P. 1 

# OAR Box 1147 Prepped by Ollie Stewart



### Document

Number: 

# 199)IV-E-7 3 Docket Number: 

# A-87-1 1

Printed 4/22/20082:42:58PM

Sheet 199of 2425 

## ^°J!

A 

## % P. 2

UNITE D STATE S ENVIRONMENTA L PROTECTIO N AGENC Y

AN N ARBOR . MICHIGA N 4810 5
OFFIC E O F AI R AN D RADIATIO N 

## OC T T 

## 198 8
MEMORANDU

M SUBJECT :
FROM : TO : Briefing o n Ford' s Onboar d Hardwar e Progra man d Running Los s Contro l Glenn W . Passavant , Senio r Projec t Manag e Standard s Developmen t an d Suppor t Branc h Publi c Docket s A-87-1 1 an d A-85-2 1 

# r J^J&^^A**"* d

On Septembe r 26 , 198 8 Mr . Donal d Buist , th e Directo r o f Ford' s Automotiv e Emission s an d Fue l Econom

yOffice , an

d severa l othe r For

d staf f member s briefe d EPAo n the statu s o f thei r evaluatio n o f th e simplifie d onboar d contro l concept . Bot h a lis t o f attendee s an d a cop

yo f th e briefing presente d b yFord ar e attached . Durin g th e cours e o f the meeting we discusse d th e concern s raised b

yFord , an

d EP Apointe d ou t .severa l ke yaspect s o f Ford' s syste

mwhic h we fel t the yha d no t full yconsidere d i n thei r attempt s t o develo p a syste mwhic h perform s satisfactorily . For d an d EP Aagree d tha t severa l follow-u p step s wer e necessar yin orde r t o identif ythe cause s o f the limitation s o f Ford' s syste man d t o addres s remaining problems . Afollow-u p lette r wil l be sen t t o Ford summarizing EPA' s perspectiv e o n thei r simplifie d syste manalysi s an

d th e follow-u

p step s agree d upon . Attachment s z.<rfy-
•i^OCP. 3



### Lis t o f Attendee s EPA/For d Meeting o n Onboar d Control s Septembe r 26 , 198 8 EP AFord Richar d Wilso n Donal d Buis t Charle s Gra

yKell yBrow n Joh n Anderso n Harol d Howey Glen n Passavan t Willia mKin g Dave Bartu s Walte r Kreuche r Pau l Laing Ti mO'Brie n Jean Schwendema n To mRolewic z Mik e Schwar z Wall yWad e

6443 WP. 4



### FINDING S FRO M TH E EVALUATION O F TH E PROTOTYP E "SIMPLIFIED " REFUELINGCONTRO L SYSTE M

SEPTEMBER , 198 8P. 5



### FINDING S FRO M TH E EVALUATIO N OF TH E PROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

PRESENTATIO N

OUTLIN E
I - DESCRIPTIO N

OF HARDWAR E
II . DESCRIPTIO N

O F TES T PROGRAM
III . EFFECT S OF A

LARGE RCARBO N

CANISTE R
IV - DEFICIENCIE S OF TH E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M
V . ADDRESSIN GTH E DEFICIENCIE S
VI - RUNNIN GLOS S CONTRO ;
V I L CONCLUSION SP R



### FINDING S FROM THE EVALUATIO N OF TH E PROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

SECTIO N I HARDWAR E DESCRIPTION SP. 7



## FOR D PRODUCTIO N

(OEM ) EVAPORATIV E EMISSION S SYSTE M 1 . FUE L TAN

K 2 - CARBON

CANISTE R(APPROXIMATEL Y1 LITER ) 3 - FUE L FILLE RPIP E (SHOW N WIT H EXTERNA L VEN T LINE ) 4 . ROLLOVER/VAPO RVEN T VALV E (0-050 " DIAMETE RORIFICE ) 5 - VAPORVEN T LIN E TO CANISTE R(0-25 " I-D- ) 6 - LIN E T O CANISTE RPURG E CONTRO L VALV E (I F FITTED ) AN D ENGIN E INTAK E MANIFOL D



# © ©P. 8



### "SIMPLIFIE D OBVR " REFUELINGCONTRO L SYSTE M (BASE D O N TH E PROTOTYP E HARDWAR E PRESENTE D B YEPA O N APRI L 13 , 1988 )
1 - FUE L TAN

K ENLARGE D CARBON

CANISTE R(SIZ E UNSPECIFIED ) 3 - FUE L FILLE RPIP E WIT H VEN T LIN E REMOVE D 4 - MODIFIE D ROLLOVER/VEN T VALV E WIT H LARG E DIAMETE R(0-350" ) ORIFIC E TO ALLO

W PASSAG E O

F REFUELIN GVAPO R 5 - ENLARGE D VAPO RVEN T LIN E 6 - PURG E LIN E 7 - ANTI-SPITBAC KCHEC KVALV E



# ©P. 9



## FOR DMODIFICATION S T O "SIMPLIFIED " OBV RSYSTE M CONCERN : "SIMPLE " SYSTE M I N IT S ORIGINA L FOR

M PERFORME DVERYPOORL Y WIT H REGAR DT O REFUELIN GFLO W RAT E ANDFUE L SPITBACK - TH E SYSTE M WOUL DACCEP T FIL L RATE S N O HIGHE RTHA

N 6 GPM TH E FOLLOWIN GCHANGE S WER E MAD E T O IMPROV E TH E SYSTEM' S PERFORMANCE : 1 . FILLE RPIP E RAISE D5 " O N F-25 0 (MOS T CURREN T PRODUCT S D O NO T ALLO W THI S MODIFICATIO N

INCLUDINGPRODUCTIO N

F-250 ) 2 - SECON DROLLOVER/VEN T VALV E ADDE D VAPO RVEN T LIN E INCREASE DT O 0-75 " I-D EP A DI DNO T SPECIF YTH E CANISTER' S VOLUM E FOR DCHOS E 3 LITER S OF CARBO N A S ADEQUAT E FORTHI S SYSTE M (SE E 3 O N DIAGRAM )


# ©
©P.1 0



## FINDING S FROM TH E EVALUATIO N OF TH E PROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

SECTIO N I I DESCRIPTIO N

OF TES T PROGRA

MP.1 1 

### TES T DESCRIPTION S VEHICLE S TESTE D 1 . 198 7 TAURU S L XSEDA N - 3-O L POR T INJECTIO N 2 - 198 7 F-25 0 PICKU P - 5-O L POR T INJECTION SAME TES T SERIE S FORBOT H VEHICLE S TES T PROGRA

M 1 . FUE L TAN

KFIL L QUALIT Y(OE

M AND "SIMPLE " SYSTEMS )

- TES T T O EVALUAT E TH E CUSTOMER' S ABILIT YTO FUE L TH E VEHICL E WIT H N O POO RFIL L BEHAVIO R

- UNDESIRABL E BEHAVIO RINCLUDE S FUE L SPITBAC K(SPRA YO R LIQUI D SURGE) , PREMATUR E NOZZL E SHUTOFF , O RINABILIT YT O FIL L TAN KCOMPLETEL Y

- CONVENTIONA L AND VAPO RRECOVER Y(CARB ) FILLE RNOZZLE S

- LO W AND HIGH VOLATILIT YFUEL S (9- 0 AND 11- 7 RVP ) 2 - STATI C ROLLOVE R(OE M AN D "SIMPLE" )

- BASE D O

N FMVS S 30 1 TES T

- N O CRAS H

- FUE L TAN

KOU T O F VEHICL E

- VAPO RLINE S REMOVE D 3 . REFUELINGEMISSION S ("SIMPLE " SYSTE M ONLY )

- TES T PROCEDUR E PERJUN E 30 , 198 8 EP A WORKSHO P

- LO W AN D HIGH VOLATILIT YFUEL S (9- 0 AN D 11- 7 RVP )

- LO W AN D HIGH FIL L RATE S (2- 0 GPM , AN D 10- 0 GPM

O RMAXIMU M ACHIEVABLE )

- CONVENTIONA L FILLE RNOZZL E 4 - EXHAUST/EVAPORATIVE/RUNNIN GLOS S EMISSION S (OE M AN D "SIMPLE" )

- BASE D O

N FT P TES T PROCEDURE , WIT H SATURATE D CANISTE R

- CV S TES T RU

N I N SHE D TO CAPTUR E RUNNINGLOSSE S

- TW O FUE L VOLATILITIE S (9- 0 AN D 11- 7 RVP )

- TW O AMBIEN T TEMPERATURE S (8 W AND 95<>F )

- HEA T LAMPS O

N FUE L TAN

KDURINGCV S FORSOM E TEST S

- EP A "DOUBL E DIURNAL " EVA P TEST S (FRO M JUN E 3 0 WORKSHOP )P.1 2



## FINDING S FRO M TH E EVALUATIO N OF TH E MODIFIE DPROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

SECTIO N II I EFFECT S OF A

LARGE RCARBO N

CANISTE RFINDING : EVAPORATIV E EMISSIO N TES TRESULT S CONFIR M THATTH E LARGE R CARBO N CANISTE R ASSOCIATE D WIT H TH E "SIMPLIFIED " SYSTE M CA N REDUC E EVAPORATIV E EMISSION S UNDE R SOM E CONDITION S O F HIGHE R VOLATILIT YTES TFUE L AN D MODERAT E AMBIEN T TEMPERATUR E
NOTE : TH E EMISSION S BENEFIT S ATTRIBUTABL E T O TH E "SIMPLIFIED " REFUELIN G CONTRO L SYSTE M WOUL D B E ACHIEVE D WITHOU TTH E ADDE D COMPLEXIT YO F REFUELIN G CONTROL EVAPORATIV E EMISSION S COMPARISO N TAURU S

tea aun j lBwmnug (an . n EVAPORATIV E EMISSION S COMPARISO N F-25 0P.1 4



### FINDINGS : EVAPORATIV E EMISSIO N TES TRESULT S CONFIR M THATTH E

LARGE R CARBO N CANISTE R ASSOCIATE D WIT H TH E "SIMPLIFIED " SYSTE M CA N REDUC E EVAPORATIV E EMISSION S DURIN G A DOUBL E HIGH-TEMPERATUR E DIURNA L HEA TBUILD NOTE : TH E EMISSION S BENEFIT S ATTRIBUTABL E TO TH E "SIMPLIFIED "

REFUELIN G CONTRO L SYSTE M WOULD B E ACHIEVE D WITHOU TTH E ADDE D COMPLEXIT YO F REFUELIN G CONTROLS EVAPORATIV E EMISSION S COMPARISO N

DOUBL E DIURNA

L TAURU S EVAPORATIV E EMISSION S COMPARISO N DOUBL E DURNA L F-25 0

SM«J)«N P 

# Z~7»

UflS t O-MfTE RP.1 5



## FINDING S FRO M TH E EVALUATIO N OF TH E MODIFIE DPROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

SECTIO N I V DEFICIENCIE S OF TH E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

### POTENTIA L FAILUR E MOD E EFFECT S ANALYSI S (FMEA )

SUMMARYOF MAJO RCONCERN S
MODIFIED , LARG E DIAMETE RORIFIC E ROLLOVE RVALV E

- VALV E MA

YALLOW VAPO RCONDENSAT E O

RRA W FUE L INT O VEN T LINE S UNDE RSOM E CONDITION S

- REFUELIN GI S IMPOSSIBL E I F VALV E STICK S CLOSE D

- FUE L SPITBAC KCOUL D OCCU RI F VALV E CLOSE S PREMATUREL Y DURIN GREFUELIN G

- VALV E DOE S NO T SEA L PROPERL YI N ROLLOVER - LARG E ORIFIC E WIL L ALLO

W MAJO RFUE L LEAKAG E I F THI S OCCUR S

- VALV E DOE S NO T ALLOW TAN KT O VEN T WHE N

FUL L 2 - LIQUI D SEA L FILLE RPIP E

- HIG H VAPO RGENERATIO N I N INITIA L STAGE S OF FIL L DU E T O FLO W DYNAMIC S O

F TH E LIQUI D SEA L MA

YLEA D T O FUE L SPITBAC KFRO M VENTLES S PIP E
LARGE-DIAMETE RVAPO RLIN E

- REFUELIN GI S IMPOSSIBL E I F LIN E I S BLOCKED , KINKED , O R CRUSHE D SHU T

- HIG H VAPO REMISSION S WIL L OCCURIF LIN E I S CU T ORREMOVE D FIR E HAZAR D EXIST S IF VAPOR S COLLEC T NEA RIGNITIO N

SOURC E 4 - LARG E CARBO N

CANISTE RCOUL D TRA P MOR E LIQUI D FUE L

- BECAUS E O

F TH E HIGHE RVAPO RFLO W RATE S WIT H TH E "SIMPLE " SYSTEM , TH E CANISTE RI S LIKEL YT O B E EXPOSE D T O LARGE R AMOUNT S OF LIQUI D NOTE : SOM E O

F THES E FAILUR E MODE S WER E OBSERVE D I N TESTING - THES E AR E TREATE D I

N GREATE RDETAI L O

N LATE RPAGES -COMPONEN T Liqui d Sea l

Modifie d (0.350 " dia. ) Rollove r Valv e POTENTIA L EP A"SIMPLE " ONBOAR

D HIG H POTENTIA

L FAILUR E MOD E Excessive fue l vapo r generatio n du e t o ho t fue l i n tan k and/o r warm , high volatilit ydispense d fue l (or othe r possibl e temperatur e combinations. ) Lac k o f sufficien t pressur e differentia l t o actuat e automati c nozzl e shutof f featur e - du e t o pressur e buildu p fro mliqui d seal . Valv e doe s no t clos e a t en d o f refueling .

Valv e Stick s Close d

- defect/misassembl y

- imprope r design •

Prematur e closur e an d sealin g shu t o f valv e durin g refueling du e t o aerodynami c lift .

- excessive vapo r generatio n

- defective/imprope r desig n o f valv e VAPOR RECOVER Y FAILUR E MODE S POTENTIA

L EFFECT S Hig h pressur e surg e durin g refueling cause s spitback .

Fue l spillage .

Fue l goe s int o ven t line s an

d canisters . Fue l overflow s fro

m canister s t o beneat h vehicle . Liqui d fue l remain s i n ven t line s an

d canister s (cras h risk) . Prevent s refueling , o r reduce s fil l rate . Spitback . Uncertai n nozzl e shutoff . Excessiv e vapo r emission s i f slow fil l i s use d t o avoi d spitback , (i.e. , n o liqui d sea l formed ) Dela yi n refueling a s pressur e bleed s down . Prematur e shutof f followe d b

yspitback , possibl ymultipl e i f custome r attempt s t o resum e refueling to o quickly . '
POTENTIA

L FI X

a2 - COMPONEN T Modifie d (0.350 " dia. ) Rollove r Valv e (Continued ) HIG H POTENTIA L FAILUR E MOD E Excessiv e vapo r generatio n du e t o ho t Ambient/Hig hRV P Fuel . POTENTIA L EFFECT S Excessiv e vapo r generatio n du e t o non-pressurize d tank coul d lea d t o condense d fue l i n canister s and/o r vapo r lines . Spurting/spitbac k i f rollove r valv e aerodynamicall y

lift s an d shut s the valve du e t o hig hvapo r flow . POTENTIA L FI X

Impac t du e t o multipl e vehicl e cras hcoul d unsea t th e rollove r sea l (due t o large r seatin g area ) Fue l sloshin g i n tank du e t o operatio n o n roug hroad s and/o r incline d surface s and/o r G-forc e fro m impact . Larg e Diamete r Vapo r Lin e Kinked/Crushe d Shu t

Open/Cut/Remove d Fue l spillag e

Fue l spillag e int o vapo r lin e and/o r caniste r a s a resul t o f th e large r valv e opening . Prevent s refueling , o r reduce s fil l rate . Spitback . Uncertai n nozzl e shutoff . Excessiv e vapo r emission s i f slo

w fil l i s use d t o avoi d spitback , (i.e. , n o liqui d sea l formed ) Possibl e leakag e pat h i n rollove r (assume s liqui d fue l i n vapo r line s o r caniste r and/o r rollove r valv e failure) .3 - COMPONEN T Larg e Diamete r Vapo r Lin e (Continued ) HIG H POTENTIA L FAILUR E MOD E Open/Cut/Remove d (Continued )

Carbo n Canister s Breakag e (Cras ho r Non-Crash ) POTENTIAL EFFECT S Excessiv e vapo r emission s i n al l drivin g an

d parkin g mode s (possibl e fir e hazar d i f vapor s collec t nea r ignitio n source) . Vapo r leakag e (als o liquid , i f othe r failure s allo

w i t t o ente r o r condens e i n caniste r and/o r lines. ) POTENTIA L FI X

Difficul t t o locat e large r canister s i n crash-protecte d are a (greate r cpncer n tha n locatio no f smalle r eva p caniste r du e t o greate r potentia l fo r condense d fuel) .

TFR.6 A

C OP.2 0



### CONCERN : EXCESSIV E EXHAUS T EMISSION S WIT H HIGH-VOLATILIT YFUE L (11- 7

RV P FUE L TESTED ) DU E T O PURG E LIMITATION S

- 11. 7 RV P FUE L VOLATILIT YI S PRESEN T I N AST M CLAS S "C " CITIE S DURIN GTH E OZON E SEASO N

- HIG H VOLATILIT YFUE L CAUSE DBOT H SYSTEM S T O PRODUC E MUC H HIGHE RH C AN DC O EMISSION S THAN STANDARD S A,LLOW , ESPECIALL Y A T HIG H AMBIEN T TEMPERATURES - BOT H SYSTEM S PERFORME D ACCEPTABL YO

N 9- 0 RVP FUE L (SE E TABL E BELOW) -

- BOT H VEHICLE S HA DHIG H PURG E RATE S BU T TH E GREATE RQUANTIT Y O F HC VAPO RGENERATE DWIT H TH E "SIMPLE " SYSTE M WER E HIGHE R THAN TH E ENGIN E COUL DEFFECTIVEL YCONSUME -

- SYSTE M

PERFORMANC E I S DEGRADE DO N HIG H VOLATILIT YFUEL , MA Y B E FOLLOWE DB YVEHICL E DRIVEABILIT YPROBLEMS -

- EMISSION S INCREASE S AN DDRIVEABILIT YPROBLEM S MAYB E FURTHE RAGGRAVATE DB YDIFFEREN T OPERATIN GPATTERN S AND/O R MOR E SEVER E WEATHER TES T RESULT S FRO M

"SIMPLE " SYSTE M TAURU S F-SERIE S RV P H C C O H C C O 11- 7 UP T O 2 XST DUP T O 7 XST DMEET S ST DUP T O 2 XST D 9- 0 MEET S ST DMEET S ST DMEET S ST DMEET S ST D

TES T RESULT S FRO M

OE M SYSTE M
RV P 11- 7 9- 0 TAUR l

H C U P T O L3 XST D MEET S ST D J

S C O J P TO 4 XST D MEET S ST D FH C MEET S ST D MEET S ST D -SERIE S C O

MEET S ST D MEET S ST D NOTE : TES T RESULT S BASE DO N JUN E 30 , 198 8 TES T PROCEDUR E

# FUE L VAPO R GENERATIO N MODE L PREDICTION S o U l I— < r cr. U J z U l CD cr o o . 1 > u _ o 2 : ( E cr C D EP R 11. 5 RV P 5 RV P

RSSUME S 9 5 F DR Y RN D RVERRG E FUE L TAN K TEMPERRTUR E PROFIL E DETERMINE D FRO M TH E EP R Cfl R LRRED O TES T PROGRR M HEA T BUIL D I UDD S AFTE R 2nd UDD S

TES T CYCL E TIM E

T J

### EXHAUST H C COMPARISO N TAURU S 1. 0 „

B0-S 4 d*] . H-

7S-S 6 dma. **> tern BUIL D TBfBvmn E <.*o . F > 

### EVAPORATIV E EMISSION S COMPARISO N TAURU S foa „
&

BP « 11. 7 RV

P

BO-8 4 fkg . H i HEfl T BUIL D TB-PSWTIJR E <d« . F ) l a oouada i a * ho i u>k i 

### EXHAUST C O COMPARISO N TAURU S

60-8 4 daQ . M i 75-8 6 -*B - h b HBt t BUIL D TBfB-WTU E (d^ . F> 

### EXHAUST NO x COMPARISO N

TAURU S

80-8 4 d^ . H i 75-« 6 Oat). M > tCH T BUIL D TEH>BWTl* 6 (T*O - F )

T J • o

### EXHAUST H C COMPARISO N F-25 0

OB I H. TRV P

60-8 4 d-« . I * 76-8 6 <ho . M i t-S- T BU1U ) TEWBWTUP E (cteQ . F ) 

### EVAPORATIV E EMISSION S COMPARISO N

F-25 0

BO-8 4 •*« . Ht

76-8 6 d-« . M i •CR T BUIL D TB-PS-MTU-

S Cr-^ . F> Mal * Sua * a a gru » » « laa l 

### EXHAUST C O COMPARISO N F-25 0

BO-8 4 d^ . H i 76-8 6 ifaB . • * HBITJ1U1LQ TB-PBW-.TU-E (d^ . F> 

### EXHAUST NO x COMPARISO N

F-25 0 ~<c =

BO-8 4 d-q . K

b 76-8 6 ifcg . h b «R T BUIL D IBVBSmXG (<*,. F )P.2 4



## REFUELIN GEMISSION S FROM "SIMPLIFIED " OBV

RSYSTE M

- A T LO W FIL L FLO

W RATES , LIQUI DSEA L FORMATIO N I S INCONSISTENT , ANDALLOW S HIG H HC EMISSIONS -

- A T MODERAT E FLO

W RATE S (4- 7 GPM) , SYSTE M APPEAR S T O CONTAI N REFUELIN GVAPO RA S DESIGNED -

- HIGHE RFLO

W RATE S THA

N SYSTE M CA N ACCEP T LEA DT O LARG E NUMBER S OF PREMATUR E SHUTOFF S ANDHIG H H C VAPO REMISSION S FRO M TH E FIL L PIP E

- SPITBAC KAT SHUTOF F NOTE DDURIN G25 % OF F-25 0 TEST S

- SYSTE M ALLOW S OVERFILLING , ESPECIALL YA T LO W FIL L FLO

W RATES - THI S CA

N B E A CONCER N WIT H SOM E VEHICLES CONCERNS : 1 . RANG E OF ACCEPTABL E FLO W RATE S I S TO O NARROW , AN DPROBABL Y CANNO T B E SIGNIFICANTL YEXPANDED 2 - IF TH E SYSTE M

CONTROL S REFUELIN GEMISSION S AT TH E LOWE RENDOF EPA' S REQUIRE DRANG E OF FLOW RATES , IT WIL L NO T OPERAT E PROPERL YAT REALISTI C GA S STATIO N RATES 3 - ATTEMPT S T O US E TH E SYSTE M AT REALISTI C RATE S CREATE S AGGRAVATIO N

ANDPOTENTIA L HAZARD S FORTH E CUSTOMER , A S WEL L A S REDUCE S TH E SYSTEM' S EMISSIO N CONTRO L EFFECTIVENES S IN-USE -

## REFUELIN G EMISSION S TAURU S WIT H TH E SMPL E SYSTE M

e 7 RJ M MTE (flat len s pmr »lruto > 1 0 

## REFUELIN G EMISSION S F-SERIE S WIT H TH E SIMPL E SYSTE M

2 0 1 0 RJ M Mff E C^ l tana fa r almte lP.2 6



## FINDING S FROM TH E EVALUATIO N O F TH E MODIFIE DPROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

SECTIO N V ADDRESSIN GTH E DEFICIENCIE S

### POSSIBL E LIQUI D SEAL SYSTE M
1 ) OEM ROLLOVER/VEN T VALV E 2 ) FILLPIP E DESIGNE D FORLIQUI D SEAL , WIT H ANTI-SPITBAC KVALV E 3 ) OE M EVA P CANISTE RPLU S ENLARGE D REFUELINGCANISTE R(OTHE RSYSTEM S UNDE REVALUATION ) 4 ) ENHANCE D ELECTRONI C PURG E CONTRO L 5 ) FIL L PIP E MODUL E

- NORMALL YCLOSE D VEN T VALV E

- VEN T ACTUATO R

- SHUTOF F ACTUATO R

- LIQUID-VAPO RSEPARATO RP.2 8



## POSSIBL E MECHANICA L SEAL SYSTEM (TAN KMOUNTE D VEN T VALVE ) 1 ) OE M ROLLOVER/VEN T VALVE 2 ) ELECTRICALLY-OPENE D REFUELINGVEN T VALV E 3 ) OEM EVAP CANISTE RPLU S ENLARGE D REFUELINGCANISTE R(OTHER SYSTEM S UNDE REVALUATION ) 4 ) ENHANCE D ELECTRONI C PURG E CONTRO L 5 ) MECHANICA L NOZZL E SEAL WIT H OVERPRESSUR E SPIL L VALV E 6 ) LIQUID/VAPO RSEPARATO RP.2 9



## POSSIBL E MECHANICA L SEAL SYSTE M (FIL L PIP E MODULE ) 1 ) OEM ROLLOVER/VEN T VALV E 2 ) CONVENTIONA L FILLE RPIP E WIT H ANTI-SPITBAC KVALV E 3 ) OE M EVAP CANISTE RPLU S ENLARGE DREFUELINGCANISTE R(OTHERSYSTEMS UNDE REVALUATION ) 4 ) ENHANCE DELECTRONI C PURG E CONTRO L 5 ) FIL L PIP E MODUL E NORMALL YCLOSE DVEN T VALV E VEN T ACTUATO R SHUTOF F ACTUATO R LIQUID-VAPO RSEPARATO R MECHANICA L SEAL OVERPRESSUR E SPIL L VALV E

# MECHANICA L DESIG N

TO CANISTER S EMERGENC Y RELIE F VALV E i VAPOR/LIQUI O DISCRIMINATO R
OA S NOZZL E
NOZZL E SEA L TRAPDOO R W/SEA L VIE W I N DIRECTIO N O F ARRO W Z CARRYOVE R EVAP . SYSTE M 

# ftK

VIE W I N DIRECTIO N O F ARRO W Y
VEN T TUB E 3M ' - 8/8 * LO . VAPOR/LIQUI O

DISCRIMINATO R

MODULA R CARBO N CANISTE R

VAPO R TUB EP.3 1



### FINDING S FRO M TH E EVALUATIO N OF TH E MODIFIE D PROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

SECTIO N V I RUNNIN GLOS S CONTRO LP.3 2



## CONCERN : OVERCOMIN GTH E DEFICIENCIE S FOUN DWIT H TH E "SIMPLE " SYSTE M

WIL L NO I RESUL T I

N EFFECTIV E RUNNIN GLOS S CONTROL -

- PRELIMINAR YEP A

RUNNIN GLOS S TES T DAT A SHOW S LARG E RUNNIN G LOSSE S UNDE RCERTAI N

CONDITIONS -

- PRELIMINAR YEP A

ANALYSI S OF OZON E DAYAMBIEN T TEMPERATURE S SHOW S A N AVERAG E HIG H TEMPERATUR E O F 95° F I N AST M CLAS S "C " CITIE S

- EP A DAT A FRO M 1 6 VEHICLE S OPERATE DO N VARIOU S DRIVIN G CYCLE S SHOW S A

N AVERAG E FUE L TAN

KTEMPERATUR E RIS E OVE R AMBIEN T O F 250F - THI S RESULT S I N 120O F FUE L TEMPERATUR E O N OZON E DAYS -

- TH E APPROXIMAT E BOILIN GPOIN T OF AST M CLAS S "C " FUE L (11- 5 PS I RVP ) A T ATMOSPHERI C PRESSUR E I S 1130F -

- EVALUATIN GTH E EP A

RUNNIN GLOS S DAT A

SHOW S N O HIG H RUNNIN G LOS S VEHICLE S BELOW

TH E APPROXIMAT E BOILIN GPOIN T O F TH E TES T FUEL -

- TH E SIGNIFICANC E O

F TH E LO W RUNNINGLOS S VEHICLE S ABOV E TH E APPROXIMAT E BOILIN GPOIN T O F TH E TES T FUE L I S UNKNOW N AN D DEPENDEN T O

N TH E

- IMPACT S OF TES T PROCEDURA L CHANGE S BETWEE N TEST S

- AMOUN T OF TIM E SPEN T ABOV E TH E BOILIN GPOIN T

- TES T VARIABILIT Y

- IMPACT S O

N EXHAUS T EMISSIO N

CONTRO L (UNMEASURE DUNDE R TH E EP A PROGRAM )

- SHIFT S I

N TH E BOILIN GPOIN T O

F FUE L I N TH E TANKDU E T O FUE L TANKPRESSUR EANALYSI S OF PRELIMINAR Y EPA RUNNIN G LOS S DAT A 11. 7 RV PTES T FUE L BOO MO ' 

### R U N N I N G L 0 S S E S BOO - •M O 400 - 98 0 • SOO - * ritwtm*mm#m*

APPROXIMATE BOILIN G POIN T O F TES T FUE L A T ATMOSPHERI C PRESSUR E

ISO aoo - — G R 1B0 - A

~ ioo< 60 * Ot Q

B B i

10 0 o 10B 11 0 U B 11 0 FUE L TEMPERATUR E IB B IS O 13 8ANALYSI S O F PRELIMINAR

Y EPA RUNNIN G LOS S DAT A 10. 4 RV PTES T FUE L BO O 88 0 w-!M » mam*mimtmm#*#mntmi(. JJBODN N 480 - 

### I 5 

### 400 - & ' -i <>.

L 380 - 

### 0 

# s S E S MO SOO 1 n 0 . G R16 0 A ¥ 100 - APPROXIMATE

BOILIN G POIN T O F TES T FUEL A T ATMOSPHERI C PRESSUR E

B 8 10 0 1 10 8 11 0 U B 1E D FUE L TEMPERATUR

E IB S 13 0 13 8

### ANALYSI S O F PRELIMINAR

Y EP A RUNNING LOS S DAT A 9. 0 RV PTES T FUE

L BOO 13 8 

### FUE L TEMPERATUR

EP.3 6



### CONCERN : COMPUTE R MODELIN G SHOW S TH E "SIMPLE " SYSTE M GENERATE S OVE R

40 % MOR E VAPO R AND GENERATE S THI S VAPO R AT AFASTE R RAT E THA NPRODUCTIO NEVAPORATIV E EMISSIO NCONTRO L SYSTEM S SYSTE M FUE L RV P (PSI ) VAPO R GENERATE D (G ) I O F FUE L BUR N
OE M

"SIMPLE " 9- 0

10- 5 11. 7 9- 0 10- 5 11- 7 10 4 17 9 26 1 11 3 23 0 38 6 9 1 3 3 6 1 6 4 3 7 3 

### MAXIMU M VAPO R GENERATIO NRAT E A S APERCENTAG E O F AVERAG E FUE L CONSUMPTIO NRAT E DURIN G CYCLE , ASSUMIN G 2 3 MP G AVERAGE POTENTIA L SOLUTION S T O CONCERNS : 1
- FUL L COMPUTE R CONTRO L O F VAPO R PURG E AN D 2
- ENHANCE D EXHAUS T EMISSIO NCONTRO L AND 3
- MOR E COMPLE X NORMALLY-CLOSE D REFUELIN G VEN T SYSTE M AND 4
- LARGE R CARBO NCANISTE R CAPACIT Y AND/O R 5
- FUE L CHILLER S OR 6
- FUE L VOLATILIT Y CONTRO L

# FUE L VAPO R GENERATIO N MODE L PREDICTION S

oc cr L U L U C D C E O 0 . c r > o c n 2 : C E cr C D EPf l 11. 5 RV P 5 RV P

RSSUME S 9 5 F DRY RN D RVERRB E FUE L TRN

K TEMPERATUR E PROFIL E DETERMINE D FROM TH E EP R CA R LAREDO TES T PROGRA M HEA T BUILD 1 UDD S AFTE R 2n d UDD S TES T CYCL E TIME

T D C O ^ 1P.3 8



## FINDING S FRO M TH E EVALUATIO N OF TH E MODIFIE DPROTOTYP E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M

SECTIO N VI I CONCLUSION SP.3 9



### PROBABL E HARDWAR E TO CONTRO L REFUELINGVAPOR FRO M LIGHT-DUT YVEHICLE S
ENHANCE D PURG E CONTRO L

- LIKEL YT O B E SAM E A S ENHANCE D EVA P SYSTE M 

### FILLE RPIP E VEN T CONTRO L MODUL E NOZZL E SEAL MECHANIS M LIQUID/VAPO RSEPARATO R ENHANCE D ROLLOVE RVALVE LARGE RCARBON

CANISTE R

- 3- 4 LITER S FO R9- 0 PS I FUE L 

### LARGE RDIAMETE RVAPORTUBE S TO CANISTE R OVER-PRESSUR E RELIE F MECHANIS M

ASSUMPTIONS : EPA

WIL L ADOP T 9- 0 PS I RV P FUE L I N CLAS S "C " REGIONS -P.4 0



### PROBABL E HARDWAR E T

O CONTRO L "EXCESS " EVAPORATIVE EMISSION S PLU S

RUNNIN GLOSSE S FRO M LIGHT-DUT YVEHICLE S
ENHANCE D PURG E CONTRO L SYSTEM

- HIGHE RFLO W

VALVE S

- FUL L ELECTRONI C CONTRO L 

### ADDITIONAL HEAT SHIELDIN G INCREASE D FUE L SYSTEM

COOLIN GMECHANIS M

- DUCTIN GT O PROVID E HIGHE RAI RFLOW S 

### MEASURE S T

O REDUC E FUE L SYSTE

M HEAT FLU

X

- VARIABL E VOLTAG E PUMP S 

### LARGE RCARBO

N CANISTE R

- 1- 2 LITER S



### ASSUMPTIONS : (1 ) EP A WILL NOT INTERPRE T TH E PROPOSE D PROHIBITION AGAINS T VAPO

RVENTIN GLITERALLY - (2 ) EP A WIL L ADOP T 9- 0 PS I RV P FUE L I N CLAS S "C " AREAS -P.4 1



### CONCLUSION S TH E "SIMPLE " SYSTE M

HA S TH E SAME , IF NO T GREATER , SAFET Y CONCERN S A S OTHE RPREVIOUSL YREVIEWE D PROTOTYP E REFUELIN G CONTRO L SYSTEMS - "SIMPLIFIED " REFUELIN GCONTRO L SYSTEM S AR E NO T READIL Y ADAPTABL E T O PRODUCTIO N VEHICLES LIQUID/VAPO RSEPARATOR S AR E REQUIRE D I N REFUELIN GCONTRO L SYSTEMS NORMALL YOPE N

FUE L TAN

KVEN T SYSTEM S CAUS E A LOS S O F EXHAUS T AND/O REVAPORATIV E EMISSION S CONTROL TH E ONL YBENEFIT S IDENTIFIE D FORTH E "SIMPLE " REFUELIN GSYSTE M CA N B E ATTRIBUTE D T O TH E LARGE RCARBO N CANISTER - THES E SAM E BENEFIT S CA

N B E ACHIEVE D AT A

LOWE RCOS T WITHOU T TH E ADDE D COMPLEXIT YOF REFUELIN GCONTROL TH E "SIMPLIFIED " REFUELIN GCONTRO L SYSTE M WIL L NO T B E CAPABL E OF CONTROLLIN GRUNNINGLOSSE S UNDE R"OZON E DAY " CONDITIONS VOLATILIT YCONTRO L PLU S ADDITIONA L RUNNINGLOS S CONTRO L AND ENHANCE D EVAPORATIV E EMISSIO N CONTRO L I S TH E MOS T COST-EFFECTIV E CONTRO L STRATEG YAND PRESENT S N O SAFET Y CONCERNS - TH E ADDITIONA L COS T AND SAFET YCONCERN S OF REFUELIN G CONTROL S SUBSTANTIALL YOUTWEIG H TH E MINIMA L ADDITIONA L EMISSION S CONTROL TFR9168 8

## TEST S REMAININ G

1 - ADDITIONA L HIG H AMBIEN T TEMPERATUR E TEST S OF "SIMPLE " SYSTE M 2 - ADDITIONA L REFUELIN GTEST S WIT H OTHE RPROTOTYP E OBV RSYSTEM S 3 - LABORATOR YHIGH-TEMPERATUR E VAPO RGENERATIO N TES T O F "SIMPLE " AN DOE M SYSTEM SEVALUATIO N O F TH E "SIMPLE " REFUELIM GCOMTBO t SYSTEM EXHAUS T / EVAPOKATIVE / RIMMIN GLOS S EM1SSI0M S DAT A SHEE T

VEHICL E TES T Tauru s 1 2

7 1 0 1 3 8 9 6

1 1

3 1 5 tt 2 # SYSTE M EP A OE M OE M EP A OE M OE M EP A

OE M

EP A EP A EP A EP A EP A H C 0.1 9 O.2 0 0.2 3 0.2 2 0.2 2 0.2 2 0.1 9

0.2 1

0.1 5 0.2 1 0.2 3 0.2 1 0.2 7 C O 1. 8 2. 6 3. 3 3. 0 3. 4 3. 8 3. 4 doubl e doubl e 3. 8 doubl e doubl e 2. 3 3. 0 2. 7 3. 4 4. 4 CC- j 44 5 42 8 43 8 44 8 44 8 43 8 44 5 NO

x .5 8 .4 3 .4 1 .71 .54 .5 0 .4 9 diurna l # 1 diurna l # 2 44 4 .5 1 diurna l # 1 diurna l # 2 45 7 43 9 441 43 5 44 6 .6 0 .4 8 .6 2 .5 8 .6 2 F E 19. 8 20. 5 20. 0 19. 6 19. 5 20. 0 19. 7

19. 7

19. 2 20. 0 19. 9 20. 1 19. 5 D I 0.7 7 0.5 9 0.6 5 0.3 2 0.3 2 0.5 9 1.2 7 0.6 4 0.8 9 0.4 2 1.2 0 15.1 1 1.6 8 1.4 4 0.5 6 0.4 5 0.8 0 H S 0.6 2 0.7 6 5.0 8 0.7 0 0.8 0 0.8 1 0.9 5

0.6 0

0.8 3 1.3 4 3.8 3 0.9 4 1.3 3 R/

L 1.3 6 1.5 7 1.3 2 1.3 8 2.7 1 2.2 2 1.8 4

1.5 3

1.5 4 1.8 6 2.8 6 2.1 3 2.6 5 PO

P
0 RV P 9. 0 9. 0 0.0 6 9. 0 0.0 8 9. 0 0 0

0.0 5 9. 0 9. 0 9. 0

9. 0

9. 0 9. 0 9. 0 9. 0 9. 0 H B 60/8 4 60/8 4 60/8 4 75/9 5 75/9 5 75/9 5 60/8 4 71/9 6 71/9 6 60/8 4 71/9 6 71/9 6 60/8 4 60/8 4 60/8 4 75/9 5 75/9 5 TEMPERATUR E FT P 8 4 8 4 8 4 9 5 10 0 9 5 8 4

8 4

8 4 8 4 8 4 9 5 9 5 TAN

K 9 8 9 7 9 8 10 7 10 3 10 6 9 8

9 8

9 7 9 9 10 6 10 7 

### .n A/ S 13 7 14 0 14 2 16 2
15 1 13 5

12 7

10 4
14 0 20 0 TAN K PRESSUR E "H g COMMENT S -0. 2 0. 4 0.7 5 -0. 2 0.7 5 0. 8 -0.2 5

0. 6

-0.2 5 -0.2 5 -0.2 5 -0.2 5 H/ S Eva pvoi d• 2

FT P Tem pto o hig h
Fixe dEva plea k i nhos e

Eva pvoi d- 2 Eva pvoi d- 2 Eva pvoi d- 2 Eva pvoi d- 2 Eva pvoi d- 2 Codes : 1 - Equipmen t Voi d 2 - Vehicl e Voi d 3 - Procedur e Voi d Notes : Th e H B (hea t build ) temperatur e i s low/high ; FTP , fue l tan k an d A/ S (ai r spac e befor e th e fue l tank ) temperature s ar e maximu mvalues . Al l test s ar e starte d uit h a saturate d caniste r (i.e . non-standar d FTP ) Septembe r 22 , 198 8

-p . c oEVALUATIO N O F TH E "SIMPLE - REFUELIN GCONTRO L SYSTEM PAG E 2

VEHICL E TES T Tauru s 1 9 2 1 1 4 1 6 2 2 " 2 0 17 1 5 # SYSTE

M EP A EP A OE M OE M EP A EP A < OE M OE M H C C O 0.3 3 6. 4 0.2 8 5. 0 0.3 0 4. 7 0.2 9 4. 5 fm.n 19.7 ^ T 0.8 7 26. 3 0.5 5 12. 5 0.5 0 11. 5 COj

43 6 43 2 48 1 43 2 y 41 3 )41 0 42 6 423 NO

n .88 .8 2 .5 9 .5 9 .8 4 .87 .7 0 .5 8 EXHAUS T / EVAPORATIV E /
FE D I 19. 9 1.0 7 20. 1 0.6 4 18. 1 4.2 7 20. 2 16.0 4 19. 9 0.6 3 19. 5 0.4 4 19. 8 30.1 0 20. 0 25.7 1 H S R/ L

0.5 3 0.7 9 0.6 1 0.6 0 1.2 5 0.6 5 2. 8 0.8 6 0.7 8 0.9 2 0.8 0 1.2 5 105. 3 32.8 0 106. 5 47.7 3 RUNNIN

GLOS S BUSSION S DAT A SHEE T
PO P 0.0 4 0.0 4 0.0 3
0.0 3 0.0 5 0.0 5 0. 0 RV P 11. 7 11. 7 11. 7 11. 7 11. 7 11. 7 11. 7 11. 7 H B 60/8 4 60/8 4 60/8 4 60/8 4 75/9 5 75/9 5 75/9 5 75/9 5 TEMPERATUR E (F ) FT P 8 4 8 4 8 4 8 4 95 95 95 95 TAN

K 9 6 9 9 100 100 11 4 11 6 11 6 120 

### A/ s N/ A 14 3 16 7 14 2 147 14 2 15 5 14 0 TAN K PRESSUR E 0. 0 -0.2 5 0. 6 1. 3 -0.2 5 0. 0 3. 4 2. 3 "H g COMMENT S

R/ L appear s lo

w Ex hVoi d• 3

R/ L I N THIR D BA G(113°F ) R/ L bega na t 114° F 2 3 EPA

0.2 0 2. 6 43 3 .8 6 20. 3 0.6 4 0.5 4

doubl e diurna l # 1 0.3 5 doubl e diurna l # 2 0.4 6 0.8 7 0.0 6 11. 7 60/8 4 8 4 9 4 N/ A -0.2 5

1 8 OE

M 0.2 9 5. 2 42 7 .7 4 20. 4 8.1 0 0.7 3

doubl e diurna l # 1 38.4 8 doubl e diurna l # 2 52.0 4 1.0 5 N/ A 11. 7 60/8 4 8 4 100 16 0 1. 0

Codes : 1 - Equipmen t Voi d 2 - Vehicl e Voi d 3 - Procedur e Voi d Notes : Th e H

B (hea t build ) temperatur e i s low/high ; FTP , fue l tan k an dA/ S (ai r spac e befor e th e fue l tank ) temperature s ar e maximu m values . Al l test s ar e startedwitha saturate dcaniste r (i.e . non-standar dFTP ) Septembe r 22 , 198 8

-p .VEHICL E TES T

F-25 0 3

1 5 8 9 6 7 1 4 1 0 2 4 1 1 1 2 1 3 1 7
1 8

1 5
1 6 # SYSTE M EP A EP A EP A OE M OE M OE M OE M OE M Ot A EP A EP A OE M OE M OE M EP A
EP A

OE M
OE M H C .4 5 .5 7 .8 3 .6 9 .4 4 .6 6 1.0 1 .5 8
.6 0 .4 9 .4 8 .8 2 .7 8 .4 6
.5 5

.9 7
.5 1

Codes : 1 * Equipmen t Voi d Notes : Th e H

B (hea t bu 

### c

o 4. 3 5. 5 13. 1 8. 4 3. 4 4. 1 16. 4 6. 6
5. 4 6. 0 3. 4 22. 8 6. 8 6. 3
4. 3

31. 5
5. 2

2 - 

### co

2 65 1 67 5
62 7 62 5 65 1 63 1 62 5
66 0 65 3 70 6 68 9 68 4 69 0 doubl e doubl e 65 7 doubl e doubl e 66 0 doubl e doubl e 67 3 doubl e doubl e Vehic l NO

x .8 1 .8 3 .7 0 .75 .7 1 .8 3 .6 9 .7 7
.9 1 .7 9 1.1 3 .6 6 .82 .7 4 EVALUATIO

N OF THE "SIMPLE " EXHAUS T / EVAPORATIV E /
F E 13. 5 13. 0 13. 4 13. 8 14. 0 13. 4 13. 4 13. 9 D I 0.4 8 3. 6 0.4 9 0.3 6 0.3 7 11. 2 0.4 5 0.4 6 H S 0.9 0 1. 6 0.8 2 0.4 5 0.5 1 2.9 0 3.5 6 0.6 4 ABORTE D - N O DAT A 13. 2 13. 3 12. 4 12. 2 12. 7 12. 7 diurna l # 1 diurna l #2 .7 9 13. 3 diurna l # 1 diurna l # 2 .7 0 12. 4 diurna l # 1 diurna l # 2 .7 7 13. 0 diurna l # 1 diurna l # 2
e Void 3 Id ) temperatur e i s low/high ; Al l test s ar e starte d wit h 0.7 3 0.4 9 0.4 1 0.6 6 0.4 6 0.3 6 0.9 8 1.0 8 0.6 7 0.8 7 0.8 3 0.7 1 ABORTE D ABORTE D 0.6 0 0.6 1 0.8 2 0.4 6 3.3 8 16.0 9 0.6 1 1.6 8 18.5 7 0.5 0

0.7 5
0.5 5 R/

L 2.3 4 3. 8 2.6 3 1.7 0 1.7 4 3.2 3 2.3 3 2.0 2
3. 1 3.1 1 2.3 5 3.1 2 1.9 2

• Procedur e Voi d REFUELIN G CONTRO

L SYSTE M RUNNIN G LOS S B-USSIONS DAT A SHEET
PO P

0. 0 0.0 5

0.0 4 0. 0 RV P 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0
9. 0 9. 0 9. 0 9. 0 9. 0 9. 0
9. 0

9. 0
9. 0 H B 60/8 4 60/8 4 60/8 4 60/8 4 60/8 4 60/8 4 60/8 4 60/8 4
75/9 5 75/9 5 75/9 5 75/9 5 75/9 5 60/8 4
60/8 4 71/9 6 71/9 6 60/8 4 71/9 6 71/9 6 60/8 4 71/9 6 71/9 6 TEMPERATUR

E FT P 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4
9 5 9 5 9 5 9 5 8 4
8 4

8 4
8 4

FTP , fue l tan

k an d A/ S (ai r space before th e a saturate

d canister (i .

e . no n standar

d FTP ) TAN K 9 9 10 0 10 0 9 8 9 9 10 0 10 1

10 6 10 6 10 8 N/ A 10 2
10 2

10 1
10 0 (F J A/ S 12 2 12 4 12 3 10 6 12 6 13 2
12 8 11 9

12 3 12 8
12 5

12 2
12 0 TAN

K PRESSUR E "H g -.2 5 -.2 5 -.3 6 0. 0 0. 0 -.2 0 0. 0 0. 0
-.2 5 -.2 5 0. 2 0.2 5 0. 0
-1. 0

0. 0
-.2 5 COMMENT S

Evap voi d - 3 Exh . voi d • 1 Exh . void - 1 Evap void • 2 Exh . voi d - 1 PRE P 9 RV P TES T U/11. 5

Exh . voi d - 1

VOID-RU N U/ O EXTR

A CANISTE

R DOUBLE 01URINA

L EVA P TES T TAN KVACUU M HIGHE R AN D MOR E FREQUEN T THA N PREVIOU S TEST S - 4 CANISTER S Exh . voi d - 1

REPEA T O F #1 5 CA

N ISTER BREAKTHROUG

H INDICATE

D 310 - MIN . INT

O d.d.# 2

fue l tank ) temperature s ar e maximu m values .EVALUATIO N O F TH E "SIMPLE " REFUELIN G CONTRO L SYSTB I PAG E 2

VEHICL E TES T F-25 0 2 5

2 7 2 2 1 9 2 6 2 8 2 0 2 4 2 1 2 9 # SYSTE M EP A EP A OE M OE M EP A, EP A\ OE M OE M
EP A H C 0.7 3 0.6 6 0.6 5 1. 0 /0.7 2 ^1.3 4 0.5 9 0.6 8
0.7 8 C O 14. 0 15. 4 7. 1 35. 6 15.2 S 20.4 , 6. 2 9. 4
7. 8 CO j 65 1 71 0 65 0 65 9 66 4 1 63 3 66 3 64 3
66 3 doubl e doubl e NO „

.6 8 .5 4 .7 7 .5 3 .7 2 .7 1 .7 8 .6 9
.7 0 EXHAUS T / EVAPORATIV E / RUNNIN

G LOS S EMISSION S DAT A SHEE T
F E 13. 1 12. 0 13. 4 12. 4 12. 6 13. 3 13. 1 13. 4
13. 1 diurna l # 1 diurna l # 2 D I

0.5 5 0.5 4 7.2 2 5.5 2 0.5 7 0.4 3 25.2 8 30. 9
2.5 3 0.4 7 1.0 7 H S 0.4 2 0.6 6 0.2 0 0.6 9 0.6 1 0.5 7 4.3 7 27. 7
0.5 1 R/ L PO P 1.6 5 2.1 7 0. 0 2.5 3 0. 0 2.0 3 2.7 3 1.8 8 2.8 4 4.3 7 0. 1
1.8 8 RV

P 11. 7 11. 7 11. 7 11. 7 11. 7 11. 7 11. 7 11. 7
11. 7 H

B 60/8 4 60/8 4 60/8 4 60/8 4 75/9 5 75/9 5 75/9 5 75/9 5
60/8 4 TEMPERATURE (F )

FT P 8 4 8 4 8 4 8 4 9 5 9 5 9 5 9 5
8 4 TAN

K 9 8 10 1 9 9 10 2 10 8 11 3 10 7 11 0
9 8 A/ S 11 2 13 3 11 5 12 5
12 0 13 2 13 0
11 5 TAN

K PRESSURE "Hg -0. 5 -0.2 5 +0. 2 •0. 4 •0.2 5 -0. 2 •1. 2 +1. 7
-0.2 5 COMMENT S

Exh . voi d • 2

WITH HEA

T LAMP S

UITH HEA

T LAMP S - N O HIS S Exh . voi d - 3

2 3 OE M CV S DOW N- N O CHEMISTR Y 2.6 0 0.5 9 doubl e diurna l # 1 25.6 2 doubl e diurna l # 2 51.1 9 11. 7 60/8 4 8 4 9 7 12 7 +0. 5 BREAKTHROUG H a 5 9 MI N 71/9 6 " a 2 4 MI N 71/9 6 CV S RECALIBRATE D BEFOR E #2 4

Codes : 1 - Equipmen t Voi d 2 - Vehicl e Voi d 3 - Procedur e Voi d Notes : Th e H B (hea t build ) temperatur e i s low/high ; FTP , fue l tank an d A/ S (ai r spac e befor e th e fue l tank ) temperature s ar e maximumvalues . Al l test s ar e starte d wit h a saturate d caniste r (i.e . non-standar d FTP) Septembe r 22 , 198 8

-p .VEHICL E

Tauru s

F-25 0 TES T #

3 6 2 7 * 4 * 5r-l00 9 1 0 1 1 8 1 0 7 9 1 2 1 4 1 1 1 3 TOTAL GAL S DIS P 18. 6 18. 5

. 19. 6 17. 5 17. 0 17. 1 16. 6 18. 4 18. 4 17. 8 17. 0 17. 0 17. 1 18. 0 17. 4 17. 1 17. 2 18. 1 17. 7 TOTA L

GRAM S 1.6 8 4.1 2 1.2 0 0.1 2 8.0 4 4.2 2 3.5 3 7.0 6 1.9 2 0.4 7 3.4 5 8. 5 35.2 4 5.1 6 19.8 1 37.4 7 91.4 8 23.4 5 31.0 6 REFUELIN

G GMS/GAL 0.0 9 0.2 2 0.0 6 0.0 1 0.4 7 0.2 5 0.2 1 0.3 8 0.1 0 0.0 3 0.2 0 0.5 0 2.0 6 0.2 9 1.1 4 2.1 9 5.3 2 1.3 0 1.7 5 EMISSION S DAT A SHEE T RV P 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0 11. 7 11. 7 11. 7 11. 7 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0 9. 0 DISPENSIN

G RAT E 2. 0 2. 0 6. 0 6. 7 10. 0 10. 0 10. 0 6. 7 2. 0 6. 7 2. 0 2. 0 2. 0 10. 0 10. 0 2. 0 2. 0 10. 0 10. 0 # O F

SHUTOFF S 0 0 3 0 5 6 3 7 4 2 0 0 0 0 3r-l 0 2 0r-l 0 0 TEMPERATURE S

FUE L 8 4 8 3 8 2 8 2 8 3 8 2 8 2 8 3 8 2 8 1 8 3 8 3 8 2 8 1 8 2 8 3 8 4 8 2 8 1 VEHICL E

8 0 8 1 7 9 7 9 8 0 7 9 7 9 8 1 8 2 8 2 8 1 8 1 8 0 8 1 8 1 8 1 8 3 8 1 8 0 COMMENT S

L O RESTRICTO R H I " /SHORT SOA

K VOI D BREAKTHROUG

H

H C s a t S/ O n o apparen t sea l 3r d ca n replace d fue l spitbac k wit h ope n slot s wit h ope n slot s wit h ope n slot s wit h ope n slot s 1 3 4 5 2 6 15. 7 18. 6 17. 9 19. 8 17. 2 1.8 0

34.6 0 7.5 9 0.1 7 12.2 2 0.1 1

1.8 6 0.4 2 0.0 1 0.7 1 11. 7

11. 7 11. 7 11. 7 11. 7 2. 0

2. 0 2. 0 9. 0 10. 0 0

0 0 1 8 1

8 2 8 1 8 1 8 2

8 3 8 2 8 2 VOID ; ZERO CHEC K abor t zer o chec k

som e spitbac k
* UNOFFICIAL PURG E HOWEVER , CANISTE R MAS S T O WITHI NON E GRA M O F PREVIOU S OFFICIA L TEST , TEMP S WITHI NACCEPTANC E RANG E Septembe r 22 , 198 8

## CONCERN : FUE L LEAKAG E FROM MODIFIE DROLLOVE RVALV E

- TEST S SHO

W "SIMPLE " SYSTE M

ROLLOVER/VEN T VALV E LEAK S LARG E VOLUM E O F FUE L DURINGSTATI C ROLLOVE RTES T POTENTIA L SOLUTION S TO CONCERN : 1 . COMPLET E REDESIGN O F ROLLOVE RVALVE

- NEE DT O BALANC E TH E REQUIREMEN T FO RREFUELINGCONTRO L (E.G. , HIG H VAPO RFLO

W DURINGFIL L SUGGEST S LARG E FORC E NEEDE DT O HOL DVALV E FLOA T OPEN ) WIT H TH E REQUIREMEN T FO R ROLLOVE RPROTECTIO N 2 - SMALLE RROLLOVE RVALV E ORIFIC E (HOWEVER , ALS O FURTHE RLIMIT S MAXIMU M FIL L RATE ) AND/O R 3 - INSTAL L LIQUID/VAPO RSEPARATO R(ONLYA PARTIA L SOLUTION ) AND/O R 4 - INSTAL L MECHANICA L SYSTE M TO CLOS E ROLLOVE RVALV E WHEN NO T REFUELIN G(MUS T US E ALTERNATIV E WA YTO VEN T VAPOR S DURING OPERATION )
TES T RESULT S FROM

SIMPL E SYSTE M 1S T 5 MINUTE S OF TEST :

- 2 8 OZ - FLUI DSPILLE D

- FMVS S 30 1 LIMI T = 5 OZ OVE RSAM E PERIO DP.4 9



## CONCERN : N

O VENTINGOF VAPOR S O

N FUL L FUE L TAN

K

- OEM SYSTEM RETAIN S US E O

F 0-05 " ORIFIC E I

N ROLLOVER/VEN T VALV E WHE N

TANKI S FUL L

- "SIMPLE " SYSTEM

ROLLOVE RVALV E I S FULL YCLOSE DWHEN TAN KI S FUL L

- THI S MA

YRESUL T I

N EXCESSIV E PRESSUR E BUILDU P I N FUE L TAN K POTENTIA L SOLUTION S T O CONCERNS : 1 - INSTAL L VEN T MECHANIS M I N VAPO RDOM E AND/O R 2 - REDESIGN

ROLLOVER/VEN T VALV E T O VEN T O N FUL L TANKAND/O R 3 - REDESIGN

SYSTE M T O US E ALTERNATIV E MEAN S OF FULL-TANKSHUTOF FP.5 0



## CONCERN : VAPO RCONDENSAT E I N VEN T LIN E

- HIG H REFUELIN GVAPO RFLOW RATE S CAUSE DB YGREATE R ENTRAINMEN T O F VAPO RCA N LEA DTO LIQUI DCONDENSATIO N I N VAPO RLIN E T O TH E CANISTE R

- TEST S SHOW

THA T MODIFIE DVEN T VALV E CA N ALLOW LIQUI DT O ENTE RVEN T LINE - THI S COUL DALS O HAPPE N UNDE RDRIVIN G CONDITION S WHER E TH E FUE L I S AGITATE DWIT H TH E TAN KNEARL Y FULL POTENTIA L SOLUTION S T O CONCERNS : 1 . INSTAL L LIQUID/VAPO RSEPARATO R 2 - REDESIG N

ROLLOVER/VEN T VALV E T O PREVEN T LIQUI DFRO M ENTERIN G VEN T LIN EP.5 1



### CONCERN : SUBSTANDAR D FUE L TANKFIL L QUALIT YWIT H "SIMPLE " SYSTE M

- F-25 0 FIL L RATE S ACHIEVE D WIT H FILLE RPIP E RAISE D - NO T FEASIBL E O

N AL L VEHICLE S INCLUDINGPRODUCTIO N F-25 0

- FIL L RAT E I S AFFECTE D BYCHOIC E OF FILLE RNOZZL E

- "SIMPLE " SYSTE M

WIL L NO T PAS S C-A-R-B - FIL L RAT E REQUIREMEN T

- LARG E NUMBER S O

F PREMATUR E SHUTOFF S OCCU RA T HIG H FLO W RATE S
POTENTIA L SOLUTION S T O CONCERNS : 1 . MECHANICA L SEA L REFUELIN GCONTRO L SYSTE M AND/O R 2 - LARGE RDIAMETE RORIFIC E I N ROLLOVER/VEN T VALV E (TO REDUC E BAC K PRESSURE ) AND/O R 3 - STANDARDIZE D FIL L NOZZLE S COMBINE D WIT H REDESIGNE D FILLE R PIPE S AND/O R 4 - INCREAS E MINIMUM PROPOSE D FLO

W RAT E AT WHIC H REFUELIN GVAPO R CONTRO L MUS T B E ACHIEVE D (CURRENTL Y3-10 GPM ) S O THA T FIL L QUALIT YMA

YB E OPTIMIZE D FORREALISTI C GA S STATIO N RATES -

### "SIMPLE " SYSTE M FIL L QUALIT YRESULTS :
CONVENTIONA L NOZZLE : F-25 0 " - 1 0 GP M TAURU S - 7 GP M

VAPO RRECOVER Y(CARB ) NOZZL E F-25 0 9 GP M TAURU S = 6- 5 GP M

NOTE : - AR B MINIMUM

FLO W RAT E = 1 0 GP M

- CORPORAT E OBJECTIV E FO R CUSTOME RSATISFACTIO N

= 1 2 GP M

MINIMUM