Test/QA Plan for Diesel Exhaust and Engine Modification Retrofit Technologies at SwRI
March 2011
Version 2.0
TEST/QA PLAN FOR THE VERIFICATION TESTING OF
DIESEL EXHAUST CATALYSTS, PARTICULATE FILTERS, AND ENGINE
MODIFICATION CONTROL TECHNOLOGIES FOR HIGHWAY AND NONROAD
USE DIESEL ENGINES
EPA Cooperative Agreement No. CR83416901-0
RTI Sub Agreement No. 2-340-0212320
Prepared by:
K. Spreen
BRTI
INTERNATIONAL
Southwest Research Institute
6220 Culebra Road
P.O. Drawer 28510
San Antonio, TX 78228-0510
Phone: 210-522-5012
FAX: 210-522-3950
E-mail: kspreen@swri.org
RTI International
3040 Cornwallis Road
P.O. Box 12194
Research Triangle Park, NC 27709-2194
Phone: 919-541-7443
FAX: 919-541-6936
E-mail: jhill@rti.org
This plan has been reviewed and approved by:
Original signed by Kent Spreen
K. Spreen, Technical Leader, Southwest Research Institute
Original signed by Michael Van Hecke
M. Van Hecke, Quality Manager, Southwest Research Institute
Original signed by Jason Hill
J. Hill, RTI ETV/APCT Center Director
Original signed by James Flanagan
J. Flanagan, RTI ETV/APCT Center Quality Manager
Original signed by Michael Kosusko
M. Kosusko, EPA Project Manager
Original signed by Robert Wright
R. Wright, EPA Quality Manager
4/5/2011
Date
4/5/2011
Date
3/4/2011
Date
3/8/2011
Date
3/23/2011
Date
3/23/2011
Date
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A2: Table of Contents
List of Figures v
List of Tables v
List of Acronyms and Abbreviations vi
A3: Distribution List viii
BACKGROUND 1
GROUP A: PROJECT MANAGEMENT 2
A4: Project/Task Organization 2
A4.1. Management Responsibilities 3
A4.1.1. EPA Project Manager 3
A4.1.2. RTI APCT Center Director 3
A4.1.3. RTI Task Leader 4
A4.1.4. SwRI Technical Leader 4
A4.1.5. SwRI Task Leader 4
A4.2. Quality Assurance Responsibilities 4
A4.2.1. EPA Quality Manager 5
A4.2.2. RTI Quality Manager 5
A4.2.3. SwRI Quality Manager 6
A5: Problem Definition/Background (Verification Approach) 6
A6: Project/Task Description 6
A6.1. Description 6
A7: Quality Objectives and Criteria 7
A8: Special Training Requirement/Certifications 10
A9: Document and Records 10
GROUP B: DATA GENERATION AND ACQUISITION 11
Bl: Sampling Process Design (Experimental Design) 11
B2: Sampling Methods 11
B2.1. Exhaust Gas Sampling System 12
B2.2. Particulate Sampling System 12
B2.3. Corrective Action for Sampling 12
B3: Sample Handling and Custody 13
B3.1. Particulate Filter Handling Custody 13
B3.2. Raw Data Handling Custody 13
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B4: Analytical Methods 14
B4.1. Gaseous Analyzers 14
B4.2. Corrective Action for Analyzers 14
B4.3. Filter Weighing 14
B5: Quality Control 15
B6: Instrument/Equipment Testing, Inspection, and Maintenance 15
B7: Instrument/Equipment Calibration and Frequency 15
B7.1. Gaseous Analyzer Calibration 16
B7.1.1. Hydrocarbon Analyzer 16
B7.1.2. Carbon Monoxide Analyzer 16
B7.1.3. Oxides of Nitrogen Analyzer 16
B7.1.4. Carbon Dioxide Analyzer 16
B7.2. Constant Volume Sampler (CVS) 16
B7.3. Gas Meter Calibration 17
B7.4. Miscellaneous Instruments 17
B7.5. Analyzer Calibration Gases 17
B8: Inspection/Acceptance of Supplies and Consumables 17
B8.1. Test Fuel 17
B8.2. Calibration Gases 17
B8.3. Paniculate Matter (PM) Filter Media 18
B9: Non-Direct Measurements 18
BIO: Data Management 19
GROUP C: ASSESSMENT AND OVERSIGHT ELEMENTS 20
Cl: Assessments and Response 20
Cl.l. Internal Audits 20
C1.2. External Audits 20
C1.3. Audits of Data Quality 20
C1.4. Corrective Action 20
C2: Reports to Management 21
GROUP D: DATA VALIDATION AND USABILITY ELEMENTS 22
Dl: Date Review, Verification, and Validation 22
D2: Verification and Validation Methods 22
D3: Reconciliation with User Requirements 22
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APPENDIX A: APPLICABLE DOCUMENTS AND PROCEDURES 23
1. EPA Documents 23
2. APCT Center Documents 23
3. SwRI AE Standard Operation Procedures 23
4. SwRIEEVRD Test and Inspection Procedures 24
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List of Figures
Figure 1. Organizational Chart 3
Figure 2. Gaseous and Particulate Emissions Sampling System 11
Figure 3. Exhaust Gas Sampling and Analytical System 14
Figure 4. ETV Data Management 19
List of Tables
Table 1. Test Equipment Specifications andDQIGs 8
Table 2. Gas Analysis Equipment Specifications and DQIGs 8
Table 3. Calibration Gas Specifications andDQIGs 9
Table 4. Emission Test Data DQIGs 9
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ADQ
AE
APCT Center
CFO
CFR
CI
CO
CO2
CVS
DOC
DPF
DQIG(s)
DQO(s)
EEVRD
EPA
EPA-ORD
ER&DD
ETIS
ETV
FRIS
FTP(s)
GVP
HC
HD
HFID
in. H2O
kPa
Ib-ft
mm Hg
MSDS
N2
NDIR
NIST
NO
NO2
NOX
02
PDF
PEA(s)
ppm
ppmC
PTFE
QA
List of Acronyms and Abbreviations
audit of data quality
Automotive Engineering
Air Pollution Control Technology Center
critical flow orifice
Code of Federal Regulations
compression-ignition
carbon monoxide
carbon dioxide
constant volume sampler
diesel oxidation catalyst
diesel particulate filter
data quality indicator goal(s)
data quality objective(s)
Engine, Emissions and Vehicle Research Division
U.S. Environmental Protection Agency
U.S. Environmental Protection Agency's Office of Research and Development
Emissions Research and Development Department
Emissions Test Information System
Environmental Technology Verification
Filter Room Interface Software
Federal Test Procedure(s)
generic verification protocol
hydrocarbons
heavy-duty
heated flame ionization detector
inches of water
kilopascals
pound-feet
millimeters of mercury
material safety data sheet
nitrogen
non-dispersive infrared
National Institute of Standards and Technology
nitric oxide
nitrogen dioxide
nitrogen oxides
oxygen
positive displacement pump
performance evaluation audit(s)PM particulate matter
parts per million
parts per million carbon
polytetrafluoroethylene
quality assurance
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QC quality control
QM quality manager
QMP quality management plan
QSA quality system audit
RTI Research Triangle Institute
SET supplemental emissions test
SOP(s) standard operating procedure(s)
SOW(s) statement(s) of work
SwRI Southwest Research Institute
TIP(s) test and inspection procedure(s)
TO test organization
TQAP test/quality assurance plan
TSA(s) technical systems audit(s)VR verification report
|j,g microgram
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A3: Distribution List
U.S. EPA
Michael Kosusko
Robert Wright
RTI International
Jason Hill
James Flanagan
Southwest Research Institute
Jeff White
Kent Spreen
Michael Van Hecke
Mike Ross
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BACKGROUND
The U.S. Environmental Protection Agency's Office of Research and Development (EPA-ORD)
directs the Environmental Technology Verification (ETV) program to verify performance of
innovative technologies that have the potential to improve protection of the environment. The
ETV program's goal is to supplement environmental protection by accelerating the entrance of
new technologies into marketplaces. ETV is a voluntary program that makes objective
performance information available to support assessment by potential users. From performance
data generated under ETV, technology buyers, financiers, and permitters in the U.S. and abroad
will be better informed to make decisions regarding environmental technology purchases. The
ETV verification provides actual performance of a technology under specific, pre-determined
criteria or protocols and a strong quality management system. ETV does not endorse, certify, or
approve technologies.
The Air Pollution Control Technology Center (APCT Center) is one of six ETV centers. EPA's
partner verification organization, RTI International (RTI), manages the APCT Center. The
APCT Center conducts verification testing of potential air pollution control technologies. The
APCT Center conducts performance evaluations according to externally reviewed verification
Test/Quality Assurance Plans (TQAPs), technology specific Test Plan addenda or Statements of
Work (SOWs), and established protocols for quality assurance.
Emissions testing for air pollution control technologies to be used on mobile sources (on-
highway or nonroad vehicles with diesel engines) and some stationary source diesel engines is
conducted at Southwest Research Institute (SwRI), an independent, not-for-profit, applied and
developmental research organization. Southwest Research Institute's Emissions Research and
Development Department (ER&DD) has had significant experience with automotive emissions
testing. ER&DD has worked with the EPA to develop automotive emissions sampling and
analytical techniques, and to develop test procedures used for regulatory purposes. ER&DD
maintains ISO 9001: 2008 certification and ISO 17025: 2005 accreditation. The APCT Center
has selected SwRI as a test organization to perform ETV testing for mobile sources.
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GROUP A: PROJECT MANAGEMENT
A4: Project/Task Organization
The EPA has overall responsibility for the ETV program for the APCT Center. The APCT
Center is managed by RTI International. SwRI is a test organization performing ETV for mobile
source technologies for the APCT Center.
Management and testing of diesel oxidation catalyst (DOC), diesel particulate filter (DPF), and
engine modification control technologies for mobile sources within the APCT Center are
performed in accordance with procedures and protocols defined by a series of quality
management documents. The primary source for the APCT Center quality system is EPA's
Policy and Program Requirements for the Mandatory Agency-wide Quality System, EPA Order
5360.1 A2 (May 2000). The quality system is in compliance with the following:
• EPA Requirements for Quality Management Plans (EPA QA/R-2)
• EPA's Environmental Technology Verification Program, Quality Management Plan
(EPA ETV QMP) for the overall ETV program
• APCT Center's Verification Testing of Air Pollution Control Technology - Quality
Management Plan (APCT Center QMP)
• APCT Center's Generic Verification Protocol (GVP)for Diesel Exhaust Catalysts,
Particulate Filters, and Engine Modification Control Technologies for Highway and
Nonroad Use Diesel Engines
SwRI's Automotive Engineering (AE) Standard Operating Procedures (SOPs)
• SwRI's EEVRD test and inspection procedures (TIPs)
• This test/quality assurance plan (TQAP).
Appendix A lists full citations for these documents. This TQAP is in conformance with EPA
Requirements for Quality Assurance Project Plans (EPA QA/R-5), EPA Guidance for Quality
Assurance Project Plans (EPA QA/G-5), and the documents listed above.
As an APCT Center qualified test organization (TO), SwRI will verify the emissions reductions
for DOC, DPF, or engine modification technologies intended for on-highway and nonroad diesel
engines. SwRI will perform the testing, evaluate the data, and submit a report documenting the
results to RTI. RTI will use the data to prepare the verification reports and verification
statements. The various QA and management responsibilities are divided among SwRI, RTI,
and EPA key personnel as defined below. The lines of authority among key personnel for this
project are shown on the project organization chart in Figure 1.
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EPA Project Manager
Michael Kosusko
EPA Quality Manager
RobertWright
RTI APCT Center Director
Jason Hill
RTI Quality Manager
James Flanagan
Technology Vendor
RTI Task Leader
Jason Hill
SwRI Organization
AE Quality Manager
Mike Van Hecke
— Normal lines of communication and responsibility
Informal communication
Organizational Independence
Automotive
Engineering
Engine, Emissions, and
Vehicle Research
Emissions R&D
Jeff White
_L
Technical Leader
KentSpreen
Task Leader
Technical Staff
FIGURE 1. ORGANIZATIONAL CHART
A4.1. Management Responsibilities
Project management responsibilities are divided among the SwRI, RTI, and EPA staff as
described below.
A4.1.1. EPA Project Manager
The EPA project manager, Michael Kosusko, has overall technical responsibility for the
program. He is responsible for granting final approval of GVPs, TQAPs, and reports, and he
recommends the resources necessary to meet project objectives and requirements.
A4.1.2. RTI APCT Center Director
The RTI APCT Center director is Jason Hill. He has overall responsibility for liaison with the
EPA project manager, technical and administrative oversight of the APCT Center and the QA
program in the APCT Center and for technology-specific verification tests. He will assign
technology verification task leaders; oversee verifications; review technical panel makeup; and
review generic verification protocol and test-specific quality documents. These responsibilities
are described in greater detail in Section 2 of the APCT Center's QMP.
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A4.1.3. RTI Task Leader
The RTI task leader is Jason Hill. He will:
• Define task objectives,
• Develop a detailed test scope,
• Work with vendors and stakeholders,
• Prepare test-specific addenda to this document,
• Review work progress to ensure that task budgets and schedules are met, and
• Prepare verification reports and verification statements.
Hill has overall responsibility for coordinating verification of technologies between applicants
and the APCT Center qualified testing organization.
A4.1.4. SwRI Technical Leader
The SwRI technical leader is Kent Spreen. He will:
• Assist the RTI task leader with the test scope,
• Review/prepare operating procedures applicable to the testing,
• Review test apparatus and procedures prior to commencement of testing,
• Oversee testing of the DOC, DPF, or engine modification technologies,
• Review test data/results for attainment of data quality objectives (DQOs) and
reasonableness,
• Initiate corrective actions when needed,
• Review test results, and
Submit test results to the RTI task leader.
Spreen has overall responsibility for technical and administrative activities, and exercises
technical leadership to promote quality in project performance. He will also function as liaison
for clients in specific technical areas and supervise the activities of project leaders.
A4.1.5. SwRI Task Leader
Task leaders assigned by the SwRI technical leader will:
• Review the statement of work,
• Develop specific instruction for test work,
• Interface between test operations and vendor, and
• Review and communicate results to RTI.
A4.2. Quality Assurance Responsibilities
QA responsibilities are divided among the EPA, RTI, and SwRI personnel as listed below.
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A4.2.1. EPA Quality Manager
The EPA quality manager (EPA QM), Robert Wright, will conduct audits of RTI's QA system
and of specific technical activities on the project. He will be available to resolve any QA issues
relating to performance and EPA's QA requirements. Specific functions and duties of the EPA
QM include approving the contents of this TQAP and subsequent revisions and reviewing QA
reports prepared by RTI, including QA evaluations and audits. In addition, the EPA QM will:
• Communicate quality systems requirements, quality procedures, and quality issues to
the EPA project manager and the RTI project manager,
• Review and approve APCT Center quality systems documents to verify conformance
with the quality provisions of the ETV quality systems documents,
• Perform technical systems audits (TSAs) and performance evaluation audits (PEAs)
of verification tests, as appropriate, and
• Provide assistance to APCT Center personnel in resolving QA issues.
For each technology tested under this TQAP, the EPA QM (or his designee) will perform the
following specific activities associated with the verification tests:
• Review and approve the GVP for diesel exhaust and engine modification retrofit
technologies,
• Review and approve this SwRI-specific TQAP and each test-specific addendum,
• Review and approve each verification report and each verification statement, and
• Perform a PEA of the verification test of SwRI's ETV testing operations.
A4.2.2. RTI Quality Manager
The RTI APCT Center quality manager (RTI QM), James Flanagan, is organizationally
independent of the RTI APCT Center director and is responsible for ensuring that QA/quality
control (QC) procedures described in this TQAP are followed. In addition, Flanagan will:
• Maintain regular communication with the EPA QM and APCT Center staff regarding
QA issues,
• Report on the adequacy, status, and effectiveness of the QA program on a regular
basis to the task leader and the APCT Center director,
• Conduct audits of lab activities as necessary and prepare audit reports,
• Ensure that corrective action, if necessary, is properly implemented and documented,
• Review and approve GVPs, TQAPs, TQAP addenda, and SOPs,
• Review the audit of data quality (ADQ) report of the SwRI quality manager (SwRI
QM),
• Review and approve test (including QC) reports, and
• Prepare the QA section of each verification statement and verification report.
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A4.2.3. SwRI Quality Manager
The SwRI QM, Mike Van Hecke, plays a central role in the introduction, implementation, and
consistent application of continuous quality improvement at SwRI's AE. He fulfills the role as
quality management representative for the department and is organizationally independent of the
unit generating the data. He will:
• ensure the official, approved version of this document is maintained,
• review and approve test-specific addenda to this document,
• reconcile test results with DQOs via attainment of data quality indicator goals
(DQIGs),
• conduct audits of all pertinent quality standards to ensure compliance, and
• conduct the test-specific ADQ as described in Element C1.3 and prepare the ADQ
report.
A5: Problem Definition/Background (Verification Approach)
The objective for ETV testing of air pollution control technologies is to quantify emissions
reduction capability and determine effectiveness for "commercial ready" technologies. Air
pollution control technologies for mobile sources are effectively used to reduce emissions from
older diesel engines. This use of engine pollution control technologies as diesel retrofit requires
proper integration with an engine or group of engines to decrease emissions, but integration is
not necessarily intended to bring the engine to current or any prior emission regulation levels.
Performance of a diesel retrofit technology to decrease emissions is verified with ETV.
Verification of diesel retrofit technologies is in the spirit of introducing innovative technologies
that have potential to improve environmental protection. Verified technologies are performance-
proven by independent and objective testing using test procedures used for air pollution
regulation, established protocols, and an EPA-approved quality management system. This
TQAP is specific to the DOC and DPF retrofit technologies that reduce PM emissions, along
with HC and CO, or engine modification retrofit technologies that reduce HC, CO, NOX, and PM
emissions. A test-specific addendum (Test Plan SOW) will provide additional information to
this TQAP to conform to Element A5 of EPA QA/R-5.
A6: Project/Task Description
A6.1. Description
The diesel retrofit technologies covered by this ETV TQAP are intended for use on on-highway
heavy-duty (HD) diesel engines and nonroad compression-ignition (CI) engines. Emissions test
procedures for the candidate technology devices will use procedures for emission regulation of
on-highway HD and nonroad CI engines. Federal Test Procedures (FTPs) are documented in
CFR Title 40 Part 86, Subpart N for on-highway HD engines and 40 CFR Part 89 for nonroad CI
engines. Procedures in 40 CFR Part 86, Subpart N include the transient FTP for heavy-duty
diesel engines and the supplemental emissions test (SET). It is important to state that as of
January 2010 these test procedures are obsolete and replaced by revised procedures. It is
assumed that candidate technology devices are intended for engines manufactured before 2010;
therefore, appropriate test procedures will come from 40 CFR Parts 86 and 89. The use of 40
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CFR Part 1065 emission test procedures will be specifically stated in a test-specific addendum to
this TQAP document, also known as the Test Plan SOW.
Primary measurement will include regulated emissions of total hydrocarbons (HC), carbon
monoxide (CO), oxides of nitrogen (NOX), and total particulate matter (PM). Based on the
specific technology, the type of FTP and number of tests are determined to conform to the
Generic Verification Protocol for Diesel Exhaust Catalysts, Particulate Filters, and Engine
Modification Control Technologies for Highway and Nonroad Use Diesel Engines., Sections 5.1
and 2.3, to satisfy test design requirement and data quality objectives. These sections of the
GVP give information on test design and objectives to determine confidence intervals that
differences in mean emission levels are measured.
A description of the specific technology, test engine, and test-specific details will be documented
as a test-specific addendum to this TQAP that will be prepared by RTI task leader, reviewed by
the SwRI technical leader, and submitted for EPA review and approval prior to beginning of the
ETV test program. The test-specific addendum will provide additional information to this TQAP
to conform to Element A6 of EPA QA/R-5.
A7: Quality Objectives and Criteria
In order to determine the emissions performance of a diesel retrofit technology, test quality must
be assured. Emissions testing by FTP must follow a large number of quality requirements given
in 40 CFR Part 86 (on-highway engine tests) or Part 89 (nonroad engine tests) to deem the data
as valid. All emissions sampling and measurement equipment along with ambient condition
measurements and engine parameter measurements have requirements in 40 CFR for accuracy
and traceability to standards.
For this ETV testing, achieving data quality objectives (DQOs) requires that test methods and
procedures adhere strictly to 40 CFR Part 86, Subpart N or 40 CFR Part 89. Test DQOs given in
Section 2.3 of the GVP give reference to the number of individual emissions tests to be
conducted to achieve desired confidence intervals that differences in mean emission levels are
detected. At a minimum, three repeated tests using a specific test cycle (Part 86 or Part 89) are
conducted. The number and type of emission tests will be specified in the test-specific
addendum to this TQAP.
Each individual measurement within an emissions test has specific data quality indicators that
must be met to ensure project DQOs. The data quality indicator goals (DQIGs) for individual
measurements are listed in Tables 1 through 4.
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TABLE 1. TEST EQUIPMENT SPECIFICATIONS AND DQIGs
Measurement
Variable
Speed
Torque
CVS Volumetric Flow Rate
Propane analysis
Mass flow verification using a
critical flow orifice (CFO)
PM Double Dilution Flow Rate
Dilution meter
Sample meter
System Pressures
System Temperatures
Accuracy
Specification
±2% of absolute
standard
±3% of true torque3
Measured mass ± 2% of
injected propane mass
± 1% of total flow
through PM filter
± 2% of point /± l%full
scale
±0.4 kPa
(± 3 mm Hg)
(± 1.6 in. H2O)
± 1.9°C(±3.4°F)
Frequency
Monthly
Weekly
Weekly
When replaced
Annually
Semi-annually
Semi-annually
Semi-annually
Semi-annually
40CFR
86.1308-84
86.1318-84
86.1316-94
86.1319-90
86.1316-94
86.1320-90
86.1309-90
86.1309-90
a Torque accuracy also defined as ± 2.5 Ib-ft for full-scale values up to and including 550 Ib-ft, ± 5 Ib-ft
for full-scale values up to and including 1050 Ib-ft, and ± 10 Ib-ft for full-scale values over 1050 Ib-ft.
TABLE 2. GAS ANALYSIS EQUIPMENT SPECIFICATIONS AND DQIGs
Measurement
Variable
HC
CO
CO2
NOX
NOX Converter Efficiency
NOX/CO2 Quench
CO/CO2 Interference
Accuracy or Result
Specification
±2% of point
and
± 0.3% of full scale at zero3
> 90%
<2%
< 3 ppm (Range 0-300 ppm)
< 1% full scale (Range > 300
ppm)
Frequency
Monthly
Monthly
Annually
Annually
40CFR
86.1321-94
86.1322-84
86.1324-84
86.1323-2007
86.1323-2007
86.1323-2007
86.1322-84
a Emission measurement accuracies in 86.1338-2007 also apply.
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TABLE 3. CALIBRATION GAS SPECIFICATIONS AND DQIGs
Gas
HC
CO
CO2
NOX
Zero Air
HFID Fuel
Specification
Named to ± 1% of NIST Value
andNO2<5%ofNO
< 1 ppmC HC
< 1 ppm CO
< 0.04% CO2
<0.1ppmNOx
18 to 21% O2
remainder N2
40 ± 2% H2
< 1 ppmC HC
remainder helium
40CFR
86.1314-94
86.1314-94
86.1314-94
TABLE 4. EMISSION TEST DATA DQIGs
Variable
CVS sample zone temperature
PM filter face temperature
Primary dilution temperature
HC (HFID) sample train temperature
Engine intake air temperature
Post-test span & zero drift
Transient cycle validation
Cold-Start soak temperature (transient)
PM weigh chamber
Conditioning temperature
Conditioning humidity
Sample filter checkout time
Reference filter weight change
Specification
191°Cmax.
52 °C max.
25 °C ± 5 °C
191 °C± 11°C
25 °C ± 5 °C
± 2% full scale (CO, CO2, NOX)
± 3% full scale (HC) of initial
per 40 CFR 86. 1341
>20°C
22 °C ± 3 °C
Dew point 9.4 °C ± 3 °C and
relative humidity 45% ± 8%
< 1 hour
< 40 (ig change
40 CFR
86.1310-903
86.1330-90
86.1340-94
86.1341-98
86.1330-90
86.1312-88b
86.1339-90
a Exhaust gas sampling and analytical system for gaseous and particulate emissions can follow methods in
40 CFR 86.1310-2007 if stated in test-specific addenda.
b PM filters can be high efficiency membrane media if specified in test-specific addenda; filter
conditioning and weighing facility will conform to 40 CFR 86. 13 12-2007.
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A8: Special Training Requirement/Certifications
The ER&DD is certified to International Organization for Standardization (ISO) 9001:2008
"Model for Quality Management Systems." This independently assessed system provides the
basis for quality management procedures that are applied to all emissions tests processes at
ER&DD.
ER&DD is accredited to ISO/IEC 17025 "General Requirements for the Competency of
Calibration and Testing Laboratories." Under American Association for Laboratory
Accreditation Certificate Number 0702-01, ER&DD has been accredited to perform evaluations
of automotive fluids; fuels; emissions; and automotive component, engine and powertrain
performance and durability using stationary engine dynamometer test stands (light-duty, heavy-
duty, and nonroad) vehicle dynamometer facilities, and automotive fleets (see
http://www.a21a.org/scopepdf/0702-01.pdf). The certificate accredits ER&DD to use specific
standards and procedures, including dynamometer procedures for regulated emissions testing.
All ER&DD personnel supporting the project will be qualified as described by AE SOP 4.18.
A9: Document and Records
The scope of test documents and records to be maintained by SwRI is given in Part A, Section
5.3 of the ETV program QMP. Section 3.6 of the APCT QMP states that project documentation
will be retained by SwRI or APCT for 7 years. These documents include: TQAP, SwRI SOPs
and TIPs, calibration data and certificates of standards, raw test data, emission results, and final
project reports.
Test plan documentation such as this TQAP and test-specific addenda will be maintained by the
SwRI quality manager. SOPs and TIPs are maintained and accessible at the EEVRD website.
Calibration records will be maintained in central storage locations at ER&DD. Records of
traceability to standards and certificates of standards will be maintained in the same storage
locations. Each individual test's data are recorded manually on pre-formatted data sheets at the
facility as the test is conducted. Test data will be assembled into a data packet and transferred to
a central location for entry into a database. Emissions calculations are conducted using compiled
software within the database. The database information and test results will be archived
electronically and the paper data packets will be stored in central storage locations. The
procedure for storage of test data forms and calibration records is documented in AE SOP 4.16.
The subagreement, subagreement modifications, correspondence between SwRI and RTI, final
reports and billing information will be maintained in central storage locations.
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GROUP B: DATA GENERATION AND ACQUISITION
Bl: Sampling Process Design (Experimental Design)
The experimental design follows the FTP for the respective on-highway or nonroad application
with the number of separate FTP tests for a specific technology determined by the algorithm
specified in Section 5.1 of the GVP. The rationale for the number of FTP test cycles will be
included in the test-specific addendum to this document, which will conform to required Element
Bl of EPA QA/R-5. Primary measurements will include brake specific emissions of HC, CO,
NOX, and PM. Noncritical emission measurements include nitrogen dioxide (NO2). Additional
emissions measurements and methods will be specified in the test-specific addendum.
Implementation of procedures from 40 CFR Parts 86 or 89 are documented in EEVRD Test and
Inspection Procedures (TIPs) listed in Elements B3 through BIO.
B2: Sampling Methods
The emissions sampling system is a constant volume sampler (CVS) system, described in 40
CFR 86.1310-90 for on-highway applications and 40 CFR 89.419 for nonroad applications, onto
which gaseous and particulate emission measurement systems are attached. An illustration of the
sampling system is given in Figure 2. This is a typical design with some variation at individual
test cells due to their instrumentation configuration.
Optional for
Particulate
Background Reading
Zero Air
Discharge
HC Span Gas
To Background Sample Bag
Dilution Air Filter
Sampling Train
A
Read Background Bag** S~
LEGEND
Flow Control Valve
Selection Valve
Particulate Filter
Pump
Flowmeter
Pressure Gauge
Recorder
Temperature Sensor
Dillution Tunnel
Heated Probe
Particulate Probe
Mixing Orifice
Exhaust Inlet
V
0
Supply Air
Primary Filter
Back-up Filter
Dilute Emission Bench
(HC, CO, CO 2, NOX|
Heat Exchanger
4-444
,To Pump Rotometer
and Gas Meter
as Diagramed
Immediately
Below
Discharge
To Formaldehyde
Sample Collection
To Methanol Sample
Collection
Manometer
Revolution Counter
Pick Up
Manometer
Discharge
FIGURE 2. GASEOUS AND PARTICULATE EMISSIONS SAMPLING SYSTEM
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B2.1. Exhaust Gas Sampling System
The exhaust gas sampling system conforms to 40 CFR 86.1310-90 or 40 CFR 89.419 in
construction, performance, and calibration requirements. CVS systems at SwRI use a positive
displacement pump (PDF) with heat exchanger. The CVS flow is sufficient to maintain a dilute
exhaust stream below 191 °C and above temperatures that would allow water condensation.
Sample probes are placed in the CVS at a position where dilution air and exhaust are well mixed
(at least ten tunnel diameters downstream from where the exhaust enters the CVS). A heated
sample probe, sample system, and analyzer for continuous HC measurement are maintained at
191 °C ± 11 °C. Continuous measurement of CO, CC>2, and NOX is sampled from one common
heated sample probe and pump. The NOX sample system is maintained at 191 °C ± 11 °C up to
the NO2/NO converter. A separate probe leads to a double dilution system for PM measurement.
B2.2. Particulate Sampling System
PM emission mass is determined by filtration of a portion of the dilute exhaust. Particulate
samples are collected on a pair of polytetrafluoroethylene (PTFE)- or Teflon-coated glass fiber
filters using a double dilution technique as outlined in 40 CFR 86.1310-90. A portion of the
diluted exhaust from the primary CVS tunnel is routed into a secondary dilution system, where it
is further diluted in order to control the temperature of the sample stream to 52 °C or less.
Particulate sample filters are conditioned and weighed according to procedures described in 40
CFR 86.1312-88 and 86.1339-90 (see Element B4.3 for specific sample filter weighing
procedures). Sample filter weighing is conducted at a central location separate from the
engine/dynamometer emissions test facility.
The double dilution technique as outlined in 40 CFR 86.1310-2007 can be used if it is stated in
the test-specific addenda. With this 2007 technique, a single PTFE- or Teflon-coated
borosilicate glass fiber high efficiency filter or PTFE or Teflon high efficiency membrane filter
is used.
Particulate sampling for nonroad applications is specified in 40 CFR 89.112 which references the
California Code of Regulations for new 1996 and later heavy-duty off-road diesel cycle engines.
There is a reference from the California Air Resources Board that particulate sampling uses
procedures from ISO 8178. ISO procedures agree with 40 CFR Part 86 with an additional
requirement for sampling gas face velocity through the filter to be between 35 and 80 cm/s and a
recommended pressure drop increase less than 25 kPa, between the beginning and end of the test.
B2.3. Corrective Action for Sampling
Any deviation of emissions sampling from requirements of the CFR that include equipment
malfunctions, nonconformances, and/or testing problems are reported by the test personnel
(technical staff) to the technical leader or task leader as per AE SOP 4.10.2. Corrective action
from any deviations to CFR procedures is conducted according to AE SOP 4.13.
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B3: Sample Handling and Custody
Collection of emissions data is performed within one building at ER&DD. Therefore, sample
handling and custody are straightforward. No data or samples are transferred to/from outside
locations. The PM sample filters and raw test data forms involve manual handling from test
facilities (test cells) to central processing locations.
B3.1. Particulate Filter Handling Custody
The PM sample filters are prepared and processed according to EEVRD TIP 07-020 (Particulate
Filter Conditioning and Weighing in Accordance with CFR Title 40 Parts 86 and 89). The TIP
specifies sample handling and custody procedures as well as a method of conditioning and
weighing filters used for PM sampling during emissions tests. The handling and custody
procedures in TIP 07-020 include: A pair of sample filters are placed into a petri dish with a
cover. Using the Filter Room Interface Software (FRIS), a unique bar code number is generated
for the petri dish and the dish with the filter set is placed inside the conditioning chamber (see
Element B4.3) for at least one hour prior to taking a tare weight. FRIS is used to record the time,
tare weight, temperature, dew point, humidity, and barometric pressure associated with the filter
set's bar code. The petri dish is returned to the conditioning chamber until the filter set is needed
for a test. When a dish is removed from the chamber for testing, FRIS is used to record the time.
The sample filter set is removed from the petri dish at the test cell and immediately placed into
the sampling system (see Element B2.2). A used filter set is replaced into the petri dish and
returned to the conditioning chamber within one hour of the removal time using FRIS to record
the check-in time. Filter sets not used within one hour are returned to the conditioning chamber
for a new tare weight unless the filters are kept in a sealed container. The filter set will remain in
the conditioning chamber for one hour prior to taking gross weight. FRIS is used to record the
time, gross weight, temperature, dew point, humidity, and barometric pressure.
B3.2. Raw Data Handling Custody
Quantitative data as required in 40 CFR 86.1342-94, 86.1343-88 and 86.1344-94 or 40 CFR
89.405 and 89.424 are recorded on formatted forms. All raw data forms are prepared according
to EEVRD TIP 07-009 (Emissions Testing During Heavy-Duty Diesel Engine Transient Cycle)
and TIP 07-038 (Steady-State Dilute Emissions Testing of Heavy-Duty Engine Using Horiba
MEXA-7200D Emissions Bench). The forms are given a unique test number, dated, and
assembled into a test packet according to respective TIPs 07-009 and 07-038. Raw data that are
recorded on the forms include CVS and double dilution information for calculation of volume
flow rates, exhaust gas analyzer concentrations and background levels, engine air temperature
and dew point, dilution air temperature and wet bulb temperature, barometric pressure, cycle
work or horsepower, and the paniculate filter bar code number. The packet is transferred to a
central location for entry into a database that is used to calculate emission test results.
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B4: Analytical Methods
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Gaseous emissions of HC, CO, and NOX are measured by gas analyzers that sample a dilute
exhaust stream from the CVS. Particulate emissions are determined by the net weight gain of
sample filters.
B4.1. Gaseous Analyzers
The gaseous analytical system, as illustrated in Figure 3, conforms to 40 CFR 86.1310-90 or 40
CFR 89.309. ER&DD test facilities use Horiba MEXA 7200D analyzer benches. Analyzer
operation is specified in EEVRD TIP 07-009 (Emissions Testing During Heavy-Duty Diesel
Engine Transient Cycle) and TIP 07-038 (Steady-State Dilute Emissions Testing of Heavy-Duty
Engine Using Horiba MEXA-7200D Emissions Bench).
Optional
Vent to f
Atmosphere vi
LEGEND
Particulate Filter
Flowmeter
Backpressure Regulator with
Internal Control Loop Shown
Line Pressure Regulator with
Internal Control Loop Shown
Ball Valve or Equivalent
(Darkened Leg Indicates
Common Port)
Flow Control or Needle Valve
As— Plug Valve or Equivalent
"^fo (Center Port is Common)
I 1 Heated Area
CL Chemiluminescent
NDIR Non-dispersive Infra-red
HFID Heated Flame lonization
Detector
V2 F4 F3 V16
FIGURE 3. EXHAUST GAS SAMPLING AND ANALYTICAL SYSTEM
B4.2. Corrective Action for Analyzers
Any deviation of gas analysis from requirements of the CFR that include equipment
malfunctions, nonconformances, and/or testing problems is reported by the test personnel
(technical staff) to the technical leader or task leader as per AE SOP 4.10.2. Corrective action
from any deviations to CFR procedure is conducted according to AE SOP 4.13.
B4.3. Filter Weighing
Particulate sample filters are conditioned in temperature and humidity controlled chambers that
conform to 40 CFR 86.1312-88 according to EEVRD TIP 07-020 (Particulate Filter
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Conditioning and Weighing in Accordance with CFR Title 40 Parts 86 and 89). Weighing
process conforms to 40 CFR 86.1339-90 and the weighing chamber conforms to 40 CFR
86.1312-88. Procedure given in TIP 07-020 for filter weighing is summarized in Element B3.1.
Use of high efficiency membrane filters for PM will be specified in the test-specific addendum.
These filters are conditioned and weighed in chambers that conform to 40 CFR 86.1312-2007
according to EEVRD TIP 07-045 (Particulate Filter Conditioning and Weighing in Accordance
with CFR Title 40 Part 1065). The ambient temperature and humidity conditions for stabilizing
and weighing these filters are identical between 40 CFR 86.1312-2007 and 40 CFR 1065.190.
Membrane filter handling custody and weighing procedures are the same as summarized in
Element B3.1 except one filter is used instead of a pair of filters, conditioning time is 30 minutes
before tare and gross weights are recorded, and the weighed filter is placed into a cassette, while
the filter remains in the clean environment of the conditioning chamber, that holds the filter for
sampling.
B5: Quality Control
Quality control limits in 40 CFR Part 86 (on-highway engine tests) are mostly the same or in a
few cases more stringent than 40 CFR Part 89 limits (nonroad engine tests). Quality control
limits for testing under this TQAP will adhere strictly to 40 CFR Part 86. Quality control
activities for calibrations of the dynamometer, CVS, analytical equipment, pressures, and
temperatures are documented in AE SOP 4.11.1 and SOP 4.10.2 and EEVRD TIPs listed in
Appendix A Table 4-1. The control limits from 40 CFR Part 86 and acceptance criteria in the
TIPs listed in Appendix A are given in Tables 1 through 3 of Element A7. Quality control
activities for individual emissions tests are documented in AE SOP 4.10.2 and EEVRD TIP 07-
009 for on-highway engine tests and TIP 07-038 for nonroad engine tests. TIP 07-020 includes
QC activities for PM sample filter handling, conditioning and weighing. These TIPs include
calibration or test methods, control limits or acceptance criteria, and personnel responsible for
assessment. The test control limits in 40 CFR Part 86 and acceptance criteria in the above TIPs
are given in Table 4 of Element A7. QC activities for data entry and reduction are documented
in AE SOP 4.15.2. QC for PM sample filters is assisted by FRIS. The software will alert the
user to filter conditioning data or reference filter weight changes that exceed CFR requirements.
Procedures for corrective action for calibration or test equipment nonconformance are
documented in AE SOP 4.13.
B6: Instrument/Equipment Testing, Inspection, and Maintenance
Inspection and maintenance activities for the dynamometer, CVS, and analytical equipment are
documented in EEVRD TIPs listed in Appendix A Table 4-1. These TIPs include acceptance
criteria and personnel responsible for review.
B7: Instrument/Equipment Calibration and Frequency
Calibration frequency of analyzers, instruments, and equipment will conform to 40 CFR
86.1316-94 for on-highway engine tests or 40 CFR 89.305 for nonroad engine tests. EEVRD
TIPs listed in Appendix A Table 4-1 include the calibration frequency of emissions sampling and
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measurement equipment, the applicable standards to be used and acceptance criteria. The
calibration frequencies in these TIPs are given in Tables 1 and 2 of Element A7. Overall QC
activities for calibrations are documented in AE SOP 4.11.1.
B7.1. Gaseous Analyzer Calibration
Emissions gas analyzers for HC, CO, CO2, and NOX are contained in a Horiba MEXA 7000
Series analyzer bench.
B7.1.1. Hydrocarbon Analyzer
The hydrocarbon analyzer is a heated flame ionization detector (HFID) instrument calibrated in
conformance with 40 CFR 86.1321-94 and 40 CFR 89.319. Calibration and other HFID
operational requirements are conducted according to EERVD TIP 06-012 (Monthly Calibration
of Analyzers for Continuous Gaseous Exhaust Using Horiba Emissions Bench), TIP 06-050 (HC
Analyzer and Sample System Response Checks of Horiba MEXA 7000 Series Emissions
Benches), and TIP 06-044 (Hydrocarbon Analyzer Optimization).
B7.1.2. Carbon Monoxide Analyzer
The CO analyzer is a non-dispersive infrared (NDIR) instrument calibrated in conformance with
40 CFR 86.1322-84 and 40 CFR 89.320. Calibration and other CO analyzer operational
requirements are conducted according to EEVRD TIP 06-012 (Monthly Calibration of Analyzers
for Continuous Gaseous Exhaust Using Horiba Emissions Bench) and TIP 06-049 (Wet CO2
Interference Check of CO Analyzer Integrated in Horiba MEXA 7000 Series Emissions
Benches).
B7.1.3. Oxides of Nitrogen Analyzer
The NOX analyzer is a chemiluminescent instrument calibrated in conformance with 40 CFR
1323-2007 and 89.321. Calibration and other NOX analyzer operational requirements are
conducted according to EEVRD TIP 06-012 (Monthly Calibration of Analyzers for Continuous
Gaseous Exhaust Using Horiba Emissions Bench), TIP 06-002 (NOX Converter Efficiency
Determination), TIP 06-051 (NOX Analyzer and Sample System Response Checks of Horiba
MEXA 7000 Series Emissions Benches), and TIP 06-041 (NOX Analyzer CO2 Quench Check).
B7.1.4. Carbon Dioxide Analyzer
The CO2 analyzer is a NDIR instrument calibrated in conformance with 40 CFR 86.1324-84 and
89.322. Calibration is conducted according to EEVRD TIP 06-012 (Monthly Calibration of
Analyzers for Continuous Gaseous Exhaust Using Horiba Emissions Bench).
B7.2. Constant Volume Sampler (CVS)
The CVS calibration is verified in conformance with 40 CFR 86.1319-90 or 40 CFR 89.422.
CVS calibration is verified according to EEVRD TIP 06-011 (Propane Recovery Check).
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B7.3. Gas Meter Calibration
Particulate sampling requires flow instrumentation or gas meters to determine secondary dilution
and sample flows. The gas meter calibration is verified in conformance with 40 CFR 86.1320-
90. Calibration verification is conducted according to EEVRD TIP 06-046 (Calibration of Gas
Meter).
B7.4. Miscellaneous Instruments
Engine speed and torque, signal conditioning, and readouts are calibrated within specifications
given in 40 CFR 86.1308-84, 86.1318-84, and 86.1316-94. Speed calibration is verified
according to EEVRD TIP 06-018 (Engine Speed Readout Verification) and torque calibration is
verified according to EEVRD TIP 06-017 (Torque Meter Calibration Check). Pressure and
temperature instruments, signal conditioning and readouts are calibrated within specifications
given in 40 CFR 86.1309-90. Pressure calibration is verified according to EEVRD TIP 06-020
(Pressure Calibration and Verification) and temperature calibration is verified according to
EEVRD TIP 06-013 (Temperature Calibration and Thermocouple Verification).
B7.5. Analyzer Calibration Gases
The gases used for analyzer calibration conform to 40 CFR 86.1314-94 and 40 CFR 89.312.
Concentrations of calibration gases are verified according to EEVRD TIP 06-007 (Naming
Monthly Calibration Gases) and zero gases are verified according to TIP 06-036 (Verification of
Zero Gas).
B8: Inspection/Acceptance of Supplies and Consumables
Supplies and consumables for diesel retrofit ETV include test fuel, calibration and zero gases,
PM sample filter media, and mechanical and electrical supplies for mounting the test engine in
the emissions facility.
B8.1. Test Fuel
Test fuel is purchased from suppliers on the EEVRD Approved Supplier List. Test fuel will
conform to specifications in 40 CFR 86.1313-2007 unless otherwise stated in the test-specific
addendum. Batch fuels are stored in underground tanks. Receipt of test fuel is accompanied by
a certificate of analysis from the supplier and a material safety data sheet (MSDS). The
analytical results are compared to CFR specifications before the fuel is used for emissions
testing.
B8.2. Calibration Gases
Calibration gases are purchased from the EEVRD Approved Supplier List. Calibration gases are
verified per Element B7.5.
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B8.3. Particulate Matter (PM) Filter Media
PM sample media are purchased from the EEVRD Approved Suppliers List in batches.
Individual sample filters are cut from the batch sheet and a pair of filters is placed into a petri
dish with a cover. The membrane filters are received pre-cut and individual filters are placed
into a petri dish with a cover.
B9: Non-Direct Measurements
No non-direct measurements are used for diesel retrofit ETV for calculation of emissions results
or the SwRI final report.
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BIO: Data Management
Version 2.0
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Quantitative data as required in 40 CFR 86.1342-94 and 86.1343-88 or 40 CFR 89.424 are
recorded on formatted forms. Element B3 gives the chain-of-custody for data forms for an
emissions test. Raw data forms are prepared according to EEVRD TIP 07-009 (Emissions
Testing During Heavy-Duty Diesel Engine Transient Cycle) and 07-038 (Steady-State Dilute
Emissions Testing of Heavy-Duty Engine Using Horiba MEXA-7200D Emissions Bench). The
forms are given a unique test number, dated, and assembled into a test packet. The packet is
transferred to a central location for entry into the Emissions Test Information System (ETIS)
database that is used to calculate emission test results. Raw data entry into the ETIS is
conducted by designated personnel according to EEVRD TIP 08-005 (Data Transfers and
Calculations of Dilute Steady-State Engine Data) and 08-016 (Heavy-Duty Transient Test Data
Processing). Personnel responsible for database entry verification and validation are documented
in AE SOP 4.15.2. ETIS contains features that will alert the user to data that exceed CFR
requirements or equipment calibration limits. PM sample filter data, conditioning and weights,
are electronically collected using FRIS. The software will alert the user to filter conditioning
data or reference filter weight changes that exceed CFR requirements. Management of test and
equipment QC data is illustrated in Figure 4.
Engine Information from
Manufacturer
Engine Performance Data
Test Facility Raw Data
Pre-testPM filter Weight
Post-test PM filter Weight
Assemble Data
Data Entry and
Calculations
QC Review
Test Report
ADQ Report
FIGURE 4. ETV DATA MANAGEMENT
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GROUP C: ASSESSMENT AND OVERSIGHT ELEMENTS
Cl: Assessments and Response
As a testing organization to APCT Center, SwRI's quality and technical systems will be
evaluated according to ETV QMP Part A Section 9.0, APCT Center QMP Section 3.4, and
retrofit devices GVP Section 11.0.
Cl.l. Internal Audits
Internal audits of AE, EEVRD, and ER&DD are conducted for compliance to ISO 9001 and ISO
17025. Procedure for internal audits is documented in AE SOP 4.17.
C1.2. External Audits
External audits by APCT Center and EPA include quality system audits (QSAs) or technical
system audits (TSAs) as described in retrofit devices GVP Section 11.1. The APCT Center or an
EPA designate will conduct a QSA before tests begin using this TQAP. Additional assessments
of SwRFs quality system will be determined by the APCT Center QM. The APCT Center or an
EPA designate will conduct a TSA before tests begin under this TQAP. Subsequent technical
systems audits will be conducted once a year or prior to testing of a candidate technology. QSAs
will be conducted in accordance with EPA QA/G-3 and TSAs will be conducted in accordance to
EPA QA/G-7
C1.3. Audits of Data Quality
In accordance to ETV QMP Part A Section 9.0, APCT Center QMP Section 3.4, and retrofit
devices GVP Section 11.0, the SwRI QM will conduct an ADQ by examining at least a 10
percent random sample of all verification test data. The QM's review of the test data will be
performed after all data are collected and 100 percent are verified by project personnel. The
QM's review will include data recording, transfer, summarizing, and reporting. Because data
calculations are performed from the emissions database using compiled software, the QM will
not be required to perform hand calculations. Verification of database calculations can be
forwarded to APCT Center upon request.
The ADQ report will include a detailed review of QA/QC data as required by DQOs and DQIGs.
The report will summarize project equipment malfunctions, nonconformances, and/or testing
problems that resulted in lost data and subsequent corrective actions.
C1.4. Corrective Action
Corrective action that results from an audit or assessment is performed according to AE SOP
4.13.
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C2: Reports to Management
Internal assessment reports will be reviewed by the SwRI QM, who will respond to APCT
Center. A written report for the ADQ will be submitted to APCT Center approximately the same
time as the final test report.
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GROUP D: DATA VALIDATION AND USABILITY ELEMENTS
Dl: Data Review, Verification, and Validation
Procedures for recording and verifying/validation test and calibration data are given in AE SOP
4.10.2 and SOP 4.15.2. The EEVRD TIPs listed in Appendix A Tables 4-1 and 4-2 contain
procedures for data acceptance criteria and personnel responsible for data verification.
D2: Verification and Validation Methods
The majority of test and calibration data are reviewed and verified manually from data forms and
calibration sheets. Verification of test data that are entered into the ETIS database is a manual
review of transcribed data. Personnel responsible for data entry verification/validation are given
in AE SOP 4.15.2. ETIS contains features that will alert the user to data that exceed CFR
requirements or equipment calibration limits. Data that are determined to be out of limits are
verified for correct entry otherwise the data are a test nonconformance. QA for PM sample
filters is assisted by FRIS. The software will alert the user to filter conditioning data, checkout
time, or reference filter weight changes that exceed CFR requirements. Filter data that are
determined to be out of limits are test nonconformances.
D3: Reconciliation with User Requirements
Emission results for an engine or emission control device are normally accepted as-is provided
that all QA/QC information is reconciled with CFR requirements. Limits for accuracy or
precision are not normally set or determined for emission results. Test data will be acceptable
for ETV if all DQOs and DQIGs are met.
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APPENDIX A: APPLICABLE DOCUMENTS AND PROCEDURES
1. EPA Documents
EPA. Policy and Program Requirements for the Mandatory Agency-wide Quality System. EPA
Order 5360.1 A2. U.S. Environmental Protection Agency. May 2000.
EPA. EPA Requirements for Quality Management Plans. EPA QA/R-2, EPA Publication No.
EPA/240/B-01/002. U.S. Environmental Protection Agency, Office of Environmental
Information. Washington, DC. March 2001.
EPA. Environmental Technology Verification Program, Quality Management Plan. EPA
Publication No. EPA/600/R-08/009. http://www.epa.gov/etv/pubs/600r08009.pdf. Office of
Research and Development, U.S. Environmental Protection Agency. Cincinnati, OH. January
2008.
EPA. EPA Requirements for Quality Assurance Project Plans. EPA QA/R-5, EPA Publication
No. EPA/240/B-01/003. Office of Environmental Information, U.S. Environmental Protection
Agency, March 2001.
EPA. Guidance for Quality Assurance Project Plans. EPA QA/G-5, EPA Publication No.
EPA/240/R-021/009. Office of Environmental Information, U.S. Environmental Protection
Agency, December 2002.
EPA. Guidance on Technical Audits and Related Assessments for Environmental Data
Operations. EPA QA/G-7, EPA Publication No. EPA/600/R-99/080. Office of Environmental
Information, U.S. Environmental Protection Agency, January 2000.
2. APCT Center Documents
APCT Center. Verification Testing of Air Pollution Control Technology - Quality Management
Plan. RTI International. Research Triangle Park, NC. March 2010.
APCT Center. Generic Verification Protocol (GVP) for Diesel Exhaust Catalyst, Paniculate
Filters, and Engine Modification Control Technologies for Highway, Nonroad, and Stationary
Use Diesel Engines. Research Triangle Institute, Research Triangle Park, NC. January 2002.
3. SwRI AE Standard Operation Procedures
These documents are proprietary but will be made available to APCT Center and EPA staff
during on-site assessments.
QSM Quality System Manual - Rev. 3, February 2009
AE SOP 4.10.2 Test Conduct and Recording of Test and Calibration Data
AE SOP 4.11.1 Calibration and Maintenance
AE SOP 4.13 Nonconformance, Preventive and Corrective Action, Customer Complaints
AE SOP 4.15.2 Data Control and Reporting
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AE SOP 4.16 Quality Records
AE SOP 4.17 Internal Quality Audits
AESOP 4.18 Training
4. SwRI EEVRD Test and Inspection Procedures
These documents are proprietary but will be made available to APCT Center and EPA staff
during on-site assessments.
TABLE 4-1. CALIBRATION PROCEDURES
TIP 06-002 NOX Converter Efficiency Determination
TIP 06-007 Naming Monthly Calibration Gas
TIP 06-011 Propane Recovery Check
TIP 06-012 Monthly Calibration of Analyzers for Continuous Gaseous Exhaust Using Horiba
Emissions Bench
TIP 06-013 Temperature Calibration and Thermocouple Verification
TIP 06-017 Torque Meter Calibration Check
TIP 06-018 Engine Speed Readout Verification
TIP 06-020 Pressure Calibration and Verification
TIP 06-036 Verification of Zero Gas
TIP 06-041 NOX Analyzer CO2 Quench Check
TIP 06-044 Hydrocarbon Analyzer Optimization
TIP 06-046 Calibration of Gas Meter
TIP 06-049 Wet CO2 Interference Check of CO Analyzer Integrated in Horiba MEXA
7000 Series Emissions Benches
TIP 06-050 HC Analyzer and Sample System Response Checks of Horiba MEXA 7000 Series
Emissions Benches
TIP 06-051 NOX Analyzer and Sample System Response Check of Horiba MEXA 7000 Series
Emissions Benches
TABLE 4-2. TEST PROCEDURES
TIP 07-009 Emissions Testing During Heavy-Duty Diesel Engine Transient Cycle
TIP 07-020 Particulate Filter Conditioning and Weighing in Accordance with CFR Title 40
Parts 86 and 89
TIP 07-038 Steady-State Dilute Emissions Testing of Heavy-Duty Engine Using Horiba
MEXA-7200D Emissions Bench
TABLE 4-3. DATA ENTRY PROCEDURES
TIP 08-005 Data Transfers and Calculations of Dilute Steady-State Engine Data
TIP 08-016 Heavy-Duty Transient Test Data Processing
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