EPA Compliant Fuel Systems IBEX Sep 28, 2010 George Bellwoar

Who should do your design? o Boat builders themselves o Tank builders o Component suppliers o System integrators o All of the above Who is responsible? o Suppliers & designers o Boat builders – your name is on the boat Just how hard is this? o Large number of details o Many design options o It isn’t rocket science Getting started

Boat builders and system integrators need new information o Collecting data first can save time & money Each model boat should be evaluated on a stand-alone basis o Evaluate needs independently o Potential for commonality of design What are the steps in the design process? o Collect data o Evaluate options o Build test boat o Test and certify

Collect Data on… o The boat itself o The fuel tank(s) o Fuel tank location and positioning in the boat o The area immediately above the fuel tank(s) o Access to installed tanks & components o The availability of space for new components (like canisters & ullage tanks) o The fuel and vent line routing

Organize & collect model specific data o Pictures o Hand sketches o Specification sheets o Measurements Focus on o Current & potential fill & vent locations o The areas around your fuel tank o Possible locations for new components Unique characteristics such as o Whether a boat will normally be refueled on the water or on a trailer o Length & beam Boat details

Dimensionally locate all existing tank components o Incoming fill pipe(s) and/or dog house(s) o Tank vent(s) o Connection(s) to engine(s) & generator(s) o Level sender o Hold down straps o Fuel pumps Note any other unique tank features 2D drawings and especially 3D files are useful Tank details

Accurately identify tank positioning relative to… o The hull for venting calculations at static rest o Fills & vents to begin evaluating fill quality Know how your customer’s use can affect tank position o While on a trailer o While in storage Fuel tank location & positioning in the boat

Note all tank clearances o Consider potential for tank expansion During pressure testing During refueling From diurnal changes Anticipate component placement o Recognize changing clearances o Pay particular attention to the center of the tank The area immediately above the tank

Marine o Passive purge o Remote fuel pump o Fill above fuel level o Fittings on top most level of tank o Refueling vapors vented to atmosphere o Tank & fittings subject to fire test o USCG requires access to our connections Automotive vs. marine systems Automotive o Active purge o Fuel pump in tank o Fill below fuel level o Fittings below top most level of tank o Refueling vapors captured at pump or on-board Automotive Marine

Access to installed tanks & components Access requirements affect component placement US Coast Guard regulations require access to…  Tank connections o Valves o Senders o All tank penetrations  Hose connections o Valves o Canisters o Ullage tanks o Fills o Vents

This configuration will affect fill quality Problem configurations include those with… o Long runs o Gentle slopes o Hard angles o Dips Collect details on current system including… o Overall run length & drop from fill & vent to tank o All slopes individually and as a system o Any dips o Any 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) PERKO DELPHI ATTWOOD STANT

Protecting canisters From water o Gravity o Inverted loops o P-trap type devices A-24 (i.e. A-16) requirements o Above the shear line o Below the shear line From fuel o Automotive style fuel system valves o Gravity - 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 tank o Must be located above the fuel tank o Must meet fuel tank requirements including fire resistance & permeation o Are sized at approximately 6% of fuel tank volume o May still require a valve to protect canisters from fuel Advantages o Eliminates or reduces access problems o Allows for complete tank filling & greater range o May be the best solution for extremely long, shallow tanks Ullage tanks

When to start o As 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 start o Meet with & select vendors/partners o Collect data o Evaluate options o Build test boat o Test and certify Getting started

Sample Design Worksheets