understanding new generation regulations and … · emission certification laboratory arai progress...

UNDERSTANDING NEW GENERATION BSVI REGULATIONS AND TECHNOLOGY AND ON-

ROAD EMISSIONS MANAGEMENT

Prashant PawarGeneral Manager

Emission Certification Laboratory

ARAI

Progress Through Research1

Mar. 2020

WORKSHOP ONADVANCING ON-ROAD EMISSIONS MANAGEMENT TO BE BSVI READY

FOR Transport Department, WB

BY Center for Science and Environment

CONTENT Overview of ARAI

Emission Certification Lab-Overview of Activities and Facilities

Overview of Different Emission Regulations around the world

Progression of Emission Control In India and technology pathways for meeting BS-VI

Overview of BS VI Regulations in India

BS VI Emission Norms for different categories of vehicles

BS VI requirements

Laboratory Testing

OBD

Real Drive Emissions

In-use vehicle emission verification on field

PUC

Summary

2Mar. 2020

Establishment : 1966

Location : Pune, INDIA (150 km from Mumbai)

Manpower : 750+

Facilities : Powertrain, Emissions, Safety & Homologation, Passive Safety, Vehicle Evaluation, Materials, Automotive Electronics, NVH, CAE, Structural Dynamics, Calibration, Post Graduate Academy, Forging Industry Division, Homologation & Technology Centre

Reginal Office : ChennaiAffiliates : China and KoreaInvestments : 110 M USD

Accreditations : ISO 9001, 14001; OHSAS 18001; TRIAS and NABL ( ISO/IEC 17025),

An Overview

3

Forging Industry Division ARAI-FID, Chakan, Pune

Homologation & Technology Centre (ARAI-HTC), Chakan, Pune

Corporate OfficeARAI, Kothrud, Pune

Mar. 2020

Kothrud, Pune

Chennai, India

Chakan, Pune

Facilities

Regional Office

Takwe (Talegaon), Pune

ARAI-Location

4Mar. 2020

PROGRESSION OF EMISSION CONTROL IN INDIA

5Mar. 2020

Year Emission Norms

1984 Bombay Motors Vehicle Act in Maharashtra StateFor all gasoline 4-W vehicles Idling CO test limit 3% For all diesel vehicles Free Acceleration smoke test limit 65 HSU

1989 Idle Emission / Smoke test Regulation in India

1991 CMVR 115(3) -Mass Emission test on chassis dyno for all gasoline vehicles (CO & HC)CMVR 115(4) - Full load smoke & Free Acceleration smoke for diesel vehicles / engines

1992 CMVR 115(5) -Mass Emission for diesel vehicles/engines on Engine Dyno. (CO, HC & NOx)

1999 Bharat Stage I norms for 4W in National Capital Region (Oct )TREM I Emission norms for tractors, Stringent emission norms for 2/3 wheeler vehicles and diesel engines

2000 /2001

BS-II norms for 4-W in Metro Cities and rest of India BSI

2005 BSIII norms for 4W 11 cities & BSII all over India , BSII 2W-3W all over India, Trem III for tractors

2010 BSIV norms for 4W 11 cities & BSIII all over India , BSIII 2W-3W all over India, Trem IIIA for tractors

2017 BSIV for 4W Nationwide , BSIV for 2W-3W

2020 BSVI for 2W, 3W & 4W Nationwide

Pollution Control In India

6Mar. 2020

BSVI- Overview for 2W, 3W And 4W

7Mar. 2020

Types of

Certification

• Type approval

• Conformity of Production

• In-service conformity

• MoRTH/CMVR/TAP-115/116 Issue No. 4 : PROCEDURE FOR TYPE

APPROVAL AND CONFORMITY OF PRODUCTION (COP)

• AIS : For filing the application for Type approval

• Government notifications : Effective dates & limits, fuel

Specification, COP requirement

Important

Documents

BS VI EMISSION NORMS FOR DIFFERENT

CATEGORIES OF VEHICLES

8Mar. 2020

BS VI EMISSION NORMS FOR DIFFERENT

CATEGORIES OF VEHICLES

9Feb. 2020

BS-VI NORMS FOR 2-WHEELER VEHICLES

BS-VI NORMS FOR 3-WHEELER VEHICLES

BS-VI NORMS FOR M & N CATEGORY VEHICLES (<3.5T

GVW)

BS-VI NORMS FOR HEAVY DUTY ENGINES (>3.5T GVW)

CONFORMITY OF PRODUCTION (COP)

BS VI EMISSION NORMS REQUIREMENTS

39Mar. 2020

BS-VI : FOCUS ON QUALITY CONTROL

40

BS VI LDV emission requirements involve following main components

o Certification tests in the lab, Post certification requirements, such as COP

o In-use verification on field Vehicle for Emission compliance from April 2020

o PEMS test on vehicleo LDV RDE: data collection till 2023; CF will be applicable from 2023

onwards

o In-use verification on field vehicle for OBD performance ( IUPR) April 2023

Mar. 2020

BS-VI : FOCUS ON QUALITY CONTROL

41

BS VI HDV emission requirements involve following main components

o Certification tests on engine in the lab,

o Post certification requirements, such as COP on engine

o Emission test on ROAD using PEMS for HDV vehicleo HDV PEMS: data collection till 2023; CF will be applicable from 2023

onwards

o In-use verification on field vehicle for OBD performance ( IUPR) April 2023

o In service compliance from 2023

Mar. 2020

Test requirements for M& N Category vehicles Type I Test : Mass emission Test, Cycle: MIDC

Type II Test :

Spark Ignition – idling CO & HC and high idle CO and lambda,

Compression Ignition – Free acceleration smoke

For Diesel vehicles, the emission of visible pollutants (smoke) shall not exceed the limit value of smoke density, when expressed as light absorption coefficient for various nominal flows when tested at constant speeds over the full load.

Type III Test : Crankcase emission from vehicle is not permitted

Type IV Test :Determination of evaporative emission (gasoline vehicles)

(Hot Soak Loss Test -1 hr +Diurnal loss Test – 24hr) Limit :2g / test

IUPRm for BS-VI Vehicles manufactured on or after 1 April 2023 shall be greater than or equal to 0.1 .

RDE: During type approval and COP applicable from 1st April, 2020, real world driving cycle emission measurement using PEMS shall be carried out for data collection and from 1st April, 2023 real world driving cycle emission conformity shall be applicable.

42Mar. 2020

43

OVERVIEW OF BSVI REQUIREMENTS

HIGHLIGHT OF BSVI:- VEHICLE BELOW 3.5T

BS-IV BS-VI

Emission norms based on fuels, diesel,

CNG, LPG, Gasoline

Norms based on PI & CI engines.

Included many fuels.

Pollutants: CO, HC, Nox, (PI)

CO, HC+NOx , Nox, PM (CI)

PI- NMHC, PM & PN (GDI)

CI- PN

Fixed DF & Durability Durability & Fixed DF increased for

gases emissions and reduced for PM

Durability- Ageing test 80000 km 160000 km

OBD-I for vehicles manufactured on

& from 1/4/2010

OBD-II 1/4/2013

OBD I- 1/4/2020

OBD II – 1/4/2023

CO2 & FC (within < 4% of TA values

From 2017)

CO2 & FC (within < 4% of TA values)

RDE emission measurement during

TA & COP

IUPR from 1/4/2023

In service conformity

Mar. 2020

BSVI Test Applicability for HDV

➢ Engine power, full load smoke and free acceleration

smoke

➢ ECU torque validation

➢ Gaseous pollutant(CO,THC,Nox), PM, PN on WHSC,

WHTC

➢ Durability (WHSC/WHTC)

➢ OCE- WNTE (CI)

➢ OBD and NOx control measures (CI)

➢ PEMS demonstration at TA

➢ In service conformity and IUPR

Mar. 202044


HIGHLIGHT OF BSVI :- VEHICLES ABOVE 3.5T

BSIV BSVI Remarks

Test cycle ESC and ETC ( Hot Startonly)

WHSC ( hot start) & WHTC (cold and hot start cycle) Cold start weighting 14%.

WHTC & WHSC representative of worldwide real life heavy-duty engine operation.

Emission --- NOx emission ↓ 88% wrt Euro IVPM emission ↓ 66% wrt Euro IV

PN emission limit not Applicable

PN ( Particulate number) limit introduces for CI & PI engines

DPF technology.

OBD OBD WWH-OBD ( Stage 1 & 2) More than 90 to 95 % change in OBD architecture and algorithm wrt BSIV.

Faults demonstration on steady state cycle

Fault demonstration on WHTC cycle.

For anti tampering of emission components,60% or 75% torque reduction is applied depending on vehicle category.

For anti tampering low level and severe level driver inducement system.Low level inducement system torque reduction to 75%Sever level inducement system speed limit to 20 kmph.

45Mar. 2020

BSIV BSVI Remarks

OBD Threshold Limit NOX = 7.0 g/kWhPM = 0.1 g/kWh

Threshold Limit NOX = 1.2 g/kWhPM = 0.025 g/kWhCO = 7.5 g/kWh

IUPR ( In use performance ratio) not applicable

IUPR for all monitor shall be greater than 0.1In India, IUPR will be applicable from April 2023

IUPR defines minimum acceptable frequencies with which monitors shall run under real world conditions over the complete fleet

Off-cycleemission

NTE ( Not to exceed ) zone emission limit not applicable

Introduces requirement for emission compliance in NTE zone for all altitude above 82.5 kPa ~ 2500 meter

Engine optimization to be done over wide range of atmospheric condition and real driving condition.

PEMS demonstration test on vehicle is not applicable.

At the time of type approval vehicle will be tested for PEMS test on vehicle with CF ( conformity factor) 1.5 in EU, India CF will be applicable 2023


HIGHLIGHT OF BSVI:- VEHICLES ABOVE 3.5T

46Mar. 2020

BSIV BSVI Remarks

In -Service compliance .

ISC not applicable to BSIV.

ISC on vehicle using PEMS isintroduced.Manufacturer has to meet ISC for durable life of vehicle.For e.g. N3 vehicle having GVW above16T, ISC to be meet for 7,00,000 km or 7 years.

Ensures low emission during vehicle durable life period.


HIGHLIGHT OF BSVI:- VEHICLES ABOVE 3.5T

47Mar. 2020

OBD and Nox Control Requirements

The purpose of the On Board Diagnostics system is to facilitate efficient repair of emission related failures during vehicle operation

“Component Monitoring” that consist of monitoringo Electrical circuit failureo Rationality failure (input component or signal)o Functionality failure (output component or signal)

"Performance threshold monitoring" that consists of monitoring parameters that are not correlated to emission thresholdso Example: differential pressure in case of DPF monitoring

"Emission threshold monitoring" that consists of:o Direct emissions measurement via a tailpipe emission sensor(s) (NOx

sensor)

48

Overview of BSVI requirementsHighlight of BSVI:- Vehicles Above 3.5T

Mar. 2020

OBD and Nox Control Requirements

49

Monitoring Requirements - Typical BSVI System

Typically all emission related components need to be monitored• Sensors : - Temperature, pressure, engine speed, exhaust gas &

level etc.• Actuators:- Valves, injectors , pumps etc.


Mar. 2020

50

NOx OTL

mg/kWh

PM OTL

mg/kWh

Reagent quality &

consumption.

CD min consumption

IUPR All vehicle

OBD Stage 1 1500 Performance.

Monitoring (DPF)

NOx more

than 900

mg/kWh

50% Exempted 1.04.2020

OBD Stage 2 1200 25 NOx more

than 460

mg/kWh

50% OBD in use

performance

statement

applicable

1.04.2023

OBD, NOx control and IUPR proposed implementation dates for BSVI


Mar. 2020

51Mar. 2020

Overview of BSVI requirementsHighlight of BSVI:- Vehicles Above 3.5TNOx control is focused on anti-tampering requirements rather than on general thresholds

Driver Warning & Inducement Scheme

o Low level inducement followed by severe inducement

o Low level inducement: 25% torque reduction

o Severe inducement: vehicle speed limited to 20 km/h

Inducement Triggers

o Empty reagent tank

o Incorrect reagent quality: 900 mg/kWh Nox, in 2023- 460 mg/kWh

o Low reagent consumption: 50%

o Blocked EGR valve, failures of the SCR system and of the monitoring system

OBD and NOx control requirements

52

Monitor Low-level inducement Severe inducement

Reagent level Tank level ≤ 2.5 % Tank empty

Reagent quality 10 engine hours afterdetection

20 engine hours afterdetection

Low reagent consumption;interruption of dosing



Blocked EGR valve 36 engine hours afterdetection


Monitoring system failure 36 engine hours afterdetection


NOx Control – Inducement Activation


Mar. 2020

IN-USE VERIFICATION IN THE FIELD

Mar. 202053

Lab tests for in service conformity: LDV (GVW<3.5t)

Each “vehicle in-service family” will be tested 6 months after registration or 15000 km of first vehicle registration and to be completed within 18 months. Second cycle will begin 12 months after 1st cycle and will continue for 18 months and so on.

The vehicles selected from field based on the data provided by manufacturer, will be tested on chassis dyno for emissions. Based on the emission results, pass-fail will be decided.

Type approval

1st Registration of vehicle

18 months

18 months18 months

t………

Min 3 vehicle per family


54

LDV: IN-USE VERIFICATION IN THE FIELD

Mar. 2020

IN-USE VERIFICATION IN THE FIELD VEHICLE ABOVE 3.5TGeneral Overview

PEMS = Portable emission measurement system

Emissions are measured with PEMS in the vehicle during normal operation / real vehicle driving conditions

Evaluation is based on ECU data and continuous measurement of emissions in exhaust flow of the vehicle

3 different purposes for PEMS testing

PEMS at the time of type approval

PEMS for in-service-conformity testing

PEMS for market surveillance

55Mar. 2020

PEMS for In-service conformity : HDV (GVW>3.5t)

Each engine family to be tested 18 months after registration of first vehicle and every 2 years

thereafter over useful life period:

For the periodical in-service-conformity tests, it is not necessary to always take the same vehicles. For every in-service-conformity PEMS test, other vehicles may be taken, which fulfil the selection criteria stated in the regulation

At the request of the manufacturer the testing may stop five years after the end of production.

Type approval

1st Registration of vehicle

18 months 24 months 24 months t………




56

IN-USE VERIFICATION IN THE FIELD

Mar. 2020

REAL DRIVING EMISSIONS (RDE)

57Mar. 2020

REAL DRIVING EMISSION (RDE) MEASUREMENT OF LDV & HDV FOR INDIA

Real Driving Emissions (RDE)

Definition

RDE is a measurement method using portable emission

measurement systems (PEMS) for emissions determination of

vehicles under realistic conditions.

Ordinary vehicles

Public roads

Operated on work days

Use of Market fuels

58Mar. 2020

Key Factors & Compliance requirement:• For all 4W, Real drive emission measurement using PEMS is applicable from April, 2020 and

conformity factor will be applicable from April, 2023

Vehicle

Speed

Shares N3,

M2, M3 (M3

Type I)

Shares N2

Urban < 40 km/h 20% (70%) 25

Rural 40-60 km/h 35% (30%) 35

Motorway > 60 km/h 45% ( 0%) 40

Urban Rural Motorway

Speed 0 to ≤ 45 (M)

0 to ≤ 40 (N1)

0 to ≤ 45

(M1/N1 Low

Power)

>45 to ≤ 65 (M)

> 40 to ≤ 60 (N1)

>45 (M1/N1 low

Power)

> 65 (M)

> 60 (N1)

Trip (M1,

N1)34 % ± 10% 33% ± 10% 33% ± 10%

Vehicle speed & %Trip

share may be reviewed

based on Indian

condition

BSVI- RDE OVERVIEW FOR 4W

59Mar. 2020

60

BSVI- RDE OVERVIEW FOR 4W

Mar. 2020

Boundary Conditions for RDE test

Market fuel to be used during test

Temperature:Passenger cars Moderate 10 to 40 Deg C

Extended 8 to 45 Deg CFor HDV 0 to 42 Deg C

Altitude : Passenger cars Moderate < 700 meter

Extended 700 to 1300 meterFor HDV Pressure >=82.5kPa

To control driver behavior, limit for trip dynamics & altitude gain during test (Only for Vehicle below 3.5T)

PUC REQUIREMENTS FOR BS-VI VEHICLES

61Mar. 2020

PUC NORMS FOR BS-VI VEHICLES

Mar. 202062

Provisions GSR 881 (E) Provided also that the test as specified in the Table-A shall not

be carried out if the On Board Diagnostics (OBD) Malfunction Indication Lamp (MIL) of Bharat Stage IV and Bharat Stage VI vehicle (as applicable) is noticed to be in switched on condition after starting of engine, and in such cases, the vehicle shall be re-submitted for the above test after repair or servicing:

Provided also that in cases of CNG and LPG vehicles as specified at Sl. Nos. 1 and 3 of the Table A, the Lambda requirement shall be applicable to only Bharat Stage VI Compressed Natural Gas or Liquefied Petroleum Gas vehicles of categories M1 (with GVW not exceeding 7.5 tonnes), M2, N1, Quadricycle and two or three wheelers.”

Mar. 202063

2-W PETROL – PROGRESSION OF PUC LIMITS

Mar. 202064

PUC NORMS FOR BS-VI VEHICLES

Mar. 202065

Summary

For the first time, India will be having one fuel through out the country.

BS-VI has very stringent emission limits for all categories of vehicles

Emission Limits for 2W SI and 4W SI are same.

Implementation of BS VI will pose significant challenges to all vehicle manufacturers

BS VI OBD, IUPR, in-use compliance and RDE will ensure robustness of the design, calibration and quality control of the product over useful life of vehicle.

ARAI is fully geared up for accommodating BSVI testing requirements for certification and development

66Mar. 2020

Thank you

67Mar. 2020