUALITY PROVISIONS
13.1 If acceptance criteria are not met, repair instrument and/or
repeat calibration.
77
-------
TP-205 ATTACHMENT No. 1
INSTRUMENT SERVICES LOG BOOK
OATS
Mrs
7SC.fl.
&IZ46
940157
S-19-74
ID-11-74
H-Z9-74
I-//-7$
! i»i) j teujr utf&t
b A
12-7-74
.'2 -9 ' 74
$-7-7$
3~? -75
7.
PPM ID QAL
-------
EPA TEST
PROCEDURE Num°er TP-206
Page x of 9
SUBJECT
BAROMETRIC PRESSURE
CALIBRATION AND CORRELATION
Reference Federal Register, Vol. 39, No. 101, May 23, 1974,
85. 075-22 (jl
Responsible Organization
Chemical Analysis
Test Witness/Review
Correlation and Maintenance
Type of Test Report
Log Book Entry
Report Distribution chemistry section, Support Services
Data Form No.
Jji-irj gi-ioV
Computer Program
None
Performance Interval
Monthly
Supersedes
New
Superseded by
REMARKS/ COMMENTS
Office
Program Mgmt.
Lab . Branch
Lab . Branch
Change
Letter
ORIGINAL RELEASE APPROVALS
Section Signature
Quality Assurance
Chief
Support Services Chief
Date
REVISIONS
Description of Change Approval
Date
79
-------
REVISIONS^
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
1 to 1 1 I\SXx*fc \J V/I\C
PROCEDURE NO.
TP-206
PARFJ2..0F .9. .
1.0 PURPOSE
To calibrate the aneroid barometers used in the test call against a Fortin
type barometer to assure accurate and uniform test cell readings.
2.0 TEST ARTICLE DESCRIPTION
Aneroid barometer compensated for temperature, brass, scale 25.1-31.1
inches of mercury (Hg), 0.02 subdivisions.
3.0 REFERENCES
3.1 PRINCO Barometer Instruction Booklet
3.2 W.G. Brombacher, D.P. Johnson, and J.L. Cross.,
"Mercury Barometers and Manometers"
NBS Monograph 8, May 1960.
4.0 REQUIRED EQUIPMENT AND CONDITIONS
4.1 Fortin type barometer, 1/4 inch bore, reading by vernier to
0.01 in. Hg
4.2 Rack for hanging the aneroid barometers
4.3 Temperature controlled room of +_3°F.
5.0 PRECAUTIONS
5.1 The Fortin type barometer readings are corrected for temperature
and gravity. The aneroid barometer is set to the corrected baro-
meter reading.
5.2 The aneroid barometers may indicate a slightly different reading from
one cell to another due to variations in the air handling system.
Large variations indicate a need for calibration or replacement.
5.3 Important factors which could affect the reading of the height
of the mercury are
o Lighting - Proper illumination is essential to define the loca-
tion of the crown of the meniscus. Precision meniscus sighting
under optimum viewing conditions can approach +_ 0.001 in.
Contact between index and mercury surface in the cistern, judged
to be made when a small dimple in the mercury first disappears
during adjustment, can be detected with proper lighting to much
better than + 0.001 in.
o Temperature - To keep the uncertainty in height within 0.01%
(0.003 in. Hg), the mercury temperature must known within
81
-------
REVISIONS^
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
1 h«9 1 I IVVXNtf b lSWl\C
PROCEDURE NO.
TP-206
PAftF_2..0F 9
5.4
±1 F. Although it is generally assumed that the scale and mercury
temperatures are identical, the scale temperature need not be
known to better than ±10 F for comparable accuracy. Uncer-
tainties caused by nonequilibrium conditions could be avoided by
installing the barometer in a uniform temperature room.
o Alignment - Vertical alignment of the barometer tube is required
for an accurate pressure determination. The Fortin barometer,
designed to hang from a hook, does not of itself hang vertically.
This must be accomplished by a separately supported ring encir-
cling the cistern; adjustment screws control the horizontal
position.
o Readings - The most reliable readings are obtained when the tem-
perature has not changed greatly over the past four hours. When
reading the barometer the reader's eye should be in the same
horizontal plane as the top of the mercury meniscus and the lower
edge of the vernier plate. This position can be checked by getting
the eye in line with the bottom of the vernier plate and the bottom
of the metal guide in back of the mercury column directly in back
of the vernier plate.
Readjustment to zero should be made whenever necessary in reading
the barometer; i.e., the adjusting screw at the bottom of the
reservoir casing should be manipulated until the surface of the
mercury exactly coincides with the tip of the ivory zero point
which is visible inside the reservoir.
The height of the meniscus will be greater on a rising barometer
than on a falling barometer. In order to bring the meniscus to
its approximate average height, tap the barometer lightly with
your fingers before taking a reading.
If it is desired to convert an english reading to a metric reading,
or vice versa, always apply the temperature and gravity corrections
before making conversion.
6.0 VISUAL INSPECTION
6.1 If an aneroid barometer has a cracked glass or dented case the complete
barometer should be replaced. Do not attempt to recalibrate as the
internal movements may have been also damaged.
6.2 If the mercury appears dull or tarnished, it is an indication that
the mercury has become contaminated in some way. It frequently occurs
when air, dirt, and moisture are admitted into the barometer tube.
In such event the instrument will no longer give accurate readings.
For proper cleaning the instrument should be returned to the factory.
82
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP -206
PAGE_!_OF_9
7.0 TEST ARTICLE PREPARATION
7.1 The aneroid barometers to be calibrated should be hung in the ±3°F
temperature controlled room for a minimum of 4 hours to allow them
to come to equilibrium with the ambient conditions.
A 1-orlin-type barometer.
Glass cylinder
ambient-vented —
Cistern
Closed end
vacuum-referred
Reading level
Glass tube
Ivory index
point
— Leather bag
patum-.idjustinfj
screw
83
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGE_JLOF 9
8.0 TEST PROCEDURE
The test requires three basic procedures: A. Reading the mercury baro-
meter, B. Calibration of the aneroid barometer and C. Correlation of
the test cell barometers.
Test Sequences
Test Description
101A In reading a barometer of the Fortin type,
which is the usual laboratory precision type,
first obtain the temperature of the case
from the small thermometer attached midway
between the top and bottom of the
instrument. Then adjust the
mercury in the reservoir to the
fixed point (an ivory pin), so that
the tip of the pin and its image
upon the mercury surface coincide.
Tap the barometer case gently to be
sure that the mercury is not stuck
in the tube and verify the zero
setting. Now bring the vernier
down until the white background
is cut off at the highest point of
the meniscus. The reading is the
uncorrected barometric height.
Data Output
Pressure,
un-corrected
102A The standard temperature for the
English scales is 62 F-; the
standard temperature for the Metric
scales is 0 C. The standard temp-
erature for the density of mercury
is 0°C. or 32°F. Since the scales
and the mercury have different co-
efficients or expansion, the pressure
indications will be affected by
variations in temperature; there-
fore, in order to obtain the
true pressure every reading
must be corrected for tempera-
ture. The Temperature Cor-
rection Tables combines the
corrections for length of
the scales and the density of
mercury.
Further, the pressure indication will
be affected by the gravity of the
place at which the reading is taken.
Latitudes from 0° to 45 have a
subtractive correction; latitudes
from 46° to 90° have an additive
correction. More precise
Temperature
correction
factor
Gravity
correction
factor
84
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
Test Sequence Test Description Data Output
determinations of the true pressure may be
made by using the Gravity Correction Tables
in conjunction with the observed readings
corrected for temperature.
EXAMPLE; Assume the barometer reads 29.91"
at a temperature of 75 F. Table 1 gives the
temperature correction for every two degrees
Fahrenheit and every one inch of atmospheric
pressure. Interpolating, we find the
correction to be -.125". The reading cor-
rected for temperature, therefore, is 29.91"
-.125', or 29.785". If the reading is
being taken at a latitude of 42 the
correction for gravity given in Table 2 is
-.010" which makes the true pressure 29.785"
-.010, or 29.775" which, if working to one
hundredths of an inch, could be rounded off
to 29.78".
101B After the aneroid barometers have attained Calib. Date
equilibrium read the Fortin barometer and Log Book
adjust the aneroid barometers at the Entry
corrected reading using the adjusting
screw on the back of the barometer. Gently
tap each gauge before taking the reading.
Cover the adjusting screw with a piece of
tape to discourage tampering.
101C Correlation is accomplished by reading all Log Book
the test cell barometers in their usual Entry By
position once a week. I.D. Number
85
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGE
: 7 np 9
TEMPERATURE CORRECTION TABLE — Table 1 — English System
To reduce the reading oi the barometer to standard temperature
Tempera-
ture in
Degrees F.
60°
62
64
66
Observed Reading of the Barometer in Inches
20"
0.057
.060
.064
.068
68 .071
70
72
21" | 22" | 23" 24" 25" | 26" 27" | 28"
ALL CORRECTIONS SUBTRACTiVE~
0.060
.063
.067
0.062
.066
.070
.071 .074
.075
.075 .079
.078 .082
74 .082
76 .086
f
78 .089
I
80 ' .093
82 i .096
84 .100
86 .104
88 i .107
90 : .111
92 i .114
94
96
98
.118
.122
.125
100 j .129
.086
.090
.094
.097
.101
.105
.109
.113
.116
.120
.124
.128
.131
.135
.078
.082
.086
.090
.094
.098
.102
.106
.110
.114
.118
.122
.126
.130
.134
:138
.142
0.065
.069
.074
.078
.082
.086
.090
0.068
.073
.077
.081
.085
.D90
.094
i
.094 .098
.098 .103
.103 .107
.107
.111
.115
.119
.123
.127
.132
.136
.140
.144
.148
.111
.116
.120
.124
.129
.133
.137
.142
.146
.150
.154
1
0.071
.076
0.074
.079
.080 .083
0.077
.082
.086
.085 .088 .091
.089 .093 .096
.094 .097 ; .101
; .098 .102
! .103
'• .107
'
.112
.116
.121
.125
.130
.134
.138
.143
.147
.152
.156
.161
.107
.111
.116
.121
.125
.130
.135
.139
.144
.149
.106
.111
.116
.120
.125
.130
.135
.140
.145
.150
.154
.153 .159
j
.158
.163
.167
.164
.169
.174
0.080
.085
.090
.095
.100
.105
.110
.115
.120
.125
.130
.135
.140
.145
.150
.155
.160
.165
.170
.175
.180
29
-
0.082
.088
.093
.098
.103
.109
.114
.119
.124
.129
.135
.140
.145
.150
.155
.161
.166
.171
.176
.181
.187
30"
0.085
.091
.096
.101
.107
.112
31"
0.088
.094
.099
.105
.110
.116
.118 ! .122
.123
.128
1 .134
.127
.133
.138
.139 .144
.145
.150
.155
.161
.166
.172
.177
.182
.188
.193
.149
.155
.161
.166
.172
.177
.183
.188
.194
.200
86
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
PROCEDURE NO.
TP-206
PAGE_S_OF ja —
GRAVITY CORRECTION TABLE — Table 2 — English System
To reduce the
1
Lati-
tude r
reading of the barometer to standard gravity
Observed Reading of the Barometer in Inches
20"
21" '
22" 23" 24" | 25" 1 26" |
27" ' 28'
1 29" 30"
LATITUDE 0° TO 45° THE CORRECTION IS TO BE SUBTRACTED
LATITUDE 46° TO 90° THE CORRECTION IS
0°
5
10
15
20
25
30
32
• 34
36
38
40
42
44
46
48
50
55
60
65
70
75
80
95
90
-0.054 -0.056
.053
.050
.047
.041
.035 •
.027
!
.024 j
• .021
' 1
.017
.014 ;
.010
.006
i-0.003
'
+0.001
.005
! .008
.017 i
| .026 |
1 !
! .033
.040
1
.045
.049
.051
:
Uo.052
.055
.053
.049
.043
.037
.029
.025
.022
.018
.014
.011
.007
-0.003
+0.001
.005
.009
.018
.027
.035
.042
0.47
.051
.054
+0.055
-0.059
.058
.055
.051
.045
.038
.030
.026
.023
.019
.015
.011
.007
-0.003
+0.001
.005
.009
.019
.028
.036
.044
} .049
! .054
.056
i
• -»-0.057
-0.062
.061
.058
.053
.047
.040
i031
.028
.024
.020
.016
.012
.007
-0.003
+0.001
.005
.010
.020
.029
.038
.046
.052
.056
.059
+0.060
-0.064 -0.067 1-0.070 t-
.063
.060
.056
.050
.042
.033
.029
.025
.021
.016
.012
.008
-0.003
+0.001
.006
.010
.021
.031
.040
.048
.054
.059
.061
+ 0.062
.066
.069
1
.063 i .066
.058 .060
.052 | .054
I
.043 j .045
.034 1 .035
.030 } .031 1
.026 j .027
i
.022 .022
.017
.013
j
.018
.013
.008 I .008
-0.003
+0.001
.006
.010
.021
.032
.041
.050
.056
.061
.064
-1-0.065
TO BE ADDED
-0.072 -0.075 i -0.078
-0.080
.071 .074 .077 .079
.068
.071 .073
.063 .065
.067
.056 j .058 j .060
.047 .049 .050
.037 1 .038 .040
!
.032 i .034 .035
.028 .029 [ .030
.023 | .024 .025
.018
.014
.009
-0.004 {-0.004
fO.OOl
.006
.011
.022
.033
.043
.052
.058
.063
.067
J-0.068
4-0.001
.006
.011
.023
.034
.045
.053
.061
.066
.069
^ 0.070
i
.019
.014
.009
-0.004
+0.001
.006
.012
.020
.015
.009
-0.004
10.001
.007
.012
.024 .025
.036 .037
.046
.055
.048
.057
1
.063
.068
.072
.065
.071
.074
-(-0.073 t-0.075
.076
.070
.062
.052
.041
.036
.031
.026
.020
.015
.010
-O.Q04
4-0.001
.007
.012
.026
.038 i
.050
.059
.067
.073
.077
J- 0.078
87
-------
REVISIONS:
BAROMETRIC PRESSURE
CALIBRATION & CORRELATION
TEST PROCEDURE
1 k «J 1 I l\V^N»fc IXwl\C
PROCEDURE NO.
oir> _ 9 n &
PAftF.9 .OF 9
9.0 DATA INPUT
9.1 Enter calibration dates in log book by I.D. number. Indicate ad-
justed or not adjusted.
9.2 Enter the amount of deviation from true barometric pressure in the
instrument log book.
10.0 DATA ANALYSIS
None required
11.0 DATA OUTPUT
11.1 A handwritten copy of the correlation data goes to Quality Assur-
ance management.
12.0 ACCEPTANCE CRITERIA
12.1 In order to achieve 0.1% accuracy the barometer readings should cor-
relate among themselves within +_ 0.03 in. Hg.
12.2 Correlation should be established over 28.5 to 30.0 in. Hg. range.
13.0 QUALITY PROVISIONS
13.1 At the Factory the Fortin-Type Barometers are adjusted as nearly as
possible to a zero correction by comparison with a certified stan-
dard. The adjustment is so made that no further correction for capil-
larity need be made.
83
-------
EPA TEST
PROCEDURE NU™
ber
p-250 Page i of 4
SUBJECT
ENGINE DYNAMOMETER CALIBRATION
Reference
Responsible Organization
CORRELATION AND MAINTENANCE
Test Witness
SUPERVISOR - HEAVY DUTY TESTING
Type of Test Report
MAINTENANCE LOG BOOK ENTRY
Report Distribution
REMARKS/ COMMENTS
Data Form No.
DYNO LOG BOOK
Computer Program
Performance Interval
MONTHLY
Supersedes
NEW
Superseded by
ORIGINAL RELEASE APPROVALS
Office
Administration
Lab. Operator
Corr . & Main .
H D Testing
Section
Quality Assurance
Chief
Supervisor
Supervisor
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
89
-------
REVISIONS:
ENGINE DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-250
1.0 PURPOSE
This procedure outlines the method used for calibrating the engine dynamometer
used for heavy duty engine emission testing.
2.0 TEST ARTICLE DESCRIPTION
2.1 G.E. Direct Current Dynamometer
600 h.p. MOD 426408AD
3.0 REFERENCES
3.1 Manufacturer's manual for operation of dynamometer and Unisystem controls
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 Strobotac with the following specification:
accuracy ±1% of dial reading
Ranges: 110 - 690 RPM
670 - 4170
4000 - 25,000
4.2 Weights in 5 Ib. increments as required by maximum torque rating of the
dynamometer.
5.0 PRECAUTIONS
5.1 Dynamometer should not be coupled to an engine during calibration as
damage could occur to an engine driven at excessive RPM by dynamometer.
5.2 Multiple images will be observed when stroboscope flashing rate is set
to a multiple of the fundamental speed of the object. The operator
should be sure that the flashing is set to a single image. The hub of
the dyno may be marked to provide a visible reference.
5.3 When adding weights in increments the total weight should be determined
each time by adding all of the individual weights.
6.0 VISUAL
6.1 Check oil level of dynamometer support trunnions.
7.0 TEST ARTICLE PREPARATION
7.1 Warm up dynamometer for 20 minutes at 2500 RPM.
7 2 Check calibration of Strobotac using line voltage frequency, synchronous
motor or other method as recommended by electronic Stroboscope manufac-
turer .
91
-------
REVISIONS:
ENGINE DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-250
PAGEJL.
8.0 TEST PROCEDURE
Basically the procedure involves calibration of the speed read out device
and the dynamometer torque bridge meter.
Test Sequence Description Data Output
Speed Meter
101 Set up Strobotac to illuminate hub of the
dynamometer.
102 Set strobotac frequency to indicate 2500, 2000 Log Book
1500, 1000, and 500 RPM. Operate dyno at each Entry
set point until single image on dyno hub is
noted. Record meter readout in dyno mainte- Indicated
mance log book. RPM
103 If meter adjustment is required, adjust at 2000,
RPM and repeat 500 2500 RPM readings. If meter
is off at either end of the scale by more than 2%
replace meter.
104 Calibrate computer input and RPM recording device
to match meter readings if required.
Torque Bridge
201 Check zero reading of torque meter and computer
input, adjust if required.
202 Add sufficient weight to reach maximum rated
torque according to the following:
T°r^e = Added Weight
Arm Length
Adjust meter and computer if required.
203 Recheck zero and if adjustment is required repeat
zero and max torque until no further adjustment
is required.
204 Starting at zero add weights in 10 Ib increments Record
until maximum reading is reached. Remove weights Indicated
and observe readings, if different from initial vs
reading repeat zero and maximum reading, record Actual
all observation in dyno maintenance log book. Torque
205 Calibrate torque recording device using torque
meter as required.
92
-------
REVISIONS:
ENGINE DYNAMOMETER CALIBRATION
TEST PROCEDURE
PROCEDURE NO.
TP-250
PAGEJ OF 4
9.0 DATA INPUT
All observed readings recorded in the dynamometer maintenance log book.
10.0 DATA ANALYSIS
None required unless significant change noted from previous calibration.
11.0 DATA OUTPUT
Calibration results reported to quality assurance and heavy duty testing
supervisor.
12.0 ACCEPTANCE CRITERIA
12.1 RPM and torque meter readings must agree within ±2% of calibrated value
across measured range.
13.0 QUALITY PROVISIONS
13.1 Quality assurance periodically audits calibration procedure, reviews
log book entries and determines acceptability of calibration procedure
in the event of significant calibration variability.
13.2 Calibration of speed and torque performed monthly.
93
-------
EPA TEST PROCEDURE
Number
TP-251
Page
SUBJECT
CALIBRATION OF THE SMOKEMETER NEUTRAL DENSITY FILTERS
Reference
FEDERAL REGISTER VOL. 37, P. 85.874-15 (A) (3)
Data Form No.
HD251-01
Responsible Organization
LABORATORY OPERATIONS - CHEMICAL ANALYSIS
Test Witness
CERTIFICATION
Type of Test Report
CERTIFICATE FORM NO. _2_51r_03_ _ _ _
Report Distribution" CHEMICAL ANALYSIS - ORIGINAL
COPIES: CERTIFICATION AND REQUESTOR
Computer Program
Performance Interval
AS REQUESTED _
Supersedes
__NEW
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
LAB. OPER.
CHEM. ANALYSIS
Section
QUALITY ASSURANCE
SUPERVISOR
Signature
Date
REVISIONS
Change
Letter
Description of Change
Approval
Date
95
-------
REVISIONS:
CALIBRATION OF THE SMOKEMETER
NEUTRAL DENSITY FILTERS
TEST PROCEDURE
PROCEDURE NO.
TP-251
PA$F2 OF 6
1 . 0 PURPOSE
This procedure outlines the method used at the EPA Laboratories in Ann Arbor
to calibrate and certify the opacity filters submitted by Manufacturers or
Laboratories involved in the measurement of smoke emissions of diesel engines
as required by Federal regulations.
2.0 TEST ARTICLE DESCRIPTION
A neutral density filter is an optical device which reduces the intensity of
the light passing through it by the same percentage at all wavelengths. The
reduction of light is linear across the entire color spectrum and thus, will
not change the color of the light passing through it, only its intensity. The
percent reduction in light intensity is called the opacity of the filter.
The percent intensity of light which passes through the filter is
referred to as the percent transmission.
Neutral density filters are used to check the calibration of smokemeters on
the theory that diesel smoke is itself neutral. Most filters used are of the
"sandwich" type composed of a filter material between two pieces of clear
glass. Coated filters are available but should be avoided since cleaning
and handling could damage this coating.
3.0 REFERENCES
3.1 Federal Register Vol. 37., P. 85.874-15 (a) (3) Dated November 15, 1972.
3.2 "Calibration of Neutral Density Filters", Cummins Technical Report
No. 5425, R.B. Rich, May 9, 1972, Columbus, Indiana.
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 Optical Bench - Spindler and Hayer, LA-3691.
4.2 Light Source - G.E. Microscope Illuminator - Nichrome Filament SR-8,
Med. Base Down, ASA Code - EDS.
4.3 Voltage Regulator for light source.
4.4 Photomultiplier with case designed to eliminate stray light.
4.5 Digital voltmeter with accuracy of 0.1% of full scale.
4.6 Neutral density filters with NBS certified calibration.
4.7 Dark room with suitable temperature control and ventilation. Room is
painted black to avoid possible unwanted stray light reflection.
4.8 Notebook for recording serial numbers of certified filters.
97
-------
REVISIONS-
CALIBRATION OF THE SMOKEMETER
NEUTRAL DENSITY FILTERS
TEST PROCEDURE
PROCEDURE NO.
TP-251
5.0 PRECAUTIONS
5.1 No smoking is allowed in calibration room at any time as the
smoke can coat the lenses and affect the calibration.
5.2 Care must be taken when handling filters. Hold only by
metal ring or mounting. Fingerprints on the lenses could
cause permanent damage.
6.0 VISUAL INSPECTION
6.1 Check optical system for dust, scratches, etc. prior to
calibration check. Clean as required with isopropyl
alcohol and lens tissue.
7.0 TEST ARTICLE PREPARATION
7.1 A serial number is assigned to each filter received and
is etched on the ring or holder for identification by
EPA. This should be done prior to calibration and the
serial number information entered in the notebook.
7.2 Clean filters using Isopropyl alcohol and lens tissue
taking care not to touch lens surfaces. Note: If lens
is the "coated" type use only lens tissue and note on
certificate "Coated lenses - cleaned with lens tissue
only. Solvents may damage coating and should not be
used for cleaning."
98
-------
REVISIONS:
CALIBRATION OF THE SMOKEMETER
NEUTRAL DENSITY FIT/l^RS
TEST PROCEDURE
PROCEDURE NO.
TP-251
PAGEi OF *
8.0 TEST PROCEDURE
After calibration check of the optical bench the lenses are inserted in the
holder and compared by alternately inserting and removing from light path.
Test Sequence Description Data Output
101 Turn on light source, detector and DVM and allow
to warm up for a minimum of two hours.
102 Check to insure light beam is centered using
target inserted in the holder. Turn off all
room lights.
103 Short out DVM and check zero reading. Adjust
if required.
104 Connect DVM to output of photomultiplier and
adjust to approximately 100% transmission with
no filter light in path.
105 Repeat zero check (103.)
106 Check calibration with neutral density filters
having nominal values of clear, 0.15 and 0.4
opacity. Reading should agree within 0.5% of
NBS calibrated value. If any or all readings
are out of specification, optical bench align-
ment must be checked and calibration performed
using all available filter standards.
NBS Traceable Standards
Serial Nominal Actual %
No. Opacity Transmission
Clear 91.54
0.1 80.35
0.15 75.04
0.4 43.88
0.5 29.68
Enter all data on Form Number HD-251.02 Date
Run By
Run No.
I, I,
99
-------
REVISIONS:
CALIBRATION OF THE SMOKEMETER
NEUTRAL DENSITY FILTERS
TEST PROCEDURE
PROCEDURE NO.
TP-251
PAGFJL-OF 6
8.0 TEST PROCEDURE (Continued)
Test Sequence
107
108
109
110
111
112
Description
113
Check filter to be tested for scratches or
other marks and record on Certificate Form
No. HD-251-03.
Insert into holder, out of beam, note light
intensity on DVM and record. When stable,
signal computer (K400) to read for 20 seconds
Insert holder with filter into light beam
and note DVM reading. When stable, signal
computer (K400) to read for 20 seconds.
Record above reading on Data Sheet HD-251-01.
Repeat sequences 108 and 109 twice more.
Computer will calculate percent trans-
mission using the average of the three read-
ings by
I x 100 = % T
% of Opacity = 100 - % T
where I = open beam reading
0 (incident light)
I = filter reading
(transmitted light)
Enter filter number, date of calibration and
% transmission on Form No. HD-251-03. Certi-
ficate signed by Supervisor - Chemical
Analysis Department. Note: Check if filter
has previously assigned serial number and
enter "recalibration" on Form No. HD-251-03.
Data Output
V
No.
Date
% T
100
-------
REVISIONS:
CALIBRATION OF THE SMOKEMETER
NEUTRAL DENSITY FILTERS
TEST PROCEDURE
1 kw 1 1 f\>^ N* b \J Wl\k
PROCEDURE NO.
TP-251
PAfiP 6 OF 6
9.0 DATA INPUT
9.1 Three separate readings of I and lo are made and read by the computer.
10.0 DATA ANALYSIS
11.1 Original certificate (Form No. HD-251-03) kept by Chemical Analysis
Department in file. Copy sent to Certification with filters and copy
of completed work order.
12.0 ACCEPTANCE CRITERIA
12.1 Calibration must agree within 0.5% of NBS value.
12.2 Test filter lo and I readings must agree within ±0.5%.
13.0 QUALITY PROVISIONS
13.1 Neutral density filters used for calibration must be sent to NBS for
recalibration every 6 months.
13.2 Complete calibration check must be repeated if out of specifications
and after optical alignment.
13.3 If readings are not repeated within specified tolerance repeat
calibration and test.
13.4 Data on computer print out and form must agree within 0.2 units. If
they do not agree repeat test after checking alignment of DVM and
computer.
13.5 If filter has been previously calibrated by EPA, compare previous
readings. Normally they should agree within 1% if calibration interval
is not greater than 1 year. If greater than 1%, note on lab order
request.
101
-------
FILTER CALIBRATION
Form No. HD-251-01
Owner
TR-251
Attachment No. 1
Date
Resistor
Filter No.
Run No.
Run 1
Run 2
Run 3
Remarks
lo
lo
lo
Ave.
I
lo
T
lo - Open Beam
I » Sample filter in beam
T * % Transmission
102
-------
BENCH CALIBRATION EPA Form No. HD-251-02 TP-251
Attachment No. 2
Date
lo
lo
lo
Run No. Resistor_
Run By
Clear ND .1 ND .15 ND .4 ND .5 1 2
Round Round
__ __
103
-------
Form No. HD-251-03 TP-251
Attachment No. 3
ENVIRONMENTAL PROTECTION AGENCY
OFFICE OF AIR AND WASTE MANAGEMENT
Certificate of Certification
For Neutral Density
Filter Number
Date of Calibration
N.D.
Transmission ± 1%
This is to certify that the above named filter has been checked and found
to have the transmission value indicated. A procedure prescribed by the
Procedures Development Branch of the Environmental Protection Agency, Office
of Air and Waste Management was used, and is traceable to standard procedures
for photometric measurements as prescribed by the National Bureau of Standards.
Certified by
on this the day of 19_
Owner
104
-------
300
-------
Section 300
VERIFICATION
107
-------
EPA TEST PROCEDURE Num°er Tp-304 Raqe i Qf 5
SUBJECT
CARBON DIOXIDE AND WATER INTERFERENCE
CHECK FOR THE NDIR CARBON MONOXIDE ANALYZER
Reference FEDERAL REGISTER, VOL 38, November 15, 1973, Data Form No.
85.075-23, fa) (7) fiiil
Responsible Organization
CORRELATION AND MAINTENANCE
Test Witness /Review
TEAM LEADER, QUALITY ASSURANCE
icid-m
Computer Program
NONE
Performance Interval
See Below
Type of Test Report Supersedes
INITIAL EQUIPMENT CHECKOUT OR WEEKLY CHECK New
Report Distribution QUALITY ASSURANCE, CORRELATION AND Superseded by
MAINTENANCE, TEST OPERATION
REMARKS/ COMMENTS
1. If the CO-NDIR meets the requirements of 85.075-20 (C) (11) without the
conditioning columns the test is performed to demonstrate conformance to
the criteria when the instrument is first put into service.
2. If the instrument does not meet the above criteria conditioning columns
must be used and checked weekly or as determined by average column life.
ORIGINAL RELEASE APPROVALS
Office Section
Program Mgmt Quality Assurance
Lab Branch Test Operations Chief
Lab Branch Support Oper Chief
Signature
Date
REVISIONS
Change
Letter Description of Change
Approval
Date
109
-------
REVISIONS:
C°2//H2° INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
PROCEDURE NO.
TP-304
PArtF , 2 ,OF 5
1.0 PURPOSE
To establish conformance with the interference requirements of
85.075-20(c)(11) with new instrument trains or to assure the proper operation
of those trains requiring conditioning columns for removal of CO and
water vapor. 2
2.0 TEST ARTICLE DESCRIPTION
The carbon monoxide analyzers are of the non-dispersive infrared type.
Certain instruments available from vendors employ an internal optical
filtering mechanism to eliminate the interference from CO and water vapor.
Instruments that are not free of interference must use sample conditioning
columns consisting of calcium sulfate or indicating silica gel to remove
water vapor and ascarite to remove carbon dioxide.
3.0 REFERENCES
3.1 Federal Register, Vol. 38, Nov 15, 1973 85.075-23(a)(7)(iii)
Federal Register, Vol. 39, No. 101, May 23,1974 85.075-20(c)(11)
4.0 REQUIRED EQUIPMENT
4.1 Gas bubbler, sized for the flow rate used for the interference check.
4.2 Calibration gas, 3 percent carbon dioxide in nitrogen. Make tolerance
on the blend should be within ±5% and the analysis for CO ±2%. When
ordering this blend the concentration of the CO impurity should be
requested not to exceed 1 ppm and/or determined by receiving inspection.
4.3 Zero Air
4.4 Zero Nitrogen
4.5 A portable manifold with selector valves for introducing the above gases
individually, wet and dry.
4.6 A hopcolite filter for removing CO from the zero air to establish a
true instrument zero.
5.0 PRECAUTIONS
5.1 If a glass bubbler is used it should not be subjected to pressure
above 2 PSI.
5.2 The bubbler should be contained or shielded to protect the operator
in case of explosion (i.e., overpressurization or sudden surge in the
glass bubbler).
Ill
-------
REVISIONS'
CO /HO INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
PROCEDURE NO.
TP-304
PAtt» 3 OF 5
5.3 Flow rates axe important and should be closely controlled.
5.4 Extreme care should be taken not to introduce any water droplets or
aerosol into the train or analyzer.
5.5 Leak check the manifold before each use by turning off each cylinder
valve and observing any drop in regulator pressure.
6.0 VISUAL INSPECTION
6.1 Check ascarite and silica gel columns for color change,
contamination, and clogging, etc., indicating need for
replacement.
6.2 Check water level of the bubbler.
7.0 TEST ARTICLE PREPARATION^
7.1 The CO analyzer should be on for at least 2 hours prior to test.
112
-------
REVISIONS:
CO2/H O INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
PROCEDURE NO.
TP-304
PAGE.
.OF
8.0 TEST PROCEDURE
Test Sequence
101
102
103
104
105
106
107
Test Description
108
109
110
111
Zero instrument using zero air passed through
the hopcolite to remove the CO using normal train
flow rate and pressure.
Pass zero nitrogen through instrument to establish
nitrogen zero. Use this reading for all subsequent
nitrogen zeros.
Span instrument on lowest range using same flow
rate as zero flow rate.
Repeat nitrogen zero and span until stability
is reached.
Pass zero nitrogen through water bubbler and
analyzer at same flow rate.
Bypass water bubbler and repeat nitrogen zero
Bypass water bubbler and introduce 3% CO gas
into instrument.
NOTE: If CO impurity in the CO gas is less
that in the nitrogen the reading may be less
than the nitrogen zero deflection.
Repeat nitrogen zero.
Pass 3% CO thru water bubbler into instrument
at same flow rate as the other gases
Repeat nitrogen zero.
Disconnect manifold, turn off cylinders, relieve
regulator pressures.
Data Output
Zero
Zero & CO
Impurity
Span
Deflection
Span
Deflection
Water vapor
deflection
minus N zerc
Zero & CO
Impurity
Dry CO
deflection
Wet CO
Deflection
113
-------
REVISIONS'
CO2/H2O INTERFERENCE CHECK
NDIR-CO
TEST PROCEDURE
1 kw 1 • IX V^ V» fc EX >* IX W
PROCEDURE NO.
TP-304
PAftF ,5 OF 5
9.0 DATA INPUT
9.1 Complete form #304-01
10.0 DATA ANALYSIS
10.1 Instrument response comparison.
11.0 DATA OUTPUT
11.1 Interference levels for CO and H2O vapor.
12.0 ACCEPTANCE CRITERIA
12.1 The wet CO reading on any range above 300 ppm must be less than 1% of
full scale; on ranges below 300 ppm the interference must be less
than 3 ppm.
13.0 QUALITY PROVISIONS
13.1 If the instrument does not meet acceptance criteria initiate corrective
action.
13.2 Repeat the procedure to assure corrective action was successful.
114
-------
C02/H2O INTERFERENCE CHECK
Analyzer Model Serial #
Date Time
1. | | Zero Instrument
2. Nitrogen zero set point
3. Span deflection (repeat 2 times)
4. H2
-------
400
-------
Section 400
CORRELATION
119
-------
EPA TEST PROCEDURE
Number
TP-401
Page
of
SUBJECT
ANALYZER CROSSCHECK
Reference EPA, ANN ARBOR, "PREVENTIVE MAINTENANCE
GUIDELINES. "
Data Form No.
401-01
Responsible Organization
CORRELATION/MAINTENANCE
Test Witness /Review
QUALITY ASSURANCE
CORRELATION/MAINTENANCE LEADER,
Type of Test Report
Computer Program
Performance Interval
DAILY
Report Distribution
QUALITY ASSURANCE, TEST OPERATIONS,CORRELATION & MAINTENANCE
Supersedes
JJEW
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch
Lab Branch
Section
Quality Assurance
Chief
Test Operations Chief
Support Services Chief
Signature
Date
Change
Letter
REVISIONS
Description of Change
Approval
Date
121
-------
REVISIONS-
ANALYZER CROSSCHECK
TEST
PROCEDURE
PROCEDURE NO.
TP-401
PAOF 2 f>F4
1.0 PURPOSE
To assure the correlation of multiple analyzer trains used for exhaust
sample analysis.
2.0 TEST ARTICLE DESCRIPTION
2.1 Gas Analysis System equipped with the following analyzers
2.1.1 Hydrocarbon - flame ionization
2.1.2 Carbon monoxide - non-dispersive infrared
2.1.3 Carbon dioxide - non-dispersive infrared
2.1.4 Oxides of Nitrogen - Chemiluminescence
3.0 REFERENCES
3.1 EPA, Ann Arbor, "Preventive Maintenance Guidelines"
4.0 REQUIRED EQUIPMENT
4.1 Composite bag sample collected from a non-test vehicle or an artificial
blend from span gases.
5.0 PRECAUTIONS
5.1 Sample bag should be leak checked.
5.1.1 (Short method) Fill the bags with background air and draw
through the sample system. If flow indication drops to
zero the bags are good, if not replace bag.
6.0 VISUAL INSPECTION
6.1 Check flow and pressure settings prior to and during bag analysis.
7.0 TEST ARTICLE PREPARATION
7.1 Perform daily start-up on each system to be checked.
7.2 Zero and span each analyzer prior to analysis.
123
-------
REVISIONS:
ANALYZER CROSSCHECK
TEST
PROCEDURE
PROCEDURE NO.
TP-401
PAftF 3 OF 4
8.0 TEST PROCEDURE
The analyzer crosscheck is performed in the following manner.
Test Sequence Test Description
101 Fill a sample bag with enough composite vehicle
exhaust to perform the crosscheck analysis on a
minimum of 4 systems. (Approximately 3.0 cubic
feet.)
102 A representative from Correlation/Maintenance will
carry the sample to the first train to be checked.
103 The analyzer operator will analyze the collected
sample in accordance with the specified analysis
procedure (TP-707).
104 The C/M rep. will collect the analyzer traces and
mark the train number on each trace.
105 The sample is taken to the remaining trains and
steps 103 and 104 are repeated for each.
Data Output
124
-------
REVISIONS:
ANALYZER CROSSCHECK
TEST
PROCEDURE
PROCEDURE NO.
TP-401
PAftF 4,np 4
9.0 DATA INPUT
9.1 Data is transcribed onto data sheet #401-01.
9.2 A complete set of analyzer traces are collected from each train,
including the sample concentration.
10.0 DATA ANALYSIS
10.1 The concentration for each pollutant HC, CO, C0? and NO is computed
from the analyzer traces for each train checked by computer program.
10.2 The concentrations from each train are then compared for any results
outside of repeatable limits.
11.0 DATA OUTPUT
11.1 The average values and percent deviation (if any) of each train.
12.0 ACCEPTANCE CRITERIA
12.1 Results from the crosscheck should repeat by ±3 percent between each
system checked.
13.0 QUALITY PROVISIONS
13.1 If "out of spec" conditions (see 12.1) exist corrective action will
be initiated.
125
-------
FORM NO. 401-01
ZERO/SPAN DATA
ANALYZER CORRELATION DATA SHEET
CALCULATED CONCENTRATION
Date:
Baroireter:
"HG.
X DEVIATION
Train
NO.
9
15
16
19
21
Sas
Type
HC
CO
C02
NOX
HC
CO
C02
NOX
HC
CO
COZ
NOX
HC
CO
C0g_
NOX
HC
CO
C02
NOX
HC
CO
CO 2
NO-
Rge.
NO,
Cone.
Set
Point
.
_ . -
Zero
Gain
— :
Span
Gain
Sample
Deflc
AVERAGE VALUES
HC
.
CO
COz
NOX
HC
• co
C02
NOX
OPERATOR
f
-------
500
-------
Section 500
MAINTENANCE
Currently no procedures are included in this section of the manual.
Procedures pertaining to this section must be supplied by the user
and may be supplied by the EPA in subsequent revisions.
129
-------
600
-------
Section 600
DAILY OPERATION
133
-------
EPA TEST
PROCEDURE
Number
IP-GDI Page i of 4
SUBJECT
OPERATION, MAINTENANCE AND INSTRUMENTATION LOG BOOK ENTRY PROCEDURES
Reference Data Form No.
EPA ANN AP-BnP "PREVENTIVE MAINTENANCE GT1IPET-INFC" L<~>G B™"1? I/"^ Rnnjr^
Responsible Organization Computer Program
CORRELATION/MAINTENANCE, TEST OPERATIONS, INSTRUMENT SERVICES NONE
Test Witness /REVIEW INST. SERVICES LEADER Performance Interval
CORR. & MAINT. LEADER, TESTING, TEAM LEADER DAILY & WHEN NECESSARY
Type of Test Report
LOG BQOK ENTRY
Report Distribution
Q.A., TEST OPERATIONS, CORRELATION MAINT., INST.
REMARKS/ COMMENTS
Office
PROGRAM MGMT
LABORATORY BRANC1
LABORATORY BRANC!
LABORATORY BRANC
Change
Letter
ORIGINAL
Supersedes
NF-W
Superseded by
SERVICES
RELEASE APPROVALS
Section
QUALITY ASSURANCE
[ CHIEF
i TEST OPERATIONS CHIEF
I SUPPORT SERVICES CHIEI
REVISIONS
Description of Change
Signature
Date
Approval
Date
135
-------
REVISIONS:
LOG BOOK ENTRY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TP-601
PAGE_2_OF
1.0 PURPOSE
To record all malfunctions, breakdowns and other items related to the CVS,
Analysis System, and dynamometers that are pertinent in effecting proper
maintenance and repair of each.
2.0 TEST ARTICLE DESCRIPTION
2.1 All test and measurement equipment.
3.0 REFERENCES
3.1 EPA, Ann Arbor, "Preventive Maintenance Guidelines."
4.0 REQUIRED EQUIPMENT
4.1 Log Book.
5.0 PRECUATIONS
5.1 Insure that all entries explain the problems/solutions thoroughly.
6.0 VISUAL INSPECTION
6.1 Log book entries will be checked before each weekly and monthly cali-
bration/check-out period.
7.0 TEST ARTICLE PREPARATION
None required.
137
-------
REVISIONS:
LOG BOOK ENTRY PROCEDURES
TEST PROCEDURE
PROCEDURE NO.
TP-601
PAGE J_OF ±
8.0 TEST PROCEDURE
In order to make clear, concise log book entries the following steps should
be followed.
Test Sequence
101
102
103
104
105
Test Description
Log the date and time of malfunction or repair
and the responsible technician's initial.
Identify the system or individual equipment item.
In clear terminology state the problem encountered
and repair made.
If the log entry is a malfunction or maintenance
description, log time and date that Correlation/
Maintenance or Instrument Services was notified.
Also identify the person notified.
If the entry is a repair item, state all maintenance
performed, and the date and time back on line. The
initials of the person responsible for the main-
tenance or corrective action should be shown.
Data Output
Date, time
Item
Initials of
responsible
party
138
-------
REVISIONS:
LOG BOOK ENTRY PROCEDURES
TEST PROrPHUDF
1 fcO 1 1 I\\M/X*C L/WlxC
PROCEDURE NO.
TP-601
PAriF .4 np 4
9.0 DATA INPUT
9.1 Record all pertinent items in the appropriate Log Book.
10.0 DATA ANALYSIS
10.1 A malfunctioning item can usually be diagnosed and repaired more
efficiently if all aspects of the failure are known.
10.2 Daily readings of pressure and temperature of the CVS should be checked
to assure repeatability from day to day.
11.0 DATA OUTPUT
11.1 Log Book becomes a permanent record of all malfunctions and repair of
equipment.
12.0 ACCEPTANCE CRITERIA
N/A
13.0 QUALITY PROVISIONS
13.1 Entries shall be checked on an audit basis and data compiled
on all malfunctions and repairs.
13.2 Frequency of maintenance actions shall be compiled by checking
the Log Books.
13.3 Audits of the Log Book will also indicate typical maintenance/repairs
of test and measurement equipment.
139
-------
INSTRUMENT SERVICES LOG BOOK
Attachment No. 1
MOIXA.
94075?
8-29-74
10-II-74
/-/ 7-75
12-7-74
12. -9 ' 74
3-r-/r
JO
«/)M>
140
-------
ANALYZER LOG
DATE
INSTRU. TYPE
GAIN
TUNE
MAINTENANCE/REMARKS
OPER.
INITIALS
> (-3
0) (Ti
O o
tn--
(D
3
ft
0
•
to
-------
CVS OPERATION LOG
DATE
£
IN.
PRESS.
OUT.
PRESS.
CVS HOURS
COUNTS :
505
867
505
REMARKS
OPER.
INITIALS
ft »ti
rt I
O
-------
EPA TEST PROCEDURE
Number
TP-602
Page
of
SUBJECT
DRIFT/NOISE/GAIN/TUNE CHECKS
Reference
SEE SECTION 3.0
Data Form No.
ANALYZER OP LOG BK
Responsible Organization
CORRELATION/MAINTENANCE, ANALYZER OPERATION
Test Witness/Review
ANALYZER OPERATOR, TEAM LEADER
Type of Test Report
ANALYZER LOG BOOK ENTRY
Report Distribution
QUALITY ASSURANCE, CORRELATION AND MAINTENANCE
Computer Program
NONE
Performance Interval
DAILY
Supersedes
__NEW.
Superseded by
REMARKS/COMMENTS
ORIGINAL RELEASE APPROVALS
Office
Program Mgmt
Lab Branch
Lab Branch_
Lab Branch
Section
Quality Assurance
Chief
Supp Services Cjiigjf
Test Operations Chief
Signature
Date
Change
Letter
REVISIONS
Description of Change
Approval
Date
143
-------
REVISIONS-
DRIFT/NOISE/GAIN/TUNE CHECKS
TEST PROCEDURE
PROCEDURE NO.
TP-602
PAGE_LOF i.
1.0 PURPOSE
To perform a daily check of the analyzers and recorders used in the
analysis system.
2.0 TEST ARTICLE DESCRIPTION
2.1 An analysis system equipped with the following analyzers.
2.1.1 Hydrocarbons - Flame ionization
2.1.2 Carbon monoxide - NDIR (non-dispersive infrared)
2.1.3 Carbon dioxide - NDIR
2.1.4 Oxides of Nitrogen - Chemiluminescence
2.2 Strip chart recorders
3.0 REFERENCES
• 3.1 EPA, Ann Arbor, Training Manual, "Light Duty Certification
Procedures"
3.2 EPA, Ann Arbor, "Preventive Maintenance Guidelines"
4.0 REQUIRED EQUIPMENT
4.1 "Working" span gases
4.2 Zero air or nitrogen gases
5.0 PRECAUTIONS
5.1 If any discrepant conditions are observed the analyzer operator
shall not attempt any repair or adjustment. The condition shall
be reported to Correlation/Maintenance and/or Instrument Services
for investigation and disposition.
6.0 VISUAL INSPECTION
See Section 8.0
7.0 TEST ARTICLE PREPARATION
7.1 The instruments shall be warmed up to stable operating conditions
(as per individual manufacturer's requirements)
145
-------
REVISIONS:
DRIFT/NOISE/GAIN/TUNE CHECKS
TEST PROCEDURE
PROCEDURE NO.
TP-602
8.0 TEST PROCEDURE
The following steps are to be accomplished to check the efficiency
of the analyzers and recorders.
Test Sequence Test Description
101 Zero drift is checked in the following manner.
A o Introduce zero gas into the analyzer
B o Adjust the analyzer to read zero
millivolts and set the chart
recorder on zero
C o Allow zero gas to flow for approxi-
mately 5 to 10 min.
D o From the strip chart determine the
difference between the highest and
lowest value of the zero trace.
E o Record difference as C
102 Excessive noise is indicated on the chart
recorder by signal spiking.
NOTE: Noise may be caused by the
recorder or the analyzer, therefore the
gain adjustment of the recorder should
be checked.
103 The gain setting should be checked daily
to assure a major shift has not occurred.
Record the analyzer gain setting and check
reading from following day. Record percent
change.
103A If the chart recorder is insensitive or
oversensitive to small changes in input
signals (0.50% of full scale), record
the problem in the log book.
104 If a normal operating span point cannot be
reached, or a negative read-out is indicated
when a span gas is introduced to an analyzer,
record out of tune. Document the type of
response in the log book. (Instrument
Services and/or Correlation will make final
decision to the type of problem encountered)
Data Input
C
Noise
Gain set.,
% change
Recorder
gain
Out of
tune
146
-------
REVISIONS^
i
DRIFT/NOISE/GAIN/TUNE CHECKS
TEST
PROCEDURE
PROCEDURE NO.
TP-602
PAGF 4 OF 4
9.0 DATA INPUT
9.1 Record any drift, noise, gain or tune problems in the Analyzer
log book (attachment A).
10.0 DATA ANALYSIS
10.1 Determine if the problem recorded is an analyzer or recorder
malfunction by comparing historical readings in the analyzer
log book.
10.2 Determine if the problem is of sufficient magnitude to warrant
maintenance.
11.0 DATA OUTPUT
11.1 Enter results in the analyzer log and history file.
12.0 ACCEPTANCE CRITERIA
12.1 Drift should not exceed ±1% of full scale
12.2 Noise should not exceed ±1% of full scale
12.3 Shifts in gain settings should not exceed ±1% in any 24 hour period.
12.4 Compare readings to those in the analyzer log.
13.0 QUALITY CONTROL PROVISIONS
13.1 If problem warrant., maintenance submit a corrective action request.
13.2 Prepare and maintain control charts for future analysis.
147
-------
ANALYZER LOG
DATE
INSTRU. TYPE
00
GAIN
TUNE
MAINTENANCE/REMARKS
OPER.
INITIALS
ft
z
o
-------
700
-------
Section 700
EMISSION TESTING
151
-------
EPA TEST PROCEDURE
Number
TP-750
Page
of
SUBJECT
RECEIPT, BUILD-UP AND INSTALLATION OF THE DIESEL TEST ENGINE
CIRCULAR NO. 22A 4/3/73
Data For*1! No.
Responsible Organization
HEAVY DUTY TEST OPERATIONS
Computer Program
NONE
ORIGINAL RELEASE APPROVAL
Test Witness
HD - TEST SUPERVISOR
Performance Interval
EACH ENGINE
Type of Test Report
CHECK LIST
OPERATIONS - DATA FILE
Supersedes
NEW_
Superseded by
REMARKS/COMMENTS
Office
Lab. Oper.
Test Oper.
HD Testing
"Certification
_Section
Qualitv Assurance^
Chief
Supervisor^
"Heavy Duty
Signature^
Date
Change
Letter
Description of Change
Approval
Date
153
-------
REVISIONS'
RECEIPT, BUILD-UP AND INSTALLATION
OF DIESEL TEST ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-750
PAGE_!_OF
1.0 PURPOSE
Outlines the proper procedure for receiving inspection and proper
installation of engine received for emission testing.
2.0 TEST ARTICLE DESCRIPTION
Heavy duty diesel engines are shipped to the EPA for certification or other
emission tests. These engines are prepared for testing by the Manufacturer
according to the prescribed procedure in MSAPC Advisory Circular No. 22A.
3.0 REFERENCES
3.1 MSAPC Advisory Circular No. 22A dated April 3, 1973.
3.2 Federal Register, paragraphs 85.874-12 and 85.974-12.
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 Small tools and necessary plumbing, thermocouple connectors etc.,
necessary for installation. See Section 8.0 for more detail.
5.0 PRECAUTIONS
5.1 Care should be taken when unloading the engine to place the forks or
other lifting device properly to prevent damage to engine or components
5.2 Engine should not be lifted nor moved by any part of the engine
except by those means provided by the manufacturer, such as bed plate
pallet, engine mounts, etc.
5.3 Never start the engine without first checking all installation
connections and alignment.
6.0 VISUAL INSPECTION
6.1 Receiving - Check engine for proper packaging and unloading require-
ments^After unloading, check for proper shipping documents and
markings. Check for any signs of damage to shipping container and
engine.
6.2 Build-up - Check engine for specified temperature, cooling, fuel,
drive shaft, and- pressure connections.
6 3 installation - Check for proper coolant and oil level, distance from
centerline of shaft to bed plate, engine lag down bolts.
7.0 TEST ARTICLE DESCRIPTION^
See Sections 6.0 and 8.0 for preparation procedures.
155
-------
REVISIONS-
RECEIPT, BUILD-UP AND INSTALLATION
OF DIESEL TEST ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-750
8.0 TEST PROCEDURE
Test Sequence Description Data Output
101 Unload from truck using fork lift. Verify Check Sheet
shipping weight does not exceed lift HD-750-01
capacity.
102 Fill out HD-receipt form. Explain all Receiving
deficiencies. List all parts, number of Inspection
shipping containers, shipping markings, other Form No.
identifying marks and pertinent information. HD-750-02
103 Build-up and Install. Check Sheet
o Thermocouple (s)
o Water Hose (s)
o Drive Shaft
Check adapter plate bolts
o Oil Pressure Line
o Fuel Feed Line and Return Line
o Fuel Pressure Line
o Manifold Pressure Line
104 Check oil level (fill if required), distance Check Sheet
from centerline of shaft to bed plate, engine
lag down bolts.
105 Move engine to test cell and install on the Check Sheet
test bed using the following sequence.
o Prepare engine test bed to receive engine
and pre-aligned stand
o Lift engine onto bed with hoist and bolt
it in place
o Bolt coupling to dynamometer and engine
shaft; connect fuel and coolant systems
using hand tools (refer to appropriate
manufacturer1s requirements for
specifications)
o Install inlet air restriction device to
provide restrictions of ±1" H2O of upper
limits of engine operation which gives
maximum air flow
o Connect thermocouples and pressure gauges
o Check engine for completeness, engine
mounting, and engine alignment
156
-------
REVISIONS:
RECEIPT, BUILD-UP AND INSTALLATION
OF DIESEL TEST ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-750
PAGE
8.0 TEST PROCEDURE (CONTINUED)
Test Sequence Description Data Output
105 o Determine necessary exhaust system
(including muffler) with final
results of:
1. Exhaust back pressure to be within
±0.2"Hg at maximum rates HP
2. Overall length of exhaust pipe to be
15 feet ± 5 feet
3. Final two feet of pipe to be straight
and round and to size specified for
rated BHP
o Fabricate exhaust system and install, making
provisions for probe location
o Install intake airflow measuring system
and leak check same
o Verify compliance maintenance procedures.
106 Engine - Dynamometer check out. After careful
inspection of the installation, the engine is run
to make adjustments.
o Using test cell dynamometer check list Check List
confirm that all the necessary connections HD-750-03
have been made, instruments and equipment
properly installed, and all controls are
properly set prior to engine start up
o Check safety interlock system for proper
installation
o Check throttle no-load, full-load
positioning
o Check oil and water for proper level
o Check operation of system safety interlocks
o Start engine and perform visual, audio, and
functional inspection
Listen for internal noises, such as piston
slap, knocks, taps and gear noises that
indicate irregularities in engine operation
Check for fuel and lubricant leaks, check for
exhaust and crankcase emission leaks
o Bring engine to rated load and speed in gradual
steps
o Use manufacturer's recommended procedure for
adjusting air and exhaust restrictions. Inlet
air restriction should be ± 1" H2O of maximum
specified by manufacturer.
157
-------
REVISIONS-
RECEIPT, BUILD-UP AND INSTALLATION
OF DIESEL TEST ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-750
8.0 TEST PROCEDURE (CONTINUED)
Test Sequence
106
(cont'd)
Description
Data Output
o
o
Exhaust restriction should be ± 0.2" Hg
of upper limit specified by manufacturer BHP
Determine when engine conditions have
stabilized and record BHP and fuel rate
Determine when engine conditions have
stabilized and record BHP and fuel rate Fuel Rate
Lug engine to peak torque speed and
record torque and fuel rate
Check engine performance for compliance
with manufacturer's specifications; if non-
compliance is noted, contact supervisor
Shut down engine and dynamometer systems and
record time and ambient temperature
Fill out request for repairs if necessary
All pretest functions should be completed with
a minimum amount of engine running time
107
Preparation of test engine for return to
Manufacturer
o Disconnect:
Check List
(Form HD-750-04)
o Drive Shaft - Both Ends,
o Engine Stand Lag Down Bolts
o LFE - Diesel, only
o Accessory Stands
o Exhaust System at exhaust manifold only
o All temperature thermocouple wires from
Control Room assembly
o All sample probe lines from engine only
o All fuel, oil, vacuum, manifold, pressure
and feed lines from Control Room assembly
only
o Oil coolant hoses from Coolant package
o Move Engine and Exhaust System
o Diesel Engine (s) to Room 319
o Disconnect
Remove and put in proper place
158
-------
REVISIONS:
RECEIPT, BUILD-UP AND INSTALLATION
fjp nTP.QF.T, TR^T KNari^ES
TEST PROCEDURE
PROCEDURE NO.
TP-750
PAGE^-OF JL_
8.0 TEST PROCEDURES (continued)
Test Sequence Description Data Output
107 o All thermocouples, wires and fitting
(cont'd) (if installed by E.P.A.)
o Water Hoses
o Drive Shaft
o All fuel, oil, vacuum, manifold, pressure
and feed lines and fittings
o Drain
o Follow manufacturer's recommended
procedure for draining coolant
Drain oil if necessary
o Re-Install
o Exhaust System and all other engine
parts and accessories received
NOTE: Check HD Receiving form to assure
shipment is complete as received
108 Complete Shipping Order No. HD-750-05
9.0 DATA INPUT
9.1 Check sheets validated by supervisor and place into test file.
10.0 DATA ANALYSIS
None
11.0 DATA OUTPUT
None
12.0 ACCEPTANCE CRITERIA
12.1 Engine as received must conform to specifications outline in MSAPC
Advisory Circular No. 22A (4-3-73) .
12.2 inlet and outlet restrictions must conform to specifications noted in
test procedure.
12.3 Engine must conform to manufacturer's specifications.
12.4 Engine must not exhibit any malfunctions such as oil leaks, engine
noise, erratic running or overheating.
159
-------
REVISIONS:
RECEIPT, BUILD-UP AND INSTALLATION
OF DIESEL TEST ENGINES
TEST PROCEDURE
1 kW 1 1 IXV^^»W*XWIXW
PROCEDURE NO.
TP-750
DAftP 7 OF 7
13.0 QUALITY PROVISIONS
13.1 Engine returned to manufacturer if all specifications not met.
13.2 Engine installation approved by supervisor and certification
engineer.
13.3 Data validation inspects check lists for discrepancies and
completeness.
13.4 Discrepancies noted during receiving inspection reported to
supervisor and quality assurance.
160
-------
TP-750
Attachment No. 1
Check List Receipt, Build-up and
Installation Diesel Test Engine
Description Oper. Init.
Unload from truck
Visual Inspection: Fill out HD-receipt form
Explain all deficiencies
Description List a11 parts
Build-up and Install; Temperature Thermocouple (s)
Water Hose (s)
Drive Shaft (check adaptor plate
bolts)
Oil Pressure Line
Fuel Feed Line
Fuel Pressure Line
Fuel Solenoid Line
Manifold Pressure Line
Check; Oil Level (fill if required)
Distance C/L shaft to bed plate
Engine Lag Down Bolts
Move to test cell; Center engine stand on
bed plate and lag down
Connect; Temperature Thermocouple (s)
Water Hoses
Drive Shaft
Oil Pressure Line
Fuel Feed Line
Fuel Pressure Line
Manifold Pressure Line
Fuel Solenoid
Accelerator Actuator
Exhaust System
Exhaust Sample Probes
Restrictor Valves
Air Cleaner
Sample Probes
Smoke Metering Equipment
Form HD-750-01
161
-------
Date
Engine C.I.D.
Test Type
# Pieces
Description
Condition
Received by
TP-750
Attachment No. 2
Manufacturer
Engine I.D.f
Cert.
Dura.
Correl.
Other
Test Date
HC
CO
NO
Test #
EPA
Manufacturer's Rep. Signature_
Certification Rep. Signature_
Returned Date
EPA
Accel.
Lug
Form HD-750-02 - Receiving Inspection Report
162
-------
TP-750
Attachment No.
Check List Test Cell 1 and 2
Diesel Engine Dynamometer Operation
Check: Water Cooler Package; Oper. Init.
Water ON_
Expansion Tank - 2/3 to 3/4 full
Pump ON
Smoke Meter Assembly:
Compressed Air - ON
Calibration
Positioning - 1 to 1 1/2 dia. to top of exhaust
stack
Control Boom Assembly;
Manifold Pressure Line - Installed
Fuel Pressure Line - Installed
Fuel Feed Line - Installed
Oil Pressure Line - Installed
Temperature Thermocouple(s) - Installed
Fuel Solenoid Wiring - Connected
Dynamometers;
Drive Shaft - Connected
Drive Shaft Guard - Connected
Engine
Water Hoses - Connected
Exhaust System - Connected
Fuel Regulator - Correct Setting
Exhaust Sample Probes - Connected
Air Cleaner - Connected
Exhaust Restrictor - Connected
Inlet Air Restrictor - Connected
L»F.E. Connected
Console
All Potentiometers in OFF position Power ON in M.G. Room_
M G set - ON- 10 min. warm-up min. Primary Power - ON _
Manometers calibrated Fuel Solenoid - ON _
Rotation - correct for engine Temp. Recorder - ON _
inertia - correct position (±) Wet Bulb thermo-filled
Mode - Manual or tape and power ON^ _
Strip chart recorder - ON Fuel Conditioner- ON _
Form HD-750-03
163
-------
TP-750
Attachment No. 4.
Check List - Preparation of Test
Engine for Return to Mfr.
Description Oper. Init.
Disconnect; Drive Shaft - Both Ends.
Engine Stand Lag Down Bolts.
L.F.E. - Diesel, only.
Accessory Stands.
Water Hoses from Coolant package.
Exhaust System at Exhaust manifold only.
All Temp, thermocouple wires from Control
Boom Assembly.
All sample probe lines from engine only.
All fuel, oil, vacuum, manifold, pressure, and
feed lines from Control Boom Assembly only.
Oil coolant hoses from Coolant package.
Move Engine and Exhaust System
Diesel Engine(s) to Room 319.
Disconnect, Remove and put in proper place:
All Thermocouples, wires and fittings
(if installed by E.P.A.)
Water Hoses
Drive Shaft
All fuel, oil, vacuum, manifold, pressure and
feed lines and fittings,
Coolant complete; oil (if required).
All pipe plugs, cap plugs and other fittings
removed by E.P.A,
Exhaust System and all other engine
Pack in Box; parts and accessories received.
Strap to Skid;
Note: Check HD Rec. form to assure shipment is
complete as received.
Form HD-750-04
164
-------
TP-750
Attachment NO. 5
Environmental Protection Agency
Office of Air & Water Programs
2565 Plymouth Road
Ann Arbor, Michigan 48105
SHIPPING ORDER
No.
Date
Ship To : Charge To:
Address : Address :
Attention: Attention:
The following listed material/equipment/engine(s) now on consigment/loan to
this facility is herewith returned per signature of your carrier (or, common
carrier, if applicable.)
Quantity Description Ser. No.
The above items were received by_
(Signature)
on . .
(Date)
Form HD-750-05
165
-------
EPA TEST PROCEDURE
Number
TP-751
Page
Of 7
SUBJECT
SMOKE MEASUREMENT TEST - HEAVY DUTY DIESEL ENGINE
Reference FEDERAL REGISTER NOVEMBER 15, 1972, PART 85
Data Form No.
751-01
Responsible Organization
HEAVY DUTY TESTING/CERTIFICATION
Witness
HD SUPERVISOR
Computer Program
Performance Interval
EACH SMOKE TEST
Type of Test Report DATA VALIDATION - CERTIFICATION
LABORATORY OPERATION - DATA FILE
Report Distribution
Supersedes
NONE
Superseded by
NONE
REMARKS/COMMENTS
Office
Oper.
>t Ope:
HP Testing
Change
Letter
ORIGINAL RELEASE APPROVALS
Section
Quality Assurance
Chief
Supervisor
Signature
Date
REVISIONS
Description of Change
Approval
Date
167
-------
REVISIONS:
SMOKE MEASUREMENT TEST -
HEAVY DUTY DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-751
PAftF2 OF 7
1.0 PURPOSE
To measure the opacity of the full smoke plume of a diesel engine during
certain prescribed operating modes.
2.0 TEST ARTICLE DESCRIPTION
Applicable to new diesel heavy duty engines beginning with the 1974 model
year. A heavy duty engine is defined as any engine which the engine
manufacturer could reasonably expect to be used for motive power in a
heavy duty vehicle.
3.0 REFERENCES
3.1 Federal Register, Vol. 37, November 15, 1972, Part 85 Subpart I,
Paragraphs 85.802 thru 85.874-18.
3.2 "Diesel Engine Smoke Measurement", SAE Information Report, J255,
June 1971.
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 Engine dynamometer with adequate characteristics to perform the
test cycle according to 85.874-11.
4.2 Smoke Meter - full flow opacity meeting specifications of 85.874-13.
4.3 Recorders for temperature, engine RPM, torque, smoke opacity, and
throttle position.
4.4 Opacity filters for calibration of the smoke meter.
5.0 PRECAUTIONS
5.1 Do not mount the optical unit on the engine exhaust pipe rigidly.
Engine vibration can shake the lamp filament which may register as
"noise" on the recorder.
5.2 Shock mount the photo cell, solder all electrical connections,
and strengthen mechanical parts.
5.3 Power Supply - Adjustable but constant voltage supply.
5.4 Air Supply - Bottled nitrogen or air or "house" air supply, properly
filtered and dried may be used. The compressed air supply must be free
of oil, water and dirt, any of which may obscure light and introduce
error in the readings.
169
-------
REVISIONS:
SMOKE MEASUREMENT TEST -
HEAVY DUTY DIESEL ENGINES
TEST PROCEDURE
1 bw 1 i I\N^X»S IXWlXb
PROCEDURE NO.
TP-751
PAftp3 OF 7
5.0 PRECAUTIONS (continued)
5.5 Chart response characteristics can affect the reading obtained. The
Federal Register (see 3.1) specifies recorder response for certification
testing. This is especially important for transient smoke tests, and it
should be established that the read out instrumentation used has the
proper response for transient work. The optical system of the opacimeter
is extremely fast and, with suitable recorders (light beam type or an
oscilloscope) the smoke puffs from individual cylinders may be observed.
5.6 The open stack, a relatively critical location for the optical unit, and
the need to calibrate on clean air are features not particularly well
suited to laboratory engine testing. Hoods or funnels have been used
successfully, but the particular exhaust gas disposal system must be
considered when this smokemeter is used. The smoke ventilation
system should not influence the shape of the exhaust plume. Exhaust
noise and room ventilation also must be considered when testing
indoors.
6.0 VISUALINSPECTION
6.1 Inspect all electrical and air supply hook-ups for proper connection.
6.2 Check for burned but lamp in smokemeter.
6.3 Check all measuring devices for hook-up to correct read out devices.
6.4 Check ink supply and chart paper on all recorders.
7.0 TEST ARTICLE PREPARATION
7.1 Check operation of engine throttle control to insure WOT confonnance
with acceleration phases of smoke test.
7.2 Run engine to determine by experimentation the inertia and dynamometer
load required to perform the acceleration phases of the smoke emission
cycle.
7.3 The test is performed on a warm engine, preconditioned for 10 minutes
at maximum rated horsepower.
170
-------
REVISIONS:
SMOKE MEASUREMENT TEST -
HEAVY DUTY DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-751
PAGE.1.OF 7
8.0 TEST PROCEDURE
The test consists of a prescribed sequence of engine operating conditions
on an engine dynamometer with continuous examination of the exhaust smoke
opacity.
Test Sequence Description Data Output
101 Move proper equipment into test cell.
102 Make all necessary electrical connections to
record smoke opacity, engine speed, engine
torque, and throttle position.
103 Hook up air supply to smoke head and adjust.
1. Optical centerline 5 ±1" from pipe outlet.
2. Optical centerline at right angles to
exhaust plume.
104 Turn on power to control unit of smokemeter
and allow minimum of 15 minutes for
stabilization.
105 Turn on power to recorder and allow sufficient
time for specified warm up.
106 Clean lenses in smoke head if necessary. Instrument
Log Entry
107 Turn on purge air to smoke head.
108 Turn on chart recorder after checking paper
supply and inking pens operation.
109 Set zero and 100 percent opacity on smoke
channel. Resolution to be within 1 percent
opacity.
Insert neutral density filters (nominal 10, 20
and 40 percent opacity) in light path on smokemeter
(same side as light source). Verify that recorded
values on the chart are within 1 percent of the
filter value as determined by EPA.
Contact instrument repairman and/or supervisor Maintenance
if desired calibration is not possible Log Entry
171
-------
REVISIONS:
SMOKE MEASUREMENT TEST -
HEAVY DUTY DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-751
8.0 TEST PROCEDURE (Continued)
Test Sequence
112
Description
113
114
115
116
117
118
119
120
121
122
Bring engine to rated speed and load. Adjust
inlet and exhaust restriction per manufacturer's
instructions (if required). Record the
following:
BHP
Fuel rate
Inlet restriction
Exhaust back pressure
Ambient air temperature
Intake air temperature (within 68 to 86 )
Humidity and barometric pressure
Lug engine to peak torque speed, record fuel
rates and torque.
Remove all dyno load and allow engine to run at
maximum governed RPM. Record that RPM.
Reduce speed to low idle.
Set zero and 100 percent on the smokemeter
recorder with smoke head away from smoke plume.
Insert neutral density filters (nominal 10, 20,
and 40 percent). The recorded values must fall
within ±1 percent of EPA established values.
Recheck calibration of speed and torque for
preconditioning.
Remove all dyno load and bring engine to low
idle. This represents start of first smoke
cycle.
Operate engine at low idle for 5 to 5.5 minutes.
Center smokemeter head over exhaust plume during
low idle.
Increase recorder chart speed to a minimum of
6" per minute at end of low idle period.
Increase engine speed to 200 ±50 RPM above low
idle within 3 seconds.
Data Output
HD-751-01
BHP
Ibs/min
"HO
F
"Hg
Ibs/min
Torque
RPM
Record
Smoke, RPM
Torque
172
-------
REVISIONS:
SMOKE MEASUREMENT TEST -
HEAVY DUTY DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-751
PAGE.S OF 1 .
8.0 TEST PROCEDURE (Continued)
Test Sequence
123
124
125
126
127
128
129
130
131
132
Description
Data Output
Accelerate engine at full throttle against
dynamometer load selected earlier so that
engine speed reaches 85 to 90 percent of rated
speed within 5.0 ±1.5 seconds. Acceleration
to be linear within ± 100 RPM.
Move throttle rapidly to closed position and
apply preselected load.
Observe RPM drop. Apply full throttle so that
engine speed reaches 60 percent of rated speed
or peak torque speed (whichever is higher)
within ± 50 RPM.
Allow engine to accelerate for 10 ±2 seconds
during which the engine speed must reach
95 percent of rated RPM.
Stabilize engine at maximum rated HP under
full throttle.
Increase dyno load to lug engine to peak
torque speed or 60 percent rated RPM (which-
ever is higher) within 35 ±5 seconds. Lug ^
phase to be linear within ±100 RPM.
Remove dyno load and reduce speed to low idle.
(Completion of One Test Cycle)
Run two additional test cycles.
Shut engine down; reduce recorder speed.
Check smokemeter calibration.
Repeat test if zero drift is greater than ±2 percent.
Reset zero if drift is less than ±2 percent.
Check 100 percent and insert neutral density filters
Repeat test if recorded values deviate by more
than ±2 percent of actual values.
173
-------
REVISIONS:
SMOKE MEASUREMENT TEST -
HEAVY DUTY DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-751
PAftF 7 OF 7
9.0 DATA INPUT
9.1 Data is recorded on Form No. HD-751-01.
10.0 DATA ANALYSIS
10.1 Verify that calibration of the smoke meter was properly performed.
10.2 Data validation verifies that all records are complete and within
specified tolerances.
11.0 DATA OUTPUT
11.1 Recorded data and information are stored in the data files.
11.2 Final copies of data go to certification and to the manufacturer's
representative.
12.0 ACCEPTANCE CRITERIA
12.1 Smokemeter calibrations must repeat within ±2 percent of zero and full
scale.
12.2 Inlet air must be within 68-86 F.
12.3 Cycle must be accomplished within the speed, time and torque specifica-
tions for the engine as outlined in the Test Procedure.
13.0 QUALITY CONTROL PROVISIONS
13.1 Test must be repeated if specifications are not met.
13.2 Quality Assurance performs equipment and data audits periodically to
determine adherence to proper procedure and instrument calibrations.
174
-------
HEAVY DUTY DIESEL ENGINE TEST DATA SHEET
ENSINE IDENTIFICATION NO.
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METER DEFLECTIONS
HC R CO R CO2 R NO R HOX R O2
TORQUE BAHO TDB TWB
FLOWMETEA Ml
n DR HP
FLOWMETER {21
Tl DPI flP
t I I t 1.
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' I I I i
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Form No. HD-751-01
175
-------
CARD CODES
CARD 1
MANUF. CODE (COL. 1-3)
CODE EQUIVALENCE
31 FORD MOTOR CO.
U6 G.M. (G.M.C.)
1*7 G.M. (DETROIT DIESEL)
95 A.M. GENERAL
200 MERCEDES-BENZ
250 HINC
270 IHC
290 isuzy
380 NISSAN
kSQ MITSUBISHI
600 AB VOLVO
720 WINEBAGO
725 ALLIS-CHALMERS
730 CATERPILLAR
7^0 CUMMINS
750 HERCULES
760 MACK
770 PERKINS
780 SCANIA-VABIS
800 TELEDYNE CONT.
810 CASE
820 DIAMOND RED
SOURCE CODE (COL. 60-61)
CODE EQUIVALENCE
1 MANUFACTURER
\k DEALER
15 EPA
16 GSA
17 MILITARY
18 PRIVATE OWNER
19 OTHER
ROTATION (COL. 62)
CODE EQUIVALENCE
1 CLOCKWISE
2 COUNTERCLOCKWISE
3 N/A
CRANKCASE (COL. 63)
CODE EQUIVALENCE
1 CLOSED
2 OTHER
ENGINE ID (COL. 14-19)- LEFT JUSTIFIED
ENGINE FAMILY (COL.20-31)- LEFT JUSTIFIED
DATE BUILT (COL.32-37)- MO-DAY-YR
EXHAUST PIPE DIAMETER - MEASURED IN INCHES
(COL.^7-^9)
MODEL YEAR (COL .5*4-55)- MODEL YEAR OF ENGINE
TEST YEAR (COL.56-57)- TEST YEAR PROCEDURE
FUEL TYPE (COL.
CODE EQUIVALENCE
1 TYPE 1-D
2 TYPE 2-D
INJ.
CODE
!
2
3
TYPE (COL.
EQUIVALENCE
DIRECT
INDIRECT
OTHER
6k)
65)
SMOKE TEST TYPE (COL.58-59)
CODE EQUIVALENCE
VOID
CERTIFICATION
DURABILITY
CORR. (CERT)
SURVEILLANCE
EXPERIMENTAL
FIELD SURV.
PARTICULATES
OTHER
CVS CORRELATION
RESEARCH
CORR. (LAB)
0
I
2
3
k
5
6
7
8
9
10
11
12
13
EXHAUST EMIS. CONTROL SYS (COL. 66)
CODE EQUIVALENCE
1 ANEROID
2
3 N/A
AIR ASPIRATION (COL. 67)
CODE EQUIVALENCE
1 NATURAL
2 TURBOCHARGED
3 SUPERCHARGED
k TURBOSUPERCHARGED
5 TURBOSUPERCHARGED AFTERCOOLED
6 OTHER
GASEOUS TEST TYPE (COL. 68-69)
(SAME AS SMOKE TEST TYPE CODING)
GOVERNEDNSPD?R(COL.38-M)- NO-LOAD GOVERNED SPEED (HIGH IDLE RPM)
INPUT ;«;; KM* RJ|L ;| MEASURED, IN LBJ/MIN
OPERAT.OJ CODE ^^ ? ^
\ - SMOKE TEST ONLY (FIRST 10 CARDS)
2 - GASEOUS TEST ONLY (CARDS 1-7 AND 11-23)
3 = ALL TESTS (ALL 23 CARDS)
FIRST LAMINAR FLOW METER UNIT NO
SECOND LAMINAR FLOW METER UNIT NO.
CCOL.«)
OPCODE (COL.W)
AFd) (COL 1+7)
AF(2) (COL 48)
176
-------
EPA TEST PROCEDURE
Number
TP-752
Page _i
of 6
SUBJECT
MEASUREMENT OF INTAKE AIR FLOW OF DIESEL ENGINE
DED PRACTICE - J244
Responsible Organization
TEST OPERATIONS - HEAVY DUTY
Test Witness
SUPERVISOR - HEAVY DUTY
Type of Test Report
Report Distribution
Computer Program
Performance Interval
EACH TEST
Supersedes
__NE_W
Superseded by
REMARKS/COMMENTS
Office
Lab. Oper.
Test Oper.
HD Testing
Certification
Change
Letter
ORIGINAL RELEASE APPROVALS
Section
_Quality Assurance
Chief
Supervisor
Heavy Duty
Signature
Date
REVISIONS
Description of Change
Approval
Date
177
-------
REVISIONS:
MEASUREMENT OF INTAKE AIR
FLOW OF DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-752
PAGE_1_OF JL_
1.0 PURPOSE
To determine the air flow of the diesel engine in pounds per minute or
kilograms per minute during the gaseous emissions measurement procedures.
2.0 TEST ARTICLE DESCRIPTION
Diesel engine mounted on dynamometer test stand.
3.0 REFERENCES
3.1 SAE recommended practices J-244 - measurement of intake air or exhaust
gas flow of diesel engines.
3.2 Instruction Manual - the Meriam Laminar Flow Meter Model 50 MC2.
4.0 REQUIRED EQUIPMENT/CONDTIONS
4.1 Filter - as required by flowmeter.
4.2 Laminar Flow Meter - Model No.
50 MC2 - 4F
50 MC2 - 6SF
50 MC2 - 8F
as required by engine flow.
4.3 Restriction valve to control engine inlet air pressure.
4.4 Chamber connection to engine which allows use of engine air filter
with tight seal to engine intake air assembly.
4.5 Pressure Sensor - Manometer for measurement of inlet air pressure.
4.6 Temperature sensor for measurement of inlet air temperature.
4.7 incline manometer for manual reading of A P across flow element.
Transducers for measuring A? for computer input.
5.0 PRECAUTIONS^
5 1 For minimum pulsation effect on the inclined manometer for measuring
AP the lines should be made of soft tubing, equal length, and equal
diameter, and isolated from other lines when reading AP.
5 2 Filters must be replaced as recommended by meter manufacturers or when
the total pressure loss through the intake system exceeds the test
requirements.
179
-------
REVISIONS:
MEASUREMENT OF INTAKE AIR
FLOW OF DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-752
PAGE-i__OF .fi —
5.3 Laminar flow elements should not be disassembled for cleaning.
Periodic cleaning and calibration by the manufacturer is recommended.
5.4 The engine must be examined and modified as required to assure that all
measured air and no unmeasured air enters the combustion chamber.
5.5 The differential pressure tubing must be clear of all liquids and all
connections must be absolutely leak free. If the manometer water is
accidentally sucked into the lines, they must be thoroughly cleaned.
5.6 It is recommended that manometer reading of AP in the lower 10 percent
of scale be avoided.
6.0 VISUAL INSPECTION
6.1 Check installation for possible areas of leakage - assure tight
connection at intersecting parts.
6.2 Check air filter for dust accumulation.
6.3 Check for proper connection of temperature and pressure devices.
7.0 TEST ARTICLE PREPARATION
Refer to procedure for receipt, build up and installation of diesel test
engines.
180
-------
REVISIONS:
MEASUREMENT OF INTAKE AIR
FLOW OF DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-752
PAGEJL-OF £__
8.0 TEST PROCEUDRE
The proper air flow element sized for the particular diesel engine being
tested is connected to the engine.
Test Sequence
loi
Test Description
Data Output
Test for air-tightness of the air metering system -
care must be exercised to prevent unmetered air
from entering the engine. Even small leaks result
in substantial errors when the flow rates are in
the range of 50-500 Ib/hr.
o Cap both ends of the assembly and pressurize
the system to approximately 12 inches HO
air pressure. Shut off the air supply, let
the pressure drop to 6 inches HO, and record
the time to drop to this pressure.
Time
(seconds)
Calculate the leakage with the following
formula:
m = 0.00038 AP Vol
TI
where
mr = Ib/hr
L
Vol = total volume, inches
p = pressure differential, inches HO
TI = time for pressure to change
o Acceptable leakage rate for this procedure is
0.5 percent of lowest flow rate to be measured
during the test.
o If vacuum check is desired simply evacuate the
assembly to a -12 inches HO. Use same formula
for calculations.
102
103
Level the inclined manometer.
Zero the meniscus. The meniscus may be zeroed during
running by venting to atmosphere.
181
-------
REVISIONS:
MEASUREMENT OF INTAKE AIR
FLOW OF DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-752
PAGE JL-OF £
Test Sequence
104
105
106
107
Test Description
The pressure differential is measured directly
using an inclined manometer graduated to permit
accuracy of 0.5 percent of the smallest AP to
be measured. The AP may be read in inches of
water or directly in flow units.
Read A P when engine has reached equilibrium
and record.
At same time as AP is measured record temp-
eratur'e, barometer, humidity, fuel flow rates,
engine speed, and torque, air system pressures
and temperature.
Calculate mass flow at each engine operation
using the calibration curve supplied by the
manufacturer.
Data Output
AP in HO
Data Sheet
Entry
182
-------
REVISIONS:
MEASUREMENT OF INTAKE AIR
FLOW OF DIESEL ENGINES
TEST PROCEDURE
PROCEDURE NO.
TP-752
PAfiF 6 OF 6
9.0 DATA INPUT
Record all ambient conditions and required flow measurement data on heavy
duty diesel engine test data sheet. (HD-751-01)
10.0 DATA ANALYSIS
10.1 Check for obvious discrepancies in data entries from one mode to the
next.
10.2 Verify all ambient conditions are within specifications (68-86 F and
28.5-31.0 inches Hg.)
10.3 Compare flow rates with manufacturer's data and previous runs on
engine.
11.0 DATA OUTPUT
11.1 The data is combined with other test data to calculate the emissions
and stored in data files.
11.2 Data on certified engines sent to Certification.
12.0 ACCEPTANCE CRITERIA
12.1 Acceptance criteria are specified in test procedure.
13.0 QUALITY PROVISIONS
13.1 Leak check of air measurement system is performed and any leaks found
are corrected.
13.2 Pressure transducer checked each test against incline manometer before
and after 13 mode cycle. Change in transducer calibration may
invalidate test or required manual reduction of data if inclined
manometer is used.
183
-------
EPA TEST PROCEDURE
=-753
Page
of 10
SUBJECT
DIESEL ENGINE EMISSION MEASUREMENT PROCEDURE
CARBON MONOXIDE (CO), NITRIC OXIDE (NO) AND OXYGEN (02)
Reference
FEDERAL REGISTER, VOLUME 37, NOVEMBER 15, 1972
Data Form No.
HD-751-01
Responsible Organization
TEST OPERATIONS - HEAVY DUTY
Computer Program
Test Witness
SUPERVISOR - HEAVY DUTY TESTING
Performance Interval
EACH TEST
Type of Test Report
DATA SHEET, PUNCH CARD - COMPUTER PRINT OUT
Report Distribution
ATA VALIDATION - D
DA
DATA FILE - CERTIFICATION
Supersedes
NEW __
Superseded by
REMARKS/ COMMENTS
Office
Lab. Oper.
Test Oper.
HD Testing
ORIGINAL RELEASE APPROVALS
Section
Quality Assurance
Chief
Supervisor
Signature
Date
Change
Letter
REVISIONS
Description of Change
Approval
Date
185
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND O
TEST PROCEDURE
PROCEDURE NO.
TP-753
PAftF2 OF 10,
1.0 PURPOSE
To determine the brake specific mass emissions of carbon monoxide (CO) and
nitrogen oxides (NO ) from heavy duty diesel engines when operated through
the prescribed cycle which spans the typical operating range of diesel
engines.
2.0 TEST ARTICLE DESCRIPTION
Heavy duty diesel engine - any compression ignition internal combustion
engine which the engine manufacturer could reasonably expect to be used for
motive power in a heavy duty vehicle.
3.0 REFERENCES
3.1 Federal Register, Title 40 Part 85, Paragraph 85.974-1 thru 85.974-18
November 15, 1972 and subsequent revisions.
3.2 SAE Recommended Pratices J177, Measurement of Carbon Dioxide, Carbon
Monoxide and Oxides of Nitrogen in Diesel Exhaust, March 1971.
3.3 SAE Recommended Practices J1003 - Diesel Engine Emission Measurement
Procedure - March 1973.
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 Instrumentation shall be provided to measure the following engine
operating data:
(a) Engine speed: RPM
(b) Torque: Ft-lbs
(c) Mass Fuel Consumption: Ib/min (Kg/min)
o Flotron or
o Cox Instrument (dead weight)
(d) Observed barometer: inches Hg (Pa)
o Bell and Howell Digital Model 4-461-002
(e) Water vapor pressure: inches Hg (Pa)
o Wet Bulb and Dry Bulb Hygrometer
(f) Intake air restriction: in. water
(g) Exhaust back pressure: in Hg (Pa)
(h) Intake air temperature °F (k) Q
(i) Fuel temperature at pump inlet F (k)
4.2 Recorders as required for above listed instruments and for the
analytical instruments.
4.3 Digital volt meter for measuring instrument output.
4.4 General Electric Direct Current Dynamometer, 600 hp, Model 426408AD
equipped with Unisystems, Inc. controls and cooling system.
187
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND O^
TEST PROCEDURE
PROCEDURE NO.
TP-753
PAGF3. OF 10
4.5 Analytical console for continuous and simultaneous analysis of CO, NO
and O . The console will be equipped with appropriate flowmeters,
condenser valves, filters and pumps as prescribed in SAE J177 and EPA
sample console design No. . The console is to consist of the
following instruments.
(a) MSA-NDIR Model 200 FR for measurement of CO with
the following ranges 2.5 percent, 1,000 PPM, 5,000 PPM.
(b) MSA-NDIR Model 202 for measurement of NO with the
following ranges 1,500 PPM, 6,000 PPM.
(c) Beckman Model 778 Polorgraphic Oxygen Analyzer
0.5 percent and 0-25 percent.
4.6 Calibration (span gases) for routine check of the instrument response,
5.0 PRECAUTIONS
5.1 Allow 2 hour minimum warm-up of analyzers.
5.2 The chemical kinetics of combustion reactions highly favor the formation
of NO over NO2. The NO formed does convert to NO2 in the presence of
oxygen, with the degree of conversion being related to time and the Q^
concentration in the sample. In order to decrease this conversion
sample, transport time to the analyzer should be kept to a minimum. In
addition parallel check with a CHEMI instrument equipped with a con-
verter can be used to determine the percent conversion of NO to NO2.
.3 Nitric oxide calibration gases used with NDIR-NO instrument should be
analyzed for NO and NO2 separately.
at a minimum (less than 10 PPM.)
NO contamination should be kept
5.4 Regulators used for NO gases should be of stainless steel and teflon
construction. In-board leakage of air (O2) can cause problems of
conversion to NO2 in the regulator. Regulators and associated plumbing
must be carefully leak checked and well purged when calibrating.
5 5 Carbon Monoxide gas mixtures may change with age, especially the lower
concentration. The span gas should be checked each time a curve check
is performed.
5 6 Exhaust from diesel engines contains a greater amount of particulate
than gasoline engines consequently the frequent cleaning of sample
lines is recommended. Use of a prefilter near the sample inlet can
reduce the contamination problem, if the prefilter is changed after
each test.
188
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND 02
TEST PROCEDURE
PROCEDURE NO.
TP-753
f»AGE_J_OF 10
6.0 VISUAL INSPECTION
6.1 Check all connections to the analytical console to insure secure
connection of sample line, gas mixtures and electrical lines.
6.2 Check all valve positions before start-up for proper position.
6.3 Check all electrical switches for proper position before start-up
instrument checks.
6.4 Insure cooling and fuel systems are operational.
7.0 TEST ARTICLE PREPARATION
7.1 The governor and fuel system should be adjusted to provide engine
performance at the levels specified by the engine manufacturer for
maximum rated horsepower and maximum rated torque.
7.2 Install instrumentation and sample probes as required.
7.3 Conduct the test on a warm engine. Start the engine, warm it up by
running it at rated speed and maximum horsepower for 10 minutes or until
all temperatures and pressures have reached equilibrium.
7.4 Determine the maximum torque at rated speed and intermediate speed to
calculate the torque values for the specified test modes. Intermediate
speed is 60 percent of rated speed or 1800 RPM, whichever is higher.
7.5 Install and check air flow measurement system according to procedure
No. TP-752.
189
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND C>2
TEST PROCEDURE
PROCEDURE NO.
TP-753
PAGE_5_OF J.o_
8.0 TEST PROCEDURE
The diesel emissions are measured at steady-state conditions during the
prescribed 13 mode cycle.
Test Sequence Test Description Data Output
Pretest System Preparation
101 o Verify appropriate zero and span gases
of appropriate concentrations and quantities
are available.
102 o Warm up instrumentation.
103 o Check sample probes and lines and clean/replace
as required.
104 o Verify appropriate probe length and location.
105 o Leak check entire sample system (before and
after test.)
106 o Clean/replace filter/filter elements as
necessary.
107 o Drain water from sample line traps in
refrigerated bath.
108 o Install driers and condition as required.
109 o Load recorder and verify functional
operation.
110 o Complete functional check out of
instrumentation system.
HI o Adjust zero gas flow rate and zero
analyzer and readout device.
112 o Adjust span gas flow rate, span analyzer
and readout device (use calibration curve
if required.)
113 o If gain has changed by more than 3 percent Maintenance
locate and correct problem. Log Entry
114 Adjust sample flow rates as applicable.
190
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND O
TEST PROCEDURE
PROCEDURE NO.
TP-753
PAGE_!_OF 10_
8.0 TEST: PROCEDURE (continued)
Test Sequence
115
116
Test Description
Data Output
o Recheck zero and span and check agreement
between primary output device (computer)
and strip chart.
Diesel Gaseous Emission Cycle
The following 13 mode cycle shall be followed
in dynamometer operation of heavy duty diesel
engines:
Mode No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Engine Speed
Low idle
Intermediate
do
do
do
do
Low idle
Rated
do
do
do
do
Low Idle
Percent Load
0
2
25
50
75
100
0
100
75
50
25
2
0
117
118
During each mode the specified speed shall be held to
within 50 RPM and the specified torque shall be held
to within 2 percent of the maximum torque at the
test speed. For example, the torque for mode 4 shall
between 48 and 52 percent of the maximum torque
measured at the intermediate speed.
During the 13 mode cycle the following should be
checked and recorded during the last 5 minutes of
each mode.
o
o
o
o
Engine speed at required tolerance for each mode RPM
Torque at required tolerance for each mode Torque
Engine operated for required time in each mode Mode Time
Fuel within specified tolerance Fuel Flow
(Lbs)
T°F
191
-------
REVISIONS-
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND O7
TEST PROCEDURE
PROCEDURE NO.
TP-753
PAGE JL- OF 10
8.0 TEST PROCEDURE (Continued)
Test Sequence Test Description Data Output
o Barometric pressure is within limits Bar. In. Hg.
o Inlet air and restriction within specified Air flow T°F
tolerances Inlet
Restriction
o Exhaust back pressure within tolerance Exhaust
Pressure
119 Fuel flow during idle or 2 percent load condition
may be determined just prior to or immediately
following the dynamometer sequence, if longer
times are required for accurate measurement.
120 Speed and load reuirements must be met during
the last minute of each mode.
121 Operate the engine for 10 minutes in each mode,
completing engine speed and load changes in the
first minute. If a delay of more than 10 minutes
occurs between the end of one mode and the start
of the next mode discontinue the sequence and
repeat the test from mode no. 1.
Analytical Procedure
122 Record the response of the analyzers on a strip Data Process
chart recorder and/or computer for the full 10 Entry
minutes with exhaust gas flowing through the
analyzers at least during the last 5 minutes.
Mode times are determined from the chart intervals
or by signal to computer of start and end of each
mode.
123 Check and reset the zero and span settings of the
emission analyzers as required, but at least at the
end of the test. If a change of over 2 percent of
full scale response is observed, make necessary
adjustments to the analyzers and repeat all test
modes since the last zero and span check.
124 Read and record the following additional information
(a) Test number
(b) Date and time of day
(c) Instrument operator
(d) Engine operator
192
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND O
TEST PROCEDURE
PROCEDURE NO.
PAGE_§_OF
8.0 TEST PROCEDURE (Continued)
Test Sequence Test Description Data Output
(e) Engine-identification numbers—date of manu-
facture—number of hours of operation accumu-
lated on engine—engine family—exhaust pipe
diameter—fuel injector type—low idle r.p.m.,
governed speed, maximum power and torque speeds—
maximum horsepower and torque—fuel consumption
at maximum power and torque—air aspiration
system—exhaust system back pressure—air
inlet restriction.
(f) All pertinent instrument information such
as tuning—gain—serial numbers—detector
numbers—range.
(g) Recorder chart. Identify zero traces—
calibration or span traces—emission
concentration traces for each test mode—
start and finish of each test.
(h) Ambient temperature in dynamometer testing
room.
125 Backflush condensate trap and replace filters as
required.
12e Chart reading - locate the last 60 seconds of
each mode and determine the average chart read- Percent
ing for CO, NO, and O2 over the 1 minute period Deflection
Concentrations may be determined for each mode
using the corresponding calibration data.
193
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
ppnr'RptTRE - CO. NO. AND Q
TEST PROCEDURE
PROCEDURE NO.
TP-753
PAGE_2L_OF 10
9.0 DATA INPUT
All data is recorded and the computer process Form No. HD 751-01 is
submitted to Data Validation for review.
If manual reduction is required refer to FR 85.97418 for applicable
formulas for calculation of brake-specific emissions.
10.0 DATA ANALYSIS
10.1 Check all entries for spurious values and out of tolerance reading
for each mode.
10.2 Compare brake-specific emissions with Federal standards and previous
engine data if available.
11.0 DATA OUTPUT
Test data is entered into data file and reported to certification and test
operations.
12.0 ACCEPTANCE CRITERIA
Specifications and tolerances are identified in test procedure sequence
no. 113, 117, 120, 122. In addition inlet air temperature must be between
68-86°F and barometric pressure between 28.5 and 31.0 inches Hg.
13.0 QUALITY PROVISIONS
13.1 Any time/speed/torque tolerance not met invalidates the test and the
complete 13 mode test must be rerun.
13.2 Out of tolerance temperature of inlet air and fuel, and barometric
pressure will invalidate test.
13 3 If the test was void, a failure report (test condition report Form No.
HD-709-01) shall accompany the test data sheet and the type of failure
should be coded in the space provided.
13.4 Final test disposition shall be indicated on the data sheet.
13.5 instrument calibration curves shall be checked monthly according to
procedure TP-203.
13 6 Periodic audits are made of each test cell to assure proper calibration
intervals have been followed for all instruments and equipment.
194
-------
REVISIONS:
DIESEL EMISSION MEASUREMENT
PROCEDURE - CO, NO, AND Oo
TEST PROCEDURE
PROCEDURE NO.
TP-753
PAGE_l°OF
10
13.7 Dynamometer torque and engine KPM are calibrated monthly. Meter/
recorder/computer input should be aligned monthly and checked daily.
13.8 Carbon Dioxide may be measured (optional) , and a comparison of fuel flow
vs total carbon in the exhaust could be used to better assure test
reliability.
195
-------
EPA TEST
SUBJECT
PROCEDURE
Number
TP-754
DIESEL ENGINE EMISSION MEASUREMENT PROCEDURE
HYDROCARBONS (HC)
Page
Of 8
Reference "CONTINUOUS HYDROCARBON ANALYSIS OF DIESEL
EMISSION," SAE. J215
I Data Form No.
' HD-751-01
Responsible Organization
TEST OPERATION - HEAVY DUTY
Test Witness
SUPERVISOR - HEAVY DUTY TESTING
Type of Test Report
DATA PROCESS PRINT OUT
Computer Program
Performance Interval
EACH TEST
Supersedes
NEW
Report Distribution
CERTIFICATION, LAB OPERATIONS, SUPERVISION
Superseded by
REMARKS/COMMENTS
Office
Lab. Oper.
Lab. Oper,
Testing Oper.
Certification
ORIGINAL RELEASE APPROVALS
Section
Quality Assurance
Chief
Supervisor HP
Chief
Signature
REVISIONS
Date
Change
Letter
Description of Change
Approval
Date
197
-------
REVISIONS^
DIESEL ENGINE EMISSION MEASUREMENT
PROCEDURE - HYDROCARBON
TEST PROCEDURE
PROCEDURE NO.
TP-754
PAGE«£.OF _fi_
1.0 PURPOSE
This procedure provides for the continuous measurement of the hydrocarbon
concentration in diesel exhaust determined as brake-specific emissions.
2.0 TEST ARTICLE DESCRIPTION
Any compression ignition internal combustion engine which the manufacturer
could reasonably expect to be used for motive power in a heavy duty vehicle.
3.0 REFERENCES
3.1 Federal Register, Title 40 Volume 37, dated November 15, 1972 and
subsequent revisions paragraphs 85.874-13 thru 85.874-18.
3.2 "Continuous Hydrocarbon Analysis of Diesel Emissions" SAE Recommended
Practice J215, November 1970.
3.3 Operating Manual - Beckman Model 402.
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 Heated flame ionization (HFID) Hydrocarbon analyzer. Beckman Model 402
with the following ranges:
4.2 Heated stainless steel sample line to maintain exhaust temperature at
375°F ± 5° from engine to instrument.
4.3 Heated and insulated sample pump and prefilter located near engine
exhaust sample probe.
4.4 Recorder for HFID output.
4.5 Required temperature measurement devices, thermocouples, meters,
recorders.
4.6 Calibration gases - propane in air for required ranges.
4.7 Zero gas - Prepurified air having a hydrocarbon concentration measured
as methane of less 0.1 PPMC.
4.8 Fuel gas - 60 percent Helium 40 percent Hydrogen.
5.0 PRECAUTIONS
5.1 Care must be taken to heat the sample line uniformly, as hot or cold
spots in the line could cause erroneous readings.
199
-------
REVISIONS:
DIESEL ENGINE EMISSION MEASUREMENT
PROCEDURE - HYDRQCARggN.
TEST PROCEDURE
1 kw 1 • 1%%^ ^* b U %f f\ b
PROCEDURE NO.
TP— 7^4
PA«F 3 r»F 8
5.0 PRECAUTIONS (Continued)
5.2 The oxygen response must be determined for each instrument. If the
correction is determined to be greater than. ±2 percent the observed
PPMC must be corrected by multiplying by the correction factor.
5.3 All air zero and fuel gases should be analyzed for hydrocarbon content
before being released for on-line use.
5.4 Instrument operating parameters such as sample, burner air and fuel
flows; detector temperatures, and detector pressure should be carefully
controlled to the same set points from test to test and when zeroing
and spanning instrument.
6.0 VISUAL INSPECTION
6.1 Check all fitting, gauges, valves, regulators, line etc. for proper
connection and operations prior to span check.
7.0 TEST ARTICLE PREPARATION
See Procedure No. TP-753 Section 7.0.
200
-------
REVISIONS:
DIESEL ENGINE EMISSION MEASUREMENT PROCEDURE NO.
TP-754
TEST PROCEDURE
PAGE_i_OF 8
8.0 TEST PROCEDURE
The hydrocarbons in diesel exhaust are measured concurrently with the CO and
NO during the 13 mode diesel cycle as described in Procedure No. TP-753.
Test Sequence Test Description Data Output
101 Follow the HFID instrument manufacturer's
specifications for startup and operating
procedures. If operating parameters determined
by experimentation or by steps, 102, 103 give
better results than those of the manufacturer,
special instructions for setting parameters
should be noted on the instrument.
102 Optimize Detector Response
(a) Set burner fuel and air settings as
prescribed by the manufacturer. Ignite
the burner.
(b) Set the oven temperature at 160 ±10 C
(320 ±18°F.) Allow at least 1/2 hour
after startup for system to reach
equilibrium.
(c) Determine optimum burner fuel flow for
maximum response. Introduce a constant
continuous concentration of propane in
N . Use about 500 ppmc hydrocarbon
concentration. Vary burner fuel flow Instrument
and determine peak response. Select Log Entry
an operating flow that gives maximum
response and the least variation in
response with minor flow variations.
Use best judgment in selecting optimum
fuel flow.
(d) Determine optimum air flow. Set burner
fuel flow as determined in paragraph (c)
and vary air flow. Although less critical
than burner fuel flow, nonoptimized
conditions may reduce quantitative accuracy.
If air flow is too low, response is low.
High air flow may result in increased noise.
Select desired air flow and, if it is
significantly different than that used in
paragraph (c) repeat step (c).
(e) Measure optimum flows accurately and
record.
"201
-------
REVISIONS:
DIESEL ENGINE EMISSION MEASUREMENT
PROCEDURE - HYDROCARBON
TEST PROCEDURE
PROCEDURE NO.
TP-754
PAGEJL.OF ^
8.0 TEST PROCEDURE (Continued)
Test Sequence Test Description Data Output
103 Oxygen Response Curve of HFID
Excess air in diesel exhaust can cause
variations in detector response. This
effect is due to the oxygen concentration
in the sample and its magnitude must be
determined and minimized.
(a) Ignite burner and set flows as deter-
mined in 102. Set oven temperature
and allow at least 1/2 hour after heat
up for system to reach equilibrium.
(b) Introduce air zero gas and zero the
analyzer.
(c) Determine oxygen response by introducing
propane calibration gases in the follow-
ing carrier gases: 100 percent N2» 15 per-
cent O2, 100 percent air.
The concentration level of the propane
should equal the expected upper HC level,
or about 1,000 ppmc. The HC concentration
and ©2 concentration should be known With-
in ±2 percent of true value.
Recheck zero after each calibration Instrument
gas is used. If zero has changed by Log Entry
more than 2 percent of the measure response
value, rezero and repeat the test.
(d) Using propane in air as the baseline for
zero 02 correction, plot a curve of oxygen
correction versus the percent of oxygen
in the sample (see Figure 1.) If the O2
correction is less than ±2 percent at the
oxygen levels present in the exhaust sample,
no O2 correction need be applied to the
observed HC concentrations. If the correc- Plot Curve
tion is greater than ±2 percent, apply an
02 correction to all measured values as
follows:
Corrected ppmc = (observed ppmc) x (O2
correction.)
202
-------
REVISIONS:
DIESEL ENGINE EMISSION MEASUREMENT
_ PROCEDURE - HYDROCARBON
TEST PROCEDURE
PROCEDURE NO.
TP-754
PAGE-JLOF 8
8.0 TEST PROCEDURE (Continued)
Test Sequence
Test Description
(e) Check effect of 02 using a propane
concentration typical of the expected
lower HC level that will be encountered
during the engine tests, or about 100
ppmc. If significantly different from
the 1,000 ppmc data in 102 paragraph (d),
establish curve and apply the 0 correc-
tion on a prorated basis as a function
of the measured concentration.
OXYGEN RESPONSE CURVE OF HFID
§
H
H
U
O
O
0.84
0.88
NORMAL 0 RANGE IN
DIESEL EXHAUST
0.92
20 15 10 5 0
PERCENT OXYGEN IN SAMPLE
Analyzer A - Oxygen correction not needed
Analyzer B - Oxygen correction needed*
*%0 Correction = (HC response in N ) - (HC response in air)
2 HC response in air
Data Output
Instrument
Log Entry
o
EH
§
6
8
E-i
2
104
105
Fig. 1 - FID OXYGEN INTERFERENCE
Pretest system preparation - refer to Test
procedure No. TP-753 test sequences 101 thru 115
Verify operating system temperature stability
203
-------
REVISIONS-
DIESEL ENGINE EMISSION MEASUREMENT
PROCEDURE - HYDROCARBON
TEST PROCEDURE
PROCEDURE NO.
TP-754
PAGE2 OF J
8.0 TEST PROCEDURE (Continued)
Test Sequence
106
Test Description
Data Output
Analyze Diesel exhaust hydrocarbons at steady
state condition according to the test sequence
122 and 123 in Test procedure No. TP-753.
Data
Process
Entry
204
-------
REVISIONS:
DIESEL ENGINE EMISSION MEASUREMENT
PROCEDURE - HYDROCARBON
TEST PROCEDURE
PROCEDURE NO.
TP-754
PAGE_!_OF JL_
9.0 DATA INPUT^
9.1 Data Processing Form (HD-751-01) is sent to data service after data
validation has been performed according to Test procedure No. TP-850.
9.2 All test records are filed by test number and manufacturer.
10.0 DATA ANALYSIS
See Test procedure No. TP-753.
11.0 DATA OUTPUT
Test data is entered into data file and reported to certification or test
requester.
12.0 ACCEPTANCE CRITERIA
12.1 HFID instrument parameters and sample line temperatures must meet
tolerances during entire test.
12 2 If oxygen response exceeds 2 percent at exhaust O2 level, data
' must be corrected using correction factor determined in test
sequence 103.
13.0 QUALITY PROVISIONS
13 1 HFID instrument span and zero are checked before, during, and after
test. Significant deviation requires rerun of test cycle from last
acceptable span and zero check.
13 2 Detector and sample lines are heated to prevent hydrocarbon condensatio
and hangup? and are held within specified tolerance, to reduce test
to test variability.
13.3 Sample flow rates adjusted for maximum response and minimum transport
time.
13.4 Oxygen response checked monthly.
13.5 Curve check performed monthly.
13.6 QA audit of maintenance log and instrument performance.
205
-------
EPA TEST PROCEDURE
Number
TP-755
Page
of
SUBJECT
FUEL FLOW MEASUREMENT - FLO-TRON LMF METER
Reference
INSTRUMENT MANUAL MODEL 10 D
Responsible Organization
HEAVY DUTY TESTING
Test Witness
SUPERVISOR
Type of Test Report
DATA PROCESS FORM NO.
Report Distribution
CERTIFICATION, MANUFACTURER REPRESENTATIVE
Data Form No.
HD-751-01
Computer Program
Performance Interval
EACH TEST
Supersedes
NEW
Superseded by
REMARKS/COMMENTS
'ORIGINAL RELEASE APPROVALS
Quality Assurance
Change
Letter
Description of Change
Approval
Date
207
-------
REVISIONS:
FUEL FLOW MEASUREMENT -
FLO-TRON LMF METER
TEST PROCEDURE
PROCEDURE NO.
TP-755
PAGE_2_OF 7
1.0 PURPOSE
This procedure describes the use of the Flo-Tron LMF for measurement of
fuel flow during an emission test.
2.0 TEST ARTICLE DESCRIPTION
This flow measuring device is designed for use with diesel fuel and gasoline.
2.1 The model 10 D Electronic Mass Flow Transmitter is based on the hydraulic
Wheatstone Bridge principle. The meter measures true mass flow rate and
has an electrical output. The electrical output signal is obtained from
a pair of integrally mounted differential pressure transmitters. These
transmitters are incorporated with a Flo-Tron Signal Conditioner and
Mass Flow Indicator.
2.2 Model 45 Recirculating Tank. The Flo-Tron Recirculating Tank is a
device for use with an instantaneous readout flowmeter to measure net
fuel consumption of a diesel engine. The unit is equipped with a float
operated valve to maintain a constant level in the tank as well as
baffles to remove entrained air and vapors from the engine return flow.
A pressure regulator, with gage, is also furnished to control the inlet
pressure to the float valve.
3.0 REFERENCES
3.1 Flo-Tron LMF meter data sheet and operation instructions for Model 10 D.
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 115 Volts 4.2 Amps.
4.2 Flo-Tron Model 45 Recirculating Tank.
4.3 Flo-Tron Model 29-16 Signal Conditioner.
4.4 Mass Flow Indicator, Flo-Tron Model 24B.
5.0 PRECAUTIONS
l LOCATION To obtain optimum performance, the flowmeter should ^
nirs
housing covers.
The baseplate of the flowmeter should be in a horizontal position to
preserve the self -venting feature.
209
-------
REVISIONS'
FUEL FLOW MEASUREMENT -
FLO-TRON IMF METER
TEST PROCEDURE
PROCEDURE NO.
TP-755
5.2 FLUID CONNECTIONS. Before making the fluid connections, remove the
protective closures and drain any preserving oil from the meter. It
is recommended that a good grade of pipe sealer be used on all fluid
connections. Loctite Hydraulic Sealant, used with Locquic Primer has
been found to work exceptionally well. Care should be exercised to keep
this material from getting into the meter.
5.3 A 25 micron filter should be located directly upstream from the flow-
meter inlet. This filter should be of sufficient capacity to insure
that its pressure drop does not allow the meter inlet pressure to fall
below 15 p.s.i. Connecting lines to and from the meter should be clean
and free of loose material.
5.4 MOTOR WIRING. The flowmeter has a pump that is driven by an electric
motor. The standard electric motor operates on 115 VAC, 60 Hz single
phase and is thermally overload protected. Check motor nameplate for
electrical characteristics of special units. The motor should be wired
through a switch per the applicable electrical codes.
5.5 If the system is to be used in a "noisy" electrical environment i.e.,
near a spark ignition engine, it is desirable to use shielded connecting
cables with the shields grounded at one location.
5.6 MOUNTING. It is important that the recirculating tank be mounted
properly. The unit is designed to sense small changes in fuel level and
therefore becomes somewhat sensitive to shock and vibration. It is
recommended that the recirculating tank be mounted securely to a
horizontal surface by the feet provided. This mounting surface should
be rigid and free of shock and vibration. The cover should be left on
the tank at all times to prevent the entrance of foreign matter.
5.7 FLUID TEMPERATURE AND PRESSURE. The fluid temperature and pressure
should be within the limits specified 90-110 F and 15 p.s.i.g. It is
possible, when operating with low vapor pressure fuels, that combinations
of high temperature and low pressure may cause the liquid to flash into
vapor. This can cause erratic and erroneous flow measurements. There-
fore, with certain fuels it may be necessary to increase the system
pressure or decrease the temperature to prevent flashing.
5.8 The indicators are factory set for desired input and output ranges. This
provides maximum precision and stability of the system. Each 29-13
Signal Conditioner/Indicator is matched to the Flo-Tron Mass Flow
Transmitter bearing the same serial number. Indicators and Transmitters
should not be interchanged.
210
-------
REVISIONS:
FUEL FLOW MEASUREMENT -
FLO-TRON LMF METER
TEST PROCEDURE
PROCEDURE NO.
TP-755
PAGE_!_OF 1
6.0 VISUAL INSPECTION
6.1 Check all fuel and electrical connections. If fuel leaks are detected,
these must be corrected before proceeding with the test.
6.2 Check diesel fuel for clarity when bleeding the flowmeter to assure
fresh fuel is being used for the test.
7.0 TEST ARTICLE PREPARATION
7.1 Secure all fuel connections. Heat exchanger must be used to assure
proper fuel temperature control.
7.2 VENTING. To obtain accurate measurements it is important that there
be no air or vapor in the flowmeter housing. The flowmeter and
integral differential pressure transmitters are designed to be
self-venting. When first starting the system the flowmeter should be
bled through vent fittings on the housing and transmitter flanges.
Bleeding should be continued until there is no indication of bubbles
in the escaping liquid. Normally, once the system is bled as described
previously, the unit can be started and stopped successively without
rebleeding. If there is a chance of the system draining and/or air
entering the flowmeter, it should be bled again.
L
211
-------
REVISIONS
FUEL FLOW MEASUREMENT -
FLO-TRON LMF METER
TEST PROCEDURE
PROCEDURE NO.
TP-755
PAGE_1_OF _L»
8.0 TEST PROCEDURE^
The fuel flow is measured during the last 5 minutes of each mode of the
13 mode diesel cycle. The Flo-Tron meter is used for all measurements except
Idle and 2 percent Load. These conditions are measured using the Cox Model
402 due to the inaccuracies of determining these low flow rates with the
Flo-Tron meter.
Test Sequence
101
102
103
Test Description
Data Output
Turn on power to the indicator and LMF meter;
allow at least 1/2 hour for warm-up. Bleed
all entrapped air from the meter. (Ref. Para. 7.2)
NOTE; DO NOT OPERATE THE METER WITHOUT LIQUID
IN THE SYSTEM. Damage can result to the
recirculating pump if it is operated dry.
Zero readings should be checked and adjusted
when installing the meter and at least once
each day of operation. All flow readings will
shift an amount equal to the zero offset.
Reduce flow to zero by stopping the flow down-
stream of the LMF meter. THE LMF meter should
be kept running with normal system pressure on
the inlet. If the readout instrument does not
zero, adjust the zero potentiometer until a
zero reading is obtained. Adjust the "Low
Zero Adjust" pot only.
To "zero" the high range tramsmitter, repeat
the procedure above while depressing the push-
button marked "High Zero Check." For this
adjustment, use the "High Zero Adjust" pot
only.
The system is now adjusted and ready for use.
Experience will dictate how often it is
necessary to check and/or readjust the zeros.
Total Flow Counter: Flow in pounds of fuel
will be accumulated by the counter continuously.
The counter display will indicate the total
accumulation as long as the toggle switch
is in the "count" position. When switched
to "Hold", the display will hold the accumul-
ation at the instant of switching. When
switched, back to "Count" mode, the display
will show the latest total INCLUDING THE FLOW
OCCURRING while the display was holding.
212
-------
REVISIONS:
FUEL FLOW THE MEASUREMENT -
FLO-TRQN IMF METER
TEST PROCEDURE
PROCEDURE NO.
PAGEA
8.0 TEST PROCEDURE (Continued)
Test Sequence
104
105
106
107
108
109
Test Description
Data Output
To erase the total and start again from zero,
press the "Reset" button. As soon as this
button is released (if there is a flow) the
counter will begin totalling again.
Recirculating tank fuel can be introduced to
the inlet of the tank. The flow meter will
read a relatively high flow rate until the
tank is filled to the proper level. The
system can now be started.
When the engine begins to use fuel, adjust
the pressure regulator to 3 p.s.i.g.
If a large, sudden change is made in flow
rate, allow a few secnds for the flowmeter
to stabilize before taking readings. If
calibrating the flowmeter, allow enough
tare weight on the calibrator for the flow
to stabilize before the time cycle begins.
To check zero on the flowmeter, turn the
pressure regulator handle counter-clockwise
until all load is removed. This will elimi-
nate waiting for the float to shut the flow
off completely. After the flow rate is
resumed, adjust the pressure regulator to
3 p.s.i.g.
Determine fuel flow rate in Lbs per unit
time for each mode. Measurement is made
for a minimum interval of 60 seconds.
Record fuel flow measurements in Lbs per
hour.
Time
Lbs.
Lbs/Hr.
213
-------
REVISIONS:
FUEL FLOW MEASUREMENT -
FJp-TPnM T.MF METER
rpcT PROCEDURE
1 CO 1 rHWV»C L/WKC
PROCEDURE NO.
TP-755
PAttF? .OF 7
9.0 DATA INPUT
All fuel flow measurements are entered on the data processing Form No.
HD-751-01. Mass units should be consistent for each entry.
10.0 DATA ANALYSIS
None required.
11.0 DATA OUTPUT
Fuel mass inputs are used to calculate brake-specific emissions. These
values are reported to test requester and maintained in the data file.
12.0 ACCEPTANCE CRITERIA
12.1 Fuel temperature must be maintained at 100 ± 10 F.
12.2 Adequate fuel pressure must be maintained per Manufacturer's
specifications to insure proper operation of the engine.
13.0 QUALITY CONTROL PROVISIONS
13.1 Calibration is accomplished using a Flo-Tron Model 30 "dead weight"
calibrator or equivalent. Calibration checks are performed monthly.
13.2 Fuel Flow measurements checked by Data Validation and compared to
theoretical values supplied by manufacturer. Suspect values may
require repetition of test.
214
-------
EPA TEST PROCEDURE
Number
TP-756
Page
of
SUBJECT
FUEL FLOW MEASUREMENT - COX INSTRUMENT_MODEL 402
Reference
Responsible Organization
HEAVY DUTY ENGINE TESTING
Test Witness
SUPERVISOR
Type of Test Report
COMPUTOR PROCESS FORM NO.
FACTURER REPRESENTATIVE
Data Form No.
HD-751-01
Computer Program
Performance Interval
EACH TEST
Supersedes
NEW
Superseded by
REMARKS/COMMENTS
This procedure is used for fuel flow during the idle and 2 percent load
conditions of Diesel Emission Tests.
Office
Admin.
Lab. Ope r.
HD Testing
Change
Letter
ORIGINAL RELEASE APPROVALS
Section
Quality Assurance
Chief
Supervisor
Signature
REVISIONS
Date
Description of Change
Approval
Date
215
-------
REVISIONS:
FUEL FLOW MEASUREMENT - COX
INSTRUMENT MODEL 402
TEST PROCEDURE
PROCEDURE NO.
TP-756
PAftF 2 OF 4
1.0 PURPOSE
This procedure describes the determination of fuel flow rates under steady
state (equilibrium) conditions during the 13 mode diesel emission cycle.
This procedure is used for the idle and 2 percent load conditions. Higher
flow rates for the other modes are determined using the Flo-Tron meter
(Procedure No. TP-755.)
2.0 TEST ARTICLE DESCRIPTION
The Cox Instrument Mode 402 is used primarily for the measurement of diesel
fuel by actual measurement of the weight of fuel consumed per unit time.
3.0 REFERENCES
3.1 Cox Instruments - Manual for model 402 fuel measuring instrument.
4.0 REQUIRED EQUIPMENT/CONDITIONS
4.1 Diesel engine fuel system accessories as required. Additional fuel
pump required by some engines.
4.2 Heat exchanger for maintaining proper fuel temperature (100± 10 F.)
4.3 Electrical 110 volts. Shop air in excess of 60 p.s.i.g.
5.0 PRECAUTIONS
5 1 instrument door must be kept closed during measurement to avoid air
drafts which could interfere with the proper operation of the balance.
5.2 Care must be taken when engine is coming off a high power mode as a
sudden surge of fuel may overflow the beaker.
6.0 VISUAL INSPECTION
6.1 Check condition of weights, look for scratches, dents, dust or spilled
fuel before each test.
6.2 Check proper operation of the solenoid which trips the timer. Timer
should trip at the balance point of the scale.
6 3 Assure unrestricted motion of the balance, and that fuel feed and return
lines do not touch the fuel reservoir container.
7.0 TEST ARTICLE PREPARATION
7.1 Attach fuel feed, return and engine fuel lines to the instrument.
Secure for leak tight operation.
7.2 Plug into 110 volt 60 #3 grounded (3 wire) receptacles.
7.3 Connect air supply to regulator and set pressure to 60 p.s.i.g.
217
-------
REVISIONS:
FUEL FLOW MEASUREMENT - COX
INSTRUMENT MODEL 402
TEST PROCEDURE
PROCEDURE NO.
TP-756
8.0 TEST PROCEDURE
Test Sequence Test Description Data Output
101 The instrument has a capacity of three
weights which can be operated electrically.
The center weight is usually used for the
amount of fuel to be measured. The other
two may be used for tare weights if required.
Place desired weight on the center bar lift
arm. Lift arm must be in weight or down Weight
position. I" Grams
102 Balance scale with tare weights as required.
Scale should rest in balanced or center
position of scale.
103 Purge system with fuel until the fuel in the
beaker is clear. Fresh fuel must be used
for each test.
104 Reset timer to zero and close instrument door.
105 When engine is operating at equilibrium
condition, trip center bar lift arm to remove
weight, timer will start and stop automatically
when scale returns to balanced condition Time
intervals of at least 60 seconds should be Time
used. Seconds
106 Record fuel used in Ibs. per hour. Data
Process
Form
Lbs./Hr.
218
-------
REVISIONS:
FUEL FLOW MEASUREMENT - COX
INSTRUMENT MODEL 402
TEST PROCEDURE
PROCEDURE NO.
PAGE__LOF
9.0 DATA INPUT
Fuel measurement units must be compatible with program and consistent for
each mode measured.
10.0 DATA ANALYSIS
None required.
11.0 DATA OUTPUT
Brake-specific emissions are calculated and reported as grams per hour and
grams per brake horsepower hour. Data reported to test requester and
maintained in data file.
12.0 ACCEPTANCE CRITERIA
12.1 Fuel temperature must be maintained between 90-110 F at pump inlet
of the engine.
12.2 Fuel pressure must be maintained at manufacturer's specification for
proper operation of the engine.
13.0 QUALITY CONTROL PROVISIONS
13.1 Temperatures, pressures and raw data checked by Data Validation.
Entries suspected as being incorrect will require repetition of the
test.
13.2 Instrument weight checked by Chemical Analysis section against NBS
traceable standards at 6 month intervals, or when weights may have
become damaged.
219
-------
800
-------
Section 800
DATA VALIDATION
223
-------
EPA TEST PROCEDURE
Number
TP-850
Page _L
of 5
SUBJECT
DATA VALIDATION - HEAVY DUTY DIESEL EMISSIONS
Reference
Data Form No.
Responsible Organization
TEST OPERATIONS -HEAVY DUTY TE_STING_
Test Witness
SUPERVISOR - HEAVY DUTY TESTING
Computer Program
Performance Interval
EACH TEST
Type of Test Report
Report Distribution
TEST OPERATIONS - CERTIFICATION - QUALITY ASSURANCE
Supersedes
NEW
Superseded by
REMARKS/COMMENTS
Office
Lab. Opera
Lab. Branch
HD Testing
ORIGINAL RELEASE APPROVALS
Section
Quality Assurance
Chief
Supervisor
Signature
Date
Change
Letter
REVISIONS
Description of Change
Approval
Date
225
-------
1 ' ' — "•— —
REVISIONS:
DATA VALIDATION - HEAVY DUTY
DIESEL EMISSIONS
TEST PROCEDURE
PROCEDURE NO.
TP-850
DArtP2 OF 5
1.0 PURPOSE
Data Validation establishes a control network to assure a smooth flow
of all data collected during the performace of Heavy Duty engine emission
tests. The Data Validation section will also check the data form to confirm
the validity of the results and assure the data is within specified limits:
2.0 TEST ARTICLE DESCRIPTION
2.1 The following data sheets, chart traces and reports are required for
a complete data validation system.
o Form HD-750-01 Check List, Buildup and Installation Diesel Test
Engine
o Form HD-750-02 Receiving Inspection
o Form HD-750-03 Check List Test Cell 1 and 2 Diesel Engine Dynamometer
Operation
o Form HD-750-04 Check List-Preparation of the Test Engine For Return
to Manufacturer
o Form HD-750-05 Shipping Order
o Form HD-751-01 Data Sheet
o Recorder charts NDIR - CO and CO2
o Recorder charts FID - HC
o Recorder chart - speed, smoke, torque
3.0 REFERENCES
3.1 "Quality Assurance Guidelines for Heavy Duty Mobile Emissions
Measurement Systems" Section 6.5 Data Validation
4.0 REQUIRED EQUIPMENT
4.1 Validation stamps
5.0 PRECAUTIONS
Not applicable
227
-------
REVISIONS:
DATA VALIDATION - HEAVY DUTY
DIESEL EMISSIONS
TEST PROCEDURE
PROCEDURE NO.
TP-850
PAGE_3.OF _5_
6.0 VISUAL INSPECTION
6.1 Contained in Section 8.0.
7.0 TEST ARTICLE PREPARATION
7.1 All forms and traces must be complete before submittal to Data
Validation.
228
-------
REVISIONS:
DATA VALIDATION - HEAVY DUTY
DIESEL EMISSIONS
TEST PROCEDURE
PROCEDURE NO.
TP-850
PAGF 4 OF 5
8.0 TEST PROCEDURE
There is presently no formal method established for conducting data
validation of the heavy duty test data. Validation is presently being
accomplished by the Supervisor and Team Leader with concurrence from
Certification. There is a need for establishing Data Validation Procedures
independent of the test group as is presently being done for Light Duty
Testing. (TP-801)
It is recommended that separate forms be used for the smoke and gaseous
test. Check sheets should be signed and witnessed and procedures developed
for quickly determining the validity of speed/time/torque traces.
Analyzer traces should be checked and compared with computer outputs.
Instrument checks should be visually checked for corrections.
A procedure for data validation should be constructed according to the EPA
requirements of paper flow and data reporting with appropriate check points
from receiving inspection testing through return of the engine to manufacturer
229
-------
REVISIONS:
DATA VALIDATION — HEAVY DUTY
DIESEL EMISSIONS
TEST PROCEDURE
1 bw 1 1 I\NXN»ta »^ Wl%»»
PROCEDURE NO.
TP-850
PAftF 5 r»F 5
9.0 DATA INPUT
9.1 This information is contained in Section 8.0.
10.0 DATA ANALYSIS
10.1 Analysis is performed by the Data Branch using the following
computer program.
11.0 DATA OUTPUT
Validated data is returned to Heavy Duty Supervisor for distribution.
12.0 ACCEPTANCE CRITERIA
12.1 Refer to table in Introduction or individual test procedures.
13.0 QUALITY PROVISIONS
13.1 The Q.A. Department should audit final results to assure all entries
and results are within acceptable limits.
13.2 A statistical inference study should also be made of typical problems
and solutions from data compiled in the data bank of previous test
results. This study can be performed by using control charts,
analysis of variance, and error analysis techniques.
230
-------
900
-------
Section 900
PROGRAM PLANNING AND QUALITY AUDIT
Currently no procedures are included in this Section of
the manual. Those procedures pertaining to this Section
must be supplied by the user and may be supplied by the
EPA in subsequent revisions.
233
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