NAVISTAR MPAPS F-7137-2016 Nonmetallic Tubing for SCR Systems.pdf

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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. 2016 by Navistar, Inc. OCTOBER 2016 Page 1 of 9 NAVISTAR, INC. Material, Parts, and Process Specificatio

2、ns (MPAPS) NUMBER: MPAPS F-7137 Former Designation: TMS-7137 TITLE: Nonmetallic Tubing for SCR Systems CURRENT REV No.: 1610 DATE: Oct. 2016 WRITTEN/EDITED BY: M. Ghaddar/ W. Cook APPROVED BY: R. Goluch SUPERSEDES: 1402 - February 2012 PRINTED COPIES OF THIS DOCUMENT MUST BE VERIFIED FOR CURRENT REV

3、ISION 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 applicability of regul

4、atory limits prior to use. 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 altitudes ranging from -3

5、00ft. 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 mbar of vacuum with

6、out 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 operating in an ambi

7、ent 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 withstand normal op

8、erating 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 in an ambient tem

9、perature 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 with the requiremen

10、ts 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: MPAPS F-7137 TITLE

11、: Nonmetallic Tubing for SCR Systems REVISION: 1610 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. 2016 by Navistar, Inc. OCTOBER 2016 Page 2 of 9 3.0 R

12、EFERENCE 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 MPAPS F-2 ISO 22241-1

13、 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 withstand repeated

14、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 (PFA), or ethylene

15、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. The core should be

16、 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 approved by NAVIS

17、TAR 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 and of uniform sa

18、turation. 4.3.1 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. 4.3.2 For all DEF return lines, the outer cover shall be blue in color. 4.4 Cleanliness All supplied DEF assemblies must meet the pa

19、rticulate contamination requirements in MPAPS F-2 Sec. 5.3. Additionally, 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

20、and processing shall be removed. All assemblies should be shipped 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. NUMBER: MPAPS F-7137 TITLE: Nonmetallic Tubing for SCR Systems REVISION: 1610 Thi

21、s 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. 2016 by Navistar, Inc. OCTOBER 2016 Page 3 of 9 4.5 Tolerances Table 1 tolerances shall be used unless the e

22、ngineering print specifically directs otherwise. TABLE 1 DEF 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 sha

23、ll be 50 mm per minute.) 4.6.2.2 Required: 24 MPa minimum tensile 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

24、 DEF line and quick connect materials, if different) in 1 kg 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

25、DEF solution shall be filtered with a general purpose paper 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 d

26、egradation including amount of filtrate separated from solution. 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

27、the retained, filtered DEF per Navistar Materials Engineering. NUMBER: MPAPS F-7137 TITLE: Nonmetallic Tubing for SCR Systems REVISION: 1610 This document is restricted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are requi

28、red to assume all patent liability. 2016 by Navistar, Inc. OCTOBER 2016 Page 4 of 9 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

29、in excess of those shown in Table 3 will result in failure. 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

30、.5 Sodium mg/kg DEF 2 Potassium mg/kg DEF 0.5 4.6.4 Media Resistance 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 D

31、EF solution shall be filtered with a general purpose paper 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 de

32、gradation including the amount of filtrate separated from solution. 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 the

33、re is an excess of filtrate indicating degradation of the plastic 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 corro

34、sion products or products of plastic degradation evident. 4.7 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

35、”), and where otherwise noted in section 4.7 of this document. 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 Requir

36、ed: Maximum leak rate 5 scc/min. (0.45 cc/min) at stabilization. 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. NUMBER: MPAPS F-7137 TITLE: Nonmetallic Tubing for SCR Systems REVISION: 1610 This document is restric

37、ted and may not be sent outside Navistar, Inc. or reproduced without permission from Corporate Technical Standards. Suppliers are required to assume all patent liability. 2016 by Navistar, Inc. OCTOBER 2016 Page 5 of 9 4.7.4 Assembly Effort 4.7.4.1 Method: SAE J2044 section 6.2.1 “Test Procedure (Ne

38、w Parts)” ONLY (do not test to SAE J2044 Sec. 6.2.2 and do not add any lubrication 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 1

39、17 4.7.8.2 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. 4.7.9 Resistance to Zinc Chloride (50% aqueous solution for 200 hours at RT) 4.7.9.1 M

40、ethod: Expose assemblies for 200 hours at 23o 3o C per SAE J2044 4.7.9.2 Required: 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 Sid

41、e Load Capability. 4.7.10 External Chemical and Environmental Resistance 4.7.10.1 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

42、hour contact time, rather than immersion. The DEF and battery acid test specimens 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 S

43、AE J2044 Sec. 6.4 Side Load Capability. 4.7.11 Pressure Impulse 4.7.11.1 Method: 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 cond

44、ition and the other set aged for 30 days in 23o 3o C DEF. 4.7.11.2 Required: No 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 NUMBER: MPAPS F-7137 TITLE: Nonmetallic Tubing

45、 for SCR Systems REVISION: 1610 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. 2016 by Navistar, Inc. OCTOBER 2016 Page 6 of 9 4.7.12.2 Required: Sample

46、s 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. 4.7.13 Vibration Test 4.7.13.1 Method: ISO 16750-3 Test VI, 700 mm lines completely filled with DOT4 brake fluid

47、and pressurized to 9 bar. 4.7.13.2 Required: No cracks or fractures of the assembly 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 o

48、f 100V DC and an ambient humidity of 50%. A deviation to use climate chamber instead 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 syst

49、em at maximum voltage, at room temperature (23 3C), for 30 minutes. 4.7.15.2 Required: 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 aforementi