5900-613 065 Emissions Laboratory Audit Checklist

									OMB No. 2060-0392 Approval Expires on 3/31/2023 EPA Form 5900-613 This collection of information is approved by OMB under the Paperwork Reduction Act, 44 U.S.C. 3501 et seq. (OMB Control No. 2060-0287). Responses to this collection of information are mandatory [40 CFR 1068.20 and 40 CFR 1068 Section E]”. An agency may not conduct or sponsor, and a person is not required to respond to, a collection of information unless it displays a currently valid OMB control number. The public reporting and recordkeeping burden for this collection of information is estimated to [“be” or “range from” xx hours or minutes] per response. Send comments on the Agency’s need for this information, the accuracy of the provided burden estimates and any suggested methods for minimizing respondent burden to the Regulatory Support Division Director, U.S. Environmental Protection Agency (2821T), 1200 Pennsylvania Ave., NW, Washington, D.C. 20460. Include the OMB control number in any correspondence. Do not send the completed form to this address.
Office of Transportation and Air Quality, Office of Air and Radiation
US Environmental Protection Agency
§1065 Emissions Laboratory Audit Checklist
Version Number: 1.0; Last Revision: February 2023
		Manufacturer:		Date:
		Laboratory Name:		Inspected By:
		Laboratory Address:		Type of tests performed:
		Manufacturer's Contacts Associated with this Checklist:
			Information & Comments	Regulations		Audit Observations	Manufacturer's Follow-up Action
1		Laboratory Equipment Description
1.1		Dynamometer - make & model		§1065.110
1.2		Exhaust Analyzers make, model		§1065 subpart C
1.3		Gas Divider make & model
1.4		Sample collection
		Batch sampling containers	Material, number
		Heated sample lines		§1065.145(c)
		Sample line path	Length kept to a minimum? 90° Bends avoided? Good engineering judgement excercised?	§1065.145(c)
1.5		CVS Considerations
		Make & model
		Dilution ratio
		Pressure control	Static pressure within ±1.2 kPa at initial dilution point?	§1065.140(c)(2)
		Temperature control	Dilution air temp?	§1065.140(a)
1.6		Mixing	Calculated Re of diluted exhaust stream >4000?	§1065.140(c)(3)
		Flow measurement	Does flow measurement device meet §1065.240? How is aqueous condensation addressed upstream of flow measurement? Are there any preconditioning devices?	§§1065.140(c)(4)-(6)
		Flow compensation method	How is a nominally constant flow maintained?	§1065.140(c)(7)
1.7		Diltution Air
		How is dilution air preconditioned?	Filters, etc
		Dilution Air	How is it controlled? What is HC background level?	§1065.140
1.8		Particulate measurement
		Filter specifications	47mm OD? PTFE?	§1065.170(c)
		Diltuion ratio	Primary DR at least 2:1; overall 5:1 - 7:1? Proportionality check	§1065.140(e)(2)
		Filter loading	What is the expected filter loading?	§1065.170(a)(2)
		Sample temperature	Filter face temp 47±5°C?	§1065.140(e)(4)
		Filter face velocity	Basis for expecting near 100 cm/s?	§1065.170(c)(1)(vi)
		Is a pre-classifier used?	If so, what type?
		PM Sample Handling	Filter holder specifications meeting 1065? Leak check method? Filter/sample storage?	§1065.170(c)
		Filter conditioning requirements	Min 30 minutes in env meeting §1065.190?	§1065.590(e)
		Microbalance specifications		§1065.190(f)
		Measurement report	Report supplied including pre/post weights, referencefilter weight, times, etc?	§1065.590
2		Gas Audit:
2.1		Analyze EPA-supplied gases:	As lab injects gas, observe the gas flow and pressures for zero, span and audit gas. All should flow at the same pressure and flow rate. Analyzers should read EPA gases within 2%.
2.2		Engine Intake Air	How are humidity, temperature, HC, CO, Nox, etc. controlled?	§1065.125
2.3		Zero gas for analyzers	Check pressure & expiration date; must have < 1ppmC, <1ppm CO; <400ppm CO2, <0.1ppm Nox.	§1065.750
2.4		Nitrogen for analyzers	Check pressure & expiration date; must have < 1ppmC, <1ppm CO; <400ppm CO2, <0.1ppm Nox.	§1065.750
2.5		Lab Calibration/Span Gases:	Check pressure & expiration date; 200 psi min	§1065.750
3		Calibration Equipment:
3.1		Gas Divider	Every 370 days; calib 15,30,45,60,75,90% on all ranges; rename all span gases initially & if monthly curve changes; recheck w/15-50% gas;	§1065.248; §1065.307 §1065.750
4		Exhaust Calibration Records:
4.1		HC analyzer methane response	185 Days: FID response to methane, ethanol	§1065.360
4.2		HC analyzer linearity	35 Days: calibrate each range w/gas divider (+2% each point)	§1065.307
4.3		CH4 analyzer linearity	35 Days: calibrate each range w/gas divider (+2% each point)	§1065.307
4.4		CO analyzer linearity	35 Day: calibrate each range w/gas divider (+2% each point)	§1065.307
4.5		CO analyzer interference	After installation and major maintenance: water vapor & CO2 interference (<1% or 3ppm);	§1065.355
4.6		CO2 analyzer linearity	35 Day: calibrate each range w/gas divider (+2% each point)	§1065.307
4.7		CO2 analyzer interference	After installation and major maintenance: water vapor interference (<1% or 3ppm);	§1065.350
4.8		NOx analyzer linearity	35 Day: calibrate each range w/gas divider (+2% each point)	§1065.307
4.9		NOx analyzer conversion verification	35 Day; Efficiency > 95% .	§1065.378
4.9.1		O2 analyzer linearity	35 Day: calibrate each range w/gas divider (+2% each point)	§1065.307
4.10		CVS propane injections	35 Day: one range (e.g. 100ppm) all analyzers, all commonly used venturis (may rotate venturis thru successive weeks); (+2%); Calibration report available? CFO or Mass balance calibration records?	§1065.341
4.11		Flow meters
		Fuel Flow (if used)	Off-site cal or through carbon/oxygen balance	§1065.320
		Intake Flow (if used)	Off-site cal or LFE, subsonic venturi, or ultrasonic flow meter	§1065.325
		Exhaust Flow (if used)	Off-site cal, subsonic venturi, or ultrasonic flow meter	§1065.330
		CVS Flow	On site reference flow meter or calibration certificate	§1065.340
4.12		Dynamometer verifications	Annually: In-line torque sensor	§1065.310
4.13		Ambient monitors	ambient temperature, humidity	§1065.315
4.14		Maintenance Records:	Must calibrate analyzers after maintenance. Recommend keeping a separate maintenance log.	§1065.503
5		Engine Setup & Test Observations:
5.1		Engine serial number	POGHG766AJ, Code 1 (cert engine)
5.2		Service accumulation
		Method/duty cycle
		Maintenance	Unscheduled or scheduled?
5.3		Fuel supply temperature/pressure	Representative of in-use operation?	§1065.120(c)
5.4		Oil/engine block cooling provisions	Are engine oil and block temperatures representative of in-use conditions?	§1065.122(a)
5.5		Engine intake air temperature	25±5°C?	§1065.125
5.6		Intake system	Is the intake system production representative?	§1065.125(d)
5.7		Charge air cooler	Is the CAC production representative? If not does CAC simulator meet §1065.125(e)?	§1065.125(e)
5.8		Exhaust system	Representative of production? Are A/T devices located in production represntative locations?	§1065.130
5.9		Laboratory tubing	Minimized length between exit of in-use exhaust system or last A/T device and first point of dilution?	§1065.130(c)
5.10		Exhaust restriction	Typical of in-use operation?	§1065.130(h)
5.11		Crankcase emissions	Self-contained or routed to dilution tunnel?	§1065.130(i)
5.12		Simulated inputs	Are any simulated engine loads applied during testing?	§1065.110
		Accessories	Are all acessories present? If not, how are loads simulated?
		Vehicle speed input	Is a simulated vehicle speed supplied?
		Other	Are other special inputs required to simulate vehicle functionality?
5.13		Ambient conditions	Approximate temperature, pressure, and RH during testing
5.14		Regeneration identification	How are regeneration events identified during testing?
5.15		Low idle speed & torque?
5.16		Maximum test speed	Observed or declared?
5.17		A, B, C Speeds
6		Test Validation
6.1		Transient cycle trace	Review a speed-load trace	§1065.514
6.2		Cycle validation report	Does test meet cycle regression statistics? Is report available?	§1065.514
6.3		Analyzer range, drift validation, and drift correction	±4% uncorrected vs corrected	§1065.550
6.4		Proportional sampling validation	SEE <3.5% of mean sample flow rate or each flow rate within 2.5% of mean or target flow rate. Is report available?	§1065.545
7		Calculations
7.1		Emission Calculations:	Review calculations. Calcs should not use negative emission (bag) values.	§1065 subpart G
7.2		Brake specific calculation method	Total mass divided by total work?	§1065.650
7.3		NOx Correction Factor (KH)	KH=1/(9.953 x XH2O + 0.832)?	§1065.670
8		Test Results
8.1		QA/QC Documentation	How are tests reviewed for accuracy, completeness?
8.2		Torque/power
8.3		Maximum test speed	Is the maximum test speed calculated correctly?	§1065.610
8.4		Speed vs torque map	Has report been supplied including a speed vs torque map?	§1065.510
8.5		Test Report	Has a test report been supplied includng emission results for each test cycle/test interval?
8.6		Final calculated emissions	Do emissions results indicated compliance with standards (with DFs and IRAFs applied)? [EPA calculated]
9		Fuel Analysis	monthly; Obtain copy of lab fuel analysis; Take fuel samples of test fuel.	§1065.710
10		DEF Analysis
10.1		AUS32	Commerical brand meeting ISO-22241?
10.2		Urea concentration	31.8 < Urea Concentration < 33.2%	ISO22241-2 Annex C
10.3		Sample drawn	1L sample taken for full chemical analysis?
11		Other/General Observations
		DEF Dosing
		NTE Point Evaluation