NAVISTAR MPAPS F-7137-2014 Nonmetallic Tubing for SCR Systems.pdf

1、 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. February 2014 Page 1 of 9 NAVISTAR, INC. Material, Parts, and Process Specificati

2、ons (MPAPS) NUMBER: MPAPS F-7137 Former Designation: TMS-7137 TITLE: Nonmetallic Tubing for SCR Systems CURRENT REV No.: 1402 DATE: Feb. 2014 WRITTEN/EDITED BY: Materials Engineering APPROVED BY: Materials Engineering SUPERSEDES: TMS-7137 - February 2012 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIF

3、IED FOR CURRENT REVISION This specification may involve hazardous materials, equipment, and procedures. This specification does not purport to address all of the safety issues associated with its use. The user is responsible to consult appropriate safety and health practices and to determine the app

4、licability of regulatory limits prior to use. Change Notice: Deleted (2.3) Type C and all subsequent references, modified (4.4) Cleanliness, modified (4.6.3) Extraction in DEF, deleted (4.6.5) Media Resistance to DEF, deleted (4.6.6) Resistance to Ammonia, modified (4.7.11) Pressure Impulse, added t

5、echnical contact (10.0), editorial changes. 1.0 APPLICATION This specification outlines the requirements for hoses used to transport Diesel Emissions Fluid (DEF) or ammonia gas for the Selective Catalytic Reduction (SCR) exhaust after-treatment system. These lines are designed to be used in altitude

6、s ranging from -300ft. to 14,000ft. 2.0 SCOPE This specification covers the general requirements, property and performance requirements, quality control, and KCC requirements for SCR lines. 2.1 Type A: Designates a 6 mm DEF suction and throttle line hose. These lines must be able to withstand 300 mb

7、ar of vacuum without collapse. Additionally, these lines must terminate in 1/4”, 5/16”, or 3/8” SAE J2044 quick connect fittings. The maximum length of these hoses is 2 m and the maximum supply line pressure loss at the dosing unit inlet must be less than 200 mbar. This tubing must be capable of ope

8、rating in an ambient temperature range of -40o C to 50o C. The line heating elements should be designed so that the DEF temperatures do not exceed 30o C sustained and do not to spike over 40o C. 2.2 Type B: Designates a 6 mm tube used in DEF pressure line applications. These lines must be able to wi

9、thstand normal operating pressures of 9 bar and spikes of 13 bar. These lines must be less than 3 m in length and exhibit a pressure loss of less than 200 mbar. The ends of these lines must terminate in a 1/4”, 5/16”, or 3/8” SAE J2044 quick connect fitting. This tubing must be capable of operating

10、in an ambient temperature range of -40o C to 50o C. The line heating elements should be designed so that the DEF temperatures do not exceed 30o C sustained and do not to spike over 40o C. 2.3 Restricted Chemical Substances All product supplied to the requirements of this specification must comply wi

11、th the requirements of the MPAPS B-50 specification. 2.4 Safety This specification does not address the safety of the chemicals or procedures used. It is up to the user to use good laboratory safety practices and take all appropriate safeguards in using, mixing and storing these chemicals. NUMBER: M

12、PAPS F-7137 TITLE: Nonmetallic Tubing for SCR Systems REVISION: 1402 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. February 2014

13、 Page 2 of 9 3.0 REFERENCE DOCUMENTS Unless otherwise specified the latest issue of all referenced standards shall apply. The following specifications and standards are referenced in this specification: Quality System Standard ISO 9001 or TS-16949 SAE J2044 Cummins AEB 21.112 ASTM D 638 NAVISTAR CEM

14、S F-2 ISO 22241-1 CFR Title 29, Part 1910 ISO 16750-2 NAVISTAR MPAPS B-50 ASTM B 117 4.0 GENERAL REQUIREMENTS All lines shall comply with Cummins AEB 21.112. 4.0.1 DEF Requirement: All references to DEF shall refer to DEF complying with ISO 22241-1 4.1 Material All types of tubing must be able to wi

15、thstand repeated freezing and thaw cycles. All electrical heating components are to function on 12 V systems. All DEF contacting materials must be chemically compatible with both DEF and water at operating temperatures. 4.1.1 Type A Construction: A core of seamless polyamide (PA), perfluoroalkoxy (P

16、FA), or ethylene propylene (EPDM) material. The core should be covered with an electrical resistance heating element and then separated by an insulating air gap before being covered by an outer cover made from PA, PP, or EPDM foam. 4.1.2 Type B Construction: A core of seamless PA or EPDM material. T

17、he core should be covered with an electrical resistance heating element and then separated by an insulating air gap before being covered by an outer cover made from PA, PP, or EPDM foam. 4.2 Appearance The tubing shall compare to and be equivalent in surface finish and color to the original samples

18、approved by NAVISTAR Integrated Product Development. Tubing supplied to this specification shall be smooth and uniform, free from any visible defects, foreign matter, kinks, seams or any other condition that would impair the performance. 4.3 Color Tubing color formulation shall be consistent in hue

19、and of uniform saturation. For all SCR line types, the outer cover and the principle color of the quick connect fittings shall be solid black in color, unless otherwise specified. 4.4 Cleanliness All supplied DEF assemblies must meet the particulate contamination requirements in CEMS F-2 Sec. 5.3. A

20、dditionally, all assemblies must be supplied free of grease and oil. The use of paper or cloth towels to clean components is prohibited to prevent contamination of the lines with fibers and fluffs. All plastic debris or flash from cutting and processing shall be removed. All assemblies should be shi

21、pped with protective shipping caps. These caps must stay in place for shipping and storage and should not be removed until final installation on the vehicle. 4.5 Tolerances Table 1 tolerances shall be used unless the engineering print specifically directs otherwise. NUMBER: MPAPS F-7137 TITLE: Nonme

22、tallic Tubing for SCR Systems REVISION: 1402 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. February 2014 Page 3 of 9 TABLE 1 DEF

23、 LINE TOLERANCES SCR Line Type OD (Tube) OD Tolerance (Tube) ID (Tube) ID Tolerance (Tube) OD (Cover) OD Tolerance (Cover) ID (Cover) ID Tolerance (Cover) A determine elongation and tensile strength from original tube area. Rate of pull shall be 50 mm per minute.) 4.6.2.2 Required: 24 MPa minimum te

24、nsile strength and 200% minimum ultimate elongation. 4.6.3 Extraction in DEF 4.6.3.1 Method: Store ten tensile bars, with dimensions per ASTM D638 Type I , or bars of equivalent surface area, for each material in contact with DEF (i.e. both DEF line and quick connect materials, if different) in 1 kg

25、 of DEF for 500 hours at a fluid temperature of 23o 3o C in polyethylene Nalgene or glass containers. Following the 500 hours exposure, the tensile bar samples shall be removed from solution and discarded, and the DEF solution drained. The DEF solution shall be filtered with a general purpose paper

26、filter and all of DEF solution retained in a polyethylene Nalgene or glass sample bottle. The general appearance, odor, turbidity, and foaminess of the solution shall be reported and recorded as well as any indicators of DEF line material degradation including amount of filtrate separated from solut

27、ion. Photographs of the filtrate shall be submitted and if an excess of filtrate is observed, indicating material degradation, samples shall be submitted to Navistar Materials Engineering for approval. ICP-OES or ICP-AES may be required on the retained, filtered DEF per Navistar Materials Engineerin

28、g. 4.6.3.2 Required: The metal concentrations in the DEF shall be within the Limit Value after Storage column shown in Table 3. Values shall be reported to the appropriate Navistar Design Engineer. Metal concentrations in excess of those shown in Table 3 will result in failure. NUMBER: MPAPS F-7137

29、TITLE: Nonmetallic Tubing for SCR Systems REVISION: 1402 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. February 2014 Page 4 of 9

30、 TABLE 3 EXTRACTION LIMITS Element Unit Limit Value after Storage (Maximum) Calcium mg/kg DEF 2 Iron mg/kg DEF 0.5 Copper mg/kg DEF 0.5 Zinc mg/kg DEF 0.2 Chrome mg/kg DEF 0.5 Nickel mg/kg DEF 0.2 Aluminum mg/kg DEF 0.5 Magnesium mg/kg DEF 0.5 Sodium mg/kg DEF 2 Potassium mg/kg DEF 0.5 4.6.4 Media R

31、esistance to DEF 4.6.4.1 Method: Fill five lines with DEF, cap and store at 23o 3o C for 1000 hours. The lines should be 35 cm in length. Every seven days, the lines shall be drained of DEF, stored, and replaced with fresh DEF. The drained DEF solution shall be filtered with a general purpose paper

32、filter and all of DEF solution retained in a polyethylene Nalgene or glass sample bottle. The general appearance, odor, turbidity, and foaminess of the solution shall be reported and recorded as well as any indicators of DEF line material degradation including the amount of filtrate separated from s

33、olution. Photographs of the filtrate shall be submitted and if an excess of filtrate is observed, indicating material degradation, samples shall be submitted to appropriate Navistar Design Engineer for approval. For plastic DEF tanks, if there is an excess of filtrate indicating degradation of the p

34、lastic tank materials, samples shall be analyzed with ATR and GCMS for evidence of plastic degradation. 4.6.4.2 Required: If filtrate is found, the analytical results shall be submitted to Navistar Design Engineering. There shall be no corrosion products or products of plastic degradation evident. 4

35、.7 Property And Performance Requirements - Tubing and Fitting Assemblies Assemblies shall meet the requirements of SAE J2044 (except sections 6.5 “Electrical Resistance”, 6.6 “Resistance to Evaporative Emissions”, and 7.4 “Fuel Compatibility”), and where otherwise noted in section 4.7 of this docume

36、nt. 4.7.1 Low Pressure Leak Test- Type A ONLY 4.7.1.1 Method: Per SAE J2044 4.7.1.2 Required: Maximum leak rate 2 scc/min. (1.19cc/min) at stabilization. 4.7.2 High Pressure Leak Test- Type B ONLY 4.7.2.1 Method: Per SAE J2044 4.7.2.2 Required: Maximum leak rate 5 scc/min. (0.45 cc/min) at stabiliza

37、tion. 4.7.3 Vacuum Leak Test- 4.7.3.1 Method: Per SAE J2044 4.7.3.2 Required: Maximum leak rate 2 scc/min. (2.14 cc/min) at stabilization. 4.7.4 Assembly Effort 4.7.4.1 Method: SAE J2044 section 6.2.1 “Test Procedure (New Parts)” ONLY (do not test to SAE J2044 Sec. 6.2.2 and do not add any lubricati

38、on to the quick connect fittings). 4.7.4.2 Required: Maximum first time assembly effort must not exceed 67 N (15 lbf) for male tubes sizes 5/16”. 4.7.8 Corrosion 4.7.8.1 Method: 500 hours salt spray exposure per ASTM B 117 4.7.8.2 Required: Samples must meet the functional requirements of the applic

39、able Leak Test from Sec. 4.7.1 or 4.7.2, 4.7.4 Assembly Effort, 4.7.5 Pull Apart Effort, and SAE J2044 Sec. 6.4 Side Load Capability. 4.7.9 Resistance to Zinc Chloride (50% aqueous solution for 200 hours at RT) 4.7.9.1 Method: Expose assemblies for 200 hours at 23o 3o C per SAE J2044 4.7.9.2 Require

40、d: No cracks or fractures of the assembly and Samples must meet the functional requirements of the applicable Leak Test from Sec. 4.7.1 or 4.7.2, 4.7.4 Assembly Effort, 4.7.5 Pull Apart Effort, and SAE J2044 Sec. 6.4 Side Load Capability. 4.7.10 External Chemical and Environmental Resistance 4.7.10.

41、1 Method: Use SAE J2044 Sec. 7.3 “External Chemical and Environmental Resistance” with additional testing using DEF and battery acid. The battery acid should be painted on with a chemical compatible brush for only a two hour contact time, rather than immersion. The DEF and battery acid test specimen

42、s should be rinsed with water fluid aging time. 4.7.10.2 Required: Samples must meet the functional requirements of the applicable Leak Test from Sec. 4.7.1 or 4.7.2, 4.7.4 Assembly Effort, 4.7.5 Pull Apart Effort, and SAE J2044 Sec. 6.4 Side Load Capability. 4.7.11 Pressure Impulse 4.7.11.1 Method:

43、 Per SAE J2044 Sec. 7.5.8 method A. The test shall be modified to run 250,000 cycles at 100o C and the DEF should be cycled from 0 to 9 bar. The test should be run using two sets of three specimens, one set in a new condition and the other set aged for 30 days in 23o 3o C DEF. 4.7.11.2 Required: No

44、leakage during the applicable leak test from Sec. 4.7.1 or 4.7.2. 4.7.12 Life Cycle 4.7.12.1 Method: SAE J2044, DOT4 brake fluid made be substituted for Mobil Arctic 155 oil 4.7.12.2 Required: Samples must meet the functional requirements of the applicable Leak Test from Sec. 4.7.1 or 4.7.2, 4.7.4 A

45、ssembly Effort, 4.7.5 Pull Apart Effort, and SAE J2044 Sec. 6.4 Side Load Capability. 4.7.13 Vibration Test 4.7.13.1 Method: ISO 16750-3 Test VI, 700 mm lines completely filled with DOT4 brake fluid and pressurized to 9 bar. NUMBER: MPAPS F-7137 TITLE: Nonmetallic Tubing for SCR Systems REVISION: 14

46、02 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2014 by Navistar, Inc. February 2014 Page 6 of 9 4.7.13.2 Required: No cracks or fractures of the asse

47、mbly and no leakage during the applicable leak test from Sec. 4.7.1 or 4.7.2. 4.7.14 Insulation Resistance 4.7.14.1 Method: Test according to ISO 16750-2 with quick connects fitted to line assemblies with a test voltage of 100V DC and an ambient humidity of 50%. A deviation to use climate chamber in

48、stead of “damp heat cycle” is permitted. 4.7.14.2 Required: Insulation resistance greater than 10 M 4.7.15 Overheating at Maximum Voltage 4.7.15.1 Method: Simulate overheating by switching-on the electrically heating system at maximum voltage, at room temperature (23 3C), for 30 minutes. 4.7.15.2 Re

49、quired: No areas of the hose are allowed or quick connects are allowed to exceed 110o C. 4.7.16 Defrost Performance 4.7.16.1 Method: Completely fill DEF lines using DEF and pressurize the lines to 0.5 bar. Place assemblies into a thermal chamber at -30o C ambient for 2 hours and then heat the assembly under normal voltage while still at -30o C. Additionally, run the aforementioned procedure with separate DEF lines conditioned for 2 hours at -40o C. 4.7.16.2 Required: Assemblies mus