CPCB

Central Pollution Control Board

Parivesh Bhawan
East Arjun Nagar, Delhi -110032
14.02.202
No. CP-29/5/2021-UPC-I-HO-CPCB-HO

INVITATION OF PUBLIC COMMENTs

Revised Emission Norms for all categories of gensets having gross

mechanical power upto 800 KWs have been notified on Nov. 03, 2022 byy
this
the Government of India and shall take effect from July 01,2023. In
document on"
matter, CPCB is the Nodal Agency and has prepared draft
Emission
System and Procedure for Compliance Testing of Revised
Standards for Power Genset Engines having Capacity Up to Gross
Mechanical Power 800 KWs. This draft document has been prepared in
consultation with Certification Agencies and National Standing
Committee on Emission from Off-road Vehicles'. Draft document is
annexed herewith for information of all concerned. Comments
suggestions (if any) may be communicated through email to
[email protected] /[email protected] by 13.03.2023.

[N.K. Gupta]
Divisional Head -UPCI
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Draft dated 10.02.2023 Document No. CPCB -XXXXXX

GENSET Standard

System and Procedure

For
Compliance to Emission Limits for Power
Generating Set Engines Up To Gross Mechanical
Power 800 kWm
As Per India Genset Emission Standard IV+

Part - A1: Compression Ignition (CI) Engines

Part - A2: Positive Ignition (PI) Engines
Part - A3: Portable Genset (PG)
Part - A4: Safety Code of Practice

DD/MM/YYYY

Issued by
CENTRAL POLLUTION CONTROL BOARD, NEW DELHI
(Ministry of Environment, Forests and Climate Change, MoEF & CC)

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FORWARD

Ministry of Environment, Forest and Climate Change (MoEF & CC) had notified emission limit
for internal Combustion engines used for power generating sets vide GSR 804(E.) dated 3-
Nov-2022. As per notification CPCB is ‘the Noda Agency’ and is mandated to prepare
compliance and testing procedure to settle disputes and technical difficulties in execution of
these rules. In consonance with the changes in the emission limits, additional requirements
such as NOx and Particulate control diagnostics, anti-tampering measure (inducement).

The document has accordingly been written along with new relevant section to
comprehensively cover compliance requirements. The document is divided into four main part
A1, A2, A3 & A4 for ease of handling & reference. Part A1 is related to Compression Ignition
(CI) base engine, part A2 is related to Positive Ignition (PI) base engine, part A3 is related to
Portable Genset (PG) engines and part A4 is related to safety code of practice. Further each
main part of document (except part A4) is divided in four parts. The Part-I is notification
incorporating its amendments from time to time by Ministry of Environment, Forest, and
Climate Change (MoEF & CC). The Part-II is Certification Systems and Procedure. This part
is an administrative part to regulate the emission limits of new gensets at manufacturing stage.
On compliance of the specified limits, Type Approval (TA) Certificate is issued by Certification
Agency (specified in notification in Part – I of this document) to an industry for its complied
family / model Genset engine.
After obtaining TA, the industry must obtain Conformity of Production Certificate (COP) during
every COP year (1st July to 30th June of the subsequent year). Part-III of the document is the
description of equipment and test procedures to be adopted in compliance testing process.
This part is to be executed by the certification agencies. The Part-IV of document consists of
newly added NOx & particulate control measure & others requirements.
The document has been prepared in due consultation and involvement of certification
agencies (ARAI and ICAT), Indian Diesel Engine Manufacturer’s Association (IDEMA) and
Standing Committee on Emissions (SCOE).
I hope the document will help all the manufacturers of Genset engines and certification
agencies in obtaining / issuing TA and COP certificates systematically and scientifically.

(dd-mm-yyyy)

Chairman, CPCB

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Central Board Team

Planning Coordination & report preparation : Mr. ……………….

Technical input provided by : ARAI, ICAT and IDEMA
Recommended by : Standing committee on Emission from off road
vehicles & construction equipment’s
In close supervision of : Mr…………………
Technically Recommended by : Mr………………..., Member Secretary

Contact details for the industry

Agency Authority Name, Email, Telephone
Central Pollution Control Board, Mr……………
CPCB, New Delhi, Email…………
Nodal Agency Ministry of Environment, Forests and Tel. ………….
Climate Change
Automotive Research Association of Mr……………
India, Email…………
ARAI, Pune Tel. ………….

Test Agency International Centre for Automotive Mr……………

Technical Agency Testing, Email…………
Certification Agency ICAT, Manesar Tel. ………….
Indian Institute of Petroleum, Mr……………
IIP, Dehradun Email…………
Tel. ………….

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INTRODUCTION

Central Pollution Control Board under direction of Ministry of Environment, Forest, and Climate
Change (MoEF & CC) has notified next stage emission norms for gensets with gross
mechanical power up to 800 kW vide G.S.R. 804 (E) dated 3-Nov-2022. These norms are
referred as Environmental Protection (Third Amendment) Rules. Said emission norm can be
also referred to as ‘CPCB IV+ emission regulation. To prescribe test methods for the above
norms a task was entrusted to ARAI. This standard CPCB -XXXXX prescribes Test Method,
Testing Equipment and related Procedures for Type Approval and Conformity of Production
(CoP) testing, NOx & Particulate control measure of Gensets up to 800 kW Mechanical Power.
While preparing this standard, considerable assistance has been taken from following
regulations/documents
i. UN Regulation 96 (05 series of amendments Date of Entry into Force: 29.12.18): Uniform
provisions concerning the approval of engines to be installed in Agricultural and Forestry
Tractors and in Non-Road Mobile Machinery with regard to the emissions of pollutants
by the engine.
ii. Commission Delegated Regulation (EU) 2017/655 of 19 December 2016 supplementing
Regulation (EU) 2016/1628 of the European Parliament and of the Council with regard
to monitoring of gaseous pollutant emissions from in-service internal combustion
engines installed in Non-Road Mobile Machinery
iii. AIS-137 (Part 7) August 2019 -Test Method, Testing Equipment and Related Procedures
for Type Approval and Conformity of Production (CoP) testing of Agricultural Tractors,
Construction Equipment Vehicles (CEVs) & Combine Harvesters for Emission Norms as
per CMV Rules 115 and 126
iv. UN Regulation 120: Uniform provisions concerning the approval of internal combustion
engines to be installed in Agricultural and Forestry Tractors and in Non-Road Mobile
Machinery, with regard to the measurement of the net power, net torque and specific fuel
consumption
v. ISO 8178- Part 1, ISO 8178-Part 3, ISO 8178-Part 4, ISO 8178-Part 7, ISO 8178-Part 9
vi. US EPA Regulation: 40 CFR Part 1039 - Control of emissions from new and in-use
nonroad compression-ignition engines
vii. US EPA Regulation: 40 CFR Part 1065 – Engine testing procedures
viii. AUTOMOTIVE INDUSTRY STANDARD – AIS 024 - Safety and procedural requirements
for type approval of gaseous fuelled vehicles
ix. AUTOMOTIVE INDUSTRY STANDARD – AIS 028 - Code of practice for use of gaseous
fuels in internal combustion engine vehicles
x. Central Motor Vehicle Rules, 1989: CMV Rule 115 – as amended time to time
The Committee Composition for formulation of this standard is given in Annex 11.
After approval of the standard by SCOE, The Central Pollution Control Board being a Nodal
Agency has published this standard. For better dissemination of this information CPCB may
publish this standard on their web site.

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OVERALL SCOPE
This document lays down the applicability and requirements; system & procedure for
compliance to the rules vide notification no. GSR 804(E.) dated 3-Nov-2022. Emission limits
for new internal combustion engine up to 800 kW gross mechanical power for generator set
(Genset) application, issued by Ministry of Environment and Forests, Government of India.
The details are covered as under:
Emission of gaseous and particulate pollutants from following distinct internal combustion
engines categories and fuel options operating with either constant speed duty cycle or variable
speed duty cycle,
a) Diesel engines
b) Dedicated alternate fuels*
c) Bi-fuel run either on Gasoline or on any one of the alternate fuels*
d) Dual Fuel# run on Diesel and any of the alternate fuels*
e) Portable Generator sets (PI engines below 19kW and up to 800 cc displacement) run on
Gasoline fuel, dedicated alternate fuels and Bi-fuel run either on Gasoline or on any one of
the alternate fuels*

#Dual fuel – Diesel and Natural Gas/Bio methane/LPG applicable only

*Alternate fuels - Natural Gas/Bio methane, LPG, Ethanol blended gasoline (E10, E12, E15,
E20, E85) Ethanol E100, ethanol blended diesel (ED95), Methanol blended gasoline (M15,
M85), Methanol M100, methanol blended diesel (MD95), DME, Hydrogen, Hydrogen blended
with CNG (18% hydrogen), Bio-diesel (B7/ B8 to B20/B100) (Fuel Specification of these fuels shall
be as notified under CMVR as amended from time to time)

Natural Gas can be used in the form of Compressed Natural Gas or Liquefied Natural Gas or
Piped Natural Gas.
This document is divided into four main Part A1, A2, A3 & A4 for easy of handling & to refer
for the industry and test agency as per the following
Part A1: Applicable for all Compression Ignition Engines
 Diesel engines
 Dual Fuel run on Diesel + any of the alternate fuels*
Part A2: Applicable for Positive Ignition Engines (above 800 cc displacement)
 Dedicated alternate fuels*
 Bi-fuel run either on Gasoline or on any one of the alternate fuels*
Part A3: Applicable for Portable Generator sets (PI engines below 19kW and up to
800 cc displacement)
 Gasoline fuel
 Dedicated alternate fuels
 Bi-fuel run either on Gasoline or on any one of the alternate fuels*
Part A4: Safety code of practice

The details are covered in each above part (except A4) are as under;
I. Exhaust emission limits, applicability & other requirement
II. Certification system and procedure
III. Test equipment & Test procedure
IV. NOx and PM control measures and other requirement

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Part - A1

Applicable for Compression Ignition (CI) Engines

CONTENTS
Clause &
Description Page
Annexures
1. Scope 15
2. Definitions and abbreviations 16
3. Exhaust emission limits & applicability and requirement 22
4. Type approval Administrative procedure 26
4.1 Engine type & engine family (ISO 8178-7) 26
4.2 Selection of certification agency 27
4.3 Application for type approval (TA) 28
4.4 Type approval 29
4.5 Certificate of type approval and validity 29
4.6 Modifications and extension of approval of the approved type 30
4.7 Type approval process flow chart 32
Appendix 1 Application to Nodal Agency. Affidavit & profile details 34
5. Conformity of Production (CoP) Administrative procedure 37
5.1 General 37
5.2 Verification of conformity of production (CoP) 37
5.3 Sample size, decision, and other criteria for verification of CoP 38
5.4 Certificate of Conformity of Production & validity 42
5.5 CoP discontinuity 42
5.6 Exemption from CoP 43
5.7 Production definitively discontinued 43
5.8 Consequences of Non-conformity of production 44
5.9 CoP process flow chart 45
Annexure 1 Information document from manufacturer 49
Appendix A.1 Template for information folder and information document 49
Appendix A.2 Confidential information on emission control strategy 53
Appendix A.3 Template for submission of engine technical specification 54
Annexure 2 Communication – Type Approval and COP Template to be attached 67
here by Test Agencies
Appendix A.1 Test report 71
Annexure 3 Labelling requirement 75
Annexure 4 Test equipment, test bed measurement system and test facility (ISO 76
8178-1, NABL accredited)
Annexure 5 Method of data evaluation and test result calculation (ISO 8178-4) 77

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Annexure 6 Technical characteristics of fuels prescribed for approval test and to 78

verify conformity of production
Appendix 1 Reference diesel fuel characteristics 78
Appendix 2 Commercial diesel fuel characteristics 80
1
Appendix 3 Other liquid fuels: Ethanol (ED95) 81
Appendix 4 Gaseous fuel for duel fuel engine: i) LPG ii) Natural Gas/Bio-methane 83
Annexure 7 Requirements, Tests & Test procedure 87
Appendix 1 Emission test cycle introduction. Characteristics of steady state test cycles 89
(ISO 8178-4)
Appendix 2 Off cycle emission over control area ((ISO 8178-4) 94
Appendix 3 Method of measuring smoke (ISO 8178-3, ISO 8178-9) 99
Appendix 4 Gross power measurement procedure 100
Appendix 5 Crankcase ventilation requirement (ISO 8178-4) 103
Appendix 6 Emission durability periods (EDP), deterioration factor and methodology for 104
adapting the emission laboratory test results to include the deterioration factor
Appendix 7 Procedures for measurement and calculation of ammonia (ISO 8178-1, ISO 111
8178-4)
Appendix 8 Method of test execution and measurement procedures. Procedure for 111
developing the infrequent regeneration adjustment factor (IRAFs) for engine
with exhaust after-treatment system (ISO 8178-4)
Appendix 9 Additional requirement for variable speed engine for demonstration/ 112
determination/ verification of declared speed values for emission test cycle
Annexure 8 Requirements with regard to emission control strategies, NO X control 116
measures and Particulate control measures
Appendix A.1 Additional technical requirements on NOX control measure including the 120
method to demonstrate these strategies
Appendix A.2 Technical requirements on particulate pollutant control measures, 142
including the method to demonstrate these measures
Appendix A.3 Technical details for prevention of tampering 149
Appendix A.4 Technical details for remote information and monitoring 150
requirements
Annexure 9 Installation in the GENSET Application 151
Appendix 1 Details of the relevant information and instructions for the GOEM 152
Appendix 2 Details of the relevant information and instructions for the end-users 154
Annexure 10 Technical requirements for dual-fuel engines 156
Appendix A.1 Dual-fuel engine dual-fuel indicator, warning system operability restriction – 162
Demonstration requirements
Appendix A.2 Emission test procedure requirements for dual-fuel engines 163
Appendix A.3 Types of dual-fuel engines operated on natural gas/biomethane or LPG and 168
a liquid fuel – illustration of the definitions and main requirements
Appendix A.4 Safety checks for use of gaseous fuelled (dual fuel / dedicated dual fuel as 169
applicable) internal combustion engine
Appendix A.5 Labelling Requirement for dual fuel engines 172
Annexure 11 Composition of Committee 173
Annexure 12 CPCB IV Plus Notification GSR copy as released 174

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Part – A2

Applicable for Positive Ignition (PI) Engines

CONTENTS

Clause &
Description Page
Annexures
1. Scope 182
2. Definitions and abbreviations 183
3. Exhaust Emission Limits, applicability and Requirement 188
4. Type Approval Administrative procedure 191
Appendix 1 Application to Nodal Agency. Specimen of submission for Affidavit & profile 198
details of Manufacturer
5. Conformity of Production (CoP) Administrative procedure 201
Annexure 1 Information document from manufacturer 213
Appendix A.1 Template for information folder and information document 213
Appendix A.2 Confidential information on emission control strategy 216
Appendix A.3 Template for submission of engine technical specification 217
Annexure 2 Communication – Type Approval and COP Template to be attached 229
here by Test Agencies
Appendix A.1 Test report 233
Annexure 3 Labelling requirements 237
Annexure 4 Test equipment, test bed measurement system and test facility (ISO 238
8178-1, NABL accredited)
Annexure 5 Data evaluation, test result calculation of gaseous & emission, test 239
execution and measurement procedures
(ISO 8178-4)
Annexure 6 Technical characteristics of fuels prescribed for approval test and to 240
verify conformity of production
Appendix 1 Reserved 240
Appendix 2 Reserved 240
Appendix 3 Reserved 240
Appendix 4 Alternate Fuel Specification 240
Annexure 7 Requirements, Tests & Test procedure 244
Appendix 1 Emission test cycle Introduction and Characteristics of steady state test cycles 246
(ISO 8178-4)
Appendix 2 Reserved 247
Appendix 3 Reserved 247
Appendix 4 Gross power measurement procedure 248
Appendix 5 Crankcase ventilation requirement (ISO 8178-4) 250
Appendix 6 Emission Durability Period (EDP), Deterioration Factor and Methodology for 251
Adapting Emission Lab Test Results.

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Appendix 7 Procedure for the Measurement & Calculation of Ammonia Emissions (ISO 258
8178-1, ISO 8178-4)
Appendix 8 Reserved 258
Appendix 9 Reserved 258
Annexure 8 Requirements regarding emission control strategies, NOX control 259
measures
Appendix A.1 Additional technical requirements on NOX control measure including the 263
method to demonstrate these strategies
Appendix A.2 Reserved 284

Appendix A.3 Technical details for prevention of tampering 284

Appendix A.4 Technical details for remote information and monitoring 285
requirements
Annexure 9 Installation in the Genset Application 286
Appendix 1 Details of the relevant information and instructions for the GOEM 287
Appendix 2 Details of the relevant information and instructions for the end-users 289
Annexure 10 Alternate Fuel System Safety Standard 291

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Part – A3

Portable Generator sets

CONTENTS
Clause &
Description Page
Annexures
1. Scope 296
2. Definitions and abbreviations 297
3. Exhaust emission limits & applicability 301
4. Type Approval Administrative procedure 303
4.1 Genset type & genset family 303
4.2 Selection of certification agency 303
4.3 Application for type approval (TA) 304
4.4 Type approval 305
4.5 Certificate of type approval and validity 305
4.6 Modifications and extension of approval of the approved type 306
4.7 Type approval process flow chart 308
Appendix -1 Application to Nodal Agency. Affidavit & profile details 310
5. Conformity of Production (CoP) Administrative procedure 313
5.1 General 313
5.2 Verification of conformity of production (CoP) 313
5.3 Sample size, decision, and other criteria for verification of CoP 313
5.4 Certificate of Conformity of Production & validity 316
5.5 CoP discontinuity 316
5.6 Exemption from CoP 317
5.7 Production definitively discontinued 317
5.8 Consequences of Non-conformity of production 317
5.9 CoP process flow chart 319
Annexure - 1 Information document- Template for submission of genset technical 323
specification
Annexure - 2 Specimen copy for Type Approval and CoP certificate 330
Annexure - 3 Labelling requirement 333
Annexure - 4 Test equipment, test fuel, test procedure & test result calculation 334
Annexure - 5 Additional requirement for emission control strategy 341
Annexure - 6 Technical characteristics of fuels prescribed for approval test and to 342
verify conformity of production
Annexure - 7 Compliance to safety code of practice for alternate fuel generator sets 349
Annexure - 8 Additional requirement for variable speed portable generator sets 350

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Part – A4

Safety Code of Practice

Applicable for engines other than Gasoline and Diesel

CONTENTS

Clause &
Description Page
Annexures
1. Scope 352
2. References 353
3. Definitions 354
4. Abbreviations 356
5. Safety requirements 357
5.1 General Design Requirements 357
5.2 Cylinder for CNG/LPG or PNG 358
5.3 Fittings on CNG cylinders & its Cascades and filling connection 358
5.4 Location, Ventilation and Mounting of NG/LPG Cylinders 359
5.5 Cylinder(s) installation 360
5.6 Shielding 365
5.7 Construction of compartments and sub-compartments 366
5.8 NG/CNG/LPG Fuel Line 367
5.9 CNG/PNG/LPG Control Equipment 369
5.10 Compliance plate 373
5.11 Labels 374
6. Instructions to be provided by the GENSET Manufacturer 376
7. Inspection, testing and commissioning by GENSET manufacturer or 377
authorized person appointed by GENSET manufacturer
7.1 Commissioning 377
7.2 Initial inspection and installation certificate 377
7.3 Periodic Inspection /preventive maintenance 377
7.4 Leak Test 377
7.5 Repair of NG/LPG System 378
7.6 Scrapping of Cylinder 379
8. Statutory authority approval 380
9. Type approval administrative procedure 381
9.1 Selection of Certifying Agency 381
9.2 Application of type approval 381
9.3 Type Approval 382

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9.4 Certificate of Type Approval and Validity 382

9.5 Modification and Extensions of approved type 383
9.6 Type Approval Process 383
Appendix A.1 Template for submission of engine technical specification 385
Annexure- 1 Freezing conditions and corrosive conditions 403
Annexure- 2 Backfire – deflector tests 404
Annexure- 3 Checklist for installation for NG/LPG GENSET 406
Annexure- 4 Installation certificate for converted CNG/PNG/ LPG GENSET engine 408
manufacturer/ authorized person of GENSET manufacturer
Annexure- 5 Component testing and safety checks for use of NG/CNG fuels in 410
internal combustion engine for generator

Annexure- 6 Safety checks for use of LPG fuels in internal combustion engine for 412
generator
Annexure- 7 Roles & responsibility of various stakeholders 414
Annexure- 8 Labelling requirements 415
Appendix-8.1 Label 416

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Part – A1

Compression Ignition (CI)

Engines

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1. SCOPE
This A1 document lays down the applicability and requirements, system & procedure for compliance to
the rules vide notification no. GSR 804(E.) dated 3-Nov-2022on emission limits for new internal
combustion engine up to 800 kW gross power used for power generating set (Genset) application,
issued by Ministry of Environment, Forests & Climate change, Government of India.
Emission of gaseous CO, HC, NOx and Particulate pollutants and Smoke from following type of
compression ignition internal combustion engines operating with either constant speed duty cycle or
variable speed duty cycle,
 Diesel engines
 Dual Fuel engine run on Diesel fuel + any of the alternate fuels*
*Alternate fuels - Natural Gas/Biomethane, LPG (Fuel Specification of these fuels shall be as notified
under CMVR as amended from time to time)

Natural Gas can be used in the form of Compressed Natural Gas or Liquefied Natural Gas or Piped
Natural Gas.

Following parts of specified standards shall be referred wherever stated.

Sr No. Standard Title
Reciprocating internal combustion engines — Exhaust emission
ISO 8178-1: 2017
1 measurement — Part 1: Test-bed measurement systems of gaseous
ISO 8178-1: 2020
and particulate emission
Exhaust emission measurement — Part 3: Test procedure for
2 ISO 8178-3: 2019 measurement of exhaust gas smoke emissions from compression
ignition engines using a filter type smoke meter
Reciprocating internal combustion engines — Exhaust emission
ISO 8178-4: 2017
3 measurement — Part 4: Steady-state and transient test cycles for
ISO 8178-4: 2020
different engine application
Reciprocating internal combustion engine-Exhaust emission
4 ISO 8178-7: 2015
measurement-Part-7: Engine family determination
Reciprocating internal combustion engines — Exhaust emission
measurement — Part 9: Test cycles and test procedures for
5 ISO 8178-9: 2019
measurement of exhaust gas smoke emissions from compression
ignition engines using an opacimeter

US EPA Regulation: 40 CFR Part 1039 - Control of emissions from

6 40 CFR Part 1039
new and in-use nonroad compression-ignition engines

7 40 CFR Part 1065 US EPA Regulation: 40 CFR Part 1065 – Engine testing procedures

8 AIS 024 (Version 5) Safety and Procedural requirements for type approval of CNG/Bio-
CNG/LNG operated vehicles (dedicated, bi-fuel & dual fuel)

9 AIS 028 (Version 5) Code of practice for use of CNG/Bio-CNG/LNG fuel in internal
combustion engined vehicles

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2. DEFINITION & ABBREVIATIONS

2.1 DEFINITIONS
1. “Approval of an engine (engine family)” means the approval of an engine type with regards to the
level of the emission of gaseous, particulate and smoke pollutants;

2. “Auxiliary emission control strategy” means any element of design that senses temperature,
engine RPM, or any other parameter for the purpose of activating, modulating, delaying, or
deactivating the operation of any part of the emission control system;

3. “Adjustment factors” mean additive (upward adjustment factor and downward adjustment factor) or
multiplicative factors to be considered during the periodic (infrequent) regeneration;

4. “Ageing cycle” means the machine or engine operation (speed, load, power) to be executed during
the service accumulation period

5. “Applicable emission limit” means an emission limit to which an engine is subject to for approval;

6. “Approval of an engine” means the approval of an engine type or family with regard to the level of
emission of gaseous and particulate pollutants by the engine;

7. “Base emission control strategy” means design strategy that is active throughout the speed and
load operating range of engine unless Auxiliary emission control is activated;

8. “Compressed natural gas (CNG / BIO CNG)” means a compressed gaseous fuel composed
predominantly of Methane (CH4) shall be used as specified by the Government of India from time to
time.

9. “Confirmed and active DTC” means a DTC that is stored during the time the NCD system concludes
that a malfunction exists;

10. “Constant speed engine” means an engine whose type approval or certification is limited to
constant-speed operation. Engines whose constant-speed governor function is removed or disabled
are no longer constant-speed engines;

11. “Constant speed operation” means engine operation with a governor that automatically controls the
operator’s demand to maintain engine speed, even under changing load. Governors do not always
maintain exactly constant speed, but shall be maintained with allowed tolerances as mentioned in the
document"

12. “Continuous regeneration” means the regeneration process of an exhaust after-treatment system
that occurs either in a sustained manner or at least once over the applicable emission test cycle; in
contrast to periodic (infrequent) regeneration;

13. “Critical emission related components” means the components which are designed primarily for
emission control, that is, any exhaust after-treatment system, the electronic engine control unit and
its associated sensors and actuators, fuel injection equipment, turbocharger and it’s integral control
actuators and the EGR system including all related filters, coolers, control valves and tubing;

14. “Critical emission related maintenance” means the maintenance to be performed on critical
emission-related components;

15. “De-NOx system” means an exhaust after-treatment system designed to reduce emissions of oxides
of nitrogen (NOx) (e.g. passive and active lean NOx catalysts, NOx absorbers and selective catalytic
reduction (SCR) systems);

16. “Dedicated Dual fuel engine” Dedicated Dual fuel engine operation shall mean a two – fuel system

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having diesel as a primary combustion fuel and CNG or Bio CNG or LPG as supplementary fuel and
such dedicated dual fuel engine shall not operate on diesel stand-alone mode in absence of gaseous
fuel and in such dedicated dual fuel engine, mass emission test will be carried out in dual fuel mode
only.”

17. “Diagnostic trouble code – DTC” means a numeric or alphanumeric identifier which identifies or
labels a NOx Control Malfunction or a Particulate Control Malfunction.

18. “Dual fuel engine” shall mean a two – fuel system having diesel as a primary combustion fuel and
CNG or Bio CNG or LPG as supplementary fuel. Such dual fuel engine may operate on diesel stand-
alone mode in absence of gaseous fuel.

19. “Discrete mode” means relating to a discrete mode type of steady-state test, as described in ISO
8178-4.

20. “Emissions-related defect” means a deviation from normal production tolerances in design,
materials, system or assembly that affects any parameter, specification or component belonging to
the emission control system. A missing component may be considered to be an emission-related
defect;

21. “Emission control system” means the exhaust after treatment system including reagent and HC
dosing system, the electronic management controllers of the engine system (if utilized) and any
emission related component of the engine system in the exhaust which supplies an input to or
receives an output from these controllers and when applicable the communication interface between
the engine system electronic control unit (ECU) and any other power train with respect to emissions
management;

22. “Engine system” means the engine, the emission control system and the communication interface
(hardware and messages) between the engine system electronic control unit (ECU) and any other
power train;

23. “Engine family” means a manufacturer’s grouping of engine systems which, through their design
have similar exhaust emission characteristics, all members of the family must comply with the
applicable emission limit values described in Clause 3.1. Also refer ISO 8178-7;

24. “Engine type” means a category of engines, which do not differ in such essential respects as engine
characteristics as defined in ISO 8178-7

25. “Exhaust after treatment system” means ‘a catalyst (oxidation or 3-way), a particulate filter, a de-
NOx system, a combined de-NOx particulate filter’ or any other emission-reducing device that is
installed downstream of the engine. This definition excludes exhaust gas recirculation, which, where
fitted is considered an integral part of the engine system;

26. “Engine governed speed” means the engine operating speed when it is controlled by the installed
governor;
27. “Electronically controlled engines” means the engines using electronic control to determine both
the quantity and timing of injecting fuel.

28. “Electronic control unit (ECU)” means an engine’s electronic device that uses data from engine
sensors to control engine parameters as primary function. ECU may contain more functionality than
stated above of interest;

29. “Emission control strategy” means a combination of an emission control system with one base
emission control strategy and with one set of auxiliary emission control strategies, incorporated into
the overall design of an engine or Genset into which the engine is installed;

30. “Emission durability period” mean the number of hours indicated in Appendix 6 of Annexure 7 used
to determine the deterioration factors

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31. “Emission related maintenance” means maintenance which substantially affects emissions, or
which is likely to affect emissions performance deterioration of the vehicle or the engine and exhaust
after treatment system during normal in-use operation;

32. “Engine-after treatment system family” means a manufacturer’s grouping of engines that complies
with the definition of engine family, but which are further grouped into a family of engine families
utilising a similar exhaust after-treatment system;

33. “Exhaust gas recirculation” means a technology that reduces emissions by routing exhaust gases
that have been exhausted from the combustion chamber(s) back into the engine to be mixed with
incoming air before or during combustion. The use of valve timing to increase the amount of residual
exhaust gas in the combustion chamber(s) that is mixed with incoming air before or during combustion
(also called ‘internal EGR’) is not considered exhaust-gas recirculation for the purposes of this
Regulation;

34. For Domestic products, Date of Manufacture means the date on which the engine or genset is
invoiced;

35. For Imported products, Date of Import means the date of payment of custom duties applicable to
the engine or Genset;
36. “Genset Engine” means engines used primarily to operate an electrical generator / alternator to
produce and supply electric power for other applications in lieu of supply of power from electric grid;

37. "Gas Energy Ratio (GER)" means in case of a dual-fuel engine the ratio (expressed as a percentage)
of the energy content of the gaseous fuel over the energy content of both fuels (diesel and gaseous).

38. “Gaseous pollutant” means carbon monoxide (CO), hydrocarbons (HC – assuming a ratio of C1H1.85)
and oxides of nitrogen (NOx), the last named being expressed in nitrogen dioxide (NO2) equivalent;

39. “High idle speed” means ‘the speed achieved by the engine under the specified test conditions at full
throttle with no external load applied on the engine flywheel
40. “Hydrocarbon (HC)” means Total Hydrocarbon (THC), non-methane hydrocarbon (NMHC) as
applicable. Hydrocarbon generally means the hydrocarbon group on which the emission standards
are based for each type of fuel and engine

41. Internal combustion engine (ICE)” means an engine, which works on the either compression-
ignition principle or positive ignition principle utilising liquid, gaseous or combination of both fuels;

42. “Idle speed” means the lowest engine speed with minimum load (greater than or equal to zero load),
where an engine governor function controls engine speed. For engines without a governor function
that controls idle speed, idle speed means the manufacturer-declared value for lowest engine speed
possible with minimum load. Note that warm idle speed is the idle speed of a warmed-up engine.

43. “Liquefied Natural Gas (LNG)” means a Natural gas that has been cooled to -259 degrees
Fahrenheit (-161 degrees Celsius) and at which point it is condensed into a liquid which is colourless,
odourless, non-corrosive and non-toxic. Characterized as a cryogenic liquid. Fuel quality for GENSET
use shall meet the requirements of BIS specification as notified from time to time by MoPNG, Govt.
of India.

44. “Manufacturer” means engine or Genset manufacturer, importer or, assembler (as noted in
notification);

45. “NCD engine family” means a manufacturer’s grouping of engine systems having common methods
of monitoring/diagnosing NCMs;

46. “NOx control diagnostic system (NCD)” means system on-board the engine which has the
capability” of: Detecting a NOx control malfunction; Identifying the likely cause of Nox control
malfunctions by means of information stored in computer memory and/or communicating that
information off-board;

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47. “NOx control malfunction (NCM)” means an attempt to tamper with the Nox control system of an
engine and/or exhaust after treatment system or a malfunction affecting that system that might be due
to tampering, that is considered by this Regulation as requiring the activation of a warning or an
inducement system once detected;

48. “Non-emission related maintenance” means maintenance which does not substantially affect
emissions, and which does not have a lasting effect on the emissions performance deterioration of
the machine or the engine during normal in-use operation once the maintenance is performed;

49. “Non-methane hydrocarbons (NMHC)” means the sum of all hydrocarbon species except methane;

50. “Oxides of Nitrogen (NOx)” means compounds containing only nitrogen and oxygen as measured
by the procedures specified in this Regulation. Oxides of nitrogen are expressed quantitatively as if
the NO is in the form of NO2, such that an effective molar mass is used for all oxides of nitrogen
equivalent to that of NO2.

51. “Opacity meter” means an instrument used to measure the opacity of smoke particles by means of
the light absorption principle;

52. “Open crankcase emissions” means any flow from an engine’s crankcase that is emitted directly
into the environment;

53. “Operator demand” means an engine operator’s input to control engine output. The “operator” may
be a person (i.e. manual), or a governor (i.e., automatic) that mechanically or electronically signals an
input that demands engine output. Input may be from an accelerator pedal or signal, a throttle-control
lever or signal, a fuel lever or signal, a speed lever or signal, or a governor set-point or signal

54. “Particulate matter (PM)” means any material collected on a specified filter medium after diluting
C.I. engine exhaust gas with clean filtered air so that the temperature is within 47 +/- 5 °C;

55. “Percent load” means the fraction of declared rated torque at an engine speed;

56. “Periodic or infrequent regeneration” means the regeneration process of an exhaust after-
treatment system that occurs periodically in typically less than 100 hours of normal engine operation.
During cycles where regeneration occurs, emission limits may be exceeded;

57. “Placing on the market” means the action of making available a product covered by this Regulation
on the market of a country applying this Regulation, for payment or free of charge, with a view to
distribution and/or use in the country

58. “Parent engine” means an engine selected from an engine family in such a way that its emissions
characteristics will be representative for that engine family and that it complies with the requirements
set out in ISO 8178-7

59. “Power generating set or Genset” means any equipment which is used for electric power
generation in absence or failure of grid power utilizing engine system defined in this document as
prime mover;

60. “Particulate after treatment device” means an exhaust after treatment system designed to reduce
emissions of particulate pollutants through a mechanical, aerodynamic, diffusion or inertial separation;

61. “Rated power” means nominal power in kW declared by manufacturer at declared rated Speed

62. “Rated speed” is the engine speed at which the declared rated power occurs with allowed tolerances
as mentioned in the document"

63. “Ramped modal steady-state test cycle” means a test cycle with a sequence of steady state engine
test modes with defined speed and torque criteria at each mode and defined speed and torque ramps
between these modes

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64. “Reagent” means any consumable or non-recoverable medium required and used for the effective
operation of the exhaust after-treatment system;

65. “Regeneration” means an event during which emissions levels change while the after-treatment
performance is being restored by design. Two types of regeneration can occur: continuous
regeneration and infrequent (periodic) regeneration;

66. “Service Mode” For dedicated dual fuel engines (Type 1A & 2A), in absence of gaseous fuel or
operation of the engine in diesel mode only shall be restricted by reduced power output to 40 percent
and in such dedicated dual fuel engine, mass emission test will be carried out in dual fuel mode only.”

67. “Smoke” means particles suspended in the exhaust stream of a diesel engine which absorb, reflect,
or refract light. Also refer ISO 8178-3 and ISO 8178-9;

68. “Scan tool” means an external test equipment used for off-board communication with NCD & PCD
system;

69. “Service accumulation schedule” means the aging cycle and the service accumulation period for
determining the deterioration factors for the engine-after treatment system family;

70. “Total hydrocarbon (THC)” means the combined mass of organic compounds measured by the
specified procedure for measuring total hydrocarbon, expressed as a hydrocarbon with a hydrogen-
to-carbon mass ratio of 1.85:1;

71. “Test Cycle” means a sequence of test points each with a defined speed and torque to be followed
by the engine during standardised emission assessment test. Also refer ISO 8178-4;

72. “Type approval” means the approval of an engine type with regard to its emissions measured in
accordance with the procedures specified in this Regulation;

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2.2 Abbreviations

BSFC Brake-specific fuel consumption

BIS Bureau of Indian Standards
CPCB Central Pollution Control Board
C1 Carbon 1 equivalent hydrocarbon
CC Cubic Centimetre
CH4 Methane
C2H6 Ethane
C3H8 Propane
CNG Compressed Natural Gas
CO Carbon monoxide
CO2 Carbon dioxide
COP Conformity of Production
COP-Year Period starting 1st July of year till 30th June of subsequent year
CI Compression-ignition (Engine)
De-NOx NOx after-treatment system
DF Deterioration factor
ECM Electronic control module
EGR Exhaust gas recirculation
FBC Fuel borne catalyst (for soot regeneration)
FID Flame Ionization Detector
GOEM Genset Original Equipment Manufacturer
HC Hydrocarbon
H2O Water
ISO International Organization for Standardization
LPG Liquefied Petroleum Gas
LNG Liquefied Natural Gas
NMHC Non-methane hydrocarbon
NOx Oxides of nitrogen
NO Nitric oxide
NO2 Nitrogen dioxide
O2 Oxygen
PM Particulate matter
PI Positive Ignition (Engine)
PPM Part per million
RHC Reactive Hydrocarbon
RMS Root-mean square
S Sulphur
THC Total hydrocarbon

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3 Exhaust Emission Limits, Applicability and Requirement

3.1 Exhaust Emission Limits
The emissions of the carbon monoxide, the emissions of hydrocarbons, the emissions of the
oxides of nitrogen and the emissions of particulate matter and smoke obtained during emission
certification and conformity of production emission test/s conducted in accord with in Annexure 7
of this regulation considering applicable deterioration factor, adjustment factor, shall not exceed
the amount shown in Table 1 below:
Table 1
Emission limits for Genset engines up to 800 kW Powered by CI engines

Power NOx HC NOx +HC CO PM Smoke

Ignition
Category,
type
kW
g/kWh m-1
P≤8 CI - - 7.5 3.5 0.30 0.7
8 < P ≤ 19 CI - - 4.7 3.5 0.30 0.7
19 < P ≤ 56 CI - - 4.7 3.5 0.03 0.7
56 < P ≤ 560 CI 0.40 0.19 - 3.5 0.02 0.7
560 <P ≤ 800 CI 0.67 0.19 - 3.5 0.03 0.7

Speed
Emission Test Cycle
operation
Constand D2 5-mode Steady-state discrete mode test cycle specified in ISO-8178-Part 4
speed engine OR
D2 5-mode Steady-state ramped mode test cycle specified in ISO-8178-Part 4
Variable C1 8-mode Steady-state discrete mode test cycle specified in ISO-8178-Part 4
speed egine OR
C1 8-mode Steady-state ramped mode test cycle specified in ISO-8178-Part 4
OR
5-mode Variable Speed Cycle as specified Appendix 9 of Annexure 7
Manufactures shall declare in TA application his choice of discrete-mode type or RMC type cycle
for each family. The chosen cycle type shall also be applicable for all the child rating within family
and not allowed to alter or further choice during COP. RMC type cycle is more relevant to
determination the infrequent regeneration adjustment factor (IRAF) for the engine equipped with
exhaust after-treatment systems that are regenerated on an infrequent (periodic) basis. Test
agency may suggest RMC type cycle in case it is difficult to determine IRFA on discrete-mode
type cycle for some cases

Notes:
(a) The above limits are applicable for constant speed & variable speed engine
(b) Smoke shall not exceed above value mentioned in tables above (where applicable)
throughout the operating load points of the test cycles.
(c) The testing shall be done as per test procedures mentioned in Annexure 7.
(d) Every manufacturer, importer or assembler (hereafter referred as manufacturer) of the
engine for genset application manufactured or imported into India shall obtain Type
Approval and comply with Conformity of Production (COP) requirements of their
product(s) for emission limits which shall be valid for next COP year.
(e) The above-mentioned limit shall be applicable to Type approval and Conformity of
Production (COP) carried out by authorized test agencies.

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The term ‘COP year’ means the period from 1st July of a calendar year to 30th June of the
following year
(f) HC* - NMHC shall be considered for dual fuel operation in case of natural gas or RHC in
case of LPG
Note: THC shall be considered for dedicated diesel engines
NMHC = THC – CH4 for natural gas dual fuel operation
RHC = 0.5 X THC for LPG dual fuel operation

3.2 Rounding off

Determine the official emission result for each pollutant to at least one more decimal place than
the applicable standard. Apply the deterioration factor to the official emission result, then round
the adjusted figure to the same number of decimal places as the emission standard. Compare
the rounded emission levels to the emission standard for each emission-data engine. In the case
of NOX+NMHC standards, apply the deterioration factor to each pollutant and then add the results
before rounding. Test report shall have both, the final rounded certificate emission result and
adjusted test result before rounding for better clarity on the decision.
Use the following rounding convention
i. If the first (left-most) digit to be removed is less than five, remove all the appropriate digits
without changing the digits that remain. For example, 3.141593 rounded to the second
decimal place is 3.14.
ii. If the first digit to be removed is greater than five, remove all the appropriate digits and
increase the lowest-value remaining digit by one. For example, 3.141593 rounded to the
fourth decimal place is 3.1416.
iii. If the first digit to be removed is five with at least one additional non-zero digit following the
five, remove all the appropriate digits and increase the lowest-value remaining digit by one.
For example, 3.141593 rounded to the third decimal place is 3.142.
iv. If the first digit to be removed is five with no additional non-zero digits following the five,
remove all the appropriate digits, increase the lowest-value remaining digit by one if it is odd
and leave it unchanged if it is even. For example, 1.75 and 1.750 rounded to the first decimal
place are 1.8; while 1.85 and 1.850 rounded to the first decimal place are also 1.8. Note that
this rounding procedure will always result in an even number for the lowest-value digit.

Examples-

# 1 2 3 4 5 5 5 6
1
0.0143 0.0238
Measured value -PM 0.0047 0.0048 0.0142 0.0239 0.0333 0.0334
(odd) (even)
2 Emission Limit -PM 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
3 DF applicable 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05
4 DF incorporated
0.0049 0.0050 0.0149 0.0150 0.0250 0.0251 0.0350 0.0351
adjusted emission
5 Final certificate
0.00 0.01 0.01 0.02 0.02 0.03 0.03 0.04
emission value
6 Decision Pass/Fail Pass Pass Pass Pass Pass Fail Fail Fail

Note: Rounding Reference taken form US EPA Regulation 40 CFR -1039 and 40 CFR- 1065
3.3 In addition, the following requirements shall apply:

a) Off cycle emission for electronically controlled constant speed Compression Ignition
engines & Dual Fuelled engines of all power categories when emission of gaseous and
particulate sampled within the applicable control area shall not exceed the applicable

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emission limit values by a factor of 2.0. (i.e., 2 times the emission limits) as set out details in
Appendix 2 of Annexure 7 of this Regulation
b) Ammonia emission over the test cycles for engines equipped with SCR shall not exceed a
mean value of 25 ppm for engine power category less than or equal to 56 kW and 10 ppm
for engine power category above 56 kW as set out details in Appendix 7 of Annexure 7 of this
Regulation
c) Engine Durability Period and Deterioration Factor shall be applicable to above 19 kW
power category only as set out in details in Appendix 6 of Annexure 7 of this Regulation in
details.

Engine Durability Period

Category (Power Band) Emission durability period
(hours)
>19 ≤ 56 kW (constant speed Engines) 3000
>19 ≤ 56 kW (Variable speed Engines) 5000
> 56 kW (All engines) 8000
Note: DF determined during type approval will be carried over.

Deterioration Factors (DF)

Category (Power Band)
CO HC NOx PM
>19 kW
1.3 1.3 1.15 1.05
(Constant / Variable Speed Engine)
Assigned multiplicative deterioration factors

Note: When opted for assigned multiplicative DF, no verification is required.

d) NOx control measures: Engines which rely on the use of any external devices and or
reagent (e.g. urea for SCR) in order to reduce emissions, shall ensure the correct operation
of NOx control measures as set out in details in Annexure 8 of this Regulation in details

e) Particulate control measures: Engines which rely on the use any external devices and or
exhaust after treatment devise to reduce Particulate Matter emissions, shall ensure the
correct operation of PM control measures, as set out in details in Annexure 8 of this
Regulation in details

f) Infrequent Regeneration Adjustment factor (IRAF) shall be applicable for the engine
above 19 kW power category equipped with exhaust after-treatment systems that are
regenerated on an infrequent (periodic) basis as set out details in Appendix 8 of Annexure 7
of this Regulation.

g) Gross Power & Speed tolerance: The gross declared power of the engine shall be
measured on the test bench at rated speed of engine. The measured power and speed may
differ from the power and speed declared by manufactured as specified below.

Gross Power Tolerance Speed Tolerance

Case Constant
Variable speed Constant speed Variable speed
speed
Type ± 5% at rated for single cylinder engines
± 1% at rated &
Approval ± 4% at rated for others engine
± 1% at rated all part load
± 6% at rated for single cylinder engines
CoP points
± 5% at rated for others engine

h) Crankcase ventilation requirement shall be applicable to above 56 kW power category

engines as set out details in Appendix 5 of Annexure 7 of this Regulation

i) Control Conditions-Altitude, Temperature: Electronically controlled engine using auxiliary

emission control strategy shall demonstrate the compliance requirement over control

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conditions at type approval as set out details in Annexure 8 of this Regulation. This clause is
applicable to for power band above 56 kW electronically controlled engine using auxiliary
emission control strategy to operate in altitude.

j) Additional requirement for dual fuelled engine shall be applicable as set out details in
Annexure 10 of this Regulation

k) Additional requirement for variable speed engine shall be applicable as set out details in
Appendix 10 of Annexure 7 of this Regulation (demonstration/ determination/ verification of
declared speed values for emission test cycle)

Summary of the requirement:

Power Category, kW
Requirement
P ≤ 19 19 < P ≤ 56 56 < P ≤ 800
Deterioration Factors (DF) N/A Yes Yes
Crankcase emission N/A N/A Yes
Adjustment factor (IRAF) N/A Yesa Yesa
Off cycle emission-Control area Yesb Yesb Yesb
Ammonia emission Yesc Yesc Yesc
c1 c1
NOx control measures Yes Yes Yesc1
d d
Particulate control measures Yes Yes Yesd
Control conditions-Altitude, Temperature N/A N/A Yese
Telematics for remote monitoring N/A N/A Yesf
a
Applicable for engine with exhaust after-treatment systems that are regenerated on an
infrequent (periodic) basis
b
Applicable for electronically controlled constant speed & variable speed engines
c
Applicable for SCR engine using reagent to reduce NOx emissions
c1
Applicable for engines using electronic control on devices which are used to reduce NOx
emission, (i.e. EGR, SCR)
d
Applicable for engine using exhaust after treatment devise to reduce Particulate emissions
e
Applicable for electronically controlled engine using auxiliary emission control strategy to
operate in altitude. Demonstration is only at time of type approval only once and not applicable
during COP.
f Applicable for electronically controlled constant speed & variable speed engines

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4 Type Approval Administrative Procedure

4.1 Engine type and Engine family

4.1.1. Engine type
The technical features of an engine type shall be those defined in its information document
drafted in accordance with the template set out in Annexure 1.
4.1.2. Operating mode (speed operation)
An engine type may be type-approved as a constant speed engine or as a variable speed
engine, as defined of this Regulation.
4.1.2.1. Variable speed engines
For a variable-speed engine of a category, the parent engine (for the purposes of type-approval)
and all engine types within the engine family (for the purposes of conformity of production),
shall be tested using the applicable test cycle as described in this regulation.
4.1.2.2. Constant speed engines

The manufacture shall declare in his application the operation of engine is constant speed or
variable speed.

4.1.2.3. Constant speed engine types equipped with alternative rated speeds
A constant speed engine shall not be designed to operate with variable speed. In the case that
the engine type is equipped with alternative speeds the requirements of this paragraph shall
additionally be met.
In the case that the engine type is the parent engine, the engine shall meet the applicable limit
values when tested using the applicable constant speed test cycle at each constant speed
applicable to the engine type. Separate test reports shall be produced and included in the
information package for each emission test.
In the case of all engine types within the engine family, when subject to a conformity of
production emissions test the engine shall meet the applicable limit values using the applicable
constant speed test cycle at each constant speed applicable to the engine type.
Each constant speed applicable to the engine type that is permitted by the manufacturer shall
be listed in information document as per Annexure 1
The engine shall be installed in a manner to ensure that:
(a) the engine is stopped prior to resetting the constant speed governor to an alternative
speed; and,
(b) the constant speed governor is only set to the alternative speeds permitted by the engine
manufacturer.
The instructions to the GOEM and end-users set out in Appendices A.1 and A.2 to Annexure 9
of this Regulation shall include information on the correct installation and operation of the
engine according to the requirements of this Annexure.

4.1.3. Engine family criteria

4.1.3.1. General
For the purpose of type approval and conformity of production certification, the manufacturer
engine range shall be divided into model families consisting of parent engine and its variant(s).
In case of import of complete genset, all the provision of this document shall be applicable to
the engine which form part of the genset.

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Engine family shall be the grouping of engines, which through their design are expected to have
similar exhaust emission characteristic where member of the family shall comply with the
applicable emission values.
Parent engine shall be the engine selected from the engine family, in such a way that it will
incorporate those features which will adversely affect the emission level of the relevant exhaust
emission.
4.1.3.2. Engine family formation & choice of the parent engine
Essential characteristic of the engine family, the parameters defining the engine family, the
determination of an engine family and the criteria for choosing the parent engine shall be taken
according to the guideline given in ISO 8178-7 Reciprocating internal combustion Engine-
Exhaust Emission Measurement-Part-7: Engine family determination. However, the decision of
selection of parent engine and family classification by the authorized test agency shall be final.
For the purpose of identification, the manufacturer shall designate the families as F1, F2, F3….
Fn.
The manufacturer shall provide to the type approval authority the appropriate information
relating to the emissions levels of the members of the engine family
4.1.3.3. Dual-fuel engines
All engine types within a dual-fuel engine family shall belong to the same type of dual-fuel
engines defined in Annexure 10 of this Regulation (for example type 1A, type 2B, etc.), and
operate with the same types of fuel or when appropriate with fuels declared according to this
Regulation as being of the same range(s).
In addition to belonging to the same dual-fuel type, they shall have a maximum gas energy ratio
on the applicable test cycle (GERcycle) within the range 70 to 100 per cent of that of the engine
type with the highest GERcycle.

4.2 Selection of Certifying Agency

4.2.1. Following test agencies are currently approved by the Nodal Agency Central Pollution Control
Board (CPCB) for purpose of type approval and subsequently conformity of production
compliance process and may be revised from time to time.
(a) Automotive Research Association of India (ARAI, Pune)
(b) International Centre for Automotive Testing (ICAT, Manesar)
(c) Indian Institute of Petroleum (IIP, Dehradun)
4.2.2. One supplier shall submit application for Type Approval to only one certification agency for all its
families / models out of those approved.
4.2.3. The same certification agency shall be responsible for carrying out the verification of Conformity
of Production (COP) for that manufacture
4.2.4. For a new OEM or importer, selection of technical agencies for type approval certification and
subsequently conformity of production shall be applicant’s choice among the technical agencies
published by central pollution control board (CPCB) in paragraph 4.2.1 and as amended from
time to time.
4.2.5. For any reason if any manufacturer wants to change the certification agency, he shall apply to
the nodal agency well in advance with justifiable reason. The nodal agency, after consultation
with the existing certification agency/ standing committee, may approve the change, if found
justified. If approved, the nodal agency shall inform to the parties concerned.
4.2.6. On receipt of information for change in certification agency from the nodal agency, the previous
certification agency shall authenticate all the relevant document of the model (type approval as
well as COP verification) and forward the same to the new certification agency. The certification
agency shall be responsible for carrying out the type approval testing and COP verification for the
manufacturer, in future.

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4.3 Application of type approval

4.3.1 The application shall be made in the format prescribed in Appendix -1 and must be complete in
all respect. Appendix -1 shall be submitted to nodal agency and on its written acceptance, engine
specification related documents to be submitted to the test agency.

4.3.2 The application for approval of an engine or an engine family with regard to the level of the
emission of gaseous and particulate pollutants shall be submitted by the engine manufacturer or
by a duly accredited representative.

4.3.3 For each engine family, the manufacturer must submit an application to the certification agency,
selected as above.

4.3.4 The application must be signed by the authorized representative of the manufacturer.

4.3.5 It shall be accompanied by the undermentioned documents and the following particulars:

A description of the engine type comprising the particulars referred to in clause 4.1. of this
Regulation and if applicable the particulars of the engine family as referred to in paragraph
4.1.3. to this Regulation. For the purpose of identification, the manufacturer shall designate the
engines families as F1, F2, F3 …. Fn in consultation with technical agency;

4.3.6 Testing of the parent model, shall, normally, be sufficient for type approval of the family. The
Testing agency has the option to carry out the testing of more than one model in the family to
satisfy itself, subject to parent engine-concept as per ISO 8178-7

4.3.7 An engine conforming to the engine type characteristics described in clause 4.1. shall be
submitted to the Test Agency responsible for conducting the approval tests. If the Test Agency
determines that the submitted engine does not fully represent the engine family described in
clause 4.1, an alternative and, if necessary, an additional engine shall be submitted for test

4.3.8 During Type Approval test, the manufacturer shall submit the qualified emission test data of all
the remaining variant engines, other than the parent engine, which is chosen for emission test by
the test agency of the family along with all other documents. Qualified emission data can be an
emission test recorded at OEMs facility. This is required only for reference of test agency for future
COP testing and it will not be part of Type Approval certification documents.

4.3.9 At later stage if the manufacturer submits the application for type approval of a model, the Testing
agency shall ascertain whether the model can be classified as belonging to a family of model(s)
already certified. If the model does not belong to a family already certified, the Testing agency
shall proceed with the testing of the model for type approval with issuance of new and unique
engine emissions family certification upon qualification;

4.3.10 If the model belongs to a family already certified, the Testing agency shall decide whether the
specific testing of the model is required. In case the specific testing of the model is not required,
the type approval certificate for the family may be extended to include the model. In such case
qualified emissions data shall be submitted to agency by manufacturer during application;

4.3.11 The Testing agency shall intimate its decision to the applicant within a fortnight of receipt of the
application, indicating need and plan (schedule) of testing for type approval;

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4.4 Type Approval

4.4.1. No person or agency shall sale, import or use an engine for Genset application in India without
valid Type Approval Certificate and Conformity of production Certificate referred to in clause 4.5.
and 5.4 of this Regulation;
4.4.2. No person or agency shall sale, import or use a Genset in India containing an Engine without
valid Type Approval Certificate and Conformity of production Certificate referred to in Clause 4.5.
and 5.4 of this Regulation;
4.4.3. In order to receive a type approval of an engine type or engine family, the manufacturer shall
demonstrate compliance, of the engine type or engine family with the provisions of this
Regulation. The manufacturer shall also ensure the use of fuels as specified in Annexure 6.
4.4.4. All the type approval tests shall be conducted in the technical agency laboratory. In case the
required test facilities are accredited by the technical agency, the type approval and / or COP
tests can be carried out at manufacturer’s laboratory also if reasons call for. In case the test is to
be carried out at any overseas test facilities, the same shall be informed to the Nodal Agency by
technical agency. The technical agency will submit a copy of accreditation letter highlighting the
details of test facilities available in the manufacture’s laboratory to the Nodal Agency;
4.4.5. In case of the manufacturer approaches the technical agency for the first time, such manufacturer
should complete the COP test(s) within three months from the commencement of commercial
production or importation of 100 units. In case, manufacturing or import is done in reference to a
specific order or requirement for one time, the supplier has to make available full quantity or as
required for COP sampling as per the procedure laid down in this regulation. Type Approval
should be conducted on the random selection and its validity shall be limited to same COP year.
4.4.6. The manufacturer may use of commercial fuels or reference fuels set out in Annexure 6, provided
to be declared in the information document.
4.4.7. Additionally, in order to receive type approval of a Genset with an approved engine with regard
to emissions or a type approval of a Genset with regard to emissions the manufacturer shall
ensure compliance with the installation requirements set out in Annexure -9
4.4.8. The Type Approval Authority shall put together an information package consisting of the
information folder accompanied by the test report and all other documents added by the technical
service or by the Type Approval Authority to the information folder in the course of carrying out
their functions (‘the information package’). The information package shall include an index listing
its contents, suitably numbered or otherwise marked so as to clearly identify all the pages and the
format of each document, in order to present a record of the successive steps in the management
of the type approval, in particular the dates of revisions and updating;

4.4.9. The approval authority shall ensure that the information contained in the information package is
available for a period of at least 10 years following the end of the validity of the type approval
concerned;

4.5 Certificate of Type Approval and Validity

4.5.1. After verification of engine(s) for the type approval, the technical agency shall issue a type
approval report to manufacturer within one month from date of testing completion indicating
acceptance or rejection decision and reason thereof. If the engine(s) submitted for approval
pursuant to clause 4.3. of this Regulation. Approval of that engine type(s) or engine family(ies)
shall be granted by the technical agency through issue of Type Approval Certificate as per format
prescribed in Annexure 2 along with report. Copy of the certificate and report shall be forwarded
to Nodal Agency by technical agency involved;
4.5.2. For the purposes of clarity and easing access to relevant data, the communication includes an
addendum containing the most relevant information related with the type-approved engine type
or engine family;
4.5.3. The certificate shall be deemed to be valid for the model(s) included herein, unless explicitly
withdrawn by separate written order by the Nodal Agency;

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i) unless explicitly withdrawn by separate written order by the Nodal Agency; or

ii) failed to conduct COP within prescribed time and/or production/ import quantity limit;
This need to be mentioned in the Type Approval Certificate
4.5.4. The Type Approval certificate for an engine family issued to the manufacturer shall be valid for
the same model(s) manufactured at any other manufacturing plant of the same manufacturer.
The Nodal Agency or technical agency concern with type approval may visit the new plant to
verify adequacy of the infrastructure;
4.5.5. Validity of Type Approval Certificate issued by type approval authority shall remain valid for
‘current’ COP-year enabling sales of such type approved engine family for that duration;
4.5.6. Validity of Type Approval Certificate issued by type approval authority shall remain valid further
as long as following conditions are met:
i) Till the engine specifications change as mentioned in Annexure 1 and modification related
clauses described in clause 4.6 below;
ii) Till the further amendments to the notification;
iii) Till COP is not missed / Till COP procedure compliance per clause 5 is obtained within
prescribed timeframe as listed in clause 5.3.10.
4.5.7. In case manufacturer has not sold engines in two subsequent COP-year period and has done
appropriate ‘Zero volume’ declaration seeking COP exemption to nodal agency, and for resuming
sale for third year of such engine family, manufacturer to conduct COP test before making any
sell or a fresh new type approval application and subsequent process needs to be carried out.
Refer clause 5.5 for COP certification.

4.6 Modification and Extensions of approved type

4.6.1. If an engine type or engine family is type approved and valid, manufacturer may approach type
approval certificate issuing technical agency for modifications pertaining to parent or any engine
type in the certified engine emissions family. Such modifications shall be ascertained by
manufacturer utilizing guidelines described in clause 4.6.5
4.6.2. Manufacturer shall submit technical document in line with type approval procedure prescribed in
this Regulation;
4.6.3. Subjected to scrutiny of manufacture’s application, technical agency shall approve or seek more
data pertaining but not limited to engine architecture, parameters, similarity with existing engine
type from emissions and performance perspective along with evidences. Decision of technical
agency will remain finally binding for allowing such amendments to existing type approval
certificate of an engine family through extension(s) vs asking manufacturer to type approve as
new engine family or new engine type;
4.6.4. Technical agency retains all rights to ask manufacture to demonstrate modified engine type for
emissions conformity through applicable type approval test procedures. Submission of
manufacturer run emissions data with valid test facility and procedure followed is mandatory
where changes are directly or indirectly pertaining to emission affecting components, engine and
after treatment system control algorithms and engine performance specifications.
4.6.5. Following generic rules may be utilized as example for extensions of type approval certificate:
4.6.5.1. No emission test requirements necessary:
(a) change to part numbers declared through type approval documentation that is not emission
affecting;
(b) part number change of emission affecting component that is just an administrative change
supported with due declarations (proto to production Part number change as an example);

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(c) change(s) to emission strategy for engine operation beyond altitude and temperature
conditions prescribed by this Regulation however with due declaration with technical agency in
this regard;

4.6.5.2. Emission test compliance required:

(a) performance or specification or source change of a component declared through type approval
documentation that is emissions affecting. This applies to any such component in engine and
after treatment system including software;
(b) emissions strategy changes such as but not limited to fuelling timing, fuelling qty, fuelling
modes, reagent dosing, regeneration timing;
(c) addition of alternate source component that is emission affecting with or without part number
change;
4.6.5.3. Emission and NOx and / or Particulate Control Diagnostics compliance required:
(a) in addition to clause 4.6.5.2 at discretion of technical agency if changes to NOx and Particulate
control diagnostics limits or strategy or software is carried out;
(b) NOx and /or Particulate control diagnostics demonstration method through failed part has
been changed;
4.6.5.4. In the event of an extension the Test Agency shall establish an updated communication denoted
by an extension number that shall be incremental in accordance with the number of successive
extensions previously granted. That communication shall clearly show the reason for the
extension and the date of extension.

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4.7. Type Approval Process Flow-chart

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Following are the logical steps for the type approval process flow chart described in brief
stepwise -
1. Application to nodal agency (CPCB) in the form of affidavit seeking permission for type
approval of Genset engine family through submission provided as draft specimen in
Appendix 1.
2. Upon written approval of nodal agency to manufacturer and chosen technical agency; (This
could be decision making node with “Yes” / “No” loop)
3. Submit type approval certification application to chosen test agency. Based on provisions
such application can be written or online through their secured portal;
4. Obtain technical agency approval (This could be decision making node with “Yes” / “No” loop
with NO means, provide additional data)
5. Upon agencies application scrutiny and negotiations, submit detailed technical
documentation as per requirements described in Annexure 1;
6. Obtain documentation approval from technical agency, family formation, choice of parent
engine, provide additional data
7. Obtain test plan / schedule from technical agency
8. Upon approval from technical agency plan for providing engine test auxiliaries like -Silencer,
air filter, after treatment systems, engine mounting, coupling plate to match dyno,
components for NCD/PCD demonstration etc.
9. Upon receipt of engine along with auxiliary technical agency examine the adaptability in test
cell, make necessary modification in exhaust line, mounts, etc, if required.
In case of dual fuel engines, certificates of the NG/LPG fuel system components as per
Appendix A.4 of Annexure 10 to be validated from test agency. In absence of valid
component certificate, the component to be tested and approved from test agency as per
applicable standard
10. Conduct applicable tests-
10.1.Conduct emissions test to qualify (This could be decision making node with “Pass” /
“Fail” loop. “Fail” means, a) current TA application is closed out with failure report b)
adjust. reset engine parameter for retest or c) further manufacturer may re-apply afresh
after redevelopment)
10.2.Conduct NCD and PCD demonstration tests to comply (This could be decision making
node with “Pass” / “Fail” loop. “Fail” means, a) current TA application is closed out with
failure report b) adjust. reset engine parameter for retest or c) further manufacturer may
re-apply afresh after redevelopment)
10.3.Demonstrate results related to infrequent regeneration, control condition if applicable;
11. Review of all test results with manufactures and decision about compliance, in case of failure
manufacture have three options to proceed a, b, & c, act accordingly.
12. Technical agency carries out part verification of critical engine components and injection
timing verification in compliance with document submission, take final review of technical
document and ask manufacture to resubmit if necessary
13. Manufacture submit the corrected technical document if found necessary
14. Examine corrected document submitted in line with the requirement
15. Technical agency prepares technical report based on tests;
16. Technical agency issues type approval certificate to manufacturer;
17. Technical agency forwards a copy of type approval certificate to nodal agency
End

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Appendix – 1
Application to Nodal Agency. Specimen for Submission of Affidavit &
Profile details of manufacturer
Part - A
NOTARISED AFFIDAVIT ON NON-JUDICIAL STAMP PAPER OF VALUE RS 10/- OR ABOVE
[To be submitted to the Nodal Agency by a supplier approaching for the first time for TA]

I, …………………., Chairman / President / Managing Director / Partner / CEO / COO / Proprietor

of M/s ………………, having Registered Office at …………… engaged in manufacturing / import
of Genset diesel/Duel fuel engines / Diesel/duel fuel Generator sets with manufacturing facilities
/ ware house at:
i) ………………….
ii) ………………….
am authorized to swear this affidavit for and on behalf of the above named Company. I do hereby
solemnly affirm and declare as under:

1. That the deponent is well conversant with the facts and competent to swear this affidavit.
2. That the deponent declares that M/s …………………… are manufacturer / importer of Genset
diesel engines in the brand name
i) ………………….
ii) ………………….
(Strike out if not applicable)

3. That the deponent declares that M/s ……………………. are importer of diesel generator sets
from M/s i) ….………….…. (ii) M/s ………………. (Complete address)
(Strike out if not applicable)

4. That the deponent declares that M/s ……………. will obtain Type Approval / Conformity of
Production verification only from (Name of the Certification Agency) …………… and will not
approach any other Certification Agency for Type Approval / Conformity of Production
verification for any of their Genset diesel engines models, without prior permission from the
nodal agency.
5. That the deponent declares that none of the Chairman, Managing Director, Partner, Director,
Proprietor, Board Member in M/s …………… has been involved with a Company / Firm which
has manufactured and sold non-compliant Genset diesel engines.
6. That the deponent declares that M/s ……………. will manufacture / import and sell only
compliant Genset diesel engines

(Name & signature with Co. stamp)

(DEPONENT)
VERIFICATION
Verified at …………. on this ……………of ……………20…… that the contents of the above
affidavit are true and correct to the best of my knowledge and belief and nothing has been
concealed therein.

Place: ………
Date…………
(Name & Signature with Co. Seal)
(DEPONENT)

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Part - B

Format for Submission of Profile and Details of the Supplier

A. Company details

 Name of the Company

 Type of Company: Proprietor / Partnership / Private Ltd / Public Ltd
 Name of the Proprietor / Partners / Directors (submit relevant documents)
 Importer / manufacturer
 Registered Office Address with phone number
 Contact Address with phone number, fax number, email etc.
 Name and designation of the authorized person for submission of documents and to
deal with the certification agency
 Plant addresses and contact details, in case of manufacturer
 Ware house address, in case of importer (This cannot be changed without prior
intimation to Nodal Agency and Certification Agency)
 Name of the company from whom to import and its contact details, in case of importer
 Plant details, from where to import
 Authenticated Copies of following documents to be submitted
i) DIC/ Udyog Adhar/ Udyam Adhar/ Manufacturing License from Directorate of
Industries / Department of Industry (in case of Manufacturer), IEC Code (in
case of importer)
ii) GST Registration
iii) Excise Registration, in case of manufacturer
iv) Consent from State Pollution Control Board/ Pollution Committee
 No. of employees
 Engineers (if any)
 Last year Turn-over
 Any other business

B. Details of Genset engine (Proposed) manufactured / assembled / imported

Model Nos. produced /imported Nos. expected to be produced /

Sr No
Names in current year imported in the next year
a
b
c
d

C. Details of Infrastructure

D. Land: Owned / Rented

Area (m2):
E. Covered Area

F. Machinery for manufacture

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a)
b)
c)
d)
G. Testing facility equipment’s
a) Load bank type and capacity
b) Measuring Instruments
c) Any other
H. Quality Control
1. Quality Control In charge
2. Quality Procedure:
ISO Certified since when (Enclose a Copy of Operating Procedure)
3. Pre-delivery Inspection Procedure on Gensets (including records maintained)
4. System of serial numbering and marking on Genset and their sub-systems – e.g. all
Enclosures, etc.)
5. Any other

Date: ...............
Place: .............

SIGNATURE OF THE
(Chairman /President / Managing Director
/ Partner / CEO / COO / Proprietor)

SEAL OF THE COMPANY

---End---

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5 Conformity of Production Administrative Procedure

5.1 General

5.1.1. Conformity of Production (COP) compliance is designed to ensure manufacture’s compliance and
control towards a type approved genset engine family to statistically ensure engines sold under
such emission certification does meet required emissions and other requirements including NOx
and / or Particulate diagnostics provisioned by this Regulation;
5.1.2. COP process compliance also ensures type approval certificate validity and hence right to
produce and sale genset engines by a manufacturer owing such type approval certification for the
next COP-year. Such provision is administratively provided by issuing Conformity of Production
Certificate;
5.1.3. Each manufacture shall subject it’s engine model range to the verification of COP, every year.
For this, the year shall mean the period from 1st July of the calendar year to 30th June of the
succeeding calendar year;
5.1.4. Each manufacturer shall subject engine model(s) for NOx Control Diagnostics (NCD) and / or
Particulate Control Diagnostics (PCD) compliance test representative of it’s NCD and or PCD
family as declared during type approval certification for it’s entire genset engine model range.
Depending on engine types certified, a manufacturer may need to submit apt and separate
representation of engine types representing NCD and / or PCD families. Such demonstration and
compliance shall be required once per COP-year per NCD and /or PCD family.
5.1.5. For this, the year shall mean the period from 1st July of the calendar year to 30th June of the
succeeding calendar year;

5.2. Verification of Conformity of Production (COP)

5.2.1. COP of domestically manufactured engine families’ up to 19 kW:
5.2.1.1. In case engines up to 19 kW power rating, the verification of COP shall be done once in a COP-
year as per plan described in following ‘Table 1’

Table 1
Number of families to be tested for verification of COP for domestic manufactures
(for engines up to 19 kW)

Total number of families of the domestic Total number of families to be tested per
manufacturer year
1– 3 1
4–7 2
8 – 11 3
12 – 15 4
>15 5

5.2.2. COP of domestically manufactured engine families more than 19 kW rated output and
imported engines of all rating:
Domestically manufactured engines of more than 19 kW rated output and imported engines of all
ratings shall be subjected to the verification of COP once for every 1000 units per family or once
a year, whichever is earlier;
5.2.3. Domestically manufactured engine models(s) and imported engines of all ratings shall be
subjected to the verification of NCD and / PCD once every COP-year by NCD and/or PCD

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family(ies) representative engine(s). Such demonstration is NCD/PCD family dependant and

irrespective of combined volumes produced and sold under such family(ies).

5.3. Sample size, Decision and Other Criteria for verification of COP
5.3.1. In case of engines defined in clauses 5.2.1.and 5.2.2. above, testing shall be done on sample(s)
randomly selected by certification agency from the production line / import warehouse, of one
model for each family selected for COP.
5.3.2. In case of engines defined in clauses 5.2.3. above, testing shall be done on sample(s) randomly
selected by certification agency from the production line / import warehouse for NCD and / or PCD
compliance;
5.3.3. In case engines up to 19 kW power rating, a minimum quantity of 10 numbers or one day’s
average production volume of the engine model selected by technical agency, whichever is more
shall be made available for random selection. Same criteria shall apply to random selection of
after treatment system that is not integrated with engine system;
5.3.4. In case of domestically manufactured engines more than 19 kW power rating, a minimum one
day’s average production volume of the engine model selected by technical agency, shall be
made available for random selection subject to minimum quantity of 3. This limit shall not be
applicable in case of import of all ratings. Same criteria shall apply to random selection of after
treatment system that is not integrated with engine system;
5.3.5. If the manufacturer is not of Indian origin, the manufacturer should establish a base office in India,
which is to be declared in the initial application submitted to Nodal Agency as per Appendix 1 This
base office will be responsible for Type Approval and COP compliance;
5.3.6. The manufacturer shall request the certification agency when they would like to make random
selection of engine(s) and to seek their schedule / availability for completing the COP test;
5.3.7. COP verification shall be carried out for each plant of the domestic manufacturer. For imported
engines, the COP testing shall be carried out on the engine manufactured for each country of
origin irrespective of engine family being same;
5.3.8. The certification agency shall intimate to the manufacturer the schedule (month) of sampling /
testing. The manufacturer shall inform the production/ import plan for the month in which the
technical agency wants to carry out the COP, to the technical agency. If the manufacturer has a
problem due to particular reasons such as the particular model is not likely to be scheduled for
production / import at that time, or enough number of engines may not be available for random
selection; the time schedule may be modified based on mutual convenience of the manufacturer
and the technical agency;
5.3.9. The manufacturer shall complete all COP activities (such as random selection, initial running-in,
emission testing, NOx and/or Particulate Diagnostics testing and documentation) at least one
month before the end of COP-year. The COP certificate shall not be issued in case of non-
adherence to above schedule unless such schedule attainment is due to unavoidable reasons
such as but not limited to test facility downtime, extended COP process encountered.
5.3.10. Following ‘Table 2’ gives the deadlines for the respective COP-year for the COP activities.
However, manufacturer can take early action on each activity to ensure compliance.
5.3.11. Manufacturer must take early action on each activity for the families (more than 19 kW rated
output) exceeding 1000 units of production to ensure the compliance of clause 5.2.2.

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Table 2
Sr No Activity Description Last Date
Submission of production / import plan / actual details to test
1 1st March
agency
2 Random Selection 1st April
Submission of engines and subsequent testing (Including
3 31st May
extended COP if any)
4 Completion of documentation and COP Certificate issuance 30th June

5.3.12. The manufacturer shall inform the test agency regarding the stoppage of production of a specific
model, in case this has not been anticipated at the start of the COP period. This shall be intimated
well in advance so that COP selection of the engine can be completed by the technical agency
before stoppage of production. Manufacture is held accountable for ensuring COP is conducted
and samples are made available per requirements of this Regulation;
5.3.13. The manufacturer shall provide all the assistance required by the technical agency for completing
the tests;
5.3.14. The latest updated technical specifications, procedure of pre-delivery inspection (PDI), running-
in and servicing of the engine, shall also be submitted before the engine selection, if there have
been revisions after the previous COP / type approval;
5.3.15. Pre-delivery inspection as per owner’s instruction manual / service manual will be carried out by
the manufacture as per procedure declared at the time of type approval and as amended and
intimated to concern technical agency from time to time for the selected engine(s), under the
control of technical agency;
5.3.16. The running-in of the engine(s) shall be carried out as per the manufacture’s recommendation
submitted during the type approval and as amended and intimated to the concern technical
agency from time to time, for engine(s) under control of the technical agency. Running-in may
also be carried out at engine manufacture’s place under the control of technical agency provided
adequate facilities are available. After such running-in procedure, manufacture will be permitted
to carry out all the adjustments recommended in their owner’s / service manual and as amended
and intimated the concern technical agency from time to time published with technical agency,
under the control of the technical agency;
5.3.17. In case of failure of any major component during the running-in or testing, the technical agency
may permit to replace component only once; which has failed and which does not affect the
performance and emission of the engine. Such decision is entirely with technical agency. In case
of failure of emission affecting component, random selection of engine at manufacture’s plant or
warehouse shall be done afresh. If for such randomly selected engine (second time) or a replaced
component fails again, it shall be reported to the nodal agency by the concern technical agency
and agency shall await instructions from the nodal agency for further action;
5.3.18. The manufacture shall submit the randomly selected engine(s) to technical agency within four
weeks (8 weeks in case of import subjected to last date as mentioned in clause 5.2.10. – Table
2) of completion of running-in for emission compliance test and NOx and / or Particulate
diagnostics test where applicable. Manufacturer also shall supply appropriate ‘failed’ parts for
NCD and/or PCD demonstration in line with agreement with technical agency during type
approval certification and documentation;
5.3.19. The technical agency should endeavour to complete the required testing of selected engine(s)
within four weeks after submission of engine(s);
5.3.20. The testing shall be done as per applicable procedures and specifications described in Annexure
7 with test facility compliant to requirements specified Annexure 4 while utilizing data evaluation
and result calculation procedures described in Annexure 5 of this Regulation;

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5.3.21. Sampling plan for COP

5.3.22. Sampling Plan-I is applicable to domestically manufactured engine upto 19 kW rated output
whereas Sampling Plan-II is applicable to domestically manufactured engine above 19kW as well
as for imported engines of all ratings (Imported as an engine or as a genset)
5.3.23. Sampling Plan-I: Upto 19kW domestic
5.3.23.1. The number of samples to be tested shall be minimum as necessary, as given in Table 3 to
arrive at a decision on whether the produciton unit complies with applicable emission limits;
5.3.23.2. A sample said to have failed for particualr criteria pollutant if the test result of the sample for the
criteria pollutant exceeds required DF and IRAF (if applicable) corrected emission limit;
5.3.23.3. The production units of all models in the family shall be deemed to comply with the emission
limits if the number of failed samples as defined in clause 5.3.23.2. above for each criteria
pollutant is less than or equal to the pass decision number appropriate to the cumulative number
of smaples tested for that criteria pollutant as given in Table 3;
5.3.23.4. The production units of all models in the family shall be deemed to be non- complying with the
emission limits if the number of failed samples as defined in clause 5.3.23.2. above for each
criteria pollutant is more than or equal to the fail decision number appropriate to the cumulative
number of smaples tested as given in Table 3;
Table 3
Sampling plan I and decision criteria for the verification of COP of the engines

Cumulative Pass decision Fail decision Cumulative Pass decision Fail decision
Samples No. of failure Samples No. of failure
1 (a) (b) 16 6 11
a b
2 ( ) ( ) 17 7 12
a b
3 ( ) ( ) 18 7 12
4 0 (b) 19 8 13
5 0 (b) 20 8 13
6 1 6 21 9 14
7 1 7 22 10 14
8 2 7 23 10 15
9 2 8 24 11 15
10 3 8 25 11 16
11 3 8 26 12 16
12 4 9 27 12 17
13 5 10 28 13 17
14 5 10 29 14 17
15 6 11 30 16 17
( a ) : Series not able to pass at this stage
( b ) : Series not able to fail at this stage
Note:
i) COP compliance or non-compliance decision is on the basis of number of failures within
the respective cumulative samples tested.
ii) During successive testing, the decision which reached first is the final.
iii) Minimum 4 samples are required to test to reach pass decision
iv) Minimum 6 samples are required to test to reach fail decision

5.3.23.5. Once a complaince or non-compliance decision is made for a particular criteria pollutant, the
result of testing of subsequent samples for that criteria pollutant shall not influnece the decision;

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5.3.24. Sampling Plan-II: Above 19kW & Imported all rating

5.3.24.1. One engine sample selected randomly shall be tested as per procedure described in Annexure
7 of this Regulation;
5.3.24.2. If the engine sample as tested fails to comply with the emisison limits, the manufacturer may
ask for measures to be performed on a sample of engines taken from the production series and
including the engine orignally tested. The manufacturer shall specify the size ‘n’ of the sample
subject to ‘n’ being minimum of 3 and maximum of 10 includive of sample orignally tested;
5.3.24.3. The production or import units of all models in the family shall be deemed to compy with
emission limits if following condition is met for each criteria pollutant except for Smoke limits:

𝑥 + k. S < L
Where,
𝑥 = arithmetic mean of the results of the tests conducted on ‘n’ number of samples, for
a particular specie
S = Standard deviation of the results of the tests conducted on ‘n’ number of samples,
for the specie = [Σ (x - 𝑥)2 / (n –1)]1/2
x = results of the tests conducted on ‘n’ number of samples, for the specie.
L = the emission limit for the specie
k = a statistical factor dependent on ‘n’ number of samples and as given in below table.

Table 4
Values of Statistical Factor ‘k’ with respect to parameter ‘n’

n 2 3 4 5 6 7 8 9 10
k 0.973 0.613 0.489 0.421 0.376 0.342 0.317 0.296 0.279

5.3.25. Miscellaneous failure during COP

5.3.25.1. Smoke failure : For verifing the conformity of production, if the selected engine does not meet
the smoke limit as applicable, the another two engines in case above 19 kW power rating or
four engines in case below 19 kW power rating, will be taken from the series at random and be
tested as per this part. All these selected engines shall meet the limit values specified. One
engine shall be subjected to the emission test for the conformance of production.
5.3.25.2. Gross Power failure : For verifing the conformity of production, if the selected engine does not
meet the gross power and rated speed limit as applicable, the another two engines in case
above 19 kW power rating or four engines in case below 19 kW power rating, will be taken from
the series at random and be tested as per this part. All these selected engines shall meet the
limit values specified. One engine shall be subjected to the emission test for the conformance
of production.
5.3.25.3. Off cycle emission failure : For verifing the conformity of production, if the selected engine
does not meet the off cycle emission limit criteria over control area as applicable, the another
two engines in case above 19 kW power rating or four engines in case below 19 kW power
rating, shall be taken from the series at random and be tested as per this part. All these selected
engines shall meet the limit values specified. One engine shall be subjected to the emission test
for the conformance of production.
5.3.25.4. NCD / PCD demostration failure : For verifing the conformity of production, if the selected
engine does not meet the compliance requirement with respect to NCD / PCD demostration as

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applicable, the another two engines in case above 19KW power rating or four engines in case
below 19KW power rating, will be taken from the series at random and be tested as per this
part. This selected all engines should meet the limit values specified. One engine shall be
subjected to the conformance of production.
5.3.25.5. If further same failure noted in any of the additionally selected samples of caluse 5.3.25.1,
5.3.25.2, 5.3.25.3 & 5.3.25.4, the production shall be considered as non-compliance and the
provision of clause 5.8, shall be put into effect.

5.4. Certificate of Conformity of Prouction (COP) and It’s Validity

5.4.1. After verification for COP, the certification agency shall issue a COP verification report to the
manufactuer within one month of the date of testing completion , indicating complinace or non-
compliance. In case of compliance, the technical agency shall issue a COP certificate to the
manufactuer as per format prescibed in Annexure 2 along with report. At the end of CoP year,
detalis of CoP & the copies of certificate as well as report shall also be forwarded to the Nodal
Agency;
5.4.2. Certificate of conformity of production is required to commence the production and sale of
domestic genset engines in immediately next COP-year. Validity of current COP certificate shall
be till successful compliance of first COP test in next COP-year
5.4.3. In given COP-year for engine type(s) described in clause 5.2.2., successful compliance of COP
for every 1000 engines invoiced by the manufacturer shall enable further production of 1000
engine(s) and thereafter, in case engine(s) volumes for a particualr engine family exceed 1000
units annually;
5.4.4. The COP certificate will be issued at the end once all the numbers of engine samples demanded
as per the production plan submitted become tested successfully. Intermediate COP certificate
i.e at each sample tested shall not be issued, However the test data report will be issued at every
test sample.

5.5. COP Discontinuity

5.5.1. If there is no production or import of model(s) of a particular engine family for two consecutive
years immediately after obtaining type approval or immediately after obtaining COP certificate,
the type approval certificate for that particular engine family becomes invalid. In case the
manufacturer wants to maufacture or import engine model(s) of such particular engine family,
then the manufacture shall approach Nodal Agency and technical agency to obtain a new Type
Approval certificate afresh following stated procedure;
5.5.2. If there is no production or import of model(s) of a particular engine family for two consecutive
years immediately after obtaining type approval and if the COP test is requested for the third year,
then the supplier shall approach Nodal Agency to obtain approval for the extention of validity of
Type Approval. This is applicable only for a new manufacturer and in case no engine(s) sale has
happended post type approval;

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5.6. Exemption from COP

In the following cases, engine family(ies) shall be exempted form COP process.
5.6.1. If Type Approval obtained in the last quarter of COP year. This clause is not applicable to the
manufactueres as mentioned in clause 4.4.5.
5.6.2. In case of no production or import, the manufacturer shall submit a declaration to technical agency
and Nodal Agency for ‘No production or import’ of a particular family models for every COP-year;
5.6.3. The COP test shall be conducted by technical agency for the next COP-year, upon receipt of
declaration by the manaufacturer that there was no productionor import during current COP-year;
5.6.4. Declaration in this regard should be submitted before end of third quarter of the current COP-
year; (i.e 31st March), if produces after 31st March, COP is applicable.
5.6.5. Any genset engine manufactured for purpose of export outside India. COP exemption shall apply
for such volumes and COP test exemption shall apply if all such engine(s) produced are exported;
5.6.6. Any domestically manufactured genset engine intended for the purpose of sample (Maximum
number of 4 units per engine family) only and not for sale in India;
5.6.7. Any genset engine imported for the purpose of sample testing, bench making and not intended
for any commercial sale (Maximum number of 4 units per year);
5.6.8. Any genset engine imported for the round robin or laboratory correlation tests. Such engines shall
be exported back within 12 months from the date of import; or it should be scraped and a scrap
certificte shall be provided.
5.6.9. For obtaining exemptions regarding clauses 5.6.6, 5.6.7 and 5.6.8, the manufacturer shall obtain
written approval from Nodal Agency.
5.6.1. For obtaining exemptions regarding ‘No production or import’ as per clauses 5.6.2, the
manufacturer shall obtain written approval from Nodal Agency. Nodal agency should endeavor to
respond within 4 week after the receipt of application.
5.6.2. COP exemption shall be maximun up to three consecutive COP year, to resume sell from fourth
year a fresh type approval shall be conducted
5.6.3. After obtaining exemption as per 5.6.2, once production resume, manufacturer shall first conduct
COP before making any sell.

5.7. Production Definitely Discontinued

5.7.1. If manufacturer decides to discontinue production / withdraw type approval certificate of a specific
engine family or multiple families from a specific plant or all plants, the manufacturer shall so
inform to Test Agency involved in type approvals and COP compliance at least three month before
the stopage of production;
5.7.2. In such case, the manufacturer shall ensure COP compliance for the engine family(ies) from every
manufacturing plant before the production of the engine family(ies) is discontinued following COP
compliance process described in clauses 5.1, 5.2, 5,3 and 5.4 of this Regulation;
5.7.3. Upon receiving the relevant communication, the Test Agency shall inform the manufacturer the
acceptance of the communication and provide an acceptance letter.

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5.8. Consequances of non compliance

5.8.1. If the COP vertification report of the technical agency for a model family indicates non-compliance,
the manufacturer must stop manufacturing with immediate effect;
5.8.2. Further, the manufactuer must analyze the reasons for non-compliance, plan to take corrective
actions in design, production line and units already produced and submit a report to the nodal
agency with a copy to concern technical agency withing four weeks of the receipt of the COP
verification report;
5.8.3. If the manufacturer is unable to diagnose the reasons for non-compliance within stipulated time,
this shall be clearly stated in the report;
5.8.4. Based on the diagnostics and corrective action plan submitted by the manufactuere, the Nodal
Agency in consultation with technical agency and if both decide to, in consultation with standing
committee, may take any of the following actions:
5.8.4.1. Allow continuation of production or import of all models in the family if it is satisfied with the
corrective actions planned or taken by the manufacturer and ability to meet emission norms;
5.8.4.2. Allow continuation of production or import of some or all other models of the engine family if it
determines that the reasons for non-conformance of the tested model are not relevant to these
models; with or without additional verification of COP in due course;
5.8.4.3. Stop production or import of some or all other models of the engine family till compliance is
demonstrated by the supplier, through a re-verification of COP. In case of imported model(s), the
non-compliant genset should be sent back to the original destination;
5.8.5. The manufacturer shall be given an opportunity to explain it’s views before taking final decision;
5.8.6. It is responsibility of the manufacturer to ensure at his cost that the modifications are carried out
such as field retro fitment campaigns within period specified by the Nodal Agency on all products
produced as well as sold / dispatched in the period between the dates from which the COP
became due and re-verification of COP or as decided by the Nodal Agency, in consultation with
standing committee; As a guarantee from the supplier, it has to deposit a BG of RS 50.00 lacs
with validity period of three years returnable after satisfactory compliance acceptable to Nodal
Agency, forfeited otherwise. Further, in case of continuation of same model and/ or introduction
of new model, the supplier has to submit additional BG of Rs 10.00 each valid for three years
during above BG validity;
5.8.7. In case COP is missed, COP on the current date shall be permitted subject submission of a Bank
Guarantee (BG) of Rs 10.00 lacs to Nodal Agency with observation period of three years and an
undertaking to follow due compliance procedure regularly. During observation period, if product
line is to be enhanced the same procedure is to be replicated. In case the same supplier misses
COP again, BG amount shall be doubled to Rs 20.00 lacs. It is returnable after satisfactory
compliance acceptable to Nodal Agency, forfeited otherwise.
5.8.8. Nodal Agency with help from Technical agency shall audits compliance in field on random basis
for corrections done and issues closure letter to manufacturer
5.8.9. Further, to avoid such non-compliances again in future, following precautionary measures shall
be initiated to strengthen the process which will be followed for next two COP cycle after re-
certification & resuming the production with new modified spec;
a) COP compliance shall be established once for every 500 units of production
b) First COP compliance to be established before crossing 50 units of production once
production resume with modified spec.
c) COP activities to be completed in all by 31st March every COP year for the next three
years. After 3-year, COP shall be as per normal practice/timeline.

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5.9 COP Process Flow Chart

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Following are the logical steps for the COP process flow chart described in brief stepwise-
COP cycle shall end with either -
I. COP compliance with regular sample testing (Steps 1-16)
II. COP compliance with extended samples testing (…. Steps 17-18)
III. COP non-compliance after extended testing (…. Steps 19-30)

CASE I:
1. Manufacturer with valid Type Approval and COP certification submits annual estimated
production/ import volume data to technical agency involved in the format provided within two
months of start of new COP-year.
2. Technical agency, based on the production/import volumes, communicates to manufacturer, the
engine type chosen and the number of samples needed for COP compliance test for all engine
families of that manufacturer within one month of submission of above production volume data;
3. Technical agency also communicates to the manufacturer plan for COP engine random selection
based on manufacture’s input above;
4. Manufacturer coordinates adhering to technical agency provided or negotiated plan and
coordinates for engine random selection at manufacturing plants/warehouses/sales points for
imported engines as the case may be.
5. At the point of selection as mentioned in Sr 4, manufacturer provides with minimum required
sample size for random selection;
6. Technical agency representative carries out random selection and does note emission critical
component part and serial numbers. Provides with appropriate seal for avoiding tampering of
assembly parameters further;
Technical agency representative randomly selects after treatment system if applicable;
Technical agency representative can also carry out random selection of an engine if from chosen
representative engine family for NCD, PCD compliance utilizing the same pool of engines offered;
7. Decision, if running–in is carried out at manufacturer’s location or technical agency location;
If running-in is agreed to be carried out at manufacture’s facility, running-in shall be started in
presence of technical agency representative.
8. Engine along with arranged after treatment shall be transported to technical agency test location;
9. Upon receipt of engine along with auxiliaries, technical agency examines the adaptability in test
cell, make necessary modification in exhaust line, mounts, etc, if required.
10. Technical agency communicates the test schedule to manufacture for his witness
11. Technical agency carries out engine qualification and emissions test per applicable procedure
and shares results with manufacturer;
12. Technical agency carries out critical component type/part numbers, injection timing verification
and match with type approved document, in case any change noted, manufacturer to provide the
declaration in this regard, till time COP certificate will be on hold.
13. Review of test result & decision on compliance;
14. If COP compliance is obtained, Technical agency prepared the compliance certificate within 4
weeks from the date of testing. Engine & after treatment, test auxiliary is returned to the
manufacturer;
15. Technical agency issue compliance certificate to manufacturer
16. Technical agency forwards a copy of compliance certificate to Nodal agency

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CASE II:
17. ECOP: If non-compliance observed after testing (at Stage No 13), process begins from extended
random selection of engine(s) as per preferred options prescribed in clause 5.3.20.
 ECOP > 19KW (Statistics is on the basis of failed emission values)

17.1 Initially test 2 more new engines

17.2 Computation of the test statistic result of 3 engines (1-originally tested + 2 new)
a) According to the appropriate clause does the test statistic result agree with the criteria for
failing the series
b) According to the appropriate clause does the test statistic result agree with the criteria for
passing the series
17.3 If, answers of a & b are NO, then; continue the testing on additional samples till pass
decision is made provided limitation of samples tested as applicable (10 numbers
maximum)

 ECOP < 19KW (Statistics is on the basis of numbers of failed engine)

17.4 For establishing the compliance minimum 4 samples are mandatory to be tested and all
4 samples should pass.
17.5 If some samples failed, the additional new more samples, are required to be tested, the
numbers depend on the number of samples failed earlier,
17.6 Initially test 2 more new engines
17.7 In the cumulative samples (4-originally tested + 2 new), note the numbers of failed
samples
c) According to the appropriate clause does the number of failed samples agree with the
criteria for failing the series
d) According to the appropriate clause does the number of failed samples agree with the
criteria for passing the series
17.8 If, answers of a & b are NO, then; continue the testing on additional samples till pass
decision is made provided limitation of samples tested as applicable (30 numbers)

18. If during testing if the pass decision criteria is reached, the series is deemed to be compliance
and COP certificate is issued (then continue from Stage14-16)

CASE III:
19. If during testing if the fail decision criteria is reached, the series is deemed to be non-compliance;
Or if Manufacturer opts to declare non-compliance without availing total number of samples
allowed to be tested, the series is deemed to be non-compliance
20. Technical agency prepares the COP failure report
21. Technical agency issue COP failure report to manufacturer
22. Technical agency informs nodal agency about COP non-compliance of said engine family
23. Manufacturer stops production or import of the said non-compliant engine family;
Manufacturer informs nodal agency about non-conformity, stoppage of production and dispatch
and their plan for failure investigation within 4 weeks of receipt of COP verification report or COP
failure intimation
24. Nodal agency discusses with test agency in details on the non-compliance notified.
25. Nodal agency replies to the manufacturer about their inputs on timelines by which compliance
shall be obtained as well as failure root cause and corrective action plan submission. Nodal
agency also informs about any financial penalty or assurance required from the manufacturer;
Manufacturer submits root cause analysis and corrective action plans to nodal agency in
consultation with technical agency;

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26. Nodal agency in consultation with technical agency reviews manufacture’s submissions and
decides if such case shall be put forth for standing committee review and guidance if found
necessary depending upon the severity of the failure.
If decided to represent at standing committee, nodal agency brings this issue to standing
committee and allows manufacture to represent their submissions. If standing committee agrees
/ approves manufacturer’s submission and plan, then;
27. Nodal Agency can also decide on their own & shall take following decision:
27.1 Gives written permission to technical agency to proceed with re-verification of COP with
improvements implemented by manufacturer and also type approval re-certification as
the case may be.
27.2 Manufacturer offers engine sample and technical documentation to technical agency and
complies with COP;
27.3 Technical agency issues compliance certificate or type approval certificate if newly
approved as an option;
27.4 Manufacture begins production after obtaining new Type Approval or COP compliance
certificate;
27.5 Manufacturer completes corrective actions on engines dispatched during period of COP
and COP failure date;
28. Manufacturer complies with ‘financial assurance related’ documents asked by Nodal Agency;
29. Manufacturer submits corrective action / campaign report with adequate evidences to Nodal
Agency
30. Nodal Agency with help from Technical agency audits compliance in field for corrections done
and issues closure letter to manufacturer;
End

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ANNEXURE – 1

Appendix – A.1
Templates for information folder and information document

1. Information folder

The information folder referred to in clause 4 of this Regulation shall contain the following:

1.1. A list of contents;

1.1.1. Approval copy from Nodal Agency with regard to Appendix 1
1.2. Manufacturer's declaration on adherence to all requirements of this Regulation in
accordance with the template set out in this Appendix
1.3. Manufacturer's statement on the compliance of the engine type or engine family with the
exhaust emission limits set out in clause 3.1 of this Regulation with regard to specified liquid
fuels, fuel mixtures or fuel emulsions other than those set out in Appendix 11 of Annexure 7
1.4. For electronically controlled engines of categories Genset , complying with the emission
limits set out in Clause 3.1 to this Regulation and using electronic control to determine both
the quantity and timing of injecting fuel or using electronic control to activate, de-activate or
modulate the emission control system used to reduce NOX, a complete overview of the
emission control strategy, including the base emission control strategy and the means by
which every auxiliary control strategy directly or indirectly controls the output variables;
1.4.1. Additional confidential information as set out in Appendix A.2 shall be made available, only
for the technical service performing the tests and not included in the information folder;
1.5. Where applicable, a full description of the functional operational characteristics of the NO X
control measures and inducement system as referred to in Annex 9 to this Regulation;
1.5.1. Where applicable, a copy of the demonstration reports set out in paragraphs A.1.10.5. and
A.1.13.4. of Appendix A.1 of Annexure 8;
1.5.2. Where applicable, a description of the connection for, and method to read, the records set
out at paragraph A.1.5.2.1.1. (e) of Appendix A.1 of Annexure 8;
1.5.3. Where the engine type or engine family is member of a NCD engine family, a justification of
its membership together with the information requested in paragraph 1.5., 1.5.1. and 1.5.2.
on the NCD engine family may be supplied alternatively, upon agreement of the Type
Approval Authority;
1.6. Where applicable, a full description of the functional operational characteristics of the
particulate control measures as referred to in Annexure 8 to this Regulation;
1.6.1. Where applicable, a copy of the demonstration report set out in Appendix A.2 of Annexure
8;
1.6.2. Where applicable, a description of the connection for, and method to read, the records set
out at paragraph A.2.5.2. of Appendix A.2 of Annexure 8;
1.6.3. Where the engine type or engine family is a member of a PCD engine family, a justification
of its membership together with the information requested in paragraph 1.6., 1.6.1. and 1.6.2.
on the PCD engine family may be supplied alternatively, upon agreement of the Type
Approval Authority;
1.7. Manufacturer's declaration, and supporting test reports or data, on deterioration factors as
referred to in clause 3.2.5 of Appendix 6 of Annexure 7 of this Regulation;

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1.7.1. Where the engine type or engine family is a member of an engine after-treatment system
family, a justification of its membership together with the information requested in paragraph
1.7 on the after-treatment system family may be supplied alternatively, upon agreement of
the Type Approval Authority;
1.8. Where applicable, the manufacturer's declaration, and supporting test reports or data, of the
infrequent regeneration adjustment factors referred to in Annex 4 to this Regulation;
1.8.1. Where the engine type or engine family is a member of an engine-after-treatment system
family, a justification of its membership together with the information requested in paragraph
1.8 on the engine-after-treatment system family may be supplied alternatively, upon
agreement of the Type Approval Authority;
1.9. Manufacturer's declaration and supporting data demonstrating that the emission control
strategies fitted are designed in such a way as to prevent tampering to the extent possible,
as referred to in Appendix 3 of Annexure 8 of this Regulation.
1.9.1. For engine types and engine families that use an Electronic Control Unit (ECU) as part of
the emission control system the information shall include a description of the provisions
taken to prevent tampering with and modification of the ECU including the facility for updating
using a manufacturer approved programme or calibration;
1.9.2. For engine types and engine families that use mechanical devices as part of the emission
control system the information shall include a description of the provisions taken to prevent
tampering with and modification of the adjustable parameters of the emission control system.
This shall include the tamper resistant components such as carburettor limiter caps or
sealing of carburettor screws or special screws not adjustable by user;
1.9.3. In order to place engines from different engine families into the same tamper prevention
engine family the manufacturer shall provide confirmation to the Type Approval Authority
that the measures used to prevent tampering are similar.
1.10. A description of overall quality-assurance management systems for conformity of production
in accordance to clause 5 of this Regulation;
1.11. A list of scheduled emission-related maintenance requirements and the period at which each
should occur including any scheduled exchange of critical emission-related components;
1.12. The completed information document as set out in clause 2 of this Annex;
1.12.1. Where the particulars appearing in the information document for an engine approval have
changed, the manufacturer shall submit revised pages to the approval authority showing
clearly the nature of the change(s) and the date of re-issue;
1.13. All relevant data, drawings, photographs and other information as required in the information
document;

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2. Information document

The information document shall have a reference number issued by the applicant.
2.1. All information documents shall contain the following:

2.1.1. the general information set out in Part A of Appendix 3;

2.1.2. the information set out in Part B of Appendix 3, to identify the common design parameters of
all engine types within an engine family or applicable to the engine type where not part of an
engine family, intended for type approval;

2.1.3. the information set out in Part C of Appendix 3 following the format of the matrix set out in
clause 2.1.3.1 to identify the items applicable to the parent engine or engine type and the
engine types within the engine family, if applicable:

2.1.3.1. Engine type or engine family matrix with example data

Parent Engine types within the engine

engine/ family (if applicable)
Item Number Item Description
engine type
type type 2 type 3 … type n

3.1 Engine Identification

3.1.1 Engine type designation A01 A02 A03 A04 A05

3.2 Performance Parameters

3.2.1 Declared rated speed(s)
2200 2200 2000 1800 1800
(rpm):

3.10 Miscellaneous devices:

Yes/No
3.10.1 Exhaust gas recirculation
(EGR)
3.10.1.1 Characteristics
(cooled/uncooled, high
pressure/low pressure, etc.):

… … …

2.1.3.2. Reserved

2.1.3.3. In the case of constant speed engines with multiple rated speeds an additional set column(s)
of data for each speed shall be recorded in paragraph 3.2 (Performance Parameters).

2.2. Explanatory notes on creation of information document:

2.2.1. Upon agreement of the approval authority, the information in paragraph 2.1.2 and 2.1.3 may
be presented in an alternative format;

2.2.2. Each engine type or the parent engine in the matrix set out in paragraph 2.1.3.1 shall be
identified in accordance with the engine family designation and engine type designation set
out in paragraph 2.3.

2.2.3. Only those paragraphs of this Annex relevant for the particular engine family, engine types

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within the engine family or engine type shall be listed; in any case, the list shall adhere to the
proposed numbering system,

2.2.4. Where several options separated by forward slash are given for an entry, the unused options
shall be struck out, or only the used option(s) shall be shown;

2.2.5. When the same value for or description of a certain engine characteristic applies for several
or all members of an engine family the corresponding cells may be merged.

2.2.6. Where a picture, diagram or detailed information is required, a reference to an appendix may
be given;

2.2.7. Where a ‘type’ of a component is requested, the information supplied shall uniquely identify
the component; this may be a list of characteristics, a manufacturers' name and part or
drawing number, a drawing, or a combination of the aforementioned or other methods that
achieves the same result.

2.3. Engine type designation and engine family designation

2.3.1. Engine family designation shall be as per ISO 8178-7 guidelines; however, engine type
designation is at the choice of manufacturer.

2.3.2. The manufacturer shall not use the same engine family designation to identify more than one
engine family

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 Appendix – A.2

Confidential information on emission control strategy

A 2.0 Confidential Information on emission control technology

A.2.1. This Appendix shall apply to electronically controlled engines, which use electronic control to
determine both the quantity and timing of injecting fuel.

A.2.2. Additional information shall be presented to the test agency but not annexed to the application
for type approval. This information shall include all the parameters modified by any auxiliary
emission control strategy and the boundary conditions under which this strategy operates and
in particular:

(a) a description of the control logic, of timing strategies and switch points, during all
modes of operation for the fuel and other essential systems, resulting in effective
emission control (such as exhaust gas recirculation (EGR) or reagent dosing);

(b) a justification for the use of any auxiliary emission control strategy applied to the
engine, accompanied by material and test data, demonstrating the effect on exhaust
emissions. This justification may be based on test data, sound engineering analysis,
or a combination of both;

(c) a detailed description of algorithms or sensors (where applicable) used for identifying,
analysing, or diagnosing incorrect operation of the NOX control system;

(d) a detailed description of algorithms or sensors (where applicable) used for identifying,
analysing, or diagnosing incorrect operation of the particulate control system.

A.2.3. The additional information required in paragraph A.2.2 shall be treated as strictly
confidential. It shall be retained by the manufacturer and made available for inspection by the
Type Approval Authority at the time of type approval or upon request at any time during the
validity of the type approval. In this case, the Type Approval Authority shall treat this
information as confidential and shall not disclose it to other parties.

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 Appendix – A.3

Template for submission of engine technical specification

PART A

1. GENERAL INFORMATION
1.1. Make (trade name(s) of manufacturer):
1.2. Commercial /Brand Name name(s) (if applicable):
1.3. Company name and address of manufacturer:
1.4. Name and address of manufacturer's authorised representative (if any):
1.5. Name(s) and address(es) of assembly/manufacture plant(s):
1.6. Engine type designation/engine family designation/FT:
1.7. Category Constant speed or variable speed:
1.8. Reserved
1.9. Reserved
1.10. Reserved
1.11. Rated Power
1.12. Test cycle: D2 5-Mode Steady State cycle discrete-mode type / RMC type
C1 8-Mode Steady State discrete-mode type / RMC type
5-mode variable speed cycle
1.13. Reserved
1.14. Restrictions on use (if applicable):

PART B

2. COMMON DESIGN PARAMETERS OF ENGINE FAMILY (1)

2.1. Combustion Cycle: four stroke cycle/two stroke cycle/other (specify):
2.2. Ignition Type: Compression ignition:
2.3. Configuration of the cylinders:
2.3.1. Position of the cylinders in the block: Single/V/in-line/opposed/radial/ other(specify):
2.3.2. Bore centre to centre dimension (mm):
2.4. Combustion chamber type/design
2.4.1. Open chamber/divided chamber/other(specify):
2.4.2. Valve and porting configuration:
2.4.3. Number of valves per cylinder:
2.5. Range of swept volume per cylinder (cm3):
2.6. Main Cooling medium: Air/Water/Oil:

54
2.7. Method of air aspiration: naturally aspirated/pressure charged/pressure
charged with charge cooler:
2.8. Fuel:
2.8.1. Fuel Type: Diesel/ Ethanol for dedicated compression ignition engines
(ED95) (Natural gas/Biomethane) / LPG / Any other alternate fuel as
specified in this document
2.8.1.1. Reserved.
2.8.2. Fuelling arrangement: Dual-fuel type 1A/Dual-fuel type 1B/Dual-fuel type
2A/Dual-fuel type 2B/Dual-fuel type
2.8.3. List of additional fuels, fuel mixtures or emulsions compatible with use by
the engine declared by the manufacturer in accordance with Appendix 3 to
paragraph 5 of this Regulation (provide reference to recognised standard or
specification):
2.8.4. Lubricant added to fuel: Yes/No
2.8.5. Fuel supply type: Pump (high pressure) line and injector/in-line pump or
distributor pump/Unit injector/ Common rail.
2.9. Engine management systems: mechanical/electronic control strategy
2.10. Miscellaneous devices: Yes/No (if yes provide a schematic diagram of the
location and order of the devices)
2.10.1. Exhaust gas recirculation (EGR): Yes/No (if yes, complete section 3.10.1
and provide a schematic diagram of the location and order of the devices)
2.10.2. Water injection: Yes/No (if yes, complete section 3.10.2 and provide a
schematic diagram of the location and order of the devices)
2.10.3. Air injection: Yes/No (if yes, complete section 3.10.3 and provide a
schematic diagram of the location and order of the devices)
2.10.4. Others: Yes/No (if yes specify, complete section 3.10.4 and provide a
schematic diagram of the location and order of the devices):
2.11. Exhaust after-treatment system: Yes/No (if yes provide a schematic diagram
of the location and order of the devices)
2.11.1. Oxidation catalyst: Yes/No
(if yes, complete section 3.11.2)
2.11.2. De NOX system with selective reduction of NOX (addition of reducing agent):
Yes/No
(if yes, complete section 3.11.3)
2.11.3. Other De NOX systems: Yes/No
(if yes, complete section 3.11.3)
2.11.4. Reserved
2.11.5. Particulate after-treatment system with passive regeneration: Yes/No
(if yes, complete section 3.11.4)
2.11.5.1. Wall-flow/non-wall-flow
2.11.6. Particulate after-treatment system with active regeneration: Yes/No
(if yes, complete section 3.11.4)
2.11.6.1. Wall-flow/non-wall-flow
55
 2.11.7. Other particulate after-treatment systems: Yes/No
(if yes, complete section 3.11.4)
2.11.8. Other after-treatment devices (specify):
(if yes, complete section 3.11.5)
2.11.9. Other devices or features that have a strong influence on emissions Yes/No
(specify):
(if yes, complete section 3.11.7)

PART C

Engine types within

Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

3.1. Engine Identification

3.1.1. Engine type designation
Engine type designation shown on
3.1.2. engine marking: yes/no
3.1.3. Location of the statutory marking:
Method of attachment of the statutory
3.1.4. marking:
Drawings of the location of the engine
3.1.5. identification number (complete example
with dimensions):
3.2. Performance Parameters
3.2.1. Declared rated speed(s) (rpm):
3.2.1.1. Declared rated gross power (kW):
Fuel delivery/stroke (mm3) for diesel
3.2.1.2. engine, fuel flow (g/h) for other engines,
at rated gross power
3.2.6. Idle speed (rpm)
3.2.7. No load speed (rpm):
Overload load speed (rpm):
3.2.8 %Overload Power load %: eg.10%
Optional at choice of
3.3. Run-in procedure manufacturer
3.3.1. Run-in time:
3.3.2. Run-in cycle:
3.4. Engine test
3.4.1. Specific fixture required: Yes/No For NRSh only
Description, including photographs
and/or drawings, of the system for
3.4.1.1 mounting the engine on the test bench
including the power transmission shaft
for connection to the dynamometer:
Exhaust mixing chamber permitted by For NRSh only
3.4.2. manufacturer: Yes/No
56
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

Exhaust mixing chamber description, If applicable

3.4.2.1. photograph and/or drawing:
Pre-conditioning for: Steady-state
3.4.3. operation
3.5. Lubrication system
3.5.1. Lubricant temperature If applicable
3.5.1.1. Minimum (⁰C):
3.5.1.2. Maximum (⁰C):
3.6. Combustion Cylinder
3.6.1. Bore(mm):
3.6.2. Stroke(mm):
3.6.3. Number of cylinders:
3.6.4. Engine total swept volume (cm3):
Swept volume per cylinder as % of If engine family
3.6.5. parent engine:
3.6.6. Volumetric compression ratio: Specify tolerance
3.6.7. Combustion system description:
Drawings of combustion chamber and
3.6.8. piston crown:
Minimum cross-sectional area of inlet
3.6.9. and outlet ports (mm2):
3.6.10. Valve timing
Maximum lift and angles of opening and
3.6.10.1. closing in relation to dead centre or
equivalent data:
3.6.10.2. Reference and/or setting range:
If applicable and where
3.6.10.3. Variable valve timing system: Yes/No intake and/or exhaust
3.6.10.3.1. Type: continuous/(on/off)
3.6.10.3.2. Cam phase shift angle:
2-stroke only, if
3.6.11. Porting configuration applicable
3.6.11.1. Positon, size and number:
Complete relevant
3.7. Cooling system section
3.7.1. Liquid cooling
3.7.1.1. Nature of liquid:
3.7.1.2. Circulating pumps: Yes/No
3.7.1.2.1. type(s):
3.7.1.2.2. Drive ratio(s): If applicable
Minimum coolant temperature at outlet
3.7.1.3. (⁰C):

57
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

Maximum coolant temperature at outlet

3.7.1.4. (⁰C):
3.8. Aspiration
Maximum allowable intake depression at
3.8.1. rated engine speed and at 100% load
(kPa)
3.8.1.1. With clean air cleaner:
3.8.1.2. With dirty air cleaner:
3.8.1.3. Location, of measurement:
3.8.2. Pressure charger(s): Yes/No
3.8.2.1. Type(s):
Description and schematic diagram of
the system (e.g. maximum charge
3.8.2.2. pressure, waste gate, VGT, Twin turbo,
etc.):
3.8.3. Charge air cooler: Yes/No
3.8.3.1. Type: air-air/air-water/other(specify)
Maximum charge air cooler outlet
3.8.3.2. temperature at rated speed and 100%
load (⁰C):
Maximum allowable pressure drop
3.8.3.3. across charge cooler at rated engine
speed and at 100% load (kPa):
3.8.4. Intake throttle valve: Yes/No
Device for recycling crankcase gases:
3.8.5. Yes/No
3.8.5.1. If yes, description and drawings:
If no, compliance with paragraph 5.7. of
3.8.5.2. this Regulation: Yes/No
3.9. Exhaust system
Description of the exhaust system (with
3.9.1. drawings, photos and/or part numbers
as required):
3.9.2. Maximum exhaust temperature (⁰C):
Maximum permissible exhaust
3.9.3. backpressure at rated engine speed and
at 100% load (kPa):
Maximum permissible exhaust
backpressure at at each mode of test
cycle (kPa):
(This data is required for the engines
with EGR)
100% Load:
75% Load:
50% Load:
25% Load:

58
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

10% Load:
3.9.3.1. Location of measurement:
Exhaust backpressure at loading level
specified by manufacturer for variable
3.9.4. restriction after-treatment at start of test
(kPa):
3.9.4.1. Location and speed/load conditions:
3.9.5. Exhaust throttle valve: Yes/No
3.10. Miscellaneous devices: Yes/No
3.10.1. Exhaust gas recirculation (EGR)
Characteristics: cooled/uncooled, high
3.10.1.1. pressure/low pressure/other (specify):
3.10.2. Water injection
3.10.2.1. Operation principle:
3.10.3. Air injection
3.10.3.1. Operation principle
3.10.4. Others
3.10.4.1. Type(s)
3.11. Exhaust after-treatment system
3.11.1. Location
Place(s) and maximum/minimum
3.11.1.1. distance(s) from engine to first after-
treatment device:
Maximum temperature drop from
3.11.1.2. exhaust or turbine outlet to first after-
treatment device (⁰C) if stated:
3.11.1.2.1. Test conditions for measurement:
Minimum temperature at inlet to first
3.11.1.3. after-treatment device, (⁰C) if stated:
3.11.1.3.1. Test conditions for measurement:
3.11.2. Oxidation catalyst
Number of catalytic converters and
3.11.2.1. elements:
Dimensions and volume of the catalytic Or drawing
3.11.2.2. converter(s):
3.11.2.3. Total charge of precious metals (g):
Relative concentration of each
3.11.2.4. compound (%):
3.11.2.5. Substrate (structure and material):
3.11.2.6. Cell density:
Type of casing for the catalytic
3.11.2.7. converter(s):
Catalytic exhaust after-treatment system
3.11.3. for NOX or three-way catalyst
59
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

3.11.3.1. Type:
Number of catalytic converters and
3.11.3.2. elements:
3.11.3.3. Type of catalytic action :
Dimensions and volume of the catalytic Or drawing
3.11.3.4. converter(s):
3.11.3.5. Total charge of precious metals (g):
Relative concentration of each
3.11.3.6. compound (%):
3.11.3.7. Substrate (structure and material):
3.11.3.8. Cell density:
Type of casing for the catalytic
3.11.3.9. converter(s):
3.11.3.10. Method of regeneration: If applicable
If yes, complete
3.11.3.10.1. Infrequent regeneration: Yes/No: section 3.11.6.
Normal operating temperature range
3.11.3.11. (⁰C):
3.11.3.12. Consumable reagent: Yes/No
Type and concentration of reagent
3.11.3.12.1. needed for catalytic action:
Lowest concentration of the active
ingredient present in the reagent that
3.11.3.12.2. does not activate warning system
(CDmin) (%vol):
Normal operational temperature range of
3.11.3.12.3. reagent:
3.11.3.12.4. International standard: If applicable
3.11.3.13. NOX sensor(s): Yes/No
3.11.3.13.1. Type:
3.11.3.13.2. Location(s)
3.11.3.14. Oxygen sensor(s): Yes/No
3.11.3.14.1. Type:
3.11.3.14.2. Location(s):
3.11.4. Particulate after-treatment system
Type of filtration: wall-flow/ non-wall-
3.11.4.1. flow/other (specify)
3.11.4.2. Type:
Dimensions and capacity of the Or drawing
3.11.4.3. particulate after-treatment system:
Location place(s) and maximum and
3.11.4.4. minimum distance(s) from engine:
Method or system of regeneration,
3.11.4.5. description and/or drawing:

60
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

If yes, complete
3.11.4.5.1. Infrequent regeneration: Yes/No section 3.11.6.
Minimum exhaust gas temperature for
3.11.4.5.2. initiating regeneration procedure (⁰C):
3.11.4.6. Catalytic coating: Yes/No
3.11.4.6.1. Type of catalytic action:
3.11.4.7. Fuel borne catalyst (FBC): Yes/No
Normal operating temperature range
3.11.4.8. (⁰C):
3.11.4.9. Normal operating pressure range (kPa)
3.11.4.10. Storage capacity soot/ash (g):
3.11.4.11. Oxygen sensor(s): Yes/No
3.11.4.11.1. Type:
3.11.4.11.2. Location(s):
3.11.5. Other after-treatment devices
3.11.5.1. Description and operation:
3.11.6. Infrequent Regeneration
3.11.6.1. Number of cycles with regeneration
3.11.6.2. Number of cycles without regeneration
3.11.7. Other devices or features
3.11.7.1. Type(s)
Fuel feed for liquid-fuelled CI or,
3.12. where applicable, dual-fuel engines
3.12.1. Feed pump
Pressure (kPa) or characteristic
3.12.1.1. diagram:
3.12.2. Injection system
3.12.2.1. Fuel Pump
3.12.2.1.1. Type(s):
3.12.2.1.2. Rated pump speed (rpm):
mm3 per stroke or cycle at full injection Specify tolerance
3.12.2.1.3. at rated pump speed:
3.12.2.1.4. Reserved
3.12.2.1.5. Reserved Specify tolerance
As alternative to entries
3.12.2.1.6. Characteristic diagram: 3.12.2.1.1. to
3.12.2.1.5.
3.12.2.1.7. Method used: on engine/on pump bench
For Mechanical
engines- static injection
3.12.2.2. Injection timing
timing values BTDC

61
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

For Electronic engines-

calibration/software
part number/ID number
of the calibration map
Specify tolerance, if
3.12.2.2.1. Injection timing curve: applicable
3.12.2.2.2. Static Timing: Specify tolerance
3.12.2.3. Injection piping
3.12.2.3.1. Length(s) (mm):
3.12.2.3.2. Internal diameter (mm):
3.12.2.4. Common rail: Yes/No
3.12.2.4.1. Type:
3.12.3. Injector(s)
3.12.3.1. Type(s):
3.12.3.2. Opening pressure (kPa): Specify tolerance
3.12.4. ECU: Yes/No
3.12.4.1. Type(s):
3.12.4.2. Software calibration number(s):
Communication standard(s) for access
to data stream information: ISO 27145
3.12.4.3. with ISO 15765-4 (CAN-based)/ISO
27145 with ISO 13400 (TCP/IP-
based)/SAE J1939-73
3.12.5. Governor
3.12.5.1. Type(s):
Speed at which cut-off starts under full Specify range, if
3.12.5.2. load: applicable
Specify range, if
3.12.5.3. Maximum no-load speed: applicable
Specify range, if
3.12.5.4. Idle speed: applicable
3.12.6. Cold-start system: Yes/No
3.12.6.1. Type(s):
3.12.6.2. Description:
Fuel temperature at the inlet to the fuel
3.12.7. injection pump
3.12.7.1. Minimum (⁰C):
3.12.7.2. Maximum (⁰C):
3.13. Reserved

For dual fuel application, please refer below additional table:

62
Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Typ Typ document)
1 2 e3 en
4.1 Details of Kit Manufacturer /
Supplier / Installer
4.1.1 Name of the Manufacturer
4.1.2 Address
4.1.3 Telephone No. & Fax No.
4.2 Gas Kit Identification
4.2.1 Identification No.
4.2.2 Variants, if any
4.2.3 Fuel system (Dedicated / Bi-Fuel /
Dual Fuel / Dedicated Dual Fuel)
4.2.4 Type of Dual- fuel system (Type 1A /
1B / 2A / 2B / 3B)
4.2.5 Fuel (Gas Fuel (Specify Name of fuel)
4.3 Solenoid Valve / Automatic shutoff
valve
4.3.1 Name of manufacturer
4.3.2 Model Name / Identification No.
4.3.3 Type
4.3.4 Working pressure (kg/cm 2)
4.3.5 Max test pressure (kg/cm2)
4.3.6 Approval reference (Test Report /
Approval Number)
4.4 High Pressure Regulator
4.4.1 Name of manufacturer
4.4.2 Model name / Identification No.
4.4.3 Type
4.4.4 Inlet pressure (kg/cm 2 )
4.4.5 Outlet pressure (kg/cm 2 )
4.4.6 No. of stages
4.4.7 Approval reference (Test Report /
TAC compliance with Date)
4.5 Low Pressure Regulator
4.5.1 Name of manufacturer
4.5.2 Model name / Identification No.
4.5.3 Type
4.5.4 Inlet pressure (kg/cm2)
4.5.5 Outlet pressure (kg/cm2)
4.5.6 No. of stages
4.5.7 Approval reference (Test Report /
TAC compliance with Date)
4.6 Zero Pressure Regulator
4.6.1 Name of manufacturer
4.6.2 Model name / Identification No.
4.6.3 Type
4.6.4 Inlet pressure (kg/cm2)
4.6.5 Outlet pressure (kg/cm2)

63
Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Typ Typ document)
1 2 e3 en
4.6.6 Approval reference (Test Report /
TAC compliance with Date)
Vaporizer / Heat exchanger (for
4.7
LNG)
4.7.1 Name of manufacturer
4.7.2 Model name / Identification No.
4.7.3 Type
4.7.4 Inlet pressure (kg/cm2)
4.7.5 Outlet pressure (kg/cm2)
Approval reference (Test Report /
4.7.6
Approval Number)
4.8 Filter
4.8.1 Name of manufacturer
4.8.2 Model name / Identification No.
4.8.3 Type
4.8.4 Inlet pressure (kg/cm2)
4.8.5 Outlet pressure (kg/cm2)
4.9 High Pressure Tubing
4.9.1 Name of manufacturer
4.9.2 Model name / Identification No.
4.9.3 Type (rigid / flexible)
4.9.4 Working pressure (kg/cm2)
4.9.5 Max. test pressure (kg/cm2)
4.9.6 Outer diameter / Inner Diameter (mm)
4.9.7 Material
Approval reference (Test Report /
4.9.8
Approval Number)
4.10 Low Pressure Tubing
4.10.1 Name of manufacturer
4.10.2 Model name / Identification No.
4.10.3 Type
4.10.4 Working pressure (kg/cm2)
4.10.5 Max test pressure (kg/cm2)
Outer diameter / Inner Diameter
4.10.6
(mm)
4.10.7 Material
Approval reference (Test Report /
4.10.8
Approval Number)
4.11 Gas-Air Mixer
4.11.1 Name of manufacturer
4.11.2 Model name / Identification No
4.11.3 Type & drawing
4.11.4 Venturi Size (mm)
Approval reference (Test Report /
4.11.5
Approval Number)
4.12 Gas Injector

64
Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Typ Typ document)
1 2 e3 en
4.12.1 Name of manufacturer
4.12.2 Model name / Identification No
4.12.3 Type & drawing
4.12.4 Injector flow specs
Approval reference (Test Report /
4.12.5
Approval Number
4.13 Wiring Harness
4.13.1 Name of manufacturer
Electrical circuit diagram / Detail
4.13.2
layout
Approval reference (Test Report /
4.13.3
Approval Number)
4.14 Interfacing Unit (ECU)
4.14.1 Name of manufacturer
4.14.2 Identification No.
4.14.3 Type
4.15 Fuel selector switch
4.15.1 Name of manufacturer
4.15.2 Model No
4.15.3 Type
Fuel flow actuation mechanism
4.16
(Mechanical / Electronic)
Brief description of system (Attach
4.16.1
Annexure)
Schematic layout (Attach
4.16.2
Drawing)
Identification of critical
components of Kit, including ECU,
Lambda sensor, Pressure sensor,
4.16.3
temperature Sensor etc with Make
and Identification number (attach
Annexure)
Brief Description of System
Including Dimensional Layout
4.17
for kit components installation
ventilation details etc.
4.18 Joints and connections
4.18.1 Name of manufacturer
4.18.2 Type
Number of Joints and connections
4.18.3 represented on Drawing (Attach
Drawing)
4.19 Current limiting Device (Fuse)
4.19.1 Name of manufacturer
4.19.2 Identification No.
4.19.3 Voltage / current rating
4.19.4 Type
65
 Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Typ Typ document)
1 2 e3 en
Approval reference (Test Report /
4.19.5
Approval Number)
4.20 Indicator
4.20.1 Pressure Indicator
4.20.2 Name of manufacturer
4.20.3 Identification No.
4.20.4 Type
4.20.5 Temperature Indicator (for LNG)
4.20.6 Name of manufacturer
4.20.7 Identification No.
4.20.8 Type
4.21 Service shut off valve
4.21.1 Name of manufacturer
4.21.2 Identification No.
4.21.3 Type
Compartment/Sub-
4.22 compartment / Gas tight
housing
4.22.1 Name of manufacturer
4.22.2 Identification No
4.22.3 Type
4.22.4 Material used
Approval reference (Test Report /
4.22.5
Approval Number)
4.23 Conduit
4.23.1 Name of manufacturer
4.23.2 Identification No.
4.23.3 Inner & outer diameter
4.23.4 Type
Approval reference (Test Report /
4.23.5
Approval Number)
Battery cut off switch (if
4.24
applicable)
4.24.1 Name of manufacturer
4.24.2 Identification No.
4.24.3 Type
4.25 Labels - Number and position
4.26 Any other information
* Mention NA wherever not applicable

Explanatory notes to Appendix 3:

(Footnote markers, footnotes, and explanatory notes not to be stated on the information document)
In the case of combined catalyst and particulate filter both pertinent sections shall be filled.

66
 ANNEXURE – 2
Communication – Type Approval and COP Template to be attached here
by Test Agencies
1. General
SECTION I
1.1. Make (trade name(s) of manufacturer):
1.2. Commercial name(s)/ Brand Name (if applicable):
1.3. Company name and address of manufacturer:
1.4. Name and address of manufacturer's authorised representative (if any):
1.5. Name(s) and address(es) of assembly/manufacture plant(s):
1.6. Engine type designation/engine family designation/FT:
1.7. Category and sub-category of the engine type/engine family:

SECTION II
1. Technical service responsible for carrying out the test(s):
2. Date(s) of the test report(s):
3. Number(s) of the test report(s):

SECTION III
The undersigned hereby certifies the accuracy of the manufacturer's description in the
attached information document of the engine type/engine family (2) described above, for
which one or more representative samples, selected by the approval authority, have been
submitted as prototypes and that the attached test results apply to the engine type/engine
family (2).
1. The engine type/engine family (2) meets/does not meet (2) the requirements laid down
in GSR 804(E.) dated 3-Nov-2022 series of amendments.
2. The approval is granted/extended/refused/withdrawn (2)
Place:
Date:
Name and signature:
Attachments:
Information folder
Test report(s)
All other documents added by the technical services or by the Type Approval Authority to
the information folder in the course of carrying out their functions.
Approval number:
2. Common design parameters of the engine type/engine family
2.1. Combustion Cycle: four stroke cycle/two stroke cycle/rotary/other:
2.2. Ignition Type: Compression ignition
67
2.3.1. Position of the cylinders in the block: V/in-line/radial/other(describe) (2)
2.6 Main Cooling medium: Air/Water/Oil (2)
2.7. Method of air aspiration: naturally aspirated/pressure charged/pressure charged with
charge cooler (2)
2.8.1. Fuel Type(s): Diesel (non-road gas-oil)/Ethanol for dedicated compression ignition
engines (ED95)/ Ethanol (E85) / (Natural gas/Biomethane) / Alternate Fuel
2.8.1.1. Reserved
2.8.2. Fuelling arrangement: Liquid-fuel only /Dual-fuel type 1A/Dual-fuel type 1B/Dual-fuel
type 2A/Dual-fuel type 2B/Dual-fuel type 3B
2.8.3. List of additional fuels compatible with use by the engine declared by the
manufacturer in accordance with paragraph A.3.1.2.3. of Annex 3 to paragraph 5 of
this Regulation (provide reference to recognised standard or specification):
2.8.4. Lubricant added to fuel: Yes/No (2)
2.8.5. Fuel supply type: Pump (high pressure) line and injector/in-line pump or distributor
pump/Unit injector/ Common rail
2.9. Engine management systems: mechanical/electronic control strategy (2)
2.10. Miscellaneous devices: Yes/No (2)
2.10.1. Exhaust gas recirculation (EGR): Yes/No (2)
2.10.2. Water injection: Yes/No (2)
2.10.3. Air injection: Yes/No (2)
2.10.4. Others (specify):
2.11. Exhaust after-treatment system: Yes/No (2)
2.11.1. Oxidation catalyst: Yes/No (2)
2.11.2. De NOX system with selective reduction of NOX (addition of reducing agent): Yes/No
(2)
2.11.3. Other De NOX systems: Yes/No (2)
2.11.4. Three-way catalyst combining oxidation and NOx reduction: Yes/No
2.11.5. Particulate after-treatment system with passive regeneration: Yes/No
2.11.6. Particulate after-treatment system with active regeneration: Yes/No
2.11.7. Other particulate after-treatment systems: Yes/No
2.11.8. Three-way catalyst combining oxidation and NOX reduction: Yes/No
2.11.9. Other after-treatment devices (specify):
2.11.10. Other devices or features that have a strong influence on emissions (specify):

68
3. Essential characteristics of the engine type(s)

Item Number Parent Engine / Engine types within the

Item Description
Engine type family (if applicable)
3.1.1. Engine Type Designation:
3.1.2. Engine type designation shown
on engine mark: Yes/No
3.1.3. Location of the manufacturer's
statutory marking:
3.2.1. Declared rated speed (rpm):
3.2.2.2. Declared Rated Power (kW)
3.2.3.2. Declared Rated torque (Nm):
3.6.3. Number of Cylinders:
3.6.4. Engine total swept volume (cm 3):
3.8.5. Device for recycling crankcase
gases: Yes/No
3.11.3.12. Consumable reagent: Yes/No
3.11.3.12.1. Type and concentration of
reagent needed for catalytic
action:
3.11.3.13. NOX sensor(s): Yes/No
3.11.3.14. Oxygen sensor: Yes/No
3.11.4.7. Fuel borne catalyst (FBC):
Yes/No

Conditions to be respected in the installation of the engine on Genset

Maximum allowable intake

depression at rated engine
3.8.1.1.
speed and at 100% load (kPa)
with clean air cleaner:
Maximum charge air cooler
3.8.3.2. outlet temperature at rated
speed and 100% load (deg. C):
Maximum allowable pressure
drop across charge cooler at
3.8.3.3.
rated engine speed and at 100%
load (kPa) (if applicable):
Maximum permissible exhaust
gas back-pressure at rated
3.9.3.
engine speed and at 100% load
(kPa):

69
 Item Number Parent Engine / Engine types within the
Item Description
Engine type family (if applicable)
Maximum permissible exhaust
backpressure at each mode of
test cycle (kPa):
(This data is required for the
engines with EGR)
100% Load:
75% Load:
50% Load:
25% Load:
10% Load:
3.9.3.1. Location of measurement:
Maximum temperature drop from
exhaust system or turbine outlet
3.11.1.2
to first exhaust after-treatment
system (deg. C) if stated:

Test conditions for

3.11.1.2.1.
measurement:

4. Cycle emission results

CO HC NOX HC+ NOX PM SMOKE Test

Emissions
-1
(g/kWh) (g/kWh) (g/kWh) (g/kWh) (g/kWh) m Cycle (4)

DF incorporated
adjusted
emission result
before rounding

Final rounded
certificate result
with DF.

CO2 result:
(CO2 g/kWh is only for the documentation purpose & does not have any impact on pass or fail
criteria the engine)
Explanatory notes to Annex 2
(Footnote markers, footnotes, and explanatory notes not to be stated on the type-
approval certificate)
(1) Distinguishing number of the contracting party which has
granted/extended/refused/withdrawn an approval.
(2) Strike out the unused options, or only show the used option(s).
3
() Indicate the applicable option for the category and sub-category in accordance with entry
1.7. of the information document set out in Part A of Appendix 3 to Annex 1.
(4) Indicate the used test cycle as prescribed in Annexure 7 to this Regulation.

70
 Appendix – A.1
Test Report

A.1.1. General requirements

One test report shall be completed for each test required for the type-approval.
Each additional (e.g. a second speed on a constant speed engine) or
supplementary test (e.g. another fuel is tested) will require an additional or
supplementary test report.
A.1.2. Explanatory notes on creation of a test report
A.1.2.1. A test report shall contain at least the information set out in paragraph A.1.3.
A.1.2.2. Notwithstanding paragraph A.1.2.1, only those sections or sub-sections relevant
for the particular test and for the particular engine family, engine types within the
engine family or engine type tested need to be stated in the test report
A.1.2.3. The test report may contain more information than that requested in paragraph
A.1.2.1 but in any case, shall adhere to the proposed numbering system;
A.1.2.4. Where several options separated by forward slash are given for an entry, the
unused options shall be struck out, or only the used option(s) shall be shown;
A.1.2.5. Where a ‘type’ of a component is requested, the information supplied shall
uniquely identify the component; this may be a list of characteristics, a
manufacturers' name and part or drawing number, a drawing, or a combination of
the aforementioned or other methods that achieves the same result.
A.1.2.6. The test report may be delivered on paper on in an electronic format agreed
between the manufacturer, technical service and Type Approval Authority.

A.1.3 Template for the test report

1. General Information
1.1. Make(s) (trade name(s) of manufacturer):
1.2. Commercial name(s) /Brand Name (if applicable):
1.3. Company name and address of manufacturer:
1.4. Name of test agency:
1.5. Address of test agency:
1.6. Location of test:
1.7. Date of test:
1.8. Test report number:
1.9. Information document reference number (if available):
1.10. Test report type: Primary test/additional test/supplementary test
Primary test -standard regular test most likely common for approval.
Additional test - additional test is for in case there are more than one options for
performance emission related components, i.e. 2 different make injector, 2 turbo
etc.
Supplementary test - supplementary test is for verification/ determination of
regeneration strategy or any other
1.10.1. Description of the purpose of the test:

71
2. General engine information (test engine)
2.1. Engine type designation/engine family designation/FT:
2.2. Engine identification number:
2.3. Engine Category and subcategory:

3. Documentation and information Check list (primary test only)

3.1. Engine mapping documentation reference:
3.2. Deterioration factor determination documentation reference:
3.3. Infrequent regeneration factors determination documentation reference, where applicable:
3.4. NOX control diagnostic demonstration documentation reference, where applicable:
3.5. Particulate control diagnostic demonstration documentation reference, where applicable:
3.6. For engine types and engine families that use an ECU as part of the emission control
system anti-tampering declaration documentation reference:
3.7. For engine types and engine families that use mechanical devices as part of the emission
control system anti- tampering and adjustable parameters declaration and demonstration
documentation reference:

4. Reference fuel(s) used for test (complete relevant subparagraph(s)

4.2. Liquid fuel for compression-ignition engines
4.2.1. Make:
4.2.2. Type:
4.2.3. Cetane number:
4.2.4. Fame content (%):
4.2.5. Density at 15 ⁰C (kg/m3):
4.3. Reserved
4.4. Reserved
4.5. Dual-fuel engine (in addition to relevant sections above)
4.5.1. Gas energy ratio on test cycle:
5. Lubricant
5.1. Make(s):
5.2. Type(s):
5.3. SAE viscosity:
5.4. Lubricant and fuel are mixed: yes/no
5.4.1. Percentage of oil in mixture:
6. Engine Speed
6.1. Declared rated speed:
6.1.1. Overload speed:
6.1.2. Idle speed:

72
7. Engine Power.
8. Conditions at test
8.1. fa within range 0.93 to 1.07: Yes/No
8.1.1. If fa is not within specified range state altitude of test facility and dry atmospheric pressure:
8.2. Applicable intake air temperature range: 20 to 30 oC (up 560kW/ 20 to 35 oC (greater than
560 kW only)
9. Test result
9.1. 5-mode cycle Emissions results
9.2. Deterioration Factor (DF): calculated/assigned
9.2.1. DF values and the cycle weighted emissions results to be stated in Table 6:
Note: In the event that a discrete mode 5-mode cycle is run where the Kru or Krd
factors have been established for individual modes then a table showing each
mode and the applied Kru or Krd should replace the shown table.

Table 6
5-mode cycle DF values and weighted emissions results

DF HC+ NOX Smoke

CO HC NOX PM
mult/add

CO HC NOX HC+ NOX PM Smoke

Emissions
(g/kWh) (g/kWh) (g/kWh) (g/kWh) (g/kWh) m-1

Test result
with/without
regeneration

kru/krd NA
mult/add

test result with

infrequent
regeneration
adjustment factors NA
(IRAFs) before
rounding

Final rounded test

result with DF

9.3 Cycle weighted CO2 (g/kWh):

9.3.1 Cycle average NH3 (ppm):
9.4. Additional control area test points (if applicable) to be stated in Table 7:

73
 Table 7
Additional control area test points

Emissions HC+
Load CO NOX PM Smoke
at test Engine (g/kWh HC NOX
Speed (%) (g/kWh) (g/kWh) (g/kW (g/kWh) m-1
point ) h)

Test
result 1

Test
result 2

9.5. Sampling systems used for the 5-mode emission test:

9.5.1. Gaseous emissions:
9.5.2. PM:
9.5.2.1. Method: single/multiple filter

10. Final emissions results

10.1 Cycle emissions results to be stated in Table 8.
Table 8
Final emissions results

CO HC NOX HC+ NOX PM Smoke Test

Emissions
(g/kWh) (g/kWh) (g/kWh) (g/kWh) (g/kWh) m-1 Cycle (1)

5-mode cycle final

rounded test
result with DF.

10.2 CO2 result:

Explanatory notes to the test report template
(Footnote markers, footnotes, and explanatory notes not to be stated on the test report)
(1) For test cycle note the cycle indicated in Appendix 1 of Annexure 7
(2) Copy the results from table 6
(3) Reserved
4
() For an engine tested on a 5-mode cycle indicate the CO2 emissions values
given in that cycle from paragraph 9.3.

74
 ANNEXURE – 3
Labelling Requirements
A3.1. The engine or the product must be affixed with a conformance label meeting the following
requirements.

A3.1.1. General Requirement

a. The label shall be durable and legible;

b. The label shall be affixed on a part necessary for normal operation of the engine or
the product and not normally requiring replacement during the life of the engine or
the product;
c. Statement that ‘this engine or product conforms to the Environment Protection Rule
1986;
d. All the information mentioned in the conformance label must be in English language;

A3.1.2. Conformance Labelling Content Requirement

a. Name the engine manufacturer or the engine or product importer

b. Manufacturing plant address from where engine is manufacture
c. Engine Model name;
d. Rated speed and corresponding gross power in kW;
e. Engine Unique Identification Number (Serial Number, etc.);
f. Date of manufacturing and in case of import, date of import of engine or Genset
product;
g. Type Approval certificate number;
h. Letter ‘G’ to denote that the engine is belongs to genset application. The Letter
‘G’ shall be engraved on the conformance label. The letter(s) should have a
minimum size of 7 mm.

75
 ANNEXURE – 4

Test equipment, test bed measurement system and test

facility

A4.1 Requirement

A4.1.1 Test facility: The test facility to be used shall be of the certification agencies or any
other facility approved by these certification agencies. The test Lab at Test Agency/
Engine Manufacturer Lab/ Third party Lab shall be accredited as per the requirement
of ISO/IEC-17025 (NABL-National Accreditation Board for Testing and Calibration
Laboratory) compliance for the related GSR/S&P/ISO-8178 Standards. The tests shall
be carried out under the control of the certification agencies.
A4.1.2 Test bed measurement system and equipment: Test bed measurement system and
equipment’s of gaseous and particulate shall be as per the guideline given in the ISO-
8178-1: 2017,2020 Reciprocating internal combustion engines — Exhaust emission
measurement — Part 1: Test-bed measurement systems of gaseous and particulate
emission.

Smoke measurement equipment shall be as per the guideline given in the ISO-8178-
3: 2019 Reciprocating internal combustion engines — Exhaust emission measurement
— Part 3: Test procedure for measurement of exhaust gas smoke emissions from
compression ignition engines using a filter type smoke meter

Smoke measurement equipment shall be the guideline given in the ISO 8178-9:2019
Reciprocating internal combustion engines — Exhaust emission measurement — Part
9: Test cycles and test procedures for measurement of exhaust gas smoke emissions
from compression ignition engines using an opacimeter

76
 ANNEXURE-5

Data evaluation, test result calculation of gaseous &

particulate emission, test execution and measurement
procedures

A5.1 Requirement

A5.1.1 Method of test execution, measurement procedures, data evaluation and

calculation of gaseous and particulate emission shall be as per the guideline given
in the ISO-8178-4: 2017, 2020 Reciprocating internal combustion engines — Exhaust
emission measurement — Part 4: Steady-state and transient test cycles for different
engine applications

A5.1.2 Method of smoke measurement shall be as per the guideline given in the ISO-8178-
3: 2019 Reciprocating internal combustion engines — Exhaust emission measurement
— Part 3: Test procedure for measurement of exhaust gas smoke emissions from
compression ignition engines using a filter type smoke meter

Method of smoke measurement shall be the guideline given in the ISO 8178-9:2019
Reciprocating internal combustion engines — Exhaust emission measurement — Part
9: Test cycles and test procedures for measurement of exhaust gas smoke emissions
from compression ignition engines using an opacimeter

A5.1.3 1980 international gravity formula

The acceleration of Earth's gravity, ag, varies depending on the location and ag is:
calculated for a respective latitude, as follows

ag  9.7803267715 1  5.2790414 103 sin 2   2.32718 10 5 sin 4   1.262 107 sin 6   7 1010 sin 8  

Where: θ = Degrees north or south latitude

Note: Reference taken from AIS-137

77
 ANNEXURE – 6
Technical characteristics of fuels prescribed for approval tests and to
verify conformity of production tests
1. Technical data on fuels for testing compression-ignition engines
1.1. Type: Diesel
For Type approval and Conformity of Production (COP) test, fuel shall be Reference fuel
or commercial fuel as recommended by manufacturer as prescribed in Table 1 and 2

78
 Appendix – 1
Reference diesel fuel characteristics
Table 1
Reference Diesel Fuel
Parameter Unit Minimum Maximum Test method
Cetane Index 46.0 EN ISO 4264
Cetane number 2 52.0 56.0 EN ISO 5165
3
Density at 15 °C kg/m 833.0 837.0 EN ISO 12185
Distillation:
- 50% point °C 245.0 — EN ISO 3405
- 95% point °C 345.0 360.0 EN ISO 3405
- final boiling point °C — 370.0 EN ISO 3405
Flash point °C 55 — EN ISO 2719
Cloud point °C - -10 EN 23015
Viscosity at 40 °C mm2/s 2.30 3.30 EN ISO 3104
Polycyclic aromatic hydrocarbons % m/m 2.0 4.0 EN 12916
EN ISO 20846
Sulphur content mg/kg — 10.0
EN ISO 20884
Copper corrosion 3hrs, 50 °C — Class 1 EN ISO 2160
Conradson carbon residue (10 % DR) % m/m — 0.20 EN ISO 10370
Ash content % m/m — 0.010 EN ISO 6245
Total contamination mg/kg - 24 EN 12662
Water content mg/kg — 200 EN ISO 12937
Acid number mg KOH/g — 0.10 EN ISO 6618
Lubricity (HFRR wear scan diameter at 60 °C) Μm — 400 EN ISO 12156
Oxidation stability @ 110 °C 3 H 20.0 EN 15751
4
FAME % v/v 6.0 7.0 EN 14078
1. The values quoted in the specifications are ‘true values’. In establishment of their limit values the
terms of ISO 4259 Petroleum products – Determination and application of precision data in relation to
methods of test have been applied and in fixing a minimum value, a minimum difference of 2R above
zero has been taken into account; in fixing a maximum and minimum value, the minimum difference is
4R (R = reproducibility). Notwithstanding this measure, which is necessary for technical reasons, the
manufacturer of fuels shall nevertheless aim at a zero value where the stipulated maximum value is 2R
and at the mean value in the case of quotations of maximum and minimum limits. Should it be necessary
to clarify whether a fuel meets the requirements of the specifications, the terms of ISO 4259 shall be
applied.

2. The range for cetane number is not in accordance with the requirements of a minimum range of
4R. However, in the case of a dispute between fuel supplier and fuel user, the terms of ISO 4259 may be
used to resolve such disputes provided replicate measurements, of sufficient number to archive the
necessary precision, are made in preference to single determinations.

3. Even though oxidation stability is controlled, it is likely that shelf life will be limited. Advice shall
be sought from the supplier as to storage conditions and life.

4. FAME content to meet the specification of EN 14214

79
 Appendix – 2
Commercial diesel fuel characteristics

Table 2
Commercial Diesel Fuel
Characteristics Unit Requirements
Ash, max % mass 0.01
Carbon Residue (Ramsbottom) on 10 % % mass 0.3
residue, max without additives
Cetane number (CN), min 51
Cetane Index (CI), min 46
Distillation :
95% vol. recovery at 0C, max 0
C 360
Flash point :
0
a) Abel, min C 35
0
Kinematic Viscosity @ 40 C Cst 2.0-4.5
Density @15 0C kg/m3 845
Total Sulphur, max. mg/kg 10
Water content, max mg/kg 200
Cold filter Plugging point (CFPP)
0
a) Summer, max C 18
0
b) Winter, max C 6
Total contaminations, max mg/kg 24
Oxidation stability, max g/m3 25
Polycyclic Aromatic Hydrocarbon (PAH), % mass 11
max
Lubricity, corrected wear scar diameter @ µm
60 0C, max (microns) 460
Copper strip corrosion for 3 hrs @ 500C Rating Class – 1
FAME content max. % v/v 7.0
Note :
• Test methods and other provisions / details along with the requirements as given above
shall be issued by Bureau of Indian Standards.
• The Cetane number (CN),( min) shall be permitted up to 48 in North Eastern States till
01.04.2023

80
 Appendix – 3
1.2. Type: Ethanol for dedicated compression ignition engines (ED95)1

Table 3
Ethanol for dedicated compression ignition engines (ED95)1

Limits2
Parameter Unit Test method3
Minimum Maximum
Total alcohol (Ethanol incl.
per cent
content on higher saturated 92.4 EN 15721
m/m
alcohols)
Other higher saturated
per cent m/m 2.0 EN 15721
mono-alcohols (C3-C5)
Methanol per cent m/m 0.3 EN 15721
Density 15ºC kg/m3 793.0 815.0 EN ISO 12185
Acidity, calculated as acetic
per cent m/m 0.0025 EN 15491
acid
Appearance Bright and clear
Flashpoint ºC 10 EN 3679
Dry residue mg/kg 15 EN 15691
EN 154894
Water content per cent m/m 6.5 EN-ISO 12937
EN15692
Aldehydes calculated as
per cent m/m 0.0050 ISO 1388-4
acetaldehyde
Esters calculated as
per cent m/m 0.1 ASTM D1617
ethylacetat
EN 15485
Sulphur content mg/kg 10.0
EN 15486
Sulphates mg/kg 4.0 EN 15492
Particulate contamination mg/kg 24 EN 12662
Phosphorus mg/l 0.20 EN 15487
EN 15484 or
Inorganic chloride mg/kg 1.0
EN 15492
Copper mg/kg 0.100 EN 15488
DIN 51627-4 or
Electrical Conductivity µS/cm 2.50
prEN 15938
1
Additives, such as cetane improver as specified by the engine manufacturer, may be added
to the ethanol fuel, as long as no negative side effects are known. If these conditions are
satisfied, the maximum allowed amount is 10 per cent m/m.
2
The values quoted in the specifications are "true values". In establishment of their limit
values the terms of ISO 4259 Petroleum products – Determination and application of
precision data in relation to methods of test have been applied and in fixing a minimum
value, a minimum difference of 2R above zero has been taken into account; in fixing a
maximum and minimum value, the minimum difference is 4R (R = reproducibility).
Notwithstanding this measure, which is necessary for technical reasons, the
manufacturer of fuels shall nevertheless aim at a zero value where the stipulated
maximum value is 2R and at the mean value in the case of quotations of maximum and

81
 minimum limits. Should it be necessary to clarify whether a fuel meets the requirements
of the specifications, the terms of ISO 4259 shall be applied.
3
Equivalent EN/ISO methods will be adopted when issued for properties listed above.
4
Should it be necessary to clarify whether a fuel meets the requirements of the
specifications, the terms of EN 15489 shall be applied.
.

82
 Appendix – 4

2.0 Technical data on gaseous fuels for single fuel and dual-fuel engines
2.1 Type: LPG
Table 4

LPG
Test
Parameter Unit Fuel A Fuel B
method
Composition: EN 27941
per cent
C3-content 30 ± 2 85 ± 2
v/v
per cent
C4-content Balance1 Balance1
v/v
per cent
< C3 , > C4 Maximum 2 Maximum 2
v/v
per cent Maximum Maximum
Olefins
v/v 12 15
Maximum Maximum
Evaporation residue mg/kg EN 15470
50 50
Water at 0 °C Free Free EN 15469
EN 24260,
ASTM D
Total sulphur content Maximum Maximum
mg/kg 3246,
including odorant 10 10
ASTM
6667
EN ISO
Hydrogen sulphide None None
8819
Copper strip
corrosion Rating Class 1 Class 1 ISO 62512
(1h at 40 °C)
Characterist Characterist
Odour
ic ic
Motor octane Minimum Minimum EN 589
number3 89.0 89.0 Annex B
Notes:
1
Balance shall be read as follows: balance = 100 - C3 - <C3 - >C4.
2
This method may not accurately determine the presence of corrosive materials if
the sample contains corrosion inhibitors or other chemicals which diminish the
corrosivity of the sample to the copper strip. Therefore, the addition of such
compounds for the sole purpose of biasing the test method is prohibited.
3
At the request of the engine manufacturer, a higher MON could be used to
perform the type approval tests.

83
2.2. Type: Natural Gas/ Bio-methane
2.2.1. Specification for reference fuels supplied with fixed properties (eg from a sealed
container)
As an alternative to the reference fuels set out in this paragraph, the equivalent fuels
in paragraph 2.1.2. of this Annex may be used
Table 5

Natural Gas/ Bio-methane

Limits
Characteristics Units Basis minimu Test method
maximum
m
Reference fuel GR
Composition:
Methane 87 84 89
Ethane 13 11 15
per cent
Balance1 — — 1 ISO 6974
mole
Sulphur content mg/m3 2 — 10 ISO 6326-5
Notes:
1
Inerts + C2+
2
Value to be determined at standard conditions 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G23
Composition:
Methane 92.5 91.5 93.5
per cent
Balance1 — — 1 ISO 6974
mole
per cent
N2 7.5 6.5 8.5
mole
Sulphur content mg/m3 2 — — 10 ISO 6326-5
Notes:
1
Inerts (different from N2) + C2+ C2+
2
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G25
Composition:
per cent
Methane 86 84 88
mole
per cent
Balance1 — — 1 ISO 6974
mole
per cent
N2 14 12 16
mole
Sulphur content mg/m3 2 — — 10 ISO 6326-5
Notes:
1
Inerts (different from N2) + C2+ C2+
2
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G20

84
 Composition:
per cent
Methane 100 99 100 ISO 6974
mole
per cent
Balance (1) — — 1 ISO 6974
mole
per cent
N2 ISO 6974
mole
Sulphur content mg/m3 (2) — — 10 ISO 6326-5
3 (3)
Wobbe Index (net) MJ/m 48.2 47.2 49.2
(1)
Inerts (different from N2) + C2 + C2+.
(2)
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
(3)
Value to be determined at 273.2 K (0 °C) and 101.3 kPa.

Note –
In absence of availablity of reference fuel for testing, commercial available fuel
as notified under CMVR shall be used for testing
2.2.2. Specification for reference fuel supplied from a pipeline with admixture of other gases
with gas properties determined by on-site measurement
As an alternative to the reference fuels in this paragraph the equivalent reference fuels
in paragraph 2.2.1. of this Annex may be used.
2.2.2.1. The basis of each pipeline reference fuel (GR, G20, …) shall be gas drawn from a
utility gas distribution network, blended, where necessary to meet the corresponding
lambda-shift (Sλ) specification in Table A.5-1, with an admixture of one or more of the
following commercially (the use of calibration gas for this purpose shall not be
required) available gases:
(a) Carbon dioxide;
(b) Ethane;
(c) Methane;
(d) Nitrogen;
(e) Propane.
2.2.2.2. The value of Sλ of the resulting blend of pipeline gas and admixture gas shall be within
the range specified in Table A.5-1 for the specified reference fuel.
Table A.5-1
Required range of Sλ for each reference fuel
Reference fuel Minimum Sλ Maximum Sλ
GR 2 0.87 0.95
G20 0.97 1.03
G23 1.05 1.10
G25 1.12 1.20

1
The engine shall not be required to be tested on a gas blend with a Methane
Number (MN) less than 70. In the case that the required range of Sλ for GR
would result in an MN less than 70 the value of Sλ for GR may be adjusted as
necessary until a value of MN no less than 70 is attained.

2.2.2.3. The engine test report for each test run shall include the following:

85
 (a) The admixture gas(es) chosen from the list in paragraph 2.2.2.1. of this Annex;
(b) The value of Sλ for the resulting fuel blend;
(c) The Methane Number (MN) of the resulting fuel blend.

2.3 Fuels and their applicable standards:

Refer the applicable standards amended time to time for the fuels
Sr. Fuel Applicable Standard
No.
1 Natural Gas Annexure IV - L -
CMVR Refer rule 115 H
2 Bio methane IS 16087: 2016
3 LPG IS 14861 : 2000
(REAFFIRMED 2020)
4 E10 IS 2796: 2017
5 E12 IS 17586: 2021
6 E15 IS 17586: 2021
7 E20 IS 17021: 2018
8 E85 IS 16634: 2017
9 E100 IS 15464: 2004
10 ED95 Is 16629: 2017
11 M15 IS 17076: 2019
12 M85 Annexure ZB - CMVR
Refer rule 115 H
13 M100 IS 17075 : 2019
14 MD 95 Annexure ZA - CMVR
Refer rule 115 H
15 DME IS 16704: 2018
16 Hydrogen IS 16061: 2021
17 Hydrogen blended with CNG (18% IS 17314: 2019
hydrogen)
18 Bio-Diesel (B7) IS 1460 : 2017
19 Bio-diesel (B8 to B20) IS 16531: 2022
20 Bio-diesel (B100) IS 15607 : 2022

86
 ANNEXURE – 7

Requirements, Tests and Test Procedures

7.1. General
Engines shall be designed, constructed and assembled so as to enable them to comply with the
provisions of this Regulation.
7.1.1. The technical measures taken by the manufacturer shall be such as to ensure that the gaseous
and particulate pollutant emissions are effectively limited, as set out in Table 1 of clause 3 of this
Regulation throughout the emission durability period of the engine, as set out in Appendix 6 to
this Annexure 7, and under normal conditions of use.
7.1.1.1. For this purpose, the engine final emission test result calculated according to the requirements of
clause 7.1.2 shall not exceed the exhaust emission limits set out in Table 1 of clause 3, when:
(a) tested in accordance with the test conditions and detailed technical procedures set out in
Annexure 5 to this Regulation,
(b) using the fuel(s) specified in paragraph 7.1.3.
(c) using the test cycles specified in Appendix 1 to Annexure 7 of this Regulation.
7.1.2 The final exhaust emission test results for engines subject to this Regulation shall be calculated
by applying all of the following to the laboratory test results:
(a) the emissions of crankcase gases as required by Appendix 5 of Annexure 7;
(b) any necessary adjustment factor, where the engine includes an infrequently regenerating
exhaust after-treatment system;
(c) in respect of all engines, as a final step in the calculation, deterioration factors appropriate
to the emission durability periods specified in Appendix 6 to this Annexure 7 and
calculated according to the prescription set out in Annexure 5.
7.1.3 In accordance to Annexure 7 of this Regulation, the testing of an engine type or engine family to
determine whether it meets the emission limits set out in this Regulation shall be carried out by
using the following reference fuels or fuel combinations, as appropriate:
(a) Diesel
(b) natural gas/Bio-methane
(c) ethanol.
(d) methanol
The engine type or engine family shall, in addition, meet the exhaust emission limits set out in this
Regulation in respect of any other specified fuels, fuel mixtures or fuel emulsions included by a
manufacturer in an application for type- approval and described in the Appendix 11 to paragraph
7 of this Regulation.

7.1.4 As regards the conduct of measurements and tests, the technical requirements shall be met in
respect of:
(a) apparatus and procedures for the conduct of tests;
(b) apparatus and procedures for emission measurement and sampling;
(c) methods for data evaluation and calculations;
(d) methods for establishing deterioration factors;
(e) methods for taking account of emissions of crankcase gases;

87
 (f) methods for determining and taking account of continuous or infrequent regeneration of
exhaust after-treatment systems;
(g) in relation to electronically controlled engines, complying with the off-cycle emission limits
set out in Regulation and using electronic control to determine both the quantity and
timing of injecting fuel or using electronic control to activate, de-activate or modulate the
emission control system used to reduce NOX & PM;
(i) emission control strategies, and shall include the documentation required to
demonstrate those strategies;
(ii) NOX & PM control measures, and shall include the method used to demonstrate
those control measures;
(iii) the area associated with the relevant steady-state test cycle, within which the
amount by which the emissions are permitted to exceed the emission limits set
out in Appendix 2 to this Annexure 7 is controlled;
(iv) the selection by the technical agency of additional measurement points from
within the control area during the emission bench test;
7.1.5. Any adjustment, repair, disassembly, cleaning or replacement of engine components or systems
which are scheduled to be performed on a periodic basis to prevent malfunction of the engine,
shall only be done to the extent that is technologically necessary to ensure proper functioning of
the emission control system.
7.2. Reserved
7.3. The technical requirements relating to emission control strategies as set out in Annexure 8 to this
regulation shall apply;
7.4. The use of defeat strategies shall be prohibited;
7.5. Engine types and engine families shall be designed and fitted with emission control strategies in
such a way as to prevent tampering to the extent possible;

88
 Appendix – 1
Emission Test Cycles Introduction
1. Test cycles
The type-approval test shall be conducted using test cycle as specified in Table A for constant
speed and variable speed application.
1.1 Steady-state test cycles
Steady-state test cycles are specified in below clause 2 of this Appendix as a list of discrete
modes (operating points), where each operating point has one value of speed and one value
of torque. A steady-state test cycle shall be measured with a warmed up and running engine
according to manufacturer's specifications
1.2. Steady-state discrete mode test cycles
The steady-state discrete mode test cycles are hot running cycles where emissions shall be
started to be measured after the engine is started, warmed up and running as per specified
boundary conditions. Each cycle consists of a number of speed and load modes (with the
respective weighing factor for each mode) which cover the typical operating range of the
specified engine category.
1.3. Steady-state ramped mode test cycles
Steady-state ramped mode test cycles are hot running cycles where emissions shall be started
to be measured after the engine is started, warmed up and running as per specified boundary
conditions. Test cycle with a sequence of steady state engine test modes with defined speed
and torque criteria at each mode and defined speed and torque ramps between these modes.
2. Characteristics of the steady-state test cycles
2.1. Test cycles applicable to Genset engine categories are set out in Table A
Table A-Test cycles

Test cycles for Genset engine categories

Speed
Category Purpose Test Cycle
operation
D2 5-mode Steady-state discrete mode test cycle
Constant specified in ISO-8178-Part 4,
Constand
speed
speed OR
engine upto
engine D2 5-mode Steady-state ramped mode test cycle
800 kW
specified in ISO-8178-Part 4
5-mode Variable Speed Cycle,
Genset
OR
Variable
Variable C1 8-mode Steady-state discrete mode test cycle
speed
speed specified in ISO-8178-Part 4),
engine upto
egine OR
800 kW
C1 8-mode Steady-state ramped mode test cycle
specified in ISO-8178-Part 4

2.2. Steady-state constant speed and variable speed test cycles:

The detailed description of the test modes and weighting factors for the steady-state discrete-
mode and ramped mode test cycles for constant speed and variable speed genset engines are
set out in Tables B, C, D, E & F
2.2.1 Constant Speed Test Cycle

89
 Table B- Discrete D2 test modes
Test modes and weighting factors
Mode number
1 2 3 4 5
(cycle D2)
Speed (a) 100%
Torque (b) (%) 100 75 50 25 10
Weighting
0.05 0.25 0.3 0.3 0.1
factor
Mode length (Second) 600 600 600 600 600
(a) Rated speeds as declared by manufactured
(b) per cent torque is relative to the torque corresponding to the rated gross power declared by the
manufacturer. Considering the applicable power tolerance, the torque setting for 2, 3, 4 & 5 mode,
shall be based on actual torque measured at 1st mode during test.

5 mode constant-speed test cycle

Rated Speed

Weighting Factor

100% Mode-1
0.05
Torque [ % ]

75% Mode-2
0.25

50% Mode-3
0.3

25% Mode-4
0.3

10% Mode-5
0.1

Speed [ rpm ]

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 Table C —RMC-D2 test modes
RMC mode number Time in mode (s) Engine speed (%) Torque (%) b c
a
1a Steady State 53 100 100
1b Transition 20 100 Linear transition
2a Steady-state 101 100 10
2b Transition 20 100 Linear transition
3a Steady-state 277 100 75
3b Transition 20 100 Linear transition
4a Steady-state 339 100 25
4b Transition 20 100 Linear transition
5 Steady-state 350 100 50
a Rated speed as declared by manufactured.
b % torque is relative to the torque corresponding to the rated power declared by the manufacturer.
c Advance from one mode to the next within a 20-second transition phase. During the transition phase,
command a linear progression from the torque setting of the current mode to the torque setting of the
next mode.

2.2.2 Variable speed test Cycle

Table D- 5-mode variable speed test modes

Test modes and weighting factors
Mode Weighting Mode length (Second)
Engine Speed (a) Power % (b)
number factor
Declared Speed
1 100 0.05 600
(Rated speed)
2 Declared Speed 75 0.25 600
3 Declared Speed 50 0.30 600
4 Declared Speed 25 0.30 600
5 Declared Speed 10 0.10 600
(a) Pre-verified declared rated & part load speed as per Appendix 9 of this Annexure
(b) per cent power is relative to the power corresponding to the rated gross power declared by the
manufacturer. Require torque values for dyno setting for each mode to be calculated based on the
declared speed values
Note:
a) The engine manufacturer shall declare rated speed, rated power, and part load speeds of the
engine. The part load speeds shall be as mentioned in above table. The part load speeds shall be
verified on actual working condition of Genset at manufacturer’s place by Test Agency before
dismantling the set and submitting the engine for emission test.

b) Refer Appendix 9 of this Annexure -Test Procedure for emission measurement from Variable
Speed Diesel Engines for Power generating set Application.

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 5 mode variable-speed test cycle

Power % Weighting Factor

100% 0.05
Mode-1

Power [ % ]
75% Mode-2
0.25
Rated speed
50% 0.3
Mode-3

25% Mode-4
0.3

10% Mode-5
0.1

Speed [ rpm ]

Table E — Discrete C1 test modes

Mode 1 2 3 4 5 6 7 8
number
Speed a 100% Intermediate Idle
Torque b 100 75 50 10 100 75 50 0
(%)
Weighting 0,15 0,15 0,15 0,1 0,1 0,1 0,1 0,15
factor
a Refer ISO-8178 Part 4 for determination of required test speeds.
b The % torque is relative to the maximum torque at the commanded engine speed.

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 Table F —RMC-C1 test modes
RMC Mode Number Time in mode(s) Engine speed a c Torque (%) b c
1a Steady-state 126 Idle 0
1b Transition 20 Linear transition Linear transition
2a Steady-state 159 Intermediate 100
2b Transition 20 Intermediate Linear transition
3a Steady-state 160 Intermediate 50
3b Transition 20 Intermediate Linear transition
4a Steady-state 162 Intermediate 75
4b Transition 20 Linear transition Linear transition
5a Steady-state 246 100% 100
5b Transition 20 100% Linear transition
6a Steady-state 164 100% 10
6b Transition 20 100% Linear transition
7a Steady-state 248 100% 75
7b Transition 20 100% Linear transition
8a Steady-state 247 100% 50
8b Transition 20 Linear transition Linear transition
9 Steady-state 128 Idle 0
a Refer ISO-8178 Part 4 for determination of required test speeds.
b % torque is relative to the maximum torque at the commanded engine speed.
c Advance from one mode to the next within a 20-second transition phase. During the transition phase,
command a linear progression from the torque setting of the current mode to the torque setting of the
next mode, and simultaneously command a similar linear progression for engine speed if there is a
change in speed setting.

Note: Reference
ISO 8178-4:2017,2020;
Reciprocating internal combustion engines — Exhaust emission measurement — Part 4: Steady-
state and transient test cycles for different engine applications.

93
 Appendix – 2

Off Cycle Emission Requirements

Measurements and tests with regard to the control area associated with the steady-state test
cycle applicable for constant speed engines & variable speed engines

A2.1. General Requirements:

This paragraph shall apply for constant speed electronically controlled Genset engines and
variable speed electronically controlled Genset engines, complying with emission limits set out
in Table 1 of clause 3 and using electronic control to determine both the quantity and timing of
injecting fuel or using electronic control to activate, de-activate or modulate the emission control
system used to reduce NOX & PM
This paragraph sets out the technical requirements relating to the area associated with the
relevant steady state test cycle, within which the amount by which that the emissions shall be
permitted to exceed the emission limits set out in Table 1 of clause 3 to this paragraph is
controlled
When an engine is tested as set out in test requirements as specified in below clause A2.4 of
this Appendix 2, the emission of gaseous and particulate pollutants sampled at any randomly
selected point within the applicable control area set out in clause A2.2.2 shall not exceed the
applicable emission limit values in Table 1 of clause 3 of this Regulation multiplied by a factor
of 2.0;
Paragraph A2.2.2. sets out the selection by the technical agency of additional measurement
points from within the control area during the emission bench test, in order to demonstrate that
the requirements of this paragraph have been met;
The installation instructions provided by the manufacturer to the GOEM in accordance with
Appendix 1 to Annexure 9 of this Regulation shall identify the upper and lower boundaries of
the applicable control area and shall include a statement to clarify that the GOEM shall not
install the engine in such a way that it constrains the engine to operate permanently at only
combinations of speed and torque outside of the control area for the torque curve corresponding
to the approved engine type or engine family;

A2.2. Engine control area

The applicable control area for conducting the engine test shall be the area identified in this
paragraph that corresponds to the applicable steady state cycle for the engine being tested;
number of random points within control area for testing during the type approval and COP
testing as well.
a) up to two points for constant speed genset engine operating on D2 cycle
b) up to two points for variable speed genset engine operating on variable speed 5-mode test
cycle
c) up to three points for variable speed genset engine operating on C1 cycle

A2.2.2. Control area

a) Control area for constant speed engines tested with D2 cycle
These engines are mainly operated very close to their designed operating speed; hence the
control area is defined as:
 Speed: 100 per cent

94
  Torque range: 50 per cent to the torque corresponding to maximum power.

Control area for constant-speed engines of category Genset

Torque [ % ] Mode-1 100%

Mode-2 75% Control

area
Mode-3 50%

Mode-4 25%

Mode-5 10%

Speed [ rpm ]

b) Control area for variable speed engines tested with variable speed 5-mode test cycle
 Speed: 50 per cent to the power corresponding to maximum power
 Torque range: 50 per cent to the power corresponding to maximum power.

c) Control area for variable speed engines tested with C1 test cycle
These engines operate with variable speed and load. The control area, as shown in following
Figure, is defined as follows:

— upper torque limit: full load torque curve

— speed range: speed A to nhi;
— torque range: 30 % to 100 %;

where:
— speed A = nlo + 0,15 (nhi − nlo);
— speed B = nlo + 0,50 (nhi − nlo);
— speed C = nlo + 0,75 (nhi − nlo);

with
nlo low speed (lowest engine speed where 50 % of the maximum power occurs)
nhi high speed (highest engine speed where 70 % of the maximum power occurs)
for more details refer ISO 8178 Part-4 on determination of nlo, nhi

If the measured engine speeds A, B and C are within ±3 % of the engine speeds declared by the
manufacturer, the declared engine speeds shall be used. If the tolerance is exceeded for any of the
test speeds, the measured engine speeds shall be used.

The following speed and torque points shall be excluded from the control area:

 points below 30 % of maximum power;

 for particulate matter only, if the C speed is below 2 400 r/min, points to the right of or below the

95
 line formed by connecting the points of 30 % of maximum torque or 30 % of maximum power,
whichever is greater, at the B speed and 70 % of maximum power at the high speed;
 for particulate matter only, if the C speed is above 2 400 r/min, points to the right of the line formed
by connecting the points of 30 % of maximum torque or 30 % of maximum power, whichever is
greater, at the B speed, 50 % of maximum power at 2 400 r/min, and 70 % of maximum power at
the high speed.

96
A2.3. Demonstration requirements
A2.3.1. The test agency shall select random load points within the control area for testing.
i) For engines subject to paragraph A2.2.2. a) & b), two points shall be selected.
1. One random point between 50 to 75% torque points but excluding these two;
2. One random point between 75 to 100% torque points but excluding these two;

ii) For engines subject to paragraph A2.2.2. c), three points shall be selected.
1. One random point between 30 to 50% torque points but excluding 50% torque point
2. One random point between 50 to 75% torque points but excluding these two;
3. One random point between 75 to 100% torque points but excluding these two;

The test agency shall also determine a random running order of the test points;
The test shall be run at Standard lab (NTP) conditions in accordance with the principal
requirements of the ISO 8178 D2 constant speed cycle but each test point shall be evaluated
separately;
A2.3.2. For the purpose of the random selections required in paragraph A2.3.1. recognised statistical
methods of randomization shall be used.

97
A2.4. Test requirements
The test shall be carried out immediately after the applicable test cycle as follows:
(a) the test of the randomly selected torque points shall be carried out immediately after
the steady state test sequence and before the post test procedures.
(b) the tests shall be carried out using the multiple filter method (one filter for each test
point) for each of the test points chosen in accordance with paragraph A2.3.;
(c) a specific emission value shall be calculated (in g/kWh) for each test point;
(d) emissions values may be calculated on a mass basis or on a molar basis using
Annexure 5, but shall be consistent with the method used for the steady state test;
(e) for gaseous emissions, a weighting factor of 1 shall be used;
(f) for particulate calculations the multiple filter method shall be used; and a weighting
factor of 1 shall be used.
A2.5 Regeneration
In the case that a regeneration event occurs during or immediately preceding the procedure in
paragraph A2.4., upon completion of that procedure the test may be voided at the request of
the manufacturer irrespective of the cause of the regeneration. In this case the test shall be
repeated. The same torque points shall be used although the running order may be changed.
It shall not be deemed necessary to repeat any torque points for which a pass result has already
been obtained. The following procedure shall be used for the repeat test:
(a) The engine shall be operated in a manner to ensure that the regeneration event has
completed and, where applicable, the soot load in the particulate after-treatment has
been re-established;
(b) The engine warm-up procedure shall be performed.
(c) The test procedure specified in paragraph A2.4. shall be repeated commencing at sub-
paragraph A2.4. (b).

Note: Reference
ISO 8178-4:2017,2020;
Reciprocating internal combustion engines — Exhaust emission measurement — Part
4: Steady-state and transient test cycles for different engine applications

98
 Appendix – 3

Method for measuring Smoke

A3.1 Method of smoke measurement shall be as per the guideline given in the ISO-
8178-3: 2019 Reciprocating internal combustion engines — Exhaust emission
measurement — Part 3: Test procedure for measurement of exhaust gas smoke
emissions from compression ignition engines using a filter type smoke meter

Method of smoke measurement shall be the guideline given in the ISO 8178-
9:2019 Reciprocating internal combustion engines — Exhaust emission
measurement — Part 9: Test cycles and test procedures for measurement of
exhaust gas smoke emissions from compression ignition engines using an
opacimeter

A3.2 Smoke limit is 0.7 m-1 & is applicable to type approval and as well conformity of
production

A3.3 Smoke shall not exceed the limit value throughout the operating load points of the
test cycles;

A3.4 If the measurement of smoke is in different unit, then to be convert it in m-1 unit with
acceptable conversion formula

A3.4 For verifing the conformity of production, if the selected engine does not meet the
smoke limit as applicable, the another two engines in case above 19 kW power rating
or four engines in case below 19 kW power rating, will be taken from the series at
random and be tested as per this part. This selected all engines should meet the limit
values specified. One engine shall be subjected to the emission test for the
conformance of production.

99
 Appendix – 4

Gross Power Measurement Procedure

1.0 Declared power (kWm) means rated gross mechanical power declared by
manufacturer for type approval at declared rated speed.

2.0 Gross observed power shall be the criteria for adjusting dynamometer load as well as
calculating the specific emission values

3.0 The declared rated gross power shall be verified with the observed gross corrected
power as mentioned below. Certification Power verification will be at reference
atmospheric condition.

4.0 Power observed in the emission test cycle for all test mode points shall be corrected
as per mentioned below formula and 1st mode corrected power is the corrected rated
gross power.

5.0 Power Corrections Factors:

Definition: The power correction factor is the coefficient by which the measured power
must be multiplied to determine the engine power under the reference atmospheric
conditions specified as below

Pcorr = α Pobs
Where,
Pcorr is the corrected power (i.e. power under reference atmospheric
conditions)
α is the correction factor
Pobs is the measured power (test power)
Reference atmospheric conditions:
 Temperature (T): 298 K
 Dry pressure (Ps): 99 kPa
Note: The dry pressure is based on a total pressure of 100 kPa and a water vapour
pressure of 1 kPa.

Test atmospheric conditions:

 The atmospheric conditions during the test shall be the following:
 Temperature (T): Between 283 K and 313 K
 Pressure (P): Between 80 kPa and 110 kPa

Determination of correction factor:

(The tests may be carried out in air -conditioned tests rooms where the atmospheric
conditions may be controlled.)
The power correction factor α for diesel engines at constant fuel delivery is obtained by
applying the formula:

α = fa fm
where,
fa – the atmospheric factor
fm- the characteristic parameter for each type of engine and adjustment

Atmospheric factor (fa):

This factor indicates effect of environmental conditions (pressure, temperature and

100
 humidity) on the air drawn in by the engine. The atmospheric factor differs according to
the type of the engines.
 Naturally aspirated and mechanically pressure charged engines:
fa = (99/Ps) x (T/298) 0.7

 Turbocharged engines with or without cooling of charge air:

fa = (99/Ps) 0.7 x (T/298) 1.5

Engine Factor (fm):

fm is a function of Qc (fuel flow corrected) as follows,
fm = 0.036 Qc – 1.14

where, Qc is Q/r and

Q – the fuel delivery in milligrams/cycle per litre of engine swept volume
(mg/1.cycle)
r is the pressure ratio of compressor outlet and compressor inlet (r = 1for
naturally aspired engines)
Note:
a. This formula is valid when Qc is 40 ≤ Qc ≤ 65
b. For Qc values lower than 40, a constant value of fm equal to 0.3 (fm=0.3) will be
taken
c. For Qc values higher than 65, a constant value of fm equal to 1.2 (fm=1.2) will be
taken

6.0 The gross declared corrected power of the engine shall be measured on a test bench
at rated speed of the engine. The measured power and speed may differ from the
power and speed specified by the manufacturer as specified below:

Declared rated corrected gross Power & speed tolerance

 For Constant speed engine
(i) For Type Approval:
 For single cylinder engines, ± 5% at the rated power point
 For all other engines, ± 4 % at the rated power point
(ii) For Conformity of Production:
 For single cylinder engines, at rated power point, ± 6% of the type
approved figure
 For all other engines, at rated power point, ± 5% of the type approved
figure

Declared rated Speed at rated power point shall vary within ± 1%

 For Variable speed engine
(i) For Type Approval:
 For single cylinder engines, ± 5% at rated & part load power point
 For all other engines, ± 4 % at rated & part load power point
(ii) For Conformity of Production:
 For single cylinder engines, at rated & part load power point, ± 6% of the
type approved figure
 For all other engines, at rated & part load power point, ± 5% of the type
approved figure

Declared rated & part load speeds shall vary within ± 1%

7.0 For verifying the conformity of production, for the selected engine, if the gross power
and rated speed does not meet the limits, two additional engines for >19kW or four in
case <19kW power rating category shall be tested for the rated gross power and rated
speed.

101
 The additional selected all engines shall meet the limits for the rated gross power and
speed, out of these engines, one engine shall be subjected to the emission test for the
conformance of production as mentioned in this part.

8.0 The fuel temperature shall be maintained at 38 ±5 deg C throughout the test

9.0 Single & two-cylinder engines shall be tested with the engine intake system. All the
other engine shall be tested with either air intake system of applying maximum declared
air intake depression of clean air intake

10.0 The engine shall be tested with the maximum exhaust back pressure values declared
by the manufacturer. In case of the engines fitted with exhaust after treatment device
and external EGR system, the manufacturer shall declare exhaust back pressure
values at all five test points. The engine will be tested with the declared exhaust back
pressure values set at laboratory condition with a tolerance of ±10% at rated load. At
part load points the tolerance shall be as low as possible in the test laboratory
conditions.

11.0 The no load speed or high idle speed and overload speed (correspondence to %
overload power declared by manufacturer) shall be verified and documented against
value specified by the manufacturer.

102
 Appendix – 5

Crankcase Ventilation Requirements

The Regulation does not enforce a specific crankcase ventilation system for Genset engines. With
option of Open and Close crankcase ventilation systems, verifying emissions of crankcase gases is
required for engines with gross power >56 kW.

Crank case ventilation requirement shall be as per the guideline given in the ISO-8178-4: 2017, 2020
Reciprocating internal combustion engines — Exhaust emission measurement — Part 4: Steady-state
and transient test cycles for different engine applications

103
 Appendix – 6

Emission Durability Period (EDP), Deterioration Factor and Methodology for

Adapting Emission Lab Test Results

1. Definitions
For the purposes of this appendix, the following definitions apply. Refer clause 2.1 for extensive
set of definitions:
1.1. “Ageing cycle” means the engine operation (speed, load, power) to be executed during the
service accumulation period.
1.2. “Critical emission-related components” means the exhaust after- treatment system, the
electronic engine control unit and its associated sensors and actuators, and the EGR system
including all related filters, coolers, control valves and tubing.
1.3. “Critical emission-related maintenance” means the maintenance to be performed on critical
emission-related components of the engine.
1.4. “Emission-related maintenance” means the maintenance which substantially affects
emissions or which is likely to affect emissions performance of the engine during normal in-use
operation.
1.5. “Engine-after-treatment system family” means a manufacturer’s grouping of engines that
comply with the definition of engine family, but which are further grouped into a family of engine
families utilising a similar exhaust after-treatment system.
1.6. “Non-emission-related maintenance” means maintenance which does not substantially
affect emissions and which does not have a lasting effect on the emissions performance
deterioration of the engine during normal in-use operation once the maintenance is performed.
1.7. “Service accumulation schedule” means the ageing cycle and the service accumulation
period for determining the deterioration factors for the engine-after-treatment system family.

2. General
2.1. This Appendix details the procedures for selecting engines to be tested over a service
accumulation schedule for the purpose of determining deterioration factors for engine type
approval and conformity of production assessments. The deterioration factors shall be applied
to the emissions measured in accordance with Annex 4 and calculated in accordance with
Annex 5 in accordance with the procedure set out in paragraph 3.2.7 of this appendix,
respectively.
2.2. The service accumulation tests or the emissions tests performed to determine deterioration
need not be witnessed by the Type Approval Authority.
2.3. This appendix also details the emission-related and non-emission-related maintenance that
should be or may be carried out on engines undergoing a service accumulation schedule. Such
maintenance shall conform to the maintenance performed on in-service engines and
communicated to the end-users of new engines.

3. Engine categories Genset

3.1. Selection of engines for establishing emission durability period deterioration factors
3.1.1. Engines shall be selected from the engine family defined in Clause 4.1 to establish emission
durability period deterioration factors.
3.1.2. Engines from different engine families may be further combined into families based on the type
of exhaust after-treatment system utilised, or where no after-treatment is used, based upon the

104
 similarity of the technical characteristics of the emission control system. Engines of different
bore and stroke, different configuration, different air management systems, different fuel
systems may be considered as equivalent in respect to emissions deterioration characteristics
if the manufacturer provides data to the Type Approval Authority that there is a reasonable
technical basis for such determination. In order to place engine families having similar technical
specifications and installation for the exhaust after-treatment systems into the same engine
after-treatment system family, the manufacturer shall provide data to the Type Approval
Authority that demonstrates that the emissions reduction performance of such engines is
similar.
3.1.3. The test engine shall represent the emission deterioration characteristics of the engine families
that will apply the resulting deterioration factors for type approval. The engine manufacturer
shall select one engine representing the engine family, group of engine families or engine-after-
treatment system family, as determined in accordance with paragraph 3.1.2. of this Appendix,
for testing over the service accumulation schedule referred to in paragraph 3.2.2. of this
Appendix, which shall be reported to the Type Approval Authority before any testing
commences.
3.1.4. If the Type Approval Authority decides that the worst-case emissions of the engine family, group
of engine families or engine-after-treatment system family can be better characterised by
another test engine, the test engine to be used shall be selected jointly by the Type Approval
Authority and the engine manufacturer.

3.2. Determination of emission durability period deterioration factors

3.2.1. General
Deterioration factors applicable to an engine family, group of engine families or engine-after-
treatment system family shall be developed from the selected engines based on a service
accumulation schedule that includes periodic testing for gaseous and particulate emissions
over each test cycle applicable to the engine category.
3.2.1.1. At the request of the manufacturer, the Type Approval Authority may allow the use of
deterioration factors that have been established using alternative procedures to those specified
in paragraphs 3.2.2. to 3.2.5. of this Appendix. In that case, the manufacturer shall demonstrate
to the satisfaction of the Type Approval Authority that the alternative procedures used are not
less rigorous than those set out in paragraphs 3.2.2. to 3.2.5. of this Annex.
3.2.2. Service accumulation schedule
Service accumulation schedules may be carried out at the choice of the manufacturer by
running a Genset equipped with the selected engine over an "in-service" accumulation
schedule or by running the selected engine over a "dynamometer service" accumulation
schedule. The manufacturer shall not be required to use reference fuel for the service
accumulation in-between emission measurement test points.
3.2.2.1. In-service and dynamometer service accumulation
3.2.2.1.1. The manufacturer shall determine the form and duration of the service accumulation and the
ageing cycle for engines in a manner consistent with good engineering judgment.
3.2.2.1.2. The manufacturer shall determine the test points where gaseous and particulate emissions
will be measured over the applicable cycles, as follows:
3.2.2.1.2.1. When running a service accumulation schedule shorter than the emission durability period
in accordance with paragraph 3.2.2.1.7. of this Appendix, the minimum number of test points
shall be three, one at the beginning, one approximately in the middle and one at the end of
the service accumulation schedule.
3.2.2.1.2.2. When completing the service accumulation up to the end of the emission durability period,
the minimum number of test points shall be two, one at the beginning and one at the end of
the service accumulation.
3.2.2.1.2.3. The manufacturer may additionally test at evenly spaced intermediate points.

105
3.2.2.1.3. The emission values at the start point and at the emission durability period endpoint either
calculated in accordance with paragraph 3.2.5.1. of this Appendix or measured directly in
accordance with paragraph 3.2.2.1.2.2. of this Appendix, shall be within the limit values
applicable to the engine family. However individual emission results from the intermediate
test points may exceed those limit values.
3.2.2.1.4. Type Approval Authority to run only one test cycle (applicable 5-mode emission cycle) at each
test point
3.2.2.1.5. Reserved
3.2.2.1.6. Service accumulation schedules may be different for different engine-after-treatment system
families.
3.2.2.1.7. Service accumulation schedules may be shorter than the emission durability period, but shall
not be shorter than the equivalent of at least one quarter of the relevant emission durability
period as specified in below table
Emission durability period for Genset Engines > 19KW
Category (Power Band) Emission durability period (hours)
>19 ≤ 56 kW (constant speed Engines) 3000
>19 ≤ 56 KW (Variable speed Engines) 5000
> 56 kW (All engines) 8000
3.2.2.1.8. Accelerated ageing by adjusting the service accumulation schedule on a fuel consumption
basis is permitted. The adjustment shall be based on the ratio between the typical in-use
fuel consumption and the fuel consumption on the ageing cycle, but fuel consumption on the
ageing cycle shall not exceed typical in-use fuel consumption by more than 30 per cent.
3.2.2.1.9. At the request of the manufacturer and with the agreement of the Type Approval Authority,
alternative methods of accelerated ageing may be permitted.
3.2.2.1.10. The service accumulation schedule shall be fully described in the application for type-
approval and reported to the Type Approval Authority before the start of any testing.
3.2.2.2. If the Type Approval Authority decides that additional measurements need to be performed
between the points selected by the manufacturer it shall notify the manufacturer. The revised
service accumulation schedule shall be prepared by the manufacturer and agreed by the
Type Approval Authority.

3.2.3. Engine testing

3.2.3.1. Engine stabilisation
3.2.3.1.1. For each engine-after-treatment system family, the manufacturer shall determine the number
of hours of engine running (or a Genset application) after which the operation of the engine-
after-treatment system has stabilised. If requested by the Type Approval Authority, the
manufacturer shall make available the data and analysis used to make this determination.
As an alternative, the manufacturer may run the engine or a Genset between 60 and 125
hours or the equivalent time on the ageing cycle to stabilise the engine-after-treatment
system.
3.2.3.1.2. The end of the stabilisation period determined in paragraph 3.2.3.1.1. of this Appendix shall
be deemed to be the start of the service accumulation schedule.
3.2.3.2. Service accumulation testing
3.2.3.2.1. After stabilisation, the engine shall be run over the service accumulation schedule selected
by the manufacturer, as described in paragraph 3.2.2. of this Appendix. At the periodic
intervals in the service accumulation schedule determined by the manufacturer, and, where
applicable, decided by the Type Approval Authority in accordance with paragraph 3.2.2.2.
of this Appendix, the engine shall be tested for gaseous and particulate emissions over
steady state cycle as applicable to the engine category

106
 The manufacturer may select to measure the pollutant emissions before any exhaust after-
treatment system separately from the pollutant emissions after any exhaust after-treatment
system.
In accordance with paragraph 3.2.2.1.4. of this Appendix, if it has been agreed that only one
steady state test cycle (applicable 5-mode emission cycle) be run at each test point, at the
beginning and at the end of the service accumulation schedule.
3.2.3.2.2. During the service accumulation schedule, maintenance shall be carried out on the engine
in accordance with paragraph 3.4. of this Appendix.
3.2.3.2.3. During the service accumulation schedule, unscheduled maintenance on the engine may be
performed, for example if the manufacturer's normal diagnostic system has detected a
problem that would have indicated to genset operator that a fault had arisen.
3.2.4. Reporting
3.2.4.1. The results of all emission tests (applicable 5-mode emission cycle) conducted during the
service accumulation schedule shall be made available to the Type Approval Authority. If an
emission test is declared to be void, the manufacturer shall provide reasons why the test
has been declared void. In such a case, another series of emission tests shall be carried out
within the following 100 hours of service accumulation.
3.2.4.2. The manufacturer shall retain records of all information concerning all the emission tests
and maintenance carried out on the engine during the service accumulation schedule. This
information shall be submitted to the Type Approval Authority along with the results of the
emission tests conducted over the service accumulation schedule.
3.2.5. Determination of deterioration factors
3.2.5.1 When running a service accumulation schedule in accordance with paragraph 3.2.2.1.2.1.
or paragraph 3.2.2.1.2.3. of this Appendix, for each pollutant measured over the applicable
D2-5-mode emission cycle at each test point during the service accumulation schedule, a
"best fit" linear regression analysis shall be made on the basis of all test results. The results
of each test for each pollutant shall be expressed to the same number of decimal places as
the limit value for that pollutant, as applicable to the engine family, plus one additional
decimal place.
Where in accordance with paragraph 3.2.2.1.4. or paragraph 3.2.2.1.5. of this Appendix,
only one steady state test cycle (applicable 5-mode emission cycle) has been run at each
test point, the regression analysis shall be made only on the basis of the test results from
the test cycle run at each test point.
The manufacturer may request the prior approval of the Type Approval Authority for a non-
linear regression.
3.2.5.2. The emission values for each pollutant at the start of the service accumulation schedule and
at the emission durability period end point that is applicable for the engine under test shall
be either:
(a) determined by extrapolation of the regression equation in paragraph 3.2.5.1. of this
Appendix, when running a service accumulation schedule in accordance with
paragraph 3.2.2.1.2.1. or paragraph 3.2.2.1.2.3. of this Appendix, or
(b) measured directly, when running a service accumulation schedule in accordance with
paragraph 3.2.2.1.2.2. of this Appendix.
Where emission values are used for engine families in the same engine-after-treatment
family or group of engine families but with different emission durability periods, then the
emission values at the emission durability period end point shall be recalculated for each
emission durability period by extrapolation or interpolation of the regression equation as
determined in paragraph 3.2.5.1. of this Appendix.
3.2.5.3. The deterioration factor (DF) for each pollutant is defined as the ratio of the applied emission
values at the emission durability period end point and at the start of the service accumulation
schedule (multiplicative deterioration factor).

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 The manufacturer may request the prior approval of the Type Approval Authority for the
application of an additive DF for each pollutant may be applied. The additive DF is defined
as the difference between the calculated emission values at the emission durability period
end point and at the start of the service accumulation schedule.
An example for determination of DFs by using linear regression is shown in Figure A.8-1.
for NOX emission.
Mixing of multiplicative and additive DFs within one set of pollutants is not permitted.
If the calculation results in a value of less than 1.00 for a multiplicative DF, or less than 0.00
for an additive DF, then the deterioration factor shall be 1.0 or 0.00, respectively.
In accordance with paragraph 3.2.2.1.4. of this Appendix, if it has been agreed that only one
steady state test cycle (D2 5-mode) be run at each test point
Figure A.8-1.
Example of DF determination
0.50
Minimum service
accumulation Extrapolation

0.45

Limit value
0.40
NOx [g/kWh]

0.35
0.390 g/kWh

25% of EDP EDP endpoint

0.30
0.352 g/kWh

Multiplicative DF = 0.390 / 0.352 = 1.109

Additive DF = 0.390 – 0.352 = 0.038 g/kWh
0.25

0.20
0 1000 2000 3000 4000 5000 6000 7000 8000
Emission Durability Period (EDP) [h]

3.2.6. Assigned deterioration factors

3.2.6.1. As an alternative to using a service accumulation schedule to determine DFs, engine
manufacturers may select to use assigned multiplicative DFs, as given in Table A.6-1.

Table A.6-1.
Assigned deterioration factors
Deterioration Factors (DF)
Category (Power Band)
CO HC NOx PM
>19 kW
(Constant / Variable Speed 1.3 1.3 1.15 1.05
Engine)

Note: When opted for assigned multiplicative DF, no verification is required.

Assigned additive DFs shall not be given. The assigned multiplicative DFs shall not be
transformed into additive DFs.
3.2.6.2. Where assigned DFs are used, the manufacturer shall present to the Type Approval Authority
robust evidence that the emission control components can reasonably be expected to have the
emission durability associated with those assigned factors. This evidence may be based upon
design analysis, or tests, or a combination of both.
3.2.7. Application of deterioration factors

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3.2.7.1. The engines shall meet the respective emission limits for each pollutant, as applicable to the
engine family, after application of the deterioration factors to the test result as measured in
accordance with Annex 5 (cycle-weighted specific emission for particulate and each individual
gas). Depending on the type of DF, the following provisions apply:
(a) Multiplicative: (cycle weighted specific emission) * DF ≤ emission limit
(b) Additive: (cycle weighted specific emission) + DF ≤ emission limit
Cycle weighted specific emission may include the adjustment for infrequent regeneration,
where applicable.
3.2.7.2. For a multiplicative NOX + HC DF, separate HC and NOX DFs shall be determined and applied
separately when calculating the deteriorated emission levels from an emissions test result
before combining the resultant deteriorated NOX and HC values to establish compliance with
the emission limit.
3.2.7.3. The manufacturer may carry across the DFs determined for an engine-after-treatment system
family to an engine that does not fall into the same engine-after-treatment system family. In
such cases, the manufacturer shall demonstrate to the Type Approval Authority that the engine
for which the engine-after-treatment system family was originally tested and the engine for
which the DFs are being carried across have similar technical specifications and installation
requirements on the Genset and that the emissions of such engine are similar.
Where DFs are carried across to an engine with a different emission durability period, the DFs
shall be recalculated for the applicable emission durability period by extrapolation or
interpolation of the regression equation as determined in paragraph 3.2.5.1. of this Appendix.
3.2.7.4. The DF for each pollutant for each applicable test cycle shall be recorded in the test report set
out in Annexure 2.
3.3. Checking of conformity of production
3.3.1. Conformity of production for emissions compliance is checked on the basis clause 5.
3.3.2. The manufacturer may measure the pollutant emissions before any exhaust after-treatment
system at the same time as the type-approval test is being performed. For that purpose, the
manufacturer may develop informal DFs separately for the engine without after-treatment
system and for the after-treatment system that may be used by the manufacturer as an aid to
end of production line auditing.
3.3.3. For the purposes of approval, only the DFs determined in accordance with paragraph 3.2.5. or
3.2.6. of this Appendix shall be recorded in the test report set out in Annexure 2.
3.4. Maintenance
For the purpose of the service accumulation schedule, maintenance shall be performed in
accordance with the manufacturer's manual for service and maintenance.
3.4.1. Scheduled emission-related maintenance
3.4.1.1. Scheduled emission-related maintenance during engine running, undertaken for the purpose
of conducting a service accumulation schedule, shall occur at equivalent intervals to those that
are specified in the manufacturer's maintenance instructions to the end-user of the engine. This
schedule maintenance may be updated as necessary throughout the service accumulation
schedule provided that no maintenance operation is deleted from the maintenance schedule
after the operation has been performed on the test engine.
3.4.1.2. Any adjustment, disassembly, cleaning, or exchange of critical emission-related components
which is performed on a periodic basis within the emission durability period to prevent
malfunction of the engine, shall only be done to the extent that is technologically necessary to
ensure proper functioning of the emission control system. The need for scheduled exchange,
within the service accumulation schedule and after a certain running time of the engine, of
critical emission-related components other than those qualifying as routine exchange items
shall be avoided. In this context, consumable maintenance items for regular renewal or items
that require cleaning after a certain running time of the engine, shall qualify as routine exchange
items.

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3.4.1.3. Any scheduled maintenance requirements shall be subject to approval by the Type Approval
Authority before type-approval is granted and shall be included in the customer's manual. The
Type Approval Authority shall not refuse to approve maintenance requirements that are
reasonable and technically necessary, including but not limited to those identified in paragraph
3.4.1.4. of this Appendix.
3.4.1.4. The engine manufacturer shall specify for the service accumulation schedules any adjustment,
cleaning, maintenance (where necessary) and scheduled exchange of the following items:
 filters and coolers in the exhaust gas re-circulation system
 positive crankcase ventilation valve, if applicable
 fuel injector tips (only cleaning is permitted)
 fuel injectors
 turbocharger
 electronic engine control unit and its associated sensors and actuators
 particulate after-treatment system (including related components)
 NOX after-treatment system (including related components)
 exhaust gas re-circulation system, including all related control valves and tubing
 any other exhaust after-treatment system.
3.4.1.5. Scheduled critical emission-related maintenance shall only be performed if it is required to be
performed in-use and that requirement is communicated to the end-user of the engine.
3.4.2. Changes to scheduled maintenance
The manufacturer shall submit a request to the Type Approval Authority for approval of any
new scheduled maintenance that it wishes to perform during the service accumulation schedule
and subsequently to recommend to end-users of engines. The request shall be accompanied
by data supporting the need for the new scheduled maintenance and the maintenance interval.
3.4.3. Non-emission-related scheduled maintenance
Non-emission-related scheduled maintenance which is reasonable and technically necessary
(for example oil change, oil filter change, fuel filter change, air filter change, cooling system
maintenance, idle speed adjustment, governor, engine bolt torque, valve lash, injector lash,
adjustment of the tension of any drive-belt, etc.) may be performed on engines selected for the
service accumulation schedule at the least frequent intervals recommended by the
manufacturer to the end-user (for example not at the intervals recommended for severe
service).
3.5. Repair
3.5.1. Repairs to the components of an engine selected for testing over a service accumulation
schedule shall be performed only as a result of component failure or engine malfunction. Repair
of the engine itself, the emission control system or the fuel system is not permitted except to
the extent defined in paragraph 3.5.2. of this Appendix.
3.5.2. If the engine, its emission control system (includes Oxidation catalyst, De-NOx catalyst,
particulate filters) or its fuel system fails during the service accumulation schedule, the service
accumulation shall be considered void, and a new service accumulation shall be started with a
new engine.
The previous paragraph shall not apply when the failed components are replaced with
equivalent components that have been subject to a similar number of hours of service
accumulation.

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 Appendix – 7

Procedure for the Measurement & calculation of Ammonia Emissions

1. Ammonia measurement equipment shall be as per the guideline given in the ISO-8178-1: 2017,
2020 Reciprocating internal combustion engines — Exhaust emission measurement — Part 1: Test-
bed measurement systems of gaseous and particulate emission.

2. Ammonia measurement procedure & calculation shall be as per the guideline given in the ISO-
8178-4: 2017, 2020 Reciprocating internal combustion engines — Exhaust emission measurement
— Part 4: Steady-state and transient test cycles for different engine applications.

Appendix – 8

Method of test execution and measurement procedures. Procedure for

developing the infrequent regeneration adjustment factor (IRAFs) for engine
with exhaust after-treatment system

Method of test execution and measurement procedures shall be as per the guideline given in the
ISO-8178-4: 2017, 2020 Reciprocating internal combustion engines — Exhaust emission measurement
— Part 4: Steady-state and transient test cycles for different engine applications

111
 Appendix – 9

Test Procedure for Emission measurement from Variable Speed Diesel

Engines for Power generating set

Variable Speed Genset Engine

Normally all equipment operating at 30% below its maximum power uses a fictitious dummy load
resistance to prevent damage; whereas these types of equipment can operate at 30% below its
maximum power without any problem.
Variable speed hybrid generator sets that reduce fuel consumption by 40% compared to a standard
generator set and 20% when compared with other fixed speed, hybrid Gensets currently available on
the market and extend maintenance periods up to 1000 hours. These hybrid Gensets provide 48 DC
for telecom applications. In addition, this equipment has a 230 AC auxiliary power output. No doubt,
these type of Gensets are perfectly designed to meet the needs of the telecommunications sector,
optimising resources, reducing consumption, ensuring an Eco-friendly system, extending maintenance
periods, and lengthening the useful life of the product.

1.0 Introduction
In the present scenario of application of Diesel Genset Engines, the requirement of variable speed
diesel genset is increasing where variable frequency of electricity is converted into constant frequency
and better fuel economy is anticipated. Hence, a test procedure is required for emission compliance
testing of variable speed diesel genset engines/Gensets.

2.0 Variable Speed Diesel Genset System Description

Variable speed diesel generating set consists of a variable speed diesel engine, axial flux Permanent
Magnet Generator or Alternator (PMG or PMA) and power electronic converters. An electronic controller
(DSP processor) controls output three phase sinusoidal voltage and adjusts engine speed according to
actual load demand. For variable speed genset system, power electronic converters are used to convert
variable-frequency variable voltage output to a constant voltage constant frequency output.
The block diagram of overall variable speed power generation system is shown in Figure 1 and Figure
2. A Permanent Magnet Generator or Alternator (PMG or PMA) is driven by a variable speed engine
and it generates a variable frequency and variable amplitude AC voltage which is fed to power electronic
converters (AC/AC converter, Rectifier, Inverter, Transformer etc.). The converter produces constant
frequency three-phase sinusoidal constant voltage which is used for end load. Some part of this
electricity is used as internal load to run engine fan, cooling motor, control panel etc. A system controller
is used to control and monitor complete generating set. When no load is applied then the engine
operates at a predefined minimum speed. When load increases then the controller runs the engine at
an optimum speed to get best fuel consumption assuring a balance between power demand and power
delivered by the engine.
The advantages of these sets over constant speed conventional generating set are mainly lighter in
weight, smaller in size and enhanced fuel economy.

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 Figure 1. Block diagram of overall variable speed power generation system

Figure 2. Block diagram of a variable speed diesel genset system

Test Cycle, Procedure & Equipment

3.1 The testing shall be done on engines with engine dynamometer. In case of import of complete
genset, the engine shall be decoupled to test with engine dynamometer. The testing shall be
done as per the following 5-mode cycle.
Test modes and weighting factors

Mode No Engine Speed % Power Weighting factor

Declared Speed
1 100 0.05
(Rated speed)

2 Declared Speed 75 0.25

3 Declared Speed 50 0.30

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 4 Declared Speed 25 0.30

5 Declared Speed 10 0.10

3.2 The engine manufacturer shall declare rated speed, rated power, and part load speeds of the
engine. The part loads shall be as mentioned in above table. The part load speeds shall be verified
on actual working condition at manufacturer’s place by Certification Agency before dismantling
the set and submitting the engine for emission test. All the electronic equipment used for the
measurement various testing shall be duly calibrated. The calibration requirement of the
equipment other than mentioned in ISO 8178 -1 in this testing activity shall be as per IS
1248.2.2003 and IS 1248.4.
3.3 The engine shall be mounted on engine dynamometer and testing will be done as per the above
cycle.
3.4 Testing shall be done with reference diesel fuel as per the specification given in annexure I of the
main document. The fuel inlet temperature shall be maintained at 38±5 Deg C throughout the test.
3.5 Declared rated corrected Power
(i) For Type Approval:
 For single cylinder engines, ± 5% at rated & part load power points
 For all other engines, ± 4 % at rated & part load power points

(ii) For Conformity of Production:

 For single cylinder engines, at rated & part load power point, ± 6% of the type approved
figure
 For all other engines, at rated & part load power point, ± 5% of the type approved figure

Declared rated and part load speeds shall vary within ± 1% 3.6 Calculation of gross mechanical
power at rated speed
3.6 Calculation of gross mechanical power at rated speed
Manufacturer has to declare the gross mechanical power and final electrical power (kVA rating)
for testing the engine on test bench considering the losses at all stages up to final output.
Losses at PMG/PMA, Rectifier, Inverter, Transformer + Internal load if any (Fan, Cooling pump,
control panel) etc. to be considered
Total Efficiency = Efficiency of PMA/PMG x Efficiency of Rectifier x Efficiency of Inverter x
Efficiency of Transformer x Efficiency of any other power electronic converters
Gross mechanical power in kW = (kVA x PF)/ (Total Efficiency) + (Internal Load in kW)/ (Total
Efficiency)
Where,
kVA = Electrical power output
PF = Power Factor

Electrical Power output, at all declared speed and load conditions of the variable speed
generator set with all necessary power electronic converters will be verified on actual working
condition at manufacturer’s place by certification agency. Manufacturers shall submit
supporting documents (duly certified and attested by the manufacturer/supplier) for efficiencies
of various power electronic converters connected in the line starting from engine end upto final
output. This data is required to calculate the gross mechanical power of the engine to be set
for emission test on test bench.
The actual electrical power output at all the test points shall be verified at manufacturer’s place
should be within ± 5 % (for single cylinder engines) or ± 4 % (for all other engines) of the
declared electrical power (kVA rating).
Example:
Electrical power output at rated speed = 50 kVA
Efficiencies:
Efficiency of PMA = 0.97
Efficiency of Invertor = 0.95
Efficiency of Transformer = 0.96

Total Efficiency = 0.97 x 0.95 x 0.96 = 0.885

Power Factor (PF) = 0.95

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 Internal Load in kW:
Fan, Cooling pump, control panel = 5 kW

Gross mechanical power in kW = (50 x 0.95)/0.885 + 5/0.885 = 59.3 kW

Manufacturer has to declare gross mechanical power in such a way that both “gross mechanical
power in kW as observed on the engine test bench” and “calculated gross mechanical power
(calculated by efficiencies applied to the observed electrical power at rated speed as declared
by the manufacturer)” should remain within ± 5 % (for single cylinder engines) or ± 4 % (for all
other engines) of the declared gross mechanical power.
3.7 Test Equipment, setup, procedure, calculation method and other relevant technical details to be
used shall be as mentioned in the main document “SYSTEM & PROCEDURE FOR
COMPLIANCE TO EMISSION LIMITS FOR NEW DIESEL ENGINES (UP TO 800 KW) FOR
GENSET APPLICATIONS”, except where it is mentioned, specifically, in this document.
Note: As the number of variable speeds generating set engines in the field are very few, the document,
test cycle and the test procedure for these engines is prepared based on the actual usage
pattern conditions on the set in the site with a limited data availability. Hence this document,
test cycle and test procedure shall be reviewed and revised if found necessary based on the
testing experience.

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 ANNEXURE – 8

Requirements regarding emission control strategies, NOX control

measures and particulate control measures

1. Definitions abbreviations and general requirements

1.1. For the purposes of this Annex, the following definitions and abbreviations apply:
(a) "diagnostic trouble code ("DTC")" means a numeric or alphanumeric identifier which
identifies or labels a NCM and/ PCM;
(b) "confirmed and active DTC" means a DTC that is stored during the time the NCD and/or
PCD system concludes that a malfunction exists;
(c) "NCD engine family" “means a manufacturer's grouping of engines having common
methods of monitoring/diagnosing NCMs
(d) "NOX Control Diagnostic system (NCD)" means a system on-board the engine/control
room which has the capability of
(i) detecting a NOX Control Malfunction,
(ii) identifying the likely cause of NOX control malfunctions by means of information
stored in computer memory and/or communicating that information off-board;
(e) "NOX Control Malfunction (NCM)" means an attempt to tamper with the NO X control
system of an engine or a malfunction affecting that system that might be due to
tampering, that is considered by this Regulation as requiring the activation of a warning
or an inducement system once detected;
(f) “Particulate Control Diagnostic system (PCD)” means a system on-board the
engine/control room which has a capability of:
(i) detecting a Particulate Control Malfunction,
(ii) identifying the likely cause of particulate control malfunctions by means of
information stored in computer memory and/or communicating that information
off-board;
(g) "Particulate Control Malfunction (PCM)" means an attempt to tamper with the
particulate after-treatment system of an engine or a malfunction affecting the particulate
after-treatment system that might be due to tampering, that is considered by this
Regulation as requiring the activation of a warning once detected;
(h) “PCD engine family” means a manufacturer’s grouping of engines having common
methods of monitoring/diagnosing PCMs;
(i) "Scan-tool" means an external test equipment used for off-board communication with
the NCD and/or PCD system.
1.2. Ambient temperature
Where reference is made to ambient temperature in relation to environments other than a
laboratory environment, the following provisions shall apply:
1.2.1 For an engine installed in a test-bed, ambient temperature shall be the temperature of the
combustion air supplied to the engine, upstream of any part of the engine being tested.

1.2.2 For an engine installed in Genset, ambient temperature shall be the air temperature immediately
outside the perimeter of the Genset. Manufacture may opt to consider temperature inside genset
enclosure as an ambient temperature for certain diagnostics in consultation with type approval
agency and using sound Engineering judgement.

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2. Technical requirements relating to emission control strategies
2.1. This paragraph 2. shall apply for electronically controlled genset engines of all powered
category complying with the emission limits set out in clause 3 of this Regulation and using
electronic control to determine both the quantity and timing of injecting fuel or using electronic
control to activate, de-activate or modulate the emission control system used to reduce NOx.
2.2. Requirements for base emission control strategy
2.2.1 The base emission control strategy shall be designed as to enable the engine, in normal use,
to comply with the provisions of this Regulation. Normal use is not restricted to the control
conditions as specified in paragraph 2.4.
2.2.2. Base emission control strategies are, but not limited to, maps or algorithms for controlling:
(a) timing of fuel injection or ignition (engine timing);
(b) exhaust gas recirculation (EGR);
(c) SCR catalyst reagent dosing.
2.2.3. Any base emission control strategy that can distinguish engine operation between a
standardised approval test and other operating conditions and subsequently reduce the level
of emission control when not operating under conditions substantially included in the approval
procedure is prohibited.
2.2.3.1. Reserved
2.2.4 The manufacturer shall demonstrate to the technical agency at the time of the type-approval
test that the operation of the base emission control strategy complies with the provisions of this
section. The demonstration shall consist of an evaluation of the documentation referred to in
paragraph 2.6. of this Annex. The manufacturer shall comply with the documentation
requirements laid down in paragraph 1.4. of Annex 1 and Appendix A.2 to that Annex.
2.3. Requirements for auxiliary emission control strategy.
2.3.1 An auxiliary emission control strategy may be activated by an engine or Genset, provided that
the auxiliary emission control strategy:
2.3.1.1. does not permanently reduce the effectiveness of the emission control system;
2.3.1.2. operates only outside the control conditions specified in paragraphs 2.4.3. of this Annex for the
purposes defined in paragraph 2.3.5. of this Annex and only as long as is needed for those
purposes, except as permitted by paragraphs 2.3.1.3., 2.3.2. and 2.3.4. of this Annex;
2.3.1.3. is activated only exceptionally within the control conditions in paragraphs 2.4.3. of this Annex,
respectively, has been demonstrated to be necessary for the purposes identified in paragraph
2.3.5. of this Annex has been approved by the Type Approval Authority, and is not activated for
longer than is needed for those purposes;
2.3.1.4. ensures a level of performance of the emission control system that is as close as possible to
that provided by the base emission control strategy;
2.3.2. Where the auxiliary emission control strategy is activated during the type-approval test,
activation shall not be limited to occur outside the control conditions set out in paragraph 2.4.
of this Annex, and the purpose shall not be limited to the criteria set out in paragraph 2.3.5. of
this Annex.
2.3.3. Where the auxiliary emission control strategy is not activated during the type-approval test, it
must be demonstrated that the auxiliary emission control strategy is active only for as long as
required for the purposes set out in paragraph 2.3.5. of this Annex.
2.3.4. Cold temperature operation.

117
 An auxiliary emission control strategy may be activated on an engine equipped with exhaust
gas recirculation (EGR) irrespective of the control conditions in paragraph 2.4. of this Annex if
the ambient temperature is below 275 K (2 °C) and one of the two following criteria is met:
(a) intake manifold temperature is less than or equal to the temperature defined by the
following equation: IMTc = PIM / 15.75 + 304.4, where: IMTc is the calculated intake
manifold temperature, K and PIM is the absolute intake manifold pressure in kPa;
(b) engine coolant temperature is less than or equal to the temperature defined by the
following equation: ECTc = PIM / 14.004 + 325.8, where: ECTc is the calculated engine
coolant temperature, K and PIM is the absolute intake manifold pressure, kPa.
2.3.5. Except as permitted by paragraph 2.3.2. of this Annex, an auxiliary emission control strategy
may solely be activated for the following purposes:
(a) by on-board signals, for protecting the engine (including air-handling device protection)
and/or Genset into which the engine is installed from damage;
(b) for operational safety reasons;
(c) for prevention of excessive emissions, during cold start or warming-up, during shut-
down;
(d) if used to trade-off the control of one regulated pollutant under specific ambient or
operating conditions, for maintaining control of all other regulated pollutants, within the
emission limit values that are appropriate for the engine concerned. The purpose is to
compensate for naturally occurring phenomena in a manner that provides acceptable
control of all emission constituents.
2.3.6. The manufacturer shall demonstrate to the technical agency at the time of the type-approval
test that the operation of any auxiliary emission strategy complies with the provisions of this
paragraph. The demonstration shall consist of an evaluation of the documentation referred to
in paragraph 2.6. of this Annex.
2.3.7. Any operation of an auxiliary emission control strategy non-compliant with paragraphs 2.3.1. to
2.3.5. of this Annex is prohibited.
2.4. Control conditions
The control conditions specify an altitude, ambient temperature and engine coolant range that
determines whether auxiliary emission control strategies may generally or only exceptionally
be activated in accordance with paragraph 2.3. of this Annex.
The control conditions specify an atmospheric pressure which is measured as absolute
atmospheric static pressure (wet or dry) ("Atmospheric pressure")
2.4.1. Reserved
2.4.2. Reserved
2.4.3. Control conditions for engines of power bands 56 ≤ P < 800 kW
(a) the atmospheric pressure greater than or equal to 82,5 kPa;
(b) the ambient temperature within the following range:
(i) equal to or above 273K (0 °C)
(ii) less than or equal to the temperature determined by the following equation at
the specified atmospheric pressure: Tc = -0.4514 • (101.3 – Pb) + 311, where:
Tc is the calculated ambient air temperature, K and Pb is the atmospheric
pressure, kPa; (With Ambient pressure Pb 100kPa, Tc=38.58 °C and Pb
82.5kPa, Altitude at 1700 meter /5500 feet, Tc=46.5 °C)
(c) the engine coolant temperature above 343 K (70 °C).
Where the auxiliary emission control strategy is activated when the engine is operating
within the control conditions set out in points (i), (ii) and (c), the strategy shall only be

118
 activated when demonstrated to be necessary for the purposes identified in clause
5.3.2.2.3. below and approved by the Test Agency.
2.5. Where the engine inlet air temperature sensor is being used to estimate ambient air
temperature the nominal offset between the two measurement points shall be evaluated for an
engine type or engine family. Where used, the measured intake air temperature shall be
adjusted by an amount equal to the nominal offset to estimate ambient temperature for an
installation using the specified engine type or engine family.
The evaluation of the offset shall be made using good engineering judgement based on
technical elements (calculations, simulations, experimental results, data etc.) including:
(a) the typical Genset enclosures into which the engine type or engine family will be
installed; and,
(b) the installation instructions provided to the OEM by the manufacturer.
A copy of the evaluation shall be made available to the Type Approval Authority upon request.
2.6. Documentation requirements
2.6.1 The manufacturer shall comply with the documentation requirements laid down in Annexure 1
2.6.2 The manufacturer shall ensure all documents used for this purpose are marked with an
identification number and date. Whenever particulars recorded are changed the relevant pages
shall be marked to clearly show the date of revision and the nature of the amendment. A
consolidated, updated version, accompanied by a detailed description of the amendments,
shall be deemed to fulfil the requirement of this paragraph. /Clause
3. Technical requirements relating to NOX control measures
3.1. Clause 3. of this Annex shall apply to electronically controlled engines complying with the
emission limits set out in clause 3 of this Regulation and using electronic control to determine
both the quantity and timing of injecting fuel or using electronic control to activate, de-activate
or modulate the emission control system used to reduce NOX.
3.2. The manufacturer shall provide complete information on the functional operational
characteristics of the NOX control measures using the documents set out in Annexure 1.
3.3. The NOX control strategy shall be operational under all environmental conditions regularly
occurring in India especially at low ambient temperatures.
3.4. The manufacturer shall demonstrate that the emission of ammonia during the applicable
emission test cycle of the type approval procedure, when a reagent is used, does not exceed
a mean value of 10 ppm for >56 kW & 25 ppm for <56 kW engine categories.
3.5. For reagent containers installed on a genset/engine, means for taking a sample of the reagent
inside the containers must be included. The sampling point must be easily accessible without
requiring the use of any specialised tool or device.
3.6 In addition to the requirements set out in clauses 3.2. to 3.5. of this Annex, the technical
requirements set out in Appendix A.1 of this Annex shall apply for engines.

4. Technical requirements relating to particulate pollutant control measures.

4.1. This paragraph shall apply to engines of sub-categories subject to meet particulate emission
limits in accordance with the emission limits set out in clause 3 of this Regulation fitted with a
particulate after-treatment system. In cases where the NOX control system and the particulate
control system share the same physical components (e.g. same substrate (SCR on filter), same
exhaust temperature sensor) the requirements of this paragraph shall not apply to any
component or malfunction where, after consideration of a reasoned assessment provided by
the manufacturer, the Type Approval Authority concludes that a particulate control malfunction
within the scope of this paragraph would lead to a corresponding NOX control malfunction within
the scope of paragraph 3. of this Annexure.
4.2. The detailed technical requirements relating to particulate pollutant control measures are
specified in Appendix A.2 of this Annex

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 Appendix – A.1

Additional technical requirements on NOx control measures for engines,

including the method to demonstrate these strategies

A.1.1. Introduction
This Appendix sets out the additional requirements to ensure the correct operation of NOX
control measures. It includes requirements for engines that rely on the use of a reagent in order
to reduce emissions. The type approval shall be made conditional upon the application of the
relevant provisions on engine/genset operator or genset control room instruction, installation
documents, operator warning system, inducement system and reagent freeze protection that
are set out in this Appendix.
A.1.2. General requirements
The engine shall be equipped with a NOX Control Diagnostic system (NCD) able to identify the
NOX control malfunctions (NCMs). Any engine covered by this paragraph shall be designed,
constructed and installed so as to be capable of meeting these requirements throughout the
normal life of the engine under normal conditions of use. In achieving this objective, it is
acceptable that engines which have been used in excess of the emission durability period as
specified in Appendix 6 to Annexure 7 of this Regulation show some deterioration in the
performance and the sensitivity of the NOX Control Diagnostic system (NCD), such that the
thresholds specified in this Annexure may be exceeded before the warning and/or inducement
systems are activated.
A.1.2.1. Required information
A.1.2.1.1. If the emission control system requires a reagent, the type of reagent, information on
concentration when the reagent is in solution, its operational temperature conditions a
reference to international standards for composition and quality and other
characteristics of that reagent shall be specified by the manufacturer in accordance
with Appendix A.3 of Annexure 1.
A.1.2.1.2. Detailed written information fully describing the functional operation characteristics of
the engine or genset operator/genset control room warning system set out in paragraph
A.1.4. of this Annexure and of the operator inducement system set out in paragraph
A.1.5. of this Annexure shall be provided to the Type Approval Authority at the time of
approval.
A.1.2.1.3. The manufacturer shall provide the OEM with documents with instructions on how to
install the engine in the Genset in such manner that the engine, its emission control
system and the Genset parts, operate in conformity with the requirements of this
Appendix. This documentation shall include the detailed technical requirements of the
engine (software, hardware, and communication) needed for the correct installation of
the engine in the Genset application.
A.1.2.2. Operating conditions
A.1.2.2.1. Monitoring for reagent level in the storage tank shall be conducted under all conditions
where measurement is technically feasible (for instance, under all conditions when a
liquid reagent is not frozen).
A.1.2.2.2. Reagent freeze protection shall apply at ambient temperatures at or below 273K (0 °C).
A.1.2.2.3. All elements of the NOX control diagnostic system other than those listed in paragraphs
A.1.2.2.1. and A.1.2.2.2. of this Annexure shall, at a minimum be operational at the
applicable control conditions set out in paragraph 2.4 of this Annexure for each engine
category. The diagnostic system shall remain operational outside of this range where
technically possible.
A.1.2.3. Reagent freeze protection

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A.1.2.3.1. It is permitted to use a heated or a non-heated reagent tank and dosing system. A
heated system shall meet the requirements of paragraph A.1.2.3.2.2. of this Annexure.
A non-heated system shall meet the requirements of paragraph A.1.2.3.2.3. of this
Annexure.
A.1.2.3.1.1. The use of a non-heated reagent tank and dosing system shall be indicated in the
written instructions to the end-user of the Genset.
A.1.2.3.2. Reagent tank and dosing system
A.1.2.3.2.1. If the reagent has frozen, the reagent shall be available for use within a maximum of
70 minutes after the start of the engine at or above 273 K (0 °C) ambient temperature.
A.1.2.3.2.2. Design criteria for a heated system
A heated system shall be so designed that it meets the performance requirements set
out in this paragraph A.1.2.3.2. when tested using the procedure defined.
Demonstration test at the time of type approval is not mandatory.
A.1.2.3.2.2.1. The reagent tank and dosing system shall be soaked at 255 K (- 18°C) for 72 hours or
until the reagent becomes solid, whichever occurs first.
A.1.2.3.2.2.2. After the soak period set out in paragraph A.1.2.3.2.2.1. of this Annexure, the Genset
engine shall be started and operated at 266 K (- 7 °C) ambient temperature or lower
as follows:
(a) 10 to 20 minutes idling, followed by
(b) up to 50 minutes at no more than 40 per cent of rated torque.
A.1.2.3.2.2.3. At the conclusion of the test procedure set out in paragraph A.1.2.3.2.2.2. of this
Annexure, the reagent dosing system shall be fully functional.
A.1.2.3.2.2.4. Evaluation of the design criteria may be performed in a cold chamber test cell using an
entire Genset or parts representative of those to be installed on such machinery or
based on field tests.
A.1.2.3.2.3. Activation of the operator warning and inducement system for a non-heated system
A.1.2.3.2.3.1. The operator warning system described in paragraph A1.4 of this Annexure shall be
activated if no reagent dosing occurs at an ambient temperature >= 273 K ( 0°C).
A.1.2.3.2.3.2. The Operator inducement system described in paragraph A1.5. of this Annexure shall
be activated if no reagent dosing occurs within a maximum of 70 minutes after engine
start at an ambient temperature >= 273 K (0°C).
A.1.2.4. Diagnostic requirements
A.1.2.4.1. The NOX Control Diagnostic system (NCD) shall be able to identify the NOX control
malfunctions (NCMs) by means of Diagnostic Trouble Codes (DTCs) stored in the
computer memory and to communicate that information off-board upon request.
A.1.2.4.2. Requirements for recording Diagnostic Trouble Codes (DTCs)
A.1.2.4.2.1. The NCD system shall record a DTC for each distinct NOX Control Malfunction (NCM).
A.1.2.4.2.2. The NCD system shall conclude within 60 minutes of engine operation whether a
detectable malfunction is present. At this time, a "confirmed and active" DTC shall be
stored and the warning system be activated according to paragraph A.1.4. of this
Annex.
A.1.2.4.2.3. In cases where more than 60 minutes running time is required for the monitors to
accurately detect and confirm a NCM (e.g. monitors using statistical models or with
respect to fluid consumption on the Genset), the Type Approval Authority may permit
a longer period for monitoring provided the manufacturer justifies the need for the
longer period (for example by technical rationale, experimental results, in house
experience, etc.).
A.1.2.4.3. Requirements for erasing Diagnostic trouble codes (DTCs)

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 (a) DTCs shall not be erased by the NCD system itself from the computer memory
until the failure related to that DTC has been remedied.
(b) The NCD system may erase all the DTCs upon request of a proprietary scan
or maintenance tool that is provided by the engine manufacturer upon request,
or using a pass code provided by the engine manufacturer.
A.1.2.4.4. An NCD system shall not be programmed or otherwise designed to deactivate partially
or totally based on age of Genset during the actual life of the engine, nor shall the
system contain any algorithm or strategy designed to reduce the effectiveness of the
NCD system over time.
A.1.2.4.5. Any reprogrammable computer codes or operating parameters of the NCD system shall
be resistant to tampering.
A.1.2.4.6. NCD engine family
The manufacturer is responsible for determining the composition of an NCD engine
family. Grouping engines within an NCD engine family shall be based on good
engineering judgment and be subject to approval by the Type Approval Authority.
Engines that do not belong to the same engine family may still belong to the same NCD
engine family.
A.1.2.4.6.1. Parameters defining an NCD engine family
An NCD engine family is characterized by basic design parameters that shall be
common to engines within the family.
In order that engines are considered to belong to the same NCD engine family, the
following list of basic parameters shall be similar:
(a) emission control systems;
(b) methods of NCD monitoring;
(c) criteria for NCD monitoring;
(d) monitoring parameters (e.g. frequency).
These similarities shall be demonstrated by the manufacturer by means of relevant
engineering demonstration or other appropriate procedures and subject to the approval
of the Type Approval Authority.
The manufacturer may request approval by the Type Approval Authority of minor
differences in the methods of monitoring/diagnosing the NCD system due to engine
configuration variation, when these methods are considered similar by the
manufacturer and they differ only in order to match specific characteristics of the
components under consideration (for example size, exhaust gas flow, etc.); or their
similarities are based on good engineering judgment.

A.1.3. Maintenance requirements

A.1.3.1. The OEM shall provide to all end-users of genset written instructions about the
emission control system and its correct operation in accordance with Appendix 2 of
Annexure 9.
A.1.4. Operator or control room warning system
A.1.4.1. The genset shall include an operator or control room warning system using visual and
audible component that informs the operator when a low reagent level, incorrect
reagent quality, interruption of dosing or a malfunction specified in clause A.1.9. of this
Annexure has been detected that will lead to activation of the operator inducement
system if not rectified in a timely manner. The warning system shall remain active when
the operator inducement system described in paragraph A.1.5. of this Annexure has
been activated.

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A.1.4.2. The warning shall not be the same as the warning used for the purposes of malfunction
or other engine maintenance, though it may use the same warning system.
A.1.4.3. The operator warning system may consist of one or more lamps, or display short
messages, which may include, for example, messages indicating clearly:
(a) the remaining time before activation of the low-level and / or severe inducements,
(b) the amount of low-level and / or severe inducement, for example the amount of
torque reduction or effective disablement of operation.,
(c) the conditions under which Genset disablement can be cleared.
Where messages are displayed, the system used for displaying these messages may
be the same as the one used for other maintenance purposes.
A.1.4.4. The warning system shall include an audible component to alert the operator in line
with A.1.14 of this Annexure. The cancelling of audible warnings by the operator shall
be permitted. An audible alarm system must be activated at minimum when the
operator inducement system described in paragraph A.1.5. of this Annexure has been
activated.
A.1.4.5. The operator warning system shall be activated as specified in paragraphs
A.1.2.3.2.3.1., A.1.6.2., A.1.7.2., A.1.8.3., and A.1.9.3. of this Annexure respectively.
A.1.4.6. The operator warning system shall be deactivated when the conditions for its activation
have ceased to exist. The operator warning system shall not be automatically
deactivated without the reason for its activation having been remedied.
A.1.4.7. The warning system may be temporarily interrupted by other warning signals providing
important safety related messages.
A.1.4.8. Details of the operator warning system activation and deactivation procedures are
described in paragraph A.1.11. of this Annexure.
A.1.4.9. As part of the application for approval under this Regulation, the manufacturer shall
demonstrate the operation of the operator warning system, as specified in paragraph
A.1.10. of this Annexure.
A.1.5. Operator inducement system
A.1.5.1. The engine shall incorporate an operator inducement system based on one of the
following principles:
A.1.5.1.1. a two-stage inducement system starting with a low-level inducement Audio-Visual
Alarm followed by a severe inducement (effective disablement of Genset operation);
A.1.5.1.2. a one-stage severe inducement system (effective disablement of Genset operation)
activated under the conditions of a low-level inducement system as specified in
paragraphs A.1.6.3.1., A.1.7.3.1., A.1.8.4.1., and A.1.9.4.1. of this Annexure.
Where the manufacturer elects to shut down the engine to fulfil the requirement for
one-stage severe inducement then the inducement for reagent level may, at the choice
of the manufacturer, be activated under the conditions of paragraph A.1.6.3.2. of this
Annexure instead of the conditions of paragraph A.1.6.3.1. of this Annexure.
A.1.5.2. Reserved
A.1.5.3. Low-level inducement system
A.1.5.3.1. The low-level inducement system shall be activated after any of the conditions specified
in paragraphs A.1.6.3.1., A.1.7.3.1., A.1.8.4.1., and A.1.9.4.1. of this Annexure has
occurred.
A.1.5.3.2. For variable speed genset engines, the low-level inducement system shall the Audio-
Visual Alarm
A.1.5.3.3. For constant speed engines, low level inducement shall the Audio-Visual Alarm
A.1.5.3.4. Other inducement measures that are demonstrated to the Type Approval Authority as
having the same or greater level of severity may be used.

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A.1.5.4. Severe inducement system
A.1.5.4.1. The severe inducement system shall be activated after any of the conditions specified
in paragraphs A.1.2.3.2.3.2., A.1.6.3.2., A.1.7.3.2., A.1.8.4.2., and A.1.9.4.2. of this
Annexure has occurred.
A.1.5.4.2. The severe inducement system shall effectively disable Genset operation to cause the
operator to remedy any problems related to paragraphs A.1.6. to A.1.9. of this
Annexure. The following strategy shall be applied:
(a) Strategy A:
An audio/visual warning and a grace period of 72 hours after which the severe
inducement will effectively disable Genset operation to cause the operator to remedy
any problems related to paragraphs A.1.6. to A.1.9. of this Annexure. (To mention no
torque de-rate with this severe inducement strategy)
(b) Strategy B:
An audio/visual warning with a torque de-rate of minimum 50% and a grace period of
120 hours after which the severe inducement will effectively disable Genset operation
to cause the operator to remedy any problems related to paragraphs A.1.6. to A.1.9. of
this Annexure.

A.1.5.4.2.1. Genset engines, torque between the peak torque speed and the governor breakpoint
shall be gradually reduce to zero torque and Minimum speed of 1 per cent per minute
to zero percent of maximum torque within same time to speed reduction to Minimum
speed and for variable speed engines the engine speed shall be gradually reduced to
Minimum speed within the same time as the torque reduction.
Genset with severe-inducement condition activated when shut down; shall not start in
next attempt barring activation of operator overrides described in paragraph A.1.5.5. of
this annexure.
A.1.5.4.2.2. Manufacturer may have option for direct disablement of engine after key off without
going to torque / torque and speed de-rate schedule for severe level inducement as
described in paragraph A.1.5.4.2.1 of this Annexure.
A.1.5.4.2.3. Other inducement measures that are demonstrated to the Type Approval Authority as
having the same or greater level of severity may be used.
A.1.5.5. In order to account for safety concerns and to allow for self-healing diagnostics, use of
an inducement override function for releasing full engine power is permitted provided it
(a) is limited to 3 activations during each activation period that the operator inducement
system is active and
(b) each activation period is limited to 30 minutes
A.1.5.6. The operator inducement system shall be deactivated when the conditions for its
activation have ceased to exist. The operator inducement system shall not be
automatically deactivated without the reason for its activation having been remedied.
A.1.5.7. Details of the operator inducement system activation and deactivation procedures are
described in paragraph A.1.11. of this Annexure.
A.1.5.8. As part of the application for approval under this Regulation, the manufacturer shall
demonstrate the operation of the operator inducement system, as specified in clause
A.1.10. of this Annexure.
A.1.6. Reagent Availability
A.1.6.1. Reagent level indicator
The genset/engine shall include an indicator that clearly informs the operator /control
room of the level of reagent in the reagent storage tank. The minimum acceptable
performance level for the reagent indicator is that it shall continuously indicate the
reagent level whilst the operator warning system referred to in paragraph A.1.4. of this

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 Annexure is activated. The reagent indicator may be in the form of an analogue or
digital display, and may show the level as a proportion of the full tank capacity, the
amount of remaining reagent, or the estimated operating hours remaining
Additionally, remote information and monitoring system described in Appendix 4 of this
Annexure where applicable shall provide with reagent level information at least when
operator warning system referred to in paragraph A.1.4. of this Annexure is activated.
A.1.6.2. Activation of the operator warning system
A.1.6.2.1. The operator warning system specified in paragraph A.1.4. of this Annexure shall be
activated when the level of reagent goes below 10 per cent of the capacity of the
reagent tank or a higher percentage at the choice of the manufacturer.
A.1.6.2.2. The warning provided shall be sufficiently clear, in conjunction with the reagent
indicator, for the operator to understand that the reagent level is low. When the warning
system includes a message display system, the visual warning shall display a message
indicating a low level of reagent. (for example, “urea level low”, “AdBlue level low”, or
“reagent low”).
A.1.6.2.3. The operator warning system does not initially need to be continuously activated (for
example a message does not need to be continuously displayed), however activation
shall escalate in intensity so that it becomes continuous as the level of the reagent
approaches empty and the point where the operator inducement system will come into
effect is approached (for example frequency at which a lamp flashes). It shall culminate
in an operator notification at a level that is at the choice of the manufacturer, but
sufficiently more noticeable at the point where the operator inducement system in
paragraph A.1.6.3. of this Annexure comes into effect than when it was first activated.
A.1.6.2.4. The continuous warning shall not be easily disabled or ignored. When the warning
system includes a message display system, an explicit message shall be displayed (for
example “fill up urea”, “fill up AdBlue”, or “fill up reagent”). The continuous warning may
be temporarily interrupted by other warning signals providing important safety related
messages.
A.1.6.2.5. It shall not be possible to turn off the operating warning system until the reagent has
been replenished to a level not requiring its activation.
A.1.6.2.6. Additionally, audio warning system described in paragraph A.1.14 of this Annexure
shall become active when the level of reagent goes below 10 per cent of the capacity
of the reagent tank or at a percentage operator warning system is activated at the
choice of the manufacturer.
A.1.6.3 Activation of the operator inducement system
A.1.6.3.1 The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if the reagent tank level goes below 2.5 per cent of its nominally full
capacity or a higher percentage at the choice of the manufacturer.
A.1.6.3.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if the reagent tank is empty, that is, when the dosing system is unable to
draw further reagent from the tank, or at any level below 2.5 per cent of its nominally
full capacity at the discretion of the manufacturer.
A.1.6.3.3. Except to the extent permitted by paragraph A.1.5.5. of this Annexure, it shall not be
possible to turn off the low-level or severe inducement system until the reagent has
been replenished to a level not requiring their respective activation.
A.1.7. Reagent Quality Monitoring
A.1.7.1. The engine, or Genset shall include a means of determining the presence of an
incorrect reagent on board.
A.1.7.1.1. The manufacturer shall specify a minimum acceptable reagent concentration CDmin,
which results in tailpipe NOX emissions not exceeding the lower of either the applicable
NOX limit multiplied by 2.25 or the applicable NOX limit plus 1.5 g/kWh. For engine sub-
categories with a combined HC and NOX limit, the applicable NOX limit value for the

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 purpose of this paragraph shall be the combined limit value for HC and NO X reduced
by 0.19 g/kWh.
A.1.7.1.1.1. The value of CDmin specified by the manufacturer shall be used during the
demonstration set out in paragraph A.1.13. of this Annexure and recorded in the
extended documentation package as specified in Appendix A.3 to Annex 1.
A.1.7.1.2. Any reagent concentration lower than CDmin shall be detected and be regarded, for the
purpose of paragraph A.1.7.1. of this Annexure, as being incorrect reagent.
A.1.7.1.3. A specific counter ("the reagent quality counter") shall be attributed to the reagent
quality. The reagent quality counter shall count the number of engine operating hours
with an incorrect reagent.
A.1.7.1.3.1. Optionally, the manufacturer may group the reagent quality failure together with one or
more of the failures listed in paragraphs A.1.8. of this Annexure and A.1.9. of this
Annexure into a single counter.
A.1.7.1.4. Details of the reagent quality counter activation and deactivation criteria and
mechanisms are described in paragraph A.1.11. of this Annexure.
A.1.7.2. Activation of the operator warning system
When the monitoring system confirms that the reagent quality is incorrect, the operator
warning system described in paragraph1.4 shall be activated. When the warning
system includes a message display system, it shall display a message indicating the
reason of the warning (for example “incorrect urea detected”, “incorrect AdBlue
detected”, or “incorrect reagent detected”).
A.1.7.3 Activation of the operator inducement system
A.1.7.3.1. The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if the reagent quality is not rectified within a maximum of 36 engine
operating hours after the activation of the operator warning system as described in
paragraph A.1.7.2. of this Annexure.
A.1.7.3.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if their emission performance does not require reagent dosing. The severe
inducement system described in clause A.1.5.4. of this Appendix shall be activated if
the reagent quality is not rectified within a maximum of 72 engine operating hours after
the activation of the operator warning system as described in clause A.1.7.2. of this
Appendix.
A.1.7.3.3. The number of hours prior to activation of the inducement systems shall be reduced in
case of a repetitive occurrence of the malfunction according to the mechanism
described in clause A.1.11. of this Appendix.
A.1.8. Reagent Dosing Activity
A.1.8.1 The engine shall include a means of determining interruption of dosing.
A.1.8.2. Reagent dosing activity counter
A.1.8.2.1. A specific counter shall be attributed to the dosing activity (the "dosing activity
counter"). The counter shall count the number of engine operating hours which occur
with an interruption of the reagent dosing activity. This is not required where such
interruption is demanded by the engine ECU because the Genset operating conditions
are such that their emission performance does not required reagent dosing.
A.1.8.2.1.1. Optionally, the manufacturer may group the reagent dosing failure together with one or
more of the failures listed in paragraphs A.1.7. and A.1.9. of this Annexure into a single
counter.
A.1.8.2.2. Details of the reagent dosing activity counter activation and deactivation criteria and
mechanisms are described in paragraph A.1.11. of this Annexure.
A.1.8.3. Activation of the operator warning system

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 The operator warning system described in paragraph A.1.4. of this Annexure shall be
activated in the case of interruption of dosing which sets the dosing activity counter in
accordance with paragraph A.1.8.2.1. of this Annexure. When the warning system
includes a message display system, it shall display a message indicating the reason of
the warning (e.g. “urea dosing malfunction”, “AdBlue dosing malfunction”, or “reagent
dosing malfunction”).
A.1.8.4. Activation of the operator inducement system
A.1.8.4.1. The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if an interruption in reagent dosing is not rectified within a maximum
of 36 engine operating hours after the activation of the operator warning system in
accordance with paragraph A.1.8.3. of this Annexure.
A.1.8.4.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if an interruption in reagent dosing is not rectified within a maximum of 72
engine operating hours after the activation of the operator warning system in
accordance with paragraph A.1.8.3. of this Annexure.
A.1.8.4.3. The number of hours prior to activation of the inducement systems shall be reduced in
case of a repetitive occurrence of the malfunction according to the mechanism
described in paragraph A.1.11. of this Annexure.
A.1.9. Other failures that may be attributed to tampering
A.1.9.1. In addition to the level of reagent in the reagent tank, the reagent quality, and the
interruption of dosing, the following failures shall be monitored because they may be
attributed to tampering:
(a) failures of the NOX Control Diagnostic (NCD) system as described in paragraph
A.1.9.2.1. of this Annexure;
(b) failures of the exhaust gas recirculation (EGR) valve as described in paragraph
A.1.9.2.2. of this Annexure;
A.1.9.2. Monitoring requirements and counters
A.1.9.2.1. NCD system
A.1.9.2.1.1. The NOX Control Diagnostic (NCD) system shall be monitored for electrical failures and
for removal or deactivation of any sensor that prevents it from diagnosing any other
failures set out in paragraphs A.1.6. to A.1.8. (component monitoring) of this Annexure.
A non-exhaustive list of sensors that affect the diagnostic capability are those directly
measuring NOX concentration, urea quality sensors, ambient sensors and sensors
used for monitoring reagent dosing activity, reagent level or reagent consumption.
A.1.9.2.1.2. A counter shall be attributed to each of the monitoring failures. The NCD system
counters shall count the number of engine operating hours when the DTC associated
to a malfunction of the NCD system is confirmed to be active. Different NCD system
failures may be grouped into a single counter.
A.1.9.2.1.2.1. The manufacturer may group the NCD system failure together with one or more of the
failures listed in paragraphs A.1.7., A.1.8. and paragraph A.1.9.2.2 of this Annexure
into a single counter.
A.1.9.2.1.3. Details of the NCD system counter(s) activation and deactivation criteria and
mechanisms are described in paragraph A.1.11. of this Annexure.
A.1.9.2.2. EGR valve
A.1.9.2.2.1. The EGR system shall be monitored for an impeded EGR valve.
A.1.9.2.2.2. A counter shall be attributed to an impeded EGR valve. The EGR valve counter shall
count the number of engine operating hours when the DTC associated to an impeded
EGR valve is confirmed to be active.

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A.1.9.2.2.2.1. The manufacturer may group the impeded EGR valve failure together with one or more
of the failures listed in paragraphs A.1.7., A.1.8. and A.1.9.2.1 of this Annexure. into a
single counter.
A.1.9.2.2.3. Details of the EGR valve counter activation and deactivation criteria and mechanisms
are described in paragraph A.1.11. of this Annexure.
A.1.9.3. Activation of the operator warning system
The operator warning system set out in paragraph1.4. shall be activated in case any of
the failures specified in paragraph A.1.9.1. of this Annexure occur, and shall indicate
that an urgent repair is required. When the warning system includes a message display
system, it shall display a message indicating either the reason of the warning (for
example “reagent dosing valve disconnected”, or "critical emission failure").
A.1.9.4. Activation of the operator inducement system
A.1.9.4.1. The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if a failure specified in paragraph A.1.9.1. of this Annexure is not
rectified within a maximum of 36 engine operating hours after the activation of the
operator warning system set out in paragraph A.1.9.3. of this Annexure.
A.1.9.4.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if a failure specified in paragraph A.1.9.1. of this Annexure is not rectified
within a maximum of 72 engine operating hours after the activation of the operator
warning system set out in paragraph A.1.9.3. of this Annexure.
A.1.9.4.3. The number of hours prior to activation of the inducement systems shall be reduced in
case of a repetitive occurrence of the malfunction according to the mechanism
described in paragraph A.1.11. of this Annexure.
A.1.9.5. As an alternative to the monitoring requirements set out in paragraph A.1.9.2. of this
Annexure, the manufacturer may monitor for failures using a NOX sensor located in the
exhaust system. In this case,
(a) the NOX value at which the NCM shall be detected shall not exceed the lower of
either the applicable NOX limit multiplied by 2.25 or the applicable NOX limit plus
1.5 g/kWh. For engine sub-categories with a combined HC and NOX limit, the
applicable NOX limit value for the purpose of this paragraph shall be the combined
limit value for HC and NOX reduced by 0.19 g/kWh.
(b) a single warning may be used, including, where messages are used, the statement
‘high NOX – root cause unknown’,
(c) in paragraph A.1.9.4.1. of this Annexure the maximum number of engine operating
hours between the activation of the operator warning system and the activation of
the low-level inducement system shall be 36 hours
(d) in paragraph A.1.9.4.2. of this Annexure the maximum number of engine operating
hours between the activation of the operator warning system and the activation of
the severe inducement system shall be 72 hours
A.1.10. Demonstration requirements
A.1.10.1. General
The compliance to the requirements of this Appendix shall be demonstrated during
type-approval by performing, as illustrated in Table A.8-1. and specified in paragraph
A.1.10. of this Annexure:
(a) a demonstration of the warning system activation
(b) a demonstration of the low-level inducement system activation, if applicable
(c) a demonstration of the severe inducement system activation
A.1.10.2. Engine families and NCD engine families
The compliance of an engine family or an NCD engine family with the requirements of
paragraph A.1.10. of this Annexure may be demonstrated by testing one of the

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 members of the considered family, provided the manufacturer demonstrates to the
Type Approval Authority that the monitoring systems necessary for complying with the
requirements of this Appendix are similar within the family.
A.1.10.2.1. The demonstration that the monitoring systems for other members of the NCD engine
family are similar may be performed by presenting to the approval authorities such
elements as algorithms, functional analyses, etc.
A.1.10.2.2. The test engine is selected by the manufacturer in agreement with the Type Approval
Authority. It may or may not be the parent engine of the considered family.
A.1.10.2.3. In the case where engines of an engine family belong to an NCD engine family that has
already been type-approved, according to paragraph A.1.10.2.1. (Figure A.8-3.) of this
Annexure the compliance of that engine family is deemed to be demonstrated without
further testing, provided the manufacturer demonstrates to the authority that the
monitoring systems necessary for complying with the requirements of this Appendix
are similar within the considered engine and NCD engine families.
Table A.8-1.
Illustration of the content of the demonstration process in accordance with the
provisions in paragraphs A.1.10.3. and A.1.10.4.

Mechanism Demonstration elements

Warning system activation - 2 activation tests (incl. lack of reagent)
specified in paragraph A.1.10.3. Supplementary demonstration elements, as
of this Annexure appropriate
Low-level inducement activation - 2 activation tests (incl. lack of reagent)
specified in paragraph A.1.10.4. - Supplementary demonstration elements, as
of this Annexure appropriate
- 1 The Audio-Visual Alarm
Severe inducement activation - 2 activation tests (incl. lack of reagent)
specified in paragraph A.1.10.4. - Supplementary demonstration elements, as
of this Annexure appropriate

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 Figure A.8-3.
Previously demonstrated conformity of an NCD engine family

Conformity of Engine Conformity of NCD engine family 1

family 1 is considered has been demonstrated
as demonstrated for Engine family 2

Engine Engine
family 1 family 2

NCD engine family 1

A.1.10.3. Demonstration of the warning system activation

A.1.10.3.1. The compliance of the warning system activation shall be demonstrated by performing
two tests: lack of reagent, and one failure category identified in paragraphs A.1.7, A.1.8.
or A.1.9. of this Annexure.
A.1.10.3.2. Selection of the failure to be tested from paragraphs A.1.7., A.1.8., or A.1.9. of this
Annexure.
A.1.10.3.2.1. The Type Approval Authority shall select one failure category. In the case that a failure
is selected from points A.1.7. or A.1.9. of this Annexure the additional requirements set
out in points A.1.10.3.2.2. or A.1.10.3.2.3. of this Annexure respectively shall apply.
A.1.10.3.2.2 For the purpose of demonstrating the activation of the warning system in case of a
wrong reagent quality, a reagent shall be selected with a dilution of the active ingredient
at least as dilute as that communicated by the manufacturer according to the
requirements set out in paragraph A.1.7. of this Annexure.
A.1.10.3.2.3. For the purpose of demonstrating the activation of the warning system in case of
failures that may be attributed to tampering, and are defined in paragraph A.1.9. of this
Annexure the selection shall be performed according to the following requirements:
A.1.10.3.2.3.1. The manufacturer shall provide the Type Approval Authority with a list of such potential
failures.
A.1.10.3.2.3.2. The failure to be considered in the test shall be selected by the Type Approval Authority
from this list referred to in paragraph A.1.10.3.2.3.1. of this Annexure.
A.1.10.3.3. Demonstration
A.1.10.3.3.1. For the purpose of this demonstration, a separate test shall be performed for the lack
of reagent and the failure selected in paragraph A.1.10.3.2. of this Annexure.
A.1.10.3.3.2. During a test, no failure shall be present other than the one addressed by the test.
A.1.10.3.3.3. Prior to starting a test, all DTC shall have been erased.
A.1.10.3.3.4. At the request of the manufacturer, and with the agreement of the Type Approval
Authority, the failures subject to testing may be simulated.
A.1.10.3.3.5. Detection of failures other than lack of reagent.

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 For failures other than lack of reagent, once the failure installed or simulated, the
detection of that failure shall be performed as follows:
A.1.10.3.3.5.1. The NCD system shall respond to the introduction of a failure selected as appropriate
by the Type Approval Authority in accordance to the provisions of this Appendix. This
is demonstrated if activation occurs within two consecutive NCD test-cycles according
to paragraph A.1.10.3.3.7. of this Annexure.
When it has been specified in the monitoring description and agreed by the Type
Approval Authority that a specific monitor needs more than two NCD test-cycles to
complete its monitoring, the number of NCD test-cycles may be increased to 3 NCD
test-cycles.
Each individual NCD test-cycle in the demonstration test may be separated by an
engine shut-off. The time until the next start-up shall take into consideration any
monitoring that may occur after engine shut-off and any necessary condition that must
exist for monitoring to occur at the next start up.
A.1.10.3.3.5.2 The demonstration of the warning system activation is deemed to be accomplished if,
at the end of each demonstration test performed according to paragraph A.1.10.3.3. of
this Annexure, the warning system has been properly activated and the DTC for the
selected failure has got the “confirmed and active” status.
A.1.10.3.3.6. Detection in case of lack of reagent availability
For the purpose of demonstrating the activation of the warning system in case of lack
of reagent availability, the engine shall be operated over one or more NCD test cycles
at the discretion of the manufacturer.
A.1.10.3.3.6.1. The demonstration shall start with a level of reagent in the tank to be agreed between
the manufacturer and the Type Approval Authority but representing not less than 10
per cent of the nominal capacity of the tank.
A.1.10.3.3.6.2. The warning system is deemed to have performed in the correct manner if the following
conditions are met simultaneously:
(a) the warning system has been activated with a reagent availability greater or
equal to 10 per cent of the capacity of the reagent tank
(b) the "continuous" warning system has been activated with a reagent availability
greater or equal to the value declared by the manufacturer in accordance with
the provisions of paragraph A.1.6. of this Annexure.
A.1.10.3.3.7. NCD test cycle
A.1.10.3.3.7.1 The NCD test cycle considered in clause A.1.10. of this Annexure for demonstrating
the correct performance of the NCD system is the 5 Mode variable speed cycle for
variable speed engine and the applicable D2- 5 Mode cycle for constant speed engine
A.1.10.3.3.7.2 On request of the manufacturer with approval of the test agency, an alternative NCD
Cycle (e.g. other than D2-5 Mode cycle) can be used for specific monitoring
A.1.10.3.4. The demonstration of the warning system activation is deemed to be accomplished if,
at the end of each demonstration test performed according to paragraph A.1.10.3.3. of
this Annexure, the warning system has been properly activated.
A.1.10.4. Demonstration of the inducement system
A.1.10.4.1. The demonstration of the inducement system shall be done by tests performed on an
engine test bench.
A.1.10.4.1.1. Any components or sub-systems not physically mounted on the engine, such as, but
not limited to, ambient temperature sensors, level sensors, and operator warning and
information systems, that are required in order to perform the demonstrations shall be
connected to the engine for that purpose, or shall be simulated, to the satisfaction of
the Type Approval Authority.
A.1.10.4.1.2. If the manufacturer chooses, and subject to the agreement of the Type Approval
Authority, the demonstration tests may be performed on a complete Genset either by

131
 mounting the same on a suitable test bed or, notwithstanding paragraph A.1.10.4.1. of
this Annexure, by running it outside test laboratory under controlled conditions.
A.1.10.4.2. The test sequence shall demonstrate the activation of the inducement system in case
of lack of reagent and in case of the failure selected by the Approval Authority according
to paragraph A.1.10.3.2.1. of this Annexure for the test of the warning system.
A.1.10.4.3. For the purpose of this demonstration,
(a) the manufacturer shall, in agreement with the Type Approval Authority, be
permitted to accelerate the test by simulating the achievement of a certain
number of operating hours,
(b) Reserved
(c) the low-level inducement, if applicable, shall be demonstrated according to the
requirements of paragraph A.1.10.4.5. of this Annexure.
(d) the severe inducement shall be demonstrated according to the requirements
of paragraph A.1.10.4.6. of this Annexure.
A.1.10.4.4. The manufacturer shall, in addition, demonstrate the operation of the inducement
system under those failure conditions defined in paragraphs A.1.7., A.1.8. or A.1.9. of
this Annexure which have not been chosen for use in demonstration tests described in
paragraphs A.1.10.4.1. to A.1.10.4.3. of this Annexure.
These additional demonstrations may be performed by presentation to the Type
Approval Authority of a technical case using evidence such as algorithms, functional
analyses, and the result of previous tests.
A.1.10.4.4.1. These additional demonstrations shall demonstrate to the satisfaction of the Type
Approval Authority the inclusion of the correct torque reduction mechanism in the
engine ECU.
A.1.10.4.5. Demonstration test of the low-level inducement system
A.1.10.4.5.1. This demonstration starts when the warning system or when appropriate "continuous"
warning system has been activated as a result of the detection of a failure selected by
the Type Approval Authority.
A.1.10.4.5.2. When the system is being checked for its reaction to the case of lack of reagent in the
tank, the engine shall be run until the reagent availability has reached a value of 2.5
per cent of the tank nominal full capacity of the tank or the value declared by the
manufacturer in accordance with paragraph A.1.6.3.1. of this Annexure at which the
low-level inducement system is intended to operate.
A.1.10.4.5.2.1. The manufacturer may, with the agreement of the Type Approval Authority, simulate
continuous running by extracting reagent from the tank, either whilst the engine is
running or is stopped.
A.1.10.4.5.3. When the system is checked for its reaction in the case of a failure other than a lack of
reagent in the tank, the engine shall be run for the relevant number of operating hours
indicated in Table A.8-4. or, at the choice of the manufacturer, until the relevant counter
has reached the value at which the low-level inducement system is activated.
A.1.10.4.5.4. The demonstration of the low-level inducement system shall be deemed to be
accomplished if, at the end of each demonstration test performed according to
paragraphs A.1.10.4.5.2. and A.1.10.4.5.3. of this Annexure, the manufacturer has
demonstrated to the Type Approval Authority that the engine ECU has activated the
Audio-Visual Alarm or torque reduction mechanism.
A.1.10.4.6. Demonstration test of the severe inducement system
A.1.10.4.6.1. This demonstration shall start from a condition where the low-level inducement system,
where applicable, has been previously activated and may be performed as a
continuation of the tests undertaken to demonstrate the low-level inducement system.
A.1.10.4.6.2. When the system is checked for its reaction in the case of lack of reagent in the tank,
the engine shall be run until the reagent tank is empty, or has reached the level below

132
 2.5 per cent of nominal full capacity of the tank at which the manufacturer has declared
to activate the severe inducement system.
A.1.10.4.6.2.1. The manufacturer may, with the agreement of the Type Approval Authority, simulate
continuous running by extracting reagent from the tank, either whilst the engine is
running or is stopped.
A.1.10.4.6.3. When the system is checked for its reaction in the case of a failure that is not a lack of
reagent in the tank, the engine shall then be run for the relevant number of operating
hours indicated in Table A.8-4. or, at the choice of the manufacturer, until the relevant
counter has reached the value at which the severe inducement system is activated.
A.1.10.4.6.4. The demonstration of the severe inducement system shall be deemed to be
accomplished if, at the end of each demonstration test performed according to
paragraphs A.1.10.4.6.2. and A.1.10.4.6.3. of this Annexure, the manufacturer has
demonstrated to the Type Approval Authority that the severe inducement mechanism
considered in this Appendix has been activated.
A.1.10.4.7. Alternatively, if the manufacturer chooses, and subject to the agreement of the Type
Approval Authority, the demonstration of the inducement mechanisms may be
performed on a complete Genset in accordance with the requirements of paragraphs
A.1.5.4. and A.1.10.4.1.2. of this Annexure, either by mounting the Genset on a suitable
test bed or by running it outside test laboratory under controlled conditions.
A.1.10.4.7.1. The Genset shall be operated until the counter associated with the selected failure has
reached the relevant number of operating hours indicated in Table A.8-4. or, as
appropriate, until either the reagent tank is empty or, has reached the level below 2.5
per cent of nominal full capacity of the tank at which the manufacturer has chosen to
activate the severe inducement system.
A.1.10.5. Documentation of the demonstration
A.1.10.5.1 A demonstration report shall be created that documents the demonstration of the NCD
system.
The report shall:
(a) identify the failures examined;
(b) describe the demonstration performed including the applicable test cycle;
(c) confirm that the applicable warnings and inducements were activated as
required by this regulation;
(d) be included in the information folder as set out in Annexure 1.
A.1.11. Description of the operator warning and inducement activation and deactivation
mechanisms
A.1.11.1 To complement the requirements specified in this Appendix concerning the warning
and inducement activation and deactivation mechanisms, paragraph A.1.11. of this
Annexure specifies the technical requirements for an implementation of those
activation and deactivation mechanisms.
A.1.11.2. Activation and deactivation mechanisms of the warning system
A.1.11.2.1. The operator warning system shall be activated when the diagnostic trouble code
(DTC) associated with a NCM justifying its activation has the status defined in Table
A.8-2.

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 Table A.8-2
Activation of the operator warning system
Failure type DTC status for activation of the
warning system

Poor reagent quality confirmed and active

Interruption of dosing confirmed and active
Impeded EGR valve confirmed and active
Malfunction of the monitoring confirmed and active
system
NOX threshold, if applicable confirmed and active

A.1.11.2.2. The operator warning system shall be deactivated when the diagnosis system
concludes that the malfunction relevant to that warning is no longer present or when
the information including DTCs relative to the failures justifying its activation is erased
by a scan tool.
A.1.11.2.2.1. Requirements for erasing " NOX control information"
A.1.11.2.2.1.1. Erasing / resetting " NOX control information" by a scan-tool
On request of the scan tool, the following data shall be erased or reset to the value
specified in this Appendix from the computer memory (see Table A.8-3.).

Table A.8-3.
Erasing / resetting "NOX control information" by a scan-tool

NOX control information Erasable Resettable

All DTCs X

The value of the counter with the

highest number of engine operating X
hours

The number of engine operating

X
hours from the NCD counter(s)

A.1.11.2.2.1.2. NOX control information shall not be erased by disconnection of the battery(ies) of the
Genset.
A.1.11.2.2.1.3. The erasing of " NOX control information" shall only be possible under “engine-off”
conditions.
A.1.11.2.2.1.4. When "NOX control information" including DTCs are erased, any counter associated
with these failures and which is specified in this Appendix shall not be erased, but reset
to the value specified in the appropriate paragraph of this Appendix.
A.1.11.3. Activation and deactivation mechanism of the operator inducement system
A.1.11.3.1. The operator inducement system shall be activated when the warning system is active
and the counter relevant to the type of NCM justifying their activation have reached the
value specified in Table A.8-4
A.1.11.3.2. The operator inducement system shall be deactivated when the system no longer
detects a malfunction justifying its activation, or if the information including the DTCs
relative to the NCMs justifying its activation has been erased by a scan tool or
maintenance tool.

134
A.1.11.3.3. The operator warning and inducement systems shall be immediately activated or
deactivated as appropriate according to the provisions of paragraph A.1.6. of this
Annexure after assessment of the reagent quantity in the reagent tank. In that case,
the activation or deactivation mechanisms shall not depend upon the status of any
associated DTC.
A.1.11.4. Counter mechanism
A.1.11.4.1. General
A.1.11.4.1.1. To comply with the requirements of this Appendix, the system shall contain counters to
record the number of hours during which the engine has been operated while the
system has detected any of the following NCM:
(a) an incorrect reagent quality;
(b) an interruption of reagent dosing activity;
(c) an impeded EGR valve;
(d) a failure of the NCD system.
A.1.11.4.1.1.1. The manufacturer may use one or more counters for grouping the NCMs indicated in
paragraph A.1.11.4.1.1. of this Annexure.
A.1.11.4.1.2. Each of the counters shall count up to the maximum value provided in a 2 byte counter
with 1 hour resolution and hold that value unless the conditions allowing the counter to
be reset to zero are met.
A.1.11.4.1.3. A manufacturer may use a single or multiple NCD system counters. A single counter
may accumulate the number of hours of 2 or more different malfunctions relevant to
that type of counter, none of them having reached the time the single counter indicates.
A.1.11.4.1.3.1. When the manufacturer decides to use multiple NCD system counters, the system shall
be capable of assigning a specific monitoring system counter to each malfunction
relevant according to this Appendix to that type of counters.
A.1.11.4.2. Principle of counters mechanism
A.1.11.4.2.1. Each of the counters shall operate as follows:
A.1.11.4.2.1.1. If starting from zero, the counter shall begin counting as soon as a malfunction relevant
to that counter is detected and the corresponding diagnostic trouble code (DTC) has
the status defined in Table A.8-2.
A.1.11.4.2.1.2. In case of repeated failures, one of the following provisions shall apply at the choice of
the manufacturer.
(a) If a single monitoring event occurs and the malfunction that originally activated
the counter is no longer detected or if the failure has been erased by a scan
tool or a maintenance tool, the counter shall halt and hold its current value. If
the counter stops counting when the severe inducement system is active, the
counter shall be kept frozen at the value defined in Table A.8-4. or a value of
greater than or equal to the counter value for severe inducement minus 30
minutes.
(b) The counter shall be kept frozen at the value defined in Table A.8-4. or a value
of greater than or equal to the counter value for severe inducement minus 30
minutes.
A.1.11.4.2.1.3. In the case of a single monitoring system counter, that counter shall continue counting
if a NCM relevant to that counter has been detected and its corresponding Diagnostic
trouble code (DTC) has the status "confirmed and active". It shall halt and hold one of
the values specified in paragraph A.1.11.4.2.1.2. of this Annexure, if no NCM that would
justify the counter activation is detected or if all the failures relevant to that counter
have been erased by a scan tool or a maintenance tool.

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 Table A.8-4.
Counters and inducement

# DTC status for Counter value Counter Frozen value

first activation of for low-level value for held by the
the counter inducement severe counter
inducement
Reagent confirmed and ≤ 10 hours ≤ 72 hours ≥ 90 per cent of
quality active counter value for
counter severe
inducement
Dosing confirmed and ≤ 10hours ≤ 72hours ≥ 90 per cent of
counter active counter value for
severe
inducement
EGR valve confirmed and ≤ 36 hours ≤ 72hours ≥ 95 per cent
counter active of counter
value for
severe
inducement
Monitoring confirmed and ≤ 36 hours ≤ 72hours ≥ 95 per cent
system active of counter
counter value for
severe
inducement
NOX confirmed and ≤ 10 hours ≤ 72hours ≥ 90 per cent
threshold, if active of counter
applicable value for
severe
inducement

A.1.11.4.2.1.4. Once frozen, the counter shall be reset to zero when the monitors relevant to that
counter have run at least once to completion of their monitoring cycle without having
detected a malfunction and no malfunction relevant to that counter has been detected
during 40 engine operating hours since the counter was last held (see Figure A.8-4.).
A.1.11.4.2.1.5. The counter shall continue counting from the point at which it had been held if a
malfunction relevant to that counter is detected during a period when the counter is
frozen (see Figure A.8-4.).

A.1.12. Illustration of the activation and deactivation and counter mechanisms

A.1.12.1. This paragraph A.1.12. of this Annexure illustrates the activation and deactivation and
counter mechanisms for some typical cases. The Figures and descriptions given in
paragraphs A.1.12.2., A.1.12.3. and A.1.12.4. of this Annexure are provided solely for
the purposes of illustration in this Appendix and should not be referenced as examples
of either the requirements of this Regulation or as definitive statements of the
processes involved. The counter hours in Figures A.8-6. and A.8-7. refer to the
maximum severe inducement values in Table A.8-4.. For simplification purposes, for
example, the fact that the warning system will also be active when the inducement
system is active has not been mentioned in the illustrations given.

136
 Figure A.8-4.
Reactivation and resetting to zero of a counter after a period when its value has
been frozen

> 40 op. hours < 40 op. hours

40 operating 40 operating
hours hours

freeze
value
Counter

repair repair
YES
Failure

NO

A.1.12.2. Figure A.8-5. illustrates the operation of the activation and deactivation mechanisms when
monitoring the reagent availability for four cases:
(a) use case 1: the operator continues operating the Genset in spite of the warning
until Genset operation is disabled;
(b) Adequate refilling case 1: the operator refills the reagent tank so that a level above
the 10 per cent threshold is reached. Warning and inducement are de-activated;
(c) Inadequate refilling cases 2 and 3: The warning system is activated. The level of
warning depends on the amount of available reagent;
(d) Very Inadequate refilling case 4: The low-level inducement is activated
immediately.

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 Figure A.8-5.
Reagent availability

SEVERE
Inducement

LOW-LEVEL

"continuous"
WARNING

WARNING

NO
reagent
level of

10%
X%
2.5%
EMPTY
refilling refilling refilling refilling
(case 1) (case 2) (case 3) (case 4)

A.1.12.3. Figure A.8-6. illustrates three cases of wrong reagent quality:

(a) use case 1: the operator continues operating the Genset in spite of the warning until
Genset operation is disabled.
(b) repair case 1 ("bad" or "dishonest" repair): after disablement of the Genset, the
operator changes the quality of the reagent, but soon after, changes it again for a poor
quality one. The warning, inducement and counting processes start from zero. The
inducement system is immediately reactivated and Genset operation is disabled after
2 engine operating hours.

(c) repair case 2 ("good" repair): after disablement of the Genset, the operator rectifies the
quality of the reagent. However, sometime afterwards, he refills again with a poor-
quality reagent. The low-level inducement system is immediately reactivated and the
counter restarts from the value it had at the time of repair. The warning, inducement
and counting processes restart from zero.

138
 Figure A.8-6.
Filling with poor reagent quality
< 40 op. hours > 40 op. hours

40 operating
hours

20 hrs
18 hrs
Counter

10 hrs

SEVERE
Inducement

LOW-LEVEL

WARNING

NO

repair repair
Wrong urea

YES

NO
repair repair
(case 1) (case 2)

A.1.12.4. Figure A.8-7. illustrates three cases of failure of the urea dosing system. This figure also
illustrates the process that applies in the case of the monitoring failures described in
paragraph A.1.9. of this Annexure.
(a) use case 1: the operator continues operating the Genset in spite of the warning
until Genset operation is disabled.
(b) repair case 1 ("good" repair): after disablement of the Genset engine, the operator
repairs the dosing system. However, some time afterwards, the dosing system
fails again. The warning, inducement and counting processes restart from zero.
(c) repair case 2 ("bad" repair): during the low-level inducement time (torque
reduction), the operator repairs the dosing system. Soon after, however, the
dosing system fails again. The low-level inducement system is immediately
reactivated and the counter restarts from the value it had at the time of repair.

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 Figure A.8-7.
Failure of the reagent dosing system

> 40 op. hours < 40 op. hours

40 operating 40 operating
hours hours

20 hrs
18 hrs
Counter

10 hrs

SEVERE
Inducement

LOW-LEVEL

WARNING

NO

repair repair
Dosing system
not working

YES

NO
repair repair
(case 1) (case 2)

A.1.13. Demonstration of the minimum acceptable reagent concentration CDmin

A.1.13.1. The manufacturer shall demonstrate the correct value of CDmin during type approval by
performing the 5-mode variable speed cycle for variable speed engines and the
applicable D2-5 mode constant speed cycle for constant speed engine using a reagent
with the concentration CDmin.
A.1.13.2. The test shall follow the appropriate NCD cycle(s), permitting a closed loop NO X control
system to perform adaptation to the quality of the reagent with the concentration CDmin.
A.1.13.3. The pollutant emissions resulting from this test shall not exceed the NOX threshold
specified in paragraph A.1.7.1.1. of this Annexure.
A.1.13.4. Documentation of the demonstration
A.1.13.4.1. A demonstration report shall be created that documents the demonstration of the
minimum acceptable reagent concentration.
The report shall:
(a) identify the failures examined;
(b) describe the demonstration performed including the applicable test cycle;
(c) confirm that the pollutant emissions arising from this demonstration did not
exceed the NOX threshold specified in point A.1.7.1.1 of this Annexure;
(d) be included in the information folder as set out in Annexure 1
A.1.14. Technical requirements for Audible Operator warning system.
This section describes technical requirements for audible operator warning system
associated with NOx and Particulate Control Diagnostics. Same could be leveraged by
manufacturer for warning of other faults such as engine de-rates due to safety reason
however with different pattern.
A.1.14.1. Specification requirements for audible warning system
Audible operator warning system as installed on Genset application shall satisfy
following requirements:
(a) Sound intensity of the system as measured at distance of 1 m facing Genset panel with
controls and displays those accompany operator warning lights shall be 80-85 decibels;

140
 (b) Such warning system (sound source) shall be all weather compatible and durable for
life of Genset;
(c) Shall have diagnostics associated with it including DTC inline with paragraph A.1.10 of
this Annexure if tampered with;
(d) Manufacturer may opt to integrate such warning system within Genset enclosure or
may provide an external hooter compliant with above requirements;
A.1.14.2. Audio warning system pattern requirements
A.1.14.2.1. Audio warning system for operator induments shall be enabled per any of the options
below:
Option: A
A.1.14.2.1.1 When operator warning has become active for low-level inducement, activate visual
warning with no alarms.
A.1.14.2.1.2. At commencement of low-level inducement, the audio warning system shall beep once
in 5 seconds with 2-second-long beep. Such audio warning shall remain active as long
as low-level inducement state is active.
A.1.14.2.1.3. At commencement of severe-level inducement, the audio warning system shall beep
once in 2 seconds with 2-second-long beep. Such audio warning shall remain active
when Engine Ignition is ON or Engine shutdown but ignition is ON.
Option: B
A.1.14.2.1.4 Any specific pattern of alarm with specific duration and frequency of beeps that will
alert the operator on Inducements as defined by the manufacturer which needs to be
demonstrated at the time of testing as part of Inducement strategy
A.1.14.2.4. Manufacture may opt to use same audio warning pattern as paragraph A.1.14.2.1.3 of
this Annexure for non-inducement fault codes those are engine and equipment safety
related and will cause immediate derate or shutdown of an engine;
A.1.14.3. Audio warning system extent requirements
A.1.14.3.1. Audio warning associated with low-level inducement commencement shall remain
active as long as low-level inducement state is active;
A.1.14.3.2. Audio warning associated with severe-level inducement commencement shall remain
active when Engine Ignition is ON or Engine shutdown but ignition is ON.
A.1.14.4. Details of the operator warning system activation and deactivation procedures are
described in paragraph A.1.11. of this Annexure those shall apply to audio warning
system;
A.1.14.5. As part of the application for approval under this Regulation, the manufacturer shall
demonstrate the operation of the audio operator warning system, as specified in
paragraph A.1.10. of this Annexure;

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 Appendix – A.2

Technical requirements on Particulate pollutant control measures

including the method to demonstrate these measures

A.2.1. Introduction
This Appendix sets out the requirements to ensure the correct operation of particulate
control measures.
A.2.2. General requirements
The engine shall be equipped with a Particulate Control Diagnostic system (PCD) able
to identify the particulate after-treatment system malfunctions considered by this
Annexure. Any engine covered by this paragraph shall be designed, constructed and
installed so as to be capable of meeting these requirements throughout the normal life
of the engine under normal conditions of use. In achieving this objective, it is acceptable
that engines which have been used in excess of the emission durability period as
specified in Appendix 6 to Annexure 7 of this Regulation show some deterioration in
the performance and the sensitivity of the PCD.
A.2.2.1. Required information
A.2.2.1.1. If the emission control system requires a reagent e.g. fuel borne catalyst, the
characteristics of that reagent, including the type of reagent, information on
concentration when the reagent is in solution, operational temperature conditions and
reference to international standards for composition and quality must be specified by
the manufacturer, in the information document set out in Annexure 1.
A.2.2.1.2. Detailed written information fully describing the functional operation characteristics of
the operator warning system in paragraph A.2.4. of this Annexure shall be provided to
the Type Approval Authority at the time of type-approval.
A.2.2.1.3. The manufacturer shall provide installation documents that, when used by the OEM,
will ensure that the engine, inclusive of the emission control system that is part of the
approved engine type or engine family, when installed in the genset, will operate, in
conjunction with the necessary machinery parts, in a manner that will comply with the
requirements of this Annexure. This documentation shall include the detailed technical
requirements and the provisions of the engine (software, hardware, and
communication) needed for the correct installation of the engine in the genset.
A.2.2.2. Operating conditions
A.2.2.2.1. The PCD system shall at a minimum be operational at the applicable control conditions
set out in paragraph 2.4 of Appendix for each engine category. The diagnostic system
shall remain operational outside of this range where technically possible.
A.2.2.3. Diagnostic requirements
A.2.2.3.1. The PCD system shall be able to identify the particulate control malfunctions (PCM)
considered by this Appendix by means of Diagnostic Trouble Codes (DTCs) stored in
the computer memory and to communicate that information off-board upon request.
A.2.2.3.2. Requirements for recording Diagnostic Trouble Codes (DTCs)
A.2.2.3.2.1. The PCD system shall record a DTC for each distinct PCM.
A.2.2.3.2.2. The PCD system shall conclude within the periods of engine operation indicated in
Table A8-5. whether a detectable malfunction is present. At this time, a “confirmed and
active” DTC shall be stored and the warning system specified in paragraph A.2.4. of
this Annexure shall be activated.
A.2.2.3.2.3. In cases where more than the period of running time indicated in Table A.8-5. is
required for the monitors to accurately detect and confirm a PCM (e.g. monitors using
statistical models or with respect to fluid consumption on the Genset), the Type

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 Approval Authority may permit a longer period for monitoring provided the manufacturer
justifies the need for the longer period (for example by technical rationale, experimental
results, in-house experience, etc.).

Table A.8-5.
Monitor types and corresponding period within which a “confirmed and active” DTC
shall be stored

Monitor type Period of accumulated running time within

which a “confirmed and active” DTC shall be
stored

Removal of the particulate 60 minutes of non-idle engine operation

after-treatment system
Loss of function of the 240 minutes of non-idle engine operation
particulate after-treatment
system
Failures of the PCD system 60 minutes of engine operation

A.2.2.3.3. Requirements for erasing Diagnostic trouble codes (DTCs):

(a) DTCs shall not be erased by the PCD system itself from the computer memory
until the failure related to that DTC has been remedied;
(b) the PCD system may erase all the DTCs upon request of a proprietary scan or
maintenance tool that is provided by the engine manufacturer upon request, or
using a pass code provided by the engine manufacturer.
(c) the record of incidents of operation with a DTC confirmed and active that are
stored in non-volatile memory as required by paragraph A.2.5.2. of this
Annexure shall not be erased.
A.2.2.3.4. A PCD system shall not be programmed or otherwise designed to partially or totally
deactivate based on age of the genset during the actual life of the engine, nor shall the
system contain any algorithm or strategy designed to reduce the effectiveness of the
PCD system over time.
A.2.2.3.5. Any reprogrammable computer codes or operating parameters of the PCD system shall
be resistant to tampering.
A.2.2.3.6. PCD engine family
The manufacturer is responsible for determining the composition of a PCD engine
family. Grouping engines within a PCD engine family shall be based on good
engineering judgment and be subject to approval by the Type Approval Authority.
Engines that do not belong to the same engine family may still belong to the same PCD
engine family.
A.2.2.3.6.1. Parameters defining a PCD engine family
A PCD engine family is characterized by basic design parameters that shall be common
to engines within the family.
In order that engines are considered to belong to the same PCD engine family, the
following list of basic parameters shall be similar:
(a) working principle of particulate after-treatment system (e.g. mechanical,
aerodynamic, diffusional, inertial, periodically regenerating, continuously
regenerating, etc.)

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 (b) methods of PCD monitoring;
(c) criteria for PCD monitoring;
(d) monitoring parameters (e.g. frequency).
These similarities shall be demonstrated by the manufacturer by means of relevant
engineering demonstration or other appropriate procedures and subject to the approval
of the Type Approval Authority.
The manufacturer may request approval by the Type Approval Authority of minor
differences in the methods of monitoring/diagnosing the PCD monitoring system due
to engine configuration variation, when these methods are considered similar by the
manufacturer and they differ only in order to match specific characteristics of the
components under consideration (for example size, exhaust flow, etc.); or their
similarities are based on good engineering judgment.
A.2.3. Maintenance Requirements
A.2.3.1. The OEM shall provide to all end-users of gensets written instructions about the
emission control system and its correct operation.
A.2.4. Operator Warning System
A.2.4.1. The genset shall include an operator warning system using visual alarms.
A.2.4.2. The operator warning system may consist of one or more lamps, or display short
messages.
The system used for displaying these messages may be the same as the one used for
other maintenance or NCD purposes
The warning system shall indicate that an urgent repair is required. When the warning
system includes a message display system, it shall display a message indicating the
reason of the warning (for example “sensor disconnected”, or “critical emission failure”)
A.2.4.3. The warning system shall include an audible component to alert the operator in line
with A.1.14 of this Annexure. An audible alarm system must be activated at minimum
when the operator inducement system described in paragraph A.2.6. of this Annexure
has been activated. The cancelling of audible warnings by the operator is permitted.
A.2.4.4. The operator warning system shall be activated as specified in paragraph A.2.2.3.2.2
of this Annexure.
A.2.4.5. The operator warning system shall be deactivated when the conditions for its activation
have ceased to exist. The operator warning system shall not be automatically
deactivated without the reason for its activation having been remedied.
A.2.4.6. The warning system may be temporarily interrupted by other warning signals providing
important safety related messages.
A.2.4.7. In the application for type-approval under this Regulation, the manufacturer shall
demonstrate the operation of the operator warning system, as specified in paragraph
A.2.9. of this Annexure.
A.2.5. System to store information on operator warning system activation
A.2.5.1. The PCD system shall include a non-volatile computer memory or counters to store
incidents of engine operation with a DTC confirmed and active in a manner to ensure
that the information cannot be intentionally deleted.
A.2.5.2. The PCD shall store in the non-volatile memory the total number and duration of all
incidents of engine operation with a DTC confirmed and active when the operator
warning system has been active for 20 hours of engine operation, or a shorter period
at the choice of the manufacturer.
A.2.5.3. It shall be possible for State and Central Pollution Control Board and other authorities
to read these records with a scan tool.

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A.2.5.4. A description of the connection for, and method to read, these records shall be included
in the information folder as set out in Annexure 1.
A.2.6. Reserved.
A.2.7. Monitoring for removal of the particulate after-treatment system
A.2.7.1. The PCD system shall detect the complete removal of the particulate after-treatment
system inclusive of the removal of any sensors used to monitor, activate, de-activate
or modulate its operation.
A.2.8. Additional requirements in the case of a particulate after-treatment system that
uses a reagent (eg fuel borne catalyst)
A.2.8.1. In the case of a confirmed and active DTC for either removal of the particulate after-
treatment system or loss of the particulate after-treatment system function the reagent
dosing shall be immediately interrupted. Dosing shall re-commence when the DTC is
no longer active.
A.2.8.2. The warning system shall be activated if the reagent level in the additive tank falls
below the minimum value specified by the manufacturer.
A.2.9. Monitoring failures that may be attributed to tampering
A.2.9.1. In addition to monitoring for removal of the particulate after-treatment system the
following failures shall be monitored because they may be attributed to tampering:
(a) loss of the particulate after-treatment system function,
(b) failures of the PCD system, as described in paragraph A.2.9.3. of this Annexure.
A.2.9.2. Monitoring of loss of the particulate after-treatment system function
The PCD shall detect the complete removal of the particulate after-treatment system
substrate (“empty can”). In this case the particulate after-treatment system housing and
sensors used to monitor, activate, de-activate or modulate its operation are still present.
A.2.9.3. Monitoring of failures of the PCD system
A.2.9.3.1. The PCD system shall be monitored for electrical failures and for removal or
deactivation of any sensor or actuator that prevents it from diagnosing any other
failures mentioned in paragraphs A.2.7.1. and A.2.9.1(a) (component monitoring) of
this Annexure.
A non-exhaustive list of sensors that affect the diagnostic capability are those directly
measuring differential pressures over the particulate after-treatment system and
exhaust temperature sensors for controlling the particulate after-treatment system
regeneration.
A.2.9.3.2. Where the failure, removal or deactivation of a single sensor or actuator of the PCD
system does not prevent the diagnosis within the required time period of the failures
mentioned in paragraphs A.2.7.1. and A.2.9.1(a) of this Annexure (redundant system),
the activation of the warning system and storage of information on operator warning
system activation shall not be required unless additional sensor or actuator failures are
confirmed and active.
A.2.10 Demonstration requirements
A.2.10.1 General
The compliance to the requirements of this Appendix shall be demonstrated during
type-approval by performing, as illustrated in Table A.8-6. and specified in paragraph
A.2.10. of this Annexure a demonstration of the warning system activation.

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 Table A.8-6.
Illustration of the content of the demonstration process in accordance with the
provisions in paragraph A.2.10.3 of this Annexure.
Mechanism Demonstration elements
Warning system - 2 activation tests (incl. loss of the
activation particulate after-treatment system
specified in function)
paragraph
A.2.4.4. of this - Supplementary demonstration
Annexure elements, as appropriate

A.2.10.2. Engine families and PCD engine families

A.2.10.2.1. In the case where engines of an engine family belong to a PCD engine family that has
already been type-approved in accordance with paragraph A.2.2.3.6. of this Annex
(Figure A.8-8), the compliance of that engine family is deemed to be demonstrated
without further testing, provided the manufacturer demonstrates to the authority that the
monitoring systems necessary for complying with the requirements of this Appendix are
similar within the considered engine and PCD engine families.

Figure A.8-8.
Previously demonstrated conformity of a PCD engine family

Conformity of PCD engine family 1 has

Conformity of Engine family 1 is been demonstrated for Engine family 2
considered as demonstrated

Engine Engine
family 1 family 2

PCD engine family 1

A.2.10.3. Demonstration of the warning system activation

A.2.10.3.1. The compliance of the warning system activation shall be demonstrated by performing
two tests: loss of the particulate after-treatment system function and one failure
category considered in paragraph A.2.7. or paragraph A.2.9.3. of this Annexure.
A.2.10.3.2. Selection of the failures to be tested
A.2.10.3.2.1. The manufacturer shall provide the Type Approval Authority with a list of such potential
failures.
A.2.10.3.2.2. The failure to be considered in the test shall be selected by the Type Approval Authority
from this list referred to in paragraph A.2.10.3.2.1. of this Annex.
A.2.10.3.3. Demonstration

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A.2.10.3.3.1. For the purpose of this demonstration, a separate test shall be performed for the loss
of the particulate after-treatment system function set out in paragraph A.2.8.2. of this
Annexure and for the failures laid down in paragraphs A.2.7. and A.2.9.3. of this
Annexure. The loss of the particulate after-treatment system function shall be created
by a complete removal of the substrate from the particulate after-treatment system
housing.
A.2.10.3.3.2. During a test, no failure shall be present other than the one addressed by the test.
A.2.10.3.3.3. Prior to starting a test, all DTC shall have been erased.
A.2.10.3.3.4. At the request of the manufacturer, and with the agreement of the Type Approval
Authority, the failures subject to testing may be simulated.
A.2.10.3.3.5. Detection of failures
A.2.10.3.3.5.1. The PCD system shall respond to the introduction of a failure selected as appropriate
by the Type Approval Authority in accordance to the provisions of this Appendix. This
is considered to be demonstrated if activation occurs within the number of consecutive
PCD test-cycles given in Table A.8-7.
When it has been specified in the monitoring description and agreed by the Type
Approval Authority that a specific monitor needs more PCD test-cycles to complete its
monitoring than indicated in Table A.8-7., the number of PCD test-cycles may be
increased by up to 50 per cent
Each individual PCD test-cycle in the demonstration test may be separated by an
engine shut-off. The time until the next start-up shall take into consideration any
monitoring that may occur after engine shut- off and any necessary condition that must
exist for monitoring to occur at the next start-up.

Table A.8-7.
Monitor types and corresponding number of PCD test cycles within which a
“confirmed and active” DTC shall be stored

Number of PCD test cycles within

Monitor type which a “confirmed and active” DTC
shall be stored
Removal of the particulate after-
2
treatment system
Loss of function of the particulate
8
after-treatment system
Failures of the PCD system 2

A.2.10.3.3.6 PCD test cycle

A.2.10.3.3.6.1. The PCD test cycle considered in this paragraph A.2.10. of this Annexure for
demonstrating the correct performance of the particulate after-treatment system
monitoring system is 5 Mode variable speed test cycle for variable speed engines and
the D2 5mode constant speed cycle for constant speed engines categories.
A.1.10.3.3.6.2 On request of the manufacturer with approval of the test agency, an alternative NCD
Cycle (e.g. other than D2-5 Mode cycle) can be used for specific monitoring
A.2.10.3.3.7 Configuration for demonstration of the warning system activation
A.2.10.3.3.7.1. The demonstration of the warning system activation shall be done by tests performed
on an engine test bench.

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A.2.10.3.3.7.2. Any components or subsystems not physically mounted on the engine, such as, but not
limited to, ambient temperature sensors, level sensors, and operator warning and
information systems, that are required in order to perform the demonstrations shall be
connected to the engine for that purpose, or shall be simulated, to the satisfaction of
the Type Approval Authority.
A.2.10.3.3.7.3. If the manufacturer chooses, and subject to the agreement of the Type Approval
Authority, the demonstration tests may be performed, notwithstanding paragraph
A.2.10.3.3.7.1. of this Annexure, on a complete Genset either by mounting the genset
on a suitable test bed or by running it outside test laboratory under controlled
conditions.
A.2.10.3.4. The demonstration of the warning system activation is deemed to be accomplished if,
at the end of each demonstration test performed in accordance with to paragraph
A.2.10.3.3. of this Annexure the warning system has been properly activated and the
DTC for the selected failure has a “confirmed and active” status.
A.2.10.3.5. Where a particulate after-treatment system that uses a reagent is subjected to a
demonstration test for loss of the particulate after-treatment system function or removal
of the particulate after-treatment system it shall also be confirmed that reagent dosing
has been interrupted.
A.2.10.3.6. Documentation of the demonstration
A.2.10.3.6.1 A demonstration report shall be created that documents the demonstration of the PCD
system.
The report shall:
(a) identify the failures examined;
(b) describe the demonstration performed including the applicable test cycle;
(c) confirm that the applicable warnings were activated as required by this regulation;
(d) be included in the information folder as set out in Annex 1.

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 Appendix – A.3

Technical details for prevention of tampering

A.3.1. For engine types and engine families that use an ECU as part of the emission control system
the manufacturer shall provide to the approval authority a description of the provisions taken to
prevent tampering with and modification of the ECU including the facility for updating using a
manufacturer-approved program or calibration;
A.3.2. For engine types and engine families that use mechanical devices as part of the emission
control system the manufacturer shall provide to the approval authority a description of the
provisions taken to prevent tampering with and modification of the adjustable parameters of the
emission control system. This shall include the tamper resistant components. Such as Fuel
injection pump limiter caps or sealing of Fuel injection pump screws or special screws not
adjustable by user.
A.3.2.1. The manufacturer shall demonstrate to the Test Agency that the adjustable parameters of the
emission control system cannot be easily tampered by applying reasonable forces, either:
(a) using the tools supplied together with the engine; or,
(b) using ordinary tools such as screwdriver, pliers (including cutting pliers) or wrenches.
Ordinary tools do not include: most cutting or grinding tools, drills and rotary cutters, or tools
that generate excessive heat or flame.
A.3.3. For the purpose of this Appendix, engines from different engine families may be further
combined into families based upon the type and design of tamper prevention measures utilized.
In order to place engines from different engine families into the same tamper prevention engine
family the manufacturer shall provide confirmation to the approval authority that the measures
used to prevent tampering are similar. In this case the requirements of paragraphs A.3.1. and
A.3.2. of this Annexure may be performed for one representative engine and the corresponding
documentation used during the type approval of all engines in the same tamper prevention
engine family.
A.3.4. Manufacturers shall provide a warning in the operator's manual stating that tampering with the
engine voids the type-approval of that particular engine.

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 Appendix – A.4

Technical details for Remote Information and Monitoring Requirements

A.4.1. General Requirements

A.4.1.1. Gensets powered by electronically controlled engines with >56 kW power shall be equipped
with remote information and monitoring system utilizing telematics.
Gensets unlike non-road machines and On road vehicles are operated typically without human
intervention and does not have an ‘Operator’ required to be present during its operation. This
makes ‘Operator Warning System’ in line with non-road machines difficult to follow through as
well as getting timely inputs to the operator of a Genset.
A.4.1.2. Manufacturer in conjunction with GOEM shall provide a cellular data based remote information
monitoring system that is capable of working with Application (App) able to work with desktop
computers and cellular hand-held devices such cellphone. Such app once installed shall be
able to provide essential information and warnings to Genset owner/s, operator/s highlighting
any mal-function related to emission control by a suitable “Engine Malfunction” icon indicated
prominently on the user interface.
A.4.1.3. Manufacturer may choose to demonstrate the remote monitoring function as mentioned in
A.4.1.2 on engine test bench during engine type approval and COP or on the Genset during
Genset type approval & COP.

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 ANNEXURE – 9

Installation in the Genset Application

9.1. Information and instructions intended for OEMs and end-users.

9.1.1. A manufacturer shall not supply to GOEMs or end-users any technical information related to the
particulars provided for in this Regulation which diverges from the particulars approved by the
Type Approval Authority;
9.1.2. The manufacturer shall make available to GOEMs all relevant information and instructions that
are necessary for the correct installation of an engine in Genset, including a description of any
special conditions or restrictions linked to the installation or use of the engine;
9.1.3. The manufacturer shall make available to GOEMs all relevant information and necessary
instructions intended for the end-user, including a description of any special conditions or
restrictions linked to the use of an engine.
9.1.4. Details of the relevant information and instructions for the GOEMs are set out in Appendix 1 to
Annexure 9.

9.2. Obligations of GOEMs concerning the installation of engines

9.2.1. GOEMs shall install approved engines in Genset in accordance with the instructions provided by
the manufacturer pursuant to paragraph 9.1.2, and in a manner that does not adversely affect the
engine's performance with regard to its gaseous and particulate pollutant emissions;
9.2.2. Where an GOEM does not follow the instructions referred to in paragraph 9.2.1., or modifies an
engine in the course of its installation of genset, in a manner that adversely affects the engine's
performance with regard to its gaseous and particulate pollutant emissions, that GOEM shall be
considered to be a manufacturer for the purposes of this Regulation and shall, in particular, be
subject to the obligations laid down in clauses 3, 4 and 5 of this Regulation;
9.2.3. OEMs shall install type-approved engine(s) in genset(s) only in accordance with the kinds of
exclusive use provided for the engine categories set out in clause 1.
9.2.5. Details of the relevant information and instructions for the end-users are set out in Appendix 2 to
Annexure 9;
9.2.6 For the use of Dual Fuel engine in GENSET, the safety code of practice to be followed along with
the instructions provided by the manufacturer pursuant to paragraph 9.1.2, and in a manner that
does not adversely affect the engine's performance with regard to its gaseous and particulate
pollutant emissions; The test agency will certify the installation of the engine in GENSET canopy
as per safety code of practice. The separate document ‘A4’ named “SAFETY CODE OF
PRACTICE” shall be referred for more clarification. The noise level certificate shall be issued only
after compliance of GENSET to safety code of practice.

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 Appendix – 1

Details of the relevant information and instructions for the GOEMs

A.1.1. As required by paragraph 9.1., the manufacturer shall provide to the GOEM all relevant
information and instructions to ensure that the engine conforms to the approved engine type when
installed in Gensets. Instructions for this purpose shall be clearly identified to the GOEM;
A.1.2. The instructions may be provided on paper or a commonly used electronic format;
A.1.3. Where a number of engines requiring the same instructions are supplied to the same GOEM it
shall be necessary to provide one set of instructions at minimum;
A.1.4. The information and instructions to the OEM shall include at minimum:
A.1.4.1. installation requirements to achieve the emissions performance of the engine type, including the
emission control system, that shall be taken into account to ensure the correct operation of the
emissions control system;
A.1.4.2. a description of any special conditions or restrictions linked to the installation or use of the
engine, as noted on the communication set out in Annexure 1
A.1.4.3. a statement indicating that the installation of the engine shall not permanently constrain the
engine to exclusively operate within a power range corresponding to a (sub-)category with
gaseous and particulate pollutant emission limits more stringent than the (sub-) category the
engine belongs to;
For e.g.:
a) Engine certified for > 56 KW power can be permanently constrained to power less than 56
KW
b) However, engine certified for > 560 KW power cannot be permanently constrained to power
less than 560 KW
A.1.4.4. for engine families to which appendix 2 of annexure7 of this Regulation applies, the upper and
lower boundaries of the applicable control area and a statement indicating that the installation
of the engine shall not constrain the engine to exclusively operate at speed and load points
outside of the control area for the torque curve of the engine;
A.1.4.5. where applicable, design requirements for the components supplied by the OEM that are not
part of the engine and are necessary to ensure that, when installed, the engine conforms to the
approved engine type;
A.1.4.6. where applicable, design requirements for the reagent tank, including freeze protection,
monitoring of reagent level and means to take samples of reagent;
A.1.4.7. where applicable, information on installation of a non-heated reagent system;
A.1.4.9. where applicable, a statement indicating that the OEM shall provide a warning system as set
out in Appendices 1, 2 and 3 of Annexure 8;
A.1.4.10. where applicable, information on the interface between the engine and genset for the operator
warning system, referred to in paragraph A.1.4.9.;
A.1.4.11. where applicable, information on the interface between the engine and Genset for the operator
inducement system, as set out in Annexure 8;
A.1.4.12. where applicable, information on a means to temporarily disable the operator inducement as
defined in Annexure 8;
A.1.4.13. where applicable, information on the inducement override function as defined in Annexure 8;
A.1.4.14. in the case of dual-fuel engines:
(a) a statement indicating that the GOEM shall provide a dual-fuel operating mode indicator
as described in clause 4.3.1 of annexure 10

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 (b) a statement indicating that the GOEM shall provide a dual-fuel warning system as
described in clause 4.3.1 of annexure 10
(c) information on the interface between the engine and the Genset for the operator
indication and warning system, referred to in paragraphs A1.4.14. (a) and (b);
A.1.4.15. In the case of a constant-speed engine equipped with alternative speeds as set out in paragraph
4.1.2.3. of Clause 4:
(a) a statement indicating that the installation of the engine shall ensure that:
i. the engine is stopped prior to resetting the constant-speed governor to an alternative
speed; and,
ii. the constant-speed governor is only set to the alternative speeds permitted by the
engine manufacturer;
(b) details of each (sub-)category and operating mode (speed operation) for which the
engine is type-approved and may be set when installed;
A.1.4.16. In the case that the engine is equipped with an idle speed for start-up and shut-down, a
statement indicating that the installation of the engine shall ensure that the constant-speed
governor function is engaged prior to increasing the load-demand to the engine from the no-
load setting.
A.1.5. The manufacturer shall provide to the GOEM all information and necessary instructions that the
GOEM shall provide to the end-users in accordance with Appendix 2 to Annexure 9.

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 Appendix – 2

Details of the relevant information and instructions for the end-users

A.2.1. The GOEM shall provide to the end-users all information and necessary instructions for the
correct operation of the engine in order to maintain the gaseous and particulate pollutant
emissions of the engine within the limits of the approved engine type or engine family.
Instructions for this purpose shall be clearly identified to the end-users.
A.2.2. The instructions to the end-users shall be:
A.2.2.1. written in a clear and non-technical manner using the same language that is used in the
instructions to end-users for gensets;
A.2.2.2. be provided on paper or, alternatively, a commonly used electronic format;
A.2.2.3. be part of the instructions to end-users for the Genset,
A.2.3. The information and instructions to the end-users shall include at least:
A.2.3.1. a description of any special conditions or restrictions linked to the use of the engine, as noted
on the type-approval communication;
A.2.3.2. a statement indicating that the engine, including the emissions control system, shall be
operated, used and maintained in accordance with the instructions provided to the end-users in
order to maintain the emissions performance of the engine within the requirements applicable
to the engine's category;
A.2.3.3. a statement indicating that no deliberate tampering with or misuse of the engine emissions
control system should take place; in particular, with regard to deactivating or not maintaining an
exhaust gas recirculation (EGR) or a reagent dosing system;
A.2.3.4. a statement indicating that it is essential to take prompt action to rectify any incorrect operation,
use or maintenance of the emissions control system in accordance with the rectification
measures indicated by the warnings referred to in paragraph A.2.3.5. and A.2.3.6.;
A.2.3.5. detailed explanations of the possible malfunctions of the emissions control system generated
by incorrect operation, use or maintenance of the installed engine and due to failure to emission
control system components, accompanied by the associated warning signals and the
corresponding rectification measures;
A.2.3.6. detailed explanations of the possible incorrect use of the Genset that would result in
malfunctions of the engine emissions control system, accompanied by the associated warning
signals and the corresponding rectification measures;
A.2.3.7. for gensets with an operator warning system, a statement indicating that the operator will be
informed by the operator warning system when the emission control system does not function
correctly;
A.2.3.8. for Genset with an operator inducement system a statement indicating that ignoring the operator
warning signals will lead to the activation of the operator inducement system, resulting in an
effective disablement of genset operation;
A.2.3.9. for Genset with an inducement override function for releasing full engine power justified by safety
concerns or to allow for self-healing diagnostics, information about the operation of this function;
A.2.3.10. where applicable, explanations of how the operator warning and inducement systems referred
to in paragraphs A.2.3.7., A.2.3.8. and A.2.3.9. operate, including the consequences, in terms
of performance and fault logging, of ignoring the warning system signals and of not replenishing,
where used, the reagent or rectifying the problem identified;
A.2.3.11. for genset with a means to disable the operator inducement, information about the operation of
this function, and a statement indicating that this function shall be only activated in case of
emergencies, that any activation will be recorded in the on-board computer log and that Central

154
 or State pollution Control Board inspection authorities will be able to read these records with a
scan tool;
A.2.3.12. information on the fuel(s) necessary to maintain the performance of the emissions control
system in particular:
(a) where the engine is to be operated on diesel, a statement indicating that a fuel with sulphur
content not greater than 10 mg/kg or 10 PPM, cetane number not less than 51 and an FAME
content not greater than 7.0 per cent v/v shall be used;
(b) where additional fuels, fuel mixtures or fuel emulsions are compatible with use by the engine,
as declared by the manufacturer and stated in the type-approval communication, these shall
be indicated. Such fuel type shall be constrained by alternate fuel definitions of this
Regulation;
A.2.3.13. information on the lubrication oil specifications necessary to maintain the performance of the
emissions control system;
A.2.3.14. where the emission control system requires a reagent, the generic name, characteristics of that
reagent, including the type of reagent, information on concentration when the reagent is in
solution, operational temperature conditions and reference to Indian and international standards
for composition and quality, consistent with the specification set-out in the engine type-approval;
A.2.3.15. where applicable, instructions specifying how consumable reagents have to be refilled by the
operator between normal maintenance intervals. They shall indicate how the operator should
refill the reagent tank and the anticipated frequency of refill, depending upon of the genset based
on average per day operation;
A.2.3.16.a statement indicating that in order to maintain the emissions performance of the engine, it is
essential to use and refill reagent in accordance with the specifications set out in clause
A.2.3.14. and A.2.3.15.;
A.2.3.17. scheduled emission-related maintenance requirements including any scheduled exchange of
critical emission-related components;
A.2.3.18. in the case of dual-fuel engines:
(a) where applicable, information on the dual-fuel indicators,
(b) where a dual-fuel engine has operability restrictions in a service mode, a statement
indicating that the activation of the service mode will result in an effective disablement of the
Genset,
(c) where an inducement override function for releasing full engine power is available,
information about the operation of this function shall be provided,

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 ANNEXURE – 10

Technical requirements for dual-fuel engines (Diesel + Alternate Fuel)

1.0 Scope
This Annex shall apply for dual-fuel engines when engine is being operated
simultaneously on both a liquid and a gaseous fuel (dual-fuel mode).
This Annex shall not apply for testing engines, including dual-fuel engines, when they
are being operated solely on liquid or solely on gaseous fuels (i.e. when the GER is
either 1 or 0 according to the type of fuel). In this case the requirements are the same
as for any single-fuel engine.
2. Definitions and abbreviations
For the purposes of this Annex the following definitions shall apply
2.1. "GER (Gas Energy Ratio)" has the meaning defined in paragraph 2 of this Regulation
based on the lower heating value;
2.2. "GERcycle" means the average GER when operating the engine on the applicable
engine test cycle;
2.3. "Dual-fuel Type 1A engine" means either:
(a) dual-fuel engine, that operates over test-cycles as mentioned in appendix1 of
annexure 7 of part 1 of this document with an average gas energy ratio that is
not lower than 90 per cent (GER ≥ 0.9) and that does not idle using exclusively
liquid fuel, and that has no liquid-fuel mode,
2.4. "Dual-Fuel Type 1B engine" means either:
(a) dual-fuel engine, that operates over test-cycles as mentioned in appendix1 of
annexure 7 of part 1 of this document with an average gas energy ratio that is
not lower than 90 % (GER ≥ 0.9) and that does not idle using exclusively liquid
fuel in dual-fuel mode, and that has a liquid-fuel mode,
2.5. "Dual-Fuel Type 2A engine" means either:
(a) dual-fuel engine, that operates over test-cycles as mentioned in appendix1 of
annexure 7 of part 1 of this document with an average gas energy ratio
between 10 per cent and 90 per cent (0.1 < GER < 0.9) and that has no liquid-
fuel mode or that operates over the hot part of the NRTC test-cycle with an
average gas energy ratio that is not lower than 90 per cent (GER ≥ 0.9), but
that idles using exclusively liquid fuel, and that has no liquid-fuel mode;
2.6. "Dual-Fuel Type 2B engine" means either:
(a) dual-fuel engine, that operates over test-cycles as mentioned in appendix1 of
annexure 7 of part 1 of this document with an average gas energy ratio
between 10 per cent and 90 per cent (0.1 < GER < 0.9) and that has a liquid-
fuel mode or that operates over the hot part of the NRTC test-cycle with an
average gas energy ratio that is not lower than 90 per cent (GER ≥ 0.9), and
that has a liquid-fuel mode but that can idle using exclusively liquid fuel in dual-
fuel mode
2.7. "Dual-Fuel Type 3B engine" means either:
(a) dual-fuel engine, that operates over test-cycles as mentioned in appendix1 of
annexure 7 of part 1 of this document with an average gas energy ratio that
does not exceed 10 per cent (GER ≤ 0.1) and that has a liquid-fuel mode,

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3. Dual-fuel specific additional approval requirements
3.1. Engines with operator-adjustable control of GERcycle.
In the case for a given engine type the value of GERcycle can be reduced from the
maximum by an operator-adjustable control, the minimum GERcycle shall not be limited
but the engine shall be capable of meeting the emission limit values at any value of
GERcycle permitted by the manufacturer.

4. General requirements
4.1. Operating modes of dual-fuel engines
4.1.1. Conditions for a dual-fuel engine to operate in liquid mode
A dual-fuel engine may only operate in liquid-fuel mode if, when operating in liquid-fuel
mode, it has been certified according to all the requirements of this Regulation
concerning operation solely on the specified liquid fuel.
When a dual-fuel engine is developed from an already certified liquid-fuel engine, then
a new type approval certificate is required in the liquid-fuel mode.
4.1.2. Conditions for a dual-fuel engine to idle using liquid fuel exclusively
4.1.2.1. Dual-fuel Type 1A engines shall not idle using liquid fuel exclusively except under the
conditions defined in paragraph 4.1.3. of this Annex for warm-up and start.
4.1.2.2. Dual-fuel Type 1B engines shall idle using liquid fuel exclusively in dual-fuel mode.
4.1.2.3. Dual-fuel Types 2A, 2B and 3B engines may idle using liquid fuel exclusively.

4.1.3. Conditions for a dual-fuel engine to warm-up or start using liquid fuel solely
4.1.3.1. A Type 1B, Type 2B, or Type 3B dual-fuel engine may warm-up or start using liquid
fuel solely. In the case that the emission control strategy during warm-up or start-up in
dual-fuel mode is the same as the corresponding emission control strategy in liquid-
fuel mode the engine may operate in dual-fuel mode during warm-up or start-up. If this
condition is not met the engine shall only warm-up or start-up using liquid fuel solely
when in liquid-fuel mode.
4.1.3.2. A Type 1A or Type 2A dual-fuel engine may warm-up or start-up using liquid fuel solely.
However, in that case, the strategy shall be declared as an AECS and the following
additional requirements shall be met:
4.1.3.2.1. The strategy shall cease to be active when the coolant temperature has reached a
temperature of 343 K (70 °C), or within 15 minutes after it has been activated,
whichever occurs first; and
4.1.3.2.2. The service mode shall be activated while the strategy is active.

4.2. Service mode

4.2.1. Conditions for dual-fuel engines to operate in service mode
When an engine is operating in service mode it is subject to an operability restriction
and is temporarily exempted from complying with the requirements related to exhaust
emissions and NOX control described in this Regulation.
4.2.2. Operability restriction in service mode
4.2.2.1. Requirement
The operability restriction applicable to a dual-fuel engine operated in service mode is
the one activated by the "severe inducement system"

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 In order to account for safety concerns and to allow for self-healing diagnostics, use of
an inducement override function for releasing full engine power is permitted
The operability restriction shall not otherwise be deactivated by either the activation or
deactivation of the warning and inducement systems.
The activation and the deactivation of the service mode shall not activate or deactivate
the warning and inducement systems
4.2.2.2. Reserved
4.2.2.3. Activation of the operability restriction
The operability restriction shall be automatically activated when the service mode is
activated.
In the case where the service mode is activated because of a malfunction of the gas
supply system, the operability restriction shall become active within 30 minutes
operating time after the service mode is activated.
In the case where the service mode is activated because of an empty gaseous fuel
tank, the operability restriction shall become active as soon as the service mode is
activated.
4.2.2.4. Deactivation of the operability restriction
The operability restriction system shall be deactivated when the engine no longer
operates in service mode.
4.2.3. Unavailability of gaseous fuel when operating in a dual-fuel mode
(a) Dual-fuel engines of Types 1A and 2A shall activate the service mode;
(b) Dual-fuel engines of Types 1B, 2B and 3B shall operate in liquid mode.
4.2.3.1. Unavailability of gaseous fuel – empty gaseous fuel tank (Here onwards, it is to be
considered for engines/gensets supplied with cascade systems for CNG/LPG)
In the case of an empty gaseous fuel tank, the service mode or, the liquid fuel mode
shall be activated as soon as the engine system has detected that the tank is empty.
When the gas availability in the tank again reaches the level that justified the activation
of the empty tank warning system, the service mode may be deactivated, or, when
appropriate, the dual-fuel mode may be reactivated.
4.2.3.2. Unavailability of gaseous fuel – malfunctioning gas supply
In the case of a malfunctioning gas supply system that causes the unavailability of
gaseous fuel, the service mode or, as appropriate, the liquid fuel mode shall be
activated when gaseous fuel supply is not available.
As soon as the gaseous fuel supply becomes available the service mode may be
deactivated, or, when appropriate, the dual-fuel mode may be reactivated.

4.3. Dual-fuel indicators

4.3.1. Dual-fuel operating mode indicator
The Genset shall provide to the operator a visual indication of the mode under which
the engine operates (dual-fuel mode, liquid mode, or service mode).
The characteristics and the location of this indicator shall be left to the discretion of the
OEM and may be part of an already existing visual indication system.
This indicator may be completed by a message display. The system used for displaying
the messages referred to in this paragraph may be the same as the ones used for NOX
control diagnostics, or other maintenance purposes.

158
 The visual element of the dual-fuel operating mode indicator shall not be the same as
the one used for the purpose of NOX control diagnostics, or for other engine
maintenance purposes.
Safety alerts always have display priority over the operating mode indication.
4.3.1.1. The dual-fuel mode indicator shall be set to service mode as soon as the service mode
is activated (i.e. before it becomes actually active) and the indication shall remain as
long as the service mode is active.
4.3.1.2. The dual-fuel mode indicator shall be set for at least one minute on dual-fuel mode or
liquid-fuel mode as soon as the engine operating mode is changed from liquid fuel to
dual-fuel mode or vice-versa. This indication is also required for at least one minute at
key-on, or at the request of the manufacturer at engine cranking. The indication shall
also be given upon the operator’s request.
4.3.2. Empty gaseous fuel tank warning system (dual-fuel warning system) (Applicable in
case of genset with CNG cascade system)
Genset fitted with a dual-fuel engine shall be equipped with a dual-fuel warning system
that alerts the operator that the gaseous fuel tank will soon become empty.
The dual-fuel warning system shall remain active until the tank is refuelled to a level
above which the warning system is activated.
The dual-fuel warning system may be temporarily interrupted by other warning signals
providing important safety-related messages.
It shall not be possible to turn off the dual-fuel warning system by means of a scan-tool
as long as the cause of the warning activation has not been rectified.
4.3.2.1. Characteristics of the dual-fuel warning system
The dual-fuel warning system shall consist of a visual alert system (icon, pictogram,
etc.) left to the choice of the manufacturer.
It may include, at the choice of the manufacturer, an audible component. In that case,
the cancelling of that component by the operator is permitted.
The visual element of the dual-fuel warning system shall not be the same as the one
used for the purpose of NOX control diagnostics, or for other engine maintenance
purposes.
In addition, the dual-fuel warning system may display short messages, including
messages indicating clearly the remaining distance or time before the activation of the
operability restriction.
The system used for displaying the warning or messages referred to in this paragraph
may be the same as the one used for displaying the warning or messages related the
NOX control diagnostics, or warning or messages for other maintenance purposes.

4.4. Communicated torque

4.4.1. Communicated torque when a dual-fuel engine operates in dual-fuel mode
When a dual-fuel engine operates in dual-fuel mode:
(a) The reference torque curve retrievable shall be the one obtained when that engine is
tested on an engine test bench in the dual-fuel mode;
(b) The recorded actual torques (indicated torque and friction torque) shall be the result of
the dual-fuel combustion and not the one obtained when operating with liquid fuel
exclusively.
4.4.2. Communicated torque when a dual-fuel engine operates in liquid-fuel mode
When a dual-fuel engine operates in liquid-fuel mode, the reference torque curve
retrievable shall be the one obtained when the engine is tested on an engine test bench
in liquid-fuel mode.

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4.5. Additional requirements
4.5.1. Where used for a dual-fuel engine, shall comply with the following requirements:
(a) The engine shall always remain within the dual-fuel engine type (that is Type 1A,
Type 2B, etc.) that has been declared for the type-approval; and
(b) In case of a Type 2 engine, the resulting difference between the highest and the
lowest maximum GERcycle within the family shall never exceed the range set out
4.6 The type approval shall be conditional upon providing to the OEM and end-users, in
accordance with the clauses mentioned in this Regulation, instructions for installation
and operation of the dual-fuel engine including the service mode set out in paragraph
4.2. and the dual-fuel indicator system set out in paragraph 4.3.

5. Performance requirements
5.1. The performance requirements, including emission limit values, and the requirements
for type-approval applicable to dual-fuel engines are identical to those of any other
diesel engine of the respective engine category as set out in this Regulation, except as
set out in this paragraph 5.
5.2 NMHC & RHC to be considered in place of THC for dual fuel engines operated on
natural gas and LPG respectively
5.3 The technical requirements on emission control strategies, including documentation
required to demonstrate these strategies, technical provisions to resist tampering and
the prohibition of defeat devices are identical to those of any other diesel engine of the
respective engine category
5.4 Reserved

6. Demonstration requirements
6.1. The demonstration requirements applicable to dual-fuel engines are identical to those
of any other diesel engine of the respective engine category as set out in this
Regulation, except as set out in paragraph 6. of this Annex.
6.2. Compliance with the applicable limit values shall be demonstrated in dual-fuel mode.
6.3. For dual-fuel engine types with a liquid-fuel mode (i.e. types 1B, 2B, 3B) compliance
with the applicable limit values shall additionally be demonstrated in liquid-fuel mode.
6.4. Additional demonstration requirements in case of a Type 2 engine
6.4.1 The manufacturer shall present the Type Approval Authority with evidence showing
that the GERcycle span of all members of the dual-fuel engine family remains within the
range specified, or in the case of engines with an operator-adjustable GERcycle satisfy
the requirements as specified in this document (for example, through algorithms,
functional analyses, calculations, simulations, results of previous tests, etc.).
6.5 Additional demonstration requirements in case of an engine with an operator-
adjustable GERcycle
6.5.1 Compliance with the applicable limit values shall be demonstrated at the minimum and
maximum value of GERcycle permitted by the manufacturer.
6.6. Requirements for demonstrating the durability of a dual-fuel engine
6.6.1 Provisions of Appendix 6 of Annex 7shall apply.
6.7. Demonstration of the dual-fuel indicators, warning and operability restriction
6.7.1 As part of the application for type-approval under this Regulation, the manufacturer
shall demonstrate the operation of dual-fuel indicators and of the warning and
operability restriction in accordance with the provision made in this document.

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6.8 Documentation of the demonstration
A demonstration report shall document the demonstration conducted to comply with
paragraph 6 of this Annex. The report shall:

(a) describe the demonstration performed, including the applicable test cycle;
(b) be included in the information folder

7. Requirements to ensure the correct operation of NOX control

measures
7.1. Annex 8 (on technical requirements on NOX control measures) shall apply to dual-fuel
engines, whether operating in dual-fuel or liquid mode.
7.2. Additional NOX control requirements in case of Type 1B, Type 2B and Type 3B dual-
fuel engines
7.2.1. The torque considered to apply to the severe inducement defined in Appendix A.1 of
Annex 8 shall be the lowest of the torques obtained in liquid-fuel mode and in dual-fuel
mode.
7.2.2 A possible influence of the mode of operation on the malfunction detection shall not be
used to extend the time until an inducement becomes active.
7.2.3. In the case of malfunctions, the detection of which does not depend on the operation
mode of the engine, the mechanisms specified in Annex 8 that are associated with the
DTC status shall not depend on the operation mode of the engine (for example, if a
DTC reached the potential status in dual-fuel mode, it will get the confirmed and active
status the next time the failure is detected, even in liquid-fuel mode).
7.2.4. In the case of malfunctions where the detection depends on the operation mode of the
engine, DTCs shall not get a previously active status in a different mode than the mode
in which they reached the confirmed and active status.
7.2.5. A change of the mode of operation (dual-fuel to liquid fuel or vice-versa) shall not stop
nor reset the mechanisms implemented to comply with the specification of Annex 8
(counters, etc.). However, in the case where one of these mechanisms (for example a
diagnostic system) depends on the actual operation mode the counter associated with
that mechanism may, at the request of the manufacturer and upon approval of the Type
Approval Authority:
(a) Halt and, when applicable, hold their present value when the operation mode
changes;
(b) Restart and, when applicable, continue counting from the point at which they have
been held when the operation mode changes backs to the other operation mode.

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 Appendix – A.1

Dual-fuel engine dual-fuel indicator, warning system, operability

restriction - Demonstration requirements

A.1.1. Dual-fuel indicators

A.1.1.1. Dual-fuel mode indicator
The ability of the engine to command the activation of the dual-fuel mode indicator when
operating in dual-fuel mode shall be demonstrated at type-approval.
A.1.1.2. Liquid-fuel mode indicator
In the case of a Type 1B, Type 2B, or Type 3B dual-fuel engine the ability of the engine to
command the activation of the liquid-fuel mode indicator when operating in liquid-fuel mode
shall be demonstrated at type-approval.
A.1.1.3. Service mode indicator
The ability of the engine to command the activation of the service mode indicator when operating
in service mode shall be demonstrated at type-approval.
A.1.1.3.1. When so-equipped it is sufficient to perform the demonstration related to the service mode
indicator by activating a service mode activation switch and to present the Type Approval
Authority with evidence showing that the activation occurs when the service mode is
commanded by the engine system itself (for example, through algorithms, simulations, result of
in-house tests, etc. …).
A.1.2. Warning system
The ability of the engine to command the activation of the warning system in the case that the
amount of gaseous fuel in the gaseous fuel tank is below the warning level, shall be
demonstrated at type-approval. For that purpose the actual amount of gaseous fuel may be
simulated.
A.1.3. Operability restriction
In the case of a Type 1A or Type 2A dual-fuel engine the ability of the engine to command the
activation of the operability restriction upon detection of an empty gaseous fuel tank and of a
malfunctioning gas supply system shall be demonstrated at type-approval. For that purpose the
empty gaseous fuel tank and the malfunctioning of the gas supply may be simulated.
A.1.3.1. It is sufficient to perform the demonstration in a typical use-case selected with the agreement
of the Type Approval Authority and to present that authority with evidence showing that the
operability restriction occurs in the other possible use-cases (for example, through algorithms,
simulations, result of in-house tests, etc).

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 Appendix – A.2

Emission test procedure requirements for dual-fuel engines

A.2.1. General
This Appendix defines the additional requirements and exceptions to enable emission testing
of dual-fuel engines independent whether these emissions are solely exhaust emissions or also
crankcase emissions added to the exhaust emissions according to Appendix 5 of Annexure 7
In the case that no additional requirement or exception is listed, the requirements of this
Regulation shall apply to dual-fuel engines in the same way as they apply to any other approved
engine types or engine families.
Emission testing of a dual-fuel engine is complicated by the fact that the fuel used by the engine
can vary between pure liquid fuel and a combination of mainly gaseous fuel with only a small
amount of liquid fuel as an ignition source. The ratio between the fuels used by a dual-fuel
engine can also change dynamically depending of the operating condition of the engine. As a
result, special precautions and restrictions are necessary to enable emission testing of these
engines.
A.2.2. Test conditions
Test conditions similar to diesel engine shall apply as given in Annexure 7
Test procedure similar to diesel engine shall apply as given in Annexure 7
A.2.4. Measurement procedures
Measurement procedures shall apply as per diesel engine given in Annex 7
A full-flow dilution measurement procedure for dual-fuel engines is similar to diesel engine and
to be followed accordingly
This measurement procedure ensures that the variation of the fuel composition during the test
will mainly influence the hydrocarbon measurement results. This shall be compensated via one
of the methods described in paragraph A.2.7 of this Appendix.
Raw gaseous/partial flow measurement procedure for dual-fuel engines is similar to diesel
engine and to be followed accordingly
A.2.5. Measurement equipment
Measurement equipment shall be as per diesel engines as given in Annexure 4
A.2.6. Particle number emissions measurement
Particle number emissions measurement shall be as per diesel engine procedure
A.2.7. Emission calculation
The emission calculation shall be performed according to diesel engine except set out in
appendix below. The additional requirements set out in Annexure 5 shall be applicable.
The emission calculation requires knowledge of the composition of the fuels being used. When
a gaseous fuel is supplied with a certificate confirming the properties of the fuel (e.g. gas from
bottles) it is acceptable to use the composition specified by the supplier. Where the composition
is not available (e.g. pipeline fuel) the fuel composition shall be analysed at least prior to and
after the engine emission test is conducted. More frequent analysis shall be permitted and the
results used in the calculation.
Where the gas energy ratio (GER) is used it shall be consistent with the definition as specified
in this document. and the specific provisions on hydrocarbon (HC) limits for fully and partially
gaseous-fuelled engines as specified in this Regulation. The average value of GER over the
cycle shall be calculated by multiplying the average GER for each test mode by the
corresponding weighting factor for that mode and calculating the sum for all modes. The
weighting factors shall be applicable similar to diesel engine.

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A.2.7.1. Mass-based emission calculation
Procedure similar to diesel engines, as given in Annexure 5 shall be applicable.
A.2.7.1.1. Dry/wet correction
A.2.7.1.1.1 Raw exhaust gas
Annexure 5 shall be used to calculate the dry/wet correction factor. The fuel specific parameters
shall be determined in accordance with paragraph A.2.7.1 of this document.
A.2.7.1.1.2. Diluted exhaust gas
Annex 5 shall be used to calculate the wet/dry correction.
The molar hydrogen ratio α of the combination of the two fuels shall be used for the dry/wet
correction. This molar hydrogen ratio shall be calculated from the fuel consumption
measurement values of both fuels in accordance with paragraph A.2.7.1
A.2.7.1.2. NOX correction for humidity
The NOX humidity correction for compression ignition engines as specified in Annex 5 shall be
used.
A.2.7.1.3. Partial flow dilution (PFS) and raw gaseous measurement
A.2.7.1.3.1. Determination of exhaust gas mass flow
The exhaust mass flow shall be determined using a raw exhaust flowmeter as described in
Annex 5.
Alternatively, the airflow and air to fuel ratio measurement method according to Annex 5 may
be used the use of a zirconia-type sensor to determine the air fuel ratio is not allowed.
In the case of testing engines subject to steady-state test cycles only the exhaust gas mass
flow may be determined by the air and fuel measurement method in accordance with Annex 5.
A.2.7.1.3.2. Determination of the gaseous components
Requirements of Annex 5 shall apply except as set out in this paragraph.
The possible variation of fuel composition will influence all the ugas factors and molar component
ratios used in the emission calculations. One of the following approaches shall be used to
determine ugas factors and molar component ratios at the choice of the manufacturer.
(a) The exact equations in Annex 5 shall be applied to calculate instantaneous values of
ugas using the instantaneous proportions of liquid and gaseous fuel (determined from
instantaneous fuel consumption measurements or calculations) and instantaneous
molar component ratios or,
(b) When the mass-based calculation in Annex 5 is used for the specific case of a dual-
fuel engine operated on gas and diesel fuel, tabulated values may be used for the molar
component ratios and ugas values. These tabulated values shall be applied as follows:

i. For engines operated on the applicable test cycle with an average gas energy ratio
greater than or equal to 90 per cent (GER ≥ 0.9) the required values shall be those
for the gaseous fuel taken from Table A.7-1
ii. For engines operated on the applicable test cycle with an average gas energy ratio
between 10 per cent and 90 per cent (0.1 < GER < 0.9) the required values shall be
assumed to be represented by those for a mixture of 50 % gaseous fuel and 50 %
diesel fuel taken from Tables A.7-2 and A.7-3
iii. For engines operated on the applicable test cycle with an average gas energy ratio
less than or equal to 10 per cent (GER ≤ 0.1) the required values shall be those for
diesel fuel taken from taken from Table A.7-4
iv. For the calculation of HC emissions, the ugas value of the gaseous fuel shall be used
in all cases irrespective of the average gas energy ratio (GER).
Table A.7-1.

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 Raw exhaust gas u and component densities for GER ≥ 0.9
(for emission concentration expressed in ppm)
Gas
NOX CO HC CO2 O2 CH4
Gaseous fuel gas [kg/m³]
 2.053 1.25 (a)
1.9636 1.4277 0.716
(b)
ugas

CNG/LNG/Bio-
1.2661 0.001621 0.000987 0.000528d 0.001551 0.001128 0.000565
Methane(c)
Propane 1.2805 0.001603 0.000976 0.000512 0.001533 0.001115 0.000559
Butane 1.2832 0.0016 0.000974 0.000505 0.00153 0.001113 0.000558
(e)
LPG 1.2811 0.001602 0.000976 0.00051 0.001533 0.001115 0.000559
(a) depending on fuel
(b) at l = 2, dry air, 273 K, 101.3 kPa

(c) u accurate within 0.2 % for mass composition of: C = 66 - 76 per cent; H = 22 - 25 per cent; N = 0
- 12 per cent (CH4, G20, G23, and G25)
(d) NMHC on the basis of CH2.93 (for total HC the ugas coefficient of CH4 shall be used)
(e) u accurate within 0.2 % for mass composition of: C3 = 27 - 90 per cent; C4 = 10 - 73 per cent (LPG
Fuels A and B)
Table A.7-2.

Molar component ratios for a mixture of 50 per cent gaseous fuel and 50 per cent
diesel fuel (mass per cent) for (0.1 < GER < 0.9)

Gaseous fuel α γ δ ε
CH4 2.8681 0 0 0.0040
GR 2.7676 0 0 0.0040
G23 2.7986 0 0.0703 0.0043
G25 2.7377 0 0.1319 0.0045
Propane 2.2633 0 0 0.0039
Butane 2.1837 0 0 0.0038
LPG 2.1957 0 0 0.0038
LPG Fuel A 2.1740 0 0 0.0038
LPG Fuel B 2.2402 0 0 0.0039

165
 Table A.7-3
Raw exhaust gas u gas values and component densities for a mixture of 50 per cent
gaseous fuel and 50 per cent diesel fuel (mass per cent) for (0.1 < GER < 0.9)

Gas

NOX CO HC CO2 O2 CH4

Gaseous fuel gas [kg/m³]

(a)
2.053 1.250 1.9636 1.4277 0.716
e
ugas(b)

CNG/LNG(c)
1.2786 0.001606 0.000978 0.000528(c) 0.001536 0.001117 0.000560

Propane 1.2869 0.001596 0.000972 0.000510 0.001527 0.001110 0.000556

Butane 1.2883 0.001594 0.000971 0.000503 0.001525 0.001109 0.000556

LPG(e) 1.2881 0.001594 0.000971 0.000506 0.001525 0.001109 0.000556

(a) depending on fuel

(b) at  = 2, dry air, 273 K, 101.3 kPa
(c) u accurate within 0.2 % for mass composition of: C = 58 - 76 per cent; H = 19 - 25 per cent; N = 0 - 14
per cent (CH4, G20, G23, and G25)
(d) NMHC on the basis of CH2.93 (for total HC the ugas coefficient of CH4 shall be used)
(e) u accurate within 0.2 % for mass composition of: C3 = 27 - 90 per cent; C4 = 10 - 73 per cent (LPG Fuels
A and B)

Table A.7-4
Raw exhaust gas u gas values and component densities for GER ≤ 0.1
Gas
NOX CO HC CO2 O2 CH4
Fuel gas [kg/m³]
(a)
2.053 1.250 1.9636 1.4277 0.716
e
(b)
ugas
Diesel 1.2943 0.001586 0.000966 0.000479 0.001517 0.001103 0.000553
(a) depending on fuel
(b) at  = 2, dry air, 273 K, 101.3 kPa

166
A.2.7.1.3.3. Particulate determination
For the determination of particulate emissions with the partial dilution measurement method the
calculation shall be performed according to the equations in Annex 5.
The requirements of Annex 5 shall apply for controlling the dilution ratio. In particular, if the
combined transformation time of the exhaust flow measurement and the partial flow system
exceeds 0.3 s, look-ahead control based on a pre-recorded test run shall be used. In this case,
the combined rise time shall be ≤ 1 s and the combined delay time ≤ 10 s. Except in the case
that the exhaust mass flow is measured directly the determination of exhaust mass flow shall
use values of α, γ, δ and ε determined according to paragraph A.2.7.1
A.2.7.1.3.4. Additional requirements regarding the exhaust gas mass flowmeter
The flowmeter shall not be sensitive to the changes in exhaust gas composition and density.
The small errors of e.g. pitot tube or orifice-type of measurement (equivalent with the square
root of the exhaust density) may be neglected.
A.2.7.1.4. Full flow dilution measurement (CVS)
Requirement as mentioned in Annex 5 shall apply except as set out in this paragraph.
The possible variation of the fuel composition will mainly influence the tabulated hydrocarbon
ugas value. The exact equations shall be applied for the calculation of the hydrocarbon
emissions using the molar component ratios determined from the fuel consumption
measurements of both fuels according to paragraph A.2.7.1
A.2.7.1.4.1. Determination of the background corrected concentrations
To determine the stoichiometric factor, the molar hydrogen ratio α of the fuel shall be calculated
as the average molar hydrogen ratio of the fuel mix during the test according to paragraph
A.2.7.1
Alternatively, the Fs value of the gaseous fuel may be used as mentioned in Annex 5.
A.2.7.1.5. Determination of molar component ratios
For molar based emission calculations, refer procedure laid down in Annexure 5
A.2.7.2. CO2 determination
Procedure applicable in Annex 5 shall apply

167
 Appendix – A.3

Types of dual-fuel engines operated on natural gas/ biomethane or LPG and a

liquid fuel – illustration of the definitions and main requirements

Dual- GERcycle Idle on Warm-up Operation Operation Comments

fuel liquid on liquid on liquid in
type fuel fuel fuel solely absence
of gas
1A GER ≥ 0.9 NOT Allowed Allowed Service
allowed only on only on mode
service service
mode mode
1B GER ≥ 0.9 Allowed Allowed Allowed Liquid-
only on only on only on fuel mode
liquid- liquid-fuel liquid-fuel
fuel mode and
mode service
modes
2A 0.1 < GER < 0.9 Allowed Allowed Allowed Service
only on only on mode
service service
mode mode
2B 0.1 < GER < 0.9 Allowed Allowed Allowed Liquid-
fuel mode
3A Neither defined nor allowed
3B GER ≤ 0.1 Allowed Allowed Allowed Liquid-
fuel mode

168
 Appendix – A.4
SAFETY CHECKS FOR USE OF GASEOUS FUELLED (DUAL FUEL /
DEDICATED DUAL FUEL AS APPLICABLE) INTERNAL COMBUSTION ENGINE
Sr. No. Gas Kit Component Certifying / Verifying Authority Applicable Standards
1 Regulator (For CNG & Testing of the component as per IS: 15713 IS: 15713 or ISO -15500
BIO-CNG) / Regulator or ISO-15500 by test agency. Alternatively,
and Vaporizer(LNG)* test agency to verify the test certificate or
report conforming to the above standard
issued by accredited testing laboratory.
LNG regulator and Vaporizer / heat UN R 110 or equivalent
exchanger shall meet requirements of UN standard
R110 or equivalent standard
2 Gas-Air Mixer* Testing of the component as per IS: 15714 IS: 15714 or ISO-15500
or ISO-15500 by test agency. Alternatively,
test agency to verify the test certificate or
report conforming to the above standard
issued by accredited testing laboratory.
3 Gas Injector* Testing of the component as per ISO- ISO-15500-7
15500-7 by test agency. Alternatively, test
agency to verify the test certificate or report
conforming to the above standard issued by
accredited testing laboratory.
4 Gas Solenoid Valve / Testing of the component as per IS: 15712 IS: 15712 or ISO-15500
Automatic Shutoff or ISO-15500 by test agency. Alternatively,
valve* test agency to verify the test certificate or
report conforming to the above standard
issued by accredited testing laboratory.

Automatic shutoff valve of LNG System Automatic shutoff Valve for

(which comes in contact with LNG shall LNG System : UN R110 or
meet requirements of UN R110 or equivalent standards
equivalent standards)
5 Testing of Conduit* Testing of the component or verification of IS: 15715
certificate or test report as per IS: 15715 by
test agency.
6 CNG / BIO-CNG /
LNG fuel line
6.1 High pressure
exceeding 100
kPa*
6.1.1 Exceeding 2.15 MPa
Rigid pipe Testing of the component or verification of IS: 15716
certificate or test report as per IS : 15716 by
test agency.

169
 LNG rigid pipeline shall meet requirements UN R 110 or IS: 15716 or
of UN R 110 or IS : 15716 or equivalent equivalent standard.
standard.
Flexible hose Testing of the component or verification of IS 15718 or AIS-028 (Rev. 1)
certificate or test report as per IS 15718 by (Part A)
test agency.

LNG flexible pipeline shall meet UN R 110 or IS: 15718

requirements of UN R110 or IS: 15718 or or equivalent standard
equivalent standard.
6.1.2 Pressure upto 2.15 Testing of the component or verification of IS : 15722 with amendments
Bar certificate or test report as per IS : 15722 by
test agency.
LNG pipeline shall meet requirements of UN R 110 or IS: 15722
UN R110 or IS : 15722 or equivalent or equivalent standard
standard.
6.2 Joints and Testing by test agency. Clause 3.1.4.1, 3.2.1 (b) of
connections* AIS-028 (Rev. 1) (Part A)

LNG joints & connection shall meet UN R 110 or equivalent

requirements of UN R 110 or equivalent standard
standard
7 Compartment or Sub- Testing of the component or verification of IS: 15720
compartment* certificate or test report as per IS: 15720 by
test agency.
8 Specific LNG Following specific components, as UN R 110 or equivalent
components applicable shall meet requirements of UN R standard
110 or equivalent standard
LNG Fuel pump, Pressure Relief valves,
Pressure sensor, check valve, excess flow
valve, manual valve and non-return valve.
9 Safety check for Safety checks to be carried out by test Relevant clauses of AIS-
installation of agency as per AIS-028 (Rev.1 ) (Part A) 028 (Rev. 1) ( Part
Gaseous fuel system A)
10 Electrical wiring and AIS 028
harness
11 Non-moisture AIS 028
retaining hard
rubber/equivalent
material
12 Electrical fuses AIS 028

* Certificate issued by accredited testing agency of the country of origin or a report issued by internationally
accredited test laboratory may also be accepted.

170
Note 1 - Only the standards, as amended from time to time, as mentioned above, shall be referred for
compliance.

Note 2 - Components downstream the Heat exchanger / vaporizer shall be considered as CNG
components and prevailing Indian standard / ISO standard or equivalent standards shall be
acceptable

171
 APPENDIX – A.5

Labelling Requirement for dual fuel engines

LABEL

The sign consists of a sticker which shall be weather resistant.

The colour and dimensions of the sticker shall fulfil the following requirements:
Colors:
Background: Orange
Letters: Black or black reflecting
Dimensions:
Border width: 4 - 6 mm
Character height:  25 mm
Character thickness:  4 mm
Sticker width: 110 - 150 mm
Sticker height: 80 - 110 mm
The word "DIESEL+CNG" shall be centred in the middle of the sticker.
The sticker shall be pasted on Engine intake side or away from hot surface & it shall be
clearly visible

172
 ANNEXURE – 11

Composition of committee for formulation of this system & procedure

Planning & Co-ordination

Mr N K Gupta Central Pollution Control Board, CPCB, New

Mr. Kedarnath Dash Delhi,

Co-ordinator
The Automotive Research Association of India
Dr. Prasanna G Bhat (ARAI), Pune

Members Representing
The Automotive Research Association of India
Representative from
(ARAI), Pune
International Centre for Automotive Technology
Representative from
(iCAT), Manesar, Gurgaon
Indian Diesel Engine Manufacturers'
Representative from
Association (IDEMA), New Delhi
Automotive Component Manufacturers
Representative from
Association of India (ACMA), New Delhi
Representative from Indian Institute of Petroleum (IIP), Dehra Dun
Emission Control Manufacturers Association
Representative from
(ECMA), New Delhi
Indian Oil Corporation Research and
Representative from
Development Centre, IOCL R&D, Faridabad

173
 ANNEXURE – 12

India Genset Emission standards- IV+ Notification GSR copy as released

174
175
176
177
178
****END****

179
180
 Part - A2

Positive Ignition
(PI) Engines

181
1. SCOPE
This A2 document lays down the applicability and requirements, system & procedure for compliance to
the rules vide notification no. GSR 804(E.) dated 3-Nov-2022 on emission limits for new internal
combustion engine up to 800 kW gross power used for power generating set (Genset) application,
issued by Ministry of Environment, Forests & Climate change, Government of India.
Emission of gaseous CO, HC and NOx from following type of positive ignition internal combustion
engines operating with either constant speed duty cycle,
 Dedicated alternate fuels*
 Bi-fuel run either on Gasoline or on any one of the alternate fuels*

*Alternate fuels - Natural Gas/Bio methane, Bio-gas, LPG, Ethanol blended gasoline (E10, E12, E15, E20,
E85) Ethanol E100, Methanol blended gasoline (M15, M85), Methanol M100, Hydrogen, Hydrogen
blended with CNG (18% hydrogen), Bio-diesel (B7/B8 to B20, B100) (Fuel Specification of these fuels
shall be as notified under CMVR as amended from time to time)

Natural Gas can be used in the form of Compressed Natural Gas or Liquefied Natural Gas or Piped
Natural Gas.
Following parts of specified standards shall be referred wherever stated.
Sr No. Standard Title
Reciprocating internal combustion engines — Exhaust emission
ISO 8178-1: 2017
1 measurement — Part 1: Test-bed measurement systems of gaseous
ISO 8178-1: 2020
and particulate emission
Exhaust emission measurement — Part 3: Test procedure for
2 ISO 8178-3: 2019 measurement of exhaust gas smoke emissions from compression
ignition engines using a filter type smoke meter
Reciprocating internal combustion engines — Exhaust emission
ISO 8178-4: 2017
3 measurement — Part 4: Steady-state and transient test cycles for
ISO 8178-4: 2020
different engine application
Reciprocating internal combustion engine-Exhaust emission
4 ISO 8178-7: 2015
measurement-Part-7: Engine family determination
Reciprocating internal combustion engines — Exhaust emission
measurement — Part 9: Test cycles and test procedures for
5 ISO 8178-9: 2019
measurement of exhaust gas smoke emissions from compression
ignition engines using an opacimeter

US EPA Regulation: 40 CFR Part 1039 - Control of emissions from

6 40 CFR Part 1039
new and in-use nonroad compression-ignition engines

7 40 CFR Part 1065 US EPA Regulation: 40 CFR Part 1065 – Engine testing procedures

8 AIS 024 (Version 5) Safety and Procedural requirements for type approval of CNG/Bio-
CNG/LNG operated vehicles (dedicated, bi-fuel & dual fuel)

9 AIS 028 (Version 5) Code of practice for use of CNG/Bio-CNG/LNG fuel in internal
combustion engine vehicles

182
2. DEFINITION & ABBREVIATIONS
2.1 DEFINITIONS
1. “Approval of an engine (engine family)” means the approval of an engine type with regards to the
level of the emission of gaseous pollutants;

2. “Auxiliary emission control strategy” means any element of design that senses temperature,
engine RPM, or any other parameter for the purpose of activating, modulating, delaying, or
deactivating the operation of any part of the emission control system;

3. “Adjustment factors” mean additive (upward adjustment factor and downward adjustment factor) or
multiplicative factors to be considered during the periodic (infrequent) regeneration;

4. “Ageing cycle” means the machine or engine operation (speed, load, power) to be executed during
the service accumulation period

5. “Applicable emission limit” means an emission limit to which an engine is subject to for approval;

6. “Approval of an engine” means the approval of an engine type or family with regard to the level of
emission of gaseous pollutants by the engine;

7. “Base emission control strategy” means design strategy that is active throughout the speed and
load operating range of engine unless Auxiliary emission control is activated;

8. “Compressed natural gas (CNG / BIO CNG)” means a compressed gaseous fuel composed
predominantly of Methane (CH4) shall be used as specified by the Government of India from time to
time.

9. “Confirmed and active DTC” means a DTC that is stored during the time the NCD system concludes
that a malfunction exists;

10. “Constant speed engine” means an engine whose type approval or certification is limited to
constant-speed operation. Engines whose constant-speed governor function is removed or disabled
are no longer constant-speed engines;

11. “Constant speed operation” means engine operation with a governor that automatically controls the
operator’s demand to maintain engine speed, even under changing load. Governors do not always
maintain exactly constant speed, but shall be maintained with allowed tolerances as mentioned in the
document"

12. “Critical emission related components” means the components which are designed primarily for
emission control, that is, any exhaust after-treatment system, the electronic engine control unit and
its associated sensors and actuators, fuel injection equipment, turbocharger and it’s integral control
actuators and the EGR system including all related filters, coolers, control valves and tubing;

13. “Critical emission related maintenance” means the maintenance to be performed on critical
emission-related components;

14. “De-NOx system” means an exhaust after-treatment system designed to reduce emissions of oxides
of nitrogen (NOx) (e.g. passive and active lean NOx catalysts, NOx absorbers and selective catalytic
reduction (SCR) systems);

15. “Diagnostic trouble code – DTC” means a numeric or alphanumeric identifier which identifies or
labels related to emission

183
16. “Discrete mode” means relating to a discrete mode type of steady-state test, as described in ISO
8178-4.

17. “Emissions-related defect” means a deviation from normal production tolerances in design,
materials, system or assembly that affects any parameter, specification or component belonging to
the emission control system. A missing component may be considered to be an emission-related
defect;

18. “Emission control system” means the exhaust after treatment system including, the electronic
management controllers of the engine system (if utilized) and any emission related component of the
engine system in the exhaust which supplies an input to or receives an output from these controllers
and when applicable the communication interface between the engine system electronic control unit
(ECU) and any other power train with respect to emissions management;

19. “Engine system” means the engine, the emission control system and the communication interface
(hardware and messages) between the engine system electronic control unit (ECU) and any other
power train;

20. “Engine family” means a manufacturer’s grouping of engine systems which, through their design
have similar exhaust emission characteristics, all members of the family must comply with the
applicable emission limit values described in Clause 3.1. Also refer ISO 8178-7;

21. “Engine type” means a category of engines, which do not differ in such essential respects as engine
characteristics as defined in ISO 8178-7

22. “Exhaust after treatment system” means ‘a catalyst (oxidation or 3-way), a particulate filter, a de-
NOx system, a combined de-NOx particulate filter’ or any other emission-reducing device that is
installed downstream of the engine. This definition excludes exhaust gas recirculation, which, where
fitted is considered an integral part of the engine system;

23. “Engine governed speed” means the engine operating speed when it is controlled by the installed
governor;
24. “Electronically controlled engines” means the engines using electronic control to determine both
the quantity and timing of injecting fuel.

25. “Electronic control unit (ECU)” means an engine’s electronic device that uses data from engine
sensors to control engine parameters as primary function. ECU may contain more functionality than
stated above of interest;

26. “Emission control strategy” means a combination of an emission control system with one base
emission control strategy and with one set of auxiliary emission control strategies, incorporated into
the overall design of an engine or Genset into which the engine is installed;

27. “Emission durability period” mean the number of hours indicated in Appendix 6 of Annexure 7 used
to determine the deterioration factors

28. “Emission related maintenance” means maintenance which substantially affects emissions, or
which is likely to affect emissions performance deterioration of the vehicle or the engine and exhaust
after treatment system during normal in-use operation;

29. “Engine-after treatment system family” means a manufacturer’s grouping of engines that complies
with the definition of engine family, but which are further grouped into a family of engine families
utilising a similar exhaust after-treatment system;

30. “Exhaust gas recirculation” means a technology that reduces emissions by routing exhaust gases
that have been exhausted from the combustion chamber(s) back into the engine to be mixed with
incoming air before or during combustion. The use of valve timing to increase the amount of residual
exhaust gas in the combustion chamber(s) that is mixed with incoming air before or during combustion

184
 (also called ‘internal EGR’) is not considered exhaust-gas recirculation for the purposes of this
Regulation;

31. For Domestic products, Date of Manufacture means the date on which the engine or genset is
invoiced;

32. For Imported products, Date of Import means the date of payment of custom duties applicable to
the engine or Genset;
33. “Genset Engine” means engines used primarily to operate an electrical generator / alternator to
produce and supply electric power for other applications in lieu of supply of power from electric grid;

34. “Gaseous pollutant” means carbon monoxide (CO), hydrocarbons (HC – assuming a ratio of C1H1.85)
and oxides of nitrogen (NOx), the last named being expressed in nitrogen dioxide (NO2) equivalent;

35. “High idle speed” means ‘the speed achieved by the engine under the specified test conditions at full
throttle with no external load applied on the engine flywheel
36. “Hydrocarbon (HC)” means Total Hydrocarbon (THC), non-methane hydrocarbon (NMHC) as
applicable. Hydrocarbon generally means the hydrocarbon group on which the emission standards
are based for each type of fuel and engine

37. Internal combustion engine (ICE)” means an engine, which works on the either compression-
ignition principle or positive ignition principle utilising liquid, gaseous or combination of both fuels;

38. “Idle speed” means the lowest engine speed with minimum load (greater than or equal to zero load),
where an engine governor function controls engine speed. For engines without a governor function
that controls idle speed, idle speed means the manufacturer-declared value for lowest engine speed
possible with minimum load. Note that warm idle speed is the idle speed of a warmed-up engine.

39. “Liquefied Natural Gas (LNG)” means a Natural gas that has been cooled to -259 degrees
Fahrenheit (-161 degrees Celsius) and at which point it is condensed into a liquid which is colourless,
odourless, non-corrosive and non-toxic. Characterized as a cryogenic liquid. Fuel quality for GENSET
use shall meet the requirements of BIS specification as notified from time to time by MoPNG, Govt.
of India.

40. “Manufacturer” means engine or Genset manufacturer, importer or, assembler (as noted in
notification);

41. “NCD engine family” means a manufacturer’s grouping of engine systems having common methods
of monitoring/diagnosing NCMs;

42. “NOx control diagnostic system (NCD)” means system on-board the engine which has the
capability” of: Detecting a NOx control malfunction; Identifying the likely cause of Nox control
malfunctions by means of information stored in computer memory and/or communicating that
information off-board;

43. “NOx control malfunction (NCM)” means an attempt to tamper with the Nox control system of an
engine and/or exhaust after treatment system or a malfunction affecting that system that might be due
to tampering, that is considered by this Regulation as requiring the activation of a warning or an
inducement system once detected;

44. “Non-emission related maintenance” means maintenance which does not substantially affect
emissions, and which does not have a lasting effect on the emissions performance deterioration of
the machine or the engine during normal in-use operation once the maintenance is performed;

45. “Non-methane hydrocarbons (NMHC)” means the sum of all hydrocarbon species except methane;

46. “Non-Methane Organic Gas (NMOG)” means the sum of non-oxygenated and oxygenated
hydrocarbons contained in a gas sample

185
47. “Oxides of Nitrogen (NOx)” means compounds containing only nitrogen and oxygen as measured
by the procedures specified in this Regulation. Oxides of nitrogen are expressed quantitatively as if
the NO is in the form of NO2, such that an effective molar mass is used for all oxides of nitrogen
equivalent to that of NO2.

48. “Open crankcase emissions” means any flow from an engine’s crankcase that is emitted directly
into the environment;

49. “Operator demand” means an engine operator’s input to control engine output. The “operator” may
be a person (i.e. manual), or a governor (i.e., automatic) that mechanically or electronically signals an
input that demands engine output. Input may be from an accelerator pedal or signal, a throttle-control
lever or signal, a fuel lever or signal, a speed lever or signal, or a governor set-point or signal

50. “Percent load” means the fraction of declared rated torque at an engine speed;

51. “Placing on the market” means the action of making available a product covered by this Regulation
on the market of a country applying this Regulation, for payment or free of charge, with a view to
distribution and/or use in the country

52. “Parent engine” means an engine selected from an engine family in such a way that its emissions
characteristics will be representative for that engine family and that it complies with the requirements
set out in ISO 8178-7

53. “Power generating set or Genset” means any equipment which is used for electric power
generation in absence or failure of grid power utilizing engine system defined in this document as
prime mover;

54. “Rated power” means nominal power in kW declared by manufacturer at declared rated Speed

55. “Rated speed” is the engine speed at which the declared rated power occurs with allowed tolerances
as mentioned in the document"

56. “Ramped modal steady-state test cycle” means a test cycle with a sequence of steady state engine
test modes with defined speed and torque criteria at each mode and defined speed and torque ramps
between these modes

57. “Scan tool” means an external test equipment used for off-board communication with NCD system;

58. “Service accumulation schedule” means the aging cycle and the service accumulation period for
determining the deterioration factors for the engine-after treatment system family;

59. “Total hydrocarbon (THC)” means the combined mass of organic compounds measured by the
specified procedure for measuring total hydrocarbon, expressed as a hydrocarbon with a hydrogen-
to-carbon mass ratio of 1.85:1;

60. “Test Cycle” means a sequence of test points each with a defined speed and torque to be followed
by the engine during standardised emission assessment test. Also refer ISO 8178-4;

61. “Type approval” means the approval of an engine type with regard to its emissions measured in
accordance with the procedures specified in this Regulation;

186
2.2 Abbreviations

BSFC Brake-specific fuel consumption

BIS Bureau of Indian Standards
CPCB Central Pollution Control Board
C1 Carbon 1 equivalent hydrocarbon
CC Cubic Centimetre
CH4 Methane
C2H6 Ethane
C3H8 Propane
CNG Compressed Natural Gas
CO Carbon monoxide
CO2 Carbon dioxide
COP Conformity of Production
COP-Year Period starting 1st July of year till 30th June of subsequent year
CI Compression-ignition (Engine)
De-NOx NOx after-treatment system
DF Deterioration factor
ECM Electronic control module
EGR Exhaust gas recirculation
FBC Fuel borne catalyst (for soot regeneration)
FID Flame Ionization Detector
GOEM Genset Original Equipment Manufacturer
HC Hydrocarbon
H2O Water
ISO International Organization for Standardization
LPG Liquefied Petroleum Gas
LNG Liquefied Natural Gas
NMHC Non-methane hydrocarbon
NMOG Non-Methane Organic Gas
NOx Oxides of nitrogen
NO Nitric oxide
NO2 Nitrogen di oxide
O2 Oxygen
PI Positive Ignition (Engine)
PPM Part per million
RHC Reactive Hydrocarbon
RMS Root-mean square
S Sulphur
THC Total Hydrocarbon

187
3 Exhaust Emission Limits, Applicability and Requirement
3.1. Exhaust Emission Limits
The emissions of the carbon monoxide, the emissions of non-methane hydrocarbons / reactive
hydrocarbon / Non-Methane Organic gas, and the emissions of the oxides of nitrogen during
emission certification and conformity of production emission test/s conducted in accord with in
Annexure 7 of this regulation considering applicable deterioration factor, adjustment factor, shall
not exceed the amount shown in Table 1 below:
Table 1
Emission limits for Genset engines up to 800 kW Powered by PI engines

Power Category, NOx HC NOx +HC CO

Ignition type
kW
g/kWh
P≤8 PI - - 7.5 3.5
8 < P ≤ 19 PI - - 4.7 3.5
19 < P ≤ 56 PI - - 4.7 3.5
56 < P ≤ 560 PI 0.40 0.19 - 3.5
560 <P ≤ 800 PI 0.67 0.19 - 3.5

Speed
Emission Test Cycle
operation
Constand D1 3-mode Steady-state discrete mode test cycle specified in ISO-8178-Part 4
speed engine OR
D1 3-mode Steady-state ramped mode test cycle specified in ISO-8178-Part 4
Manufactures shall declare in TA application his choice of discrete-mode type or RMC type cycle
for each family. The chosen cycle type shall also be applicable for all the child rating within family
and not allowed to alter or further choice during COP.

Notes:
a) The above limits are applicable for constant speed
b) Every manufacturer, importer or assembler (hereafter referred as manufacturer) of the
engine for genset application manufactured or imported into India shall obtain Type
Approval and comply with Conformity of Production (COP) requirements of their
product(s) for emission limits which shall be valid for next COP year.
c) The above-mentioned limit shall be applicable to Type approval and Conformity of
Production (COP) carried out by authorized test agencies.
d) The term ‘COP year’ means the period from 1st July of a calendar year to 30th June of
the following year
e) HC* - NMHC shall be considered for natural gas or RHC in case of LPG or NMoG in case
of alcohol-based fuels
Note:
NMHC = THC – CH4 for natural gas operation
RHC = 0.5 X THC for LPG operation

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3.2. Rounding off
Determine the official emission result for each pollutant to at least one more decimal place than
the applicable standard. Apply the deterioration factor to the official emission result, then round
the adjusted figure to the same number of decimal places as the emission standard. Compare
the rounded emission levels to the emission standard for each emission-data engine. In the case
of NOX+NMHC standards, apply the deterioration factor to each pollutant and then add the results
before rounding. Test report shall have both, the final rounded certificate emission result and
adjusted test result before rounding for better clarity on the decision.
Use the following rounding convention
i. If the first (left-most) digit to be removed is less than five, remove all the appropriate digits
without changing the digits that remain. For example, 3.141593 rounded to the second
decimal place is 3.14.
ii. If the first digit to be removed is greater than five, remove all the appropriate digits and
increase the lowest-value remaining digit by one. For example, 3.141593 rounded to the
fourth decimal place is 3.1416.
iii. If the first digit to be removed is five with at least one additional non-zero digit following the
five, remove all the appropriate digits and increase the lowest-value remaining digit by one.
For example, 3.141593 rounded to the third decimal place is 3.142.
iv. If the first digit to be removed is five with no additional non-zero digits following the five,
remove all the appropriate digits, increase the lowest-value remaining digit by one if it is odd
and leave it unchanged if it is even. For example, 1.75 and 1.750 rounded to the first decimal
place are 1.8; while 1.85 and 1.850 rounded to the first decimal place are also 1.8. Note that
this rounding procedure will always result in an even number for the lowest-value digit.

Examples-

# 1 2 3 4 5 5 5 6
1
Measured value – 0.0143 0.0238
0.0047 0.0048 0.0142 0.0239 0.0333 0.0334
PM (odd) (even)
2 Emission Limit – PM 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
3 DF applicable 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05
4 DF incorporated
0.0049 0.0050 0.0149 0.0150 0.0250 0.0251 0.0350 0.0351
adjusted emission
5 Final certificate
0.00 0.01 0.01 0.02 0.02 0.03 0.03 0.04
emission value
6 Decision Pass/Fail Pass Pass Pass Pass Pass Fail Fail Fail

Note: Rounding Reference taken form US EPA Regulation 40 CFR -1039 and 40 CFR- 1065

3.3 In addition, the following requirements shall apply:

a) Ammonia emission over the test cycles for engines equipped with SCR shall not exceed a
mean value of 25 ppm for engine power category less than or equal to 56 kW and 10 ppm
for engine power category above 56 kW as set out details in Appendix 7 of Annexure 7 of this
Regulation
b) Engine Durability Period and Deterioration Factor shall be applicable to above 19 kW
power category only as set out in details in Appendix 6 of Annexure 7 of this Regulation in
details.

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 Engine Durability Period
Category (Power Band) Emission durability period
(hours)
>19 ≤ 56 kW (constant speed Engines) 3000
> 56 kW (All engines) 8000
Note: DF determined during type approval will be carried over.

Deterioration Factors (DF)

Category (Power Band)
CO HC NOx
>19 kW
1.3 1.3 1.15
(Constant Speed Engine)
Assigned multiplicative deterioration factors

Note: When opted for assigned multiplicative DF, no verification is required.

c) Reserved

d) Gross Power & Speed tolerance: The gross declared power of the engine shall be
measured on the test bench at rated speed of engine. The measured power and speed may
differ from the power and speed declared by manufactured as specified below.

Gross Power Tolerance Speed Tolerance

Case Constant speed
Constant speed
Type ± 5% at rated for single cylinder engines
Approval ± 4% at rated for others engine
± 1% at rated
± 6% at rated for single cylinder engines
CoP
± 5% at rated for others engine

e) Crankcase ventilation requirement shall be applicable to above 56 kW power category

engines as set out details in Appendix 5 of Annexure 7 of this Regulation

f) Control Conditions-Altitude, Temperature: Electronically controlled engine using auxiliary

emission control strategy shall demonstrate the compliance requirement over control
conditions at type approval as set out details in Annexure 8 of this Regulation. This clause is
applicable to for power band above 56 kW electronically controlled engine using auxiliary
emission control strategy to operate in altitude.

Summary of the requirement:

Power Category, kW
Requirement
P ≤ 19 19 < P ≤ 56 56 < P ≤ 800
Deterioration Factors (DF) N/A Yes Yes
Crankcase emission N/A N/A Yes
Ammonia emission Yesa Yesa Yesa
Control conditions-Altitude, Temperature N/A N/A Yesb
a
Applicable SCR engine using reagent to reduce NOx emissions
b
Applicable for electronically controlled engine using auxiliary emission control strategy to operate
in altitude. Demonstration is only at time of type approval only once and not applicable during
COP.

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4 Type Approval Administrative Procedure

4.1 Engine type and Engine family

4.1.1. Engine type
The technical features of an engine type shall be those defined in its information document
drafted in accordance with the template set out in Annexure 1.
4.1.2. Operating mode (speed operation)
An engine type may be type-approved as a constant speed engine, as defined of this
Regulation.
4.1.2.1. Reserved
4.1.2.2. Constant speed engines

The manufacture shall declare in his application the operation of engine is constant speed.

4.1.2.3. Constant speed engine types equipped with alternative rated speeds
A constant speed engine shall not be designed to operate with variable speed. In the case that
the engine type is equipped with alternative speeds the requirements of this paragraph shall
additionally be met.
In the case that the engine type is the parent engine, the engine shall meet the applicable limit
values when tested using the applicable constant speed test cycle at each constant speed
applicable to the engine type. Separate test reports shall be produced and included in the
information package for each emission test.
In the case of all engine types within the engine family, when subject to a conformity of
production emissions test the engine shall meet the applicable limit values using the applicable
constant speed test cycle at each constant speed applicable to the engine type.
Each constant speed applicable to the engine type that is permitted by the manufacturer shall
be listed in information document as per Annexure 1
The engine shall be installed in a manner to ensure that:
(a) the engine is stopped prior to resetting the constant speed governor to an alternative
speed; and,
(b) the constant speed governor is only set to the alternative speeds permitted by the engine
manufacturer.
The instructions to the GOEM and end-users set out in Appendices A.1 and A.2 to Annexure 9
of this Regulation shall include information on the correct installation and operation of the
engine according to the requirements of this Annexure.

4.1.3. Engine family criteria

4.1.3.1. General
For the purpose of type approval and conformity of production certification, the manufacturer
engine range shall be divided into model families consisting of parent engine and its variant(s).
In case of import of complete genset, all the provision of this document shall be applicable to
the engine which form part of the genset.
Engine family shall be the grouping of engines, which through their design are expected to have
similar exhaust emission characteristic where member of the family shall comply with the
applicable emission values.

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 Parent engine shall be the engine selected from the engine family, in such a way that it will
incorporate those features which will adversely affect the emission level of the relevant exhaust
emission.
4.1.3.2. Engine family formation & choice of the parent engine
Essential characteristic of the engine family, the parameters defining the engine family, the
determination of an engine family and the criteria for choosing the parent engine shall be taken
according to the guideline given in ISO 8178-7 Reciprocating internal combustion Engine-
Exhaust Emission Measurement-Part-7: Engine family determination. However, the decision of
selection of parent engine and family classification by the authorized test agency shall be final.
For the purpose of identification, the manufacturer shall designate the families as F1, F2, F3….
Fn.
The manufacturer shall provide to the type approval authority the appropriate information
relating to the emissions levels of the members of the engine family
4.1.3.3. Reserved
4.2 Selection of Certifying Agency
4.2.1. Following test agencies are currently approved by the Nodal Agency Central Pollution Control
Board (CPCB) for purpose of type approval and subsequently conformity of production
compliance process and may be revised from time to time.
(a) Automotive Research Association of India (ARAI, Pune)
(b) International Centre for Automotive Testing (ICAT, Manesar)
(c) Indian Institute of Petroleum (IIP, Dehradun)
4.2.2. One supplier shall submit application for Type Approval to only one certification agency for all its
families / models out of those approved.
4.2.3. The same certification agency shall be responsible for carrying out the verification of Conformity
of Production (COP) for that manufacture
4.2.4. For a new OEM or importer, selection of technical agencies for type approval certification and
subsequently conformity of production shall be applicant’s choice among the technical agencies
published by central pollution control board (CPCB) in paragraph 4.2.1 and as amended from
time to time.
4.2.5. For any reason if any manufacturer wants to change the certification agency, he shall apply to
the nodal agency well in advance with justifiable reason. The nodal agency, after consultation
with the existing certification agency/ standing committee, may approve the change, if found
justified. If approved, the nodal agency shall inform to the parties concerned.
4.2.6. On receipt of information for change in certification agency from the nodal agency, the previous
certification agency shall authenticate all the relevant document of the model (type approval as
well as COP verification) and forward the same to the new certification agency. The certification
agency shall be responsible for carrying out the type approval testing and COP verification for the
manufacturer, in future.
4.3 Application of type approval
4.3.1 The application shall be made in the format prescribed in Appendix -1 and must be complete in
all respect. Appendix -1 shall be submitted to nodal agency and on its written acceptance, engine
specification related documents to be submitted to the test agency.

4.3.2 The application for approval of an engine or an engine family with regard to the level of the
emission of gaseous pollutants shall be submitted by the engine manufacturer or by a duly
accredited representative.

4.3.3 For each engine family, the manufacturer must submit an application to the certification agency,

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 selected as above.

4.3.4 The application must be signed by the authorized representative of the manufacturer.

4.3.5 It shall be accompanied by the undermentioned documents and the following particulars:

A description of the engine type comprising the particulars referred to in clause 4.1. of this
Regulation and if applicable the particulars of the engine family as referred to in paragraph
4.1.3. to this Regulation. For the purpose of identification, the manufacturer shall designate the
engines families as F1, F2, F3 …. Fn in consultation with technical agency;

4.3.6 Testing of the parent model, shall, normally, be sufficient for type approval of the family. The
Testing agency has the option to carry out the testing of more than one model in the family to
satisfy itself, subject to parent engine-concept as per ISO 8178-7

4.3.7 An engine conforming to the engine type characteristics described in clause 4.1. shall be
submitted to the Test Agency responsible for conducting the approval tests. If the Test Agency
determines that the submitted engine does not fully represent the engine family described in
clause 4.1, an alternative and, if necessary, an additional engine shall be submitted for test

4.3.8 During Type Approval test, the manufacturer shall submit the qualified emission test data of all
the remaining variant engines, other than the parent engine, which is chosen for emission test by
the test agency of the family along with all other documents. Qualified emission data can be an
emission test recorded at OEMs facility. This is required only for reference of test agency for future
COP testing and it will not be part of Type Approval certification documents.

4.3.9 At later stage if the manufacturer submits the application for type approval of a model, the Testing
agency shall ascertain whether the model can be classified as belonging to a family of model(s)
already certified. If the model does not belong to a family already certified, the Testing agency
shall proceed with the testing of the model for type approval with issuance of new and unique
engine emissions family certification upon qualification;

4.3.10 If the model belongs to a family already certified, the Testing agency shall decide whether the
specific testing of the model is required. In case the specific testing of the model is not required,
the type approval certificate for the family may be extended to include the model. In such case
qualified emissions data shall be submitted to agency by manufacturer during application;

4.3.11 The Testing agency shall intimate its decision to the applicant within a fortnight of receipt of the
application, indicating need and plan (schedule) of testing for type approval;

4.4 Type Approval

4.4.1. No person or agency shall sale, import or use an engine for Genset application in India without
valid Type Approval Certificate and Conformity of production Certificate referred to in clause 4.5.
and 5.4 of this Regulation;
4.4.2. No person or agency shall sale, import or use a Genset in India containing an Engine without
valid Type Approval Certificate and Conformity of production Certificate referred to in Clause 4.5.
and 5.4 of this Regulation;
4.4.3. In order to receive a type approval of an engine type or engine family, the manufacturer shall
demonstrate compliance, of the engine type or engine family with the provisions of this
Regulation. The manufacturer shall also ensure the use of fuels as specified in Annexure 6.
4.4.4. All the type approval tests shall be conducted in the technical agency laboratory. In case the
required test facilities are accredited by the technical agency, the type approval and / or COP
tests can be carried out at manufacturer’s laboratory also if reasons call for. In case the test is to
be carried out at any overseas test facilities, the same shall be informed to the Nodal Agency by

193
 technical agency. The technical agency will submit a copy of accreditation letter highlighting the
details of test facilities available in the manufacture’s laboratory to the Nodal Agency;
4.4.5. In case of the manufacturer approaches the technical agency for the first time, such manufacturer
should complete the COP test(s) within three months from the commencement of commercial
production or importation of 100 units.
4.4.6. The manufacturer may use of commercial fuels or reference fuels set out in Annexure 6, provided
to be declared in the information document.
4.4.7. Additionally, in order to receive type approval of a Genset with an approved engine with regard
to emissions or a type approval of a Genset with regard to emissions the manufacturer shall
ensure compliance with the installation requirements set out in Annexure -9
4.4.8. The Type Approval Authority shall put together an information package consisting of the
information folder accompanied by the test report and all other documents added by the technical
service or by the Type Approval Authority to the information folder in the course of carrying out
their functions (‘the information package’). The information package shall include an index listing
its contents, suitably numbered or otherwise marked so as to clearly identify all the pages and the
format of each document, in order to present a record of the successive steps in the management
of the type approval, in particular the dates of revisions and updating;

4.4.9. The approval authority shall ensure that the information contained in the information package is
available for a period of at least 10 years following the end of the validity of the type approval
concerned;

4.5 Certificate of Type Approval and Validity

4.5.1. After verification of engine(s) for the type approval, the technical agency shall issue a type
approval report to manufacturer within one month from date of testing completion indicating
acceptance or rejection decision and reason thereof. If the engine(s) submitted for approval
pursuant to clause 4.3. of this Regulation. Approval of that engine type(s) or engine family(ies)
shall be granted by the technical agency through issue of Type Approval Certificate as per format
prescribed in Annexure 2 along with report. Copy of the certificate and report shall be forwarded
to Nodal Agency by technical agency involved;
4.5.2. For the purposes of clarity and easing access to relevant data, the communication includes an
addendum containing the most relevant information related with the type-approved engine type
or engine family;
4.5.3. The certificate shall be deemed to be valid for the model(s) included herein, unless explicitly
withdrawn by separate written order by the Nodal Agency;
4.5.4. The Type Approval certificate for an engine family issued to the manufacturer shall be valid for
the same model(s) manufactured at any other manufacturing plant of the same manufacturer.
The Nodal Agency or technical agency concern with type approval may visit the new plant to
verify adequacy of the infrastructure;
4.5.5. Validity of Type Approval Certificate issued by type approval authority shall remain valid for
‘current’ COP-year enabling sales of such type approved engine family for that duration;
4.5.6. Validity of Type Approval Certificate issued by type approval authority shall remain valid further
as long as following conditions are met:
j) Till the engine specifications change as mentioned in Annexure 1 and modification related
clauses described in clause 4.6 below;
ii) Till the further amendments to the notification;
iii) Till COP is not missed / Till COP procedure compliance per clause 5 is obtained within
prescribed timeframe as listed in clause 5.3.10.
4.5.7. In case manufacturer has not sold engines in two subsequent COP-year period and has done
appropriate ‘Zero volume’ declaration seeking COP exemption to nodal agency, and for resuming
sale for third year of such engine family, manufacturer to conduct COP test before making any

194
 sell or a fresh new type approval application and subsequent process needs to be carried out.
Refer clause 5.5 for COP certification.

4.6 Modification and Extensions of approved type

4.6.1. If an engine type or engine family is type approved and valid, manufacturer may approach type
approval certificate issuing technical agency for modifications pertaining to parent or any engine
type in the certified engine emissions family. Such modifications shall be ascertained by
manufacturer utilizing guidelines described in clause 4.6.5
4.6.2. Manufacturer shall submit technical document in line with type approval procedure prescribed in
this Regulation;
4.6.3. Subjected to scrutiny of manufacture’s application, technical agency shall approve or seek more
data pertaining but not limited to engine architecture, parameters, similarity with existing engine
type from emissions and performance perspective along with evidences. Decision of technical
agency will remain finally binding for allowing such amendments to existing type approval
certificate of an engine family through extension(s) vs asking manufacturer to type approve as
new engine family or new engine type;
4.6.4. Technical agency retains all rights to ask manufacture to demonstrate modified engine type for
emissions conformity through applicable type approval test procedures. Submission of
manufacturer run emissions data with valid test facility and procedure followed is mandatory
where changes are directly or indirectly pertaining to emission affecting components, engine and
after treatment system control algorithms and engine performance specifications.
4.6.5. Following generic rules may be utilized as example for extensions of type approval certificate:
4.6.5.1. No emission test requirements necessary:
(a) change to part numbers declared through type approval documentation that is not emission
affecting;
(b) part number change of emission affecting component that is just an administrative change
supported with due declarations (proto to production Part number change as an example);
(c) change(s) to emission strategy for engine operation beyond altitude and temperature
conditions prescribed by this Regulation however with due declaration with technical agency in
this regard;

4.6.5.2. Emission test compliance required:

(a) performance or specification or source change of a component declared through type approval
documentation that is emissions affecting. This applies to any such component in engine and
after treatment system including software;
(b) emissions strategy changes such as but not limited to fuelling timing, fuelling qty, fuelling
modes,
(c) addition of alternate source component that is emission affecting with or without part number
change;
4.6.5.3. Emission and NOx Control Diagnostics compliance required:
(a) in addition to clause 4.6.5.2 at discretion of technical agency if changes to NOx control
diagnostics limits or strategy or software is carried out;
(b) NOx control diagnostics demonstration method through failed part has been changed;
4.6.5.4. In the event of an extension the Test Agency shall establish an updated communication denoted
by an extension number that shall be incremental in accordance with the number of successive
extensions previously granted. That communication shall clearly show the reason for the
extension and the date of extension.

195
4.7 Type Approval Process Flow-chart

4.8 Following are the logical steps for the type approval process flow
chart described in brief stepwise -

196
1. Application to nodal agency (CPCB) in the form of affidavit seeking permission for type
approval of Genset engine family through submission provided as draft specimen in
Appendix 1.
2. Upon written approval of nodal agency to manufacturer and chosen technical agency; (This
could be decision making node with “Yes” / “No” loop)
3. Submit type approval certification application to chosen test agency. Based on provisions
such application can be written or online through their secured portal;
4. Obtain technical agency approval (This could be decision making node with “Yes” / “No” loop
with NO means, provide additional data)
5. Upon agencies application scrutiny and negotiations, submit detailed technical
documentation as per requirements described in Annexure 1;
6. Obtain documentation approval from technical agency, family formation, choice of parent
engine, provide additional data
7. Obtain test plan / schedule from technical agency
8. Upon approval from technical agency plan for providing engine test auxiliaries like -Silencer,
air filter, after-treatment systems, engine mounting, coupling plate to match dyno,
components for NCD demonstration etc.
9. Upon receipt of engine along with auxiliary technical agency examine the adaptability in test
cell, make necessary modification in exhaust line, mounts, etc, if required.
Certificates of the NG/LPG fuel system components as per Annexure 10 to be validated from
test agency. In absence of valid component certificate, the component to be tested and
approved from test agency as per applicable standard
Alternate Fuel Gensets to be Type Approved as per safety code of practice as mentioned in
document A4 before applying for noise certification. Competent authority will perform safety
audit at Genset manufacturer location based on the part A4 document.
10. Conduct applicable tests-
10.4.Conduct emissions test to qualify (This could be decision making node with “Pass” /
“Fail” loop. “Fail” means, a) current TA application is closed out with failure report b)
adjust. reset engine parameter for retest or c) further manufacturer may re-apply afresh
after redevelopment)
10.5.Conduct NCD demonstration tests to comply (This could be decision making node with
“Pass” / “Fail” loop. “Fail” means, a) current TA application is closed out with failure
report b) adjust. reset engine parameter for retest or c) further manufacturer may re-
apply afresh after redevelopment)
10.6.Demonstrate results related to infrequent regeneration, control condition if applicable;
11. Review of all test results with manufactures and decision about compliance, in case of failure
manufacture have three options to proceed a, b, & c, act accordingly.
12. Technical agency carries out part verification of critical engine components and injection
timing verification in compliance with document submission, take final review of technical
document and ask manufacture to resubmit if necessary
13. Manufacture submit the corrected technical document if found necessary
14. Examine corrected document submitted in line with the requirement
15. Technical agency prepares technical report based on tests;
16. Technical agency issues type approval certificate to manufacturer;
17. Technical agency forwards a copy of type approval certificate to nodal agency
End

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 Appendix – 1
Application to Nodal Agency. Specimen for Submission of Affidavit & Profile
details of manufacturer
Part - A
NOTARISED AFFIDAVIT ON NON-JUDICIAL STAMP PAPER -
[To be submitted to the Nodal Agency by a supplier approaching for the first time for TA]

I, …………………., Chairman / President / Managing Director / Partner / CEO / COO / Proprietor

of M/s ………………, having Registered Office at …………… engaged in manufacturing / import
of Genset diesel/dedicated alternate fuel/Bi-fuel /dedicated gasoline / Portable Generator sets
with manufacturing facilities / ware house at:
i) ………………….
ii) ………………….
am authorized to swear this affidavit for and on behalf of the above named Company. I do hereby
solemnly affirm and declare as under:

1. That the deponent is well conversant with the facts and competent to swear this affidavit.
2. That the deponent declares that M/s …………………… are manufacturer / importer of Genset
diesel / dedicated alternate fuel/Bi-fuel /dedicated gasoline / Portable engines in the brand
name
i) ………………….
ii) ………………….
(Strike out if not applicable)

3. That the deponent declares that M/s ……………………. are importer of diesel /dedicated
alternate fuel/Bi-fuel /dedicated gasoline / Portable generator sets from M/s i) ….………….….
(ii) M/s ………………. (Complete address)
(Strike out if not applicable)

4. That the deponent declares that M/s ……………. will obtain Type Approval / Conformity of
Production verification only from (Name of the Certification Agency) …………… and will not
approach any other Certification Agency for Type Approval / Conformity of Production
verification for any of their Genset diesel / dedicated alternate fuel/Bi-fuel /dedicated gasoline
/ Portable engines models, without prior permission from the nodal agency.
5. That the deponent declares that none of the Chairman, Managing Director, Partner, Director,
Proprietor, Board Member in M/s …………… has been involved with a Company / Firm which
has manufactured and sold non-compliant Genset diesel/ dedicated alternate fuel/Bi-fuel
/dedicated gasoline / Portable engines.
6. That the deponent declares that M/s ……………. will manufacture / import and sell only
compliant Genset diesel/ dedicated alternate fuel/Bi-fuel /dedicated gasoline / Portable
engines

(Name & signature with Co. stamp)

(DEPONENT)

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 VERIFICATION
Verified at …………. on this ……………of ……………20…… that the contents of the above
affidavit are true and correct to the best of my knowledge and belief and nothing has been
concealed therein.

Place: ………
Date…………
(Name & Signature with Co. Seal)
(DEPONENT)

Part - B

Format for Submission of Profile and Details of the Supplier

A. Company details

 Name of the Company

 Type of Company: Proprietor / Partnership / Private Ltd / Public Ltd
 Name of the Proprietor / Partners / Directors (submit relevant documents)
 Importer / manufacturer
 Registered Office Address with phone number
 Contact Address with phone number, fax number, email etc.
 Name and designation of the authorized person for submission of documents and to
deal with the certification agency
 Plant addresses and contact details, in case of manufacturer
 Ware house address, in case of importer (This cannot be changed without prior
intimation to Nodal Agency and Certification Agency)
 Name of the company from whom to import and its contact details, in case of importer
 Plant details, from where to import
 Authenticated Copies of following documents to be submitted
v) Manufacturing License from Directorate of Industries / Department of Industry
(in case of Manufacturer), IEC Code (in case of importer)
vi) VAT and CST/GST Registration
vii) Excise Registration, in case of manufacturer
viii) Consent from State Pollution Control Board/ Pollution Committee
 No. of employees
 Engineers (if any)
 Last year Turn-over
 Any other business

B. Details of Genset engine (Proposed) manufactured / assembled / imported

Model Nos. produced /imported Nos. expected to be produced /

Sr No
Names in current year imported in the next year
a
b

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 c
d

C. Details of Infrastructure

D. Land: Owned / Rented

Area (m2):
E. Covered Area

F. Machinery for manufacture

a)
b)
c)
d)
G. Testing facility equipment’s
a) Load bank type and capacity
b) Measuring Instruments
c) Any other
H. Quality Control
1. Quality Control In charge
2. Quality Procedure:
ISO Certified since when (Enclose a Copy of Operating Procedure)
3. Pre-delivery Inspection Procedure on Gensets (including records maintained)
4. System of serial numbering and marking on Genset and their sub-systems – e.g. all
Enclosures, etc.)
5. Any other

Date: ...............
Place: .............

SIGNATURE OF THE
(Chairman /President / Managing Director
/ Partner / CEO / COO / Proprietor)

SEAL OF THE COMPANY

---End---

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5. Conformity of Production Administrative Procedure
5.1 General

5.1.1. Conformity of Production (COP) compliance is designed to ensure manufacture’s compliance and
control towards a type approved genset engine family to statistically ensure engines sold under
such emission certification does meet required emissions and other requirements including NOx
diagnostics provisioned by this Regulation;
5.1.2. COP process compliance also ensures type approval certificate validity and hence right to
produce and sale genset engines by a manufacturer owing such type approval certification for the
next COP-year. Such provision is administratively provided by issuing Conformity of Production
Certificate;
5.1.3. Each manufacture shall subject it’s engine model range to the verification of COP, every year.
For this, the year shall mean the period from 1st July of the calendar year to 30th June of the
succeeding calendar year; - For above 19kW power rating
5.1.4. Each manufacturer shall subject engine model(s) for NOx Control Diagnostics (NCD) compliance
test representative of it’s NCD family as declared during type approval certification for it’s entire
genset engine model range. Depending on engine types certified, a manufacturer may need to
submit apt and separate representation of engine types representing NCD families. Such
demonstration and compliance shall be required once per COP-year per NCD family.
5.1.5. For this, the year shall mean the period from 1st July of the calendar year to 30th June of the
succeeding calendar year;

5.2. Verification of Conformity of Production (COP)

5.2.1. COP of domestically manufactured engine families’ up to 19 kW:
5.2.1.1. In case engines up to 19 kW power rating, the verification of COP shall be done once in a COP-
year as per plan described in following ‘Table 1’

Table 1
Number of families to be tested for verification of COP for domestic manufactures
(for engines up to 19 kW)

Total number of families of the domestic Total number of families to be tested per
manufacturer year
1– 3 1
4–7 2
8 – 11 3
12 – 15 4
>15 5

5.2.2. COP of domestically manufactured engine families more than 19 kW rated output and
imported engines of all rating:
Domestically manufactured engines of more than 19 kW rated output and imported engines of all
ratings shall be subjected to the verification of COP once for every 1000 units per family or once
a year, whichever is earlier;
5.2.3. Domestically manufactured engine models(s) and imported engines of all ratings shall be
subjected to the verification of NCD once every COP-year by NCD family(ies) representative

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 engine(s). Such demonstration is NCD family dependant and irrespective of combined volumes
produced and sold under such family(ies).

5.3. Sample size, Decision and Other Criteria for verification of COP
5.3.1. In case of engines defined in clauses 5.2.1.and 5.2.2. above, testing shall be done on sample(s)
randomly selected by certification agency from the production line / import warehouse, of one
model for each family selected for COP.
5.3.2. In case of engines defined in clauses 5.2.3. above, testing shall be done on sample(s) randomly
selected by certification agency from the production line / import warehouse for NCD compliance;
5.3.3. In case engines up to 19 kW power rating, a minimum quantity of 10 numbers or one day’s
average production volume of the engine model selected by technical agency, whichever is more
shall be made available for random selection. Same criteria shall apply to random selection of
after treatment system that is not integrated with engine system;
5.3.4. In case of domestically manufactured engines more than 19 kW power rating, a minimum one
day’s average production volume of the engine model selected by technical agency, shall be
made available for random selection subject to minimum quantity of 3. This limit shall not be
applicable in case of import of all ratings. Same criteria shall apply to random selection of after
treatment system that is not integrated with engine system;
5.3.5. If the manufacturer is not of Indian origin, the manufacturer should establish a base office in India,
which is to be declared in the initial application submitted to Nodal Agency as per Appendix 1 This
base office will be responsible for Type Approval and COP compliance;
5.3.6. The manufacturer shall request the certification agency when they would like to make random
selection of engine(s) and to seek their schedule / availability for completing the COP test;
5.3.7. COP verification shall be carried out for each plant of the domestic manufacturer. For imported
engines, the COP testing shall be carried out on the engine manufactured for each country of
origin irrespective of engine family being same;
5.3.8. The certification agency shall intimate to the manufacturer the schedule (month) of sampling /
testing. The manufacturer shall inform the production/ import plan for the month in which the
technical agency wants to carry out the COP, to the technical agency. If the manufacturer has a
problem due to particular reasons such as the particular model is not likely to be scheduled for
production / import at that time, or enough number of engines may not be available for random
selection; the time schedule may be modified based on mutual convenience of the manufacturer
and the technical agency;
5.3.9. The manufacturer shall complete all COP activities (such as random selection, initial running-in,
emission testing, NOx Diagnostics testing and documentation) at least one month before the end
of COP-year. The COP certificate shall not be issued in case of non-adherence to above schedule
unless such schedule attainment is due to unavoidable reasons such as but not limited to test
facility downtime, extended COP process encountered.
5.3.10. Following ‘Table 2’ gives the deadlines for the respective COP-year for the COP activities.
However, manufacturer can take early action on each activity to ensure compliance.
5.3.11. Manufacturer must take early action on each activity for the families (more than 19 kW rated
output) exceeding 1000 units of production to ensure the compliance of clause 5.2.2.

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 Table 2
Sr No Activity Description Last Date
Submission of production / import plan / actual details to test
1 1st March
agency
2 Random Selection 1st April
Submission of engines and subsequent testing (Including
3 31st May
extended COP if any)
4 Completion of documentation and COP Certificate issuance 30th June

5.3.12. The manufacturer shall inform the test agency regarding the stoppage of production of a specific
model, in case this has not been anticipated at the start of the COP period. This shall be intimated
well in advance so that COP selection of the engine can be completed by the technical agency
before stoppage of production. Manufacture is held accountable for ensuring COP is conducted
and samples are made available per requirements of this Regulation;
5.3.13. The manufacturer shall provide all the assistance required by the technical agency for completing
the tests;
5.3.14. The latest updated technical specifications, procedure of pre-delivery inspection (PDI), running-
in and servicing of the engine, shall also be submitted before the engine selection, if there have
been revisions after the previous COP / type approval;
5.3.15. Pre-delivery inspection as per owner’s instruction manual / service manual will be carried out by
the manufacture as per procedure declared at the time of type approval and as amended and
intimated to concern technical agency from time to time for the selected engine(s), under the
control of technical agency;
5.3.16. The running-in of the engine(s) shall be carried out as per the manufacture’s recommendation
submitted during the type approval and as amended and intimated to the concern technical
agency from time to time, for engine(s) under control of the technical agency. Running-in may
also be carried out at engine manufacture’s place under the control of technical agency provided
adequate facilities are available. After such running-in procedure, manufacture will be permitted
to carry out all the adjustments recommended in their owner’s / service manual and as amended
and intimated the concern technical agency from time to time published with technical agency,
under the control of the technical agency;
5.3.17. In case of failure of any major component during the running-in or testing, the technical agency
may permit to replace component only once; which has failed and which does not affect the
performance and emission of the engine. Such decision is entirely with technical agency. In case
of failure of emission affecting component, random selection of engine at manufacture’s plant or
warehouse shall be done afresh. If for such randomly selected engine (second time) or a replaced
component fails again, it shall be reported to the nodal agency by the concern technical agency
and agency shall await instructions from the nodal agency for further action;
5.3.18. The manufacture shall submit the randomly selected engine(s) to technical agency within four
weeks (8 weeks in case of import subjected to last date as mentioned in clause 5.2.10. – Table
2) of completion of running-in for emission compliance test and NOx diagnostics test where
applicable. Manufacturer also shall supply appropriate ‘failed’ parts for NCD and/or PCD
demonstration in line with agreement with technical agency during type approval certification and
documentation;
5.3.19. The technical agency should endeavour to complete the required testing of selected engine(s)
within four weeks after submission of engine(s);
5.3.20. The testing shall be done as per applicable procedures and specifications described in Annexure
7 with test facility compliant to requirements specified Annexure 4 while utilizing data evaluation
and result calculation procedures described in Annexure 5 of this Regulation;

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5.3.21. Sampling plan for COP
5.3.22. Sampling Plan-I is applicable to domestically manufactured engine upto 19 kW rated output
whereas Sampling Plan-II is applicable to domestically manufactured engine above 19kW as well
as for imported engines of all ratings (Imported as an engine or as a genset)
5.3.23. Sampling Plan-I: Upto 19kW domestic
5.3.23.1. The number of samples to be tested shall be minimum as necessary, as given in Table 3 to
arrive at a decision on whether the produciton unit complies with applicable emission limits;
5.3.23.2. A sample said to have failed for particualr criteria pollutant if the test result of the sample for the
criteria pollutant exceeds required DF and IRAF (if applicable) corrected emission limit;
5.3.23.3. The production units of all models in the family shall be deemed to comply with the emission
limits if the number of failed samples as defined in clause 5.3.23.2. above for each criteria
pollutant is less than or equal to the pass decision number appropriate to the cumulative number
of smaples tested for that criteria pollutant as given in Table 3;
5.3.23.4. The production units of all models in the family shall be deemed to be non- complying with the
emission limits if the number of failed samples as defined in clause 5.3.23.2. above for each
criteria pollutant is more than or equal to the fail decision number appropriate to the cumulative
number of smaples tested as given in Table 3;
Table 3
Sampling plan I and decision criteria for the verification of COP of the engines

Cumulative Pass decision Fail decision Cumulative Pass decision Fail decision
Samples No. of failure Samples No. of failure
1 (a) (b) 16 6 11
a b
2 ( ) ( ) 17 7 12
a b
3 ( ) ( ) 18 7 12
4 0 (b) 19 8 13
5 0 (b) 20 8 13
6 1 6 21 9 14
7 1 7 22 10 14
8 2 7 23 10 15
9 2 8 24 11 15
10 3 8 25 11 16
11 3 8 26 12 16
12 4 9 27 12 17
13 5 10 28 13 17
14 5 10 29 14 17
15 6 11 30 16 17
( a ) : Series not able to pass at this stage
( b ) : Series not able to fail at this stage
Note:
v) COP compliance or non-compliance decision is on the basis of number of failures within
the respective cumulative samples tested.
vi) During successive testing, the decision which reached first is the final.
vii) Minimum 4 samples are required to test to reach pass decision
viii) Minimum 6 samples are required to test to reach fail decision

5.3.23.5. Once a complaince or non-compliance decision is made for a particular criteria pollutant, the
result of testing of subsequent samples for that criteria pollutant shall not influnece the decision;

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5.3.24. Sampling Plan-II: Above 19kW & Imported all rating
5.3.24.1. One engine sample selected randomly shall be tested as per procedure described in Annexure
7 of this Regulation;
5.3.24.2. If the engine sample as tested fails to comply with the emisison limits, the manufacturer may
ask for measures to be performed on a sample of engines taken from the production series and
including the engine orignally tested. The manufacturer shall specify the size ‘n’ of the sample
subject to ‘n’ being minimum of 3 and maximum of 10 includive of sample orignally tested;
5.3.24.3. The production or import units of all models in the family shall be deemed to compy with
emission limits if following condition is met for each criteria pollutant except for Smoke limits:

𝑥 + k. S < L
Where,
𝑥 = arithmetic mean of the results of the tests conducted on ‘n’ number of samples, for
a particular specie
S = Standard deviation of the results of the tests conducted on ‘n’ number of samples,
for the specie = [Σ (x - 𝑥)2 / (n –1)]1/2
x = results of the tests conducted on ‘n’ number of samples, for the specie.
L = the emission limit for the specie
k = a statistical factor dependent on ‘n’ number of samples and as given in below table.

Table 4
Values of Statistical Factor ‘k’ with respect to parameter ‘n’

n 2 3 4 5 6 7 8 9 10
k 0.973 0.613 0.489 0.421 0.376 0.342 0.317 0.296 0.279

5.3.25. Miscellaneous failure during COP

5.3.25.1. Reserved
5.3.25.2. Gross Power failure : For verifing the conformity of production, if the selected engine does not
meet the gross power and rated speed limit as applicable, the another two engines in case
above 19 kW power rating or four engines in case below 19 kW power rating, will be taken from
the series at random and be tested as per this part. All these selected engines shall meet the
limit values specified. One engine shall be subjected to the emission test for the conformance
of production.
5.3.25.3. Reserved
5.3.25.4. NCD / demostration failure : For verifing the conformity of production, if the selected engine
does not meet the compliance requirement with respect to NCD demostration as applicable, the
another two engines in case above 19KW power rating or four engines in case below 19KW
power rating, will be taken from the series at random and be tested as per this part. This selected
all engines should meet the limit values specified. One engine shall be subjected to the
conformance of production.
5.3.25.5. If further same failure noted in any of the additionally selected samples of caluse 5.3.25.1,
5.3.25.2, 5.3.25.3 & 5.3.25.4, the production shall be considered as non-compliance and the
provision of clause 5.8, shall be put into effect.

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5.4. Certificate of Conformity of Prouction (COP) and It’s Validity
5.4.1. After verification for COP, the certification agency shall issue a COP verification report to the
manufactuer within one month of the date of testing completion , indicating complinace or non-
compliance. In case of compliance, the technical agency shall issue a COP certificate to the
manufactuer as per format prescibed in Annexure 2 along with report. At the end of CoP year,
detalis of CoP & the copies of certificate as well as report shall also be forwarded to the Nodal
Agency;
5.4.2. Certificate of conformity of production is required to commence the production and sale of
domestic genset engines in immediately next COP-year. Validity of current COP certificate shall
be till successful compliance of first COP test in next COP-year
5.4.3. In given COP-year for engine type(s) described in clause 5.2.2., successful compliance of COP
for every 1000 engines invoiced by the manufacturer shall enable further production of 1000
engine(s) and thereafter, in case engine(s) volumes for a particualr engine family exceed 1000
units annually;
5.4.4. The COP certificate will be issued at the end once all the numbers of engine samples demanded
as per the production plan submitted become tested successfully. Intermediate COP certificate
i.e at each sample tested shall not be issued, However the test data report will be issued at every
test sample.

5.5. COP Discontinuity

5.5.1. If there is no production or import of model(s) of a particular engine family for two consecutive
years immediately after obtaining type approval or immediately after obtaining COP certificate,
the type approval certificate for that particular engine family becomes invalid. In case the
manufacturer wants to maufacture or import engine model(s) of such particular engine family,
then the manufacture shall approach Nodal Agency and technical agency to obtain a new Type
Approval certificate afresh following stated procedure;
5.5.2. If there is no production or import of model(s) of a particular engine family for two consecutive
years immediately after obtaining type approval and if the COP test is requested for the third year,
then the supplier shall approach Nodal Agency to obtain approval for the extention of validity of
Type Approval. This is applicable only for a new manufacturer and in case no engine(s) sale has
happended post type approval;

5.6. Exemption from COP

In the following cases, engine family(ies) shall be exempted form COP process.
5.6.1. If Type Approval obtained in the last quarter of COP year. This clause is not applicable to the
manufactueres as mentioned in clause 4.4.5.
5.6.2. In case of no production or import, the manufacturer shall submit a declaration to technical agency
and Nodal Agency for ‘No production or import’ of a particular family models for every COP-year;
5.6.3. The COP test shall be conducted by technical agency for the next COP-year, upon receipt of
declaration by the manaufacturer that there was no productionor import during current COP-year;
5.6.4. Declaration in this regard should be submitted before end of third quarter of the current COP-
year; (i.e 31st March), if produces after 31st March, COP is applicable.
5.6.5. Any genset engine manufactured for purpose of export outside India. COP exemption shall apply
for such volumes and COP test exemption shall apply if all such engine(s) produced are exported;
5.6.6. Any domestically manufactured genset engine intended for the purpose of sample (Maximum
number of 4 units per engine family) only and not for sale in India;
5.6.7. Any genset engine imported for the purpose of sample testing, bench making and not intended
for any commercial sale (Maximum number of 4 units per year);

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5.6.8. Any genset engine imported for the round robin or laboratory correlation tests. Such engines shall
be exported back within 12 months from the date of import; or it should be scraped and a scrap
certificte shall be provided.
5.6.9. For obtaining exemptions regarding clauses 5.6.6, 5.6.7 and 5.6.8, the manufacturer shall obtain
written approval from Nodal Agency.
5.8.10. For obtaining exemptions regarding ‘No production or import’ as per clauses 5.6.2, the
manufacturer shall obtain written approval from Nodal Agency. Nodal agency should endeavor to
respond within 4 week after the receipt of application.
5.6.10. COP exemption shall be maximun up to three consecutive COP year, to resume sell from fourth
year a fresh type approval shall be conducted
5.6.11. After obtaining exemption as per 5.6.2, once production resume, manufacturer shall first conduct
COP before making any sell.

5.7. Production Definitely Discontinued

5.7.1. If manufacturer decides to discontinue production / withdraw type approval certificate of a specific
engine family or multiple families from a specific plant or all plants, the manufacturer shall so
inform to Test Agency involved in type approvals and COP compliance at least three month before
the stopage of production;
5.7.2. In such case, the manufacturer shall ensure COP compliance for the engine family(ies) from every
manufacturing plant before the production of the engine family(ies) is discontinued following COP
compliance process described in clauses 5.1, 5.2, 5,3 and 5.4 of this Regulation;
5.7.3. Upon receiving the relevant communication, the Test Agency shall inform the manufacturer the
acceptance of the communication and provide an acceptance letter.
5.8. Consequances of non compliance
5.8.1. If the COP vertification report of the technical agency for a model family indicates non-compliance,
the manufacturer must stop manufacturing with immediate effect;
5.8.2. Further, the manufactuer must analyze the reasons for non-compliance, plan to take corrective
actions in design, production line and units already produced and submit a report to the nodal
agency with a copy to concern technical agency withing four weeks of the receipt of the COP
verification report;
5.8.3. If the manufacturer is unable to diagnose the reasons for non-compliance within stipulated time,
this shall be clearly stated in the report;
5.8.4. Based on the diagnostics and corrective action plan submitted by the manufactuere, the Nodal
Agency in consultation with technical agency and if both decide to, in consultation with standing
committee, may take any of the following actions:
5.8.4.1. Allow continuation of production or import of all models in the family if it is satisfied with the
corrective actions planned or taken by the manufacturer and ability to meet emission norms;
5.8.4.2. Allow continuation of production or import of some or all other models of the engine family if it
determines that the reasons for non-conformance of the tested model are not relevant to these
models; with or without additional verification of COP in due course;
5.8.4.3. Stop production or import of some or all other models of the engine family till compliance is
demonstrated by the supplier, through a re-verification of COP. In case of imported model(s), the
non-compliant genset should be sent back to the original destination;
5.8.5. The manufacturer shall be given an opportunity to explain it’s views before taking final decision;
5.8.6. It is responsibility of the manufacturer to ensure at his cost that the modifications are carried out
such as field retro fitment campaigns within period specified by the Nodal Agency on all products
produced as well as sold / dispatched in the period between the dates from which the COP

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 became due and re-verification of COP or as decided by the Nodal Agency, in consultation with
standing committee;
5.8.7. Nodal Agency with help from Technical agency shall audits compliance in field on random basis
for corrections done and issues closure letter to manufacturer
5.8.8. Further, to avoid such non-compliances again in future, following precautionary measures shall
be initiated to strengthen the process which will be followed for next two COP cycle after re-
certification & resuming the production with new modified spec;
a) COP compliance shall be established once for every 500 units of production
b) First COP compliance to be established before crossing 50 units of production once
production resume with modified spec.
c) COP activities to be completed in all by 31st March every COP year for the next three
years. After 3-year, COP shall be as per normal practice/timeline.

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5.9 COP Process Flow Chart

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Following are the logical steps for the COP process flow chart described in brief stepwise-
COP cycle shall end with either -
I. COP compliance with regular sample testing (Steps 1-16)
II. COP compliance with extended samples testing (…. Steps 17-18)
III. COP non-compliance after extended testing (…. Steps 19-30)

CASE I:
1. Manufacturer with valid Type Approval and COP certification submits annual estimated
production/ import volume data to technical agency involved in the format provided within two
months of start of new COP-year.
2. Technical agency, based on the production/import volumes, communicates to manufacturer, the
engine type chosen and the number of samples needed for COP compliance test for all engine
families of that manufacturer within one month of submission of above production volume data;
3. Technical agency also communicates to the manufacturer plan for COP engine random selection
based on manufacture’s input above;
4. Manufacturer coordinates adhering to technical agency provided or negotiated plan and
coordinates for engine random selection at manufacturing plants/warehouses/sales points for
imported engines as the case may be.
5. At the point of selection as mentioned in Sr 4, manufacturer provides with minimum required
sample size for random selection;
6. Technical agency representative carries out random selection and does note emission critical
component part and serial numbers. Provides with appropriate seal for avoiding tampering of
assembly parameters further;
Technical agency representative randomly selects after treatment system if applicable;
Technical agency representative can also carry out random selection of an engine if from chosen
representative engine family for NCD compliance utilizing the same pool of engines offered;
7. Decision, if running–in is carried out at manufacturer’s location or technical agency location;
If running-in is agreed to be carried out at manufacture’s facility, running-in shall be started in
presence of technical agency representative.
8. Engine along with arranged after treatment shall be transported to technical agency test location;
9. Upon receipt of engine along with auxiliaries, technical agency examines the adaptability in test
cell, make necessary modification in exhaust line, mounts, etc, if required.
10. Technical agency communicates the test schedule to manufacture for his witness
11. Technical agency carries out engine qualification and emissions test per applicable procedure
and shares results with manufacturer;
12. Technical agency carries out critical component type/part numbers, injection timing verification
and match with type approved document, in case any change noted, manufacturer to provide the
declaration in this regard, till time COP certificate will be on hold.
13. Review of test result & decision on compliance;
14. If COP compliance is obtained, Technical agency prepared the compliance certificate within 4
weeks from the date of testing. Engine & after treatment, test auxiliary is returned to the
manufacturer;
15. Technical agency issue compliance certificate to manufacturer
16. Technical agency forwards a copy of compliance certificate to Nodal agency

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CASE II:
17. ECOP: If non-compliance observed after testing (at Stage No 13), process begins from extended
random selection of engine(s) as per preferred options prescribed in clause 5.3.20.
 ECOP > 19KW (Statistics is on the basis of failed emission values)

17.1 Initially test 2 more new engines

17.2 Computation of the test statistic result of 3 engines (1-originally tested + 2 new)
a) According to the appropriate clause does the test statistic result agree with the criteria for
failing the series
b) According to the appropriate clause does the test statistic result agree with the criteria for
passing the series
17.3 If, answers of a & b are NO, then; continue the testing on additional samples till pass
decision is made provided limitation of samples tested as applicable (10 numbers
maximum)

 ECOP < 19KW (Statistics is on the basis of numbers of failed engine)

17.4 For establishing the compliance minimum 4 samples are mandatory to be tested and all
4 samples should pass.
17.5 If some samples failed, the additional new more samples, are required to be tested, the
numbers depend on the number of samples failed earlier,
17.6 Initially test 2 more new engines
17.7 In the cumulative samples (4-originally tested + 2 new), note the numbers of failed
samples
c) According to the appropriate clause does the number of failed samples agree with the
criteria for failing the series
d) According to the appropriate clause does the number of failed samples agree with the
criteria for passing the series
17.8 If, answers of a & b are NO, then; continue the testing on additional samples till pass
decision is made provided limitation of samples tested as applicable (30 numbers)

18. If during testing if the pass decision criteria is reached, the series is deemed to be compliance
and COP certificate is issued (then continue from Stage14-16)

CASE III:
19. If during testing if the fail decision criteria is reached, the series is deemed to be non-compliance;
Or if Manufacturer opts to declare non-compliance without availing total number of samples
allowed to be tested, the series is deemed to be non-compliance
20. Technical agency prepares the COP failure report
21. Technical agency issue COP failure report to manufacturer
22. Technical agency informs nodal agency about COP non-compliance of said engine family
23. Manufacturer stops production or import of the said non-compliant engine family;
Manufacturer informs nodal agency about non-conformity, stoppage of production and dispatch
and their plan for failure investigation within 4 weeks of receipt of COP verification report or COP
failure intimation
24. Nodal agency discusses with test agency in details on the non-compliance notified.
25. Nodal agency replies to the manufacturer about their inputs on timelines by which compliance
shall be obtained as well as failure root cause and corrective action plan submission. Nodal
agency also informs about any financial penalty or assurance required from the manufacturer;
Manufacturer submits root cause analysis and corrective action plans to nodal agency in
consultation with technical agency;

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26. Nodal agency in consultation with technical agency reviews manufacture’s submissions and
decides if such case shall be put forth for standing committee review and guidance if found
necessary depending upon the severity of the failure.
If decided to represent at standing committee, nodal agency brings this issue to standing
committee and allows manufacture to represent their submissions. If standing committee agrees
/ approves manufacturer’s submission and plan then;
27. Nodal Agency can also decide on their own & shall take following decision:
27.1 Gives written permission to technical agency to proceed with re-verification of COP with
improvements implemented by manufacturer and also type approval re-certification as
the case may be.
27.2 Manufacturer offers engine sample and technical documentation to technical agency and
complies with COP;
27.3 Technical agency issues compliance certificate or type approval certificate if newly
approved as an option;
27.4 Manufacture begins production after obtaining new Type Approval or COP compliance
certificate;
27.5 Manufacturer completes corrective actions on engines dispatched during period of COP
and COP failure date;
28. Manufacturer complies with ‘financial assurance related’ documents asked by Nodal Agency;
29. Manufacturer submits corrective action / campaign report with adequate evidences to Nodal
Agency
30. Nodal Agency with help from Technical agency audits compliance in field for corrections done
and issues closure letter to manufacturer;
End

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 ANNEXURE – 1
Information Document from Manufacturer
Appendix – A.1
Templates for information folder and information document

1. Information folder

The information folder referred to in clause 4 of this Regulation shall contain the following:

1.1 A list of contents;

1.1.1 Approval copy from Nodal Agency with regard to Appendix 1
1.2 Manufacturer's declaration on adherence to all requirements of this Regulation in accordance with
the template set out in this Appendix
1.3 Manufacturer's statement on the compliance of the engine type or engine family with the exhaust
emission limits set out in clause 3.1 of this Regulation with regard to specified liquid fuels, fuel
mixtures or fuel emulsions other than those set out in Appendix 11 of Annexure 7
1.4 For electronically controlled engines of categories Genset , complying with the emission limits
set out in Clause 3.1 to this Regulation and using electronic control to determine both the quantity
and timing of injecting fuel or using electronic control to activate, de-activate or modulate the
emission control system used to reduce NOX, a complete overview of the emission control
strategy, including the base emission control strategy and the means by which every auxiliary
control strategy directly or indirectly controls the output variables;
1.4.1 Additional confidential information as set out in Appendix A.2 shall be made available, only for the
technical service performing the tests and not included in the information folder;
1.5 Where applicable, a full description of the functional operational characteristics of the NOX control
measures and inducement system as referred to in Annex 9 to this Regulation;
1.5.1 Where applicable, a copy of the demonstration reports set out in paragraphs A.1.10.5. and
A.1.13.4. of Appendix A.1 of Annexure 8;
1.5.2 Where applicable, a description of the connection for, and method to read, the records set out at
paragraph A.1.5.2.1.1. (e) of Appendix A.1 of Annexure 8;
1.5.3 Where the engine type or engine family is member of a NCD engine family, a justification of its
membership together with the information requested in paragraph 1.5., 1.5.1. and 1.5.2. on the
NCD engine family may be supplied alternatively, upon agreement of the Type Approval Authority;
1.6 Reserved
1.6.1 Reserved
1.6.2 Reserved
1.7 Reserved Manufacturer's declaration, and supporting test reports or data, on deterioration factors
as referred to in clause 3.2.5 of Appendix 6 of Annexure 7 of this Regulation;
1.7.1 Where the engine type or engine family is a member of an engine after-treatment system family,
a justification of its membership together with the information requested in paragraph 1.7 on the
after-treatment system family may be supplied alternatively, upon agreement of the Type
Approval Authority;
1.8 Where applicable, the manufacturer's declaration, and supporting test reports or data, of the
infrequent regeneration adjustment factors referred to in Annex 4 to this Regulation;
1.8.1 Where the engine type or engine family is a member of an engine-after-treatment system family,
a justification of its membership together with the information requested in paragraph 1.8 on the

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 engine-after-treatment system family may be supplied alternatively, upon agreement of the Type
Approval Authority;
1.9 Manufacturer's declaration and supporting data demonstrating that the emission control strategies
fitted are designed in such a way as to prevent tampering to the extent possible, as referred to in
Appendix 3 of Annexure 8 of this Regulation.
1.9.1 For engine types and engine families that use an Electronic Control Unit (ECU) as part of the
emission control system the information shall include a description of the provisions taken to
prevent tampering with and modification of the ECU including the facility for updating using a
manufacturer approved programme or calibration;
1.9.2 For engine types and engine families that use mechanical devices as part of the emission control
system the information shall include a description of the provisions taken to prevent tampering
with and modification of the adjustable parameters of the emission control system. This shall
include the tamper resistant components such as carburettor limiter caps or sealing of carburettor
screws or special screws not adjustable by user;
1.9.3 In order to place engines from different engine families into the same tamper prevention engine
family the manufacturer shall provide confirmation to the Type Approval Authority that the
measures used to prevent tampering are similar.
1.10 A description of overall quality-assurance management systems for conformity of production in
accordance to clause 5 of this Regulation;
1.11 A list of scheduled emission-related maintenance requirements and the period at which each
should occur including any scheduled exchange of critical emission-related components;
1.12 The completed information document as set out in clause 2 of this Annex;
1.12.1 Where the particulars appearing in the information document for an engine approval have
changed, the manufacturer shall submit revised pages to the approval authority showing clearly
the nature of the change(s) and the date of re-issue;
1.13. All relevant data, drawings, photographs and other information as required in the information
document;

2. Information document

The information document shall have a reference number issued by the applicant.

2.1. All information documents shall contain the following:

2.1.1. The general information set out in Part A of Appendix 3;

2.1.2. The information set out in Part B of Appendix 3, to identify the common design parameters of all
engine types within an engine family or applicable to the engine type where not part of an engine
family, intended for type approval;

2.1.3. The information set out in Part C of Appendix 3 following the format of the matrix set out in clause
2.1.3.1 to identify the items applicable to the parent engine or engine type and the engine types
within the engine family, if applicable:

2.1.3.1. Engine type or engine family matrix with example data

Parent Engine types within the engine

engine/ family (if applicable)
Item Number Item Description
engine type
type type 2 type 3 … type n

214
 3.1 Engine Identification
3.1.1 Engine type designation A01 A02 A03 A04 A05

3.2 Performance Parameters

3.2.1 Declared rated speed(s)
2200 2200 2000 1800 1800
(rpm):

3.10 Miscellaneous devices:

Yes/No
3.10.1 Exhaust gas recirculation
(EGR)
3.10.1.1 Characteristics
(cooled/uncooled, high
pressure/low pressure, etc.):

… … …

2.1.3.2. Reserved

2.1.3.3. In the case of constant speed engines with multiple rated speeds an additional set column(s) of
data for each speed shall be recorded in paragraph 3.2 (Performance Parameters).

2.2. Explanatory notes on creation of information document:

2.2.1. Upon agreement of the approval authority, the information in paragraph 2.1.2 and 2.1.3 may be
presented in an alternative format;

2.2.2. Each engine type or the parent engine in the matrix set out in paragraph 2.1.3.1 shall be identified
in accordance with the engine family designation and engine type designation set out in paragraph
2.3.

2.2.3. Only those paragraphs of this Annex relevant for the particular engine family, engine types within
the engine family or engine type shall be listed; in any case, the list shall adhere to the proposed
numbering system,

2.2.4. Where several options separated by forward slash are given for an entry, the unused options shall
be struck out, or only the used option(s) shall be shown;

2.2.5. When the same value for or description of a certain engine characteristic applies for several or all
members of an engine family the corresponding cells may be merged.

2.2.6. Where a picture, diagram or detailed information is required, a reference to an appendix may be
given;

2.2.7. Where a ‘type’ of a component is requested, the information supplied shall uniquely identify the
component; this may be a list of characteristics, a manufacturers' name and part or drawing
number, a drawing, or a combination of the aforementioned or other methods that achieves the
same result.

2.3. Engine type designation and engine family designation

2.3.1. Engine family designation shall be as per ISO 8178-7 guidelines; however, engine type
designation is at the choice of manufacturer.

2.3.2. The manufacturer shall not use the same engine family designation to identify more than one
engine family

215
 Appendix – A.2
Confidential information on emission control strategy

A 2.0 Confidential Information on emission control technology

A.2.1. This Appendix shall apply to electronically controlled engines, which use electronic control to
determine both the quantity and timing of injecting fuel.

A.2.2. Additional information shall be presented to the test agency but not annexed to the application
for type approval. This information shall include all the parameters modified by any auxiliary
emission control strategy and the boundary conditions under which this strategy operates and
in particular:

(a) a description of the control logic, of timing strategies and switch points, during all
modes of operation for the fuel and other essential systems, resulting in effective
emission control (such as exhaust gas recirculation (EGR) or reagent dosing);

(b) a justification for the use of any auxiliary emission control strategy applied to the
engine, accompanied by material and test data, demonstrating the effect on exhaust
emissions. This justification may be based on test data, sound engineering analysis,
or a combination of both;

(c) a detailed description of algorithms or sensors (where applicable) used for identifying,
analysing, or diagnosing incorrect operation of the NOX control system;

(d) reserved

A.2.3. The additional information required in paragraph A.2.2 shall be treated as strictly
confidential. It shall be retained by the manufacturer and made available for inspection by the
Type Approval Authority at the time of type approval or upon request at any time during the
validity of the type approval. In this case, the Type Approval Authority shall treat this
information as confidential and shall not disclose it to other parties.

216
 Appendix – A.3

Template for submission of engine technical specification

PART A

1. GENERAL INFORMATION
1.1. Make (trade name(s) of manufacturer):
1.2. Commercial /Brand Name name(s) (if applicable):
1.3. Company name and address of manufacturer:
1.4. Name and address of manufacturer's authorised representative (if any):
1.5. Name(s) and address(es) of assembly/manufacture plant(s):
1.6. Engine type designation/engine family designation/FT:
1.7. Category Constant speed or variable speed:
1.8. Reserved
1.9. Reserved
1.10. Reserved
1.11. Rated Power
1.12. Test cycle: D1 3-Mode Steady State cycle discrete-mode type / RMC type

1.13. Reserved
1.14. Restrictions on use (if applicable):

PART B

2. COMMON DESIGN PARAMETERS OF ENGINE FAMILY (1)

2.1. Combustion Cycle: four stroke cycle/two stroke cycle/other (specify):
2.2. Ignition Type: Positive ignition:
2.3. Configuration of the cylinders:
2.3.1. Position of the cylinders in the block: Single/V/in-line/opposed/radial/
other(specify):
2.3.2. Bore centre to centre dimension (mm):
2.4. Combustion chamber type/design
2.4.1. Open chamber/divided chamber/other(specify):
2.4.2. Valve and porting configuration:
2.4.3. Number of valves per cylinder:
2.5. Range of swept volume per cylinder (cm3):
2.6. Main Cooling medium: Air/Water/Oil:
2.7. Method of air aspiration: naturally aspirated/pressure
charged/pressure charged with charge cooler:
2.8. Fuel:

217
2.8.1. Fuel Type: (Natural gas/Biomethane) / LPG / Any other alternate fuel
as specified in this document
2.8.1.1. Reserved.
2.8.2. Fuelling arrangement: Dedicated / Bi -Fuel
2.8.3. List of additional fuels, fuel mixtures or emulsions compatible with use
by the engine declared by the manufacturer in accordance with
Appendix 3 to paragraph 5 of this Regulation (provide reference to
recognised standard or specification):
2.8.4. Lubricant added to fuel: Yes/No
2.8.5. Fuel supply type: Pump (high pressure) line and injector/in-line pump
or distributor pump/Unit injector/ Common rail./ Any other
2.9. Engine management systems: mechanical/electronic control strategy
2.10. Miscellaneous devices: Yes/No (if yes provide a schematic diagram
of the location and order of the devices)
2.10.1. Exhaust gas recirculation (EGR): Yes/No (if yes, complete section
3.10.1 and provide a schematic diagram of the location and order of
the devices)
2.10.2. Water injection: Yes/No (if yes, complete section 3.10.2 and provide
a schematic diagram of the location and order of the devices)
2.10.3. Air injection: Yes/No (if yes, complete section 3.10.3 and provide
a schematic diagram of the location and order of the devices)
2.10.4. Others: Yes/No (if yes specify, complete section 3.10.4 and provide
a schematic diagram of the location and order of the devices):
2.11. Exhaust after-treatment system: Yes/No (if yes provide a schematic
diagram of the location and order of the devices)
2.11.1. Oxidation catalyst: Yes/No
(if yes, complete section 3.11.2)
2.11.2. De NOX system with selective reduction of NOX (addition of reducing
agent): Yes/No
(if yes, complete section 3.11.3)
2.11.3. Other De NOX systems: Yes/No
(if yes, complete section 3.11.3)
2.11.4. Reserved
2.11.5. Reserved
2.11.5.1. Reserved
2.11.6. Reserved
2.11.6.1. Reserved
2.11.7. Reserved
2.11.8. Reserved
2.11.9. Reserved

218
 PART C

Engine types within

Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

3.1. Engine Identification

3.1.1. Engine type designation
Engine type designation shown on
3.1.2. engine marking: yes/no
3.1.3. Location of the statutory marking:
Method of attachment of the statutory
3.1.4. marking:
Drawings of the location of the engine
3.1.5. identification number (complete example
with dimensions):
3.2. Performance Parameters
3.2.1. Declared rated speed(s) (rpm):
3.2.1.1. Declared rated gross power (kW):
Fuel delivery/stroke (mm3) for diesel
3.2.1.2. engine, fuel flow (g/h) for other engines,
at rated gross power
3.2.6. Idle speed (rpm)
3.2.7. No load speed (rpm):
Overload load speed (rpm):
3.2.8 %Overload Power load %: eg.10%
Optional at choice of
3.3. Run-in procedure manufacturer
3.3.1. Run-in time:
3.3.2. Run-in cycle:
3.4. Engine test
3.4.1. Specific fixture required: Yes/No For NRSh only
Description, including photographs
and/or drawings, of the system for
3.4.1.1 mounting the engine on the test bench
including the power transmission shaft
for connection to the dynamometer:
Exhaust mixing chamber permitted by For NRSh only
3.4.2. manufacturer: Yes/No
Exhaust mixing chamber description, If applicable
3.4.2.1. photograph and/or drawing:
Pre-conditioning for: Steady-state
3.4.3. operation
3.5. Lubrication system
3.5.1. Lubricant temperature If applicable
3.5.1.1. Minimum (⁰C):
3.5.1.2. Maximum (⁰C):
3.6. Combustion Cylinder
3.6.1. Bore(mm):
3.6.2. Stroke(mm):
3.6.3. Number of cylinders:

219
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

3.6.4. Engine total swept volume (cm3):

Swept volume per cylinder as % of If engine family
3.6.5. parent engine:
3.6.6. Volumetric compression ratio: Specify tolerance
3.6.7. Combustion system description:
Drawings of combustion chamber and
3.6.8. piston crown:
Minimum cross-sectional area of inlet
3.6.9. and outlet ports (mm2):
3.6.10. Valve timing
Maximum lift and angles of opening and
3.6.10.1. closing in relation to dead centre or
equivalent data:
3.6.10.2. Reference and/or setting range:
If applicable and where
3.6.10.3. Variable valve timing system: Yes/No intake and/or exhaust
3.6.10.3.1. Type: continuous/(on/off)
3.6.10.3.2. Cam phase shift angle:
2-stroke only, if
3.6.11. Porting configuration applicable
3.6.11.1. Positon, size and number:
Complete relevant
3.7. Cooling system section
3.7.1. Liquid cooling
3.7.1.1. Nature of liquid:
3.7.1.2. Circulating pumps: Yes/No
3.7.1.2.1. type(s):
3.7.1.2.2. Drive ratio(s): If applicable
Minimum coolant temperature at outlet
3.7.1.3. (⁰C):
Maximum coolant temperature at outlet
3.7.1.4. (⁰C):
3.8. Aspiration
Maximum allowable intake depression at
3.8.1. rated engine speed and at 100% load
(kPa)
3.8.1.1. With clean air cleaner:
3.8.1.2. With dirty air cleaner:
3.8.1.3. Location, of measurement:
3.8.2. Pressure charger(s): Yes/No
3.8.2.1. Type(s):
Description and schematic diagram of
the system (e.g. maximum charge
3.8.2.2. pressure, waste gate, VGT, Twin turbo,
etc.):
3.8.3. Charge air cooler: Yes/No

220
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

3.8.3.1. Type: air-air/air-water/other(specify)

Maximum charge air cooler outlet
3.8.3.2. temperature at rated speed and 100%
load (⁰C):
Maximum allowable pressure drop
3.8.3.3. across charge cooler at rated engine
speed and at 100% load (kPa):
3.8.4. Intake throttle valve: Yes/No
Device for recycling crankcase gases:
3.8.5. Yes/No
3.8.5.1. If yes, description and drawings:
If no, compliance with paragraph 5.7. of
3.8.5.2. this Regulation: Yes/No
3.9. Exhaust system
Description of the exhaust system (with
3.9.1. drawings, photos and/or part numbers
as required):
3.9.2. Maximum exhaust temperature (⁰C):
Maximum permissible exhaust
3.9.3. backpressure at rated engine speed and
at 100% load (kPa):
Maximum permissible exhaust
backpressure at at each mode of test
cycle (kPa):
(This data is required for the engines
with EGR)
100% Load:
75% Load:
50% Load:
25% Load:
10% Load:
3.9.3.1. Location of measurement:
Exhaust backpressure at loading level
specified by manufacturer for variable
3.9.4. restriction after-treatment at start of test
(kPa):
3.9.4.1. Location and speed/load conditions:
3.9.5. Exhaust throttle valve: Yes/No
3.10. Miscellaneous devices: Yes/No
3.10.1. Exhaust gas recirculation (EGR)
Characteristics: cooled/uncooled, high
3.10.1.1. pressure/low pressure/other (specify):
3.10.2. Water injection
3.10.2.1. Operation principle:
3.10.3. Air injection
3.10.3.1. Operation principle
3.10.4. Others
3.10.4.1. Type(s)

221
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

3.11. Exhaust after-treatment system

3.11.1. Location
Place(s) and maximum/minimum
3.11.1.1. distance(s) from engine to first after-
treatment device:
Maximum temperature drop from
3.11.1.2. exhaust or turbine outlet to first after-
treatment device (⁰C) if stated:
3.11.1.2.1. Test conditions for measurement:
Minimum temperature at inlet to first
3.11.1.3. after-treatment device, (⁰C) if stated:
3.11.1.3.1. Test conditions for measurement:
3.11.2. Oxidation catalyst
Number of catalytic converters and
3.11.2.1. elements:
Dimensions and volume of the catalytic Or drawing
3.11.2.2. converter(s):
3.11.2.3. Total charge of precious metals (g):
Relative concentration of each
3.11.2.4. compound (%):
3.11.2.5. Substrate (structure and material):
3.11.2.6. Cell density:
Type of casing for the catalytic
3.11.2.7. converter(s):
Catalytic exhaust after-treatment system
3.11.3. for NOX or three-way catalyst
3.11.3.1. Type:
Number of catalytic converters and
3.11.3.2. elements:
3.11.3.3. Type of catalytic action :
Dimensions and volume of the catalytic Or drawing
3.11.3.4. converter(s):
3.11.3.5. Total charge of precious metals (g):
Relative concentration of each
3.11.3.6. compound (%):
3.11.3.7. Substrate (structure and material):
3.11.3.8. Cell density:
Type of casing for the catalytic
3.11.3.9. converter(s):
3.11.3.10. Reserved
3.11.3.10.1. Reserved
Normal operating temperature range
3.11.3.11. (⁰C):
3.11.3.12. Consumable reagent: Yes/No
Type and concentration of reagent
3.11.3.12.1. needed for catalytic action:
Lowest concentration of the active
3.11.3.12.2. ingredient present in the reagent that

222
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

does not activate warning system

(CDmin) (%vol):
Normal operational temperature range of
3.11.3.12.3. reagent:
3.11.3.12.4. International standard: If applicable
3.11.3.13. NOX sensor(s): Yes/No
3.11.3.13.1. Type:
3.11.3.13.2. Location(s)
3.11.3.14. Oxygen sensor(s): Yes/No
3.11.3.14.1. Type:
3.11.3.14.2. Location(s):
3.11.4. Reserved
3.11.5. Other after-treatment devices
3.11.5.1. Description and operation:
3.11.6. Reserved
3.11.7. Other devices or features
3.11.7.1. Type(s)
Fuel feed for liquid-fuelled CI or,
3.12. where applicable,
3.12.1. Feed pump
Pressure (kPa) or characteristic
3.12.1.1. diagram:
3.12.2. Injection system
3.12.2.1. Fuel Pump
3.12.2.1.1. Type(s):
3.12.2.1.2. Rated pump speed (rpm):
mm3 per stroke or cycle at full injection
3.12.2.1.3. at rated pump speed:
3.12.2.1.4. Reserved
3.12.2.1.5. Reserved
As alternative to entries
3.12.2.1.6. Characteristic diagram: 3.12.2.1.1. to
3.12.2.1.5.
3.12.2.1.7. Method used: on engine/on pump bench
For Mechanical
engines- static injection
timing values BTDC

3.12.2.2. Injection timing For Electronic engines-

calibration/software
part number/ID number
of the calibration map
Specify tolerance, if
3.12.2.2.1. Injection timing curve: applicable
3.12.2.2.2. Static Timing: Specify tolerance

223
 Engine types within
Parent the engine family (if Explanatory notes
engine/ applicable) (not included in
Item Number Item Description engine
typ type type type document)
type
e2 3 … n

3.12.2.3. Injection piping

3.12.2.3.1. Length(s) (mm):
3.12.2.3.2. Internal diameter (mm):
3.12.2.4. Common rail: Yes/No
3.12.2.4.1. Type:
3.12.3. Injector(s)
3.12.3.1. Type(s):
3.12.3.2. Opening pressure (kPa): Specify tolerance
3.12.4. ECU: Yes/No
3.12.4.1. Type(s):
3.12.4.2. Software calibration number(s):
Communication standard(s) for access
to data stream information: ISO 27145
3.12.4.3. with ISO 15765-4 (CAN-based)/ISO
27145 with ISO 13400 (TCP/IP-
based)/SAE J1939-73
3.12.5. Governor
3.12.5.1. Type(s):
Speed at which cut-off starts under full Specify range, if
3.12.5.2. load: applicable
Specify range, if
3.12.5.3. Maximum no-load speed: applicable
Specify range, if
3.12.5.4. Idle speed: applicable
3.12.6. Cold-start system: Yes/No
3.12.6.1. Type(s):
3.12.6.2. Description:
Fuel temperature at the inlet to the fuel
3.12.7. injection pump
3.12.7.1. Minimum (⁰C):
3.12.7.2. Maximum (⁰C):
3.13. Reserved

224
 Part D
Please refer below additional table for alternate fuel system:
Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Ty Ty document)
1 2 pe pe
3 n
4.1 Details of Kit Manufacturer /
Supplier / Installer
4.1.1 Name of the Manufacturer
4.1.2 Address
4.1.3 Telephone No. & Fax No.
4.2 Gas Kit Identification
4.2.1 Identification No.
4.2.2 Variants, if any
4.2.3 Fuel system (Dedicated / Bi-Fuel /)
4.2.4 Reserved
4.2.5 Fuel (Gas Fuel (Specify Name of fuel)
4.3 Solenoid Valve / Automatic shutoff
valve
4.3.1 Name of manufacturer
4.3.2 Model Name / Identification No.
4.3.3 Type
4.3.4 Working pressure (kg/cm 2)
4.3.5 Max test pressure (kg/cm 2)
4.3.6 Approval reference (Test Report /
Approval Number)
4.4 High Pressure Regulator
4.4.1 Name of manufacturer
4.4.2 Model name / Identification No.
4.4.3 Type
4.4.4 Inlet pressure (kg/cm 2 )
4.4.5 Outlet pressure (kg/cm 2 )
4.4.6 No. of stages
4.4.7 Approval reference (Test Report /
TAC compliance with Date)
4.5 Low Pressure Regulator
4.5.1 Name of manufacturer
4.5.2 Model name / Identification No.
4.5.3 Type
4.5.4 Inlet pressure (kg/cm2)
4.5.5 Outlet pressure (kg/cm2)
4.5.6 No. of stages
4.5.7 Approval reference (Test Report /
TAC compliance with Date)
4.6 Zero Pressure Regulator
4.6.1 Name of manufacturer
4.6.2 Model name / Identification No.
4.6.3 Type
4.6.4 Inlet pressure (kg/cm2)
4.6.5 Outlet pressure (kg/cm2)
4.6.6 Approval reference (Test Report /
TAC compliance with Date)

225
Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Ty Ty document)
1 2 pe pe
3 n
Vaporizer / Heat exchanger (for
4.7
LNG)
4.7.1 Name of manufacturer
4.7.2 Model name / Identification No.
4.7.3 Type
4.7.4 Inlet pressure (kg/cm2)
4.7.5 Outlet pressure (kg/cm2)
Approval reference (Test Report /
4.7.6
Approval Number)
4.8 Filter
4.8.1 Name of manufacturer
4.8.2 Model name / Identification No.
4.8.3 Type
4.8.4 Inlet pressure (kg/cm2)
4.8.5 Outlet pressure (kg/cm2)
4.9 High Pressure Tubing
4.9.1 Name of manufacturer
4.9.2 Model name / Identification No.
4.9.3 Type (rigid / flexible)
4.9.4 Working pressure (kg/cm2)
4.9.5 Max. test pressure (kg/cm2)
4.9.6 Outer diameter / Inner Diameter (mm)
4.9.7 Material
Approval reference (Test Report /
4.9.8
Approval Number)
4.10 Low Pressure Tubing
4.10.1 Name of manufacturer
4.10.2 Model name / Identification No.
4.10.3 Type
4.10.4 Working pressure (kg/cm2)
4.10.5 Max test pressure (kg/cm2)
Outer diameter / Inner Diameter
4.10.6
(mm)
4.10.7 Material
Approval reference (Test Report /
4.10.8
Approval Number)
4.11 Gas-Air Mixer
4.11.1 Name of manufacturer
4.11.2 Model name / Identification No
4.11.3 Type & drawing
4.11.4 Venturi Size (mm)
Approval reference (Test Report /
4.11.5
Approval Number)
4.12 Gas Injector
4.12.1 Name of manufacturer
4.12.2 Model name / Identification No
4.12.3 Type & drawing
4.12.4 Injector flow specs

226
Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Ty Ty document)
1 2 pe pe
3 n
Approval reference (Test Report /
4.12.5
Approval Number
4.13 Wiring Harness
4.13.1 Name of manufacturer
Electrical circuit diagram / Detail
4.13.2
layout
Approval reference (Test Report /
4.13.3
Approval Number)
4.14 Interfacing Unit (ECU)
4.14.1 Name of manufacturer
4.14.2 Identification No.
4.14.3 Type
4.15 Fuel selector switch
4.15.1 Name of manufacturer
4.15.2 Model No
4.15.3 Type
Fuel flow actuation mechanism
4.16
(Mechanical / Electronic)
Brief description of system (Attach
4.16.1
Annexure)
4.16.2 Schematic layout (Attach Drawing)
Identification of critical components of
Kit, including ECU, Lambda sensor,
4.16.3 Pressure sensor, temperature Sensor
etc with Make and Identification
number (attach Annexure)
Brief Description of System
Including Dimensional Layout for
4.17
kit components installation
ventilation details etc.
4.18 Joints and connections
4.18.1 Name of manufacturer
4.18.2 Type
Number of Joints and connections
4.18.3 represented on Drawing (Attach
Drawing)
4.19 Current limiting Device (Fuse)
4.19.1 Name of manufacturer
4.19.2 Identification No.
4.19.3 Voltage / current rating
4.19.4 Type
Approval reference (Test Report /
4.19.5
Approval Number)
4.20 Indicator
4.20.1 Pressure Indicator
4.20.2 Name of manufacturer
4.20.3 Identification No.
4.20.4 Type
4.20.5 Temperature Indicator (for LNG)
4.20.6 Name of manufacturer

227
 Item Item Description Parent Engine types within the Explanatory
Number engine/ engine family (if notes (not
engine type applicable) included in
type Type Ty Ty document)
1 2 pe pe
3 n
4.20.7 Identification No.
4.20.8 Type
4.21 Service shut off valve
4.21.1 Name of manufacturer
4.21.2 Identification No.
4.21.3 Type
Compartment/Sub-compartment /
4.22
Gas tight housing
4.22.1 Name of manufacturer
4.22.2 Identification No
4.22.3 Type
4.22.4 Material used
Approval reference (Test Report /
4.22.5
Approval Number)
4.23 Conduit
4.23.1 Name of manufacturer
4.23.2 Identification No.
4.23.3 Inner & outer diameter
4.23.4 Type
Approval reference (Test Report /
4.23.5
Approval Number)
4.24 Battery cut off switch (if applicable)
4.24.1 Name of manufacturer
4.24.2 Identification No.
4.24.3 Type
4.25 Labels - Number and position
4.26 Any other information
* Mention NA wherever not applicable
Explanatory notes to Appendix 3:
(Footnote markers, footnotes, and explanatory notes not to be stated on the information document)

228
 ANNEXURE – 2
Communication – Type Approval and COP Template to be attached
here by Test Agencies
1. General
SECTION I
1.1. Make (trade name(s) of manufacturer):
1.2. Commercial name(s)/ Brand Name (if applicable):
1.3. Company name and address of manufacturer:
1.4. Name and address of manufacturer's authorised representative (if any):
1.5. Name(s) and address(es) of assembly/manufacture plant(s):
1.6. Engine type designation/engine family designation/FT:
1.7. Category and sub-category of the engine type/engine family:

SECTION II
1. Technical service responsible for carrying out the test(s):
2. Date(s) of the test report(s):
3. Number(s) of the test report(s):

SECTION III
The undersigned hereby certifies the accuracy of the manufacturer's description in
the attached information document of the engine type/engine family (2) described
above, for which one or more representative samples, selected by the approval
authority, have been submitted as prototypes and that the attached test results apply
to the engine type/engine family (2).
1. The engine type/engine family (2) meets/does not meet (2) the requirements laid
down in GSR 804(E.) dated 3-Nov-2022 series of amendments.
2. The approval is granted/extended/refused/withdrawn (2)
Place:
Date:
Name and signature:
Attachments:
Information folder
Test report(s)
All other documents added by the technical services or by the Type Approval
Authority to the information folder in the course of carrying out their functions.
Approval number:
2. Common design parameters of the engine type/engine family

2.1. Combustion Cycle: four stroke cycle/two stroke cycle/rotary/other:

2.2. Ignition Type: Positive ignition
2.3.1. Position of the cylinders in the block: V/in-line/radial/other(describe) (2)

229
 2.6 Main Cooling medium: Air/Water/Oil (2)
2.7. Method of air aspiration: naturally aspirated/pressure charged/pressure
charged with charge cooler (2)
2.8.1. Fuel Type(s): (Natural gas/Biomethane) / Alternate Fuel
2.8.1.1. Reserved
2.8.2. Fuelling arrangement: Dedicated / Bi-Fuel
2.8.3. List of additional fuels compatible with use by the engine declared by the
manufacturer in accordance with paragraph A.3.1.2.3. of Annex 3 to paragraph
5 of this Regulation (provide reference to recognised standard or specification):
2.8.4. Lubricant added to fuel: Yes/No (2)
2.8.5. Fuel supply type: Pump (high pressure) line and injector/in-line pump or
distributor pump/Unit injector/ Common rail
2.9. Engine management systems: mechanical/electronic control strategy (2)
2.10. Miscellaneous devices: Yes/No (2)
2.10.1. Exhaust gas recirculation (EGR): Yes/No (2)
2.10.2. Water injection: Yes/No (2)
2.10.3. Air injection: Yes/No (2)
2.10.4. Others (specify):
2.11. Exhaust after-treatment system: Yes/No (2)
2.11.1. Oxidation catalyst: Yes/No (2)
2.11.2. De NOX system with selective reduction of NOX (addition of reducing agent):
Yes/No (2)
2.11.3. Other De NOX systems: Yes/No (2)
2.11.4. Three-way catalyst combining oxidation and NOx reduction: Yes/No
2.11.5. Reserved
2.11.6. Reserved
2.11.7. Reserved
2.11.8. Three-way catalyst combining oxidation and NOX reduction: Yes/No
2.11.9. Other after-treatment devices (specify):
2.11.10. Other devices or features that have a strong influence on emissions (specify):

3. Essential characteristics of the engine type(s)

Item Number Parent Engine types within the family

Item Description Engine / (if applicable)
Engine type
3.1.1. Engine Type Designation:
3.1.2. Engine type designation shown
on engine mark: Yes/No

230
Item Number Parent Engine types within the family
Item Description Engine / (if applicable)
Engine type
3.1.3. Location of the manufacturer's
statutory marking:
3.2.1. Declared rated speed (rpm):
3.2.2.2. Declared Rated Power (kW)
3.2.3.2. Declared Rated torque (Nm):
3.6.3. Number of Cylinders:
3.6.4. Engine total swept volume
(cm3):
3.8.5. Device for recycling crankcase
gases: Yes/No
3.11.3.12. Reserved
3.11.3.12.1. Reserved
3.11.3.13. NOX sensor(s): Yes/No
3.11.3.14. Oxygen sensor: Yes/No
3.11.4.7. Fuel borne catalyst (FBC):
Yes/No

Conditions to be respected in the installation of the engine on Genset

Maximum allowable intake

depression at rated engine
3.8.1.1.
speed and at 100% load (kPa)
with clean air cleaner:
Maximum charge air cooler
3.8.3.2. outlet temperature at rated
speed and 100% load (deg. C):
Maximum allowable pressure
drop across charge cooler at
3.8.3.3.
rated engine speed and at
100% load (kPa) (if applicable):
Maximum permissible exhaust
gas back-pressure at rated
3.9.3.
engine speed and at 100% load
(kPa):
Maximum permissible exhaust
backpressure at each mode of
test cycle (kPa):
(This data is required for the
engines with EGR)
100% Load:
75% Load:
50% Load:
25% Load:
10% Load:
3.9.3.1. Location of measurement:

231
Item Number Parent Engine types within the family
Item Description Engine / (if applicable)
Engine type
Maximum temperature drop
from exhaust system or turbine
3.11.1.2 outlet to first exhaust after-
treatment system (deg. C) if
stated:

Test conditions for

3.11.1.2.1.
measurement:

4. Cycle emission results

CO HC NOX HC+ NOX Test

Emissions
(g/kWh) (g/kWh) (g/kWh) (g/kWh) Cycle (4)

DF incorporated
adjusted emission
result before rounding

Final rounded
certificate result with
DF.

CO2 result:
(CO2 g/kWh is only for the documentation purpose & does not have any impact on pass
or fail criteria the engine)
Explanatory notes to Annex 2
(Footnote markers, footnotes, and explanatory notes not to be stated on the type-
approval certificate)
1
() Distinguishing number of the contracting party which has
granted/extended/refused/withdrawn an approval.
(2) Strike out the unused options, or only show the used option(s).
3
() Indicate the applicable option for the category and sub-category in accordance
with entry 1.7. of the information document set out in Part A of Appendix 3 to Annex
1.
(4) Indicate the used test cycle as prescribed in Annexure 7 to this Regulation.

232
 Appendix – A.1
Test Report

A.1.1. General requirements

One test report shall be completed for each test required for the type-approval.
Each additional (e.g. a second speed on a constant speed engine) or
supplementary test (e.g. another fuel is tested) will require an additional or
supplementary test report.
A.1.2. Explanatory notes on creation of a test report
A.1.2.1. A test report shall contain at least the information set out in paragraph A.1.3.
A.1.2.2. Notwithstanding paragraph A.1.2.1, only those sections or sub-sections relevant
for the particular test and for the particular engine family, engine types within the
engine family or engine type tested need to be stated in the test report
A.1.2.3. The test report may contain more information than that requested in paragraph
A.1.2.1 but in any case, shall adhere to the proposed numbering system;
A.1.2.4. Where several options separated by forward slash are given for an entry, the
unused options shall be struck out, or only the used option(s) shall be shown;
A.1.2.5. Where a ‘type’ of a component is requested, the information supplied shall
uniquely identify the component; this may be a list of characteristics, a
manufacturers' name and part or drawing number, a drawing, or a combination of
the aforementioned or other methods that achieves the same result.
A.1.2.6. The test report may be delivered on paper on in an electronic format agreed
between the manufacturer, technical service and Type Approval Authority.

A.1.3 Template for the test report

1. General Information
1.1. Make(s) (trade name(s) of manufacturer):
1.2. Commercial name(s) /Brand Name (if applicable):
1.3. Company name and address of manufacturer:
1.4. Name of test agency:
1.5. Address of test agency:
1.6. Location of test:
1.7. Date of test:
1.8. Test report number:
1.9. Information document reference number (if available):
1.10. Test report type: Primary test/additional test/supplementary test
Primary test -standard regular test most likely common for approval.
Additional test - additional test is for in case there are more than one options for
permeance/emission related components, i.e. 2 different make injector, 2 turbo
etc.
1.10.1. Description of the purpose of the test:

233
2. General engine information (test engine)
2.1. Engine type designation/engine family designation/FT:
2.2. Engine identification number:
2.3. Engine Category and subcategory:

3. Documentation and information Check list (primary test only)

3.1. Engine mapping documentation reference:
3.2. Deterioration factor determination documentation reference:
3.3. Reserved
3.4. NOX control diagnostic demonstration documentation reference, where applicable:
3.5. Reserved
3.6. For engine types and engine families that use an ECU as part of the emission control
system anti-tampering declaration documentation reference:
3.7. For engine types and engine families that use mechanical devices as part of the emission
control system anti- tampering and adjustable parameters declaration and demonstration
documentation reference:

4. Reference fuel(s) used for test (complete relevant subparagraph(s)

4.2. Fuels for spark ignition engine
4.2.1. Make:
4.2.2. Type:
4.2.3. Octane number:
4.2.4. Fame content (%):
4.2.5. Density at 15 ⁰C (kg/m3):
4.3. Reserved
4.4. Reserved
4.5. Reserved
4.5.1. Reserved
5. Lubricant
5.1. Make(s):
5.2. Type(s):
5.3. SAE viscosity:
5.4. Lubricant and fuel are mixed: yes/no
5.4.1. Percentage of oil in mixture:
6. Engine Speed
6.1. Declared rated speed:
6.1.1. Overload speed:
6.1.2. Idle speed:
7. Engine Power.

234
8. Conditions at test
8.1. fa within range 0.93 to 1.07: Yes/No
8.1.1. If fa is not within specified range state altitude of test facility and dry atmospheric pressure:
If no - If these limits are exceeded, the corrected value obtained shall be given and the test
conditions (temperature and pressure) shall be stated precisely in the test report
8.2. Applicable intake air temperature range: 20 to 30 oC (up 560kW/ 20 to 35 oC (greater than
560 kW only)
9. Test result 9.1. 3-mode cycle Emissions results
9.2. Deterioration Factor (DF): calculated/assigned
9.2.1. DF values and the cycle weighted emissions results to be stated in Table 6:
Note: In the event that a discrete mode 3-mode cycle is run where the Kru or Krd
factors have been established for individual modes then a table showing each
mode and the applied Kru or Krd should replace the shown table.

Table 6
3-mode cycle DF values and weighted emissions results

DF HC+ NOX
CO HC NOX
mult/add

CO HC NOX HC+ NOX

Emissions
(g/kWh) (g/kWh) (g/kWh) (g/kWh)

Test result
with/without regeneration

kru/krd
mult/add

Final rounded test result with

DF

9.3 Cycle weighted CO2 (g/kWh):

9.3.1 Cycle average NH3 (ppm):
9.4. Reserved
Table 7
Reserved

9.5. Sampling systems used for the 3-mode emission test:

9.5.1. Gaseous emissions:
9.5.2. Reserved
9.5.2.1. Reserved

10. Final emissions results

235
10.1 Cycle emissions results to be stated in Table 8.
Table 8
Final emissions results

CO HC NOX HC+ NOX Test

Emissions
(g/kWh) (g/kWh) (g/kWh) (g/kWh) Cycle (1)

3-mode cycle final

rounded test result with
DF.

10.2 CO2 result:

Explanatory notes to the test report template
(Footnote markers, footnotes, and explanatory notes not to be stated on the test report)
(1) For test cycle note the cycle indicated in Appendix 1 of Annexure 7
(2) Copy the results from table 6
3
() Reserved
(4) For an engine tested on a 3-mode cycle indicate the CO2 emissions values
given in that cycle from paragraph 9.3.

236
 ANNEXURE – 3

Labelling Requirements

A3.1. The engine or the product must be affixed with a conformance label meeting the following
requirements.

A3.1.1. General Requirement

e. The label shall be durable and legible;

f. The label shall be affixed on a part necessary for normal operation of the engine or
the product and not normally requiring replacement during the life of the engine or
the product;
g. Statement that ‘this engine or product conforms to the Environment Protection Rule
1986;
h. All the information mentioned in the conformance label must be in English language;

A3.1.2. Conformance Labelling Content Requirement

i. Name the engine manufacturer or the engine or product importer

j. Manufacturing plant address from where engine is manufacture
k. Engine Model name;
l. Rated speed and corresponding gross power in kW;
m. Engine Unique Identification Number (Serial Number, etc.);
n. Date of manufacturing and in case of import, date of import of engine or Genset
product;
o. Type Approval certificate number;
p. Letter ‘G’ to denote that the engine is belongs to genset application. The Letter
‘G’ shall be engraved on the conformance label. The letter(s) should have a
minimum size of 7 mm.

237
 ANNEXURE – 4

Test equipment, test bed measurement system and test

facility

A4.1 Requirement

A4.1.1 Test facility: The test facility to be used shall be of the certification agencies or any
other facility approved by these certification agencies. The test Lab at Test Agency/
Engine Manufacturer Lab/ Third party Lab shall be accredited as per the requirement
of ISO/IEC-17025 (NABL-National Accreditation Board for Testing and Calibration
Laboratory) compliance for the related GSR/S&P/ISO-8178 Standards. The tests shall
be carried out under the control of the certification agencies.
A4.1.2 Test bed measurement system and equipment: Test bed measurement system and
equipment’s of gaseous and particulate shall be as per the guideline given in the ISO-
8178-1: 2017,2020 Reciprocating internal combustion engines — Exhaust emission
measurement — Part 1: Test-bed measurement systems of gaseous and particulate
emission.

238
 ANNEXURE–5

Data evaluation, test result calculation of gaseous &

emission, test execution and measurement procedures

A5.1 Requirement

A5.1.1 Method of test execution, measurement procedures, data evaluation and

calculation of gaseous emission shall be as per the guideline given in the ISO-
8178-4: 2017, 2020 Reciprocating internal combustion engines — Exhaust emission
measurement — Part 4: Steady-state and transient test cycles for different engine
applications

A5.1.2 Reserved

A5.1.3 1980 international gravity formula

The acceleration of Earth's gravity, ag, varies depending on the location and ag is:
calculated for a respective latitude, as follows

ag  9.7803267715 1  5.2790414 103 sin 2   2.32718 10 5 sin 4   1.262 107 sin 6   7 1010 sin 8  

Where: θ = Degrees north or south latitude

Note: Reference taken from AIS-137

239
 ANNEXURE – 6
Technical characteristics of fuels prescribed for approval tests and to
verify conformity of production tests

Appendix – 1 & Table 1

Reserved

Appendix – 2 & Table 2

Reserved

Appendix – 3 & Table 3

Reserved

Appendix – 4
Alternate Fuel Specification
2.0 Technical data on gaseous fuels for single fuel engines
2.1 Type: LPG
Table 4

LPG
Test
Parameter Unit Fuel A Fuel B
method
Composition: EN 27941
per cent
C3-content 30 ± 2 85 ± 2
v/v
per cent
C4-content Balance1 Balance1
v/v
per cent
< C3 , > C4 Maximum 2 Maximum 2
v/v
per cent Maximum Maximum
Olefins
v/v 12 15
Maximum Maximum
Evaporation residue mg/kg EN 15470
50 50
Water at 0 °C Free Free EN 15469
EN 24260,
ASTM D
Total sulphur content Maximum Maximum
mg/kg 3246,
including odorant 10 10
ASTM
6667
EN ISO
Hydrogen sulphide None None
8819
Copper strip
corrosion Rating Class 1 Class 1 ISO 62512
(1h at 40 °C)

240
 Characterist Characterist
Odour
ic ic
Motor octane Minimum Minimum EN 589
number3 89.0 89.0 Annex B
Notes:
1
Balance shall be read as follows: balance = 100 - C3 - <C3 - >C4.
2
This method may not accurately determine the presence of corrosive materials if
the sample contains corrosion inhibitors or other chemicals which diminish the
corrosivity of the sample to the copper strip. Therefore, the addition of such
compounds for the sole purpose of biasing the test method is prohibited.
3
At the request of the engine manufacturer, a higher MON could be used to
perform the type approval tests.

2.2. Type: Natural Gas/ Bio-methane

2.2.1. Specification for reference fuels supplied with fixed properties (eg from a sealed
container)
As an alternative to the reference fuels set out in this paragraph, the equivalent fuels
in paragraph 2.1.2. of this Annex may be used
Table 5

Natural Gas/ Bio-methane

Limits
Characteristics Units Basis minimu Test method
maximum
m
Reference fuel GR
Composition:
Methane 87 84 89
Ethane 13 11 15
per cent
Balance1 — — 1 ISO 6974
mole
Sulphur content mg/m3 2 — 10 ISO 6326-5
Notes:
1
Inerts + C2+
2
Value to be determined at standard conditions 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G23
Composition:
Methane 92.5 91.5 93.5
per cent
Balance1 — — 1 ISO 6974
mole
per cent
N2 7.5 6.5 8.5
mole
Sulphur content mg/m3 2 — — 10 ISO 6326-5
Notes:
1
Inerts (different from N2) + C2+ C2+
2
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G25
Composition:

241
 per cent
Methane 86 84 88
mole
per cent
Balance1 — — 1 ISO 6974
mole
per cent
N2 14 12 16
mole
Sulphur content mg/m3 2 — — 10 ISO 6326-5
Notes:
1
Inerts (different from N2) + C2+ C2+
2
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G20
Composition:
per cent
Methane 100 99 100 ISO 6974
mole
per cent
Balance (1) — — 1 ISO 6974
mole
per cent
N2 ISO 6974
mole
Sulphur content mg/m3 (2) — — 10 ISO 6326-5
3 (3)
Wobbe Index (net) MJ/m 48.2 47.2 49.2
(1)
Inerts (different from N2) + C2 + C2+.
(2)
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
(3)
Value to be determined at 273.2 K (0 °C) and 101.3 kPa.

Note –
In absence of availablity of reference fuel for testing, commercial available fuel
as notified under CMVR (ammended time to time ) shall be used for testing
2.2.2. Specification for reference fuel supplied from a pipeline with admixture of other gases
with gas properties determined by on-site measurement
As an alternative to the reference fuels in this paragraph the equivalent reference fuels
in paragraph 2.2.1. of this Annex may be used.
2.2.2.1. The basis of each pipeline reference fuel (GR, G20, …) shall be gas drawn from a
utility gas distribution network, blended, where necessary to meet the corresponding
lambda-shift (Sλ) specification in Table A.5-1, with an admixture of one or more of the
following commercially (the use of calibration gas for this purpose shall not be
required) available gases:
(a) Carbon dioxide;
(b) Ethane;
(c) Methane;
(d) Nitrogen;
(e) Propane.
2.2.2.2. The value of Sλ of the resulting blend of pipeline gas and admixture gas shall be within
the range specified in Table A.5-1 for the specified reference fuel.
Table A.5-1
Required range of Sλ for each reference fuel
Reference fuel Minimum Sλ Maximum Sλ

242
 GR 2 0.87 0.95
G20 0.97 1.03
G23 1.05 1.10
G25 1.12 1.20

1
The engine shall not be required to be tested on a gas blend with a Methane
Number (MN) less than 70. In the case that the required range of Sλ for GR
would result in an MN less than 70 the value of Sλ for GR may be adjusted as
necessary until a value of MN no less than 70 is attained.

2.2.2.3. The engine test report for each test run shall include the following:
(a) The admixture gas(es) chosen from the list in paragraph 2.2.2.1. of this Annex;
(b) The value of Sλ for the resulting fuel blend;
(c) The Methane Number (MN) of the resulting fuel blend.

2.3 Fuels and their applicable standards:

Refer the applicable standards amended time to time for the fuels
Sr. Fuel Applicable Standard
No.
1 Natural Gas Annexure IV - L -
CMVR Refer rule 115 H
2 Bio methane IS 16087: 2016
3 Bio Gas IS 16087: 2016
4 LPG IS 14861 : 2000
(REAFFIRMED 2020)
5 E10 IS 2796: 2017
6 E12 IS 17586: 2021
7 E15 IS 17586: 2021
8 E20 IS 17021: 2018
9 E85 IS 16634: 2017
10 E100 IS 15464: 2004
11 M15 IS 17076: 2019
12 M85 Annexure ZB - CMVR
Refer rule 115 H
13 M100 IS 17075 : 2019
14 Hydrogen IS 16061: 2021
15 Hydrogen blended with CNG (18% IS 17314 : 2019
hydrogen)

243
 ANNEXURE – 7

Requirements, Tests and Test Procedures

7.1. General
Engines shall be designed, constructed and assembled so as to enable them to comply with the
provisions of this Regulation.
7.1.1. The technical measures taken by the manufacturer shall be such as to ensure that the gaseous
pollutant emissions are effectively limited, as set out in Table 1 of clause 3 of this Regulation
throughout the emission durability period of the engine, as set out in Appendix 6 to this Annexure
7, and under normal conditions of use.
7.1.1.1. For this purpose, the engine final emission test result calculated according to the requirements of
clause 7.1.2 shall not exceed the exhaust emission limits set out in Table 1 of clause 3, when:
(a) tested in accordance with the test conditions and detailed technical procedures set out in
Annexure 5 to this Regulation,
(b) using the fuel(s) specified in paragraph 7.1.3.
(c) using the test cycles specified in Appendix 1 to Annexure 7 of this Regulation.
7.1.2 The final exhaust emission test results for engines subject to this Regulation shall be calculated
by applying all of the following to the laboratory test results:
(a) the emissions of crankcase gases as required by Appendix 5 of Annexure 7;
(b) any necessary adjustment factor, where the engine includes an infrequently regenerating
exhaust after-treatment system;
(c) in respect of all engines, as a final step in the calculation, deterioration factors appropriate
to the emission durability periods specified in Appendix 6 to this Annexure 7 and
calculated according to the prescription set out in Annexure 5.
7.1.3 In accordance to Annexure 7 of this Regulation, the testing of an engine type or engine family to
determine whether it meets the emission limits set out in this Regulation shall be carried out by
using the following reference fuels or fuel combinations, as appropriate:
(a) natural gas/bio methane
(b) ethanol.
(c) methanol
The engine type or engine family shall, in addition, meet the exhaust emission limits set out in this
Regulation in respect of any other specified fuels, fuel mixtures or fuel emulsions included by a
manufacturer in an application for type- approval and described in the Appendix 11 to paragraph
7 of this Regulation.

7.1.4 As regards the conduct of measurements and tests, the technical requirements shall be met in
respect of:
(a) apparatus and procedures for the conduct of tests;
(b) apparatus and procedures for emission measurement and sampling;
(c) methods for data evaluation and calculations;
(d) methods for establishing deterioration factors;
(e) methods for taking account of emissions of crankcase gases;
(f) methods for determining and taking account of continuous or infrequent regeneration of
exhaust after-treatment systems;

244
 (g) Reserved
7.1.5. Any adjustment, repair, disassembly, cleaning or replacement of engine components or systems
which are scheduled to be performed on a periodic basis to prevent malfunction of the engine,
shall only be done to the extent that is technologically necessary to ensure proper functioning of
the emission control system.
7.2. Reserved
7.3. The technical requirements relating to emission control strategies as set out in Annexure 8 to this
regulation shall apply;
7.4. The use of defeat strategies shall be prohibited;
7.5. Engine types and engine families shall be designed and fitted with emission control strategies in
such a way as to prevent tampering to the extent possible;

245
 Appendix – 1
Emission Test Cycles Introduction
1. Test cycles
The type-approval test shall be conducted using test cycle as specified in Table A for constant
speed speed application.
1.1 Steady-state test cycles
Steady-state test cycles are specified in below clause 2 of this Appendix as a list of discrete
modes (operating points), where each operating point has one value of speed and one value
of torque. A steady-state test cycle shall be measured with a warmed up and running engine
according to manufacturer's specifications
1.2. Steady-state discrete mode test cycles
The steady-state discrete mode test cycles are hot running cycles where emissions shall be
started to be measured after the engine is started, warmed up and running as per specified
boundary conditions. Each cycle consists of a number of speed and load modes (with the
respective weighing factor for each mode) which cover the typical operating range of the
specified engine category.
1.3. Steady-state ramped mode test cycles
Steady-state ramped mode test cycles are hot running cycles where emissions shall be started
to be measured after the engine is started, warmed up and running as per specified boundary
conditions. Test cycle with a sequence of steady state engine test modes with defined speed
and torque criteria at each mode and defined speed and torque ramps between these modes.
2. Characteristics of the steady-state test cycles
2.1. Test cycles applicable to Genset engine categories are set out in Table A
Table A-Test cycles

Test cycles for Genset engine categories

Speed
Category Purpose Test Cycle
operation
D1 3-mode Steady-state discrete mode test cycle
Constant specified in ISO-8178-Part 4,
Constand
speed
Genset speed OR
engine upto
engine D1 3-mode Steady-state ramped mode test cycle
800 kW
specified in ISO-8178-Part 4

2.2. Steady-state constant speed and test cycles:

The detailed description of the test modes and weighting factors for the steady-state discrete-
mode genset engine is are set out in Tables B.
2.2.1 Constant Speed test Cycle

Table B- Discrete D1 test modes

Test modes and weighting factors
Mode number
1 2 3
(cycle D1)
Speed (a) 100%
Torque (b) (%) 100 75 50

246
 Weighting
0.3 0.5 0.2
factor
Mode length (Second) 600 600 600
(a) Rated speeds as declared by manufactured
(b) per cent torque is relative to the torque corresponding to the rated gross power declared by the
manufacturer. Considering the applicable power tolerance, the torque setting for 2 &, 3 mode, shall
be based on actual torque measured at 1st mode during test.

3 mode constant-speed test cycle

Rated Speed

Weighting Factor

100% Mode-1
0.3
Torque [ % ]

75% Mode-2
0.5

50% Mode-3
0.2

Speed [ rpm ]

Table C
Reserved
2.2.2 Reserved

Table D, E & F
Reserved

Note: Reference
ISO 8178-4:2017,2020;
Reciprocating internal combustion engines — Exhaust emission measurement — Part 4: Steady-
state and transient test cycles for different engine applications.

Appendix – 2
Reserved
A2.1, A2.2. A2.3, A2.4 and A2.5 - Reserved

Appendix – 3
Reserved
A3.1, A3.2, A3.3, A3.4, A3.4 - Reserved

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 Appendix – 4

Gross Power Measurement Procedure

1.0 Declared power (kWm) means rated gross mechanical power declared by
manufacturer for type approval at declared rated speed.

2.0 Gross observed power shall be the criteria for adjusting dynamometer load as well as
calculating the specific emission values

3.0 The declared rated gross power shall be verified with the observed gross corrected
power as mentioned below. Certification Power verification will be at reference
atmospheric condition.

4.0 Power observed in the emission test cycle for all test mode points shall be corrected
as per mentioned below formula and 1st mode corrected power is the corrected rated
gross power.

5.0 Power Corrections Factors:

Definition: The power correction factor is the coefficient by which the measured power
must be multiplied to determine the engine power under the reference atmospheric
conditions specified as below

Pcorr = α Pobs
Where,
Pcorr is the corrected power (i.e. power under reference atmospheric
conditions)
α is the correction factor
Pobs is the measured power (test power)
Reference atmospheric conditions:
 Temperature (T): 298 K
 Dry pressure (Ps): 99 kPa
Note: The dry pressure is based on a total pressure of 100 kPa and a water vapour
pressure of 1 kPa.

Test atmospheric conditions:

 The atmospheric conditions during the test shall be the following:
 Temperature (T): Between 283 K and 313 K
 Pressure (P): Between 80 kPa and 110 kPa

Determination of correction factor:

(The tests may be carried out in air -conditioned tests rooms where the atmospheric
conditions may be controlled.)

The power correction factor αa for Positive Ignition Engines (Naturally aspirated or supercharged)
obtained by applying the formula:
The correction Factor (αa) is obtained by applying the formula:
αa = (99 /Ps)1.2 ( T/298)0.6
Where,

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 Ps= the dry atmospheric pressure in kPa, that is the total barometric pressure minus water vapour
pressure and
T= the absolute temperature in Kelvin (K) at the engine air inlet
The formula applies to carburetted engines and to other engines where the management system
is designed to maintain relatively constant fuel / air ratio as ambient conditions change.
(The references for Power correction factor are taken from IS 14599:1999 clause
6.4.1)

6.0 The gross declared corrected power of the engine shall be measured on a test bench
at rated speed of the engine. The measured power and speed may differ from the
power and speed specified by the manufacturer as specified below:

Declared rated corrected gross Power & speed tolerance

 For Constant speed engine
(i) For Type Approval:
 For single cylinder engines, ± 5% at the rated power point
 For all other engines, ± 4 % at the rated power point
(ii) For Conformity of Production:
 For single cylinder engines, at rated power point, ± 6% of the type
approved figure
 For all other engines, at rated power point, ± 5% of the type approved
figure

Declared rated Speed at rated power point shall vary within ± 1%

7.0 For verifying the conformity of production, for the selected engine, if the gross power
and rated speed does not meet the limits, two additional engines for >19kW or four in
case <19kW power rating category shall be tested for the rated gross power and rated
speed.

The additional selected all engines shall meet the limits for the rated gross power and
speed, out of these engines, one engine shall be subjected to the emission test for the
conformance of production as mentioned in this part.

8.0 Single & two-cylinder engines shall be tested with the engine intake system. All the
other engine shall be tested with either air intake system of applying maximum declared
air intake depression of clean air intake

9.0 The engine shall be tested with the maximum exhaust back pressure values declared
by the manufacturer. In case of the engines fitted with exhaust after treatment device
and external EGR system, the manufacturer shall declare exhaust back pressure
values at all five test points. The engine will be tested with the declared exhaust back
pressure values set at laboratory condition with a tolerance of ±10% at rated load. At
part load points the tolerance shall be as low as possible in the test laboratory
conditions.

10.0 The no load speed or high idle speed and overload speed (correspondence to %
overload power declared by manufacturer) shall be verified and documented against
value specified by the manufacturer.

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 Appendix – 5

Crankcase Ventilation Requirements

The Regulation does not enforce a specific crankcase ventilation system for Genset engines. With
option of Open and Close crankcase ventilation systems, verifying emissions of crankcase gases is
required for engines with gross power >56 kW.

Crank case ventilation requirement shall be as per the guideline given in the ISO-8178-4: 2017, 2020
Reciprocating internal combustion engines — Exhaust emission measurement — Part 4: Steady-state
and transient test cycles for different engine applications

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 Appendix – 6

Emission Durability Period (EDP), Deterioration Factor and Methodology for

Adapting Emission Lab Test Results

1. Definitions
For the purposes of this appendix, the following definitions apply. Refer clause 2.1 for extensive
set of definitions:
1.1. “Ageing cycle” means the engine operation (speed, load, power) to be executed during the
service accumulation period.
1.2. “Critical emission-related components” means the exhaust after- treatment system, the
electronic engine control unit and its associated sensors and actuators, and the EGR system
including all related filters, coolers, control valves and tubing.
1.3. “Critical emission-related maintenance” means the maintenance to be performed on critical
emission-related components of the engine.
1.4. “Emission-related maintenance” means the maintenance which substantially affects
emissions or which is likely to affect emissions performance of the engine during normal in-use
operation.
1.5. “Engine-after-treatment system family” means a manufacturer’s grouping of engines that
comply with the definition of engine family, but which are further grouped into a family of engine
families utilising a similar exhaust after-treatment system.
1.6. “Non-emission-related maintenance” means maintenance which does not substantially
affect emissions and which does not have a lasting effect on the emissions performance
deterioration of the engine during normal in-use operation once the maintenance is performed.
1.7. “Service accumulation schedule” means the ageing cycle and the service accumulation
period for determining the deterioration factors for the engine-after-treatment system family.

2. General
2.1. This Appendix details the procedures for selecting engines to be tested over a service
accumulation schedule for the purpose of determining deterioration factors for engine type
approval and conformity of production assessments. The deterioration factors shall be applied
to the emissions measured in accordance with Annex 4 and calculated in accordance with
Annex 5 in accordance with the procedure set out in paragraph 3.2.7 of this appendix,
respectively.
2.2. The service accumulation tests or the emissions tests performed to determine deterioration
need not be witnessed by the Type Approval Authority.
2.3. This appendix also details the emission-related and non-emission-related maintenance that
should be or may be carried out on engines undergoing a service accumulation schedule. Such
maintenance shall conform to the maintenance performed on in-service engines and
communicated to the end-users of new engines.

3. Engine categories Genset

3.1. Selection of engines for establishing emission durability period deterioration factors
3.1.1. Engines shall be selected from the engine family defined in Clause 4.1 to establish emission
durability period deterioration factors.
3.1.2. Engines from different engine families may be further combined into families based on the type
of exhaust after-treatment system utilised, or where no after-treatment is used, based upon the

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 similarity of the technical characteristics of the emission control system. Engines of different
bore and stroke, different configuration, different air management systems, different fuel
systems may be considered as equivalent in respect to emissions deterioration characteristics
if the manufacturer provides data to the Type Approval Authority that there is a reasonable
technical basis for such determination. In order to place engine families having similar technical
specifications and installation for the exhaust after-treatment systems into the same engine
after-treatment system family, the manufacturer shall provide data to the Type Approval
Authority that demonstrates that the emissions reduction performance of such engines is
similar.
3.1.3. The test engine shall represent the emission deterioration characteristics of the engine families
that will apply the resulting deterioration factors for type approval. The engine manufacturer
shall select one engine representing the engine family, group of engine families or engine-after-
treatment system family, as determined in accordance with paragraph 3.1.2. of this Appendix,
for testing over the service accumulation schedule referred to in paragraph 3.2.2. of this
Appendix, which shall be reported to the Type Approval Authority before any testing
commences.
3.1.4. If the Type Approval Authority decides that the worst-case emissions of the engine family, group
of engine families or engine-after-treatment system family can be better characterised by
another test engine, the test engine to be used shall be selected jointly by the Type Approval
Authority and the engine manufacturer.

3.2. Determination of emission durability period deterioration factors

3.2.1. General
Deterioration factors applicable to an engine family, group of engine families or engine-after-
treatment system family shall be developed from the selected engines based on a service
accumulation schedule that includes periodic testing for gaseous emissions over each test
cycle applicable to the engine category.
3.2.1.1. At the request of the manufacturer, the Type Approval Authority may allow the use of
deterioration factors that have been established using alternative procedures to those specified
in paragraphs 3.2.2. to 3.2.5. of this Appendix. In that case, the manufacturer shall demonstrate
to the satisfaction of the Type Approval Authority that the alternative procedures used are not
less rigorous than those set out in paragraphs 3.2.2. to 3.2.5. of this Annex.
3.2.2. Service accumulation schedule
Service accumulation schedules may be carried out at the choice of the manufacturer by
running a Genset equipped with the selected engine over an "in-service" accumulation
schedule or by running the selected engine over a "dynamometer service" accumulation
schedule. The manufacturer shall not be required to use reference fuel for the service
accumulation in-between emission measurement test points.
3.2.2.1. In-service and dynamometer service accumulation
3.2.2.1.1. The manufacturer shall determine the form and duration of the service accumulation and the
ageing cycle for engines in a manner consistent with good engineering judgment.
3.2.2.1.2. The manufacturer shall determine the test points where gaseous emissions will be measured
over the applicable cycles, as follows:
3.2.2.1.2.1. When running a service accumulation schedule shorter than the emission durability period
in accordance with paragraph 3.2.2.1.7. of this Appendix, the minimum number of test points
shall be three, one at the beginning, one approximately in the middle and one at the end of
the service accumulation schedule.
3.2.2.1.2.2. When completing the service accumulation up to the end of the emission durability period,
the minimum number of test points shall be two, one at the beginning and one at the end of
the service accumulation.
3.2.2.1.2.3. The manufacturer may additionally test at evenly spaced intermediate points.

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3.2.2.1.3. The emission values at the start point and at the emission durability period endpoint either
calculated in accordance with paragraph 3.2.5.1. of this Appendix or measured directly in
accordance with paragraph 3.2.2.1.2.2. of this Appendix, shall be within the limit values
applicable to the engine family. However individual emission results from the intermediate
test points may exceed those limit values.
3.2.2.1.4. Type Approval Authority to run only one test cycle) at each test point
3.2.2.1.5. Reserved
3.2.2.1.6. Service accumulation schedules may be different for different engine-after-treatment system
families.
3.2.2.1.7. Service accumulation schedules may be shorter than the emission durability period, but shall
not be shorter than the equivalent of at least one quarter of the relevant emission durability
period as specified in below table
Emission durability period for Genset Engines > 19KW
Category (Power Band) Emission durability period (hours)
>19 ≤ 56 kW (constant speed Engines) 3000
> 56 kW (All engines) 8000
3.2.2.1.8. Accelerated ageing by adjusting the service accumulation schedule on a fuel consumption
basis is permitted. The adjustment shall be based on the ratio between the typical in-use
fuel consumption and the fuel consumption on the ageing cycle, but fuel consumption on the
ageing cycle shall not exceed typical in-use fuel consumption by more than 30 per cent.
3.2.2.1.9. At the request of the manufacturer and with the agreement of the Type Approval Authority,
alternative methods of accelerated ageing may be permitted.
3.2.2.1.10. The service accumulation schedule shall be fully described in the application for type-
approval and reported to the Type Approval Authority before the start of any testing.
3.2.2.2. If the Type Approval Authority decides that additional measurements need to be performed
between the points selected by the manufacturer it shall notify the manufacturer. The revised
service accumulation schedule shall be prepared by the manufacturer and agreed by the
Type Approval Authority.

3.2.3. Engine testing

3.2.3.1. Engine stabilisation
3.2.3.1.1. For each engine-after-treatment system family, the manufacturer shall determine the number
of hours of engine running (or a Genset application) after which the operation of the engine-
after-treatment system has stabilised. If requested by the Type Approval Authority, the
manufacturer shall make available the data and analysis used to make this determination.
As an alternative, the manufacturer may run the engine or a Genset between 60 and 125
hours or the equivalent time on the ageing cycle to stabilise the engine-after-treatment
system.
3.2.3.1.2. The end of the stabilisation period determined in paragraph 3.2.3.1.1. of this Appendix shall
be deemed to be the start of the service accumulation schedule.
3.2.3.2. Service accumulation testing
3.2.3.2.1. After stabilisation, the engine shall be run over the service accumulation schedule selected
by the manufacturer, as described in paragraph 3.2.2. of this Appendix. At the periodic
intervals in the service accumulation schedule determined by the manufacturer, and, where
applicable, decided by the Type Approval Authority in accordance with paragraph 3.2.2.2.
of this Appendix, the engine shall be tested for gaseous and particulate emissions over
steady state cycle as applicable to the engine category

253
 The manufacturer may select to measure the pollutant emissions before any exhaust after-
treatment system separately from the pollutant emissions after any exhaust after-treatment
system.
In accordance with paragraph 3.2.2.1.4. of this Appendix, if it has been agreed that only one
steady state test cycle (applicable 3-mode emission cycle) be run at each test point, at the
beginning and at the end of the service accumulation schedule.
3.2.3.2.2. During the service accumulation schedule, maintenance shall be carried out on the engine
in accordance with paragraph 3.4. of this Appendix.
3.2.3.2.3. During the service accumulation schedule, unscheduled maintenance on the engine may be
performed, for example if the manufacturer's normal diagnostic system has detected a
problem that would have indicated to genset operator that a fault had arisen.
3.2.4. Reporting
3.2.4.1. The results of all emission tests (applicable 3-mode emission cycle) conducted during the
service accumulation schedule shall be made available to the Type Approval Authority. If an
emission test is declared to be void, the manufacturer shall provide reasons why the test
has been declared void. In such a case, another series of emission tests shall be carried out
within the following 100 hours of service accumulation.
3.2.4.2. The manufacturer shall retain records of all information concerning all the emission tests
and maintenance carried out on the engine during the service accumulation schedule. This
information shall be submitted to the Type Approval Authority along with the results of the
emission tests conducted over the service accumulation schedule.
3.2.5. Determination of deterioration factors
3.2.5.1 When running a service accumulation schedule in accordance with paragraph 3.2.2.1.2.1.
or paragraph 3.2.2.1.2.3. of this Appendix, for each pollutant measured over the applicable
D1 – 3 mode emission cycle at each test point during the service accumulation schedule, a
"best fit" linear regression analysis shall be made on the basis of all test results. The results
of each test for each pollutant shall be expressed to the same number of decimal places as
the limit value for that pollutant, as applicable to the engine family, plus one additional
decimal place.
Where in accordance with paragraph 3.2.2.1.4. or paragraph 3.2.2.1.5. of this Appendix,
only one steady state test cycle (applicable 3-mode emission cycle) has been run at each
test point, the regression analysis shall be made only on the basis of the test results from
the test cycle run at each test point.
The manufacturer may request the prior approval of the Type Approval Authority for a non-
linear regression.
3.2.5.2. The emission values for each pollutant at the start of the service accumulation schedule and
at the emission durability period end point that is applicable for the engine under test shall
be either:
(a) determined by extrapolation of the regression equation in paragraph 3.2.5.1. of this
Appendix, when running a service accumulation schedule in accordance with
paragraph 3.2.2.1.2.1. or paragraph 3.2.2.1.2.3. of this Appendix, or
(b) measured directly, when running a service accumulation schedule in accordance with
paragraph 3.2.2.1.2.2. of this Appendix.
Where emission values are used for engine families in the same engine-after-treatment
family or group of engine families but with different emission durability periods, then the
emission values at the emission durability period end point shall be recalculated for each
emission durability period by extrapolation or interpolation of the regression equation as
determined in paragraph 3.2.5.1. of this Appendix.
3.2.5.3. The deterioration factor (DF) for each pollutant is defined as the ratio of the applied emission
values at the emission durability period end point and at the start of the service accumulation
schedule (multiplicative deterioration factor).

254
 The manufacturer may request the prior approval of the Type Approval Authority for the
application of an additive DF for each pollutant may be applied. The additive DF is defined
as the difference between the calculated emission values at the emission durability period
end point and at the start of the service accumulation schedule.
An example for determination of DFs by using linear regression is shown in Figure A.8-1.
for NOX emission.
Mixing of multiplicative and additive DFs within one set of pollutants is not permitted.
If the calculation results in a value of less than 1.00 for a multiplicative DF, or less than 0.00
for an additive DF, then the deterioration factor shall be 1.0 or 0.00, respectively.
In accordance with paragraph 3.2.2.1.4. of this Appendix, if it has been agreed that only one
steady state test cycle (D1 – 3 Mode) be run at each test point
Figure A.8-1.
Example of DF determination
0.50
Minimum service
accumulation Extrapolation

0.45

Limit value
0.40
NOx [g/kWh]

0.35
0.390 g/kWh

25% of EDP EDP endpoint

0.30
0.352 g/kWh

Multiplicative DF = 0.390 / 0.352 = 1.109

Additive DF = 0.390 – 0.352 = 0.038 g/kWh
0.25

0.20
0 1000 2000 3000 4000 5000 6000 7000 8000
Emission Durability Period (EDP) [h]

3.2.6. Assigned deterioration factors

3.2.6.1. As an alternative to using a service accumulation schedule to determine DFs, engine
manufacturers may select to use assigned multiplicative DFs, as given in Table A.6-1.
Table A.6-1.
Assigned deterioration factors
Deterioration Factors (DF)
Category (Power Band)
CO HC NOx
>19 kW
1.3 1.3 1.15
(Constant Speed Engine)

Note: When opted for assigned multiplicative DF, no verification is required.

Assigned additive DFs shall not be given. The assigned multiplicative DFs shall not be
transformed into additive DFs.
3.2.6.2. Where assigned DFs are used, the manufacturer shall present to the Type Approval Authority
robust evidence that the emission control components can reasonably be expected to have the
emission durability associated with those assigned factors. This evidence may be based upon
design analysis, or tests, or a combination of both.
3.2.7. Application of deterioration factors
3.2.7.1. The engines shall meet the respective emission limits for each pollutant, as applicable to the
engine family, after application of the deterioration factors to the test result as measured in

255
 accordance with Annex 5 (cycle-weighted specific emission for each individual gas). Depending
on the type of DF, the following provisions apply:
(a) Multiplicative: (cycle weighted specific emission) * DF ≤ emission limit
(b) Additive: (cycle weighted specific emission) + DF ≤ emission limit
Cycle weighted specific emission may include the adjustment for infrequent regeneration,
where applicable.
3.2.7.2. For a multiplicative NOX + HC DF, separate HC and NOX DFs shall be determined and applied
separately when calculating the deteriorated emission levels from an emissions test result
before combining the resultant deteriorated NOX and HC values to establish compliance with
the emission limit.
3.2.7.3. The manufacturer may carry across the DFs determined for an engine-after-treatment system
family to an engine that does not fall into the same engine-after-treatment system family. In
such cases, the manufacturer shall demonstrate to the Type Approval Authority that the engine
for which the engine-after-treatment system family was originally tested and the engine for
which the DFs are being carried across have similar technical specifications and installation
requirements on the Genset and that the emissions of such engine are similar.
Where DFs are carried across to an engine with a different emission durability period, the DFs
shall be recalculated for the applicable emission durability period by extrapolation or
interpolation of the regression equation as determined in paragraph 3.2.5.1. of this Appendix.
3.2.7.4. The DF for each pollutant for each applicable test cycle shall be recorded in the test report set
out in Annexure 2.
3.3. Checking of conformity of production
3.3.1. Conformity of production for emissions compliance is checked on the basis clause 5.
3.3.2. The manufacturer may measure the pollutant emissions before any exhaust after-treatment
system at the same time as the type-approval test is being performed. For that purpose, the
manufacturer may develop informal DFs separately for the engine without after-treatment
system and for the after-treatment system that may be used by the manufacturer as an aid to
end of production line auditing.
3.3.3. For the purposes of approval, only the DFs determined in accordance with paragraph 3.2.5. or
3.2.6. of this Appendix shall be recorded in the test report set out in Annexure 2.
3.4. Maintenance
For the purpose of the service accumulation schedule, maintenance shall be performed in
accordance with the manufacturer's manual for service and maintenance.
3.4.1. Scheduled emission-related maintenance
3.4.1.1. Scheduled emission-related maintenance during engine running, undertaken for the purpose
of conducting a service accumulation schedule, shall occur at equivalent intervals to those that
are specified in the manufacturer's maintenance instructions to the end-user of the engine. This
schedule maintenance may be updated as necessary throughout the service accumulation
schedule provided that no maintenance operation is deleted from the maintenance schedule
after the operation has been performed on the test engine.
3.4.1.2. Any adjustment, disassembly, cleaning, or exchange of critical emission-related components
which is performed on a periodic basis within the emission durability period to prevent
malfunction of the engine, shall only be done to the extent that is technologically necessary to
ensure proper functioning of the emission control system. The need for scheduled exchange,
within the service accumulation schedule and after a certain running time of the engine, of
critical emission-related components other than those qualifying as routine exchange items
shall be avoided. In this context, consumable maintenance items for regular renewal or items
that require cleaning after a certain running time of the engine, shall qualify as routine exchange
items.
3.4.1.3. Any scheduled maintenance requirements shall be subject to approval by the Type Approval
Authority before type-approval is granted and shall be included in the customer's manual. The

256
 Type Approval Authority shall not refuse to approve maintenance requirements that are
reasonable and technically necessary, including but not limited to those identified in paragraph
3.4.1.4. of this Appendix.
3.4.1.4. The engine manufacturer shall specify for the service accumulation schedules any adjustment,
cleaning, maintenance (where necessary) and scheduled exchange of the following items:
 filters and coolers in the exhaust gas re-circulation system
 positive crankcase ventilation valve, if applicable
 fuel injector tips (only cleaning is permitted)
 fuel injectors
 turbocharger
 electronic engine control unit and its associated sensors and actuators
 NOX after-treatment system (including related components)
 exhaust gas re-circulation system, including all related control valves and tubing
 any other exhaust after-treatment system.
3.4.1.5. Scheduled critical emission-related maintenance shall only be performed if it is required to be
performed in-use and that requirement is communicated to the end-user of the engine.
3.4.2. Changes to scheduled maintenance
The manufacturer shall submit a request to the Type Approval Authority for approval of any
new scheduled maintenance that it wishes to perform during the service accumulation schedule
and subsequently to recommend to end-users of engines. The request shall be accompanied
by data supporting the need for the new scheduled maintenance and the maintenance interval.
3.4.3. Non-emission-related scheduled maintenance
Non-emission-related scheduled maintenance which is reasonable and technically necessary
(for example oil change, oil filter change, fuel filter change, air filter change, cooling system
maintenance, idle speed adjustment, governor, engine bolt torque, valve lash, injector lash,
adjustment of the tension of any drive-belt, etc.) may be performed on engines selected for the
service accumulation schedule at the least frequent intervals recommended by the
manufacturer to the end-user (for example not at the intervals recommended for severe
service).
3.5. Repair
3.5.1. Repairs to the components of an engine selected for testing over a service accumulation
schedule shall be performed only as a result of component failure or engine malfunction. Repair
of the engine itself, the emission control system or the fuel system is not permitted except to
the extent defined in paragraph 3.5.2. of this Appendix.
3.5.2. If the engine, its emission control system (includes Oxidation catalyst, De-NOx catalyst,) or its
fuel system fails during the service accumulation schedule, the service accumulation shall be
considered void, and a new service accumulation shall be started with a new engine.
The previous paragraph shall not apply when the failed components are replaced with
equivalent components that have been subject to a similar number of hours of service
accumulation.

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 Appendix – 7

Procedure for the Measurement & Calculation of Ammonia Emissions

3. Ammonia measurement equipment shall be as per the guideline given in the ISO-8178-1: 2017,
2020 Reciprocating internal combustion engines — Exhaust emission measurement — Part 1: Test-
bed measurement systems of gaseous and particulate emission.

4. Ammonia measurement procedure & calculation shall be as per the guideline given in the ISO-
8178-4: 2017, 2020 Reciprocating internal combustion engines — Exhaust emission measurement
— Part 4: Steady-state and transient test cycles for different engine applications

Appendix – 8
Reserved

Appendix – 9
Reserved

258
 ANNEXURE – 8

Requirements regarding emission control strategies, NOX control

measures

1. Definitions abbreviations and general requirements

1.1. For the purposes of this Annex, the following definitions and abbreviations apply:
(a) "diagnostic trouble code ("DTC")" means a numeric or alphanumeric identifier which
identifies or labels a NCM and/ PCM;
(b) "confirmed and active DTC" means a DTC that is stored during the time the NCD
system concludes that a malfunction exists;
(c) "NCD engine family" “means a manufacturer's grouping of engines having common
methods of monitoring/diagnosing NCMs
(d) "NOX Control Diagnostic system (NCD)" means a system on-board the engine/control
room which has the capability of
(i) detecting a NOX Control Malfunction,
(ii) identifying the likely cause of NOX control malfunctions by means of information
stored in computer memory and/or communicating that information off-board;
(e) "NOX Control Malfunction (NCM)" means an attempt to tamper with the NO X control
system of an engine or a malfunction affecting that system that might be due to
tampering, that is considered by this Regulation as requiring the activation of a warning
or an inducement system once detected;
(i) "Scan-tool" means an external test equipment used for off-board communication with
the NCD system.
1.2. Ambient temperature
Where reference is made to ambient temperature in relation to environments other than a
laboratory environment, the following provisions shall apply:
1.2.1 For an engine installed in a test-bed, ambient temperature shall be the temperature of the
combustion air supplied to the engine, upstream of any part of the engine being tested.

1.2.2 For an engine installed in Genset, ambient temperature shall be the air temperature immediately
outside the perimeter of the Genset. Manufacture may opt to consider temperature inside genset
enclosure as an ambient temperature for certain diagnostics in consultation with type approval
agency and using sound Engineering judgement.

2. Technical requirements relating to emission control strategies

2.1. This paragraph 2. shall apply for electronically controlled genset engines of all powered
category complying with the emission limits set out in clause 3 of this Regulation and using
electronic control to determine both the quantity and timing of injecting fuel or using electronic
control to activate, de-activate or modulate the emission control system used to reduce NOx.
2.2. Requirements for base emission control strategy
2.2.1 The base emission control strategy shall be designed as to enable the engine, in normal use,
to comply with the provisions of this Regulation. Normal use is not restricted to the control
conditions as specified in paragraph 2.4.
2.2.2. Base emission control strategies are, but not limited to, maps or algorithms for controlling:
(a) timing of fuel injection or ignition (engine timing);

259
 (b) exhaust gas recirculation (EGR);
(c) SCR catalyst reagent dosing.
2.2.3. Any base emission control strategy that can distinguish engine operation between a
standardised approval test and other operating conditions and subsequently reduce the level
of emission control when not operating under conditions substantially included in the approval
procedure is prohibited.
2.2.3.1. Reserved
2.2.4 The manufacturer shall demonstrate to the technical agency at the time of the type-approval
test that the operation of the base emission control strategy complies with the provisions of this
section. The demonstration shall consist of an evaluation of the documentation referred to in
paragraph 2.6. of this Annex. The manufacturer shall comply with the documentation
requirements laid down in paragraph 1.4. of Annex 1 and Appendix A.2 to that Annex.
2.3. Requirements for auxiliary emission control strategy.
2.3.1 An auxiliary emission control strategy may be activated by an engine or Genset, provided that
the auxiliary emission control strategy:
2.3.1.1. does not permanently reduce the effectiveness of the emission control system;
2.3.1.2. operates only outside the control conditions specified in paragraphs 2.4.3. of this Annex for the
purposes defined in paragraph 2.3.5. of this Annex and only as long as is needed for those
purposes, except as permitted by paragraphs 2.3.1.3., 2.3.2. and 2.3.4. of this Annex;
2.3.1.3. is activated only exceptionally within the control conditions in paragraphs 2.4.3. of this Annex,
respectively, has been demonstrated to be necessary for the purposes identified in paragraph
2.3.5. of this Annex has been approved by the Type Approval Authority, and is not activated for
longer than is needed for those purposes;
2.3.1.4. ensures a level of performance of the emission control system that is as close as possible to
that provided by the base emission control strategy;
2.3.2. Where the auxiliary emission control strategy is activated during the type-approval test,
activation shall not be limited to occur outside the control conditions set out in paragraph 2.4.
of this Annex, and the purpose shall not be limited to the criteria set out in paragraph 2.3.5. of
this Annex.
2.3.3. Where the auxiliary emission control strategy is not activated during the type-approval test, it
must be demonstrated that the auxiliary emission control strategy is active only for as long as
required for the purposes set out in paragraph 2.3.5. of this Annex.
2.3.4. Cold temperature operation.
An auxiliary emission control strategy may be activated on an engine equipped with exhaust
gas recirculation (EGR) irrespective of the control conditions in paragraph 2.4. of this Annex if
the ambient temperature is below 275 K (2 °C) and one of the two following criteria is met:
(a) intake manifold temperature is less than or equal to the temperature defined by the
following equation: IMTc = PIM / 15.75 + 304.4, where: IMTc is the calculated intake
manifold temperature, K and PIM is the absolute intake manifold pressure in kPa;
(b) engine coolant temperature is less than or equal to the temperature defined by the
following equation: ECTc = PIM / 14.004 + 325.8, where: ECTc is the calculated engine
coolant temperature, K and PIM is the absolute intake manifold pressure, kPa.
2.3.5. Except as permitted by paragraph 2.3.2. of this Annex, an auxiliary emission control strategy
may solely be activated for the following purposes:
(a) by on-board signals, for protecting the engine (including air-handling device protection)
and/or Genset into which the engine is installed from damage;
(b) for operational safety reasons;

260
 (c) for prevention of excessive emissions, during cold start or warming-up, during shut-
down;
(d) if used to trade-off the control of one regulated pollutant under specific ambient or
operating conditions, for maintaining control of all other regulated pollutants, within the
emission limit values that are appropriate for the engine concerned. The purpose is to
compensate for naturally occurring phenomena in a manner that provides acceptable
control of all emission constituents.
2.3.6. The manufacturer shall demonstrate to the technical agency at the time of the type-approval
test that the operation of any auxiliary emission strategy complies with the provisions of this
paragraph. The demonstration shall consist of an evaluation of the documentation referred to
in paragraph 2.6. of this Annex.
2.3.7. Any operation of an auxiliary emission control strategy non-compliant with paragraphs 2.3.1. to
2.3.5. of this Annex is prohibited.
2.4. Control conditions
The control conditions specify an altitude, ambient temperature and engine coolant range that
determines whether auxiliary emission control strategies may generally or only exceptionally
be activated in accordance with paragraph 2.3. of this Annex.
The control conditions specify an atmospheric pressure which is measured as absolute
atmospheric static pressure (wet or dry) ("Atmospheric pressure")
2.4.1. Reserved
2.4.2. Reserved
2.4.3. Control conditions for engines of power bands 56 ≤ P < 800 kW
(a) the atmospheric pressure greater than or equal to 82,5 kPa;
(b) the ambient temperature within the following range:
(i) equal to or above 273K (0 °C)
(ii) less than or equal to the temperature determined by the following equation at
the specified atmospheric pressure: Tc = -0.4514 • (101.3 – Pb) + 311, where:
Tc is the calculated ambient air temperature, K and Pb is the atmospheric
pressure, kPa; (With Ambient pressure Pb 100kPa, Tc=38.58 °C and Pb
82.5kPa, Altitude at 1700 meter /5500 feet, Tc=46.5 °C)
(c) the engine coolant temperature above 343 K (70 °C).
Where the auxiliary emission control strategy is activated when the engine is operating
within the control conditions set out in points (i), (ii) and (c), the strategy shall only be
activated when demonstrated to be necessary for the purposes identified in clause
5.3.2.2.3. below and approved by the Test Agency.
2.5. Where the engine inlet air temperature sensor is being used to estimate ambient air
temperature the nominal offset between the two measurement points shall be evaluated for an
engine type or engine family. Where used, the measured intake air temperature shall be
adjusted by an amount equal to the nominal offset to estimate ambient temperature for an
installation using the specified engine type or engine family.
The evaluation of the offset shall be made using good engineering judgement based on
technical elements (calculations, simulations, experimental results, data etc.) including:
(a) the typical Genset enclosures into which the engine type or engine family will be
installed; and,
(b) the installation instructions provided to the OEM by the manufacturer.
A copy of the evaluation shall be made available to the Type Approval Authority upon request.
2.6. Documentation requirements

261
2.6.1 The manufacturer shall comply with the documentation requirements laid down in Annexure 1
2.6.2 The manufacturer shall ensure all documents used for this purpose are marked with an
identification number and date. Whenever particulars recorded are changed the relevant pages
shall be marked to clearly show the date of revision and the nature of the amendment. A
consolidated, updated version, accompanied by a detailed description of the amendments,
shall be deemed to fulfil the requirement of this paragraph. /Clause
3. Technical requirements relating to NOX control measures
3.1. Clause 3. of this Annex shall apply to electronically controlled engines complying with the
emission limits set out in clause 3 of this Regulation and using electronic control to determine
both the quantity and timing of injecting fuel or using electronic control to activate, de-activate
or modulate the emission control system used to reduce NOX.
3.2. The manufacturer shall provide complete information on the functional operational
characteristics of the NOX control measures using the documents set out in Annexure 1.
3.3. The NOX control strategy shall be operational under all environmental conditions regularly
occurring in India especially at low ambient temperatures.
3.4. The manufacturer shall demonstrate that the emission of ammonia during the applicable
emission test cycle of the type approval procedure, when a reagent is used, does not exceed
a mean value of 10 ppm for >56 kW & 25 ppm for <56 kW engine categories.
3.5. For reagent containers installed on a genset/engine, means for taking a sample of the reagent
inside the containers must be included. The sampling point must be easily accessible without
requiring the use of any specialised tool or device.
3.6 In addition to the requirements set out in clauses 3.2. to 3.5. of this Annex, the technical
requirements set out in Appendix A.1 of this Annex shall apply for engines.

4.0 Reserved

262
 Appendix – A.1

Additional technical requirements on NOx control measures for engines,

including the method to demonstrate these strategies

A.1.1. Introduction
This Appendix sets out the additional requirements to ensure the correct operation of NOX
control measures. It includes requirements for engines that rely on the use of a reagent in order
to reduce emissions. The type approval shall be made conditional upon the application of the
relevant provisions on engine/genset operator or genset control room instruction, installation
documents, operator warning system, inducement system and reagent freeze protection that
are set out in this Appendix.
A.1.2. General requirements
The engine shall be equipped with a NOX Control Diagnostic system (NCD) able to identify the
NOX control malfunctions (NCMs). Any engine covered by this paragraph shall be designed,
constructed and installed so as to be capable of meeting these requirements throughout the
normal life of the engine under normal conditions of use. In achieving this objective, it is
acceptable that engines which have been used in excess of the emission durability period as
specified in Appendix 6 to Annexure 7 of this Regulation show some deterioration in the
performance and the sensitivity of the NOX Control Diagnostic system (NCD), such that the
thresholds specified in this Annexure may be exceeded before the warning and/or inducement
systems are activated.
A.1.2.1. Required information
A.1.2.1.1. If the emission control system requires a reagent, the type of reagent, information on
concentration when the reagent is in solution, its operational temperature conditions a
reference to international standards for composition and quality and other
characteristics of that reagent shall be specified by the manufacturer in accordance
with Appendix A.3 of Annexure 1.
A.1.2.1.2. Detailed written information fully describing the functional operation characteristics of
the engine or genset operator/genset control room warning system set out in paragraph
A.1.4. of this Annexure and of the operator inducement system set out in paragraph
A.1.5. of this Annexure shall be provided to the Type Approval Authority at the time of
approval.
A.1.2.1.3. The manufacturer shall provide the OEM with documents with instructions on how to
install the engine in the Genset in such manner that the engine, its emission control
system and the Genset parts, operate in conformity with the requirements of this
Appendix. This documentation shall include the detailed technical requirements of the
engine (software, hardware, and communication) needed for the correct installation of
the engine in the Genset application.
A.1.2.2. Operating conditions
A.1.2.2.1. Monitoring for reagent level in the storage tank shall be conducted under all conditions
where measurement is technically feasible (for instance, under all conditions when a
liquid reagent is not frozen).
A.1.2.2.2. Reagent freeze protection shall apply at ambient temperatures at or below 273K (0 °C).
A.1.2.2.3. All elements of the NOX control diagnostic system other than those listed in paragraphs
A.1.2.2.1. and A.1.2.2.2. of this Annexure shall, at a minimum be operational at the
applicable control conditions set out in paragraph 2.4 of this Annexure for each engine
category. The diagnostic system shall remain operational outside of this range where
technically possible.
A.1.2.3. Reagent freeze protection

263
A.1.2.3.1. It is permitted to use a heated or a non-heated reagent tank and dosing system. A
heated system shall meet the requirements of paragraph A.1.2.3.2.2. of this Annexure.
A non-heated system shall meet the requirements of paragraph A.1.2.3.2.3. of this
Annexure.
A.1.2.3.1.1. The use of a non-heated reagent tank and dosing system shall be indicated in the
written instructions to the end-user of the Genset.
A.1.2.3.2. Reagent tank and dosing system
A.1.2.3.2.1. If the reagent has frozen, the reagent shall be available for use within a maximum of
70 minutes after the start of the engine at or above 273 K (0 °C) ambient temperature.
A.1.2.3.2.2. Design criteria for a heated system
A heated system shall be so designed that it meets the performance requirements set
out in this paragraph A.1.2.3.2. when tested using the procedure defined.
Demonstration test at the time of type approval is not mandatory.
A.1.2.3.2.2.1. The reagent tank and dosing system shall be soaked at 255 K (- 18°C) for 72 hours or
until the reagent becomes solid, whichever occurs first.
A.1.2.3.2.2.2. After the soak period set out in paragraph A.1.2.3.2.2.1. of this Annexure, the Genset
engine shall be started and operated at 266 K (- 7 °C) ambient temperature or lower
as follows:
(a) 10 to 20 minutes idling, followed by
(b) up to 50 minutes at no more than 40 per cent of rated torque.
A.1.2.3.2.2.3. At the conclusion of the test procedure set out in paragraph A.1.2.3.2.2.2. of this
Annexure, the reagent dosing system shall be fully functional.
A.1.2.3.2.2.4. Evaluation of the design criteria may be performed in a cold chamber test cell using an
entire Genset or parts representative of those to be installed on such machinery or
based on field tests.
A.1.2.3.2.3. Activation of the operator warning and inducement system for a non-heated system
A.1.2.3.2.3.1. The operator warning system described in paragraph A1.4 of this Annexure shall be
activated if no reagent dosing occurs at an ambient temperature >= 273 K ( 0°C).
A.1.2.3.2.3.2. The Operator inducement system described in paragraph A1.5. of this Annexure shall
be activated if no reagent dosing occurs within a maximum of 70 minutes after engine
start at an ambient temperature >= 273 K (0°C).
A.1.2.4. Diagnostic requirements
A.1.2.4.1. The NOX Control Diagnostic system (NCD) shall be able to identify the NOX control
malfunctions (NCMs) by means of Diagnostic Trouble Codes (DTCs) stored in the
computer memory and to communicate that information off-board upon request.
A.1.2.4.2. Requirements for recording Diagnostic Trouble Codes (DTCs)
A.1.2.4.2.1. The NCD system shall record a DTC for each distinct NOX Control Malfunction (NCM).
A.1.2.4.2.2. The NCD system shall conclude within 60 minutes of engine operation whether a
detectable malfunction is present. At this time, a "confirmed and active" DTC shall be
stored and the warning system be activated according to paragraph A.1.4. of this
Annex.
A.1.2.4.2.3. In cases where more than 60 minutes running time is required for the monitors to
accurately detect and confirm a NCM (e.g. monitors using statistical models or with
respect to fluid consumption on the Genset), the Type Approval Authority may permit
a longer period for monitoring provided the manufacturer justifies the need for the
longer period (for example by technical rationale, experimental results, in house
experience, etc.).
A.1.2.4.3. Requirements for erasing Diagnostic trouble codes (DTCs)

264
 (a) DTCs shall not be erased by the NCD system itself from the computer memory
until the failure related to that DTC has been remedied.
(b) The NCD system may erase all the DTCs upon request of a proprietary scan
or maintenance tool that is provided by the engine manufacturer upon request,
or using a pass code provided by the engine manufacturer.
A.1.2.4.4. An NCD system shall not be programmed or otherwise designed to deactivate partially
or totally based on age of Genset during the actual life of the engine, nor shall the
system contain any algorithm or strategy designed to reduce the effectiveness of the
NCD system over time.
A.1.2.4.5. Any reprogrammable computer codes or operating parameters of the NCD system shall
be resistant to tampering.
A.1.2.4.6. NCD engine family
The manufacturer is responsible for determining the composition of an NCD engine
family. Grouping engines within an NCD engine family shall be based on good
engineering judgment and be subject to approval by the Type Approval Authority.
Engines that do not belong to the same engine family may still belong to the same NCD
engine family.
A.1.2.4.6.1. Parameters defining an NCD engine family
An NCD engine family is characterized by basic design parameters that shall be
common to engines within the family.
In order that engines are considered to belong to the same NCD engine family, the
following list of basic parameters shall be similar:
(a) emission control systems;
(b) methods of NCD monitoring;
(c) criteria for NCD monitoring;
(d) monitoring parameters (e.g. frequency).
These similarities shall be demonstrated by the manufacturer by means of relevant
engineering demonstration or other appropriate procedures and subject to the approval
of the Type Approval Authority.
The manufacturer may request approval by the Type Approval Authority of minor
differences in the methods of monitoring/diagnosing the NCD system due to engine
configuration variation, when these methods are considered similar by the
manufacturer and they differ only in order to match specific characteristics of the
components under consideration (for example size, exhaust gas flow, etc.); or their
similarities are based on good engineering judgment.

A.1.3. Maintenance requirements

A.1.3.1. The OEM shall provide to all end-users of genset written instructions about the
emission control system and its correct operation in accordance with Appendix 2 of
Annexure 9.
A.1.4. Operator or control room warning system
A.1.4.1. The genset shall include an operator or control room warning system using visual and
audible component that informs the operator when a low reagent level, incorrect
reagent quality, interruption of dosing or a malfunction specified in clause A.1.9. of this
Annexure has been detected that will lead to activation of the operator inducement
system if not rectified in a timely manner. The warning system shall remain active when
the operator inducement system described in paragraph A.1.5. of this Annexure has
been activated.

265
A.1.4.2. The warning shall not be the same as the warning used for the purposes of malfunction
or other engine maintenance, though it may use the same warning system.
A.1.4.3. The operator warning system may consist of one or more lamps, or display short
messages, which may include, for example, messages indicating clearly:
(a) the remaining time before activation of the low-level and / or severe inducements,
(b) the amount of low-level and / or severe inducement, for example the amount of
torque reduction or effective disablement of operation.,
(c) the conditions under which Genset disablement can be cleared.
Where messages are displayed, the system used for displaying these messages may
be the same as the one used for other maintenance purposes.
A.1.4.4. The warning system shall include an audible component to alert the operator in line
with A.1.14 of this Annexure. The cancelling of audible warnings by the operator shall
be permitted. An audible alarm system must be activated at minimum when the
operator inducement system described in paragraph A.1.5. of this Annexure has been
activated.
A.1.4.5. The operator warning system shall be activated as specified in paragraphs
A.1.2.3.2.3.1., A.1.6.2., A.1.7.2., A.1.8.3., and A.1.9.3. of this Annexure respectively.
A.1.4.6. The operator warning system shall be deactivated when the conditions for its activation
have ceased to exist. The operator warning system shall not be automatically
deactivated without the reason for its activation having been remedied.
A.1.4.7. The warning system may be temporarily interrupted by other warning signals providing
important safety related messages.
A.1.4.8. Details of the operator warning system activation and deactivation procedures are
described in paragraph A.1.11. of this Annexure.
A.1.4.9. As part of the application for approval under this Regulation, the manufacturer shall
demonstrate the operation of the operator warning system, as specified in paragraph
A.1.10. of this Annexure.
A.1.5. Operator inducement system
A.1.5.1. The engine shall incorporate an operator inducement system based on one of the
following principles:
A.1.5.1.1. a two-stage inducement system starting with a low-level inducement Audio-Visual
Alarm followed by a severe inducement (effective disablement of Genset operation);
A.1.5.1.2. a one-stage severe inducement system (effective disablement of Genset operation)
activated under the conditions of a low-level inducement system as specified in
paragraphs A.1.6.3.1., A.1.7.3.1., A.1.8.4.1., and A.1.9.4.1. of this Annexure.
Where the manufacturer elects to shut down the engine to fulfil the requirement for
one-stage severe inducement then the inducement for reagent level may, at the choice
of the manufacturer, be activated under the conditions of paragraph A.1.6.3.2. of this
Annexure instead of the conditions of paragraph A.1.6.3.1. of this Annexure.
A.1.5.2. Reserved
A.1.5.3. Low-level inducement system
A.1.5.3.1. The low-level inducement system shall be activated after any of the conditions specified
in paragraphs A.1.6.3.1., A.1.7.3.1., A.1.8.4.1., and A.1.9.4.1. of this Annexure has
occurred.
A.1.5.3.2. Reserved
A.1.5.3.3. For constant speed engines, low level inducement shall the Audio-Visual Alarm
A.1.5.3.4. Other inducement measures that are demonstrated to the Type Approval Authority as
having the same or greater level of severity may be used.

266
A.1.5.4. Severe inducement system
A.1.5.4.1. The severe inducement system shall be activated after any of the conditions specified
in paragraphs A.1.2.3.2.3.2., A.1.6.3.2., A.1.7.3.2., A.1.8.4.2., and A.1.9.4.2. of this
Annexure has occurred.
A.1.5.4.2. The severe inducement system shall effectively disable Genset operation to cause the
operator to remedy any problems related to paragraphs A.1.6. to A.1.9. of this
Annexure. The following strategy shall be applied:
(a) Strategy A:
An audio/visual warning and a grace period of 72 hours after which the severe
inducement will effectively disable Genset operation to cause the operator to remedy
any problems related to paragraphs A.1.6. to A.1.9. of this Annexure. (To mention no
torque de-rate with this severe inducement strategy)
(b) Strategy B:
An audio/visual warning with a torque de-rate of minimum 50% and a grace period of
120 hours after which the severe inducement will effectively disable Genset operation
to cause the operator to remedy any problems related to paragraphs A.1.6. to A.1.9. of
this Annexure.

A.1.5.4.2.1. Genset engines, torque between the peak torque speed and the governor breakpoint
shall be gradually reduce to zero torque and Minimum speed of 1 per cent per minute
to zero percent of maximum torque within same time to speed reduction to Minimum
speed within the same time as the torque reduction.
Genset with severe-inducement condition activated when shut down; shall not start in
next attempt barring activation of operator overrides described in paragraph A.1.5.5. of
this annexure.
A.1.5.4.2.2. Manufacturer may have option for direct disablement of engine after key off without
going to torque / torque and speed de-rate schedule for severe level inducement as
described in paragraph A.1.5.4.2.1 of this Annexure.
A.1.5.4.2.3. Other inducement measures that are demonstrated to the Type Approval Authority as
having the same or greater level of severity may be used.
A.1.5.5. In order to account for safety concerns and to allow for self-healing diagnostics, use of
an inducement override function for releasing full engine power is permitted provided it
(a) is limited to 3 activations during each activation period that the operator inducement
system is active and
(b) each activation period is limited to 30 minutes
A.1.5.6. The operator inducement system shall be deactivated when the conditions for its
activation have ceased to exist. The operator inducement system shall not be
automatically deactivated without the reason for its activation having been remedied.
A.1.5.7. Details of the operator inducement system activation and deactivation procedures are
described in paragraph A.1.11. of this Annexure.
A.1.5.8. As part of the application for approval under this Regulation, the manufacturer shall
demonstrate the operation of the operator inducement system, as specified in clause
A.1.10. of this Annexure.
A.1.6. Reagent Availability
A.1.6.1. Reagent level indicator
The genset/engine shall include an indicator that clearly informs the operator /control
room of the level of reagent in the reagent storage tank. The minimum acceptable
performance level for the reagent indicator is that it shall continuously indicate the
reagent level whilst the operator warning system referred to in paragraph A.1.4. of this
Annexure is activated. The reagent indicator may be in the form of an analogue or

267
 digital display, and may show the level as a proportion of the full tank capacity, the
amount of remaining reagent, or the estimated operating hours remaining
Additionally, remote information and monitoring system described in Appendix 4 of this
Annexure where applicable shall provide with reagent level information at least when
operator warning system referred to in paragraph A.1.4. of this Annexure is activated.
A.1.6.2. Activation of the operator warning system
A.1.6.2.1. The operator warning system specified in paragraph A.1.4. of this Annexure shall be
activated when the level of reagent goes below 10 per cent of the capacity of the
reagent tank or a higher percentage at the choice of the manufacturer.
A.1.6.2.2. The warning provided shall be sufficiently clear, in conjunction with the reagent
indicator, for the operator to understand that the reagent level is low. When the warning
system includes a message display system, the visual warning shall display a message
indicating a low level of reagent. (for example, “urea level low”, “AdBlue level low”, or
“reagent low”).
A.1.6.2.3. The operator warning system does not initially need to be continuously activated (for
example a message does not need to be continuously displayed), however activation
shall escalate in intensity so that it becomes continuous as the level of the reagent
approaches empty and the point where the operator inducement system will come into
effect is approached (for example frequency at which a lamp flashes). It shall culminate
in an operator notification at a level that is at the choice of the manufacturer, but
sufficiently more noticeable at the point where the operator inducement system in
paragraph A.1.6.3. of this Annexure comes into effect than when it was first activated.
A.1.6.2.4. The continuous warning shall not be easily disabled or ignored. When the warning
system includes a message display system, an explicit message shall be displayed (for
example “fill up urea”, “fill up AdBlue”, or “fill up reagent”). The continuous warning may
be temporarily interrupted by other warning signals providing important safety related
messages.
A.1.6.2.5. It shall not be possible to turn off the operating warning system until the reagent has
been replenished to a level not requiring its activation.
A.1.6.2.6. Additionally, audio warning system described in paragraph A.1.14 of this Annexure
shall become active when the level of reagent goes below 10 per cent of the capacity
of the reagent tank or at a percentage operator warning system is activated at the
choice of the manufacturer.
A.1.6.3 Activation of the operator inducement system
A.1.6.3.1 The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if the reagent tank level goes below 2.5 per cent of its nominally full
capacity or a higher percentage at the choice of the manufacturer.
A.1.6.3.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if the reagent tank is empty, that is, when the dosing system is unable to
draw further reagent from the tank, or at any level below 2.5 per cent of its nominally
full capacity at the discretion of the manufacturer.
A.1.6.3.3. Except to the extent permitted by paragraph A.1.5.5. of this Annexure, it shall not be
possible to turn off the low-level or severe inducement system until the reagent has
been replenished to a level not requiring their respective activation.
A.1.7. Reagent Quality Monitoring
A.1.7.1. The engine, or Genset shall include a means of determining the presence of an
incorrect reagent on board.
A.1.7.1.1. The manufacturer shall specify a minimum acceptable reagent concentration CDmin,
which results in tailpipe NOX emissions not exceeding the lower of either the applicable
NOX limit multiplied by 2.25 or the applicable NOX limit plus 1.5 g/kWh. For engine sub-
categories with a combined HC and NOX limit, the applicable NOX limit value for the

268
 purpose of this paragraph shall be the combined limit value for HC and NO X reduced
by 0.19 g/kWh.
A.1.7.1.1.1. The value of CDmin specified by the manufacturer shall be used during the
demonstration set out in paragraph A.1.13. of this Annexure and recorded in the
extended documentation package as specified in Appendix A.3 to Annex 1.
A.1.7.1.2. Any reagent concentration lower than CDmin shall be detected and be regarded, for the
purpose of paragraph A.1.7.1. of this Annexure, as being incorrect reagent.
A.1.7.1.3. A specific counter ("the reagent quality counter") shall be attributed to the reagent
quality. The reagent quality counter shall count the number of engine operating hours
with an incorrect reagent.
A.1.7.1.3.1. Optionally, the manufacturer may group the reagent quality failure together with one or
more of the failures listed in paragraphs A.1.8. of this Annexure and A.1.9. of this
Annexure into a single counter.
A.1.7.1.4. Details of the reagent quality counter activation and deactivation criteria and
mechanisms are described in paragraph A.1.11. of this Annexure.
A.1.7.2. Activation of the operator warning system
When the monitoring system confirms that the reagent quality is incorrect, the operator
warning system described in paragraph1.4 shall be activated. When the warning
system includes a message display system, it shall display a message indicating the
reason of the warning (for example “incorrect urea detected”, “incorrect AdBlue
detected”, or “incorrect reagent detected”).
A.1.7.3 Activation of the operator inducement system
A.1.7.3.1. The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if the reagent quality is not rectified within a maximum of 36 engine
operating hours after the activation of the operator warning system as described in
paragraph A.1.7.2. of this Annexure.
A.1.7.3.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if their emission performance does not require reagent dosing. The severe
inducement system described in clause A.1.5.4. of this Appendix shall be activated if
the reagent quality is not rectified within a maximum of 72 engine operating hours after
the activation of the operator warning system as described in clause A.1.7.2. of this
Appendix.
A.1.7.3.3. The number of hours prior to activation of the inducement systems shall be reduced in
case of a repetitive occurrence of the malfunction according to the mechanism
described in clause A.1.11. of this Appendix.
A.1.8. Reagent Dosing Activity
A.1.8.1 The engine shall include a means of determining interruption of dosing.
A.1.8.2. Reagent dosing activity counter
A.1.8.2.1. A specific counter shall be attributed to the dosing activity (the "dosing activity
counter"). The counter shall count the number of engine operating hours which occur
with an interruption of the reagent dosing activity. This is not required where such
interruption is demanded by the engine ECU because the Genset operating conditions
are such that their emission performance does not required reagent dosing.
A.1.8.2.1.1. Optionally, the manufacturer may group the reagent dosing failure together with one or
more of the failures listed in paragraphs A.1.7. and A.1.9. of this Annexure into a single
counter.
A.1.8.2.2. Details of the reagent dosing activity counter activation and deactivation criteria and
mechanisms are described in paragraph A.1.11. of this Annexure.
A.1.8.3. Activation of the operator warning system

269
 The operator warning system described in paragraph A.1.4. of this Annexure shall be
activated in the case of interruption of dosing which sets the dosing activity counter in
accordance with paragraph A.1.8.2.1. of this Annexure. When the warning system
includes a message display system, it shall display a message indicating the reason of
the warning (e.g. “urea dosing malfunction”, “AdBlue dosing malfunction”, or “reagent
dosing malfunction”).
A.1.8.4. Activation of the operator inducement system
A.1.8.4.1. The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if an interruption in reagent dosing is not rectified within a maximum
of 36 engine operating hours after the activation of the operator warning system in
accordance with paragraph A.1.8.3. of this Annexure.
A.1.8.4.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if an interruption in reagent dosing is not rectified within a maximum of 72
engine operating hours after the activation of the operator warning system in
accordance with paragraph A.1.8.3. of this Annexure.
A.1.8.4.3. The number of hours prior to activation of the inducement systems shall be reduced in
case of a repetitive occurrence of the malfunction according to the mechanism
described in paragraph A.1.11. of this Annexure.
A.1.9. Other failures that may be attributed to tampering
A.1.9.1. In addition to the level of reagent in the reagent tank, the reagent quality, and the
interruption of dosing, the following failures shall be monitored because they may be
attributed to tampering:
(a) failures of the NOX Control Diagnostic (NCD) system as described in paragraph
A.1.9.2.1. of this Annexure;
(b) failures of the exhaust gas recirculation (EGR) valve as described in paragraph
A.1.9.2.2. of this Annexure;
A.1.9.2. Monitoring requirements and counters
A.1.9.2.1. NCD system
A.1.9.2.1.1. The NOX Control Diagnostic (NCD) system shall be monitored for electrical failures and
for removal or deactivation of any sensor that prevents it from diagnosing any other
failures set out in paragraphs A.1.6. to A.1.8. (component monitoring) of this Annexure.
A non-exhaustive list of sensors that affect the diagnostic capability are those directly
measuring NOX concentration, urea quality sensors, ambient sensors and sensors
used for monitoring reagent dosing activity, reagent level or reagent consumption.
A.1.9.2.1.2. A counter shall be attributed to each of the monitoring failures. The NCD system
counters shall count the number of engine operating hours when the DTC associated
to a malfunction of the NCD system is confirmed to be active. Different NCD system
failures may be grouped into a single counter.
A.1.9.2.1.2.1. The manufacturer may group the NCD system failure together with one or more of the
failures listed in paragraphs A.1.7., A.1.8. and paragraph A.1.9.2.2 of this Annexure
into a single counter.
A.1.9.2.1.3. Details of the NCD system counter(s) activation and deactivation criteria and
mechanisms are described in paragraph A.1.11. of this Annexure.
A.1.9.2.2. EGR valve
A.1.9.2.2.1. The EGR system shall be monitored for an impeded EGR valve.
A.1.9.2.2.2. A counter shall be attributed to an impeded EGR valve. The EGR valve counter shall
count the number of engine operating hours when the DTC associated to an impeded
EGR valve is confirmed to be active.

270
A.1.9.2.2.2.1. The manufacturer may group the impeded EGR valve failure together with one or more
of the failures listed in paragraphs A.1.7., A.1.8. and A.1.9.2.1 of this Annexure. into a
single counter.
A.1.9.2.2.3. Details of the EGR valve counter activation and deactivation criteria and mechanisms
are described in paragraph A.1.11. of this Annexure.
A.1.9.3. Activation of the operator warning system
The operator warning system set out in paragraph1.4. shall be activated in case any of
the failures specified in paragraph A.1.9.1. of this Annexure occur, and shall indicate
that an urgent repair is required. When the warning system includes a message display
system, it shall display a message indicating either the reason of the warning (for
example “reagent dosing valve disconnected”, or "critical emission failure").
A.1.9.4. Activation of the operator inducement system
A.1.9.4.1. The low-level inducement system described in paragraph A.1.5.3. of this Annexure
shall be activated if a failure specified in paragraph A.1.9.1. of this Annexure is not
rectified within a maximum of 36 engine operating hours after the activation of the
operator warning system set out in paragraph A.1.9.3. of this Annexure.
A.1.9.4.2. The severe inducement system described in paragraph A.1.5.4. of this Annexure shall
be activated if a failure specified in paragraph A.1.9.1. of this Annexure is not rectified
within a maximum of 72 engine operating hours after the activation of the operator
warning system set out in paragraph A.1.9.3. of this Annexure.
A.1.9.4.3. The number of hours prior to activation of the inducement systems shall be reduced in
case of a repetitive occurrence of the malfunction according to the mechanism
described in paragraph A.1.11. of this Annexure.
A.1.9.5. As an alternative to the monitoring requirements set out in paragraph A.1.9.2. of this
Annexure, the manufacturer may monitor for failures using a NOX sensor located in the
exhaust system. In this case,
(a) the NOX value at which the NCM shall be detected shall not exceed the lower of
either the applicable NOX limit multiplied by 2.25 or the applicable NOX limit plus
1.5 g/kWh. For engine sub-categories with a combined HC and NOX limit, the
applicable NOX limit value for the purpose of this paragraph shall be the combined
limit value for HC and NOX reduced by 0.19 g/kWh.
(b) a single warning may be used, including, where messages are used, the statement
‘high NOX – root cause unknown’,
(c) in paragraph A.1.9.4.1. of this Annexure the maximum number of engine operating
hours between the activation of the operator warning system and the activation of
the low-level inducement system shall be 36 hours
(d) in paragraph A.1.9.4.2. of this Annexure the maximum number of engine operating
hours between the activation of the operator warning system and the activation of
the severe inducement system shall be 72 hours
A.1.10. Demonstration requirements
A.1.10.1. General
The compliance to the requirements of this Appendix shall be demonstrated during
type-approval by performing, as illustrated in Table A.8-1. and specified in paragraph
A.1.10. of this Annexure:
(a) a demonstration of the warning system activation
(b) a demonstration of the low-level inducement system activation, if applicable
(c) a demonstration of the severe inducement system activation
A.1.10.2. Engine families and NCD engine families
The compliance of an engine family or an NCD engine family with the requirements of
paragraph A.1.10. of this Annexure may be demonstrated by testing one of the

271
 members of the considered family, provided the manufacturer demonstrates to the
Type Approval Authority that the monitoring systems necessary for complying with the
requirements of this Appendix are similar within the family.
A.1.10.2.1. The demonstration that the monitoring systems for other members of the NCD engine
family are similar may be performed by presenting to the approval authorities such
elements as algorithms, functional analyses, etc.
A.1.10.2.2. The test engine is selected by the manufacturer in agreement with the Type Approval
Authority. It may or may not be the parent engine of the considered family.
A.1.10.2.3. In the case where engines of an engine family belong to an NCD engine family that has
already been type-approved, according to paragraph A.1.10.2.1. (Figure A.8-3.) of this
Annexure the compliance of that engine family is deemed to be demonstrated without
further testing, provided the manufacturer demonstrates to the authority that the
monitoring systems necessary for complying with the requirements of this Appendix
are similar within the considered engine and NCD engine families.
Table A.8-1.
Illustration of the content of the demonstration process in accordance with the
provisions in paragraphs A.1.10.3. and A.1.10.4.

Mechanism Demonstration elements

Warning system activation - 2 activation tests (incl. lack of reagent)
specified in paragraph A.1.10.3. Supplementary demonstration elements, as
of this Annexure appropriate
Low-level inducement activation - 2 activation tests (incl. lack of reagent)
specified in paragraph A.1.10.4. - Supplementary demonstration elements, as
of this Annexure appropriate
- 1 The Audio-Visual Alarm
Severe inducement activation - 2 activation tests (incl. lack of reagent)
specified in paragraph A.1.10.4. - Supplementary demonstration elements, as
of this Annexure appropriate

Figure A.8-3.
Previously demonstrated conformity of an NCD engine family

Conformity of Engine Conformity of NCD engine family 1

family 1 is considered has been demonstrated
as demonstrated for Engine family 2

Engine Engine
family 1 family 2

NCD engine family 1

A.1.10.3. Demonstration of the warning system activation

272
A.1.10.3.1. The compliance of the warning system activation shall be demonstrated by performing
two tests: lack of reagent, and one failure category identified in paragraphs A.1.7, A.1.8.
or A.1.9. of this Annexure.
A.1.10.3.2. Selection of the failure to be tested from paragraphs A.1.7., A.1.8., or A.1.9. of this
Annexure.
A.1.10.3.2.1. The Type Approval Authority shall select one failure category. In the case that a failure
is selected from points A.1.7. or A.1.9. of this Annexure the additional requirements set
out in points A.1.10.3.2.2. or A.1.10.3.2.3. of this Annexure respectively shall apply.
A.1.10.3.2.2 For the purpose of demonstrating the activation of the warning system in case of a
wrong reagent quality, a reagent shall be selected with a dilution of the active ingredient
at least as dilute as that communicated by the manufacturer according to the
requirements set out in paragraph A.1.7. of this Annexure.
A.1.10.3.2.3. For the purpose of demonstrating the activation of the warning system in case of
failures that may be attributed to tampering, and are defined in paragraph A.1.9. of this
Annexure the selection shall be performed according to the following requirements:
A.1.10.3.2.3.1. The manufacturer shall provide the Type Approval Authority with a list of such potential
failures.
A.1.10.3.2.3.2. The failure to be considered in the test shall be selected by the Type Approval Authority
from this list referred to in paragraph A.1.10.3.2.3.1. of this Annexure.
A.1.10.3.3. Demonstration
A.1.10.3.3.1. For the purpose of this demonstration, a separate test shall be performed for the lack
of reagent and the failure selected in paragraph A.1.10.3.2. of this Annexure.
A.1.10.3.3.2. During a test, no failure shall be present other than the one addressed by the test.
A.1.10.3.3.3. Prior to starting a test, all DTC shall have been erased.
A.1.10.3.3.4. At the request of the manufacturer, and with the agreement of the Type Approval
Authority, the failures subject to testing may be simulated.
A.1.10.3.3.5. Detection of failures other than lack of reagent.
For failures other than lack of reagent, once the failure installed or simulated, the
detection of that failure shall be performed as follows:
A.1.10.3.3.5.1. The NCD system shall respond to the introduction of a failure selected as appropriate
by the Type Approval Authority in accordance to the provisions of this Appendix. This
is demonstrated if activation occurs within two consecutive NCD test-cycles according
to paragraph A.1.10.3.3.7. of this Annexure.
When it has been specified in the monitoring description and agreed by the Type
Approval Authority that a specific monitor needs more than two NCD test-cycles to
complete its monitoring, the number of NCD test-cycles may be increased to 3 NCD
test-cycles.
Each individual NCD test-cycle in the demonstration test may be separated by an
engine shut-off. The time until the next start-up shall take into consideration any
monitoring that may occur after engine shut-off and any necessary condition that must
exist for monitoring to occur at the next start up.
A.1.10.3.3.5.2 The demonstration of the warning system activation is deemed to be accomplished if,
at the end of each demonstration test performed according to paragraph A.1.10.3.3. of
this Annexure, the warning system has been properly activated and the DTC for the
selected failure has got the “confirmed and active” status.
A.1.10.3.3.6. Detection in case of lack of reagent availability
For the purpose of demonstrating the activation of the warning system in case of lack
of reagent availability, the engine shall be operated over one or more NCD test cycles
at the discretion of the manufacturer.

273
A.1.10.3.3.6.1. The demonstration shall start with a level of reagent in the tank to be agreed between
the manufacturer and the Type Approval Authority but representing not less than 10
per cent of the nominal capacity of the tank.
A.1.10.3.3.6.2. The warning system is deemed to have performed in the correct manner if the following
conditions are met simultaneously:
(a) the warning system has been activated with a reagent availability greater or
equal to 10 per cent of the capacity of the reagent tank
(b) the "continuous" warning system has been activated with a reagent availability
greater or equal to the value declared by the manufacturer in accordance with
the provisions of paragraph A.1.6. of this Annexure.
A.1.10.3.3.7. NCD test cycle
A.1.10.3.3.7.1 The NCD test cycle considered in clause A.1.10. of this Annexure for demonstrating
the correct performance of the NCD system is the D1- 3 Mode cycle for constant speed
engine
A.1.10.3.3.7.2 On request of the manufacturer with approval of the test agency, an alternative NCD
Cycle (e.g. other than D1-3 Mode cycle) can be used for specific monitoring
A.1.10.3.4. The demonstration of the warning system activation is deemed to be accomplished if,
at the end of each demonstration test performed according to paragraph A.1.10.3.3. of
this Annexure, the warning system has been properly activated.
A.1.10.4. Demonstration of the inducement system
A.1.10.4.1. The demonstration of the inducement system shall be done by tests performed on an
engine test bench.
A.1.10.4.1.1. Any components or sub-systems not physically mounted on the engine, such as, but
not limited to, ambient temperature sensors, level sensors, and operator warning and
information systems, that are required in order to perform the demonstrations shall be
connected to the engine for that purpose, or shall be simulated, to the satisfaction of
the Type Approval Authority.
A.1.10.4.1.2. If the manufacturer chooses, and subject to the agreement of the Type Approval
Authority, the demonstration tests may be performed on a complete Genset either by
mounting the same on a suitable test bed or, notwithstanding paragraph A.1.10.4.1. of
this Annexure, by running it outside test laboratory under controlled conditions.
A.1.10.4.2. The test sequence shall demonstrate the activation of the inducement system in case
of lack of reagent and in case of the failure selected by the Approval Authority according
to paragraph A.1.10.3.2.1. of this Annexure for the test of the warning system.
A.1.10.4.3. For the purpose of this demonstration,
(a) the manufacturer shall, in agreement with the Type Approval Authority, be
permitted to accelerate the test by simulating the achievement of a certain
number of operating hours,
(b) Reserved
(c) the low-level inducement, if applicable, shall be demonstrated according to the
requirements of paragraph A.1.10.4.5. of this Annexure.
(d) the severe inducement shall be demonstrated according to the requirements
of paragraph A.1.10.4.6. of this Annexure.
A.1.10.4.4. The manufacturer shall, in addition, demonstrate the operation of the inducement
system under those failure conditions defined in paragraphs A.1.7., A.1.8. or A.1.9. of
this Annexure which have not been chosen for use in demonstration tests described in
paragraphs A.1.10.4.1. to A.1.10.4.3. of this Annexure.
These additional demonstrations may be performed by presentation to the Type
Approval Authority of a technical case using evidence such as algorithms, functional
analyses, and the result of previous tests.

274
A.1.10.4.4.1. These additional demonstrations shall demonstrate to the satisfaction of the Type
Approval Authority the inclusion of the correct torque reduction mechanism in the
engine ECU.
A.1.10.4.5. Demonstration test of the low-level inducement system
A.1.10.4.5.1. This demonstration starts when the warning system or when appropriate "continuous"
warning system has been activated as a result of the detection of a failure selected by
the Type Approval Authority.
A.1.10.4.5.2. When the system is being checked for its reaction to the case of lack of reagent in the
tank, the engine shall be run until the reagent availability has reached a value of 2.5
per cent of the tank nominal full capacity of the tank or the value declared by the
manufacturer in accordance with paragraph A.1.6.3.1. of this Annexure at which the
low-level inducement system is intended to operate.
A.1.10.4.5.2.1. The manufacturer may, with the agreement of the Type Approval Authority, simulate
continuous running by extracting reagent from the tank, either whilst the engine is
running or is stopped.
A.1.10.4.5.3. When the system is checked for its reaction in the case of a failure other than a lack of
reagent in the tank, the engine shall be run for the relevant number of operating hours
indicated in Table A.8-4. or, at the choice of the manufacturer, until the relevant counter
has reached the value at which the low-level inducement system is activated.
A.1.10.4.5.4. The demonstration of the low-level inducement system shall be deemed to be
accomplished if, at the end of each demonstration test performed according to
paragraphs A.1.10.4.5.2. and A.1.10.4.5.3. of this Annexure, the manufacturer has
demonstrated to the Type Approval Authority that the engine ECU has activated the
Audio-Visual Alarm or torque reduction mechanism.
A.1.10.4.6. Demonstration test of the severe inducement system
A.1.10.4.6.1. This demonstration shall start from a condition where the low-level inducement system,
where applicable, has been previously activated and may be performed as a
continuation of the tests undertaken to demonstrate the low-level inducement system.
A.1.10.4.6.2. When the system is checked for its reaction in the case of lack of reagent in the tank,
the engine shall be run until the reagent tank is empty, or has reached the level below
2.5 per cent of nominal full capacity of the tank at which the manufacturer has declared
to activate the severe inducement system.
A.1.10.4.6.2.1. The manufacturer may, with the agreement of the Type Approval Authority, simulate
continuous running by extracting reagent from the tank, either whilst the engine is
running or is stopped.
A.1.10.4.6.3. When the system is checked for its reaction in the case of a failure that is not a lack of
reagent in the tank, the engine shall then be run for the relevant number of operating
hours indicated in Table A.8-4. or, at the choice of the manufacturer, until the relevant
counter has reached the value at which the severe inducement system is activated.
A.1.10.4.6.4. The demonstration of the severe inducement system shall be deemed to be
accomplished if, at the end of each demonstration test performed according to
paragraphs A.1.10.4.6.2. and A.1.10.4.6.3. of this Annexure, the manufacturer has
demonstrated to the Type Approval Authority that the severe inducement mechanism
considered in this Appendix has been activated.
A.1.10.4.7. Alternatively, if the manufacturer chooses, and subject to the agreement of the Type
Approval Authority, the demonstration of the inducement mechanisms may be
performed on a complete Genset in accordance with the requirements of paragraphs
A.1.5.4. and A.1.10.4.1.2. of this Annexure, either by mounting the Genset on a suitable
test bed or by running it outside test laboratory under controlled conditions.
A.1.10.4.7.1. The Genset shall be operated until the counter associated with the selected failure has
reached the relevant number of operating hours indicated in Table A.8-4. or, as
appropriate, until either the reagent tank is empty or, has reached the level below 2.5

275
 per cent of nominal full capacity of the tank at which the manufacturer has chosen to
activate the severe inducement system.
A.1.10.5. Documentation of the demonstration
A.1.10.5.1 A demonstration report shall be created that documents the demonstration of the NCD
system.
The report shall:
(a) identify the failures examined;
(b) describe the demonstration performed including the applicable test cycle;
(c) confirm that the applicable warnings and inducements were activated as
required by this regulation;
(d) be included in the information folder as set out in Annexure 1.
A.1.11. Description of the operator warning and inducement activation and deactivation
mechanisms
A.1.11.1 To complement the requirements specified in this Appendix concerning the warning
and inducement activation and deactivation mechanisms, paragraph A.1.11. of this
Annexure specifies the technical requirements for an implementation of those
activation and deactivation mechanisms.
A.1.11.2. Activation and deactivation mechanisms of the warning system
A.1.11.2.1. The operator warning system shall be activated when the diagnostic trouble code
(DTC) associated with a NCM justifying its activation has the status defined in Table
A.8-2.

Table A.8-2
Activation of the operator warning system
Failure type DTC status for activation of the
warning system

Poor reagent quality confirmed and active

Interruption of dosing confirmed and active
Impeded EGR valve confirmed and active
Malfunction of the monitoring confirmed and active
system
NOX threshold, if applicable confirmed and active

A.1.11.2.2. The operator warning system shall be deactivated when the diagnosis system
concludes that the malfunction relevant to that warning is no longer present or when
the information including DTCs relative to the failures justifying its activation is erased
by a scan tool.
A.1.11.2.2.1. Requirements for erasing " NOX control information"
A.1.11.2.2.1.1. Erasing / resetting " NOX control information" by a scan-tool
On request of the scan tool, the following data shall be erased or reset to the value
specified in this Appendix from the computer memory (see Table A.8-3.).

Table A.8-3.
Erasing / resetting "NOX control information" by a scan-tool

NOX control information Erasable Resettable

276
 All DTCs X

The value of the counter with the

highest number of engine operating X
hours

The number of engine operating

X
hours from the NCD counter(s)

A.1.11.2.2.1.2. NOX control information shall not be erased by disconnection of the battery(ies) of the
Genset.
A.1.11.2.2.1.3. The erasing of " NOX control information" shall only be possible under “engine-off”
conditions.
A.1.11.2.2.1.4. When "NOX control information" including DTCs are erased, any counter associated
with these failures and which is specified in this Appendix shall not be erased, but reset
to the value specified in the appropriate paragraph of this Appendix.
A.1.11.3. Activation and deactivation mechanism of the operator inducement system
A.1.11.3.1. The operator inducement system shall be activated when the warning system is active
and the counter relevant to the type of NCM justifying their activation have reached the
value specified in Table A.8-4
A.1.11.3.2. The operator inducement system shall be deactivated when the system no longer
detects a malfunction justifying its activation, or if the information including the DTCs
relative to the NCMs justifying its activation has been erased by a scan tool or
maintenance tool.
A.1.11.3.3. The operator warning and inducement systems shall be immediately activated or
deactivated as appropriate according to the provisions of paragraph A.1.6. of this
Annexure after assessment of the reagent quantity in the reagent tank. In that case,
the activation or deactivation mechanisms shall not depend upon the status of any
associated DTC.
A.1.11.4. Counter mechanism
A.1.11.4.1. General
A.1.11.4.1.1. To comply with the requirements of this Appendix, the system shall contain counters to
record the number of hours during which the engine has been operated while the
system has detected any of the following NCM:
(a) an incorrect reagent quality;
(b) an interruption of reagent dosing activity;
(c) an impeded EGR valve;
(d) a failure of the NCD system.
A.1.11.4.1.1.1. The manufacturer may use one or more counters for grouping the NCMs indicated in
paragraph A.1.11.4.1.1. of this Annexure.
A.1.11.4.1.2. Each of the counters shall count up to the maximum value provided in a 2 byte counter
with 1 hour resolution and hold that value unless the conditions allowing the counter to
be reset to zero are met.
A.1.11.4.1.3. A manufacturer may use a single or multiple NCD system counters. A single counter
may accumulate the number of hours of 2 or more different malfunctions relevant to
that type of counter, none of them having reached the time the single counter indicates.
A.1.11.4.1.3.1. When the manufacturer decides to use multiple NCD system counters, the system shall
be capable of assigning a specific monitoring system counter to each malfunction
relevant according to this Appendix to that type of counters.
A.1.11.4.2. Principle of counters mechanism

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A.1.11.4.2.1. Each of the counters shall operate as follows:
A.1.11.4.2.1.1. If starting from zero, the counter shall begin counting as soon as a malfunction relevant
to that counter is detected and the corresponding diagnostic trouble code (DTC) has
the status defined in Table A.8-2.
A.1.11.4.2.1.2. In case of repeated failures, one of the following provisions shall apply at the choice of
the manufacturer.
(a) If a single monitoring event occurs and the malfunction that originally activated
the counter is no longer detected or if the failure has been erased by a scan
tool or a maintenance tool, the counter shall halt and hold its current value. If
the counter stops counting when the severe inducement system is active, the
counter shall be kept frozen at the value defined in Table A.8-4. or a value of
greater than or equal to the counter value for severe inducement minus 30
minutes.
(b) The counter shall be kept frozen at the value defined in Table A.8-4. or a value
of greater than or equal to the counter value for severe inducement minus 30
minutes.
A.1.11.4.2.1.3. In the case of a single monitoring system counter, that counter shall continue counting
if a NCM relevant to that counter has been detected and its corresponding Diagnostic
trouble code (DTC) has the status "confirmed and active". It shall halt and hold one of
the values specified in paragraph A.1.11.4.2.1.2. of this Annexure, if no NCM that would
justify the counter activation is detected or if all the failures relevant to that counter
have been erased by a scan tool or a maintenance tool.
Table A.8-4.
Counters and inducement

# DTC status for Counter value Counter Frozen value

first activation of for low-level value for held by the
the counter inducement severe counter
inducement
Reagent confirmed and ≤ 10 hours ≤ 72 hours ≥ 90 per cent of
quality active counter value for
counter severe
inducement
Dosing confirmed and ≤ 10hours ≤ 72hours ≥ 90 per cent of
counter active counter value for
severe
inducement
EGR valve confirmed and ≤ 36 hours ≤ 72hours ≥ 95 per cent
counter active of counter
value for
severe
inducement
Monitoring confirmed and ≤ 36 hours ≤ 72hours ≥ 95 per cent
system active of counter
counter value for
severe
inducement
NOX confirmed and ≤ 10 hours ≤ 72hours ≥ 90 per cent
threshold, if active of counter
applicable value for
severe
inducement

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A.1.11.4.2.1.4. Once frozen, the counter shall be reset to zero when the monitors relevant to that
counter have run at least once to completion of their monitoring cycle without having
detected a malfunction and no malfunction relevant to that counter has been detected
during 40 engine operating hours since the counter was last held (see Figure A.8-4.).
A.1.11.4.2.1.5. The counter shall continue counting from the point at which it had been held if a
malfunction relevant to that counter is detected during a period when the counter is
frozen (see Figure A.8-4.).

A.1.12. Illustration of the activation and deactivation and counter mechanisms

A.1.12.1. This paragraph A.1.12. of this Annexure illustrates the activation and deactivation and
counter mechanisms for some typical cases. The Figures and descriptions given in
paragraphs A.1.12.2., A.1.12.3. and A.1.12.4. of this Annexure are provided solely for
the purposes of illustration in this Appendix and should not be referenced as examples
of either the requirements of this Regulation or as definitive statements of the
processes involved. The counter hours in Figures A.8-6. and A.8-7. refer to the
maximum severe inducement values in Table A.8-4.. For simplification purposes, for
example, the fact that the warning system will also be active when the inducement
system is active has not been mentioned in the illustrations given.

Figure A.8-4.
Reactivation and resetting to zero of a counter after a period when its value has
been frozen

> 40 op. hours < 40 op. hours

40 operating 40 operating
hours hours

freeze
value
Counter

repair repair
YES
Failure

NO

A.1.12.2. Figure A.8-5. illustrates the operation of the activation and deactivation mechanisms when
monitoring the reagent availability for four cases:
(a) use case 1: the operator continues operating the Genset in spite of the warning
until Genset operation is disabled;
(b) Adequate refilling case 1: the operator refills the reagent tank so that a level above
the 10 per cent threshold is reached. Warning and inducement are de-activated;

279
 (c) Inadequate refilling cases 2 and 3: The warning system is activated. The level of
warning depends on the amount of available reagent;
(d) Very Inadequate refilling case 4: The low-level inducement is activated
immediately.

Figure A.8-5.
Reagent availability

SEVERE
Inducement

LOW-LEVEL

"continuous"
WARNING

WARNING

NO
reagent
level of

10%
X%
2.5%
EMPTY
refilling refilling refilling refilling
(case 1) (case 2) (case 3) (case 4)

A.1.12.3. Figure A.8-6. illustrates three cases of wrong reagent quality:

(a) use case 1: the operator continues operating the Genset in spite of the warning until
Genset operation is disabled.
(b) repair case 1 ("bad" or "dishonest" repair): after disablement of the Genset, the
operator changes the quality of the reagent, but soon after, changes it again for a poor
quality one. The warning, inducement and counting processes start from zero. The
inducement system is immediately reactivated and Genset operation is disabled after
2 engine operating hours.

(c) repair case 2 ("good" repair): after disablement of the Genset, the operator rectifies the
quality of the reagent. However, sometime afterwards, he refills again with a poor-
quality reagent. The low-level inducement system is immediately reactivated and the
counter restarts from the value it had at the time of repair. The warning, inducement
and counting processes restart from zero.

280
 Figure A.8-6.
Filling with poor reagent quality
< 40 op. hours > 40 op. hours

40 operating
hours

20 hrs
18 hrs
Counter

10 hrs

SEVERE
Inducement

LOW-LEVEL

WARNING

NO

repair repair
Wrong urea

YES

NO
repair repair
(case 1) (case 2)

A.1.12.4. Figure A.8-7. illustrates three cases of failure of the urea dosing system. This figure also
illustrates the process that applies in the case of the monitoring failures described in
paragraph A.1.9. of this Annexure.
(a) use case 1: the operator continues operating the Genset in spite of the warning
until Genset operation is disabled.
(b) repair case 1 ("good" repair): after disablement of the Genset engine, the operator
repairs the dosing system. However, some time afterwards, the dosing system
fails again. The warning, inducement and counting processes restart from zero.
(c) repair case 2 ("bad" repair): during the low-level inducement time (torque
reduction), the operator repairs the dosing system. Soon after, however, the
dosing system fails again. The low-level inducement system is immediately
reactivated and the counter restarts from the value it had at the time of repair.

281
 Figure A.8-7.
Failure of the reagent dosing system

> 40 op. hours < 40 op. hours

40 operating 40 operating
hours hours

20 hrs
18 hrs
Counter

10 hrs

SEVERE
Inducement

LOW-LEVEL

WARNING

NO

repair repair
Dosing system
not working

YES

NO
repair repair
(case 1) (case 2)

A.1.13. Demonstration of the minimum acceptable reagent concentration CDmin

A.1.13.1. The manufacturer shall demonstrate the correct value of CDmin during type approval by
performing the applicable D1-3 mode constant speed cycle for constant speed engine
using a reagent with the concentration CDmin.
A.1.13.2. The test shall follow the appropriate NCD cycle(s), permitting a closed loop NO X control
system to perform adaptation to the quality of the reagent with the concentration CDmin.
A.1.13.3. The pollutant emissions resulting from this test shall not exceed the NO X threshold
specified in paragraph A.1.7.1.1. of this Annexure.
A.1.13.4. Documentation of the demonstration
A.1.13.4.1. A demonstration report shall be created that documents the demonstration of the
minimum acceptable reagent concentration.
The report shall:
(a) identify the failures examined;
(b) describe the demonstration performed including the applicable test cycle;
(c) confirm that the pollutant emissions arising from this demonstration did not
exceed the NOX threshold specified in point A.1.7.1.1 of this Annexure;
(d) be included in the information folder as set out in Annexure 1
A.1.14. Technical requirements for Audible Operator warning system.
This section describes technical requirements for audible operator warning system
associated with NOx Control Diagnostics. Same could be leveraged by manufacturer
for warning of other faults such as engine de-rates due to safety reason however with
different pattern.
A.1.14.1. Specification requirements for audible warning system
Audible operator warning system as installed on Genset application shall satisfy
following requirements:
(a) Sound intensity of the system as measured at distance of 1 m facing Genset panel with
controls and displays those accompany operator warning lights shall be 80-85 decibels;
(b) Such warning system (sound source) shall be all weather compatible and durable for
life of Genset;

282
 (c) Shall have diagnostics associated with it including DTC inline with paragraph A.1.10 of
this Annexure if tampered with;
(d) Manufacturer may opt to integrate such warning system within Genset enclosure or
may provide an external hooter compliant with above requirements;
A.1.14.2. Audio warning system pattern requirements
A.1.14.2.1. Audio warning system for operator induments shall be enabled per any of the options
below:
Option: A
A.1.14.2.1.1 When operator warning has become active for low-level inducement, activate visual
warning with no alarms.
A.1.14.2.1.2. At commencement of low-level inducement, the audio warning system shall beep once
in 5 seconds with 2-second-long beep. Such audio warning shall remain active as long
as low-level inducement state is active.
A.1.14.2.1.3. At commencement of severe-level inducement, the audio warning system shall beep
once in 2 seconds with 2-second-long beep. Such audio warning shall remain active
when Engine Ignition is ON or Engine shutdown but ignition is ON.
Option: B
A.1.14.2.1.4 Any specific pattern of alarm with specific duration and frequency of beeps that will
alert the operator on Inducements as defined by the manufacturer which needs to be
demonstrated at the time of testing as part of Inducement strategy
A.1.14.2.4. Manufacture may opt to use same audio warning pattern as paragraph A.1.14.2.1.3 of
this Annexure for non-inducement fault codes those are engine and equipment safety
related and will cause immediate derate or shutdown of an engine;
A.1.14.3. Audio warning system extent requirements
A.1.14.3.1. Audio warning associated with low-level inducement commencement shall remain
active as long as low-level inducement state is active;
A.1.14.3.2. Audio warning associated with severe-level inducement commencement shall remain
active when Engine Ignition is ON or Engine shutdown but ignition is ON.
A.1.14.4. Details of the operator warning system activation and deactivation procedures are
described in paragraph A.1.11. of this Annexure those shall apply to audio warning
system;
A.1.14.5. As part of the application for approval under this Regulation, the manufacturer shall
demonstrate the operation of the audio operator warning system, as specified in
paragraph A.1.10. of this Annexure;

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 Appendix – A.2

Reserved

Appendix – A.3

Technical details for prevention of tampering

A.3.1. For engine types and engine families that use an ECU as part of the emission control system
the manufacturer shall provide to the approval authority a description of the provisions taken to
prevent tampering with and modification of the ECU including the facility for updating using a
manufacturer-approved program or calibration;
A.3.2. For engine types and engine families that use mechanical devices as part of the emission
control system the manufacturer shall provide to the approval authority a description of the
provisions taken to prevent tampering with and modification of the adjustable parameters of the
emission control system. This shall include the tamper resistant components. Such as Fuel
injection pump limiter caps or sealing of Fuel injection pump screws or special screws not
adjustable by user.
A.3.2.1. The manufacturer shall demonstrate to the Test Agency that the adjustable parameters of the
emission control system cannot be easily tampered by applying reasonable forces, either:
(a) using the tools supplied together with the engine; or,
(b) using ordinary tools such as screwdriver, pliers (including cutting pliers) or wrenches.
Ordinary tools do not include: most cutting or grinding tools, drills and rotary cutters, or tools
that generate excessive heat or flame.
A.3.3. For the purpose of this Appendix, engines from different engine families may be further
combined into families based upon the type and design of tamper prevention measures utilized.
In order to place engines from different engine families into the same tamper prevention engine
family the manufacturer shall provide confirmation to the approval authority that the measures
used to prevent tampering are similar. In this case the requirements of paragraphs A.3.1. and
A.3.2. of this Annexure may be performed for one representative engine and the corresponding
documentation used during the type approval of all engines in the same tamper prevention
engine family.
A.3.4. Manufacturers shall provide a warning in the operator's manual stating that tampering with the
engine voids the type-approval of that particular engine.

284
 Appendix – A.4

Technical details for Remote Information and Monitoring Requirements

A.4.1. General Requirements

A.4.1.1. Gensets powered by electronically controlled engines with >56 kW power shall be equipped
with remote information and monitoring system utilizing telematics.
Gensets unlike non-road machines and On road vehicles are operated typically without human
intervention and does not have an ‘Operator’ required to be present during its operation. This
makes ‘Operator Warning System’ in line with non-road machines difficult to follow through as
well as getting timely inputs to the operator of a Genset.
A.4.1.2. Manufacturer in conjunction with GOEM shall provide a cellular data based remote information
monitoring system that is capable of working with Application (App) able to work with desktop
computers and cellular hand-held devices such cellphone. Such app once installed shall be
able to provide essential information and warnings to Genset owner/s, operator/s highlighting
any mal-function related to emission control by a suitable “Engine Malfunction” icon indicated
prominently on the user interface.
A.4.1.3. Manufacturer/GOEM may choose to demonstrate the remote monitoring function as mentioned
in A.4.1.2 on engine test bench during engine type approval and COP or on the Genset during
Genset type approval & COP.

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 ANNEXURE – 9

Installation in the Genset Application

9.1. Information and instructions intended for OEMs and end-users.

9.1.1. A manufacturer shall not supply to GOEMs or end-users any technical information related to the
particulars provided for in this Regulation which diverges from the particulars approved by the
Type Approval Authority;
9.1.2. The manufacturer shall make available to GOEMs all relevant information and instructions that
are necessary for the correct installation of an engine in Genset, including a description of any
special conditions or restrictions linked to the installation or use of the engine;
9.1.3. The manufacturer shall make available to GOEMs all relevant information and necessary
instructions intended for the end-user, including a description of any special conditions or
restrictions linked to the use of an engine.
9.1.4. Details of the relevant information and instructions for the GOEMs are set out in Appendix 1 to
Annexure 9.

9.2. Obligations of GOEMs concerning the installation of engines

9.2.1. GOEMs shall install approved engines in Genset in accordance with the instructions provided by
the manufacturer pursuant to paragraph 9.1.2, and in a manner that does not adversely affect the
engine's performance with regard to its gaseous pollutant emissions;
9.2.2. Where an GOEM does not follow the instructions referred to in paragraph 9.2.1., or modifies an
engine in the course of its installation of genset, in a manner that adversely affects the engine's
performance with regard to its gaseous pollutant emissions, that GOEM shall be considered to
be a manufacturer for the purposes of this Regulation and shall, in particular, be subject to the
obligations laid down in clauses 3, 4 and 5 of this Regulation;
9.2.3. OEMs shall install type-approved engine(s) in genset(s) only in accordance with the kinds of
exclusive use provided for the engine categories set out in clause 1.
9.2.5. Details of the relevant information and instructions for the end-users are set out in Appendix 2 to
Annexure 9;
9.2.6 The safety code of practice to be followed along with the instructions provided by the manufacturer
pursuant to paragraph 9.1.2, and in a manner that does not adversely affect the engine's
performance with regard to its gaseous pollutant emissions; The test agency will certify the
installation of the engine in GENSET canopy as per safety code of practice. The separate
document ‘A4’ named “SAFETY CODE OF PRACTICE” shall be referred for more clarification.
The noise level certificate shall be issued only after compliance of GENSET to safety code of
practice.

286
 Appendix – 1

Details of the relevant information and instructions for the GOEMs

A.1.1. As required by paragraph 9.1., the manufacturer shall provide to the GOEM all relevant
information and instructions to ensure that the engine conforms to the approved engine type when
installed in Gensets. Instructions for this purpose shall be clearly identified to the GOEM;
A.1.2. The instructions may be provided on paper or a commonly used electronic format;
A.1.3. Where a number of engines requiring the same instructions are supplied to the same GOEM it
shall be necessary to provide one set of instructions at minimum;
A.1.4. The information and instructions to the OEM shall include at minimum:
A.1.4.1. installation requirements to achieve the emissions performance of the engine type, including the
emission control system, that shall be taken into account to ensure the correct operation of the
emissions control system;
A.1.4.2. a description of any special conditions or restrictions linked to the installation or use of the
engine, as noted on the communication set out in Annexure 1
A.1.4.3. a statement indicating that the installation of the engine shall not permanently constrain the
engine to exclusively operate within a power range corresponding to a (sub-)category with
gaseous pollutant emission limits more stringent than the (sub-) category the engine belongs to;
For e.g.:
c) Engine certified for > 56 KW power can be permanently constrained to power less than 56
KW
d) However, engine certified for > 560 KW power cannot be permanently constrained to power
less than 560 KW
A.1.4.4. for engine families to which appendix 2 of annexure7 of this Regulation applies, the upper and
lower boundaries of the applicable control area and a statement indicating that the installation
of the engine shall not constrain the engine to exclusively operate at speed and load points
outside of the control area for the torque curve of the engine;
A.1.4.5. where applicable, design requirements for the components supplied by the OEM that are not
part of the engine and are necessary to ensure that, when installed, the engine conforms to the
approved engine type;
A.1.4.6. where applicable, design requirements for the reagent tank, including freeze protection,
monitoring of reagent level and means to take samples of reagent;
A.1.4.7. where applicable, information on installation of a non-heated reagent system;
A.1.4.9. where applicable, a statement indicating that the OEM shall provide a warning system as set
out in Appendices 1, 2 and 3 of Annexure 8;
A.1.4.10. where applicable, information on the interface between the engine and genset for the operator
warning system, referred to in paragraph A.1.4.9.;
A.1.4.11. where applicable, information on the interface between the engine and Genset for the operator
inducement system, as set out in Annexure 8;
A.1.4.12. where applicable, information on a means to temporarily disable the operator inducement as
defined in Annexure 8;
A.1.4.13. where applicable, information on the inducement override function as defined in Annexure 8;
A.1.4.14. Reserved
(a) Reserved
(b) Reserved

287
 (c) Reserved
A.1.4.15. In the case of a constant-speed engine equipped with alternative speeds as set out in paragraph
4.1.2.3. of Clause 4:
(a) a statement indicating that the installation of the engine shall ensure that:
i. the engine is stopped prior to resetting the constant-speed governor to an
alternative speed; and,
ii. the constant-speed governor is only set to the alternative speeds permitted by the
engine manufacturer;
(b) details of each (sub-)category and operating mode (speed operation) for which the
engine is type-approved and may be set when installed;
A.1.4.16. In the case that the engine is equipped with an idle speed for start-up and shut-down, a
statement indicating that the installation of the engine shall ensure that the constant-speed
governor function is engaged prior to increasing the load-demand to the engine from the no-
load setting.
A.1.5. The manufacturer shall provide to the GOEM all information and necessary instructions that the
GOEM shall provide to the end-users in accordance with Appendix 2 to Annexure 9.

288
 Appendix – 2

Details of the relevant information and instructions for the end-users

A.2.1. The GOEM shall provide to the end-users all information and necessary instructions for the
correct operation of the engine in order to maintain the gaseous pollutant emissions of the
engine within the limits of the approved engine type or engine family. Instructions for this
purpose shall be clearly identified to the end-users.
A.2.2. The instructions to the end-users shall be:
A.2.2.1. written in a clear and non-technical manner using the same language that is used in the
instructions to end-users for gensets;
A.2.2.2. be provided on paper or, alternatively, a commonly used electronic format;
A.2.2.3. be part of the instructions to end-users for the Genset,
A.2.3. The information and instructions to the end-users shall include at least:
A.2.3.1. a description of any special conditions or restrictions linked to the use of the engine, as noted
on the type-approval communication;
A.2.3.2. a statement indicating that the engine, including the emissions control system, shall be
operated, used and maintained in accordance with the instructions provided to the end-users in
order to maintain the emissions performance of the engine within the requirements applicable
to the engine's category;
A.2.3.3. a statement indicating that no deliberate tampering with or misuse of the engine emissions
control system should take place; in particular, with regard to deactivating or not maintaining an
exhaust gas recirculation (EGR) or a reagent dosing system;
A.2.3.4. a statement indicating that it is essential to take prompt action to rectify any incorrect operation,
use or maintenance of the emissions control system in accordance with the rectification
measures indicated by the warnings referred to in paragraph A.2.3.5. and A.2.3.6.;
A.2.3.5. detailed explanations of the possible malfunctions of the emissions control system generated
by incorrect operation, use or maintenance of the installed engine and due to failure to emission
control system components, accompanied by the associated warning signals and the
corresponding rectification measures;
A.2.3.6. detailed explanations of the possible incorrect use of the Genset that would result in
malfunctions of the engine emissions control system, accompanied by the associated warning
signals and the corresponding rectification measures;
A.2.3.7. for gensets with an operator warning system, a statement indicating that the operator will be
informed by the operator warning system when the emission control system does not function
correctly;
A.2.3.8. for Genset with an operator inducement system a statement indicating that ignoring the operator
warning signals will lead to the activation of the operator inducement system, resulting in an
effective disablement of genset operation;
A.2.3.9. for Genset with an inducement override function for releasing full engine power justified by safety
concerns or to allow for self-healing diagnostics, information about the operation of this function;
A.2.3.10. where applicable, explanations of how the operator warning and inducement systems referred
to in paragraphs A.2.3.7., A.2.3.8. and A.2.3.9. operate, including the consequences, in terms
of performance and fault logging, of ignoring the warning system signals and of not replenishing,
where used, the reagent or rectifying the problem identified;
A.2.3.11. for genset with a means to disable the operator inducement, information about the operation of
this function, and a statement indicating that this function shall be only activated in case of
emergencies, that any activation will be recorded in the on-board computer log and that Central

289
 or State pollution Control Board inspection authorities will be able to read these records with a
scan tool;
A.2.3.12. information on the fuel(s) necessary to maintain the performance of the emissions control
system in particular:
(a) reserved
(b) where additional fuels, fuel mixtures or fuel emulsions are compatible with use by the engine,
as declared by the manufacturer and stated in the type-approval communication, these shall
be indicated. Such fuel type shall be constrained by alternate fuel definitions of this
Regulation;
A.2.3.13. information on the lubrication oil specifications necessary to maintain the performance of the
emissions control system;
A.2.3.14. where the emission control system requires a reagent, the generic name, characteristics of that
reagent, including the type of reagent, information on concentration when the reagent is in
solution, operational temperature conditions and reference to Indian and international standards
for composition and quality, consistent with the specification set-out in the engine type-approval;
A.2.3.15. where applicable, instructions specifying how consumable reagents have to be refilled by the
operator between normal maintenance intervals. They shall indicate how the operator should
refill the reagent tank and the anticipated frequency of refill, depending upon of the genset based
on average per day operation;
A.2.3.16.a statement indicating that in order to maintain the emissions performance of the engine, it is
essential to use and refill reagent in accordance with the specifications set out in clause
A.2.3.14. and A.2.3.15.;
A.2.3.17. scheduled emission-related maintenance requirements including any scheduled exchange of
critical emission-related components;

290
 ANNEXURE – 10

ALTERNATE FUEL SYSTEM SAFETY STANDARDS

Sr. No. Component Certifying / Verifying Authority Applicable Standards

1 Regulator (For CNG & Testing of the component as per IS: IS: 15713 or ISO -15500
BIO-CNG) / Regulator and 15713 or ISO-15500 by test agency.
Vaporizer(LNG)* Alternatively, test agency to verify the
test certificate or report conforming to
the above standard issued by
accredited testing laboratory.
LNG regulator and Vaporizer / heat UN R 110 or equivalent
exchanger shall meet requirements of standard
UN R110 or equivalent standard
2 Gas-Air Mixer* Testing of the component as per IS: IS: 15714 or ISO-15500
15714 or ISO-15500 by test agency.
Alternatively, test agency to verify the
test certificate or report conforming to
the above standard issued by
accredited testing laboratory.
3 Gas Injector* Testing of the component as per ISO- ISO-15500-7
15500-7 by test agency. Alternatively,
test agency to verify the test certificate
or report conforming to the above
standard issued by accredited testing
laboratory.
4 Gas Solenoid Valve / Testing of the component as per IS: IS: 15712 or ISO-15500
Automatic Shutoff valve* 15712 or ISO-15500 by test agency.
Alternatively, test agency to verify the
test certificate or report conforming to
the above standard issued by
accredited testing laboratory.

Automatic shutoff valve of LNG Automatic shutoff Valve for

System (which comes in contact with LNG System : UN R110 or
LNG shall meet requirements of UN equivalent standards
R110 or equivalent standards)
5 Testing of Conduit* Testing of the component or IS: 15715
verification of certificate or test report
as per IS: 15715 by test agency.
6 CNG / BIO-CNG / LNG fuel
line
6.1 High pressure exceeding
100 kPa*
6.1.1 Exceeding 2.15 MPa

291
 Rigid pipe Testing of the component or IS: 15716
verification of certificate or test report
as per IS : 15716 by test agency.
LNG rigid pipeline shall meet UN R 110 or IS: 15716 or
requirements of UN R 110 or IS : equivalent standard.
15716 or equivalent standard.
Flexible hose Testing of the component or IS 15718 or AIS-028 (Rev. 1)
verification of certificate or test report (Part A)
as per IS 15718 by test agency.

LNG flexible pipeline shall meet UN R 110 or IS: 15718

requirements of UN R110 or IS: or equivalent standard
15718 or equivalent standard.
6.1.2 Pressure upto 2.15 Bar Testing of the component or IS : 15722 with amendments
verification of certificate or test report
as per IS : 15722 by test agency.

LNG pipeline shall meet UN R 110 or IS: 15722

requirements of UN R110 or IS : or equivalent standard
15722 or equivalent standard.
6.2 Joints and connections* Testing by test agency. Clause 3.1.4.1, 3.2.1 (b) of
AIS-028 (Rev. 1) (Part A)

LNG joints & connection shall meet UN R 110 or equivalent

requirements of UN R 110 or standard
equivalent standard
7 Compartment or Sub- Testing of the component or IS: 15720
compartment* verification of certificate or test report
as per IS: 15720 by test agency.
8 Specific LNG components Following specific components, as UN R 110 or equivalent
applicable shall meet requirements of standard
UN R 110 or equivalent standard
LNG Fuel pump, Pressure Relief
valves, Pressure sensor, check
valve, excess flow valve, manual valve
and non-return valve.
9 Safety check for Safety checks to be carried out by test Relevant clauses of AIS-
installation of Gaseous fuel agency as per AIS-028 (Rev.1 ) (Part 028 (Rev. 1) ( Part
system A) A)
10 Electrical wiring and AIS 028
harness
11 Non-moisture retaining AIS 028
hard rubber/equivalent
material
12 Electrical fuses AIS 028

292
 * Certificate issued by accredited testing agency of the country of origin or a report
issued by internationally accredited test laboratory may also be accepted.

Note 1 - Only the standards, as amended from time to time, as mentioned above, shall be referred for
compliance.

Note 2 - Components downstream the Heat exchanger / vaporizer shall be considered as CNG
components and prevailing Indian standard / ISO standard or equivalent standards shall be
acceptable

****END****

293
294
 Part – A3

Portable Generator
sets

295
1. SCOPE
This Part-A3 document lays down the applicability and requirements, system & procedure for
compliance to the rules vide notification no. GSR 804(E.) dated 3-Nov-2022 on emission limits for
Portable Generator sets (PI engines below 19kW and up to 800 cc displacement) application, issued
by Ministry of Environment, Forests & Climate change, Government of India.

Portable Generator sets running on,

 Gasoline fuel
 Dedicated alternate fuels
 Bi-fuel run either on Gasoline or on any one of the alternate fuels*
*Alternate fuels - Natural Gas/ Bio-CNG, LPG

Following standards has been referred while drafting this system & procedure.

Sr No. Standard Title

Reciprocating internal combustion engines — Exhaust emission
ISO 8178-1 :2017
1 measurement — Part 1: Test-bed measurement systems of gaseous and
ISO 8178-1 :2020
particulate emission
Reciprocating internal combustion engines — Exhaust emission
ISO 8178-4: 2017
3 measurement — Part 4: Steady-state and transient test cycles for different
ISO 8178-4: 2020
engine application
Reciprocating internal combustion engine-Exhaust emission measurement-
4 ISO 8178-7:2015
Part-7: Engine family determination

IS 14599 :1999 Automotive vehicles- performance requirements (Measurement of Power,

5
(Reaffirmed 2019) SFC, Opacity) of positive and compression ignition engines- Method of test

US EPA Regulation: 40 CFR Part 1039 - Control of emissions from new and
6 40 CFR Part 1039
in-use nonroad compression-ignition engines

7 40 CFR Part 1065 US EPA Regulation: 40 CFR Part 1065 – Engine testing procedures

296
2. DEFINITION & ABBREVIATTIONS

2.1 DEFINITIONS
1. “Approval of a genset (genset family)” means the approval of portable genset type/portable genset
family with regards to the level of the gaseous emission pollutants by the genset;

2. “Declared electrical power output (VA)” means rated gross electrical power declared by
manufacturer for type approval at declared rated speed;

3. “Mechanical power output (kW)” means mechanical power at engine crank shaft output at rated
speed which is calculated as V x A /1000 x Alternator efficiency;

4. “Internal combustion engine (ICE)” means an engine, which works on the either compression-
ignition principle or positive ignition principle utilising liquid, gaseous or combination of both fuels;

5. “Emissions-related defect” means a deviation from normal production tolerances in design,

materials, system or assembly that affects any parameter, specification or component belonging to
the emission control system. A missing component may be considered to be an emission-related
defect;

6. “Emission control system” means the exhaust after treatment system, the electronic management
controllers of the engine system (if utilized) and any emission related component of the engine system
in the exhaust which supplies an input to or receives an output from these controllers and when
applicable the communication interface between the engine system electronic control unit (ECU) and
any other power train with respect to emissions management;

7. “Engine system” means the engine, the emission control system and the communication interface
(hardware and messages) between the engine system electronic control unit (ECU) and any other
power train;

8. “Genset family” means a manufacturer’s grouping of engine systems which, through their design
have similar exhaust emission characteristics, all members of the family must comply with the
applicable emission limit values described in Clause 3.1. Also refer ISO 8178-7;

9. “Parent genset” means a genset selected from genset family in such a way that its emissions
characteristics will be representative for that genset family and that it complies with the requirements
set out in ISO 8178-7

10. “Genset type” means a category of genset, which do not differ in such essential respects as genset
characteristics as defined in ISO 8178-7

11. “High idle speed” High idle speed is the speed reached under governor control at full throttle
condition.

12. “Exhaust after treatment system” means ‘a catalyst (oxidation or 3-way), or any other emission-
reducing device that is installed downstream of the engine. This definition excludes exhaust gas
recirculation, which, where fitted is considered an integral part of the engine system;

13. “Power generating set or Genset” means any equipment which is used for electric power generation
in absence or failure of grid power utilizing engine system defined in this document as prime mover;

14. “Percent load” means the fraction of available current(A)/mechanical power at a rated engine speed.

15. “Test Cycle” means a sequence of test points each with a defined speed and torque to be followed
by the engine during standardised emission assessment test. Also refer ISO 8178-4;

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16. For Domestic products, Date of Manufacture means the date on which the engine is invoiced; This
is in with consideration the production volume declaration for COP.

17. For Imported products, Date of Import means the date of payment of custom duties applicable to
the Genset; This is with consideration with the import volume declaration for COP

18. “Manufacturer” means engine or Genset manufacturer, importer or, assembler (as noted in
notification);

19. “Applicable emission limit” means an emission limit to which an engine is subject to for approval;

20. “Constant speed engine” means an engine whose type approval or certification is limited to
constant-speed operation. Engines whose constant-speed governor function is removed or disabled
are no longer constant-speed engines;

21. “Constant speed operation” means engine operation with a governor that automatically controls the
operator’s demand to maintain engine speed, even under changing load. Governors do not always
maintain exactly constant speed.

22. “Engine governed speed” means the engine operating speed when it is controlled by the installed
governor;

23. “Critical emission related components” means the components which are designed primarily for
emission control, that is, any exhaust after-treatment system, the electronic engine control unit and
its associated sensors and actuators, fuel injection equipment and it’s integral control actuators;

24. “Critical emission related maintenance” means the maintenance to be performed on critical
emission-related components;

25. “Discrete mode” means relating to a discrete mode type of steady-state test, as described in ISO
8178-4.

26. “Electronic control unit (ECU)” means an engine’s electronic device that uses data from engine
sensors to control engine parameters as primary function. ECU may contain more functionality than
stated above of interest;

27. “Emission control strategy” means a combination of an emission control system with one base
emission control strategy and with one set of auxiliary emission control strategies, incorporated into
the overall design of an engine or Genset into which the engine is installed;

28. “Emission related maintenance” means maintenance which substantially affects emissions, or
which is likely to affect emissions performance deterioration of the vehicle or the engine and exhaust
after treatment system during normal in-use operation;

29. “Non-emission related maintenance” means maintenance which does not substantially affect
emissions, and which does not have a lasting effect on the emissions performance deterioration of
the machine or the engine during normal in-use operation once the maintenance is performed;

30. “Gaseous pollutant” means carbon monoxide (CO), hydrocarbons (HC – assuming a ratio of C1H1.85)
and oxides of nitrogen (NOx), the last named being expressed in nitrogen dioxide (NO2) equivalent;
Actual CH ratio of the test fuel may be considered as per fuel specification certificate.

31. “Oxides of Nitrogen (NOx)” means compounds containing only nitrogen and oxygen as measured
by the procedures specified in this Regulation. Oxides of nitrogen are expressed quantitatively as if
the NO is in the form of NO2, such that an effective molar mass is used for all oxides of nitrogen
equivalent to that of NO2.

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32. “Hydrocarbon (HC)” means Total Hydrocarbon (THC), non-methane hydrocarbon (NMHC) as
applicable. Hydrocarbon generally means the hydrocarbon group on which the emission standards
are based for each type of fuel and engine;

33. “Non-methane hydrocarbons (NMHC)” means the sum of all hydrocarbon species except methane;

34. “Idle speed” means the lowest engine speed with minimum load (greater than or equal to zero load),
where an engine governor function controls engine speed. For engines without a governor function
that controls idle speed, idle speed means the manufacturer-declared value for lowest engine speed
possible with minimum load. Note that warm idle speed is the idle speed of a warmed-up engine.

35. “Portable Generator” Electric Generator is defined as Portable if it suits the definition and satisfies
the following condition.

A portable generator is the combination of an electrical generator and an engine (prime mover)
mounted together to form a single piece of equipment. This combination is also called an engine-
generator set or a gen-set which usually can be moved, pulled, pushed by a person, and not build
permanently into a structure such as power house or station.
Portable Electric Generator, a generator which satisfy the following condition-
 Power output is up to 19 kW & up to 800 cc engine displacement
 Power by PI air cooled engine
 It is on Hand-cart mounted units

36. “Placing on the market” means the action of making available a product covered by this Regulation
on the market of a country applying this Regulation, for payment or free of charge, with a view to
distribution and/or use in the country

37. “Type approval” means the approval of portable genset type/portable genset family with regard to
its emissions measured in accordance with the procedures specified in this Regulation;

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2.2 Abbreviations

A Ampere
BSFC Brake-specific fuel consumption
BIS Bureau of Indian Standards
CPCB Central Pollution Control Board
C1 Carbon 1 équivalent hydrocarbon
cc Cubic Centimetre
CH4 Methane
C2H6 Ethane
C3H8 Propane
CNG Compressed Natural Gas
CO Carbon monoxide
CO2 Carbon dioxide
COP Conformity of Production
COP-Year Period starting 1st July of preceding year till 30th June of subsequent
year
ECM Electronic control module
IS Indian Standard
GOEM Genset Original Equipment Manufacturer
HC Hydrocarbon
H2O Water
ISO International Organization for Standardization
LPG Liquefied Petroleum Gas
NMHC Non-methane hydrocarbon
NOx Oxides of nitrogen
NO Nitric oxide
NO2 Nitrogen dioxide
O2 Oxygen
PI Positive Ignition (Engine)
PPM Part per million
RMS Root-mean square
S Sulphur
THC Total hidrocarbonos
RHC Reactive Hydrocarbones
V Voltage

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3 Exhaust Emission Limits, Applicability and Requirement

3.1 Exhaust Emission Limits

The emissions of the carbon monoxide, the emissions of hydrocarbons and the emissions of the
oxides of nitrogen obtained during emission certification and conformity of production emission
test/s conducted in accord with in Annexure 4 of this regulation shall not exceed the amount
shown in Table 1 below:
Table 1
Emission limits for Portable Genset engines

NOx +THC
NOx + NMHC
Engine CO
Class NOx + RHC Test Cycle
displacement (cc) (g/kWh)
(g/kWh)

1 Up to 99 cc 250 10 D1-3-mode test

2 > 99 and up to 225 cc 250 8 cycle as
3 specified in ISO
> 225 cc 250 6
8178 Part 4

Notes:
1) The test shall be done on resistive load bank.
2) The testing shall be done as per test procedures mentioned in Annexure 4.
3) Test method shall be as specified in ISO 8178: Part 1 & 4, Reciprocating internal
combustion engines — Exhaust emission measurement; Steady-state and transient test
cycles for different engine applications. The measurement mode shall be D1-3 mode
cycle specified under ISO 8178: Part 4 (Weighting Factor of 0.3 for 100 percent load, 0.5
for 75 percent load and 0.2 for 50 percent load). Detail procedure is laid down in
Annexure 4 of this document.
4) Every manufacturer, importer or assembler (hereafter referred as manufacturer) of the
genset manufactured or imported into India shall obtain Type Approval and comply with
Conformity of Production (COP) requirements of their product(s) for emission limits which
shall be valid for next COP year.
5) The above mentioned limit shall be applicable to Type approval and Conformity of
Production (COP) carried out by authorized test agencies.
The term ‘COP year’ means the period from 1st July of a preceding calendar year to 30th
June of the following year
6) Specific provisions on total hydrocarbon (HC) limits for fully and partially gaseous-fuelled
engines (This shall apply to dual fuel engines)
7) NOx + NMHC shall be measured in case of NG genset. NMHC shall be equal to 0.3×Total
Hydrocarbon (THC) in case of NG. Alternatively, NMHC can be measured by subtracting
CH4 emission from THC.
NOx + RHC shall be measured in case of LPG genset and RHC is equal to 0.5×THC in
case of LPG
8) Testing shall be on complete genset which includes silencer, air filter, alternator, canopy
etc. the prototype shall be acceptable.

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3.2 Rounding off
Determine the official emission result for each pollutant to at least one more decimal place than
the applicable standard. then round the figure to the same number of decimal places as the
emission standard. Compare the rounded emission levels to the emission standard for each
emission-data engine. In the case of NOX+HC standards, add the results before rounding. Test
report shall have both, the final rounded certificate emission result and test result before rounding
for better clarity on the decision.
Use the following rounding convention
i. If the first (left-most) digit to be removed is less than five, remove all the appropriate digits
without changing the digits that remain. For example, 3.141593 rounded to the second
decimal place is 3.14.
ii. If the first digit to be removed is greater than five, remove all the appropriate digits and
increase the lowest-value remaining digit by one. For example, 3.141593 rounded to the
fourth decimal place is 3.1416.
iii. If the first digit to be removed is five with at least one additional non-zero digit following
the five, remove all the appropriate digits and increase the lowest-value remaining digit
by one. For example, 3.141593 rounded to the third decimal place is 3.142.
iv. If the first digit to be removed is five with no additional non-zero digits following the five,
remove all the appropriate digits, increase the lowest-value remaining digit by one if it is
odd and leave it unchanged if it is even. For example, 1.75 and 1.750 rounded to the first
decimal place are 1.8; while 1.85 and 1.850 rounded to the first decimal place are also
1.8. Note that this rounding procedure will always result in an even number for the lowest-
value digit.
Examples-
# 1 2 3 4 5 6
1 Measured value -
0.49 0.50 5.49 5.50 6.49 6.50
HC+NOx
2 Emission Limit 6 6 6 6 6 6
3 Final rounded
certificate emission 0 1 5 6 6 7
value
4 Decision Pass/Fail Pass Pass Pass Pass Pass Fail

Note: Rounding Reference taken form US EPA Regulation 40 CFR -1039 and 40 CFR- 1065
3.3 Gross Power & Speed tolerance
The measured power and speed/frequency may differ from the power and speed/frequency
declared by manufactured as specified below.

# Gross Power Tolerance Speed/Frequency Tolerance

Type Approval ± 5% at rated

± 2% at rated & all part load points
COP ± 6% at rated

3.4 Compliance to Safety

All Genset run on dedicated Natural Gas (NG) or Liquified Petroleum Gas (LPG) or Bio-CNG,
Gasoline and Natural Gas (NG)/ Liquefied Petroleum Gas (LPG), shall meet Safety requirements
prescribed in the SAFETY CODE OF PRACTICE as per specified in Part A4.
3.5 Additional requirement for variable speed portable generator sets
Additional requirement for variable speed portable generator set shall be applicable as set out
details in Annexure 8 of this Regulation.

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4 Type Approval Administrative Procedure
4.1 Genset type and Genset family
4.1.1. Genset type
The technical features of an Genset type shall be those defined in its information document
drafted in accordance with the template set out in Annexure 1.

4.1.2. Genset family criteria

4.1.2.1. General
For type approval and conformity of production certification, the manufacturer genset range
shall be divided into model families consisting of parent genset and its variant(s).
Genset family shall be the grouping of genset, which through their design are expected to have
similar exhaust emission characteristic where member of the family shall comply with the
applicable emission values.
Parent genset shall be the genset selected from the genset family, in such a way that it will
incorporate those features which will adversely affect the emission level of the relevant exhaust
emission.
4.1.2.2. Genset family formation & choice of the parent genset
The essential characteristic of the genset family, the parameters defining the genset family, the
determination of a genset family and the criteria for choosing the parent genset shall be taken
according to the guideline given in ISO 8178-7 Reciprocating internal combustion Engine-
Exhaust Emission Measurement-Part-7: Engine family determination. However, the decision of
selection of parent genset and family classification by the authorized test agency shall be final.
For identification, the manufacturer shall designate the families as F1, F2, F3…. Fn.
The manufacturer shall provide to the type approval authority the appropriate information
relating to the emissions levels of the members of the genset family

4.2 Selection of Certifying Agency

4.2.1. Following test agencies are currently approved by the Nodal Agency Central Pollution Control
Board (CPCB) for purpose of type approval and subsequently conformity of production
compliance process and may be revised from time to time.
a) Automotive Research Association of India (ARAI, Pune)
b) International Centre for Automotive Testing (ICAT, Manesar)
c) Indian Institute of Petroleum (IIP, Dehradun)
4.2.2. One supplier shall submit application for Type Approval to only one certification agency for all its
families / models out of those approved.
4.2.3. The same certification agency shall be responsible for carrying out the verification of Conformity
of Production (COP) for that manufacture
4.2.4. For a new OEM or importer, selection of technical agencies for type approval certification and
subsequently conformity of production shall be applicant’s choice among the technical agencies
published by central pollution control board (CPCB) in paragraph 4.2.1 and as amended from
time to time.
4.2.5. For any reason if any manufacturer wants to change the certification agency, he shall apply to
the nodal agency well in advance with justifiable reason. The nodal agency, after consultation
with the existing certification agency/ standing committee, may approve the change, if found
justified. If approved, the nodal agency shall inform to the parties concerned.

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4.2.6. On receipt of information for change in certification agency from the nodal agency, the previous
certification agency shall authenticate all the relevant document of the model (type approval as
well as COP verification) and forward the same to the new certification agency. The certification
agency shall be responsible for carrying out the type approval testing and COP verification for the
manufacturer, in future.
4.3 Application of type approval
4.3.1 The application shall be made in the format prescribed in Appendix -1 and must be complete in
all respect. Appendix -1 shall be submitted to nodal agency and on its written acceptance, genset
specification related documents to be submitted to the test agency.

4.3.2 The application for approval of genset or genset family with regard to the level of the emission of
gaseous pollutants shall be submitted by the genset manufacturer or by a duly accredited
representative.

4.3.3 For each genset family, the manufacturer must submit an application to the certification agency,
selected as above.

4.3.4 The application must be signed by the authorized representative of the manufacturer.

4.3.5 It shall be accompanied by the undermentioned documents and the following particulars:

A description of the gesnet type comprising the particulars referred to in clause 4.1. of this
Regulation and if applicable the particulars of the genset family as referred to in paragraph
4.1.3. to this Regulation. For the purpose of identification, the manufacturer shall designate the
genset families as F1, F2, F3 …. Fn in consultation with technical agency;

4.3.6 Testing of the parent model, shall, normally, be sufficient for type approval of the family. The
Testing agency has the option to carry out the testing of more than one model in the family to
satisfy itself, subject to parent genset-concept as per ISO 8178-7.

4.3.7 Genset conforming to the genset type characteristics described in clause 4.1. shall be submitted
to the Test Agency responsible for conducting the approval tests. If the Test Agency determines
that the submitted genset does not fully represent the genset family described in clause 4.1, an
alternative and, if necessary, an additional genset shall be submitted for test. A prototype can be
submitted; however, it must be completely built up and conforming to the design to be
productionized. Relevant authorised valid document for the alternator efficiency declaration shall
be submitted.

4.3.8 During Type Approval test, the manufacturer shall submit the qualified emission test data of all
the remaining variant genset, other than the parent genset, which is chosen for emission test by
the test agency of the family along with all other documents.

4.3.9 At later stage if the manufacturer submits the application for type approval of a model, the Testing
agency shall ascertain whether the model can be classified as belonging to a family of model(s)
already certified. If the model does not belong to a family already certified, the Testing agency
shall proceed with the testing of the model for type approval with issuance of new and unique
genset emissions family certification upon qualification;

4.3.10 If the model belongs to a family already certified, the Testing agency shall decide whether the
specific testing of the model is required. In case the specific testing of the model is not required,
the type approval certificate for the family may be extended to include the model. In such case
qualified emissions data shall be submitted to agency by manufacturer during application;

4.3.11 The Testing agency shall intimate its decision to the applicant within a fortnight of receipt of the
application, indicating need and plan (schedule) of testing for type approval;

4.3.12 In case of alternate fuel (Natural Gas/Bio-CNG, LPG) running generator sets, manufacture to

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 ensure that the related genset components shall have been approved for safety compliance in
advance and genset with certified components shall be submitted for type approved. Safety
compliance certificates of all related components shall be submitted along with type approval
application. Safety compliance shall meet requirements prescribed in the SAFETY CODE OF
PRACTICE as per Part A4 of this Regulation. Manufacturer shall apply separately to test agency
for safety compliance certification.

4.4 Type Approval

4.4.1. No person or agency shall sale, import or use genset in India without valid Type Approval
Certificate and Conformity of production Certificate referred to in clause 4.5. and 5.4 of this
Regulation;
4.4.2. In order to receive a type approval of genset type or genset family, the manufacturer shall
demonstrate compliance, of the genset type or genset family with the provisions of this
Regulation. The manufacturer shall also ensure the use of fuels as specified in Annexure 6.
4.4.3. All the type approval tests shall be conducted in the technical agency laboratory. In case the
required test facilities are accredited by the technical agency, the type approval and / or COP
tests can be carried out at manufacturer’s laboratory also if reasons call for. In case the test is to
be carried out at any overseas test facilities, the same shall be informed to the Nodal Agency by
technical agency. The technical agency will submit a copy of accreditation letter highlighting the
details of test facilities available in the manufacturer’s laboratory to the Nodal Agency;
4.4.4. In case of the manufacturer approaches the technical agency for the first time, such manufacturer
should complete the COP test(s) within three months from the commencement of commercial
production or importation of 100 units whichever is earlier.
4.4.5. The Type Approval Authority shall put together an information package consisting of the
information folder accompanied by the test report and all other documents added by the technical
service or by the Type Approval Authority to the information folder in the course of carrying out
their functions (‘the information package’). The information package shall include an index listing
its contents, suitably numbered or otherwise marked so as to clearly identify all the pages and the
format of each document, in order to present a record of the successive steps in the management
of the type approval, in particular the dates of revisions and updating;

4.4.6. The approval authority shall ensure that the information contained in the information package is
available for a period of at least 10 years following the end of the validity of the type approval
concerned;

4.5 Certificate of Type Approval and Validity

4.5.1 After verification of genset(s) for the type approval, the technical agency shall issue a type
approval report to manufacturer within one month from date of testing completion indicating
acceptance or rejection decision and reason thereof. If the genset(s) submitted for approval
pursuant to clause 4.3. of this Regulation. Approval of that genset type(s) or genset family(ies)
shall be granted by the technical agency through issue of Type Approval Certificate as per format
prescribed in Annexure 2 along with report. Copy of certificate and report shall be forwarded to
Nodal Agency by technical agency involved;
4.5.2 For the purposes of clarity and easing access to relevant data, the communication includes an
addendum containing the most relevant information related with the type-approved genset type
or genset family;
4.5.3 The certificate shall be deemed to be valid for the model(s) included herein, unless explicitly
withdrawn by separate written order by the Nodal Agency;
4.5.4 The Type Approval certificate for a genset family issued to the manufacturer shall be valid for the
same model(s) manufactured at any other manufacturing plant of the same manufacturer. The
Nodal Agency or technical agency concern with type approval may visit the new plant to verify
adequacy of the infrastructure;

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4.5.5 Validity of Type Approval Certificate issued by type approval authority shall remain valid for
‘current’ COP-year enabling sales of such type approved genset family for that duration;
4.5.6 Validity of Type Approval Certificate issued by type approval authority shall remain valid further
as long as following conditions are met:
i) Till the genset specifications change as mentioned in Annexure 1 and modification related
clauses described in clause 4.6 below;
ii) Till the further amendments to the notification;
iii) Till COP is not missed / Till COP procedure compliance per clause 5 is obtained within
prescribed timeframe as listed in clause 5.3.10.
4.5.7 In case manufacturer has not sold gensets in two subsequent COP-year period after immediate
type approval and has done appropriate ‘Zero volume’ declaration seeking COP exemption to
nodal agency, and for resuming sale for third year of such genset family, manufacture to conduct
COP test before making any sell or a new fresh type approval application and subsequent process
needs to be carried out. Refer clause 5.5 for COP certification.

4.6 Modification and Extensions of approved type

4.6.1. If genset type or genset family is type approved and valid, manufacturer may approach type
approval certificate issuing technical agency for modifications pertaining to parent or any genset
type in the certified genset emissions family. Such modifications shall be ascertained by
manufacturer utilizing guidelines described in clause 4.6.5
4.6.2. Manufacturer shall submit technical document in line with type approval procedure prescribed in
this Regulation;
4.6.3. Subjected to scrutiny of manufacture’s application, technical agency shall approve or seek more
data pertaining but not limited to genset architecture, parameters, similarity with existing genset
type from emissions and performance perspective along with evidences. Decision of technical
agency will remain finally binding for allowing such amendments to existing type approval
certificate of a genset family through extension(s) vs asking manufacturer to type approve as new
genset family or new genset type;
4.6.4. Technical agency retains all rights to ask manufacture to demonstrate modified genset type for
emissions conformity through applicable type approval test procedures. Submission of
manufacturer run emissions data with valid test facility and procedure followed is mandatory
where changes are directly or indirectly pertaining to emission affecting components, genset and
after treatment system control algorithms and genset performance specifications.
4.6.5. Following generic rules may be utilized as example for extensions of type approval certificate:
4.6.5.1. No emission test requirements necessary:
(a) change to part numbers declared through type approval documentation that is not emission
affecting;
(b) part number change of emission affecting component that is just an administrative change
supported with due declarations (proto to production part number change as an example);

4.6.5.2. Emission test compliance required:

(a) performance or specification or source change of a component declared through type approval
documentation that is emissions affecting. This applies to any such component in genset and
after treatment system including software;
(b) emissions strategy changes such as but not limited to fuelling timing, fuelling qty,
(c) addition of alternate source component that is emission affecting with or without part number
change;

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 Changes as mentioned in above clause 4.6.5.1 and 4.6.5.2 may be verified during COP and not
mandatorily confirmed by additional if requested by manufacturer. However, final decision will be
with Test Agency.
4.6.5.3. In the event of an extension the Test Agency shall establish an updated communication denoted
by an extension number that shall be incremental in accordance with the number of successive
extensions previously granted. That communication shall clearly show the reason for the
extension and the date of extension.

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4.7. Type Approval Process Flow-chart

Genest and test EmissionGenest

test
auxiliary like-
Silencer,
Air filter,
Genset
After treatment.

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Following are the logical steps for the type approval process flow chart described in brief stepwise
1. Application to nodal agency (CPCB) in the form of affidavit seeking permission for type approval of
Genset family through submission provided as draft specimen in Appendix 1.
2. Upon written approval of nodal agency to manufacturer and chosen technical agency; (This could be
decision making node with “Yes” / “No” loop)
3. Submit type approval certification application to chosen test agency. Based on provisions such
application can be written or online through their secured portal;
4. Obtain technical agency approval (This could be decision making node with “Yes” / “No” loop with
NO means, provide additional data)
5. Upon agencies application scrutiny and negotiations, submit detailed technical documentation as per
requirements described in Annexure 1;
6. Obtain documentation approval from technical agency, family formation, choice of parent genset,
provide additional data
7. Obtain test plan/schedule from technical agency
8. Upon approval from technical agency plan for providing genset test auxiliaries like -Silencer, air filter,
after treatment systems.
9. Upon receipt of genset along with auxiliary technical agency examine the adaptability in test cell,
make necessary modification in exhaust line, mounts, etc, if required.
10. Conduct applicable tests-
Conduct emissions test to qualify (This could be decision making node with “Pass” / “Fail” loop. “Fail”
means, a) current TA application is closed out with failure report b) adjust. reset genset parameter
for retest or c) further manufacturer may re-apply afresh after redevelopment)
11. Review of all test results with manufactures and decision about compliance, in case of failure
manufacture have three options to proceed a, b, & c, act accordingly.
12. Technical agency carries out part verification of critical genset components and take final review of
technical document and ask manufacture to resubmit if necessary
13. Manufacture submit the corrected technical document if found necessary
14. Examine corrected document submitted in line with the requirement
15. Technical agency prepares technical report based on tests;
16. Technical agency issues type approval certificate to manufacturer;
17. Technical agency forwards a copy of type approval certificate to nodal agency
End

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 Appendix – 1

Application to Nodal Agency. Specimen for Submission of Affidavit &

Profile details of manufacturer

Part - A
NOTARISED AFFIDAVIT ON NON-JUDICIAL STAMP PAPER
[To be submitted to the Nodal Agency by a supplier approaching for the first time for TA]

I, …………………., Chairman / President / Managing Director / Partner / CEO / COO / Proprietor

of M/s ………………, having Registered Office at …………… engaged in manufacturing / import
of Portable Generator sets with manufacturing facilities / ware house at:
iii) ………………….
iv) ………………….
am authorized to swear this affidavit for and on behalf of the above named Company. I do hereby
solemnly affirm and declare as under:

1. That the deponent is well conversant with the facts and competent to swear this affidavit.
2. That the deponent declares that M/s …………………… are manufacturer / importer of
Portable generator sets in the brand name
iii) ………………….
iv) ………………….
(Strike out if not applicable)

3. That the deponent declares that M/s ……………………. are importer of Portable generator
sets from M/s i) ….………….…. (ii) M/s ………………. (Complete address)
(Strike out if not applicable)
4. That the deponent declares that M/s ……………. will obtain Type Approval / Conformity of
Production verification only from (Name of the Certification Agency) …………… and will not
approach any other Certification Agency for Type Approval / Conformity of Production
verification for any of their portable generator sets models, without prior permission from the
nodal agency.
5. That the deponent declares that none of the Chairman, Managing Director, Partner, Director,
Proprietor, Board Member in M/s …………… has been involved with a Company / Firm which
has manufactured and sold non-compliant portable genset.
6. That the deponent declares that M/s ……………. will manufacture / import and sell only
compliant Portable generator sets

(Name & signature with Co. stamp)

(DEPONENT)
VERIFICATION

Verified at …………. on this ……………of ……………20…… that the contents of the above
affidavit are true and correct to the best of my knowledge and belief and nothing has been
concealed therein.

Place: ………

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Date…………
(Name & Signature with Co. Seal)
(DEPONENT)

Part - B

FORMAT FOR SUBMISSION OF PROFILE AND DETAILS OF THE SUPPLIER

A. Company details

 Name of the Company

 Type of Company: Proprietor / Partnership / Private Ltd / Public Ltd
 Name of the Proprietor / Partners / Directors (submit relevant documents)
 Importer / manufacturer
 Registered Office Address with phone number
 Contact Address with phone number, fax number, email etc.
 Name and designation of the authorized person for submission of documents and to
deal with the certification agency
 Plant addresses and contact details, in case of manufacturer
 Ware house address, in case of importer (This cannot be changed without prior
intimation to Nodal Agency and Certification Agency)
 Name of the company from whom to import and its contact details, in case of importer
 Plant details, from where to import
 Authenticated Copies of following documents to be submitted
ix) Manufacturing License from Directorate of Industries / Department of Industry
(in case of Manufacturer), IEC Code (in case of importer)
x) VAT and CST/GST Registration
xi) Excise Registration, in case of manufacturer
xii) Consent from State Pollution Control Board/ Pollution Committee
 No. of employees
 Engineers (if any)
 Last year Turn-over
 Any other business

B. Details of Genset (Proposed) manufactured / assembled / imported

Model Nos. produced /imported Nos. expected to be produced /

Sr No
Names in current year imported in the next year
a
b
c
d

C. Details of Infrastructure
D. Land: Owned / Rented
Area (m2):

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E. Covered Area

F. Machinery for manufacture

e)
f)
g)
h)
G. Testing facility equipment’s
d) Load bank type and capacity
e) Measuring Instruments
f) Any other
H. Quality Control
6. Quality Control In charge
7. Quality Procedure:
ISO Certified since when (Enclose a Copy of Operating Procedure)
8. Pre-delivery Inspection Procedure on Gensets (including records maintained)
9. System of serial numbering and marking on Genset and their sub-systems – e.g. all
Enclosures, etc.)
10. Any other

Date: ...............
Place: .............
SIGNATURE OF THE
(Chairman /President / Managing Director
/ Partner / CEO / COO / Proprietor)

SEAL OF THE COMPANY

---End---

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5 Conformity of Production Administrative Procedure
5.1 General

5.1.1. Conformity of Production (COP) compliance is designed to ensure manufacture’s compliance and
control towards a type approved genset family to statistically ensure genset sold under such
emission certification does meet required emissions.
5.1.2. COP process compliance also ensures type approval certificate validity and hence right to
produce and sale genset by a manufacturer owing such type approval certification for the next
COP-year. Such provision is administratively provided by issuing Conformity of Production
Certificate;
5.1.3. Each manufacture shall subject it’s genset model range to the verification of COP, every year.
For this, the year shall mean the period from 1st July of the calendar year to 30th June of the
succeeding calendar year;
5.2 Verification of Conformity of Production (COP)
5.2.1 COP of domestically manufactured genset families
5.2.1.1 the verification of COP shall be done once in a COP-year as per plan described in following
‘Table 1’
Table 1
Number of families to be tested for verification of COP for domestic manufactures

Total number of families of the domestic Total number of families to be tested

manufacturer per year
1– 3 1
4–7 2
8 – 11 3
12 – 15 4
>15 5

5.2.2 COP of imported genset families

Imported genset shall be subjected to the verification of COP once for every 1000 units per family
imported or once a year, whichever is earlier.
5.3. Sample size, Decision and Other Criteria for verification of COP
5.3.1 In case of genset defined in clauses 5.2.1.and 5.2.2. above, testing shall be done on sample(s)
randomly selected by certification agency from the production line / import warehouse.
5.3.2 Minimum quantity of 25 numbers or one day’s average production volume of the genset model
selected by technical agency, whichever is more shall be made available for random selection.
The limit shall be minimum 10 units in case of import. Averaging of production volume will be
based on total working days at time of selection.
5.3.3 If the manufacturer is not of Indian origin, the manufacturer should establish a base office in India,
which is to be declared in the initial application submitted to Nodal Agency as per Appendix 1 This
base office will be responsible for Type Approval and COP compliance;
5.3.4 The manufacturer shall request the certification agency when they would like to make random
selection of genset(s) and to seek their schedule/availability for completing the COP test;

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5.3.5 COP verification shall be carried out for each plant of the domestic manufacturer. For imported
genset, the COP testing shall be carried out on the genset manufactured for each country of origin
irrespective of genset family being same;
5.3.6 The certification agency shall intimate to the manufacturer the schedule (month) of sampling /
testing. The manufacturer shall inform the production/ import plan for the month in which the
technical agency wants to carry out the COP, to the technical agency. If the manufacturer has a
problem due to particular reasons such as the particular model is not likely to be scheduled for
production / import at that time, or enough number of gensets may not be available for random
selection; the time schedule may be modified based on mutual convenience of the manufacturer
and the technical agency;
5.3.7 The manufacturer shall complete all COP activities (such as random selection, initial running-in,
emission testing and documentation) at least one month before the end of COP-year. The COP
certificate shall not be issued in case of non-adherence to above schedule unless such schedule
attainment is due to unavoidable reasons such as but not limited to test facility downtime,
extended COP process encountered.
5.3.8 Following ‘Table 2’ gives the deadlines for the respective COP-year for the COP activities.
However, manufacturer can take early action on each activity to ensure compliance.
Table 2
Sr. No Activity Description Last Date
1 Submission of production / import plan / actual details to technical agency 1st March
2 Random Selection 1st April
3 Submission of genset and subsequent testing (Including extended COP if any) 31st May
4 Completion of documentation and COP Certificate issuance 30th June

However, the above schedule shall be preponed, subjected to mutual agreement between test
agency and manufacturer keeping in view financial year closing and other reasonable cause.
5.3.9 The manufacturer shall inform the technical agency regarding the stoppage of production of a
specific model, in case this has not been anticipated at the start of the COP period. This shall be
intimated well in advance so that COP selection of the genset can be completed by the technical
agency before stoppage of production. Manufacture is held accountable for ensuring COP is
conducted and samples are made available per requirements of this Regulation;
5.3.10 The manufacturer shall provide all the assistance required by the technical agency for completing
the tests;
5.3.11 The latest updated technical specifications, procedure of pre-delivery inspection (PDI), running-
in and servicing of the genset, shall also be submitted before the genset selection, if there have
been revisions after the previous COP / type approval;
5.3.12 Pre-delivery inspection as per owner’s instruction manual / service manual will be carried out by
the manufacturer as per procedure declared at the time of type approval and as amended and
intimated to concern technical agency from time to time for the selected genset(s), under the
control of technical agency;
5.3.13 The running-in of the genset(s) shall be carried out as per the manufacture’s recommendation
submitted during the type approval and as amended and intimated to the concern technical
agency from time to time, for genset(s) under control of the technical agency. Running-in may
also be carried out at genset manufacture’s place under the control of technical agency provided
adequate facilities are available. After such running-in procedure, manufacture will be permitted
to carry out all the adjustments recommended in their owner’s / service manual and as amended
and intimated the concern technical agency from time to time published with technical agency,
under the control of the technical agency;

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5.3.14 In case of failure of any major component during the running-in or testing, the technical agency
may permit to replace component only once; which has failed and which does not affect the
performance and emission of the genset. Such decision is entirely with technical agency. In case
of failure of emission affecting component, random selection of genset at manufacture’s plant or
warehouse shall be done afresh. If for such randomly selected genset (second time) or a replaced
component fails again, it shall be reported to the nodal agency by the concern technical agency
and agency shall await instructions from the nodal agency for further action;
5.3.15 The manufacture shall submit the randomly selected genset(s) to technical agency within four
weeks (8 weeks in case of import subjected to last date as mentioned in clause 5.3.8. – Table 2)
of completion of running-in for emission compliance test;
5.3.16 The technical agency should endeavor to complete the required testing of selected genset(s)
within four weeks after submission of genset(s);
5.3.17 The testing shall be done as per applicable procedures and specifications described in Annexure
4
5.3.18 Sampling plan for COP
5.3.18.1 The number of samples to be tested shall be minimum as necessary, as given in Table 3 to
arrive at a decision on whether the produciton unit complies with applicable emission limits;
5.3.18.2 A sample said to have failed for particular criteria pollutant if the test result of the sample for the
criteria pollutant exceeds emission limit;
5.3.18.3 The production units of all models in the family shall be deemed to comply with the emission
limits if the number of failed samples as defined in clause 5.3.18.2 above for each criteria
pollutant is less than or equal to the pass decision number appropriate to the cumulative number
of samples tested for that criteria pollutant as given in Table 3;
5.3.18.4 The production units of all models in the family shall be deemed to be non- complying with the
emission limits if the number of failed samples as defined in clause 5.3.18.2 above for each
criteria pollutant is more than or equal to the fail decision number appropriate to the cumulative
number of samples tested as given in Table 3;
Table 3
Sampling plan and decision criteria for the verification of COP

Cumulative Pass decision Fail decision Cumulative Pass decision Fail decision
Samples No. of failure Samples No. of failure
1 (a) (b) 16 6 11
a b
2 ( ) ( ) 17 7 12
a b
3 ( ) ( ) 18 7 12
b
4 0 ( ) 19 8 13
b
5 0 ( ) 20 8 13
6 1 6 21 9 14
7 1 7 22 10 14
8 2 7 23 10 15
9 2 8 24 11 15
10 3 8 25 11 16
11 3 8 26 12 16
12 4 9 27 12 17
13 5 10 28 13 17
14 5 10 29 14 17

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 15 6 11 30 16 17
a
( ) : Series not able to pass at this stage
( b ) : Series not able to fail at this stage
Note:
ix) COP compliance or non-compliance decision is on the basis of number of failures within
the respective cumulative samples tested.
x) During successive testing, the decision which reached first is the final.
xi) Minimum 4 samples are required to test to reach pass decision
xii) Minimum 6 samples are required to test to reach fail decision

5.3.18.5 Once a complaince or non-compliance decision is made for a particular criteria pollutant, the
result of testing of subsequent samples for that criteria pollutant shall not influnece the decision;

5.3.19 Gross Power failure during COP

5.3.19.1 For verifying the conformity of production, if anyone selected genset does not meet the gross
power and rated speed limit as applicable, another four gensets will be taken from the series at
random and be tested as per this part. All these selected gensets shall meet the limit values
specified. One genset shall be subjected to the emission test for the conformance of production.
5.3.19.2 If further same failure is noted in any of the additionally selected samples of clause 5.3.19.1 the
production shall be considered as non-compliance and the provision of clause 5.8, shall be put
into effect.

5.4 Certificate of Conformity of Production (COP) and It’s Validity

5.4.1 After verification for COP, the certification agency shall issue a COP verification report to the
manufactuer within one month of the date of testing completion , indicating compliance or non-
compliance. In case of compliance, the technical agency shall issue a COP certificate to the
manufactuer as per format prescibed in Annexure 2 along with report. At the end of COP year,
details of COP & the Copies of certificate as well as report shall also be forwarded to the Nodal
Agency;
5.4.2 Certificate of conformity of production is required to commence the production and sale
of portable generator sets in immediately next COP-year. Validity of current COP certificate shall
be till successful compliance of COP test in next COP-year
5.4.3 The COP certificate will be issued at the end once all the numbers of genset samples
demanded as per the production plan submitted become tested successfully. Intermediate COP
certificate i.e at each sample tested shall not be issued, However the test data report will be
issued at every test sample.

5.5 COP Discontinuity

5.5.1 If there is no production or import of model(s) of a particular genset family for two consecutive
years immediately after obtaining type approval or immediately after obtaining COP certificate,
the type approval certificate for that particular genset family becomes invalid. In case the
manufacturer wants to maufacture or import genset model(s) of such particular genset family,
then the manufacture shall approach Nodal Agency and technical agency to obtain a new Type
Approval certificate afresh following stated procedure;
5.5.2 If there is no production or import of model(s) of a particular genset family for two consecutive
years immediately after obtaining type approval and if the COP test is requested for the third year,
then the supplier shall approach Nodal Agency to obtain approval for the extention of validity of

316
 Type Approval. This is applicable only for a new manufacturer and in case no genset(s) sale has
happenned post type approval;

5.6 Exemption from COP

In the following cases, genset family(ies) shall be exempted form COP process.
5.6.1 If Type Approval obtained in the last quarter (Apr–Jun) of COP year. This clause is not
applicable to the manufactueres as mentioned in clause 4.4.4.
5.6.2 In case of no production or import, the manufacturer shall submit a declaration to technical agency
and Nodal Agency for ‘No production or import’ of a particular family models for every COP-year;
5.6.3 The COP test shall be conducted by technical agency for the next COP-year, upon
receipt of declaration by the manaufacturer that there was no production or import during current
COP-year;
5.6.4 Declaration in this regard should be submitted before end of third quarter of the current
COP-year; (i.e 31st March). In case, If produces after 31st March, COP is applicable.
5.6.5 Any genset manufactured for purpose of export outside India. COP exemption shall apply
for such volumes and COP test exemption shall apply if all such genset(s) produced are exported;
5.6.6 Any domestically manufactured genset intended for the purpose of sample (Maximum
number of 4 units per genset family) only and not for sale in India;
5.6.7 Any genset imported for the purpose of sample testing, bench making and not intended
for any commercial sale (Maximum number of 4 units per year);
5.6.8 Any genset imported for the round robin or laboratory correlation tests. Such genset shall
be exported back within 12 months from the date of import; or it should be scraped and a scrap
certificte shall be provided.
5.6.9 For obtaining exemptions regarding clauses 5.6.2, 5.6.6, 5.6.7 and 5.6.8, the
manufacturer shall obtain written approval from Nodal Agency. Nodal agency should endeavor to
respond within 4 week after the receipt of application.
5.6.10 COP exemption shall be maximun up to three consecutive COP year, to resume sell from fourth
year a fresh type approval shall to be conducted.
5.6.11 After obtaining exemption as per 5.6.2, manufacturer shall first conduct COP before making any
sell.

5.7 Production Definitely Discontinued

5.7.1 If manufacturer decides to discontinue production / withdraw type approval certificate of a specific
genset family or multiple families from a specific plant or all plants, the manufacturer shall so
inform to Test Agency involved in type approvals and COP compliance at least three month before
the stopage of production;
5.7.2 In such case, the manufacturer shall ensure COP compliance for the genset family(ies)
from every manufacturing plant before the production of the genset family(ies) is discontinued
following COP compliance process described in clauses 5 of this Regulation;
5.7.3 Upon receiving the relevant communication, the Test Agency shall inform the manufacturer the
acceptance of the communication and provide an acceptance letter.

5.8 Consequances of non compliance

5.8.1 If the COP vertification report of the technical agency for a model family indicates non-compliance,
the manufacturer must stop manufacturing with immediate effect;

317
5.8.2 Further, the manufactuer must analyze the reasons for non-compliance, plan to take corrective
actions in design, production line and units already produced and submit a report to the nodal
agency with a copy to concern technical agency within four weeks of the receipt of the COP
verification report;
5.8.3 If the manufacturer is unable to diagnose the reasons for non-compliance within stipulated time,
this shall be clearly stated in the report;
5.8.4 Based on the diagnostics and corrective action plan submitted by the manufactuere, the
Nodal Agency in consultation with technical agency and if both decide to, in consultation with
standing committee, may take any of the following actions:
5.8.4.1 Allow continuation of production or import of all models in the family if it is satisfied with the
corrective actions planned or taken by the manufacturer and ability to meet emission norms;
5.8.4.2 Allow continuation of production or import of some or all other models of the genset family if it
determines that the reasons for non-conformance of the tested model are not relevant to these
models; with or without additional verification of COP in due course;
5.8.4.3 Stop production or import of some or all other models of the genset family till compliance is
demonstrated by the supplier, through a re-verification of COP. In case of imported model(s), the
non-compliant genset should be sent back to the original destination;
5.8.5 The manufacturer shall be given an opportunity to explain it’s views before taking final decision;
5.8.6 It is responsibility of the manufacturer to ensure at his cost that the modifications are
carried out such as field retro fitment campaigns within period specified by the Nodal Agency on
all products produced as well as sold / dispatched in the period between the dates from which the
COP became due and re-verification of COP or as decided by the Nodal Agency, in consultation
with standing committee;
5.8.7 Nodal Agency with help from Technical agency shall audits compliance in field on random basis
for corrections done and issues closure letter to manufacturer
5.8.8 Further, to avoid such non-compliances again in future, additional precautionary measures shall
be initiated to strengthen the process after re-certification & resuming the production with new
modified spec;

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5.9 COP Process Flow Chart

Genest

Genest
Genest

Test additional
engines (4+2)

Conduct
Checking nos of failures emission test

319
Following are the logical steps for the COP process flow chart described in brief stepwise-
COP cycle shall end with either -
I. COP compliance with regular sample testing (Steps 1-16)
II. COP compliance with extended samples testing (…. Steps 17-18)
III. COP non-compliance after extended testing (…. Steps 19-30)

CASE I:
1. Manufacturer with valid Type Approval and COP certification submits annual estimated
production/import volume data to technical agency involved in the format provided within two
months of start of new COP-year.
2. Technical agency, based on the production/import volumes, communicates to manufacturer, the
genset type chosen and the number of samples needed for COP compliance test for all genset
families of that manufacturer within one month of submission of above production volume data;
3. Technical agency also communicates to the manufacturer plan for COP genset random selection
based on manufacture’s input above;
4. Manufacturer coordinates adhering to technical agency provided or negotiated plan and
coordinates for genset random selection at manufacturing plants/warehouses/sales points for
imported genset as the case may be.
5. At the point of selection as mentioned in Sr 4, manufacturer provides with minimum required
sample size for random selection;
6. Technical agency representative carries out random selection and does note emission critical
component part and serial numbers. Provides with appropriate seal for avoiding tampering of
assembly parameters further;
Technical agency representative randomly selects after treatment system if applicable;
7. Decision, if running–in is carried out at manufacturer’s location or technical agency location;
If running-in is agreed to be carried out at manufacture’s facility, running-in shall be started in
presence of technical agency representative.
8. Genset along with arranged after treatment shall be transported to technical agency test location;
9. Upon receipt of genset along with auxiliaries, technical agency examines the adaptability in test
cell, make necessary modification in exhaust line, mounts, etc, if required.
10. Technical agency communicates the test schedule to manufacture for his witness
11. Technical agency carries out genset qualification and emissions test per applicable procedure
and shares results with manufacturer;
12. Technical agency carries out critical component type/part numbers, injection timing verification
and match with type approved document, in case any change noted, manufacturer to provide the
declaration in this regard, till time COP certificate will be on hold.
13. Review of test result & decision on compliance;
14. If COP compliance is obtained, Technical agency prepared the compliance certificate within 4
weeks from the date of testing. Genset & after treatment, test auxiliary is returned to the
manufacturer;
15. Technical agency issue compliance certificate to manufacturer
16. Technical agency forwards a copy of compliance certificate to Nodal agency

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 CASE II:
17. ECOP: If non-compliance observed after testing (at Stage No 13), process begins from extended
random selection of genset(s) as per preferred options prescribed in clause 5.3.18.

17.1 For establishing the compliance minimum 4 samples are mandatory to be tested and all 4
samples should pass.
17.2 If some samples failed, the additional new more samples, are required to be tested, the
numbers depend on the number of samples failed earlier,
17.3 Initially test 2 more new gensets
17.4 In the cumulative samples (4-originally tested + 2 new), note the numbers of failed samples
a) According to the appropriate clause does the number of failed samples agree with the
criteria for failing the series
b) According to the appropriate clause does the number of failed samples agree with the
criteria for passing the series
17.5 If, answers of a & b are NO, then; continue the testing on additional samples till pass decision
is made provided limitation of samples tested as applicable (30 numbers)

18. If during testing if the pass decision criteria is reached, the series is deemed to be compliance
and COP certificate is issued (then continue from Stage14-16)

CASE III:
19. If during testing if the fail decision criteria is reached, the series is deemed to be non-compliance;
Or if Manufacturer opts to declare non-compliance without availing total number of samples
allowed to be tested, the series is deemed to be non-compliance

20. Technical agency prepares the COP failure report

21. Technical agency issue COP failure report to manufacturer
22. Technical agency informs nodal agency about COP non-compliance of said genset family
23. Manufacturer stops production or import of the said non-compliant genset family;
Manufacturer informs nodal agency about non-conformity, stoppage of production and dispatch
and their plan for failure investigation within 4 weeks of receipt of COP verification report or COP
failure intimation
24. Nodal agency discusses with test agency in details on the non-compliance notified.
25. Nodal agency replies to the manufacturer about their inputs on timelines by which compliance
shall be obtained as well as failure root cause and corrective action plan submission. Nodal
agency also informs about any financial penalty or assurance required from the manufacturer;
Manufacturer submits root cause analysis and corrective action plans to nodal agency in
consultation with technical agency;
26. Nodal agency in consultation with technical agency reviews manufacture’s submissions and
decides if such case shall be put forth for standing committee review and guidance if found
necessary depending upon the severity of the failure.
If decided to represent at standing committee, nodal agency brings this issue to standing
committee and allows manufacture to represent their submissions. If standing committee agrees
/ approves manufacturer’s submission and plan then;
27. Nodal Agency can also decide on their own & shall take following decision:
27.1 Gives written permission to technical agency to proceed with re-verification of COP with
improvements implemented by manufacturer and also type approval re-certification as
the case may be.

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 27.2 Manufacturer offers genset sample and technical documentation to technical agency and
complies with COP;
27.3 Technical agency issues compliance certificate or type approval certificate if newly
approved as an option;
27.4 Manufacture begins production after obtaining new Type Approval or COP compliance
certificate;
27.5 Manufacturer completes corrective actions on genset dispatched during period of COP
and COP failure date;
28. Manufacturer complies with ‘financial assurance related’ documents asked by Nodal Agency;
29. Manufacturer submits corrective action / campaign report with adequate evidences to Nodal
Agency
30. Nodal Agency with help from Technical agency audits compliance in field for corrections done
and issues closure letter to manufacturer;
End

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 ANNEXURE – 1

Information document-Template for submission of portable genset technical

specification

1.0 NAME & ADDRESS OF THE GENSET

MANUFACTURER / IMPORTER –
Type approval certificate holder.

2.0 AUTHORISED CONTACT PERSON DETAILS-

Name, Designation, Email, Contact number

2.1 GENSET CATEGORY –

Indigenous or Imported

2.2 ADDRESS OF THE MANUFACTURING PLANT/S

3.0 PRODUCT CATEGORY

4.0 MODEL NAME / BRAND NAME

5.0 GENSET CANOPY TYPE: HALF /FULL

6.0 CLASS OF THE GENSET AS SPECIFIED IN THE

REGULATION

7.0 MODEL FAMILY DESIGNATION ASSIGNED TO THE

MODEL

8.0 GENSET OUTPUT SPECIFICATIONS

8.1 No. of phases

8.2 Rated voltage (V)

8.3 Rated current (A)

8.4 Rated frequency (Hz)

8.5 Overall efficiency of the alternator %
(Submit relevant document)
8.6 Max. output declared by manufacturer with tolerance
(VA)

9.0 Alternator Make

9.1 No. of Poles used

10.0 PRODUCTION / IMPORT PLAN (SCHEDULE) AND

ESTIMATED VOLUME PER ANNUM

11.0 DESCRIPTION OF THE GENSET ENGINE

11.1 Make
11.2 Type

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11.3 Working principle, Four stroke / Two stroke
11.4 Bore (mm)
11.5 Stroke (mm)

11.6 Number of cylinders

11.7 Engine Displacement (cc)

11.8 Compression ratio (with the tolerance)

11.9 Max. power of the Engine (kW)@ rpm

11.10 Drawings of combustion chamber and piston crown

11.11 Minimum cross-sectional area of inlet and outlet ports (mm²)

12.0 COOLING SYSTEM

12.1 Liquefied / air cooling
Liquefied cooling: Max. temp. at Engine Outlet
12.2 Engine Lub oil Temperature:
Minimum:
Maximum:
12.3 Characteristics of air-cooling system
12.4 Blower: Characteristics of make(s) and type (s)
12.5 Air ducting (standard production)

12.6 Temperature regulating system

12.7 Intake system

12.8 Intake manifold description

12.9 Air filter: Make & Type

12.10 Device for recycling crank-case gases: Description and

diagrams

13.0 ADDITIONAL ANTI-POLLUTION DEVICES

13.1 Catalytic Converter

a) Make:

b) Type:
c) I.D:
d) Substrate Dimension:

e) Loading:

f) CPSI:
13.2 Secondary air Injection system details

a) Make:
b) Type:

c) I.D:

324
 c) Quantity of valve
14.0 Fuel feed system

a) Make:
b) Type:
c) I.D:

14.1 Carburetor Air screw settings (specify the

tolerance)

14.2 Jet size: a) Main Jet:

b) Pilot jet:
14.3 Carburetor Venturi Diameter (mm)

14.4 Float-chamber level

14.5 Mass of float in grams.

14.6 Float needle

14.7 Dimensions mixture duct

14.8 Manual / automatic choke, closure setting
14.9 Fuel Feed (By fuel injection/Carburation) including
details of NG/LPG kit and Cylinder details to be
specified:
Gas Air mixer Make /Type:
Gas Air mixer diameter:
No. of holes:
System description
Working principle: intake manifold / direct injection /
injection pre-chamber / swirl chamber
14.10 Fuel Injection System:
a) Make

b) Type
c) I.D No.

d) Injection timing

e) Injection advance curve

14.11 a) Injectors:

b) Make
c) Type
d) Opening pressure (specify tolerance)

14.12 Governor /ECU/Controller

a) Make
b) Type, Mechanical /Electronic/Hydraulic
c) ID. No.

d) Max. speed without load / min

325
 e) Idle speed
14.13 Exhaust Gas Recirculation (EGR) System

a) Make
b) Type
(Internal/External/cooled/uncooled/progressive ON-
OFF/Electrical/Vacuum based/Other)
c) ID No.
14.14 Other Pollution Control Device

a) Make

b) Type (Give Complete Details of the system

with necessary drawings)
c) ID No

14.15 Cold start device

a) Make

b) Type
c) System description

14.16 Starting aid

a) Make
b) Type

c) System description
15.0 VALVE TIMING OR EQUIVALENT DATA

i. Maximum lift of inlet valve, (mm)

ii. Maximum lift of Exhaust Valve, (mm)
Angles of Valves (w.r.t. top dead center)
a) Inlet valve opening angle (IVO)
b) Inlet Valve Closing angle (IVC)
c) Exhaust valve opening angle (EVO)
d) Exhaust valve Closing angle (EVC)

16.0 Description of reed valves if any (with

dimensional drawing)

16.1 Description (with dimensional drawing) of inlet ports,

scavenging and exhaust, with corresponding timing
diagram
17.0 IGNITION

a) Ignition system

b) Make
c) Type

d) Ignition timing (specify the tolerance)

326
 e) Contact point gap and dwell-angle (specify the
tolerance)
f) Spark plug –
Make
Type
Gap setting
Spark seat temperature at max. output
18.0 EXHAUST SYSTEM

Description and diagrams

Specify the Back Pressure (kPa) at rated power
19.0 SETTING AND LIMIT DECLARED BY THE MANUFACTURER

Lubricating Oil Temperatures Deg C

Minimum / Maximum
Please specify if any
Please specify if any
19.0 LUBRICATION SYSTEM

a) Description of systems
b) Position of lubricant reservoir

c) Feed system (pump, injection into intake, mixing with

fuel, etc.)

d) Lubricating pump

e) Make
f) Type
g) Lub oil mixed with fuel

h) Oil Percentage in fuel

i) Lubricant Used

j) Make

k) Type
20.0 ADDITIONAL INFORMATION ON TEST CONDITIONS
Please specify if any

Please specify if any

21.0 Ignition coil

a) Make

b) Type

22.0 Ignition condenser

a) Make
b) Type
23.0 Radio interference suppression equipment

327
 a) Make
b) Type
24.0 Details of LPG / CNG Kit

24.1 a) Kit Manufacturer Name

b) Kit Manufacturer Address
24.2 Cylinders

a) No. Of Cylinders
b) Type of Cylinders
c) Cylinder Sr.No
d) Make
e) Water Capacity (litres)
f) Working Pressure (kg/cm2 )
g) Approval reference of DOE
24.3 Multifunctional valve

a) Make
b) ID
c) Sr. No
24.4 Fuel Line

a) High pressure pipe diameter (ID/OD)

b) Low pressure pipe diameter (ID/OD)
24.5 Shut Off Valve (Solenoid Valves)

a) Make
b) Type
c) Operation Voltage
24.6 Fuel selection switch

a) Make
b) Type
24.7 Regulator

a) Make
b) Type
24.9 Gas-Air Mixer/Injector

a) Make
b) Type
25.0 Attachments to be Enclosed
25.1 Combustion Chamber (Piston Crown) Drawing

328
25.2 Valve Timing Diagram
25.3 Oxidation Catalyst Layout and drawing along with specifications
25.4 Air Intake system layout (from air-filter to intake manifold)
25.5 Exhaust system layout which includes catalyst position/location
25.6 Others. Please specify

Note:-
1. Strike out whichever is not applicable
2. In addition to the names of the manufacturers of items mentioned above, the
manufacturers shall inform the test agency that carries out the type approval, the names
of new alternate manufacturers for these items as and when they are being introduced.

Test Agency: Manufacturer Document No. (indicating also

Signature Signature revision status)
Name Name
Designation Designation Revision date
Date Date Sheet No.

329
 ANNEXURE – 2

Specimen Copy for Type Approval and COP certificate

a) Type Approval Certificate Format

Type Approval Certificate No: ______ Date: dd-mm-yyyy

Cert Rep. Spec. Drg. Total

CERTIFICATE OF TYPE APPROVAL

for
COMPLIANCE TO MASS EMISSION NORMS FOR
Gasoline or Dedicated NG or LPG or Bio-CNG or BI Fuel- Gasoline and NG/LPG/Bio-CNG fuel run
PORTABLE GENERATOR SETS

1. In order to establish compliance to the provisions of mass emission limits, applicable as on date,
documental verification /necessary testing was carried out on the following Portable Generator set
model(s), submitted by the manufacture/importer

Portable Generator Set Supplier: ____________ Portable Generator Set Test Report
Manufacturer: ______ Reference: _____

Generator Set Model(s)/Brand

Name Type Family Category

Parent Variants

2. It is certified that the above mentioned Generator Set model(s) comply with the emission limits applicable
for Gasoline, dedicated NG or LPG or Bio-CNG or BI fuel- gasoline and NG/LPG/Bio-CNG fuel run genset,
as prescribed under the following rules notified by Ministry of Environment & Forest and Climate Change,
Govt. of India:

Notification Date Rule.No Description Date Of

Compliance of
Emission Norms
Mass Emission Norms for
Rule ,1986, in
Gasoline, Dedicated NG or
G.S.R. 804(E) GSR 804(E.) schedule I,
LPG or Bio-CNG, BI fuel-
dated 3- Serial number
Gasoline and NG/LPG/Bio-
Nov-2022 88 and 95
CNG fuel

330
3. Validity of the Certificate:

This Type Approval 1.Further amendment to notification No. GSR 804(E.) dated 3-Nov-2022
Certificate is valid till 2.No change in technical specification of the Generator Set specified
3.Explicitly the Type Approval Certificate withdrawn by the Generator Set
manufacturer/Supplier /Assembler/Importer

4. Conformity of Production (COP) requirements:

COP test shall be carried out once in a year (between the period 1st July of Calendar year to 30st June
of succeeding calendar year

Note: Refer overleaf for disclaimer.

Authorized Signatory Authorized Signatory

(Head) Test Agency (Head)
Certification Laboratory Seal/Stamp Certification Body

Place of Issue: dd-mm-yyyy

331
 b) COP Certificate Format

COP Certificate No.________________ Date:dd-mm-yyyy

Cert Rep Total

CERTIFICATE OF CONFORMITY OF PRODUCTION (COP) FOR THE YEAR yy-yy

For
COMPLIANCE TO MASS EMISSION NORMS FOR
Gasoline or Dedicated NG or LPG or Bio-CNG or BI Fuel- Gasoline and NG/LPG/Bio-CNG fuel run
PORTABLE GENERATOR SETS

Company Name: _____________

1. Based on the verification of documents and trials conducted on portable genset model manufactured by
and randomly selected from their (plant address___), It is certified that the portable genset model of
families FXX complies with the provisions of Verification of the Conformity of Production (COP) as per
para 5.0 of CPCB procedure (System & Procedure for Compliance to Emission Limits for Gasoline,
dedicated NG or LPG or Bio-CNG, BI fuel- Gasoline and NG/LPG as per requirements of Rule 88 and 95
of Environments (Protection) Rule 1986, of GSR 804(E.) dated 3-Nov-2022 notified by Ministry of
Environment, Forests and Climate Change Govt. of India.
2. This certificate covers the genset families and its models as listed in below table, declared by the
manufacturer to have been produced / planned to be produced, during the stipulated period from 1st July
to 30th June.

Reference Type
Sr. Manufacturing Manufacturing COP
Family Model Approval Certificate
No. Plant Period Year
No.

3. Validity of Certificate:
a) This COP certificate is valid up to 30th Jun yyyy. Validity of this certificate is subjected to completion of
next COP before 1st July yyyy for the production of portable genset model/s during the period 1st July
to 30th Jun once.
b) As confirmed by the manufacturer this COP certificate is issued for the planned production during the
manufacturing period.
4. Disclaimer: Refer overleaf for disclaimer

Authorized Signatory Test Agency Authorized Signatory

(Head) Seal/Stamp (Head)
Certification Laboratory Certification Body

Enclosure: Test report No.: ____________________ dated dd-mm-yyyy

Place of Issue: dd-mm-yyyy

332
 ANNEXURE – 3

Labelling Requirements

A3.1. The genset or the product must be affixed with a conformance label meeting the following
requirements.

A3.1.1. General Requirement

i. The label shall be durable and legible;

j. The label shall be affixed on a part necessary for normal operation of the genset or
the product and not normally requiring replacement during the life of the genset or
the product;
k. All the information mentioned in the conformance label must be in English language;

A3.1.2. Conformance Labelling Content Requirement

q. Name of Genset manufacturer or product importer

r. Manufacturing plant address from where Genset is manufacture
s. Genset Model name;
t. Rated maximum output of Genset in kVA
u. Genset Unique Identification Number (Serial Number, etc.);
v. Date of manufacturing and in case of import, date of import of Genset product; format
in mm/yy shall be acceptable.
w. Type Approval certificate number;
x. Statement that ‘this engine or product conforms to the Environment Protection Rule
1986;

Compliance name plate model

Manufacturer

Mfg. Plant

Rated output
Genset Model
(kVA)

Genset Sr No Date of Mfg.

Type Approval Cert. No.

This genset or product conforms to the Environment Protection Rule 1986

333
 ANNEXURE– 4

Test equipment, Test fuel, Test procedure & Test result calculation

1.0 Overview
The test facility to be used shall be of the certification agencies or any other facility approved by these
certification agencies. The test Lab at Test Agency/ Engine Manufacturer Lab/ Third party Lab shall be
accredited as per the requirement of ISO/IEC-17025 (NABL-National Accreditation Board for Testing
and Calibration Laboratory) compliance for the related GSR/S&P/ISO-8178 Standards. The tests shall
be carried out under the control of the certification agencies.
For portable genset, test shall be done on resistive load bank

2.0 Test Fuel

The reference fuel or commercially available fuel as prescribed by Govt. of India in CMVR document,
Gasoline, or NG or LPG or Bio-CNG as applicable shall be used for testing. As per the choice of
manufacturer, fuel spec reference or commercial may be used. As specified in this document no other
fuel, other than stipulated by CPCB, shall be used to start and run the genset without consent from
CPCB.

3.0 Test equipment

Test equipment & other relevant technical details to be used shall be as per following standards, except
where it is mentioned, specifically, in this document.
ISO 8178 – 1 2017, 2020: Reciprocating internal combustion engines — Exhaust emission
measurement — Part 1: Test-bed measurement systems of gaseous and particulate emission
4.0 Emission test cycle using resistive load bank
Emissions from the portable gensets powered by SI engine (up to 800 cc displacement) shall be tested
using Resistive Load Bank as per following 3-mode test cycle. (Reference ISO 8178-Part-4)

Mode No. Load current Frequency Weighting Factor

Maximum output declared by the

1 manufacturer of the genset (tolerance 50 +1Hz 0.3
± 5% for TA and ± 6% for COP)
2 75% of Mode 1 50 +1Hz 0.5
3 50% of Mode 1 50 +1Hz 0.2

334
 3 mode test cycle

Rated Speed

Weighting Factor

100% Mode-1
0.3
Load [ % ]
75% Mode-2
0.5

50% Mode-3
0.2

Speed [ rpm ]

5.0 Specification of the equipment and set up

a) The equipment and setup necessary for testing of exhaust emissions of genset as per method
prescribed herein, consists of:
b) Resistive load bank for electrical loading of the genset, equipped with voltmeter, ammeter, and
frequency meter for measurement of the load.
c) Exhaust gas analysers for measurement of molar concentrations of CO, CO2, HC, NOX and O2.
d) Arrangement for sampling raw or dilution (CVS) exhaust gases, their conditioning for and transfer
to analysers.
e) Apparatus for measurement of fuel consumption rate.
f) Instruments for measurement of:
 Ambient air pressure and humidity
 Genset engine inlet air and other temperatures
 Temperatures of exhaust sample
g) Instrumentation and set up for measurement of genset engine inlet air flow rate
h) Requirement of type, accuracy, calibration etc. of these equipment

6.0 Resistive Load Bank

a) The load bank shall be a single phase (for single phase Gensets only) or 3 phase load circuit,
with each phase consisting of:

 A combination of stable resistive elements of appropriate rating, wired such that the total load
current is adjustable to any value up to 125% of max. full throttle current per phase of the genset
under test with accuracy of ± 0.1 Amp.

i. The resistive elements shall be capable of withstanding continuous energisation at 150% of

the rated voltage of the genset without overheating.
ii. The ratings of other circuit elements such as switches, cords etc., shall be consistent with
the highest current I voltage to which they may be subjected to in actual operation.

 A voltmeter, frequency meter and ammeter for measuring the output voltage and frequency of the
genset and the total load current respectively.

335
 i. Voltmeter and ammeter shall be AC RMS meters, direct acting analogue/ digital type
conforming to IS 1248 (part 2), accuracy class 0.5. The range and rating shall be appropriate
for the genset output to be measured.
ii. Frequency meter shall be direct acting analogue (pointer)/ digital type conforming to IS 1248
(part 4), accuracy class 1. The range of frequency meter shall be 45 - 65 Hz.
iii. The meters should be calibrated once in a year. The calibration must be traceable to within
the specified accuracy with respect to NPL/International standard.

b) The entire circuit shall be housed in a suitable enclosure for safety and convenience of operation.
The configuration shall ensure that under normal conditions:

i. Accidental touches to live/ hot parts are not possible.

ii. There shall be no possibility of short-circuiting. The insulation resistance between each
independent conducting path and between conducting path and body of the enclosure
shall be 10 µΩ min. Further, the insulation system shall withstand 1500 V AC for 1 minute
without breakdown and shall be consistent with the maximum temperature to which it may
be subjected in operation.
iii. The resistive elements and the enclosure do not overheat. If necessary, a cooling fan of
adequate capacity shall be provided.

7.0 The Exhaust sampling setup

The Exhaust sampling arrangement shall consist of an extension pipe fitted with an exhaust sample
probe connected with the outlet of the normal exhaust system supplied with the product (genset) has
shown in fig. 1 & fig.2

336
8.0 Test condition
i. The ambient temperature throughout the test shall be within 10 to 40 deg C.
ii. The absolute ambient temperature (designated as T & expressed in Kelvin) and dry
atmospheric pressure (designated as Ps & expressed in kPa) must meet the following
condition for a test to be valid.

1. 0.93 ≤ Fa = (99/Ps) x (T / 298) 0.7

≤ 1.07

(Reference for the test condition taken form ISO-8178 and IS-14599)

9.0 Power Correction Factor

The power correction factor is the coefficient by which the measured power must be multiplied to
determine the engine power under the reference atmospheric conditions specified as below

Pcorr = α x Pobs
Where,
Pcorr is the corrected power (i.e., power under reference atmospheric conditions)
α is the correction factor
Pobs is the measured (observed) power (test power)

Reference atmospheric conditions:

Temperature (T): 298K, Dry pressure (Pso): 99kPa
Note: The dry pressure is based on a total pressure of 100 kPa and water Vapour pressure of 1kPa.

Test atmospheric conditions:

The atmospheric conditions during the test shall be the following

337
 Temperature (T): Between 283 K and 313 Pressure (P): Between 80 kPa and 110 kPa

Determination of correction factor:

(The tests may be carried out in air -conditioned tests rooms where the atmospheric conditions may be
controlled)

The power correction factor α for Positive Ignition Engines (Naturally aspirated or supercharged) obtained
by applying the formula:

The correction Factor (α) is obtained by applying the formula:

α = (99 /Ps) 1.2 x (T/298) 0.6

Where,
Ps= the dry atmospheric pressure in kPa, that is the total barometric pressure minus water vapour
pressure
T= the absolute temperature in Kelvin (K) at the engine air inlet

The formula applies to carburetted engines and to other engines where the management system is
designed to maintain relatively constant fuel / air ratio as ambient conditions change.
(The references for Power correction factor are taken from IS-14599)

10.0 Declared rated corrected Power

The gross declared corrected power of the engine shall be measured at rated speed/frequency
of the genset. The measured power and speed may differ from the power and speed declared
by the manufacturer as specified below.
a) For Type Approval:
 ± 5% at the rated power point

b) For Conformity of Production:

 ± 6% of the type approved figure

Declared rated speed/ frequency at rated power point shall vary within ± 2 %

11.0 Test Procedure

 Preparations and Pre-Checks

a) Check and confirm that the equipment and test setup confirm to the specifications
b) Carry out the pre-test calibration and other checks as specified
c) Install thermocouples or other suitable temperature measuring devices to monitor the
temperatures, which constitute criteria of thermal stability as specified by the manufacturer.
d) Subject the Genset to running in, as per the manufacturer’s recommendation, to stabilize its
emission characteristics. During and after running-in normal maintenance, as specified by the
manufacturer, shall be carried out.
e) Run the Genset at mode 1 of test cycle as specified and note the corresponding maximum output
and fuel consumption. Repeat the check after installation of exhaust sampling set up. If the drop
in maximum output or increase in fuel consumption rate, due to installation of exhaust sampling
system is greater than 5%, modify the exhaust sampling arrangement keeping in mind the
essential requirements specified.

 Emission test
a) Run the genset and adjust the load, engine speed and throttle as per mode 1 of test cycle
specified in Annexure 4. Run the genset for a sufficient period of time to achieve thermal stability

338
 (Engine temperature to remain within a band of 10 deg C for 10 minutes). Genset shall be warm
up/run as per manufacturer’s recommendation to achieve thermal stability,
b) After achieving thermal stability, initiate the measurement of fuel consumption rate, air flow rate
(optional) and emissions:
 A minimum of 3 readings of fuel consumption rate shall be taken and the duration of each
measurement must be minimum 30 seconds. Average of the 3 readings shall be reported.
 Emission values of each specie shall be monitored / recorded for a continuous period of 2
minutes. Average value of the period shall be reported.
 Record the appropriate load data
c) Repeat a to b for modes 2 & 3 respectively
d) The following guidelines must be strictly observed during the testing:
 Modes shall be performed in the numerical order specified in the test cycle (Annexure 4)
 In case of doubt in any mode, may be repeated before switching over to the next mode.
 The load and the engine speed must be maintained as per the test cycle during the period
of measurement of emissions, fuel consumption and load. If this requirement is not met, the
mode is void and must be completely repeated.
 If a delay of more than one hour occurs between the end of one mode and the beginning of
another mode, the test is void and must be completely repeated.
 If at any time, during a mode the test equipment malfunctions or the specifications cannot
be met, the test is void and must be aborted. Corrective action should be taken and the test
restarted.

12.0 Determination of cycle weighted average specific emissions - g/kWh

a) Calculation of emission mass flow rate g/hr
Mass emission rate g/hr shall be calculated as per procedure given in ISO-8178-1 & 4. Caron
balance method may be used in case air-flow meter not used considering the availability, simplicity
and difficulties for accurate air flow measurement for such small capacity engines. Appropriate dry-
wet correction factor & humidity correction factor shall be applied as per formula given in ISO ISO-
8178-1 & 4.

b) Calculation of engine power generated during each mode

𝑉×𝐴
𝑃𝑖 = × η
1000
Where,
𝑃𝑖 – Power in kW
V -Genset output voltage in volts
A- Load Current in Amps
η - Alternator efficiency, as declared by the supplier

339
 c) Cycle weighted average specific emissions- g/kWh

13.0 Remark

All other specifications shall also be subject to review as and when necessary based on the experience
gained in implementation of emission testing as prescribed in this document.

340
 ANNEXURE – 5

Additional requirement for emission control strategy

Portable genset which rely on the use any external devices, use of regent, or exhaust after treatment
devise to reduce emissions, shall ensure the correct operation of emission control measures. In this
regard as of now no such emission strategy data is available for the positive ignition portable genset
engine category (below 19 kW & upto 800cc engine displacement). However, in future when ample
data is available on emission control strategy, the emission control measures requirement will be laid
down accordingly.

341
 ANNEXURE – 6

Technical characteristics of fuels prescribed for approval tests and to

verify conformity of production tests

The commercially available fuel as prescribed by Govt. of India in CMVR document, Gasoline or NG or
Bio-CNG and LPG as applicable shall be used for testing. As specified in this document no other fuel,
other than stipulated by CPCB, shall be used to start and run the genset without consent from CPCB.
As per the choice of manufacturer, fuel spec reference or commercial may be used.

342
 Following are the fuel specification form CMVR BSVI document
1) Gasoline fuel specification

343
344
2) Alternate Fuel specification: Natural Gas/Bio-CNG, LPG
2.1 Liquefied Petroleum Gas

LPG
Test
Parameter Unit Fuel A Fuel B
method
Composition: EN 27941
per cent
C3-content 30 ± 2 85 ± 2
v/v
per cent
C4-content Balance1 Balance1
v/v
per cent
< C3 , > C4 Maximum 2 Maximum 2
v/v
per cent Maximum Maximum
Olefins
v/v 12 15
Maximum Maximum
Evaporation residue mg/kg EN 15470
50 50
Water at 0 °C Free Free EN 15469
EN 24260,
ASTM D
Total sulphur content Maximum Maximum
mg/kg 3246,
including odorant 10 10
ASTM
6667
EN ISO
Hydrogen sulphide None None
8819
Copper strip
corrosion Rating Class 1 Class 1 ISO 62512
(1h at 40 °C)
Characterist Characterist
Odour
ic ic
Motor octane Minimum Minimum EN 589
number3 89.0 89.0 Annex B
Notes:
1
Balance shall be read as follows: balance = 100 - C3 - <C3 - >C4.
2
This method may not accurately determine the presence of corrosive materials if
the sample contains corrosion inhibitors or other chemicals which diminish the
corrosivity of the sample to the copper strip. Therefore, the addition of such
compounds for the sole purpose of biasing the test method is prohibited.
3
At the request of the engine manufacturer, a higher MON could be used to
perform the type approval tests.

345
2.2. Type: Natural Gas/ Bio-methane
2.2.1. Specification for reference fuels supplied with fixed properties (eg from a sealed
container)
As an alternative to the reference fuels set out in this paragraph, the equivalent fuels
in paragraph 2.1.2. of this Annex may be used

Natural Gas/ Bio-methane

Limits
Test
Characteristics Units Basis minimu
maximum method
m
Reference fuel GR
Composition:
Methane 87 84 89
Ethane 13 11 15
per cent
Balance1 — — 1 ISO 6974
mole
Sulphur content mg/m3 2 — 10 ISO 6326-5
Notes:
1
Inerts + C2+
2
Value to be determined at standard conditions 293.2 K (20 °C) and 101.3
kPa.
Reference fuel G23
Composition:
Methane 92.5 91.5 93.5
per cent
Balance1 — — 1 ISO 6974
mole
per cent
N2 7.5 6.5 8.5
mole
Sulphur content mg/m3 2 — — 10 ISO 6326-5
Notes:
1
Inerts (different from N2) + C2+ C2+
2
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G25
Composition:
per cent
Methane 86 84 88
mole
per cent
Balance1 — — 1 ISO 6974
mole
per cent
N2 14 12 16
mole
Sulphur content mg/m3 2 — — 10 ISO 6326-5
Notes:
1
Inerts (different from N2) + C2+ C2+
2
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
Reference fuel G20

346
 Composition:
per cent
Methane 100 99 100 ISO 6974
mole
per cent
Balance (1) — — 1 ISO 6974
mole
per cent
N2 ISO 6974
mole
Sulphur content mg/m3 (2) — — 10 ISO 6326-5
3 (3)
Wobbe Index (net) MJ/m 48.2 47.2 49.2
(1)
Inerts (different from N2) + C2 + C2+.
(2)
Value to be determined at 293.2 K (20 °C) and 101.3 kPa.
(3)
Value to be determined at 273.2 K (0 °C) and 101.3 kPa.
Note –
In absence of availablity of reference fuel for testing, commercial available
fuel as notified under CMVR shall be used for testing
2.2.2. Specification for reference fuel supplied from a pipeline with admixture of other gases
with gas properties determined by on-site measurement
As an alternative to the reference fuels in this paragraph the equivalent reference fuels
in paragraph 2.2.1. of this Annex may be used.
2.2.2.1. The basis of each pipeline reference fuel (GR, G20, …) shall be gas drawn from a
utility gas distribution network, blended, where necessary to meet the corresponding
lambda-shift (Sλ) specification in Table A.5-1, with an admixture of one or more of the
following commercially (the use of calibration gas for this purpose shall not be
required) available gases:
(a) Carbon dioxide;
(b) Ethane;
(c) Methane;
(d) Nitrogen;
(e) Propane.
2.2.2.2. The value of Sλ of the resulting blend of pipeline gas and admixture gas shall be within
the range specified in Table A.5-1 for the specified reference fuel.
Table A.5-1
Required range of Sλ for each reference fuel
Reference fuel Minimum Sλ Maximum Sλ
2
GR 0.87 0.95
G20 0.97 1.03
G23 1.05 1.10
G25 1.12 1.20

1
The engine shall not be required to be tested on a gas blend with a Methane
Number (MN) less than 70. In the case that the required range of Sλ for GR
would result in an MN less than 70 the value of Sλ for GR may be adjusted as
necessary until a value of MN no less than 70 is attained.

2.2.2.3. The engine test report for each test run shall include the following:
(a) The admixture gas(es) chosen from the list in paragraph 2.2.2.1. of this Annex;
(b) The value of Sλ for the resulting fuel blend;
(c) The Methane Number (MN) of the resulting fuel blend.

347
 ANNEXURE – 7

Compliance to Safety code of practice for alternate fuel generator sets

All Genset run on dedicated Natural Gas (NG) or Liquid Petroleum Gas (LPG), Gasoline and Natural Gas
(NG) or Gasoline and Liquid Petroleum Gas (LPG), shall meet Safety requirements prescribed in the
SAFETY CODE PRACTICE published by CPCB (Refer PART A4 of this regulation)

348
 ANNEXURE – 8

Additional requirement for variable speed portable generator sets

As of now, no such related data is available for variable speed portable generator sets, hence additional
requirement for variable speed portable generator will be formulated in future when ample data is
available.

****END****

349
Part - A4: Safety code of practice

DD/MM/YYYY

350
 Part – A4

Safety code of
practice

351
1. SCOPE

This A4 document lays down safety code of practice requirements for compliance to the rules vide notification
no. GSR 804(E.) dated 3-Nov-2022 on emission limits for new internal combustion engine up to 800 kW gross
power used for power generating set (Genset) application, issued by Ministry of Environment, Forests &
Climate change, Government of India.
This document covers general safety, installation and Component testing requirements and methods of test
for checking the functionality of NG/LPG Gensets as per various categories as mentioned below,

a) Dedicated Genset means a Genset powered by a mono-fuel SI engine started and operating
with only one fuel at a time. i.e. NG/LPG*
b) A bi-fuel Genset means a Genset powered by an SI engine started and operating either on any
one type of fuel at a time i.e. Petrol or NG/LPG*
c) Dual fuel engine operation means a two-fuel system having diesel as a primary combustion fuel
and NG/LPG as supplementary fuel, both in a certain proportion, throughout the engine
operating zone. Such dual fuel Genset engine may operate on diesel stand-alone mode in
absence of supplementary gaseous fuel i.e. NG/LPG*

*Alternate fuels - Natural Gas/Bio-methane, LPG (Fuel Specification of these fuels shall be as notified under
CMVR as amended from time to time)
Genset to be certified as per safety code of practice as defined in this document at the time of applying for
Type Approval of NVH certification. NVH TA certificate shall be issued only after successful completion of
safety code of practice certification of the Genset.

352
2. REFERENCES

The following standards contain provisions, which, through reference in this text, constitute provisions of this
document. At the time of publication, the editions indicated were valid. All standards are subject to revision,
and parties to agreements based on this standard are encouraged to investigate the possibility of applying
the most recent editions of the standards indicated below:

Standard Title
Hexagon head bolts, screws and nuts of product grades A and B Part 1:
1364(Part 1): 2002
Hexagon head bolts (Size range M1.6 to M 64) (fourth revision)
Hexagon head bolts, screws and nuts of product grades A and B Part 3:
1364(Part 3): 2002
Hexagon nuts, style 1 (Size range M1.6 to M 64) (fourth revision)
Specification for portable fire extinguishers, dry powder (cartridge type) (fourth
IS 2171:1999
revision)
Valve fittings for compressed gas cylinders excluding liquefied petroleum gas
IS 3224:2002
(LPG) Cylinders – Specification (third revision)
IS 2379:1990 Pipelines – Identification – Colour Code
IS 6044:2000 Code of practice for liquefied petroleum gas storage installations
GSR 1109 (E) dtd.
Stationary and Mobile Pressure Vessels (Unfired) Rules (SMPV)
13.10.2015
Gas Cylinder Rules, 2016 Released by Petroleum & Explosives Safety Organization (PESO)
Fire Extinguisher, carbon di-oxide type (portable and trolley mounted)
IS 2878:2004
specification
IS 7285 (Part 1):2004 Refillable Seamless steel gas cylinders – Specification
Indian Explosives Act-
Indian Explosives Act- 1884
1884
Stationary and Mobile Pressure Vessels (Unfired) Rules (SMPV)
IS 5844: 2014 Hydrostatic stretch testing of compressed gas cylinders - Recommendations
IS 5903:1970 (2006) Recommendation Safety Devices of Gas Cylinders
Road vehicles - Compressed natural gas (CNG) fuel system components -
IS 15720: 2008
Compartments/sub-compartments
Road vehicles - Compressed natural gas (CNG) fuel system components -
IS 15715:2008
Conduits
Road vehicles - Compressed natural gas (CNG) fuel system components -
IS 15716:2006 CNG high Pressure fuel line (RIGID) with end connections having pressure
exceeding 2.15 MPa
IS 3224:2002 Valve Fittings for Compressed Gas Cylinders

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3. DEFINITIONS

1. “Applicable emission limit”: Means an emission limit to which an engine is subject to for
approval
2. “Approval of an engine (engine family)”: Means the approval of an engine type with regards
to the level of the emission of gaseous, particulate and smoke pollutants;
3. “Approval of an engine”: Means the approval of an engine type or family with regard to the
level of emission of gaseous and particulate pollutants by the engine;
4. “Authorized Person”: A person, normally a well-acquainted workshop person, authorized by
the Genset manufacturer for specially trained for installation, maintenance and periodic
inspection of bi-fuel / dedicated /Dual fuel Gensets
5. “Bi-fuel Genset”: Means a Genset powered by an SI engine started and operating either on
any one type of fuel at a time i.e. Petrol or NG/LPG
6. “Compressed natural gas (CNG / BIO CNG)”: Means a compressed gaseous fuel composed
predominantly of Methane (CH4) shall be used as specified by the Government of India from
time to time.
7. “Declared power (kWm)”: Means rated gross mechanical power declared by manufacturer for
type approval at declared rated speed.
8. “Dedicated Dual fuel engine”: Dedicated Dual fuel engine operation shall mean a two – fuel
system having diesel as a primary combustion fuel and CNG or Bio CNG or LPG as
supplementary fuel and such dedicated dual fuel engine shall not operate on diesel stand-alone
mode in absence of gaseous fuel or operation of the engine in diesel mode only shall be
restricted by reduced power output to 40 percent to cater limp home mode and in such
dedicated dual fuel engine, mass emission test will be carried out in dual fuel mode only.”
9. “Dedicated NG or LPG (Alternate Fueled) Genset engine”: Shall mean a mono-fuel engine
starting and operating with only one fuel, i.e., NG or LPG
10. “Dual fuel engine”: Shall mean a two – fuel system having diesel as a primary combustion
fuel and CNG or Bio CNG or LPG as supplementary fuel. Such dual fuel engine may operate
on diesel stand-alone mode in absence of gaseous fuel.
11. “Electronic control unit (ECU)”: Means an engine’s electronic device that uses data from
engine sensors to control engine parameters as primary function. ECU may contain more
functionality than stated above of interest;

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12. “For Domestic products”: Date of Manufacture means the date on which the engine is
invoiced;
13. “For Imported products”: Date of Import means the date of payment of custom duties
applicable to the engine or Genset;
14. “GENSET manufacturer”: Every manufacturer, importer or assembler (hereinafter referred to
as the ‘manufacturer’) of the dedicated NG or LPG engine (hereinafter referred to as ‘engine’)
for genset application manufactured or imported into India or dedicated NG or LPG genset
(hereinafter referred to as ‘product’), assembled or imported into India.
15. “Liquefied Natural Gas (LNG)”: Means a Natural gas that has been cooled to -259 degrees
Fahrenheit (-161 degrees Celsius) and at which point it is condensed into a liquid which is
colorless, odorless, non-corrosive and non-toxic. Characterized as a cryogenic liquid. Fuel
quality for GENSET use shall meet the requirements of BIS specification as notified from time
to time by MoPNG, Govt. of India.
16. “Liquefied Petroleum Gas (LPG)”: Hereinafter referred as LPG: means a mixture of certain
light hydrocarbons derived from petroleum which are gaseous at normal ambient temperature
and atmospheric pressure but may be condensed to the liquid state at normal ambient
temperature by the application of moderate pressure and meet specification as notified by the
Government of India from time to time.
17. “Manufacturer”: Means engine or Genset manufacturer, importer or, assembler (as noted in
notification);
18. “Placing on the market”: Means the action of making available a product covered by this
Regulation on the market of a country applying this Regulation, for payment or free of charge,
with a view to distribution and/or use in the country
19. “Power generating set or Genset”: Means any equipment which is used for electric power
generation in absence or failure of grid power utilizing engine system defined in this document
as prime mover;
20. “Type approval”: Means the approval of an engine type with regard to its emissions measured
in accordance with the procedures specified in this regulation.

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4. ABBREVIATIONS

BIS Bureau of Indian Standards

CC Cubic Centimetre
CI Compression-ignition (Engine)
COP Conformity of Production
COP-Year Period starting 1st July of year till 30th June of subsequent year
CPCB Central Pollution Control Board
ECM Electronic control module
EGR Exhaust gas recirculation
GOEM Genset Original Equipment Manufacturer
ISO International Organization for Standardization
LPG Liquefied Petroleum Gas
PI Positive Ignition (Engine)

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5. SAFETY REQUIREMENTS

5.1 General Design Requirements

5.1.1 The NG/LPG fuel system components shall comply with this standard. The Equipment and
systems, approved by the relevant Test Agency notified by MoEF/CPCB, shall be used.
5.1.2 The high-pressure system shall be designed on the basis of the service pressures.
5.1.3 For bi-fuel Gensets, provision shall be made to avoid accelerated deterioration of the non -
NG/LPG fuel system as a result of sustained operation on NG/LPG. Such measures shall be
as recommended by the original Genset manufacturer (for example, fuel hoses etc.).
5.1.4 All fuel system, Genset and its engine components shall fulfil the following conditions:
They shall withstand the environmental temperatures and other environmental conditions
safely during their operational life.

a) They shall be located with full guard for anticipated damage while the Genset is being
used safely. Such damage may be caused by the Genset itself, by extraneous factors
such as heat, Genset engine chemical splash (Fuel, oil, cooling liquid, etc.) or by rust.
b) They shall be located so that they will not suffer corrosion damage by accumulation of
water or any type of chemicals.
c) The blow by of Gaseous fueled engine shall be properly vented out of Canopy of the
Genset assembly.
d) All the fuel lines used for Genset application shall have color coding as per IS 2379
e) Confirmatory of Production (CoP) testing and its periodicity for NG/CNG/LPG regulators
or any other kit components for Genset application shall be as per CMVR applicable for
Genset run on NG or LPG, from time to time as per policy of Government of India.

5.1.5 Gas cylinder valve(s) shall be approved by PESO & it shall be located with suitable protection
in an accessible and safe place.
5.1.6 Cylinder valves
5.1.6.1 The NG fuel system shall include:

a) An automatic shut off valve.

b) A manual or manual override valve located on each gas cylinder or PNG line.

5.1.6.2 LPG valve(s)

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 LPG valve assembly / cylinder valve and its manifolding system used for Genset application
shall conform to requirements of IS:6044-Part 1(amended from time to time). Cylinder Valve
shall be approved / endorsed by Petroleum Explosive Safety Organization (PESO) Govt of
India.
5.1.7 The NG fuel system may include a device (excess flow valve) inside the gas cylinder or a
functionally equivalent system to control gas leakage in the event of a rupture in the fuel supply
system.
5.1.8 The automatic shut off valve shall be in closed position when engine is not running and only
be open when:

a) NG/LPG operation has been selected, either manually or automatically, and

b) The engine is cranking or running.

5.2 Cylinder for CNG/LPG or PNG

5.2.1 Design approval.

5.2.1.1 CNG Cylinder(s) used in Cascade form for Genset application shall be approved / endorsed
by the Petroleum Explosives Safety Organization (PESO), Govt of India as per Gas Cylinder
Rules, 2016 (as amended from time to time).
5.2.1.2 LPG Cylinders (Industrial/Commercial) used for Genset application shall be approved /
endorsed by the PESO. Single LPG cylinder shall not be used for Genset application. Usage
of Domestic LPG cylinder(s) for Genset application is strictly prohibited.
5.2.1.3 PNG line including its joints and connection for Genset application shall be approved /
endorsed by the City Gas Distribution Company (CGD) or Gas Dispensing Agency, as
approved by Govt of India from time to time.
5.2.2 Periodic retesting of CNG/LPG cylinder (s) shall be carried out as per Gas Cylinder Rules
2016 as amended from time to time.

5.3 Fittings on CNG cylinders & its Cascades and filling connection

5.3.1 CNG Cylinder Valve - Each cylinder shall have a manual cylinder shut off valve mounted
directly on it capable of shutting off all gas flow from that cylinder. Cylinders and shut-off valve
assemblies shall be approved / endorsed by PESO, (including for storage/ refilling permission)
as per IS 3224 and Gas Cylinder Rules, 2016 (as amended from time to time).

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5.3.2 CNG Filling Connection - The filling connection shall be of the NZS/NGV-1 or any other type
as specified by the Government of India from time to time. The filling connection shall be
provided on structure of Cascade of CNG cylinder(s).
The basic dimensions for NZS for CNG type are as given in AIS 028 and recommended sizes
of NGV – 1 type of filling connections are SAE 9/16” and 7/8”. However, the Genset
manufacturer / kit installer may seek the guidance from The Gas Authority of India Ltd. /
Ministry of Petroleum and Natural Gas about the use of specific type of NGV – 1 nozzle.
5.3.3 The NZS type filling connection shall be provided with a captive dust plug and NGV-1 type
filling connection shall be provided with dust protection cap.
5.3.4 Position of filling connection - The filling connection shall be located in suitably protected and
ventilated location of Cascade or CNG/LPG Cylinder mounting structure, and shall comply
with the following:

a) The filling connection is made and filling is supervised from outside the Cylinder
mounting Structure.
b) The filling connection is protected by being located by providing suitable mean.
c) The filling connection shall be mounted in such a manner as to resist, without permanent
deformation of the mounting attachment, a proof load of 50 kgf applied in any direction.
The proof load shall be applied by full engagement of the filling connection and shall be
representative of attempted movement of the Cylinder/ its Structure while refueling.
d) The filling operation can be carried out without requiring the operator to lie or crawl or be
otherwise subjected to inconvenience, discomfort or hazard.

5.3.5 Non-igniting material: Filling connections material shall be of non-igniting material.

5.3.6 Non-Return Valve: There shall be a non-return valve fitted on the refuelling line to prevent the
return flow of gas from the cylinder to the filling connection. The non-return valve shall be
located as close to the filling connection as it is practicable.
5.3.7 Excess Flow Valve: A device may be fitted in the fuel line preferably at the inlet or outlet of
the NG/LPG cylinder valve which prevents the total contents of the cylinder from discharging
to atmosphere in the event of rupture to any part of the fuel line or components.

5.4 Location, Ventilation and Mounting of NG/LPG Cylinders

5.4.1 Cylinders, Fittings and Pipe work

5.4.1.1 Cylinders shall be located so that the safety characteristics shall not be adversely affected

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5.4.1.2 Shielding to NG/LPG cylinders or NG/LPG joints & connection:
In case of NG/LPG cylinder or NG / LPG line shall be routed such that, it shall not get damage
from loose metal or other objects being thrown up from the outside, effective shielding
against these shall be provided.
5.4.1.3 The cylinder shall be situated and vented so that any gas escaping due to leakage from the
cylinder valve shall not enter the Canopy space of Genset. Leak sensors shall be provided
to avoid any fire hazard in case of leakage.
5.4.1.4 The clearance between the cylinder(s) and the exhaust shall not be less than 75 mm. or
Heat shielding is must.
5.4.1.5 Cylinders and/or NG /LPG pipeline shall not be fitted in any inaccessible position.

5.4.2 Effective protection to Cylinder/NG/LPG line:

a) The whole body of the cylinder(s) together with its attached components Shall not be
fitted inside the Canopy of Genset
b) The valves and pipe connections associated with or attached to the cylinder shall be well
ventilated to the atmosphere. Provision shall be made for ready access to the cylinder
valve in all installation arrangements.

5.5 Cylinder(s) installation

5.5.1 LPG Cylinders Mounting Safety:

LPG Cylinders, valve assembly and manifolding system used for Genset application shall conform to
requirements of IS:6044 (amended from time to time) and following requirements shall be met:

a) Those responsible for the installation of cylinders, equipment and piping should understand the
characteristics of LPG and be trained in good practice of handling, installing and maintaining
installations.
b) Cylinders and cylinder valves shall comply with the standard approved by the Chief Controller
of Explosives (CCoE). All other equipment such as pressure regulators and other installation
material shall comply with distributing company's stipulations and meet IS specifications,
wherever available. Wherever any thread joint is provided, a suitable jointing compound be used
on male thread.
c) Gas piping shall be of the color stipulated by the explosive authorities to distinguish it from other
piping and the piping shall be painted silver grey with red band of 150 mm width.
d) Fire extinguishers of dry powder type (see IS 2171) or carbon dioxide (see IS 2878) type shall
be provided in places where LPG cylinder installations are situated and shall be located near
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 such installations. Two buckets filled with sand and two with water shall also be installed nearby.
The number, type and size of the fire extinguishers for LPG shall be as per IS 6044 (Part 1)
amended from time to time
e) If total weight of gas exceeds 100 kg, then license is required to be obtained from PESO as per
Gas Cylinder Rule 2016 (amended from time to time)
f) Before any system of gas piping is finally put into service, it shall be carefully tested to ensure
that it is gas-tight.
g) Naked flames shall never be used for checking gas-tightness of the installation.

5.5.2 CNG Cylinders & its Cascade Safety:

5.5.2.1 Cylinders conforming to IS :7285 duly approved by PESO shall be used in CNG Cascade
form. The Cascade shall be equipped with safety devices such as shut off valve, excess flow
valve (if required), Check valve (if required), Pressure gauge etc.
5.5.2.2 The design, construction, manufacture, testing and other general requirements of the
Storage Cascades should be strictly in accordance with the Applicable Standards and Codes
and should comply fully with relevant Indian / International standards, Gas Cylinder Rules
2016, Indian Explosives Act- 1884, Stationary and Mobile Pressure Vessels (Unfired) Rules
(SMPV), CNG Cylinder Design Code IS:7285 , CNG Cylinder Valves as per IS:3224,
Hydrostatic Stretch Test as per IS: 5844, Safety Devices of Gas Cylinders as per IS : 5903,
etc. and their amendments time to time.
5.5.2.3 CNG cascade and its storage area shall be equipped with the following safety equipment /
firefighting equipment:

a) The burst disc shall rupture on excess pressure as well as excess temperature either
individually or in combination. Discharge from the burst discs shall be manifolded to a
common header for safe venting.
b) The sizing of connecting tubing between each outlet and its associated cylinder shall be
such that where they join the total incoming flow areas shall not be less than the total
outgoing area. The loops in the tube work shall be provided for absorbing contraction,
expansion and vibration. Piping/ tubing shall be suitably clamped to the frame structure.
c) Cylinders installed horizontally should be separated from one another in each storage
unit by a distance of not less than 30 mm. The material used to separate the cylinders
should be sufficiently strong enough and should not absorb moisture. Special
precautions should be taken to avoid corrosion at the point of contact.
d) CNG cascade structure shall be made of corrosion resistant material and to be protected
by painting or other equivalent means necessary to prevent corrosion. All structural items
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 used in the frame shall be weather proof. Frame shall be suitably covered with canopy
from top to avoid the ingress of rain water.
e) All manifold piping to be tested after assembly to a pressure equal to that of the pressure
relief device setting and shall be leak free.
f) Every CNG storage unit including each manifold group or bulk storage tank should be
provided with a suitable pressure gauge for each bank. The pressure gauge should be
directly connected to the tank or storage system. The dial gauge should be graduated to
read approximately double the operating pressure. Pressure gauge should be equipped
with 3-way relief/ isolation valve.
g) All cylinder tubing, manual isolation valves and pressure relief valves should be protected
from hitting by any moving object and should not protrude outside the metal frame or
brackets.
h) Flame proof light shall be used inside Cascade area.
i) Leak Detection Sensor(s) shall be used.
j) Fire Extinguishers and sand buckets shall be used as per Gas Cylinder Rules 2016.
k) Remote Operated valve / Solenoid valve shall be used.
l) Quick release Coupling (if required) and Vent to release pressure before disconnection
of quick release coupling hose shall be used.
m) Water Sprinkling arrangement shall be used, if required, above cascade storage area.
n) Safety Sign board, such as - No smoking, No mobile, Entry Restricted for Authorized
Person Only, etc. - shall be displayed on all four sides of the storage area.
o) If total number of CNG cylinders exceed 25 Nos and/or the total weight of CNG exceeds
200 kg., then license is required to be obtained from PESO as per Gas Cylinder Rules
2016 (amended time to time).

5.5.2.4 CNG Cylinders shall be securely attached to structure of Cascade to prevent slipping;
rotating and jarring loose, in accordance with the following requirements:

a) The method of attachment shall not cause undue stresses or wear in the cylinder shell;
b) The mounting method shall not significantly weaken the mounting structure, and
reinforcement shall be added where necessary to ensure compliance with (c) below. An
air gap of not less than 5 mm shall be provided between the cylinders and its mounting
structure and in between cylinders.
c) The force necessary to separate the cylinder from the e shall not be less than 20 times
the mass of the full cylinder in any direction.
d) The strength of the anchorages may be established by static test (forces directed through
the center of mass of the cylinder).

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e) In the absence of testing or where calculations are impracticable, the following design
requirements shall apply:
i. There shall be at least 4 points of attachment to the mounting structure. The spacing
between these shall be sufficient to ensure the stability of the cylinder. These bands
shall not mask the identification markings of the cylinder.
ii. Where a cylinder is anchored to steel sheet metal the sheet metal shall be reinforced
by a plate of not less than 3600 mm2 and a thickness of not less than 2.5 mm or
appropriate thickness supported by the calculation or test report. It is preferred that a
round washer be used but where a square plate is fitted the corners shall be rounded.
Any such reinforcement plate/washer shall be contoured to the shape of the sheet
metal or mounting structure.
iii. Where anchorage bolts pass through a hollow section, provision shall be made to
prevent collapse of that section under load.
iv. Anchorage bolts or studs shall have a diameter not less than that shown in Table 1
and shall conform to strength grade 8.8 of IS 1364 (Part 1) and nuts also to IS: 1364
(Part 3).
v. Where clamping bands are used, at least two steel bands per cylinder shall be
provided, the dimensions, of which shall not be less than those in Table 1.
vi. Screwed fasteners or clamping devices shall either be inherently resistant to
loosening or be locked or pinned after tightening.

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 Table 1: Band and Bolt or Stud Dimensions

Bolt or stud diameter for strap or

Cylinder size Band dimensions –
flange mountings minimum
(water capacity in l) Minimum nominal size
nominal size
Over, up to and including (l) (mm)
(mm)
0 -30 30 x 2 10
30-100 30x3 10
100 150 50 x 6 12
Above 150 Specific design required --

NOTE: To prevent possibility of external corrosion where clamping bands are used, check that the material
of the padding / lining provided for inner side of cylinder mounting band (s) is made up of EPDM rubber
(hardness Shore A 60 min.) as approved by the test agency during type approval certification. Similar
adequate protection to the cylinder shall also be provided wherever the cylinder rests against other metal
objects such as the mounting frame.

5.5.3 Cylinder Manifolding

CNG Cascade cylinders to be manifolded together in such a way that all cylinders can be
simultaneously filled from any filling point. Each cylinder shall retain its required individual NG/LPG
cylinder valve/MFV respectively.
In case of LPG cylinders and its Manifolding, Non-Return Valves (NRVs) shall be used to avoid flow
of gas from one cylinder to another and installation shall meet requirements of IS:6044 (part 1) as
amended from time to time

5.5.4 Cylinder identification markings should be capable of being read when in the installed position.

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5.6 Shielding

Cylinders/ NG/LPG joints shall be installed to ensure that valves and connections on cylinders/NG/LPG
line shall be protected to minimize the possibility of damage due to accidental contact with stationary
objects or from loose objects thrown up from outside.

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5.7 Construction of compartments and sub-compartments

5.7.1 A cylinder compartment or sub-compartment shall be provided if cylinder is mounted in the

enclosed space & comply with the following requirements & shall meet component test
requirements as per IS 15720.

a) Construction shall be such that any gas which might leak from any fittings, component or
piping, cannot pass to any other enclosed compartment canopy space.
b) It shall be possible to operate the cylinder service shut-off valve in the installed position. The
valve may be arranged so that it can be operated from some internal area of the Genset
Canopy. Gas installation provided that the sealing of the compartment or sub-compartment
shell is maintained by one of the following means, as appropriate:
i. If a valve actuating device passes through the shell a gas-tight seal shall be provided.
ii. If the actuating handle is wholly within the shell, access shall be a gas-tight captive
hatch. The design shall not need tools to open the hatch.
c) A compartment or sub-compartment shall not contain ignition sources or electrical equipment
or wiring unless it is intrinsically safe.

5.7.2 Ventilation

One or more vents to the outside of the enclosed space shall be provided, the aggregate area of which
shall not be less than 550 mm2. The vent line shall be so located as to exhaust any gas, which may
accumulate in the compartment or sub- compartment to atmosphere and shall not exit less than 75
mm from an exhaust pipe or other heat source of Genset.

5.7.3 Ducting
5.7.3.1 All piping or hoses that pass through an enclosed space shall be within a conduit gas-tight,
vented unobstructed to outside atmosphere and protected from external damage and shall
meet component test requirements as per IS 15715 (for NG/CNG) /AIS 26(LPG) and comply
with the following requirements:

a) The ducting shall be as short as practicable.

b) The connections shall be mechanically clamped and shall not depend on adhesives or
sealing compounds to retain them in place. Protection in the form of a gasket shall be
provided to prevent damage to the ducting material by the clamping device.

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 c) The material of the conduit used for ducting shall be sufficiently strong to resist
mechanical damage, preserve venting integrity, protect the piping or hose within it, shall
not support combustion

5.7.3.2 Where the sub-compartment is removed to initiate repairs or at the periodic inspection
special attention shall be given to the inspection of the material to ensure that no degradation
of material has taken place. Any sub-compartment showing signs of degradation shall be
replaced.
5.7.3.3 The cylinder valve actuating device position shall be clearly identified and shall have
provided adequate material to allow closing of the valve without damage to the sub-
compartment sealing.
5.7.3.4 The pliable sub-compartment (for NG) shall be shielded or installed in a protected location
to prevent damage, from unsecured objects and abrasion. The material shall be sufficiently
strong to resist mechanical damage, preserve venting integrity, shall not support combustion.

5.8 NG/CNG/LPG Fuel Line

5.8.1 NG/CNG fuel line - pressure exceeding 100 kPa (high pressure fuel line)
5.8.1.1 Rigid piping and connections for use with pressures exceeding 2.15 MPa shall be made up
of cold Drawn Steel/ SS and conform to IS 15716. In case of PNG, the pipeline shall be
approved by CGD company.
5.8.1.2 CNG/PNG fuel line and connections for use with pressures exceeding 100 kPa but less than
2.15 MPa shall be tested as per IS 15722 or the pipeline shall be approved by CGD
company.
5.8.2 Flexible hose exceeding 2.15 MPa
5.8.2.1 NG Flexible hose shall meet the requirements of AIS 028. Each flexible hose assembly shall
be permanently and clearly marked with the manufacturer’s name and trademark, type, size
and design working pressure. It shall be identifiable as being suitable for CNG/PNG use
either by marking it with ‘CNG/PNG’ or with a specification mark.
5.8.3 LPG pipe line shall meet requirements as specified in IS:6044(part 1) as amended from time
to time.

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 a) Inspection: At the time of periodic inspection the hose shall be inspected for twists, kinks
and damage or abrasions to the cover which expose the wire. The hose shall be condemned
on detection of any one of these defects. At no time shall flexible hose be placed back into
service after removal from the Genset Engine.
b) Joints and connections:
i. The number of joints and connections shall be the minimum for the inclusion of all
components.
ii. Joints or connections in LPG fuel lines shall be in accessible positions for easy
inspection.
c) Flexibility
i. Low pressure hose shall be of sufficient length and flexible to accommodate engine
movement.
ii. High pressure fuel line shall be installed so as to accommodate any relative movement
between chassis/body and fuel system components or temperature variations in the fuel
line.

5.8.4 All runs or rigid fuel line piping between any two components shall be installed with a ‘pigtail’
or U bend to provide this essential flexibility.
5.8.5 Inspection
5.8.5.1 The hose shall be inspected for twists, kinks and damage or abrasions to the cover, which
expose the wire. The hose shall be condemned on detection of any one of these defects.
5.8.5.2 At no time shall flexible hose be placed back into service after removal for service.
5.8.5.3 Joints and connections for CNG.
5.8.5.4 Every joint or connective filling in rigid high-pressure fuel line shall be as per IS 15716.
5.8.5.5 The number of joints and connections shall be the minimum for the inclusion of all
components.
5.8.5.6 Joints or connections in a CNG/PNG fuel line shall be in accessible positions for easy
inspection.
5.8.5.7 Connection means shall provide positive retention of the fuel line in the fitting (e.g. by double
inverted flaring of the tube end or by ferrule type compression fitting).
5.8.6 Securing and location.
CNG/PNG /LPG pressure piping and hoses shall comply with the following:

a) CNG/PNG/LPG fuel line inside the part of any Canopy shall have leak free joints.
b) All CNG/PNG/LPG fuel lines shall be positioned for protection from the possibility of damage
by impact, accident or loose objects.

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 c) CNG/PNG/LPG fuel lines shall not be located inside box sections or in other in accessible
locations nor shall they be installed in any location, which is not adequately protected from
sources of heat, abrasion, or from impact.
d) Fuel lines shall follow the shortest practical route considering the requirements
e) Rigid fuel lines shall be effectively secured by clips spaced not more than 600 mm apart. In
order to prevent the possibility of fretting corrosion or erosion of the fuel line cushioning must
be provided to protect the fuel line from both the mounting structure and the clips
themselves. Suitable grommets must be provided where the fuel line passes through any
panel of Canopy.
f) PNG/LPG pipe line & Manifolds used in multi-cylinder shall be installed in a protected
location. Manifold branch pipelines shall be sufficiently flexible to prevent damage to the
lines, valves and fittings due to vibration, expansion or contraction.
g) In no case shall the clearance between the exhaust system and the fuel line be less than 75
mm.
h) Fuel lines shall not be installed where any part will be permanently hidden from sight or
cannot be inspected or easily replaced.

5.8.7 All CNG/PNG fuel lines for use for service pressure not exceeding 100 kPa (low pressure
hose) shall be of flexible material and shall meet requirements of IS 15722. Joints and
connections for low pressure fuel lines shall be suitable for use with CNG/PNG and shall meet
requirements of IS 15722.
5.8.8 Flexibility
5.8.8.1 Low pressure hose shall be of sufficient length to accommodate engine movement.
5.8.8.2 High pressure fuel line shall be installed so as to accommodate any relative movement
between engine and fuel system components or temperature variations in the fuel line.
5.8.8.3 All runs of rigid fuel line piping between any two components shall be installed with a ‘pigtail’
or U bend to provide this essential flexibility. The dimension for U bend shall be not less than
50 mm radius at the bend portion of U or 100 mm diameter for the pig tail coil and number
of coils shall not be more than two.

5.9 CNG/PNG/LPG Control Equipment

5.9.1 Definition

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 The CNG/PNG/LPG fuel control equipment includes all the equipment necessary to convert
PNG/CNG/LPG at high pressure at the cylinder/PNG line to CNG/PNG air mixer/fuel injector for supply
to the engine & shall meet requirements of corresponding component standards as applicable.
The Genset engine control equipment includes all the equipment used to convert a compression
ignition engine to run on a dedicated gaseous fuel or Dual fuel (diesel + Gas). This includes devices
such as fuel provision and control device, the ignition system (if one is used), the speed and/or load
governing device (if any), and any engine protection devices such as temperature and pressure
alarms, and knock detection systems.

5.9.2 Control Equipment

5.9.2.1 Filter

At the termination of every CNG/PNG/LPG service fuel line immediately prior to any regulator
component there shall be a properly designed filter capable of removing all particulate matter from the
fuel that could cause malfunction of such regulator components.

5.9.2.2 CNG/PNG/LPG shut-off valve

This valve shall shut-off fuel supply to the engine when activated by the fuel change over control on
bi-fuel operation and by the ignition switch on single fuel operation. Normally this is a regulator
component but, in any case, it shall be located downstream of the filter. This valve shall automatically
shut-off the fuel supply to the engine unless the following conditions are satisfied:

a) The ignition is on;

b) The engine is turning;

5.9.2.3 Service shut-off valve

A service shut-off valve shall be installed in the high-pressure line between the cylinder valve and any
other valve or component within the engine compartment and as close as practicable to the
Regulator/vaporizer (for LPG), however it is acceptable to install the valve at the refuelling point. It
shall be possible to readily operate the valve in the installed position at all times in particular during
the refuelling operation. A permanent label shall be provided ‘CNG/PNG/LPG service shut- off valve’
or similar wording to positively indicate its purpose and a positive indication of “Closed” and “Open”
positions of the valve shall be clearly marked.

5.9.2.4 Regulator (NG/CNG)/Vaporizer (LPG) system for Genset Engine

The regulator/vaporizer system shall not permit gas to pass after the engine has stopped turning,
irrespective of whether the ignition is on or off. The regulator shall be installed so that:

a) It is securely mounted as far as practical from the extremities of the Genset engine.
b) It is mounted securely and as close to the engine Gas Air Mixer or Injector position as
convenient.
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 c) It is easily accessible for routine maintenance, adjustment and inspection.
d) It is situated as far from the exhaust system as practical. Where this distance is less than
150 mm it shall be shielded from radiant heat and any impingement from exhaust gases
due to exhaust system failure.
e) It is reasonably protected from impact in a collision.
f) It allows sufficient free movement of all hoses.
g) The water circulating system (where required) is connected in accordance with the
manufacturer’s instructions, and no flow control valve in the system can shut-off original
equipment water flow.
h) Where possible, the regulator should be at lower level than top of the radiator, as
insufficient water may cause freezing.

5.9.2.5 The regulator/vaporizer assembly shall not be attached to the engine assembly unless
otherwise specified by the manufacturer and then shall be fitted only in accordance with the
manufacturer’s recommended instructions.
5.9.2.6 Gas air mixer /Injector
5.9.2.6.1 A backfire deflector to arrest back-fire shall be installed in the air intake immediately prior
to the mixer/injector. The back-fire deflector shall meet the requirements of Annexure 2 of
this standard.
5.9.2.6.2 In case of Genset engines more than 19kW & up to 800 kW, there shall be installed in the
air intake prior to the mixer a backfire deflector (original air filter acceptable). In turbo
charged applications where rigid piping is fitted from the turbo charger to the intake
manifold a pressure relief valve shall be fitted as close as practicable to the intake manifold.
Where a volume of gas/air mixer, due to turbo charging or inter/after coolers is contained
downstream of the mixer, special precautions will need to be applied to avoid damage to
components downstream of the mixer/injector due to backfire.
5.9.2.6.3 Genset manufacturer / kit manufacturer / kit supplier shall submit test report or certificate
complying with the above requirement. It is not necessary to carry out the test if declaration
is not submitted.
5.9.2.6.4 The mixer/injector shall be securely mounted and when remotely fitted shall be suitably
bracketed to support its own weight and applied working forces.
5.9.2.6.5 There shall be no filter element fitted downstream of the gas air mixer/injector.

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 5.9.2.7 Bi- fuel /Dedicated/Dual fuel system.

Bi- fuel type.

a) A bi-fuel system is defined as a system equipped to operate with either on CNG/PNG/LPG

or some other fuel e.g. petrol.
b) Dedicated fuel type. A dedicated system is defined as a system equipped to operate wholly
on CNG/PNG/LPG.
c) Dual fuel engine operation means a two-fuel system having diesel as a primary combustion
fuel and CNG/PNG/LPG as supplementary fuel, both in a certain proportion, throughout the
engine operating zone. Such dual fuel Genset engine may operate on diesel stand-alone
mode in absence of supplementary gaseous fuel i.e. NG/CNG/LPG

For bi-fuel type

5.9.2.8 A shut-off device shall be installed in the bi-fuel fuel system. This device shall shut-off the
optional fuel supply to the engine when this fuel is not required.
5.9.2.9 If the shut-off device is in the form of a solenoid operated shut-off valve it must be fitted
between the fuel pump and the carburettor. The valve shall be mounted securely so that its
weight is not transferred to any part of the carburettor or fuel lines.
5.9.2.10 Where the shut-off device is mounted remotely from the engine, flexible hose shall be
used of sufficient length to accommodate engine movement. In all cases the device shall be
mounted in a position reasonably protected from damage in a collision and shall be as far
as practicable from high tension electrical equipment.
5.9.2.11 Bypass relief device

A bypass relief device shall be installed in the fuel pump or between the fuel pump and the automatic
shut-off valve in the liquid fuel line to the carburettor on Genset engine equipped with bi- fuel systems
for the use of petrol and gaseous fuel. The relief device need not be installed on fuel pumps
containing a bypass relief device as original equipment.

5.9.2.12 Fuel selection control

A fuel selection control shall be provided which shall have at least three positions in case of bi fuel
and two positions in case of Dual fuel, clearly marked for the selection of each of the two fuels or two
mode of operation. The selection control shall be placed within easy reach of operator.

5.9.3 Installation

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 The CNG/PNG/LPG control equipment shall be:

a) Installed in positions that are accessible for routine inspection, maintenance adjustment.
b) Mounted securely and reasonably protected from damage in a collision.
c) Remote from the Genset engine exhaust system or protected therefrom by a metal shield.
d) No closer than is avoidable and practicable to any electrical equipment capable of sparking.

5.9.4 Electrical wiring used for CNG/LPG system.

5.9.4.1 All wiring shall be properly installed, taped, clipped or contained in a loom along its length.
5.9.4.2 Wiring cables shall comply with the requirements of IS 15719 or clause No 4.3 of AIS 028 or
clause No 12 of 026. The kit supplier / kit manufacturer or Genset manufacturer shall submit
test certificate / test report complying with requirements of IS 15719.
5.9.4.3 The electrical circuit shall be provided with a current limiting device conforming to IS 15723
or clause No 4.3 of AIS 028 or clause No 12 of 026. This equipment or fuse shall be dedicated
to the CNG/PNG/LPG fuel system.
5.9.5 Connectors and terminals.

Connectors and terminals shall be insulated to prevent accidental earthing during operations or routine
servicing.

5.9.6 Pressure indicator (NG)/ Level indicator (LPG)

5.9.6.1 A pressure/level indicator to indicate pressure in the CNG/PNG/LPG (in case of LPG ref
IS:6044 requirements) system shall be fitted in an easily visible position to service personnel
at the regulator or fill point preferably within the engine compartment.
5.9.6.2 A supplementary gauge or electronic gauge may be placed in the Genset Control panel
provided any gauge shall be gas isolated from the cylinder or piping to prevent gas leaking
into the compartment.

5.10 COMPLIANCE PLATE

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 In addition to Label as prescribed, a compliance shall be provided on LPG/CNG cylinder(s)
structure/Cascade, displaying the following information, shall be installed near the filling
connection and be clearly visible to the re-fueller:

NG/CNG CASCADE COMPLIANCE PLATE FOR

GENERATOR

 CNG cascade Cylinder Identification Number(s)

 Date of Installation
 Water Capacity (liter) of the individual cylinder of Cascade
 water capacity (liter) of the Total Installation
 Date of the Last test
 Genset /engine identification No.
 Next Due Date of Testing of each cylinder
The NG installation complies with the safety requirements of Code of
Practice issued by CPCB
 Installed by

5.11 LABELS

5.11.1 Identification labels

Genset using a CNG/PNG/LPG system shall be labelled as follows:

Labels conforming with the following specification shall be affixed in a vertical position on
Canopy & shall ensure visibility from the front sides.
Gensets, individually or as part of the product shall be clearly labelled on Canopy ‘Dedicated
NG/LPG Genset’ ‘bi-fuel NG/LPG Genset’ or ‘Duel fuel LPG/NG Genset’ as the case may be.

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5.11.2 The label shall always be in position, shall be in good condition, and the shape, colour and
lettering shall be easily visible.

LPG COMPLIANCE PLATE FOR GENRATOR

 Date of Installation
 Water Capacity (liter) of the individual cylinder
 water capacity (liter) of the Total Installation
 Genset /engine identification No.
The LPG installation complies with the safety requirements of Code of Practice
issued by CPCB and LPG Installation meets requirements of IS:6044 (Part 1)
 Installed by

a) All the engines, individually or as part of the product shall be clearly engraved on the cylinder
block for respective Genset, as the case may be.
b) The engine or the product shall be affixed with a conformance label meeting the following
requirements namely: -
i. The label shall be durable and legible.
ii. The labels shall be affixed on a part necessary for normal operation of the engine or the
product and not normally requiring replacement during the life of the engine or the
product.
c) The conformance label shall contain the following information, namely: -
i. Name and address of the manufacturer of engine or product, as the case may be;
ii. Statement that the engine or product conforms to the stipulation in the Environment
(Protection) Rules, 1986;
iii. Type Approval certificate number for emission standards and Noise Limits;
iv. Date of manufacture of engine and the product or, the date of import of the engine and
the product, as the case may be; and
v. Rated speed and corresponding gross power in kW for engine and ‘Noise Limit viz. 75
dB(A) at 1m’ for product.

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6. INSTRUCTIONS TO BE PROVIDED BY THE GENSET MANUFACTURER

a) Clear, concise printed instructions and diagrams, stated in terms clearly understandable and
adequate for proper assembly, installation, maintenance and safe operation, shall be made
available by the Genset manufacturer for CNG/PNG/LPG kit component and component
package.
b) Instructions for periodic maintenance of components, as required, shall be provided. Parts,
which require replacement, shall be identified.
c) Printed instructions shall state that the installation shall be in accordance with the prevailing
regulations of Govt. of India or, in the absence of which, in accordance with this standard.
d) This information shall be easily understood.
e) An instruction manual shall be provided including specific instructions regarding NG/LPG
operation and alerting the owner to the cylinder inspection and expiry date.

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7. INSPECTION, TESTING AND COMMISSIONING BY GENSET
MANUFACTURER OR AUTHORIZED PERSON APPOINTED BY GENSET
MANUFACTURER

7.1 Commissioning

Prior to initial use, an inspection of the CNG/PNG/LPG system and components shall be carried
out by, or under the supervision of trained person, who shall also carry out a complete
examination to ensure the system complies of all relevant sections of this standard and any
other statutory requirements as specified by the Central Government.

7.2 Initial inspection and installation certificate

The system shall be leak tested. The installation shall be inspected for compliance with this
Standard and all components shall be checked for operational performance. In the case of bi-
fuel/dual fuel installations, the ability for the Genset engine to operate on the optional fuel shall
also be tested.
When the system conforms to this standard, an installation certificate, as per Annex D of this
standard, signed by Genset Manufacturer/its authorized person shall be issued to the owner.

7.3 Periodic Inspection /preventive maintenance

The cylinder or NG/LPG manifold, piping and all components of the system shall be examined
for corrosion, deterioration and for any modification affecting compliance with this Standard, at
least once in a year or in case of malfunction or accident. The inspection shall include leak
testing
NOTE: Every NG/CNG /LPG Genset manufacturer shall incorporate periodic inspection
schedules in the operation and owner’s manuals.

7.4 Leak Test

7.4.1 Initial Test

At the time of commissioning, the complete pressure system shall be subjected to a pressure test of
20 ± 1 MPa by using CNG or pressure of NG/LPG or a gas inert to NG/LPG such as Nitrogen.
Procedure:

a) With vapor sealing removed from cylinder valve area, and cylinder valve closed slowly
pressurize the system.
WARNING. The system must not be subjected to a shock loading as insecure fittings could
blow out with dangerous results, and burst discs could rupture.

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 b) Leak test lines, fittings and components using a non-corrosive foaming agent and when leak
free.
c) Open valve, pressurize system and check for leaks at valve and all joints.
d) When the system is passed leak free seal venting area.

7.4.2 Where CNG/PNG/LPG is used for testing, the following precautions shall be observed:

a) Testing shall be carried out under adequately vented conditions.

b) Testing shall be carried out at least 5 m from any open flame or other source of ignition.

7.4.3 The operation of the equipment and controls shall also be tested with PNG/CNG/LPG under
normal working conditions to prove satisfactory performance of the entire system and a further
leak test shall be carried out using a non- corrosive foaming agent.
7.4.4 BCF fire extinguisher and dry powder fire extinguisher conforming to IS 2171 and each of 5
kg shall be kept ready within a safe distance. If ignition occurs the service valve should be
closed and the extinguisher(s) used to quell any fire, which may continue.

7.5 Repair of NG/LPG System

7.5.1 Repairing of NG/LPG System

a) There shall be no leaks in the fuel system

b) There shall not be any ignition source within 3 m
c) CNG/PNG/LPG fueled engines being repaired, unless the fuel is required for engine
operation, shall have the shut-off valve closed and the CNG/PNG/LPG fuel in the service
line exhausted by running the engine or depressurizing the line in a well-ventilated area
d) Such NG Gensets undergoing repairs involving welding or the application of heat, to any
part within 1 m of the cylinder/PNG connection, shielded from the source of heat.

7.5.2 Repair Operation

a) Repair operation involving heat shall be carried out with due regard to fire safety.
b) Damaged fuel lines shall not be repaired; in all cases they shall be replaced.
c) Welding, brazing and the application of heat shall not be carried out on any part of the
cylinder/PNG line subsequent to manufacture.

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7.6 Scrapping of Cylinder

7.6.1 A Cylinder of Genset, which is about to be scrapped, shall have its cylinder removed prior to
disposal.
7.6.2 Where the cylinder has been subjected to impact or fire damage the cylinder shall be
inspected and re-tested by the owner of the Genset as per Gas Cylinder Rules, 2016, as
amended from time to time.

NOTE: There will always be combustible gas in the cylinder until it has been cleared of all traces of
flammable vapour or gas.

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8. STATUTORY AUTHORITY APPROVAL
The type of component in question and its use determine the Statutory Authority Approval in respect
of CNG/PNG/LPG fuel system components for Genset application. The Statutory areas of
responsibility are:

Government Agency Statutory powers Scope of application

All CNG/LPG kit components

Ministry of Environment and Forest,
(excluding CNG/LPG
Government of India. (MoEF) Environment (P)
cylinder & its valve(s)) and
Central Pollution Control Board (CPCB) Act 1986
systems used for Genset
Test Agencies as notified by CPCB
application.
Petroleum and Explosive safety
CNG/LPG cylinder with
Organization (PESO), Government of Gas Cylinder Rules
valves and their accessories.
India
Ministry of Petroleum & Natural Gas
PNG Pipeline & its joints /
(MoPNG) or CGD Company approved by Petroleum Act
connection
PNGRB/MoPNG.

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9. TYPE APPROVAL ADMINISTRATIVE PROCEDURE

9.1 Selection of Certifying Agency

9.1.1 Following test agencies are currently approved by the Nodal Agency Central Pollution Control
Board (CPCB) for purpose of type approval and subsequently conformity of production
compliance process and may be revised from time to time.

a) Automotive Research Association of India (ARAI, Pune)

b) International Centre for Automotive Testing (ICAT, Manesar)
c) Indian Institute of Petroleum (IIP, Dehradun)
d) Indian Oil Corporation Research and Development Centre (IOCL R&D, Faridabad).

9.1.2 One supplier shall submit application for Type Approval to only one certification agency for all
its families / models out of those approved.
9.1.3 The same certification agency shall be responsible for carrying out the verification of
Conformity of Production (COP) for that manufacture
9.1.4 For a new OEM or importer, selection of technical agencies for type approval certification and
subsequently conformity of production shall be applicant’s choice among the technical
agencies published by central pollution control board (CPCB) and as amended from time to
time.
9.1.5 For any reason if any manufacturer wants to change the certification agency, he shall apply
to the nodal agency well in advance with justifiable reason. The nodal agency, after
consultation with the existing certification agency/ standing committee, may approve the
change, if found justified. If approved, the nodal agency shall inform to the parties concerned.
9.1.6 On receipt of information for change in certification agency from the nodal agency, the
previous certification agency shall authenticate all the relevant document of the model (type
approval as well as COP verification) and forward the same to the new certification agency.
The certification agency shall be responsible for carrying out the type approval testing and
COP verification for the manufacturer, in future.

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9.2 Application of type approval

9.2.1 To apply for the safety type approval of the Genset, the engine should be certified for emission
compliance first.
9.2.2 The noise certificate shall be granted to supplier once the safety certification is accomplished.
9.2.3 The application shall be made in the format prescribed in this document and must be complete
in all respect.
9.2.4 For each engine family, the manufacturer must submit, an application to the certification
agency.
9.2.5 The application must be signed by the authorized representative of the manufacturer.
9.2.6 It shall be accompanied by the undermentioned documents and the following particulars:
9.2.7 A description of the engine type comprising the particulars and all the necessary documents
related to engine certification, fuel system test reports, Genset layout, etc. For the purpose of
identification, the manufacturer shall designate the engines families as F1, F2, F3 …. Fn in
consultation with technical agency;
9.2.8 The Testing agency shall intimate its decision to the applicant within a fortnight of receipt of
the application, indicating need and plan (schedule) of testing for type approval.

9.3 Type Approval

9.3.1 No person or agency shall sale, import or use an engine for Genset application in India without
valid Type Approval Certificate and Conformity of production Certificate
9.3.2 No person or agency shall sale, import or use a Genset in India containing an Engine without
valid Type Approval Certificate and Conformity of production Certificate
9.3.3 The manufacturer may use of commercial fuels or reference fuels, provided to be declared in
the information document.
9.3.4 Additionally, in order to receive type approval of a Genset with an approved engine with regard
to emissions or a type approval of a Genset with regard to emissions the manufacturer shall
ensure compliance with the installation requirements.

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9.4 Certificate of Type Approval and Validity

9.4.1 After verification of engine(s) for the type approval, the technical agency shall issue a type
approval report to manufacturer within one month from date of testing completion indicating
acceptance or rejection decision and reason thereof.
9.4.2 The certificate shall be deemed to be valid for the model(s) included herein, unless explicitly
withdrawn by separate written order by the Nodal Agency;
9.4.3 The Type Approval certificate for an engine family issued to the manufacturer shall be valid
for the same model(s) manufactured at any other manufacturing plant of the same
manufacturer. The Nodal Agency or technical agency concern with type approval may visit
the new plant to verify adequacy of the infrastructure;
9.4.4 Validity of Type Approval Certificate issued by type approval authority shall remain valid
further as long as following conditions are met:

a) Till the engine specifications unchanged

b) Till the further amendments to the notification;

9.5 Modification and Extensions of approved type

9.5.1 If an engine type or engine family is type approved and valid, manufacturer may approach
type approval certificate issuing technical agency for modifications pertaining to parent or any
engine type in the certified engine emissions family. Such modifications shall be ascertained
by manufacturer utilizing defined guidelines.
9.5.2 Manufacturer shall submit technical document in line with type approval procedure prescribed
in this Regulation;
9.5.3 Subjected to scrutiny of manufacture’s application, technical agency shall approve or seek
more data pertaining but not limited to engine architecture, parameters, similarity with existing
engine type from emissions and performance perspective along with evidences. Decision of
technical agency will remain finally binding for allowing such amendments to existing type
approval certificate of an engine family through extension(s) vs asking manufacturer to type
approve as new engine family or new engine type;
9.5.4 Technical agency retains all rights to ask manufacture to demonstrate modified engine type
for emissions conformity through applicable type approval test procedures. Submission of
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 manufacturer run emissions data with valid test facility and procedure followed is mandatory
where changes are directly or indirectly pertaining to emission affecting components, engine
and after treatment system control algorithms and engine performance specifications.

9.6 Type Approval Process

Genset to be certified as per safety code of practice as defined in this document at the time of applying
for Type Approval of NVH certification. NVH TA certificate shall be issued only after successful
completion of safety code of practice certification of the Genset.
Following are the logical steps for the type approval process flow chart described in brief stepwise -

a) Application to nodal agency (CPCB) in the form of affidavit seeking permission for type approval
of Genset engine family through submission provided as draft specimen.
b) Upon written approval of nodal agency to manufacturer and chosen technical agency; (This
could be decision making node with “Yes” / “No” loop).
c) Submit type approval certification application to chosen test agency. Based on provisions such
application can be written or online through their secured portal.
d) Obtain technical agency approval (This could be decision making node with “Yes” / “No” loop
with NO means, provide additional data).
e) Upon agencies application scrutiny and negotiations, submit detailed technical documentation
as per requirements described in Annexure 1.
f) Obtain documentation approval from technical agency
g) Obtain test plan / schedule from technical agency.
h) Upon approval from technical agency plan for safety procedural demonstration.
i) Review of all test results with manufactures and decision about compliance, in case of failure
manufacture to follow guidelines provided by test agency.
j) Technical agency carries out part verification of critical engine components, CNG/LPG/NG
components, safety layout with document submission, take final review of technical document
and ask manufacture to resubmit if necessary.
k) Manufacture submit the corrected technical document if found necessary.
l) Examine corrected document submitted in line with the requirement.
m) Technical agency prepares technical report based on the observations.
n) Technical agency gives clearance to NVH for issuing the NVH certificate.

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 APPENDIX A.1
Template for submission of engine technical specification
(Template for information document)
PART A

1. GENERAL INFORMATION
1.1. Make (trade name(s) of manufacturer):
1.2. Commercial /Brand Name name(s) (if applicable):
1.3. Company name and address of manufacturer:
1.4. Name and address of manufacturer's authorized representative (if any):
1.5. Name(s) and address(es) of assembly/manufacture plant(s):
1.6. Engine type designation/engine family designation/FT:
1.7. Category Constant speed or variable speed:
1.8. Rated Power

PART B

2. COMMON DESIGN PARAMETERS OF ENGINE FAMILY (1)

2.1. Combustion Cycle: four stroke cycle/two stroke cycle/other (specify):
2.2. Ignition Type: Compression ignition / Spark Ignition
2.3. Configuration of the cylinders:
2.3.1. Position of the cylinders in the block: Single/V/in-line/opposed/radial/ other(specify):
2.3.2. Bore center to center dimension (mm):
2.4. Combustion chamber type/design
2.4.1. Open chamber/divided chamber/other(specify):
2.4.2. Valve and porting configuration:
2.4.3. Number of valves per cylinder:
2.5. Range of swept volume per cylinder (cm3):
2.6. Main Cooling medium: Air/Water/Oil:
2.7. Method of air aspiration: naturally aspirated/pressure charged/pressure charged with charge
cooler:
2.8. Fuel:
2.8.1. Fuel Type: Diesel / Gasoline/ CNG/ LPG
2.8.1.1. Reserved.
2.8.2. Fueling arrangement: Dual-fuel type 1A/Dual-fuel type 1B/Dual-fuel type 2A/Dual-fuel type
2B/Dual-fuel type 3B
2.8.3. List of additional fuels, fuel mixtures or emulsions compatible with use by the engine declared
by the manufacturer (provide reference to recognized standard or specification):
2.8.4. Lubricant added to fuel: Yes/No

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2.8.5. Fuel supply type: Pump (high pressure) line and injector/in-line pump or distributor
pump/Unit injector/ Common rail.
2.9. Engine management systems: mechanical/electronic control strategy
2.10. Miscellaneous devices: Yes/No (if yes provide a schematic diagram of the location and order
of the devices)
2.10.1. Exhaust gas recirculation (EGR): Yes/No (if yes, complete section 3.10.1 and provide a
schematic diagram of the location and order of the devices)
2.10.2. Water injection: Yes/No (if yes, complete section 3.10.2 and provide a schematic diagram
of the location and order of the devices)
2.10.3. Air injection: Yes/No (if yes, complete section 3.10.3 and provide a schematic diagram of
the location and order of the devices)
2.10.4. Others: Yes/No (if yes specify, complete section 3.10.4 and provide a schematic diagram of
the location and order of the devices):
2.11. Exhaust after-treatment system: Yes/No (if yes provide a schematic diagram of the location
and order of the devices)
2.11.1. Oxidation catalyst: Yes/No
(if yes, complete section 3.11.2)
2.11.2. De NOX system with selective reduction of NOX (addition of reducing agent): Yes/No
(if yes, complete section 3.11.3)
2.11.3. Other De NOX systems: Yes/No
(if yes, complete section 3.11.3)
2.11.4. Reserved
2.11.5. Particulate after-treatment system with passive regeneration: Yes/No
(if yes, complete section 3.11.4)
2.11.5.1. Wall-flow/non-wall-flow
2.11.6. Particulate after-treatment system with active regeneration: Yes/No
(if yes, complete section 3.11.4)
2.11.6.1. Wall-flow/non-wall-flow
2.11.7. Other particulate after-treatment systems: Yes/No
(if yes, complete section 3.11.4)
2.11.8. Other after-treatment devices (specify):
(if yes, complete section 3.11.5)
2.11.9. Other devices or features that have a strong influence on emissions Yes/No (specify):
(if yes, complete section 3.11.7)

386
 PART C

Engine types within

Parent the engine family
engin Explanatory notes
Item (if applicable)
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

3.1 Engine Identification

3.1.1 Engine type designation
Engine type designation shown
3.1.2
on engine marking: yes/no
Location of the statutory
3.1.3
marking:
Method of attachment of the
3.1.4
statutory marking:
Drawings of the location of the
engine identification number
3.1.5
(complete example with
dimensions):
3.2 Performance Parameters
3.2.1 Declared rated speed(s) (rpm):
Declared rated gross power
3.2.1.1
(kW):
Fuel delivery/stroke (mm3) for
3.2.1.2 diesel engine, fuel flow (g/h), at
rated gross power
3.2.6 Idle speed (rpm)
3.2.7 No load speed (rpm):
3.2.8 Overload load speed (rpm):
Optional at choice
3.3 Run-in procedure
of manufacturer
3.3.1 Run-in time:
3.3.2 Run-in cycle:
3.4 Engine test
3.4.1 Specific fixture required: Yes/No For NRSh only
Description, including
photographs and/or drawings, of
the system for mounting the
3.4.1.1 engine on the test bench
including the power transmission
shaft for connection to the
dynamometer:
Exhaust mixing chamber
3.4.2 permitted by manufacturer: For NRSh only
Yes/No
Exhaust mixing chamber
3.4.2.1 description, photograph and/or If applicable
drawing:
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 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

Pre-conditioning for: Steady-

3.4.3
state operation
3.5 Lubrication system
3.5.1 Lubricant temperature If applicable
3.5.1.1 Minimum (⁰C):
3.5.1.2 Maximum (⁰C):
3.6 Combustion Cylinder
3.6.1 Bore(mm):
3.6.2 Stroke(mm):
3.6.3 Number of cylinders:
Engine total swept volume
3.6.4
(cm3):
Swept volume per cylinder as %
3.6.5 If engine family
of parent engine:
3.6.6 Volumetric compression ratio: Specify tolerance
3.6.7 Combustion system description:
Drawings of combustion
3.6.8
chamber and piston crown:
Minimum cross-sectional area of
3.6.9
inlet and outlet ports (mm2):
3.6.10 Valve timing
Maximum lift and angles of
3.6.10.1 opening and closing in relation to
dead center or equivalent data:
3.6.10.2 Reference and/or setting range:
If applicable and
Variable valve timing system:
3.6.10.3 where intake and/or
Yes/No
exhaust
3.6.10.3.1 Type: continuous/(on/off)
3.6.10.3.2 Cam phase shift angle:
2-stroke only, if
3.6.11 Porting configuration
applicable
3.6.11.1 Position, size and number:
Complete relevant
3.7 Cooling system
section
3.7.1 Liquid cooling
3.7.1.1 Nature of liquid:
3.7.1.2 Circulating pumps: Yes/No
3.7.1.2.1 type(s):
3.7.1.2.2 Drive ratio(s): If applicable
Minimum coolant temperature at
3.7.1.3
outlet (⁰C):

388
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

Maximum coolant temperature at

3.7.1.4
outlet (⁰C):
3.7.2 Reserved

3.8 Aspiration
Maximum allowable intake
3.8.1 depression at rated engine
speed and at 100% load (kPa)
3.8.1.1 With clean air cleaner:
3.8.1.2 With dirty air cleaner:
3.8.1.3 Location, of measurement:
3.8.2 Pressure charger(s): Yes/No
3.8.2.1 Type(s):
Description and schematic
diagram of the system (e.g.
3.8.2.2 maximum charge pressure,
waste gate, VGT, Twin turbo,
etc.):
3.8.3 Charge air cooler: Yes/No
Type: air-air/air-
3.8.3.1
water/other(specify)
Maximum charge air cooler
3.8.3.2 outlet temperature at rated
speed and 100% load (⁰C):
Maximum allowable pressure-
drop across charge cooler at
3.8.3.3
rated engine speed and at 100%
load (kPa):
3.8.4 Intake throttle valve: Yes/No
Device for recycling crankcase
3.8.5
gases: Yes/No
3.8.5.1 If yes, description and drawings:
If no, compliance with paragraph
3.8.5.2
5.7. of this Regulation: Yes/No
3.9 Exhaust system
Description of the exhaust
system (with drawings, photos
3.9.1
and/or part numbers as
required):
Maximum exhaust temperature
3.9.2
(⁰C):

389
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

Maximum permissible exhaust

3.9.3 backpressure at rated engine
speed and at 100% load (kPa):
3.9.3.1 Location of measurement:
Exhaust backpressure at loading
level specified by manufacturer
3.9.4
for variable restriction after-
treatment at start of test (kPa):
Location and speed/load
3.9.4.1
conditions:
3.9.5 Exhaust throttle valve: Yes/No
3.10 Miscellaneous devices: Yes/No
3.10.1 Exhaust gas recirculation (EGR)
Characteristics:
cooled/uncooled, high
3.10.1.1
pressure/low pressure/other
(specify):
3.10.2 Water injection
3.10.2.1 Operation principle:
3.10.3 Air injection
3.10.3.1 Operation principle
3.10.4 Others
3.10.4.1 Type(s)
3.11 Exhaust after-treatment system
3.11.1 Location
Place(s) and maximum/minimum
3.11.1.1 distance(s) from engine to first
after-treatment device:
Maximum temperature drops
from exhaust or turbine outlet to
3.11.1.2
first after-treatment device (⁰C) if
stated:
Test conditions for
3.11.1.2.1
measurement:
Minimum temperature at inlet to
3.11.1.3 first after-treatment device, (⁰C) if
stated:
Test conditions for
3.11.1.3.1
measurement:
3.11.2 Oxidation catalyst
Number of catalytic converters
3.11.2.1
and elements:

390
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

Dimensions and volume of the

3.11.2.2 Or drawing
catalytic converter(s):
Total charge of precious metals
3.11.2.3
(g):
Relative concentration of each
3.11.2.4
compound (%):
Substrate (structure and
3.11.2.5
material):
3.11.2.6 Cell density:
Type of casing for the catalytic
3.11.2.7
converter(s):
Catalytic exhaust after-treatment
3.11.3 system for NOX or three-way
catalyst
3.11.3.1 Type:
Number of catalytic converters
3.11.3.2
and elements:
3.11.3.3 Type of catalytic action:
Dimensions and volume of the
3.11.3.4 Or drawing
catalytic converter(s):
Total charge of precious metals
3.11.3.5
(g):
Relative concentration of each
3.11.3.6
compound (%):
Substrate (structure and
3.11.3.7
material):
3.11.3.8 Cell density:
Type of casing for the catalytic
3.11.3.9
converter(s):
3.11.3.10 Method of regeneration: If applicable
3.11.3.10. If yes, complete
Infrequent regeneration: Yes/No:
1 section 3.11.6.
Normal operating temperature
3.11.3.11
range (⁰C):
3.11.3.12 Consumable reagent: Yes/No
Type and concentration of
3.11.3.12.
reagent needed for catalytic
1
action:
Lowest concentration of the
3.11.3.12. active ingredient presents in the
2 reagent that does not activate
warning system (CDmin) (%vol):

391
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

3.11.3.12. Normal operational temperature

3 range of reagent:
3.11.3.12.
International standard: If applicable
4
3.11.3.13 NOX sensor(s): Yes/No
3.11.3.13.
Type:
1
3.11.3.13.
Location(s)
2
3.11.3.14 Oxygen sensor(s): Yes/No
3.11.3.14.
Type:
1
3.11.3.14.
Location(s):
2
Particulate after-treatment
3.11.4
system
Type of filtration: wall-flow/ non-
3.11.4.1
wall-flow/other (specify)
3.11.4.2 Type:
Dimensions and capacity of the
3.11.4.3 particulate after-treatment Or drawing
system:
Location place(s) and maximum
3.11.4.4 and minimum distance(s) from
engine:
Method or system of
3.11.4.5 regeneration, description and/or
drawing:
If yes, complete
3.11.4.5.1 Infrequent regeneration: Yes/No
section 3.11.6.
Minimum exhaust gas
3.11.4.5.2 temperature for initiating
regeneration procedure (⁰C):
3.11.4.6 Catalytic coating: Yes/No
3.11.4.6.1 Type of catalytic action:
Fuel borne catalyst (FBC):
3.11.4.7
Yes/No
Normal operating temperature
3.11.4.8
range (⁰C):
Normal operating pressure range
3.11.4.9
(kPa)
3.11.4.10 Storage capacity soot/ash (g):
3.11.4.11 Oxygen sensor(s): Yes/No
392
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

3.11.4.11.
Type:
1
3.11.4.11.
Location(s):
2
3.11.5 Other after-treatment devices
3.11.5.1 Description and operation:
3.11.6 Infrequent Regeneration
Number of cycles with
3.11.6.1
regeneration
Number of cycles without
3.11.6.2
regeneration
3.11.7 Other devices or features
3.11.7.1 Type(s)
Fuel feed for liquid-fuelled CI or,
3.12 where applicable, dual-fuel
engines
3.12.1 Feed pump
Pressure (kPa) or characteristic
3.12.1.1
diagram:
3.12.2 Injection system
3.12.2.1 Fuel Pump
3.12.2.1.1 Type(s):
3.12.2.1.2 Rated pump speed (rpm):
mm3 per stroke or cycle at full
3.12.2.1.3 Specify tolerance
injection at rated pump speed:
3.12.2.1.4 Reserved
3.12.2.1.5 Reserved Specify tolerance
As alternative to
3.12.2.1.6 Characteristic diagram: entries 3.12.2.1.1.
to 3.12.2.1.5.
Method used: on engine/on
3.12.2.1.7
pump bench
3.12.2.2 Injection timing
Specify tolerance, if
3.12.2.2.1 Injection timing curve:
applicable
3.12.2.2.2 Static Timing: Specify tolerance
3.12.2.3 Injection piping
3.12.2.3.1 Length(s) (mm):
3.12.2.3.2 Internal diameter (mm):
3.12.2.4 Common rail: Yes/No
3.12.2.4.1 Type:
3.12.3 Injector(s)

393
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

3.12.3.1 Type(s):
3.12.3.2 Opening pressure (kPa): Specify tolerance
3.12.4 ECU: Yes/No
3.12.4.1 Type(s):
3.12.4.2 Software calibration number(s):
Communication standard(s) for
access to data stream
information: ISO 27145 with ISO
3.12.4.3
15765-4 (CAN-based)/ISO
27145 with ISO 13400 (TCP/IP-
based)/SAE J1939-73
3.12.5 Governor
3.12.5.1 Type(s):
Speed at which cut-off starts Specify range, if
3.12.5.2
under full load: applicable
Specify range, if
3.12.5.3 Maximum no-load speed:
applicable
Specify range, if
3.12.5.4 Idle speed:
applicable
3.12.6 Cold-start system: Yes/No
3.12.6.1 Type(s):
3.12.6.2 Description:
Fuel temperature at the inlet to
3.12.7
the fuel injection pump
3.12.7.1 Minimum (⁰C):
3.12.7.2 Maximum (⁰C):
3.13 Reserved
Fuel feed for gaseous fuel
engines or where applicable,
dual-fuel engines (in the case of
3.14. systems laid out in a different
manner, supply equivalent
information) (Need to check if
something missed out)
Fuel: LPG /NG-H/NG-L /NG-
3.14.1.
HL/LPG
Pressure regulator(s)/vaporizer
3.14.2.
(s)
3.14.2.1. Type(s)
Number of pressure reduction
3.14.2.2.
stages

394
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

Pressure in final stage minimum

3.14.2.3.
and maximum. (kPa)
Number of main adjustment
3.14.2.4.
points:
Number of idle adjustment
3.14.2.5.
points:
Fuelling system: mixing unit/gas
3.14.3. injection/liquid injection/direct
injection
3.14.3.1. Mixture strength regulation
System description and/or
3.14.3.1.1.
diagram and drawings:
3.14.4. Mixing unit
3.14.4.1. Number:
3.14.4.2. Type(s):
3.14.4.3. Location:
3.14.4.4. Adjustment possibilities:
3.14.5. Inlet manifold injection
3.14.5.1. Injection: single-point/multi-point
Injection:
3.14.5.2. continuous/simultaneously
timed/ sequentially timed
3.14.5.3. Injection equipment
3.14.5.3.1. Type(s):
3.14.5.3.2. Adjustment possibilities:
3.14.5.4. Supply pump If applicable
3.14.5.4.1. Type(s):
3.14.5.5. Injector(s)
3.14.5.5.1. Type(s):
3.14.6. Direct injection
Injection pump/pressure
3.14.6.1.
regulator
3.14.6.1.1. Type(s):
3.14.6.1.2. Injection timing (specify):
3.14.6.2. Injector(s)
3.14.6.2.1. Type(s):
Opening pressure or
3.14.6.2.2.
characteristic diagram:
3.14.7. Electronic Control Unit (ECU)
3.14.7.1. Type(s):
3.14.7.2. Adjustment possibilities:
3.14.7.3. Software calibration number(s):

395
 Engine types within
Parent
the engine family
engin (if applicable) Explanatory notes
Item
Item Description e/ (not included in
Number
engin typ typ typ typ document)
e type e2 e3 e… en

Approvals of engines for several

3.14.8.
fuel compositions
3.14.8.1. Self-adaptive feature: Yes/No
Calibration for a specific gas
3.14.8.2. composition: NG-H/NG-L/NG-
HL/ LNG/Fuel specific LNG
Transformation for a specific gas
3.14.8.3. composition: NG-HT/NG-LT/NG-
HLT
Fuel temperature pressure
3.14.9.
regulator final stage
3.14.9.1. Minimum ((⁰C):
3.14.9.2. Maximum ((⁰C):
3.15. Ignition system
3.15.1. Ignition coil(s)
3.15.1.1. Type(s):
3.15.1.2. Number:
3.15.2. Spark plug(s)
3.15.2.1. Type(s):
3.15.2.2. Gap setting:
3.15.3. Magneto
3.15.3.1. Type(s):
3.15.4. Ignition timing control: Yes/No
Static advance with respect to
3.15.4.1. top dead center (crank angle
degrees):
3.15.4.2. Advance curve or map: If applicable
3.15.4.3. Electronic control: Yes/No

Part D – For Gaseous Fuel System

1. Details of Kit Manufacturer / Supplier / Installer
a) Name of the Manufacturer
b) Address
c) Telephone No. & Fax No.
2. Gas Kit Identification
a) Identification No.
b) Variants, if any
c) Fuel system (Dedicated / Bi-Fuel / Dual Fuel /
Dedicated Dual Fuel)

396
 d) Type of Dual- fuel system (Type 1A / 1B / 2A /
2B / 3B)
e) Fuel (Gas Fuel (Specify Name of fuel)
3. Solenoid Valve / Automatic shutoff valve
a) Name of manufacturer
b) Model Name / Identification No.
c) Type
d) Working pressure (kg/cm2)
e) Max test pressure (kg/cm2)
f) Approval reference (Test Report / Approval
Number)
4. High Pressure Regulator
a) Name of manufacturer
b) Model name / Identification No.
c) Type
d) Inlet pressure (kg/cm2)
e) Outlet pressure (kg/cm2)
f) No. of stages
g) Approval reference (Test Report / TAC
compliance with Date)
5. Low Pressure Regulator
a) Name of manufacturer
b) Model name / Identification No.
c) Type
d) Inlet pressure (kg/cm2)
e) Outlet pressure (kg/cm2)
f) No. of stages
g) Approval reference (Test Report / TAC
compliance with Date)
6. Zero Pressure Regulator
a)Name of manufacturer
b)Model name / Identification No.
c)Type
d)Inlet pressure (kg/cm2)
e)Outlet pressure (kg/cm2)
f)Approval reference (Test Report / TAC
compliance with Date)
7. Vaporizer / Heat exchanger (for LNG)
a) Name of manufacturer
b) Model name / Identification No.
c) Type

397
 d) Inlet pressure (kg/cm2)
e) Outlet pressure (kg/cm2)
f) Approval reference (Test Report / Approval
Number)
8. Filter
a) Name of manufacturer
b) Model name / Identification No.
c) Type
d) Inlet pressure (kg/cm2)
e) Outlet pressure (kg/cm2)
9. High Pressure Tubing
a) Name of manufacturer
b) Model name / Identification No.
c) Type (rigid / flexible)
d) Working pressure (kg/cm2)
e) Max. test pressure (kg/cm2)
f) Outer diameter / Inner Diameter (mm)
g) Material
h) Approval reference (Test Report / Approval
Number)
10. Low Pressure Tubing
a) Name of manufacturer
b) Model name / Identification No.
c) Type
d) Working pressure (kg/cm2)
e) Max test pressure (kg/cm2)
f) Outer diameter / Inner Diameter (mm)
g) Material
h) Approval reference (Test Report / Approval
Number)
11. Gas-Air Mixer
a) Name of manufacturer
b) Model name / Identification No
c) Type & drawing
d) Venturi Size (mm)
e) Approval reference (Test Report / Approval
Number)
12. Gas Injector
a) Name of manufacturer
b) Model name / Identification No
c) Type & drawing

398
 d) Injector flow specs
e) Approval reference (Test Report / Approval
Number)
13. Wiring Harness
a) Name of manufacturer
b) Electrical circuit diagram / Detail layout
c) Approval reference (Test Report / Approval
Number)
14. Interfacing Unit (ECU)
a) Name of manufacturer
b) Identification No.
c) Type
15. Fuel selector switch
a) Name of manufacturer
b) Model No
c) Type
16. Fuel flow actuation mechanism (Mechanical /
Electronic)
a) Brief description of system (Attach Annexure)
b) Schematic layout (Attach Drawing)
c) Identification of critical components of Kit,
including ECU, Lambda sensor, Pressure
sensor, temperature Sensor etc. with Make and
Identification number) (attach Annexure)
17. Brief Description of System Including
Dimensional Layout for kit components
installation ventilation details etc.
18. Joints and connections
a) Name of manufacturer
b) Type
c) Number of Joints and connections represented
on Drawing (Attach Drawing)
19. Current limiting Device (Fuse)
a) Name of manufacturer
b) Identification No.
c) Voltage / current rating
d) Type
e) Approval reference (Test Report / Approval
Number)
20. Indicator
A. Pressure Indicator

399
 a) Name of manufacturer
b) Identification No.
c) Type
B. Temperature Indicator (for LNG)
a) Name of manufacturer
b) Identification No.
c) Type
21. Service shut off valve
a) Name of manufacturer
b) Identification No.
c) Type
22. Compartment/Sub-compartment / Gas tight
housing
a)Name of manufacturer
b)Identification No
c)Type
d)Material used
e)Approval reference (Test Report / Approval
Number)
23. Conduit
a) Name of manufacturer
b) Identification No.
c) Inner & outer diameter
d) Type
e) Approval reference (Test Report / Approval
Number)
24. Battery cut off switch (if applicable)
a) Name of manufacturer
b) Identification No.
c) Type
25. Labels - Number and position
26. Any other information
* Mention NA wherever not applicable

Part E
Gaseous Fuel Safety Component – Test Applicability
Sr. No. Gas Kit Component Certifying / Verifying Authority Applicable Standards
Testing of the component as per IS: 15713
Regulator (For CNG & or ISO-15500 by test agency. Alternatively,
1 BIO-CNG) / Regulator test agency to verify the test certificate or IS: 15713 or ISO -15500
and Vaporizer (LNG)* report conforming to the above standard
issued by accredited testing laboratory.
400
 LNG regulator and Vaporizer / heat
UN R 110 or equivalent
exchanger shall meet requirements of UN
standard
R110 or equivalent standard
Testing of the component as per IS: 15714
or ISO-15500 by test agency. Alternatively,
2 Gas-Air Mixer* test agency to verify the test certificate or IS: 15714 or ISO-15500
report conforming to the above standard
issued by accredited testing laboratory.
Testing of the component as per ISO-
15500-7 by test agency. Alternatively, test
3 Gas Injector* agency to verify the test certificate or report ISO-15500-7
conforming to the above standard issued by
accredited testing laboratory.

Testing of the component as per IS: 15712

or ISO-15500 by test agency. Alternatively,
test agency to verify the test certificate or IS: 15712 or ISO-15500
report conforming to the above standard
Gas Solenoid Valve / issued by accredited testing laboratory.
4 Automatic Shutoff
valve*
Automatic shutoff valve of LNG System Automatic shutoff Valve
(which comes in contact with LNG shall for LNG System: UN
meet requirements of UN R110 or R110 or equivalent
equivalent standards) standards

Testing of the component or verification of

5 Testing of Conduit* certificate or test report as per IS: 15715 by IS: 15715
test agency.
CNG / BIO-CNG / LNG
6
fuel line
High pressure
6.1 exceeding 100
kPa*
6.1.1 Exceeding 2.15 MPa
Testing of the component or verification of
certificate or test report as per IS: 15716 by IS: 15716
test agency.
Rigid pipe
LNG rigid pipeline shall meet requirements
UN R 110 or IS: 15716
of UN R 110 or IS: 15716 or equivalent
or equivalent standard.
standard.
Testing of the component or verification of
IS 15718 or AIS-028
certificate or test report as per IS 15718 by
(Rev. 1) (Part A)
test agency.
Flexible hose
LNG flexible pipeline shall meet UN R 110 or IS:
requirements of UN R110 or IS: 15718 or 15718 or equivalent
equivalent standard. standard

401
 Testing of the component or verification of
IS: 15722 with
certificate or test report as per IS: 15722 by
amendments
Pressure up to 2.15 test agency.
6.1.2
Bar LNG pipeline shall meet requirements of UN R 110 or IS:
UN R110 or IS: 15722 or equivalent 15722 or equivalent
standard. standard
Clause 3.1.4.1, 3.2.1 (b)
Testing by test agency. of AIS-028 (Rev. 1)
Joints and (Part A)
6.2
connections* LNG joints & connection shall meet
UN R 110 or equivalent
requirements of UN R 110 or equivalent
standard
standard
Testing of the component or verification of
Compartment or Sub-
7 certificate or test report as per IS: 15720 by IS: 15720
compartment*
test agency.
Following specific components, as
applicable shall meet requirements of UN R
Specific LNG 110 or equivalent standard UN R 110 or equivalent
8
components LNG Fuel pump, Pressure Relief valves, standard
Pressure sensor, check valve, excess flow
valve, manual valve and non-return valve.
Safety check for Relevant clauses of
Safety checks to be carried out by test
9 installation of AIS-028 (Rev. 1) (Part
agency as per AIS-028 (Rev.1) (Part A)
Gaseous fuel system A)
Electrical wiring and
10 AIS 028
harness
Non-moisture
retaining hard
11 AIS 028
rubber/equivalent
material

12 Electrical fuses AIS 028

* Certificate issued by accredited testing agency of the country of origin or a report issued by
internationally accredited test laboratory may also be accepted.
Note 1 - Only the standards, as amended from time to time, as mentioned above, shall be referred
for compliance.
Note 2 - Components downstream the Heat exchanger / vaporizer shall be considered as CNG
components and prevailing Indian standard / ISO standard or equivalent standards shall
be acceptable.
Note 3 - Test agency to conduct applicable CMVR test with LNG fuel as notified by Govt of India.

402
 ANNEXURE - 1

Freezing conditions and corrosive conditions

1.1 Where regulator heat is drawn from the engine cooling water, care should be taken to ensure
that the water does not freeze in the regulator during cold weather. Expansion of the water on
freezing can cause serious damage to the pressure regulator assembly.

1.2 Most CNG/PNG/LPG regulators are made from non-ferrous alloys, which can suffer pinhole
corrosion under certain conditions. If this is allowed to take place CNG/ PNG/LPG can be
admitted to the cooling water system where it will pressurize the radiator and cause a potential
hazard. It is important, therefore, to have an effective anticorrosion additive present in the
cooling water.

1.3 It is important to ensure that the coolant additive and the dilatant ratio comply fully with the
engine manufacturer’s requirements.

403
 ANNEXURE - 2

Backfire – Deflector tests

2.1 A backfire deflector under backfire conditions shall contain a visible flame front within its confines
and shall not be displaced, physically damaged or distorted, or show evidence of burning or
smoldering of internal parts. If the deflector is of the oil-bath type, it shall be free of any overflow
or discharge permitting accumulation of oil on electrical, hot-engine or exhaust system parts.

2.2 A complete Genset engine is to be used for this test. Tests are not required on backfire deflectors
employed diesel engines.

2.3 The backfire deflector (air cleaner, oil-bath or dry element type) and connecting hose are to be
removed from the engine. The spark timing is to be advanced (approximately 8 degrees) and the
spark plug leads are to be interchanged to obtain sharp backfires under the following conditions.
The engine is to be alternately raced and idled and the ignition switch is to be operated to
alternately energize and de-energize the ignition system. During the test, the intensity of the
backfire and the issuance and extent of the accompanying flame are to be noted.

2.4 The backfire deflector (air cleaner) is then to be installed on the truck in the intended location. An
oil-bath type deflector (air cleaner) is to be filled to the marked “full level-line” of the bowl. Paper
is to be placed beneath the intake orifices of an oil-bath type and over adjacent surfaces of parts
likely to be affected by accumulations of oil.

2.5 The engine is then to be operated in the several manners determined in the preliminary test to
provide for the most severe backfire conditions. At least ten and not more than twenty backfires
are to be produced.

2.6 Observations for containment of flame are to be made under semi-darkened conditions by at
least two observers. No visible flame is to be in evidence at any time during the tests. In the tests
of an oil-bath type, paper is not to show evidence of oil deposits in the form of droplets.

2.7 A dry-type filter element is to be tested in the above manner, then removed and then subjected
to five consecutive washing and drying cycles. Washing is to consist of immersion in plain water
together with sufficient agitation to remove bulk material adhering to the outside surface. The test
element is then to be remounted as intended in operation, and the backfire test is to be repeated.

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2.8 The side of the filter media normally exposed to backfire is then to be subjected to a flame source
of sufficient intensity to cause the media to burn or glow. The flame source is then to be removed
and an acceptable filter media is not to continue to burn or smolder.

405
 ANNEXURE - 3
Checklist for installation for NG/LPG GENSET

This checklist is a guide for the installer when carrying out the inspection prior to issuing installation
Certificate. Reference to relevant clauses in this Standard and guidelines issued by Central
Government from time to time should be made where appropriate.

3.1 Cylinder/ PNG connection: Approved by PESO / CGD Company as applicable Validity of
Certificate Free from corrosion Mounted securely
Mounting points free from corrosion and fractures Shielded and valves protected where
necessary 5 mm clearance in between cylinders.
3.2 Valves/MFVs: Approved by PESO / CGD Company as applicable Cylinder valve/MFV
operating correctly, burst disc fitted.
3.3 Filling connection: Refueling connection made external to Genset Engine/Canopy interior
Captive dust plug fitted Meets proof loading of 50 kgf.
3.4 Refueling interlock: Operation corrects
3.5 Non-return valve: Operation correct free from bypass leakage
3.6 Leak test: All valves and fittings leak free
3.7 Vapor sealing: Gas tight
3.8 Ducting: Free from damage and secure to outlets
3.9 Pliable sub-compartment: Ease of operation of cylinder valve satisfactory Position identified
3.10 Fuel line: Free from damage and corrosion Secured to Genset Engine Protected and shielded
where necessary
3.11 Joints and connections: Leak free
3.12 CNG shut off valve/solenoid valve: Mounting secure Operation Correct Leak free
3.13 Service shut off valve: Operation satisfactory Mounted Securely Leak Free Identified and
operation clearly marked
3.14 Regulator/Vaporizer: Mounting secure No gas bypass after engine has stopped turning
Shielded where necessary Leak free
3.15 Control equipment: Approved type
3.16 Gas air mixer: Securely mounted Backfire deflector where applicable
3.17 Bi-fuel /Dual fuel shut-off device: Operation correct Petrol lock off where fitted is mounted
securely Petrol hose secure joints leak free and free from cracks Sufficient flexibility for engine
movement Bypass device fitted where applicable

406
3.18 Electrical wiring: Current limiting device fitted Connections secure. Terminals insulated to
prevent shorting Wiring taped and clipped securely.
3.19 Compliance Plate/label: Installed and carries correct markings
3.20 Identification labels: Located front on Genset Engine and Canopy

407
 ANNEXURE -4

Installation certificate for converted CNG/PNG/ LPG GENSET engine

manufacturer/ authorized person of genset manufacturer

A. Details of Installer Approval

1. Installation Certificate issued by Name and address of Authorized Person
2. Approval details Name of Genset manufacturer
3. Rating of Genset and its engine
4. Approval of the CNG /PNG/LPG kit
a) Name of the Test Agency
b) Approval Certificate No. & Date
B. Details of Genset Engines
1. Sr. No. & year of manufacture
2. Engine No.
3. Type of Operation Bi-fuel / dedicated fuel/Dual fuel
C. Details of CNG/PNG/LPG Kit
1. Cylinders:
a) No. of Cylinder/s
b) Type of Cylinder/s
c) Cylinder No/s.
d) Make
e) Water Capacity (liters)
f) Working Pressure (kg/cm2)
g) Approval reference of PESO
h) Validity of PESO Certificate
2. Cylinder CNG/PNG/LPG Valves
a) Make
b) Valve No.
c) Working Pressure (kg/cm2)
d) Approval reference of PESO
3. Refilling Valve:
a) Make
b) Type
4. Fuel Line
a) High pressure pipe dia (ID/OD)
b) Low pressure pipe dia (ID/OD)
5. Shut Off Valve (Solenoid Valves)
a) Make
b) Type
c) Operation Voltage

408
6. Fuel selection switch
a) Make
b) Type
7. Regulator/Vaporizer
a) Make
b) Type
c) Sr. No.
8. Gas-Air Mixer/Injector
a) Make
b) Type
Note: This certificate shall be filled and provided to NG/LPG Genset owner

Signature & Seal of Installer

409
 ANNEXURE - 5

Component testing and safety checks for use of NG/CNG fuels in

internal combustion engine for generator

Clause of Safety code of

No. CNG Kit Component Certifying / Verifying Authority practice / Other Rules,
Standards, etc.
PESO, Nagpur to certify or endorse in case of
1 Cylinder* Gas cylinder rules, 2016
foreign make
Clause no. 5.2 to 5.5 of
1.1 Fitment of cylinder Verify as per Safety Code of practice
Safety Code of Practice
PESO, Nagpur to certify or endorse in case of IS: 3224 or Gas cylinder
2 Cylinder valves*
foreign make rules 2016
Testing of the component as per IS:15713-
2006 or ISO-15500 by test agency.
Alternatively, test agency to verify the test IS: 15713-2006 or ISO-
3 Regulator*
certificate or report conforming to the above 15500
standard issued by accredited testing
laboratory.
Testing of the component as per S:15714-
2006 or ISO-15500 by test Agency. Injectors
to be tested as per ECE R110/ISO 15500
Gas-Air Mixer* / IS: 15714-2006 or ISO-
4 Alternatively, test agency to verify the test
Injectors 15500
certificate or report conforming to the above
standard issued by accredited testing
laboratory.
Testing of the component as per IS:15717-
2006 by test agency.
Petrol Solenoid Alternatively, test agency to verify the test
5 IS: 15717-2006
Valve* certificate or report conforming to the above
standard issued by accredited testing
laboratory.
Testing of the component as per IS: 15712-
2006 or ISO-15500 by test agency.
Alternatively, test agency to verify the test IS: 15712-2006 or ISO-
5.1 Gas Solenoid Valve*
certificate or report conforming to the above 15500
standard issued by accredited testing
laboratory.
Filling Connection
Installation to be checked by test agency as Clauses 5.3.2 to 5.3.6 of
6 (NZS & NGV- 1 type)
per Safety code of practice Safety Code of Practice
(if Applicable)
Ventilation (if 5.7.2 of Safety Code of
7 Test agency to verify.
Applicable) Practice
Testing of the component or verification of
Testing of Conduit*
8 certificate or test report as per IS: 15715- IS: 15715-2008
(if Applicable)
2008 by test agency.
9 CNG fuel line

410
 Clause of Safety code of
No. CNG Kit Component Certifying / Verifying Authority practice / Other Rules,
Standards, etc.
High pressure
9.1
exceeding 100 kPa*
Exceeding 2.15 MPa
Testing of the component or verification of
Rigid pipe certificate or test report as per IS: 15716- IS: 15716-2006
9.1.1 2006 by test agency.
Testing of the component or verification of
3.1.3.1, 3.1.3.2 and
Flexible hose certificate or test report as per AIS -028 by
3.1.3.3.1 of AIS-028
test agency.
Exceeding 100 kPa Testing of the component or verification of
9.1.2 and less than 2.15 certificate or test report as per IS: 15722- IS: 15722-2006
MPa 2006 by test agency.
Testing of the component or verification of
Low pressure – Not
9.2 certificate or test report as per IS: 15722- IS: 15722-2006
exceeding 100 kPa*
2006 by test agency.
Joints and Clause 5.8 of Safety
9.3 Testing by test agency.
Connections* Code of Practice
Compartment or Sub Testing of the component or verification of
10 compartment* (if certificate or test report as per IS: 15720- IS: 15720-2008
Applicable) 2008 by test agency.
Safety check for
Safety checks to be carried out by test Relevant clauses of
11 installation of CNG
agency as per AIS 028. Safety code of Practice
system

* Certificate issued by accredited testing agency of the country of origin or a report issued by
internationally accredited test laboratory may also be accepted.
Note 1: - Even though all above standards are applicable for automotive applications,
considering the use of same or equivalent fuel for Generator application these standards shall
be used for CNG components certifications of Generator.
Note 2: - Only the standards, as amended from time to time, as mentioned above, shall be
referred for compliance.
Note 3: - Approvals issued prior to implementation of these rules shall be extended for
compliance to above requirements without revalidation.

411
 ANNEXURE - 6

Safety checks for use of LPG fuels in internal combustion engine for
generator

Clause of Safety code

Sr.
LPG Kit Component Certifying /Verifying Authority of practice / Other
No.
Standards, Rules, etc.
PESO, Nagpur to certify or endorse in
1 Cylinder* Gas cylinder rules, 2016
case of foreign make
Cylinder valves / Multi- PESO, Nagpur to certify or endorse in
2 Gas cylinder rules, 2016
Functional Valve* case of foreign make
Regulators which are used to reduce the
pressure in LPG installation shall meet
IS:6044 (Part 1)
the requirements of IS :6044(Part 1) as
amended from time to time.
Regulator/ Vaporizer which is used to
meter Gas for Genset engine shall be
3 Regulator/Vaporizer *
Tested as per ECE Regulation No. 67 by
test agency.
ECE Regulation No. 67
Alternatively, test agency to verify the
test certificate or report conforming to
the above standard issued by accredited
testing laboratory.
Testing of the component as per ECE
Regulation No. 67 by test agency.
Alternatively, test agency to verify the
4 Gas-Air Mixer/Injectors* ECE Regulation No. 67
test certificate or report conforming to
the above standard issued by accredited
testing laboratory.
ECE Regulation No. 67
Testing of the component as per ECE Note: Petrol solenoid
Regulation No. 67 by test agency. valve is to be tested, as
Petrol and Gas Solenoid Alternatively, test agency to verify the per ECE Regulation No.
5
Valve* test certificate or report conforming to 67, for endurance only
the above standard issued by accredited at a pressure 1.5 times
testing laboratory. the working pressure for
6,000 no. of cycles.
Inspection, Testing &
Commissioning Certificate
Leak testing
6 Excess flow valve test* To be as per Safety Code of Practice
Automatic fill limiter*
Compartment / sub
compartment
Filling Connection Installation to be checked as per Safety Clauses 5.3.2 to 5.3.6 of
7
(if Applicable) Code of Practice Safety Code of Practice
Ventilation to be checked as per Safety Code of 5.7.2 of Safety Code of
8
(if Applicable) Practice Practice

412
 Clause of Safety code
Sr.
LPG Kit Component Certifying /Verifying Authority of practice / Other
No.
Standards, Rules, etc.
Testing of Conduit*
9 To be tested as per AIS 026 AIS 026
(if Applicable)
10 LPG fuel line Shall be tested as per IS:6044 (Part 1)
Fuel line Shall be tested as per IS:6044 (Part 1)
Testing/Verification of Certificate with
Pressure testing Test Report by Test Agency as per
equivalent standard.
a) Size of tube as per Engine Manufacturer’s declaration to be verified b
capacity by Test Agency y
Installer shall meet the installation
On site Fitment on Genset requirements as per IS: 6044 (Part 1)
and this standard
Flexible Hose / fuel line Shall be tested as per IS: 6044 (Part 1)
Testing/Verification of Certificate with
b)
Material Test Report by Test Agency as per IS
:6044 or equivalent standard.
Installer shall meet the installation
Fitment on Genset requirements as per IS: 6044 (Part 1)
c) and this standard.
Pressure Shall be tested as per IS: 6044 (Part 1)
Joints and connections to Installer shall meet the installation
d) Withstand Pressure without requirements as per IS: 6044(Part 1)
any leakage and this standard
Compartment or Sub Test to be carried out by test agency as Relevant clauses of
11
compartment* (if Applicable) per Safety Code of Practice Safety code of Practice
Safety check for installation of Safety checks to be carried out by test Relevant clauses of
12
LPG system agency as per Safety Code of Practice Safety code of Practice

* Certificate issued by accredited testing agency of the country of origin or a report issued by
internationally accredited test laboratory may also be accepted.
Note 1 - Even though all above standards are applicable for automotive applications,
considering the use of same or equivalent fuel for Generator application these standards shall
be used for LPG components certifications of Generator.
Note 2 - Only the standards, as amended from time to time, as mentioned above, shall be
referred for compliance.
Note 3 - Approvals issued prior to implementation of these rules shall be extended for
compliance to above requirements without revalidation.

413
 ANNEXURE - 7

Roles & responsibility of various stakeholders

Sr
Activity Responsibility Remark
No
Getting the approval of NG/LPG/CNG Kit Genset / Engine manufacturer
1
components, approval of cylinders and valves, as the case may be.
Getting the Type approval of engines / Gensets Genset / Engine manufacturer
2
for emission and noise compliance. as the case may be.
Genset manufacturers / its
Getting the approval of PNG lines, joints and
3 authorized
connections for NG Gensets.
person or agency.
Test agencies approved by
4 Approval of NG/LPG/CNG Kit components MoEF /
CPCB
5 Approval of Cylinders and valves PESO, Govt of India
Test agencies approved by
Type approval of engines / Gensets for emission
6 MoEF/
and noise compliance
CPCB
Installation of Genset with CNG/NG/LPG system
at site as per type approved specifications.
Genset manufacturer / its
7 Installation of LPG cylinders and it manifolding
authorized person or agency
system at site as per IS 6044 (Part 1) as
amended from time to time.
Genset manufacturer / its
8 Issue of Installation Certificate authorized
person or agency
Re-testing of CNG/LPG cylinders as per Gas
9 End User
Cylinder Rules after installation
Training to end user about safety and operation
Genset manufacturer/ its
10 of Genset using gaseous fuels in any
authorized person or agency
combination – dedicated / bi-fuel / dual-fuel
Scrapping of CNG/LPG cylinders as per Gas
11 End User
cylinder rules
Periodic leak testing and inspection of gaseous
12 fuel system as per training imparted by End use
Authorized person / Genset manufacturer
City Gas Distribution companies
Approval of PNG lines and its joints and
13 approved by PNGRB, Govt of
connections
India
System Procedure and Safety Procedure
14 CPCB (Nodal agency)
documents

414
 ANNEXURE - 8

Labelling requirements

The engine or the product must be affixed with a conformance label meeting the following
requirements.

8.1 General Requirement

a. The label shall be durable and legible;

b. The label shall be affixed on a part necessary for normal operation of the engine
or the product and not normally requiring replacement during the life of the engine
or the product;

c. Statement that ‘this engine or product conforms to the Environment Protection

Rule 1986;

d. All the information mentioned in the conformance label must be in English

language;

8.2 Conformance Labelling Content Requirement

a. Name the engine manufacturer or the engine or product importer
b. Manufacturing plant address from where engine is manufacture
c. Engine Model name;
d. Rated speed and corresponding gross power in kW;
e. Engine Unique Identification Number (Serial Number, etc.);
f. Date of manufacturing and in case of import, date of import of engine or Genset
product;
g. Type Approval certificate number;
h. Letter ‘G’ to denote that the engine is belongs to Genset application. The Letter
‘G’ shall be engraved on the conformance label. The letter(s) should have a
minimum size of 7 mm.

415
 APPENDIX 8.1

LABEL

The sign consists of a sticker which shall be weather resistant.

The color and dimensions of the sticker shall fulfil the following requirements:
Colors:
Background: Orange
Letters: Black or black reflecting
Dimensions:
Border width: 4 - 6 mm
Character height:  25 mm

416
Character thickness:  4 mm
Sticker width: 110 - 150 mm
Sticker height: 80 - 110 mm
The word "DIESEL+CNG" shall be centered in the middle of the sticker.

∞∞End of The Document∞∞

417