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HomeMy WebLinkAbout10/20/2009, C7 - RETROFIT FIVE TRUCKS WITH DIESEL PARTICULATE-MATTER FILTERS, SPECIFICATION NO. 90988. council M n October 20,2009 j agen6a Repom 6FIRNuPA, r CITY O F SAN L U I S O B I S P0 FROM: Jay D. Walter, Director of Public Wor Prepared By: Ron Holstine, Fleet Main ance Supervisor , SUBJECT: RETROFIT FIVE TRUCKS WITH DIESEL PARTICULATE-MATTER FILTERS, SPECIFICATION No. 90988. RECOMMENDATIONS 1. Appropriate funding in the amount of $66,470 from the Capital Improvement Program Reserve account to retrofit five(5) trucks with diesel particulate-matter filters and installation of a filter maintenance system at the Corporation Yard. 2. Approve the transfer of$66,470 from the CIP Reserve Account to the projects' equipment acquisition account for the purchase of particulate-matter filters and a filter maintenance system. 3. Authorize the Finance Director to execute a sole-source Purchase Order in the amount of $63,303 to Robert V. Jensen Petroleum Distributor for the retrofitting of five (5) trucks and a filter maintenance system. DISCUSSION Background The California Air Resources Board (CARB) regulations require the City of San Luis Obispo (City) to bring five of the diesel trucks in the City's General Fleet to compliance by December 31, 2009. CARB rules allow for the replacement or retrofitting of a percentage of the City's fleet over several years to assist in meeting this percentage goal. This means the City has the option of retrofitting 20% of the non-compliant heavy duty diesel vehicles per year until compliance is met. Compliance can be accomplished by any combination of normal fleet replacement cycles and retrofitting diesel trucks with exhaust particulate-matter(PM) filtration. Retrofitting of existing trucks to meet current emission standards is part of the Particulate Matter Control Measure (PMCM) for on—road, heavy-duty diesel fueled vehicles. The City started the first 20% phase in January 2007, which involved measuring exhaust temperatures and determined two trucks to be non-compliant and retrofitted them with PM filters in 2007. Overview of diesel inventory All on-road diesel truck engines are registered in groups with GARB; Groups 1, 2 and 3. All City trucks categorized in Group 1 have been replaced to achieve compliance. The City has twelve (12) trucks in Group 2. Four of these Group 2 trucks have been replaced and two have been retrofitted with PM filters, leaving six trucks for retrofit or replacement. Of the six 6 -111 CAR Retrofit Five Trucks With Diesel Particulate Filters Page 2 remaining Group 2 trucks, two are mandated for retrofitting by December 31, 2009 and four by December 31, 2011. The two trucks required for retrofitting by December 31, 2009 are low-usage dump trucks. The four trucks slated for December 2011 were scheduled for replacement in 2009, but ultimately were deferred in the 2009-11 Financial Planning process. These vehicles are no longer eligible for retrofitting as they have passed their expected service-lives and therefore must be replaced by December 31, 2011 in order to maintain compliance. This City has seven (7) trucks categorized in Group 3. Of these seven trucks, three are also mandated for retrofitting by December 31, 2009 and four by December 31, 2010. This brings the City's mandated truck retrofitting to five (5) vehicles (two in Group 2 and three in Group 3) by December 31, 2009. (See Table 1 below) Table 1: CARB - PM Retrofitting Schedule Retrofit or Est.Cost to Rplenint Est.Cost to Replacement Group I Group_1 Rple'"111 Group 3 Details Due Date Schedule Retrofit Schedule Retrofit 0116 2009 $ 10,800 0234 2009 $ 10,800 12-31-2009 C 0507 2009 $ 10,800 Current truck retrofit request 0 0508 2009 $ 10,800 M 0421 2009 $ 10,800 P 0414 2015 $ 11,400 Truck retrofitting request at 12-31-2010 L 0718 2015 $ 11,400 Financial Plan Supplement E 0510 2016 $ 11,400 (July 2010) T 0611 2017 $ 11,400 E 9106 2009* $86.900 D 9107 2009* $86,900 12-31-2011 Trucks to be replaced as part 9109 2009* $22,000 of 2011-13 Financial Plan 9713 2009* $182,366 * Replacements of these vehicles was scheduled in 1009,but replacement was deferred as part of the 1009-11 Financial Planning Process. These vehicles will not be eligible for retrofitting. 1 Replacement of Water Tank only The five (5) trucks that are mandated for retrofitting by December 31, 2009 will not accept the passive-style PM traps typically used. The passive-traps would have been the Diesel Particulate filter of choice but, due to budget constraints the City went beyond the acceptable years-of- service range for the affected trucks, so they will have to have traps installed in order for the City to meet the CARB requirements for 2009-10. Why.Now? At the start of the 2009-11 Financial Planning process, Fleet staff initially proposed to replace nine diesel trucks by December 31, 2009 with new trucks. This replacement would have met the phased-in percentage replacement requirement of CARB and the City's fleet would have met current emissions standards. However, replacements of four vehicles (9106, 9107, 9109 & 9713) were deferred due to budget constraints. 7 CAR Retrofit Five Trucks With Diesel Particulate Filters Page 3 A request for funding to retrofit the remaining five vehicles was not submitted as part of the 2009-11 Financial Plan as there were no available PM retrofit systems in place at that time. The approved PM technology for the affected trucks was not made available for purchase until late April 2009. The budget process was well underway by that time and staff did not believe enough information was available on the new technology to justify a late budget request. However, in order to continue to use all the diesel trucks in the City's fleet beyond December 31, 2009; these five trucks will need to be retrofitted with particulate traps or filters to be able to legally operate them on-road. New Technology for Retrofitting There are two types of PM retrofit systems for consideration: Low Temperature Filter(LTF) and Semi-Electric Diesel Particulate Filter (DPF). LTF's are also referred to as passive-particulate traps and can be used on trucks that meet minimal exhaust performance (measured through a technique called data-logging testing). DPF is the newer, more advanced particulate filter technology required for trucks that do not pass data-logging tests. This technology did not enter the market until April of 2009. Five of the City's fleet trucks have failed data-logging tests due to lack of sufficient heat in the exhaust system and can only be retrofitted with the advanced DPF technology. R.V. Jensen Company of Fresno is currently the only supplier available for this new DPF Technology retrofit system. Therefore, staff recommends approval of a sole-source purchase with R.V. Jensen for this advanced technology retrofitting system. Staff has requested a quote from R.V. Jensen Company for the affected vehicles. To keep compliant with CARB mandates, the City of San Luis Obispo will need to install PM filters on four Ford F550 trucks (0116, 0234, 0507, 0508) and one International Boom Truck(042 1) with the semi-electric filters by December 31, 2009. To maintain the advance DPFs on the trucks, a maintenance system will need to be installed as a wall-mounted unit on the outside, north-east end of the fleet maintenance shop. This system comes as a complete unit except for the need for an electrical contractor to provide the electrical system wiring and connection work. Retrofit vs. Replacement Staff has reviewed the possibility of accelerating replacement of the affected vehicles in lieu of retrofitting should it prove more economically feasible to expend a little more for replacements should it provide a vehicle with an extended service-life. This approach would make sense if the affected vehicles were nearing their replacement schedule or if this is a standard-type purchase from a dealer's lot. However, the vehicles noted for retrofitting by December 31, 2010 have replacement schedules about 6-8 years out. Additionally, the price of vehicle replacement is much greater than retrofitting as each vehicle has its own unique function and is specially equipped to perform exact duties for each department. These vehicles are purchased as a cab and chasis only. After the standard purchase is made, these vehicles are then modified and a work- body is fabricated for the specific use of the truck. For example, a typical cab and chasis to replace a vehicle costs approximately$ 40,000. Modifying the truck beds, depending on the work. C° �-3 � I CAR Retrofit Five Trucks With Diesel Particulate Filters Page 4 function, can cost an additional $35,000 to $100,000. This brings the total vehicle replacement costs from $75,000 to $140,000 per vehicle. Thus, staff has recommended retrofitting for those vehicles not slated for replacement as it is determined more economically feasible to retrofit at this time. The cost of retrofitting is roughly 8-15% of a vehicle replacement cost. Consequences of Non-Compliance The City will face possible fines if the percentage of the diesel fleet is not retrofitted or replaced by the provided mandated deadline dates. Doing nothing could cost the City $10,000 per day for each affected vehicle. The cost of one PM trap is roughly equal to a daily fine. Funding for Future Retrofits & Replacements The City still has eight (8) trucks in the diesel inventory that will need to be replaced or retrofitted in the next two years. Four trucks will require PM filter retrofits by December 31, 2010 and four trucks will require replacement or retrofit by December 31, 2011. Staff anticipates the PM filters to remain steady in pricing with a moderate Consumer Pricing Index (CPI) increase of five percent. Staff estimates the costs of the December 31, 2010 retrofits to be approximately$45,600. The four vehicles slated for replacement by December 31, 2011 have already been deferred in the 2009-11 Financial Plan. These vehicles were scheduled for replacement in 2009 and deferred due to budget constraints. These vehicles are no longer eligible for retrofitting and therefore must be replaced in order to maintain compliance with the City's diesel fleet regulations. The December 31, 2011 fleet replacement costs are estimated at $378,166. These replacement costs were included as part of the 2009-11 Financial Plan. City staff will continue to evaluate the diesel truck inventory as part of the Financial Plan process to determine if future replacement or retrofit is more cost effective. Staff will continue to pursue grant funding opportunities where available to help off-set these costs. FISCAL IMPACT Retrofitting of five (5) diesel trucks and the installation of a maintenance system will cost $63,303 plus an additional 5% contingency, bringing the total project cost to $66,470. Staff recommends funding in the amount of$66,470 be transferred from the CIP Reserve account in support of this retrofitting project. Currently, there is $548,483 in funding available in the CEP Reserve account. There is sufficient funding to support this request.. C qJ q CAR Retrofit Five Trucks With Diesel Particulate Filters Page 5 PINI TRAP RETROFIT - Deceinber 3112009 Description Ford F550 (#0116) $ 10,813 Ford F550 (#0234) $ 10,813 Ford F550 (#0508) $ 10,813 Ford F550 (#0507) $ 10,813 International (#0421) $ 10,813 Control panel installed at shop $ 9,238 Contingency(5%) $ 3,167 Total Project Budget $ 66,470 Available Funding CIP Reserve Account (90215) $ 548,483 ALTERNATIVES Fund the Purchase of the Particulate Traps with Grant Funds. Staff had sought other grant funding opportunities but heavy competition from other agencies across the State has precluded that from occurring to date. Staff will continue to pursue other grant opportunities for the retrofitting of the City's fleet trucks in 2010. Without additional grant funding, a new funding request will be necessary with the Financial Plan Supplement to provide funding for the four remaining mandated retrofits by December 31, 2010. ATTACHMENT Quotation for retrofitting \\chstore2\Team\Counci1 Agenda Reports\Public Works CAR\2009\Fleet\Diesel Traps\_CAR-diesel traps new CIP.DOC ATTACHMENT'--. AWN. "7 lei v.3 11� N PE MLEUEO UMMMUMR SINCE 1952 P.O.BOX 12907 a FRESNO,CA 93779-2907 PHONE:(559)485.8210 • FM(559)485-8503 TOLL FREE:(800)366-8210 May 5, 2009 Ron Bolstine Fleet Supervisor City of San Luis Obispo 25 Prado Road San Luis Obispo. CA 93401 Hello Ron, Thank you for the opportunity of providing this quote to yon. Donaldson was approved 3 weeks ago for the Semi-Electric DPF, which is a good DPF for those vehicles that didn't pass on the data logging because of insufficient heat to burn the ash_ in the City of San Luis Obispo's case, this was 3 vehicles, 80116, #0234, and #0421 . I have provided a quote for these 3. Donaldson was approved on 4/28/09 for it's passive trap, called the LNF. This trap is much like the ones that were installed on 2 of your vehicles, excerpt that it has a pre filter to remove excess NOx before it gets to the main centercore. The prefilter is in essence a DOC, or, Diesel Oxidation Catalytic converter. The only problem with quoting on the new LNF is the fact that it is only verified for 1993 to 2003, and #0507, 0508, and 0718 are 2004 and 2006 engines, so I have included 0507 and 0508 with the semi-electric DPF. By doing the 5, you are in compliance for 12/31 /09 for both Group 2 (1988-2002) and Group 3 (2003-2006) engines. As mentioned, Stephen Davis and myself are going to Los Angeles next Mon. Tues and Wed. We will have info on the DPF's, as well as more info about the requirements of the control. panel. I have a meeting with a major construction company on Monday 5%18 , and maybe we can meet with you on Thur 5/21 if you have time to reconfirm on the engine families, as well as to talk further about the semi-electric DPF, and the status of the DOORS program for your off-road equipment. Also, if you have either a contracted electrician, or, an in-house electrician, it would be great to' talk to that person too. The costfor the semi-electric DPI' have risen as compared to the DrF' 9 that were installed in 2007, and the quotation I have piepared takes that into much consideration. 013MM M OP r OMM FOR 3 AND LHRNMANTS .PENSM(IIIAKEIi STATE 1118WANTS SHELL LUBRICANTS•76 RKS •VALERO FUELS SERVING THE SAN JOAOUIN VALLEY Alm CeRNAL COAST 05/01/2009 14:49 5592611947 BOB GAFFNEY PAGE 02/03 ATTACHMENT QUOTATION T&M(Time&Materials) VEH#&ENGINE YR DPP COST ACCESSORIES TAX FREIGHT INSTALL SST TOTAL #0116-2000 $8,515 $350 $798 $150 T&M-$1 ,000 $10,813 (EST$750-11000) (Using 1 ,000 for est; #0234-2000 $8,515 $350 $798 $150 T&M-est$1 ,000 $10,81 #0421 2005 $8,515 $350 $798 $150 T&M-$1 ,000 $100813 #0507-2004 $8,515 $350 $798 $150 T&M-$11000 $10,813 #0508-2004 $8,515 $350 $798 $150 T&M-$1 ,000 $10,813 ESTIMATED TOTAL $54,065 CONTROL PANEL, Unit Cost @ $8,475 Sales Tax $ 763 Total $9,238 PLUS ELECTRICIAN'S BID TO INSTALL By At DATA 5 o24G i to lt'lVl11.1GLV L Mir Level S+ ReberN EndWon Solution... • The Donaldson SEF Muffler System Delivers the Highest PM Reduction Using Semi-active DPF Technology ]11 [1 f% .- �. �Rl i.krite Y11_•. � t•^.t:'".1:H.7F^d' Yf:: _.. ►a(sr.n ni vehinln 0-1+A.ty cvclec :m&4 n.+i.ia+oc .Dust connect to the automated DPF Regeneration Station overnight for routine DPF cleaning_ ,,3bcer muiQiers are aesignetz ana vermeui ror . .. .. I 1..• 1. :�'.fig ATTACHMENT u A Semi-active DPF System ... the Donaldson SEF Muffler System The Donaldson SEF Muffler System is designed The SEF Muffler incarporates an electric heater to reduce emissions from in-use diesel engines. to periodically bum PM captured in the DPF.The Besides reducing diesel particulate matter(PM) EDM informs the operator when DPF regeneration emissions by over 90%,the SEF Muffler is also is needed.When connected via the junction box,a effective at reducing hydrocarbon and carbon DPF Regeneration Station manages the regeneration mono>ade emissions. cycle to ensure a safe and thorough burn. Emissions Device Monitor(EDMI • Mnnuurs c;aL:S of SEF Mnf•h;r • Indlt'atcs Wl1P.':DPF retlenrtrltaon s n:^uired SEF Muffler • Ehmm,l::s PM::nd gascu,s ermssmns ttum thu.el xhaust • Ituyuucs heal ir.gnmaw.u"r.yclu to Lunt I'M m thr.IIP • Up 1114 lanes heave-than OEM nu ff-ir i ej s Junction Box • nnuses rommi^umstrr DPF regeneranan •1 ,pnwor uml thcnnucuuplol i � install nn vr.b::aP m autes.dhl-:lucauo:' • 1 \j1 � i 1 4 DPF Regeneration Station • Provides auunnaled conrrnl rf ''�• . S=F MUPier rr,;;r:uur;cn:'cycle • C:vnrr1is up to twr DPF regnn P.ra:mn cycles consecuPvely • R;gnur.S ul P.cir,:ul power and cnnipn:ssed au supphcs .,_• Regeneration Cable-25 h. • Prnvules pma'rr,rncnmrcnupin ar.d an r.unncrhuns I- 9EF Aulliw I.-r DPF rr.11ennrauun.y,.1,: Patent pernhng - 2 �w ATTACHMENT , r Ideal for Nome-based Fleets • Semi-active DPF technology—relies on an integrated electric heater to provide heatfor DPF regeneration i0 Ideal for colder duty cycles: No specific minimum application temperature criteria;therefore no data 4"% logging required Time between DPF regens depends on engine certification level (soot output rate),duty cycle and maintenance level IF DPF Regeneration Cycle—4.5 hours for one vehicle; „o- 7 hours for two vehicles • Broad on-road engine coverage (1991-2006 MY) non-EGR engines. Pursuing broader coverage. • Designed for engines with less than 2100 cfm exhaust flow and less than 350 HP • Typical SEF Muffler installation time is 3-5 hours Features Benefits semi-;user.OFF system • P�!rmils ull-cycle DPF v;grnrranon • 1 liecbve ful colder encnle dlit%-•.rc es • Nunlnates neer!rr.r d;:u1 Inggmg Riva-rata ymil sl:con rdrb:dr OFF sa!lst:,eli: • lietter th:;nllal C�Chng 1'111;1101'., ll-;nl•:=r,u e:sullsuate: • Nu NO ma!:r: Ruggvd;ied o'ecti c aeale• • Pr•rndrs:!ndn:m,'rhahlehral sonrrl::rn OPI ep�lraal.nu ;:mo Cs:;crl aF to:DPF rqr a nt oa • Ilrrnuts owI:Im!;ul fle a!::'Invd to risme-rh.11 c.;:0-S1.icnl :PI moerer%II orl • Nt !1111,s sleln,:asl axsur.ct:ed tedh srparat .Iaot+.Cr 1 herma'veep r:suia;es SHF Pvhd!-e• • Shonr.is ru!en::rl-rn cyl:le uric • Heducrs t:nrrgy us:nfo,hurn nwares,and temp gradients cross DIT • Stay',oo muiller t,l all Ines.easily r•;mucr:d fol DIT arerss OIIC osta.Iad lglsbc:r,.[it Ijh Hckcc CU and I I;.t:r as>nuls • UI e)soot Io eele'ld III1le II'1h.1" ;11'.a1411s • 1 uhaucca Him,LI Sl;'bululr Uruwln:d tli.w d05tnballnn I'rq,ndos t:mlolm`nr:;rmi enorc 1119 face • I11CWtI r:�I!Ilw(h:)roonq of munim • 1 0,1nt:s u­u:ante vol I"1 bumeen i11'I relle,rlauuns • Imp,rvos rrgrncalgr rtIne.nci Re!nute-muunted DPF Reuc:w. alien Smtial Itcdures'p,:0 e,:ho"r,;r:;mslllun I.nsl :rge•lo'ates two DPF, 'wu,sccut.vOy I Ilrmnates e.epusmr:to .•:;hltae sh( :k•incases re w1i):w; • licence's f cit umc Wale supo:y vcllage range • Incl easrs•:n:le a a,:,;eptablr,c o•a::r surply opo.:ns 195-"!•10V. 1-r,: 3-o`I) • Hedoces Inslalleow"tusk J5 It.O'CN-awaycabi'dos;gn liednres:;amrrgc.n:ern:fit Inver'ff,:',11:11(1III'f rcq;:nr.m;nn Inru:e;:nrootld t;illlt a,:un :tcrolr;tw Hrdores:.sk of:;hock Froroe:rlrupcne'ds Ir, ntilai • Pellucrs mtalk?lin^!imf,_!:osI 0:omc,nad UI :mlpetuu; ':.tem:. fvlod.ra drsiy 1 IVITHIS rivaddllon Ilcxliully and rc;iucta:nshllabrn Ur e • Ilcducws survic Iron:Hl.m r,lcallnul the lll'I bodated FDM • Inlprovos opera:ot Intrttac • I nae;srs nternor� lin:!oil dnrl Id d:'.d'e,:u(iu 11;'I.11;ort;nnnar;ahtu l: q • I'r,�r-Its r:mprranu:^:onr r.nng • Prov ies rmvemutt fush huunn rrc;rt • ap,luds•:nllapr.laage W MV) 3 ATTACHMENT A Closer Look at the SEF Muffler System Inside the SEF Muffler Inlet Assembly Heater Assembly Outlet Assembly • Includes::_ngi,air.nts Ihal P.^hance flow Pruvulus the rr.rt nrr,Pszary to r.omhusl :rlcludes c•?egrtvi IIts Ihal enhance distribuuun and rudur•n bnrkprv,soc di�sul Pv du•nc;DPr rng P.neratum cycle "PF rr•.gerr:ratmn cfhcumcy • Houses[1111 umguessed air connec,w•- Hnu,ea ti a Iherr nn:nupla lir mnnllo,if, for C-Pr regercaaunn dnd cunt-Ahoy thu regen pr.:cess Thermal Wrap if,_ J,.;.+ • Shortens rt:gen;ruuun Lyr.'e Gn+,: • Reduces energy usage•from ha/ards,and Innry Ip adlunh e.cnua DPF Compressed i-- Air �� Connection DOC Assembly 0 P Assembly • Reduces ga•.r:nus ecafhnn nns and,:dch • cautures dwsrl PM and dsh hmaunt u :bc uxl 1^yd nu.arhr:ns sir Palo morox del • USeI s+:ylur.:d+al vll:nu :d+frnlu DPF walurf.ds • RP.flcrts heal ndu DPF darirg III enham:e.Ili-filialdm,-+hthry r r.gencr atinn cyc;r.to rnnumue • Mus:be ealrch:;uir+:pe:u.h�a'ly t.,pnrvenl n•g rnehdlnn lime r.nlpne performance.iegrddztlin Broad Selection Four muffler styles with different inlet/outlet connections available to simplify installation 10E::D DED UET Junction Box EDM Simple Connection for DPF Regeneration(hard-wired to SEF Muffler) Emissions Device Monitor-Item No. X009650 Quick Connect Air Supply Electrical Grab thecable fromtheDPF Cable Thermocouple a++ •.1,: An EOM Kit is included Regener anon Station,open Connection with every SEF Muffler Kit. the door to the junction box In-cab display show. and connect the air,power Thu junction box comes hard-wired to the and thermocouple to permit SEF Muffler via a Eft(2 m)cable. regeneration. Ensure easy access during installation. 4 ATTACHMENT More about the Automated, DPF Regeneration Station Item No. X009584 Operation of the DPF Regeneration Station The DPF Regeneration Station is designed to clean a single DPF or two DPFs consecutively. The automated cycle includes preheat, burn and cool-down phases.When two are regenerated consecutively,the cycle time is reduced by overlapping the cool-dowel phase of the first �{ cycle with the pre-heating and burn phases of the second cycle. The length of the cleaning cycle is shown below. Trucks Filters Regen Time Truck A Filter A 4.5 hours Truck B Filter B 4.5 hours Trucks A& B Filters A& B 1 hours ADonaldson. DPF Regeneration Station Where to Install at Your Facility The narrow profile of the DPF Regeneration Stationn ' a ° • allows for a variety of possible installations, l ' including: • On a free.-standing pole arpillar • Against a wall or fence • At the corner of a building The simple,automated control panel at the DPF Regeneration Station. Installation Information �-- 21'H /533 i mm Unit weight: 120 Itis. 154 Kg(with cables)a o • Height.Mount control face plate at eye level — Station Dimensions:see illustration i 9999 j -- Clearance:(1)Allow 20'clearance fui dour to upen; i iEllaoAdmim 12)minimum 9 12'clearance on three remaining sides 24'H cvr A sum• 610 mm • Compressed Air:Requires a clean,dry source of y0 i PSI §4 SUM 6 • Electric Power:220V/30A single-phase;Standard- i 3-prong power cord;Optional-hard-wire directly to the unit • External Mount: Install cover or awning to protect i the control panel!not included) TD • Cable.Storage.;Use r.ahlr hangers to prevent damage 229 mm when not in use(not included) i I ' 5 - ATTACHMENT How1WAREy RWeeled en Stations wilt you for Your Fleet? Extending Time Between Regens (U ) I Under normal operating conditions, Service Service service service i exhaust system backpressure increases now Now Now Now over time as the SEF Muffler loads with PM.The EDM In-Cab Display (Service Now)will alert the operator to regenerate the DPF when it exceeds i the preset limit. After the rugen.the AF j backpressure will reset to the initial Ail I All levels. The time between regens,©,is affected by several factors including snuffler design,engine emissions rating j and maintenance level. Older engines will have shorter regen intervals la because they emit more PM. Maintain a the engine within manufacturer's o Time(MM) specifications to maximize the regen Typical SEF Muffler Backpressure Interval. Exhaust backpressure curve for a California School Bus 210 HP EGO Engine with over 200 Hours over 2-month period I "Poorly maintained vehicles will result in shorter time between regen,or more frequent DPF regeneration.Engine issues,like defective injectors,turbos or intake manifolds. must be eliminated to prevent DPF damage and to extend the DPF regeneration intervals. This is important no matter what brand of emissions reduction system you apply." Ian Frick,Donaldson Retrofit Engineering 6 ATTACHMENT ( i I DPF Regen Stations & Fleet Type/Size Detcnuinnlg the proper uunlbor at DPF Regen SLatimis to install for your fleet depends un Mary factors, inCIuding: • the number ul vehicles in the fleet equipped with SEF nudflers • the soot output rate(0.6,0.25 or 0.1 gfbhp-hr)for those engines • the avoragu hursupuwei usage over the ungine duty cyelCs • the maintenance level of the engines To estimate the optimum number,use the following procedure.First,find the soot output rate of the engines n1 ynar fleet.Next,find the average horsepower usagP,for each vehicle,during its normal dilly cycle Ithis information play be avaiiable from the Engine ECU).Use the tables below to help estimate the 'time hrtwrnn regmis (®). The first table(Calculated)uses a formulaic approach to estimating the regen interval based nn snnL generation and filter size.This approach is useful,but has proven to he conservative and may result in an excessive number of stations.The second table(Experience)is based on actual field res(ilts.Fnr hest results,consider both values befnre finalizing the number.Actual results may vary. Calculated Time Between Regens, Avg.HP am Daq Cycle 50 10D 150. 1 200 1 250 1 300 Soot Output MY 1994-1005 0.1 64.0 32.0 21.3 16.0 1 12.8 1 10.7 Rate(g/bhp-hr) MY 19911993 0.25 285 14.9 9.9 7.4 5.9 4A _ MY 1986.1990. 0.6 13.3 8 7 4.4 3.3 2.7 2.2 n hou s Experience-based Time Between Regens, Aug.HP over Duty Cycle* 50 TIM 150 200 250 300 AppBeeuon School Bus Refuse Truck Refuse Truck Muni.Truck Muni.rruck On-Hwy Daily Wage Ikra.l 3.6 6-.10_ 8-10 3.6 316 8.10 Soot output MY 1994-1006 0.1 9d8 80-200 557130 20.00 1&50 Rate tg/hhp-hr) MY 1991-1993 0.25 MY 19tl6-1990 0.6 6-30 _ _ - in hmns i •Average horsepower estimates based on operating experience Fleet Examples School Bus FleetRefuse Truck Fleet 20 Vehicles f 20 Vehicles Fifteen 1994-2002 MY; Fifteen 1994-2002 MY; t .- Five 1991-1993 MY Five 1991-1993 MY j Asanmptionx The typical school bus operates at an average power Assumptions The typical refuse level of 50 hp.According to the table above,each MY group has a truck operates at an average power level of 100 hp.According to the different regeneration interval.Assume the buses are used six hours/ table above,each emissions grouping has a dilferent regeneration day.The corresponding number of OF Regeneration Stations is interval.Assume the trucks are operated eight hourslday.The shown below. corresponding number of DPF Regeneration Stations is shown below. Engine Regeneration Irllervel M Vebie[as with a of Regen Engine Rageneration Interval p Vehicles with k of Ragan My Hnurs nays SEF mufflers stations MY Hours Das SEF Mufflers Stations R§':-%DRi i':I 1-1 15 I F 1994-2006 3% 15 375 1;Fn-IRi�+. J-. 1991-1993 616 G 5 :. . Net Regent Stations Needed 2 Net Regain Stations Needed 6 or 7 ) 7 ATTACHMENT J � - SEF Muffler System Order Information Select the proper SEF Muffler model by: Style 1 Style 3 11 Ensuring the engine family number is permitted bythe CARB Executive Order 2) Ensuring the engine exhaust flow rate is less than 2100 cfm and less than 350 HP. Style 4 St le 6 2) Selectingthe muffler kit that bestmatches the existing muffler style andinlet/olnlet dimensions,when possible. DPF Regeneration Station Part No.X009594 SEF MulAer IGte Sertriee lusts Inlet outlet Body Body Inlet outlet OF Regeneration Station Muffler I.D. I.D. Length Dia' rt No. Assembly Asserltbly Description Part No. Style 1 4.0" 4.0" 44.25" 13.9' X009568 P232153 P232157 25-ft Regeneration Cable P232342 4.0" 5.0" 44.25" 13.9" X009570 P232153 P232160 Instrument Cluster Lights&Switch Kit P232343 5.0" SA' 44.15' 13.9' X009576 P232156 P232150 Temperature Controller P232344 Style 3 4.0" 4.0" 45.75" 13.9" X009572 P232154 P232157 4.0" 5.0" 45.75 13.9" XM9574 P232154 P232150 Circuit Breaker&Mounting Base P232345 5.0" 5.0' 45.75' 13.9' X009581 P232155 P232160 Air Manifold Assembly P232346 Style 4 4.0' 4.0" 46.63' 13.9" X009569 P232153 P232158 Fuses,5-Pack P232347 4.0' 5.0" 46.63" 13.9' X009511 P232153 P232159 Contactor P232348 5.0" 5.0" 46.63" 13.9" X009577 P232156 P232159 Din-A-Mite Controller P232349 Style 6 4.0' 4.0' 48.13" 13.9" X009573 P232154 P232158 Relay P232350 4.0' 5A' 48.13" 13.9" X009575 P232154 P232159 5.0" 5:0" 48.13' 13.9" X009580 P232155 P232159 SEF Mofger 'Body dia.with wrap.Kits include EDM and Junction Box Description Part No. ' The SEF Muffler Kit includes two DPFAssembly X009811 l -----"-- $ separate installation,operation and Heater Assembly P232177 maintenance manuals;one for the SEF He ater Thermocouple P232577 nMuffler System,and a second manual for DOC Assembly P232181 A t� �]4� the set-up,and operation of the EOM. t06% Thermal Wrap P232189 at ��rl�•�4 o For technical assistance,call your EOM Kit X009650 nearest emissions dealer or our our V-band Clamp P212925 toll-free technical line to talk with our field engineers. A&A Donaldson, Donaldson Company,Inc. North America 0 Minneapuhs,MN Sales:866.675-2847 V33440-1299 Email:emissionssalcs@donaldson.com uuu:donaldson.com Technical Support:966-817-8733 Email:emissions@dnnaldson.com Brochure No.F111249(4/91 02111 Donaldson Company.Inc waid'm g.SA D maldson Ctmpany,Inc.rnawaa The [J' 'rlghtto change at ducknimm any modal or specification 9 any we and wt how notice.