EPA Compliant Fuel Systems IBEX Oct 18, 2011 Sean Whelan P.E

1

EPA Compliant Fuel SystemsIBEX Oct 18, 2011

Sean Whelan P.E.

2

Agenda

1. I have chosen a Diurnal path, now what?

2. Validation and Testing

3. Common Pitfalls to Avoid

3

Planning Overview

1. Diurnal

2. Refueling

3. Venting

4. Engine

Compatibility

1. 3rd party

2. Internal

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

1. Validation

2. Performance

4

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

FMEA

Failure Modes

DVPR

Validation Plan

Project# PARTICIPANTS:

Responsible UPDATED: 6/2/2011

ID Procedure Validation Description Method Acceptance Criteria Target RequirementsValidation

ResponsibilityValidation Resource Phase Duration

Available Start

Required Completion

Part Number/ Design Status Report No. Actual Results Status

Re-validate Trace Notes

If RequiredDescribe the product constraint or

product improvement opportunity that Design or Engineering must consider

(T)est(O)bserve(R)euse(A)nalyze(D)emo

Quantify cycles, hours, volts, minimum value, no failure, etc.

Accountable for completion and interpretation of this activity (Must be name)

Facility, Department, or outside resource which will perform actual activity

QtySample Size

Rev

TYPEProto1st ShotsPre-PilotPilotProduction(O)ther

Cavity #

Program or build phase to be performedExample: Phase 2, DV1,BM (benchmark), PV1, CV1

From beginning ofpreparation to results

Projected earliest available start referencing predecessor

Latest possible completion to maintain established program timing

Identifying number, Change Level, design phase or other indicator that can discriminatepre-production parts

Identify the report no. that supports the test results.- Location if not part of controlled repository

Summarize results in terms of Acceptance Criteria

P = PassDNP = Did Not PassR = Retest RequiredI = In ProcessD = DelayedBlank - Not due

DVP&R Item number of required retesting

Describe or elaborate on unique criteria, results, etc.

System Verification

DV1

Automatic Nozzle Shut Off

Conduct L18 orthoginal array DOE to determine feasability of automatic nozzle shut off.

TestNo liquid spitback or wellback

Sean Stant18 systems

NA Proto NA DV 12 week 9/16/2010 12/16/2010 NADOE file & PAC presentations

ICV required1.5" hose workssmall/med/large tanks workhose length works from 6" to 15'hose routing criticalAll deckfills workFLVV & snorkle work……..

P

DV2

Snorkle Performance

Conduct DOE to determine fill level repeatability performance evaluation of snorkle and FLVV

Test

ExperimentalTank level repeatability +/- 0.5%

Sean/ Adrian Stant 3 Systems NA Proto NA Phase 3 4 week 3/14/2010 4/14/2010 NA

DOE files NPD

PROJECTS\FUEL_HARDWARE

_FISHING\Fuel\Integrated

Fuel\Proj#537 Next Gen Marine

Fuel System\Engineering

Data\DOE Fill Level

Snorkle could not prevent liquid gasoline from passing.

DV3Next Gen Deckfill Fill Performance

Conduct confirmation filling events to prove deckfill geometry can contribute to propoer nozzle shut off. Required for both straight and angled deckfill bodies

Test

No liquid spitback or wellback

Sean/ TonyAttwood Boat Yard

6 Proto NA Phase 3 4 week 4/15/2010 5/15/2010 FDM proto NA No spitback or wellback P

DV4 Fire TestConduct fire test on tank asm with FLVV, GRV, ICV, FDV on tank

Test Must remain sealed after test

Chris TSG 2 systems NA Various NA Phase 3 8 week 3/5/2010 5/5/2010 Parts remained sealed P

DV5Pressure Lifecycle

Conduct lifecycle durability study on entire fuel system to proove out feasability of PRV system.

TestNo vapor or liquid liquid leak at end of test.

7500 cycles (20.5 years) Sean/ ChrisAttwood Test Lab

3 systems 6months 10/20/2010 4/13/2011 TR2010-555 pMoeller Low Perm Tank, leaks through FLVV screw holes post cycling

DV5-1Pressure Lifecycle



Attwood 3 systems TR2010-572 p TR2011-75FMT Aluminum Tanks: leak through FLVV screw holes




Attwood 3 systems TR2010-639 p Inca Fuel tanks




Attwood 2 systems TR2010-688 p RDS aluminum fuel tanks




Attwood 2 systems TR2011-75 pRetest of TR2010-572(FMT aluminum fuel tanks; "new gaskets"




Attwood 3 systems TR2011-178 pKracor Fuel tanks(two FLVV's leak at weld post 10,000 cycles at ambient

DV6 Fill Level Prediction DOE

Study the repeatability & predictability of fuel fill levels with known system design variables.

TestExperimental

Tank level repeatability +/- 0.5%

Attwood Boat Yard

20 systems

pull aheads Proto NA 4 6weeks p Not DueNo longer required due to DV13-DV18

DV7 Component Contributions

Sigularly quantify the individual backpressure vs flow performance for each component in the next gen fuel system

Test

ExperimentalAttwood Test Lab

3 per component

pull aheads Proto NA 4 12 weeks 12/2/2010 3/3/2011 TR2010-642 pWaiting on additional deckfills(SS)

DV8

Jerry Can filling

Attempt to fill a fuel system via a 5gal commercially available jerry can.

TestSystem must not over pressurize to a pressure 0.5kpa greater than intended (i.e. 0psi or 1.1psi). Liquid must not exit the fuel system in any mannor that may result in liquid in the bilge.

TSG (Or Attwood if we simulate 5% expansion)

6 systems representing best and worst case of each architecture

Pull Aheads proto NA 4 4 weeks 11/4/2010 12/15/2010 TR2010-628 p

TR628 need additional samples(components) RFQ#TSG 0C277ANeed test report from TSG; need to review TSG report for clarification. Contacted TSG, they are working on updating their report for clarification

DV8-1 Jerry Can filling





4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling

Build various systems with current & next gen fuel components. Measure pressure drop.Reference Mercury FS.M.11

Test

Experimentalless than 1kPa total backpressure at flow rate between 0-250lph

Eric & Josh Stillwater 13 Pull Aheads Proto NA 4 4weeks 8/9/2010 1/7/2011 pReceived data from Eric(3/5/2011); need to review.

DV10

Thermal expansion

Fill tanks to predetermined liquid level with low temperature fuel and warm fuel system to understand actual affects of thermal expansion on the system.

Test

Experimental TSG3 systems per tank material

Pull ahead proto NA 4weeks 11/4/2010 12/3/2010TR2010-619, TR2010- 684

pTested Low perm plastic PRV and CC and aluminum PRV and CC systems.

DV11

Vapor condensation

Determine how much vapor can condence in a vapor line and study the affects of liquid in vapor line.

Test

ExperimentalAttwood or TSG

12/4/2010 12/16/2010 TR2010-629 p Complete

Design Validation Plan and Report

VALIDATION REPORT

Sample

VALIDATION PLAN





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN

Boat is a system

Fuel is a sub-system

Project#

Responsible PE, ME, QE UPDATED:

FMEA START DATE:

PARTICIPANTS: Results

Part/Design, orFunction

Potential Failure Mode

Potential Effect(s) of

Failure

Sev

Potential Cause(s) /

Mechanism(s) of Failure

Occur

Current Design Controls

Prevention

Current Design Controls Detection

Detec

RPN

Recommended Action(s)

Responsibility & Target Completion

DateNew Sev

New Occ

New Det

New RPN

item SYSTEM

42Allows fuel to flow to engine for operation

Ethanol/water mix is picked up by engine feed line in lue of gasoline

Engine may not run: Engines overheat, improper lubrication, calibrations off etc 8

Phase separation due to water entering system from external environment 5

Design to Prevent water from entering system via P-trap and Teflon screen (use of existing water-resistant components)

PV builds, test fleets, DVP&R 8 320

Use (water resistant) Attwood P-Trap and (water resistant) Attwood Deck Fill Boat Builder 8 1 8 64

56Store Fuel Inside Vessel

May leak fuel into vessel

Gasoline in Bilge (inboard) 9

Tank is punctured by vibration of hull 4

Tank mounting scheme to eliminate tank movement

PV builds, test fleets, DVP&R…BOAT BUILDER 8 288

tank must be isolated from abrasive surfaces and prevented from movement Boat Builder 9 2 3 54




Routing of hoses coupled with vent locations (closing off the relief system) 4

Installation instructions, web based tool


Install OPR Deck Fill such that liquid gasoline will exit the vessel. Boat Builder 9 1 3 27


Maximum fill level is too large (i.e. ullage is too small)

Consumer can overfill tank and result in fuel spilling out of system 8


Fill level DOE. Use of web based design tool.


Install OPR Deck Fill such that liquid gasoline will exit the vessel Boat Builder 8 1 3 24


Fuel may leak outside of vessel

Gasoline leak into exterior of deck (outboard) 8

Tank looses shape and is flexible not rigid 4

Use of existing Tank design and geometry


CFR33 3psi check fully installed. Include in installation check list Boat Builder 8 3 3 72





Use of existing Tank mounting scheme eliminates tank movement. Web based design tool.


tank must be isolated from abrasive surfaces and prevented from movement. Does web based design tool help here? Boat Builder 8 2 3 48





Installation instructions, web based design tool/approval






Tank is punctured by deck screws 4

Clearance between deck and tank, installation instruction



Design Failure Modes and Effects Analysis (DFMEA)Project#


FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM

























































Design Failure Modes and Effects Analysis (DFMEA)

5

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

Example Validation Plans

BOAT MODEL XYZ VALIDATION PLANOne (1) DV Boatbuilt with each

unique EPA tank/system

Each Unique Model built with an EPA System?

(All DV Boats)Some PV Boats All PV Boats Some Production Boats All Production Boats

Pressure test - inspect for leaks Pass Pass Pass Pass Pass PassMercury/Attwood Fuel Vacuum Test Pass Pass Pass Pass Pass PassFill & Automatic Shut Off Test Pass Pass Pass Pass Pass PassDiurnal Test - 4 days on trailer @ 100% capacity Pass Pass Pass Pass Pass PassEndurance Test - 50 hours Pass Pass Pass Pass Pass Pass

Automatic Shut Off & No Spitback Test (At PD&E Center)One (1) DV Boatbuilt with each




4 gpm @ static float Pass Pass Pass Pass Pass Pass4 gpm @ 4 Port Pass Pass Pass Pass Pass Pass4 gpm @ 4° Stbd Pass Pass Pass Pass Pass Pass4 gpm @ 4° Bow Up Pass Pass Pass Pass Pass Pass4 gpm @ 4° Bow Down Pass Pass Pass Pass Pass Pass10 gpm @ static float Pass Pass Pass Pass Pass Pass10 gpm @ 4° Port Pass Pass Pass Pass Pass Pass10 gpm @ 4° Stbd Pass Pass Pass Pass Pass Pass10 gpm @ 4° Bow Up Pass Pass Pass Pass Pass Pass10 gpm @ 4° Bow Down Pass Pass Pass Pass Pass Pass

Automatic Shut Off & No Spitback Test (At Gas Station)One (1) DV Boatbuilt with each




X gpm @ static float Pass Pass Pass Pass Pass Pass

Automatic Shut Off & No Spitback Test (At Marina)One (1) DV Boatbuilt with each




Y gpm @ static float (Assumes Y >> X) Pass Pass Pass Pass Pass Pass

Jerry Can Filling TestOne (1) DV Boatbuilt with each




Trailer Pass Pass Pass Pass Pass PassStatic floating Pass Pass Pass Pass Pass Pass

Post Endurance TestsOne (1) DV Boatbuilt with each




Z gpm @ static float (Z = 4, 10, X, or Y) Pass Pass Pass Pass Pass PassDiurnal Test - 4 days on trailer @ 100% capacity Pass Pass Pass Pass Pass PassMercury/Attwood Fuel Vacuum Test Pass Pass Pass Pass Pass Pass

6

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

Example Validation Plans DV



ID Procedure Validation Description Method Acceptance Criteria Target Requirements StatusRe-validate

Trace







System Verification

DV1Automatic Nozzle Shut Off



P

DV2Snorkle Performance


TestExperimental



Conduct confirmation filling events to prove deckfill geometry can contribute to propoer nozzle shut off. Required for both

Test No liquid spitback or wellback

P

DV4Fire Test

Conduct fire test on tank asm with FLVV, GRV, ICV, FDV on tank


P



Test No vapor or liquid liquid leak at end of test.

7500 cycles (20.5 years) p

DV6Fill Level Prediction DOE


TestExperimental


p Not Due

DV7Component Contributions

Sigularly quantify the individual backpressure vs flow performance for each component in the next gen fuel

TestExperimental p

DV8Jerry Can filling


Test System must not over pressurize to a pressure 0.5kpa greater than

p

DV8-1 Jerry Can fillingAttempt to fill a fuel system via a 5gal commercially available jerry can.

Test System must not over pressurize to a pressure 0.5kpa greater than

p

DV9Hot Fuel Handling

Build various systems with current & next gen fuel components. Measure pressure drop.

TestExperimental

less than 1kPa total backpressure at flow rate between 0-250lph

p

DV10Thermal expansion

Fill tanks to predetermined liquid level with low temperature fuel and warm fuel system to understand actual affects of

TestExperimental p

DV11Vapor condensation


TestExperimental p

DV12System level leak test Define the system acceptable leak rates to

meet CFR33 3psi check. Measure leak rate of each component at 3psi.

Test cummulative leak rate results in less than 0.1psi pressure loss in

0.1 p

DV13FLVV Shut Off Heights

fill (non-rigid) test tank with automatic nozzle and 2.3in FLVV

Test None- Experimenmtal only. Results will affect Fill Predictability DOE

Delta between fill heights of 2.3FLVV & 0.8FLVV shall be equal

p

DV14GRV Linearity between 0 and 3

Test tank with 0,1,2,& 3 GRV's, fill tank via automatic nozzle shut off


Desired linear relationship of fuel volume to number of

p

DV15ICV Orientation

test typical system with ICV horizontal & verticle, determine


oreintation shall not affect final voilume of fuel in tank

p

DV16ICV spring force- maximize force @ worst case 6"height

test system with 6" height (deckfill to tank top), flow at 4gpm,


maximize spring torque value

p

DV17PRV vs CC. -

test typical system with CC and typical system with PRV and


fill level shall be approximatly equal for both systems

p

DV18Tank Flex at FLVV-

test constrained FLVV & unconstrained, check that delta of


delta of fill level heights between constrained and unconstrained shall

p

Fuel Sub-System

VALIDATION REPORTVALIDATION PLAN

7

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

Example Validation Plans PV



ID Procedure Validation Description Method Acceptance Criteria Target Requirements StatusRe-validate

Trace







System Validation p

PV1Static Pressure & Leak test Install entire system per installation

instructions at high and low end of acceptable tolerances. Then conduct

Test no bubbles Pass

PV2Shock Test Reference CFR33 183.584

conduct leak test, 30day fuel soak, conduct 1000 25g load shock filled to


PV3Pressure Impulse Reference CFR33 183.586

conduct leak test, 30day fuel soak, conduct 25,000 cycles from -0.15 to 3psig,


PV4Slosh Reference CFR33 183.588

conduct leak test, pressure impulse, fill with 1/4 capicty with water and apply


PV4-1

Slosh Reference CFR33 183.588conduct leak test, pressure impulse, fill with 1/4 capicty with water and apply 500,000 cycles rocking 15deg to each side, leak test


PV5

Fire Reference CFR33 183.590conduct leak test, ignite fire undernethe tank asm , leak test


PV6

Fuel feed line pressure Install each approved architecture with PV samples and measure vacuum required to flow fuel to engine. Reference DV test hot fuel handling.

Testunknown until we complete DV Hot fuel handling test

Pass

PV7

Refueling performance Install each approved architecture with PV samples at max & min conditions and measure refueling performance.Reference SAE J398) Insert nozzle into deckfill to maximum penetration then allow it to latch on the retention feature. Set and latch nozzle to maximum flow until nozzle shuts off automatically. After 5 seconds set and latch nozzle to minimum flow rate p

TestNo liquid spitback or wellback.

Pass

Fuel Sub-System

VALIDATION REPORTVALIDATION PLAN

8

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

How well does it perform?

High RVP fuels? Hot Days?

With Jerry Cans? At Marinas?

With engine? Etc…

9

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

Who Owns Liability

Who is responsible for

-over pressurization -Un-fillable

-diurnal performance -Customer Satisfaction

-leaks -USCG violation

-Engine compatibility -Etc…

Beware finger pointing

10

1. Validation

2. Performance

3. Field Liability

4. EPA compliance

5. ABYC Compliance

Who Owns EPA & ABYC Compliance

Who is responsible for

-diurnal performance -EPA filing

-EPA Audit -Certificate of Conformance

-Record retention -Exemption tracking

-ABYC H24 compliance -NMMA inspection

-Weathertight/ Watertight -3psi pressure test

Beware finger pointing

EPA Civil Penalty $32,500 per vessel (40CFR1068.101(a)(1))

11

Components-

Carbon Canister, Deckfill, Fuel Tank, Valves, Pressure Release Valve etc.

11

Project#


FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM



























































FMEA START DATE:





Failure

Sev



Occur


Prevention


Detec

RPN



DateNew Sev

New Occ

New Det

New RPN

item SYSTEM

























































Design Failure Modes and Effects Analysis (DFMEA)

FMEA

Failure Modes

DVPR

Validation Plan





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN





Available Start

Required Completion









QtySample Size

Rev


Cavity #











System Verification

DV1







P

DV2

Snorkle Performance


Test



DOE files NPD





Data\DOE Fill Level




Test


































TestExperimental


Attwood Boat Yard

20 systems




Test


3 per component


DV8

Jerry Can filling












4 4 weeks 8/29/2011 TR2011-420(TSG-1C630A)

p

DV9

Hot Fuel Handling


Test



DV10

Thermal expansion


Test




DV11

Vapor condensation


Test


12/4/2010 12/16/2010 TR2010-629 p Complete


VALIDATION REPORT

Sample

VALIDATION PLAN

1. Validation

2. Performance

Responsible

ID Procedure Validation Description Status

If RequiredDescribe the product constraint or product improvement opportunity that Design or

Engineering must consider


Design Validation

Production Validation

1ASamples to be exposed in Xenon Test Chamber for 500 hours using the following cycle: 102 minutes of light at 0.55 W/m^2 at 340nm

Xenon Arc exposure test pass

1BSamples to be exposed in Xenon Test Chamber for 500 hours using the following cycle: 102 minutes of light at 0.55 W/m^2 at 340nm


1CSamples to be exposed in Xenon Test Chamber for 500 hours using the following cycle: 102 minutes of light at 0.55 W/m^2 at 340nm


2Samples to be exposed in Xenon Test Chamber for 120 hours using the following cycle: 102 minutes of light at 0.55 W/m^2 at 340nm


3AMercury LT.G.29 (900 hours) (include legacy product)Cap closed

UV exposure test (plastic and metal) pass

4Mercury LT.G.29 (216 hours) (include legacy product)Cap open


5Dry air age samples at 210-212° F for 70 hours, then allow to cool at room temperature for a minimum of 2-3 hours, 30 day fuel soak at

Chemical exposure test to interior of assembly

pass

6Mercury test procedure LT.G.30a) Mercury Power Tune - Engine Cleaner P/N 92-802878 57

Chemical exposure test to exterior of assembly

pass

7AMercury M-074-TStress o-ring to max % strain (based on tolerance stack)

Ozone test pass

7CMercury M-074-TStress o-ring to max % strain (based on tolerance stack)

Ozone test pass


Ozone test pass

8Thermal shock at 80c for 10 min, lower temperature at a steady rate to -40c for 60 min, hold at -40c for 10 min, increase temperature at a

Thermo Testing - withstand temperatures encountered during storage / use

pass

9AES-310Perform external water sealing test before torque test

Body Strength Torque Test pass

11Precondition with 500 hour Xenon Arc & 900 hour UVPrecondition per exterior chemical test (LT.G.30)

Cap Impact Test pass


Cap Side Load Testing pass


Cap Step Test pass

14APrecondition per interior chemical resistance testPrecondition samples with ozone test in closed position

External Water Sealing Test pass

15SAE J19283 per assembly X 6 assemblies

Flame arrestingpass

16ATLP004Attwood 96 (plastic, stainless) 48 hour (zamak) hour salt spray

Corrosion Resistance (plastic and metal) pass

17A. Mount the straight assembly to a horizontal surfacde & the angled assembly to a 35° from horizontal surface, attach cap to the fill hose

Dust ingestion pass

COMPONENT VALIDATION PLAN

VALIDATION PLAN

Responsible





Design Validation
















pass



pass


Ozone test pass


Ozone test pass


Ozone test pass



pass








Cap Step Test pass




Flame arrestingpass




Dust ingestion pass


VALIDATION PLAN

Responsible





Design Validation
















pass



pass


Ozone test pass


Ozone test pass


Ozone test pass



pass








Cap Step Test pass




Flame arrestingpass




Dust ingestion pass


VALIDATION PLAN

Example Validation Plans

Responsible





Design Validation
















pass



pass


Ozone test pass


Ozone test pass


Ozone test pass



pass








Cap Step Test pass




Flame arrestingpass




Dust ingestion pass


VALIDATION PLAN

1. Validation

2. Performance

How well does component perform?

Vacuum pressure vs. volume flow rate

0

150

300

450

600

750

900

1050

1200

1350

1500

1650

1800

1950

0.1 0.3 0.5 0.7 0.9 1.1 1.3 1.5

vacuum, ΔP (kPa)

Vo

lum

e fl

ow

rat

e, V

(sl

ph

)

1 valve

3 valve

Max flow rate

Max restriction

Power packagePeak

power, P (hp)

Mass flow rate, m* (lbm/hr)

Volume flow rate, v (gal/hr)

Volume flow rate, v (L/min)

Volume flow rate, single, v1

(L/hr)

Volume flow rate, dual, v2 (L/hr)

Volume flow rate, triple, v3

(L/hr)

Volume flow rate, quad, v4

(L/hr)


(L/hr)


(L/hr)300 Verado 300 193.8 31.2 2.0 118.0 236.0 354.1 472.1 590.1 708.1

350 SCi Verado 350 213.5 34.4 2.2 130.0 260.0 390.0 520.1 650.1 780.1Yamaha F350 350 231.0 37.2 2.3 140.7 281.3 422.0 562.7 703.4 844.0

496 HO/502 HO 425 212.5 34.2 2.2 129.4 258.8 388.2 517.6 647.0 776.41200 SCi 1350 769.5 123.8 7.8 468.6 937.2 1405.8 1874.4 2343.0 2811.6

1. Validation

2. Performance

How well does component perform?

1. Validation

2. Performance

1. Do not assume water will act like gasoline.

2. Make sure all needs are met, not just one.

3. If boat refuels well at 70°F, do not assume it fills well at 90°F.

4. Don’t assume that an initial demonstration means that system will work after years on the water.

5. Verify plant installation early in process.

6. Consult with engine manufacturer and measure pressure drop at engine.

7. Plan for future CARB regulations now.

8. Do not underestimate the task of implementation.

Common Pitfalls to Avoid

16

Thank you

Questions?

Documents

EPA Compliant Fuel Systems IBEX Oct 18, 2011 Sean Whelan P.E