EPA Compliant Fuel SystemsIBEX Sep 28, 2010

George Bellwoar

•Who should do your design?oBoat builders themselvesoTank buildersoComponent suppliersoSystem integratorsoAll of the above

•Who is responsible?oSuppliers & designersoBoat builders – your name is on the boat

•Just how hard is this?oLarge number of detailsoMany design optionsoIt isn’t rocket science

Getting started

•Boat builders and system integrators need new informationoCollecting data first can save time & money

•Each model boat should be evaluated on a stand-alone basisoEvaluate needs independentlyoPotential for commonality of design

•What are the steps in the design process?oCollect dataoEvaluate optionsoBuild test boatoTest and certify

•Collect Data on…

oThe boat itself

oThe fuel tank(s)

oFuel tank location and positioning in the boat

oThe area immediately above the fuel tank(s)

oAccess to installed tanks & components

oThe availability of space for new components

(like canisters & ullage tanks)

oThe fuel and vent line routing

•Organize & collect model specific dataoPicturesoHand sketchesoSpecification sheetsoMeasurements

•Focus on oCurrent & potential fill & vent locationsoThe areas around your fuel tankoPossible locations for new components

•Unique characteristics such as oWhether a boat will normally be refueled on the water or on a traileroLength & beam

Boat details

•Dimensionally locate all existing tank componentsoIncoming fill pipe(s) and/or dog house(s)oTank vent(s)oConnection(s) to engine(s) & generator(s)oLevel senderoHold down strapsoFuel pumps

•Note any other unique tank features

•2D drawings and especially 3D files are useful

Tank details

•Accurately identify tank positioning relative to…oThe hull for venting calculations at static restoFills & vents to begin evaluating fill quality

•Know how your customer’s use can affect tank positionoWhile on a traileroWhile in storage

Fuel tank location & positioning in the boat

•Note all tank clearancesoConsider potential for tank expansion

•During pressure testing•During refueling•From diurnal changes

•Anticipate component placementoRecognize changing clearancesoPay particular attention to the center of the tank

The area immediately above the tank

•MarineoPassive purgeoRemote fuel pumpoFill above fuel leveloFittings on top most level of tankoRefueling vapors vented to atmosphereoTank & fittings subject to fire testoUSCG requires access to our connections

Automotive vs.marine systems

•AutomotiveoActive purgeoFuel pump in tankoFill below fuel leveloFittings below top most level of tankoRefueling vapors captured at pump or on-board

Automotive

Marine

Access to installedtanks & components

•Access requirements affect component placement

•US Coast Guard regulations require access to…Tank connections

oValvesoSendersoAll tank penetrations

Hose connectionsoValvesoCanistersoUllage tanksoFillsoVents

•This configuration will affect fill quality

•Problem configurations include those with…oLong runsoGentle slopesoHard anglesoDips

•Collect details on current system including…oOverall run length & drop from fill & vent to tankoAll slopes individually and as a systemoAny dipsoAny hard curves or bends (>45 )

Fill & vent line routing

Canisters

•Function

•Installation•Positioning•Supporting

•Potential failure modes•Cracked housing or fittings•Carbon breakdown•Flooded (water or fuel)

PERKODELPHI

ATTWOODSTANT

Protecting canisters

•From wateroGravityoInverted loopsoP-trap type devices

•A-24 (i.e. A-16) requirementsoAbove the shear lineoBelow the shear line

•From fueloAutomotive style fuel system

valvesoGravity - Alternate system

approaches• Sebek Technology• Enviro-Fill by Ameri-Kart• Air/fuel separators

•Ullage tanks…o Are vent-line devices containing airspace outside

of the fuel tanko Must be located above the fuel tanko Must meet fuel tank requirements including fire

resistance & permeationo Are sized at approximately 6% of fuel tank volumeo May still require a valve to protect canisters from

fuel

•Advantageso Eliminates or reduces access problemso Allows for complete tank filling & greater rangeo May be the best solution for extremely long,

shallow tanks

Ullage tanks

•When to startoAs soon as possible…this will take time

•System design help & components are available now•This is practical•The tools exists•There are vendors ready & able to help

•How to startoMeet with & select vendors/partnersoCollect dataoEvaluate optionsoBuild test boatoTest and certify

Getting started

Sample Design Worksheets