Aftertreatment Exhaust Leakage

CES Application Engineering - AE Training

May 2013
 Trainers
Syed Ullah (OEM Integration Engineer – QSX 15 Aftertreatment)
Vivek Jaryal (Application Support Engineer – Current Product)

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 Tier4 Final IQA Test List

Exhaust Leakage Test

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 Information Security

Protect Information - Competitors desire to know what

we are doing

Discuss only with other team members who have a

“Valid Right and Need to Know”

Information shared should be clearly stated as

Cummins Confidential and the vehicle OEM should
use same “Need to Know” criteria for distribution
within their company

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 Objectives

 After completing this course you will be able to:

 Understand the importance for performing Aftertreatment
Leakage Testing
 Know the background of how the Downpipe Leak Rate was
Developed
 Understand the Test Procedure and Acceptance Criteria
 Be familiar with the Test Equipment
 Be able to use the Advisor Leakage Estimate Tool

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 Reference AEB’s

AEB Description
AEB 24.61 Industrial MR (QSB6.7 and QSL9) Tier 4 Final / Euro Stage IV Aftertreatment Installation
Off-Highway

Requirement
AEB 24.62 Industrial Tier 4 Final Aftertreatment Installation Requirements – QSX15

AEB 24.62 Exhaust Leakage Calculator

Attachment A
 Importance of Leakage Testing
 All exhaust emissions from the engine must be treated to meet
emission requirements
 Leakage in exhaust tubing, joints, and flexible sections could result in
noticeable leaks and odors. Heat may be also an issue from hot gas
leakage.
 Dosing fuel used for active regeneration has a strong odor even in a
moving vehicle
 Urea deposits can form at joints with exhaust leaks where urea is
present Diesel Exhaust Fluid (DEF)
• Used to deliver Ammonia to SCR catalyst
• Non-toxic solution of 32.5% Urea and 67.5% Deionized Water
• DEF is safe to handle and store
•Non-toxic
•Non-polluting
•Non-flammable
• DEF freezes at 12° F (-11° C). Concentration does not change
with freezing (partial freezing / thawing of vehicle tank)
• DEF is slightly alkaline with a pH of approximately 9
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 How Was the Downpipe Leak Rate Developed?

 Equipment
– Portable emissions analyzer
– 6-10 observers to quantify the odor
 Evaluation method
– Orifices of various sizes with valves were installed in a downpipe
– Engine was operated in regeneration mode with stationary vehicle
– Orifices were opened in combinations to simulate leaks
– Evaluators determined when the smell became offensive
– Constituents of the emissions were measured
– Allowable pressure and flows determined for a test method to
simulate the maximum allowable leak without offensive smell

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 Difference between Tier4i and Tier4 Final Leakage Test

Metric Tier4i Tier4 Final

Components subjected for Downpipe Downpipe and Ancillary

leakage test Tubing
Tools Required CES Exhaust Leakage kit CES Exhaust Leakage kit*

Leakage Calculator AEB 24.40 Attachment D AEB 24.62 Attachment A

*Different leakage plugs will be required for Ancillary tubing test.

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 Advisor Leak Test Tool
For Industrial Applications
 Leakage test is waived if Advisor/Leakage Calculator estimate is within
leakage specification
 An identical calculator is available for download on GCE as AEB24.40
Attachment D (Tier4i) and AEB 24.62 Attachment A (Tier4 Final)

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 Tier4 Final Leakage Calculator

Data Input

Ancillary Tubing
Downpipe Input
Input Form Downpipe
Form
Results
Ancillary Tubing
Results

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 Test for Aftertreatment System Downpipe

Aftertreatment Test 1 of 3: Measure leakage

of Downpipe only (Required)

General Testing Procedure (Refer to appropriate AEB for detailed instructions)

1. Disconnect the engine downpipe from the turbo out and from the aftertreatment inlet
connection.
2. Plug the ends of the downpipe leak test end caps and connect leak testing equipment.
Ensure that all clamps are properly torqued.
3. Slowly pressurize the system per specification in AEB
4. Check to ensure that the plugged ends are not causing leakage. If leakage is seen,
turn the pressure off and fix the area of leak. If no leakage, move to next step
5. Wait for flow rate reading to stabilize and then record the flow. An acceptable system
must not exceed the flow requirements specified in AEB
6. Determine flow rate from individual leak paths, compare to limits in applicable AEB

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 Test for System with DPF / DOC and SCR (Whole assembly leakage test)

Test #2 of 3: Measure
leakage from DPF to
SCR (Recommended)

General Testing Procedure (Refer to appropriate AEB for detailed instructions)

1. Disconnect the engine downpipe from the turbo out and from the aftertreatment inlet connection. For
Total system leak test disconnect the downpipe from aftertreatment inlet connection and disconnect the
tail pipe from the SCR outlet connection.
2. Plug the ends of the system you are testing with leak tester plugs and connect leak testing equipment.
Ensure that all clamps are properly torqued.
3. Slowly pressurize the system per specification in AEB
4. Check to ensure that the plugged ends are not causing leakage. If leakage is seen, turn the pressure off
and fix the area of leak. If no leakage move to next step
5. Wait for flow rate reading to stabilize and then record the flow. An acceptable system must not exceed
the flow requirements specified in AEB
6. Determine flow rate from individual leak paths, compare to limits in applicable AEB

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 Test for System with Ancillary Tubing

Test #3 of 3: Measure
leakage between DPF
and SCR (Required)
Decomp Tube

When ancillary tubing (all components between the DPF outlet and SCR inlet) contains any
component not supplied by CES, than a separate leak check of this assembly will be required.
1. Leakage from all tubing and joints connecting the DPF to the SCR device must not exceed 0.7 scfm
when pressurized to 4.5 psig.
2. The system must not have any single leak path greater than 0.2 scfm.
3. An on-vehicle or bench test of the system must be carried out to validate this requirement.
4. When a flexible member/joint is incorporated into the ancillary tubing design the leakage from all
tubing and joints connecting the DPF to the SCR device must not exceed 1.0 scfm when
pressurized to 4.5 psig.
5. The flexible member/joint contribution to the total leakage must not exceed 0.3 scfm. A leak proof
flex (bellows) is typically required in order to meet this specification.

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 Acceptance Criteria
*Always download latest AEB from GCE to determine latest procedure and acceptance criteria

Test Ref Doc Air Pressure Max Leak Max Flow Adjustment for
Configuration Rate From One Multiple Joints
Location

Add’l 0.5 cfm from

Downpipe to DPF 4.5 psig 1.0 CFM 0.5 CFM flex section
AEB24.61
AEB 24.62

2 – 1.5 CFM
3 – 1.6 CFM
Based on # of
DPF / SCR Assy AEB24.61 4.5 psig N/A 4 – 1.7 CFM
AEB 24.62 joints 5 – 1.8 CFM
6 or more -1.9 CFM
Add’l 0.3 CFM
Ancillary Tubing AEB24.61 4.5 psig 0.7 CFM 0.2 CFM from flex section
AEB 24.62

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 Acceptance Criteria
*Always download latest AEB from GCE to determine latest procedure and acceptance criteria
Test Ref Doc Test Set Up Information to Document
Configuration

1. Total leakage flow rate (SCFM)

2. Leakage flow rate from largest single
Downpipe to DPF Bench or In Chassis
AEB24.61 source(SCFM)
AEB 24.62 3. Contribution from flex section (SCFM)

1. Total Leakage Flow Rate

DPF / SCR Assy AEB24.61 In Chassis 2. Number of joints between DPF and
AEB 24.62
SCR

1. Total leakage flow rate (SCFM)

2. Leakage flow rate from largest single
Ancillary Tubing AEB24.61 Bench or In Chassis
AEB 24.62 source(SCFM)
3. Contribution from flex section (SCFM)

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 Additional Thoughts
 Not all exhaust systems are designed equally
– Depending upon packaging constraints the AT is located in different
locations and in different configurations
– Different number of joints or type of joints are used to design the exhaust
system routing
 Design for zero leakage (OEM responsibility)
– Use gaskets whenever possible
– Use low leakage flex sections
– Ensure proper alignment between various components (Axial, radial,
and angular alignment of aftertreatment components is critical to ensure
low joint assembly stress and to meet exhaust leak requirements)
– Pay attention to welded joints on flex tubing
– Avoid slip joints for DPF, SCR systems
– Slip joints with U-Bolt-style clamp will not pass leakage limits for any
CES system
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 Test Equipment
 Safety equipment (PPE)
 Leak test end caps (4)
1. 3.5” diameter full Marmon end cap (MR Automotive /Industrial)
2. 4” diameter full Marmon end cap (MR&HD Automotive /Industrial)
3. 5” diameter full Marmon end cap (MR&HD Automotive /Industrial)
4. 4” and 5” Spherical flare end Cap (MR&HD Automotive /Industrial)
5. 4” and 5” Spherical Marmon end cap (MR&HD Automotive /Industrial)
 Leak test kits (2)
1. MR&HD leak test kit (Automotive /Industrial)
 Spray bottle with soap
 Plug(s) for drain holes in DPF, SCR, etc
 Duct tape and Teflon tape
 Plumbers putty
 Wrenches to tighten clamps
 Long-Stem Test Plugs

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 Leak Test Kit (MR&HD Automotive/Industrial)
Flow meter Stratoflex hose
(0.4 to 4 scfm)

Notes
Pressure gauge 1. Connect ends A-A
(0 to 15 psi) 2. Connect ends B-B
3. Connect end C to pressurized
air supply
Air Regulator
4. Connect end D to leak test
(1 to 30 psi, 250 psi max)
end cap
 Contact CES Application Engineering team (Vivek Jaryal) at CES to borrow this kit
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 Leak Test End Caps- MR&HD Automotive / Industrial
4 inch Diameter
Full Marmon End Cap
PN: A034P979

3.5 inch Diameter 5 Inch Diameter

Full Marmon End Cap Full Marmon End Cap
PN: A034P978 PN: A034P980

 Contact Brenda Slovacek at CES to order the Leak Check Caps.

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 Leak Test End Caps- MR&HD Automotive / Industrial

4 inch Spherical 5 inch Spherical 4 inch Spherical 5 inch Spherical

flare end Cap flare end Cap Marmon end cap Marmon end cap
CES PN: CES PN: CES PN: CES PN:
A034P988 A045S286 A034P982 A045S284

 Contact Brenda Slovacek at CES to order the Leak Check Caps.

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 Long-Stem Test Plug

3 inch Long-Stem Test

Plug

 Available on McMaster-Carr to purchase (Select required size)

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 CES IQA Tools Page in GCE

Step 2: Link to Leakage test kit info

Step 1: Link to CES IQA Tools page in GCE

Link:
https://gce.cummins.com/ces/ces_main/index.html

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 CES IQA Tools Page in GCE (Cont.)

BOM list for Leakage test kit

Part no Supplier Name Price

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 Summary – Exhaust Leakage

Exhaust Leakage Testing:

 Understand the importance for
performing Aftertreatment Leakage
Testing
 Know the background of how the
Downpipe Leak Rate was
Developed
 Understand the Test Procedure
and Acceptance Criteria
 Be familiar with the Test Equipment
 Be familiar to use the Advisor
Leakage Estimate Tool

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 Change Control

Date Author Description Pages

Dec 11, 2012 Vivek Jaryal, Orvin Original document published All
Kendall
Jan 28, 2013 Orvin Kendall Revised pages to reflect updated AEB 21, 22, 23
21.112 information
Feb 4, 2013 Orvin Kendall Included Appendix Items regarding plug 29-34
usage
Mar 18, 2013 Vivek Jaryal Added slide no. 16, Revised slide 13 and 16, 13, 31-35
Appendix

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 Appendix

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 Downpipe Leakage plug requirement

Engine Family Turbo out Turbo out Downpipe Aftertreatment Aftertreatment Downpipe
connection connection inlet plug inlet connection outlet plug
type size required connection size required
type

QSB 4.5 Half marmon 3.1” 3.1” half Standard 4” 4” standard

marmon marmon Marmon
QSB 6.7<174 Standard 3.5” 3.5” Standard Standard 4” 4” standard
marmon Marmon marmon Marmon
QSB 6.7>174 Standard 3.5” 3.5” Standard Standard 5” 5” standard
marmon Marmon marmon Marmon
QSL 9 Standard 4” 4” Standard Standard 5” 5” standard
marmon Marmon marmon Marmon
QSX 15 Standard 4” 4” Standard Standard 5” 5” Standard
marmon Marmon marmon Marmon
 Ancillary tubing Leakage plug requirement

Engine Family DPF/DOC/DRT DPF/DOC/DRT Ancillary tube SCR inlet SCR Ancillary tube
out connection out connection inlet plug connection connection outlet plug
type size required type size required

QSB 4.5 Spherical 4”(side out 4” – 4”/5” spherical Spherical flare 4”(sidein)/5”(ei) 4”/5” spherical
Marmon eo – 5”) Marmon flare
QSB 6.7<174 Spherical 4”(side out 4” – 4”/5” spherical Spherical flare 4”(sidein)/5”(ei) 4”/5” spherical
Marmon eo – 5”) Marmon flare
QSB 6.7>174 Spherical 5” 5” spherical Spherical flare 4”(sidein)/5”(ei) 4”/5” spherical
Marmon Marmon flare
QSL 9 Spherical 5” 5” spherical Spherical flare 4”(sidein)/5”(ei) 4”/5” spherical
Marmon Marmon flare
QSX 15 Spherical 5” 5” spherical Spherical flare 5” 5” spherical
marmon Marmon flare
 System Leakage Test plug requirement

Engine Family System in System in System in plug System out System out System outlet
connection connectio required connection connection plug required
type n size type size

QSB 4.5 Standard 4” 4” Long Stem test Torca 4” 4” Long Stem

marmon plug test plug

QSB 6.7<174 Standard 4” 4” Long Stem test Torca 4” 4” Long Stem

marmon plug test plug

QSB 6.7>6.7 Standard 5” 5” Long Stem test Torca 4” (EO V -5”) 4/5” Long Stem
marmon plug test plug

QSL 9 Standard 5” 5” Long Stem test Torca 4” (EO V -5”) 4/5” Long Stem
marmon plug test plug

QSX 15 Standard 5” 5” Long Stem test Torca 5” 5” Long Stem

marmon plug test plug
 Summary of Leakage plug requirement
Leakage Plug Type Leakage Plug Size
Half marmon 3.1” Available (See Exhaust leakage
Presentation)
Standard flare 3.5” Not Required

Standard flare 4” Not Required

Standard flare 5” Not Required
Spherical flare 4” Not available

Spherical flare 5” Not available

Standard flare 5” Not Required (Required 4” Long Stem

test plug for system leak test )

Spherical marmon 4” Not available

Spherical marmon 5” Not available

Long Stem test plug 4” Need to Order from Mc Master

Long Stem test plug 5” Need to Order from Mc Master

Standard Marmon 3.5” Available (See Exhaust leakage

Presentation)

Standard Marmon 4” Available (See Exhaust leakage

Presentation)
 Summary of Leakage plug requirement

Leakage Plug Type Leakage Plug Size

Half marmon 3.1”

Standard flare 3.5”

Standard flare 4”

Standard flare 5”

Spherical marmon 4”

Spherical marmon 5”

Torca 4”

Torca 5”