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# OAR Box 1147 Prepped by Ollie Stewart



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Number: 

# 177 ) IV-E-50 Docket Number: 

# A-87-1 1

Printed 4/22/2008 2:42:57

PM Sheet 177 of 242P. 2

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## M 2 0198 7

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H SUBJECT i KPA/FOIU ) nestin g Regardin g Onboar dVapo rRecover y FROH t TOJ GlennW . Passavant , Senio r Projec t Manage r

Standard s Developmen t an dSuppor t Branc h Publi c Docke t A-87-1 1 THRU : Cheste r J . France , Chie f

Standard s Developoen t an dSuppor t Branc h

wer e als o presen t attached . EC S wa s For dt o tes t thei r C nSeptenbe r 16 , 198 7 severa l representative s o f EPA' s Offic e o f Mobil e Source s se t wit hForda t Engin e andcontro l Systems , Inc . (ECS ) Laboratorie s i nLivonia , Michiga nt o discus s thei r designan dtestin g effort s for bot hcaniste r base dan

dbladde r tank onboar d refueling contro l systems . Representative s o f EC S an dP A Technology

o f Princeton , N.J . at th e meeting . A nattendee s lis t i s presen t becaus e the y ar e unde r contrac t t o bladde r systems . For d hire d P A Technolog y t o hel p determin e th e feasibilit yo f bladde r aysten s b y furthe r investigatin g potentia l bladde r material s and designs . Acop y o f th e handou t whic h include s th e agend a followe d a t th e weetin g ia attached . Fot d -ils o provide d othe r desig n and tes t informatio n whic h the yspecifie d a s confidentU: i material . Severa l point s wer e raise d durin g th e .Jiscujssions a t t'- e seeting . A t th e tin e o f tn e meetin g For d ha d a relativel y saal l projec t underwa yt o asses s design s fo r onboar d vapo r

systens . Tv o fue l syste a engineer s wer e assigne d t o an d ligh t recovery designin g onooar dsystein s fo r Ford' s passenge r ca r truc k fue l systens . in the
- cours e o r th e discussion s For d state d tha t thei r cesi^ n option s wer e socewha t limite d becaus e constrain t tha t onboar d system s coul d D**

•tite r th e i:.ina

i rul e i s signe.o .

. ti' . ::csit:u

n on loadtin e i

d state d t o t:.e i-Pi^K , zidimi^nco-jra-je u i-'or d t o pfovio s o f th e perceive d require d a s soo n I n response , LPA J S .2. yea r i n th e Preambl e cownent s on th e in ayatt mutsign . C C X . 3 t X c n-.j

: i i c •.•c-t''. : i'tr . J.ml t XTM -.

i r. a c no l c s sP. 3

Por dals o state dtha t they fel t tha t . the perceive d leadtim e constrain t force dthe nt o targe t a t syste a design s whic hcoul db e applie dquickl y t o a s man

y vehicl e model s a s possible . A t thi s tin e thi s ledthe s t o prefe r mechanica l B**1* ove r liqui dseal s sinc e tbe applicatio no f liqui dseal s woul d1 » some case s requir e tank codification s no t neede dfo r sechanica l seals . We briefl y discusse dtbe merit s o f mechanica l andliqui dseal s an dinvite dPordt o visi t tPA' s Ann Arbo r la bt o furthe r discus s applicatio no f th e J-Tub e syste a develope db

y KPA . BP A

expresse dconcer ntha t tha J-tub e syste a picture dby

Por di nthei r handou t wa s no t applie dl a tb e Banne r envisione dby

BPA * Pur ther , pordstate dtha t upt o thi s poin t they

hadno t conducte danindependen t assessaen t o f fil l heigh t requirement s fo r thei r vehicl e models , bu t ver a usin g thos e presente db

y BPA i nthei r liqui dseal s tec hreport . A s par t o f th e discussio nregarding bladders , Por dstate d tha t th

e majo r impetu s fo r investigatin g the approac hwa s t o reduc e refuelin g eaissions . Tw o test s wer e conducte dby por d durin g it s demonstratio nyieldin g reduction s o f 80-8 5 percent , bu t thes e wer e relativel y simpl e prototype s an dwor k wa s neede d t o mak e tbe design s feasibl e for us e o nvehicle s an

dt o furthe r reduc e emission s i f possible . Attachment sP. 4

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POR D ^S*# : ' " Hik e Tokarsk i Nik a Barriga n Kik e Schvart a Kell y Brow n Bo a Buis t Wal t Kreucha r Chri s Lill y Bil l ling BC * Laborator y Pra dNarse a P ATechnolog y JohnKlin e Jo e Terrel l EP A Jea nSchwendema n Kath y Steile n Pau l Lalng Le e Jone s Joh n Anderso n Glen n Passavan t Che t Franc e Cnarle s Gra y Dic k Wilso n Attendee s Lis t Pord/BP A

Mt g 9-16-8 7

•P. 5

COLLAPSIBL

E BLADDE

RFUE L TAN K
DESIG N STATU

S BRIEFIN

G WII H EP A Septembe r17 , 198 7 Livonia , Michiga n

1 . Agend a 2 . Hardwar e Overvie w 3 . Unresolve d Bladde r Issue s 4 . For

d Tes t Result s 5 . Hardwar e Demonstration s 

## £-0133 4

WMK..5 3P. 6

INTRODUCTIO

N AN D OVERVIE

W REMARK S HARDWAR

E OVERVIE

W Liqui d Sea l Syste m Nozzl e Sea l Syste m Bladde rTan kSyste m AGEND A
D . R . Buis t R . D . Wilso n M . E . Tokarsk y

UNRESOLVE

D BLADDE

RISSUE S Partner s Futur e Plan s R . Nawrock i

FOR D TES T RESULTS HARDWAR

E DEMONSTRATION

S F . Marse e (ECS ) M. E . Tokarsk y

WMK.5 3Slide:X16531-0 1 Opid : Job#: C 15 3 DDS:600 0 Size:12 6 Tu e Au g 1 1 21:21:01 198 7 

# O N BOAR D VAPO R RECOVER Y

(OBVR ) HARDWAR E OVERVIE

W

T J ^ 1

# CURREN TSYSTE M

FUE L TAN K

VEN T & ROLLOVE R VALV E

CURREN TMODE L CANISTE R

P l o oSlide:X16531-0 2 Opid : Job#: C 15 3 DDS:600 0 Size:48 0 Tu e Au g 1 1 21:21:4 7 198 7



# TECHNICA L REQUIREMENT S

•PREVEN TREFUELIN G VAPOR S FRO M ESCAPIN G T O TH E ATMOSPHER E
•VEN TTH E FUE L SYSTE M DURIN G REFUELIN G AN D DURIN G VEHICL E OPERATIO N
•STOR E AND/O R DISPOS E O F TH E FUE L VAPOR S
•ANTICIPAT E AN D MINIMIZ E ADDE D SAFET YRIS K

T J C Oilide:Xl6531-0 3 Opid : Job#: C 15 3 DDS:600 0 Size:22 2 Tu e Au g 1 1 21:23:0 2 198 7



# APPROACHE S LIQUI D SEA L IN-TAN KBLADDE R MECHANICA L NOZZL E SEA L

o31ide:Xl6531-0 4 Opid : Job#: C 15 3 DDS:600 0 Size:53 2 Tu e Au g 1 1 21:23:4 2 1987 ;



# LIQUI D SEA L FUNCTIO N FILLE R OUTLE TUNDE R FUE L SURFAC E O R "J " TRA P SEAL S TH E SYSTE M COLUM N O F FUE L I N TH E FILLE R PIP E DURIN G REFUELIN G FORCE S TH E VAPO R INT O A N ACTIVATE D CHARCOA L CANISTE R CANISTE R STORE S TH E FUE L VAPO R FO R LATE R CONSUMPTIO N BYTH E ENGIN E

# EP

A LIQUI D SEA L SYSTE M

FUE L TAN KVEN T & ROLLOVE R VALV E NOZZL E ACTIVATE D VALV E

PURG E T O ENGIN E COMBINE D REFUELIN G AN D EVA P EMISSIO N CANISTE R

|F 3Job#- C 15 3 DDS:600 0 Size:50 8 Tu e Au. j 1 1 21:27:3 8 198 7 Slide:X16531-0 6 Opid : u *



# MECHANICA L NOZZL E SEA L

FUNCTIO N SEAL S TH E FILLE R INLE TTO CLOS E OF F TH E NORMA L ESCAP E PAT H FO R TH E VAPOR S FUE L BEIN G PUMPE D I N FORCE S TH E VAPOR S OU T THROUG H A N ACTIVATE D CHARCOA L CANISTE R TH E CANISTE R STORE S TH E VAPOR S FO R LATE R CONSUMPTIO N B

YTH E ENGIN E

# MECHANICA L NOZZL E SEA L
ORV R VEN TTUB E ,TO ENGIN E INTAK E FUE L TAN KVEN T& ROLLOVE R VALV E

CARRYOVE R CANNISTE R ORV R PURG E LIN E T O ENGIN E INTAK E

PURG E AI R HEATE RSlide:X16531-05 Opid : Job#: C 15 3 DDS:600 0 Size:108 2 Tu e Au g 1 1 21:25:0 4 198 7



# IN-TAN KBLADDE R THEORETICA L FUNCTIO N A S ENVISIONE D B YEPA A FLEXIBLE , FUE L RESISTANT , TOUGH , DURABLE , NONPERMEABL E MEMBRAN E ENVELOPE S TH E ENTIR E FUE L SURFAC E INSID E A CONVENTIONA L FUE L TAN K TH E MEMBRAN E RIDE S U P AN D DOW N O N TH E FUE L SURFAC E A S TH E FUE L I S USE D TH E MEMBRANE-FUE L INTERFAC E PREVENT S FUE L VAPO R FORMATIO N THATOCCUR S A TA N AIR-FUE L INTERFACE . N O FUE L TAN KVENTIN G O R CANISTE R SYSTEM S AR E REQUIRE D TH E BLADDE R REINFLATE S DURIN G REFUELING ; N O VAPO R I S DISPLACE D O R EVOLVED . N O VENTIN G O R CANISTE R SYSTE M I S REQUIRE D I N CRAS H SITUATION S TH E BLADDE R PROVIDE S ADDITIONA L PUNCTUR E PROTECTIO N FO R TH E FUE L SYSTE M

# IN-TAN KBLADDE R

VENT WIT H ROLLOVE R PROTECTIO

N BLADDE RSlide:Xl6531-0 7 Opid : Job#: C 15 3 DDS:600 0 Size:131 4 Tu e Au g 1 1 21:29:0 7 198 7 

# LIQUI D SEA L EVALUATIO N ADVANTAGE S •N O ISSUE S WIT H SEA L DURABILIT YO R TAMPERIN G •N O OVERPRESSUR E RELIE F REQUIRE D DURIN G REFUELIN G •N O CHANG E FO R VEHICL E OWNE R DISADVANTAGE S •FILLE R NEC KVULNERABILIT Y •CANNO TPACKAG E FILLE R HEIGH TT O MEE TEPA REQUIREMENT S (1 0 GP M FIL L RATE ) •MAN YFUE L TANK S AR E TO O SHALLO WFO R "J " TRA P ABOV E TH E FUE L •INCREASE D RIS KO F SPI TBAC KAN D FUE L EXPULSIO N •HIGHE R COMPLEXIT YSYSTE M FO R ADDE D VALVE S AN D CONTROL S T O MINIMIZ E SPITBAC KAN D FUE L EXPULSIO N •GENERATE S MOR E VAPOR S DURIN G REFUELIN G REQUIRIN G LARGE R CANISTE R CAPACIT Y •REQUIRE S FUE L TAN KAN D FILLE R PIP E REDESIG N •LIQUID/VAPO R SEPARATO R RELIABILIT YSlide:Xl6531-1 0 Opid : Job#: C 15 3 DDS-.600 0 Size:77 2 Tu e Au g 1 1 21:37:0 0 198 7



# MECHANICA L NOZZL E SEA L

EVALUATIO N ADVANTAGE S •MINIMU M CHANG E T O TH E TOTA L SYSTE M •AL L PARTS CONTAINE D I N ON E UNI TA T TH E FILLE R INLE T •SIMPL E MECHANICA L ACTIVATIO N DISADVANTAGE S •FILLE R INLE TVULNERABILITY •NOZZL E SEA L DURABILITYAN D TAMPERIN G •REQUIRE S OVERPRESSUR E RELIE F VALV E •LIQUI D VAPO R SEPARATO R RELIABILIT YSlide:Xl6531-0 8 Opid : Job#: C 15 3 DDS:600 0 Size:144 6 Tu e Au g 1 1 21:31:5 3 198* 7



# IN-TAN KBLADDE R EVALUATIO N ADVANTAGE S •MIGH TPROVID E ADDITIONA L PUNCTUR E PROTECTIO N UNDE R A LIMITE D NUMBE R O F CIRCUMSTANCE S DISADVANTAGE S •DOE S NO TPERFOR M A S THEORIZED . A NOZZE L SEA L SYSTE M MUS TB E ADDED .

- REFUELIN G VAPOR S EXCEEDE D EP A RULE S

- TH E PUR E BLADDE R SYSTE M WIL L NO TFIL L

- VAPOR S FRO M INSID E TH E BLADDE R DURIN G NORMA L VEHICL E OPERATIO N

- KNOW N MEMBRAN E MATERIAL S AR E PERMEABL E

- - VAPO R LOS S COUL D EXCEE D EP A RULE S

- - LIQUI D FUE L COUL D CONDENS E BETWEE N TH E BLADDE R AN D TH E TAN K

- AL L KNOW N BLADDE R MATERIAL S WIL L NO TFUNCTIO N PROPERL YBELO W BLADDE R MATERIA L DURABILIT YI S UNKNOW N WATE R CONDENSATIO N BETWEE N TAN KAN D BLADDE R POSE S A CORROSIO N RIS KAN D IC E FORMATIO N COUL D CU TTH E BLADDE R NE WFUE L TAN KMANUFACTURIN G PROCESSE S MUS TB E DEVELOPE D REQUIRE S NE WCONCEP TFUE L PIC K U P AN D FUE L GAG E SENDE R 0° F

C OSlide:Xl6531-0 9 Opid : Job#: C 15 3 DDS:600 0 Size:71 8 Tu e Au g 1 1 21:35:1 0 1987 '



# IN-TAN KBLADDE R (EVALUATIO N CONTINUED )

•BLADDE R MATERIA L DURABILIT YI S UNKNOW N
•WATE R CONDENSATIO N BETWEE N TAN KAN D BLADDE R POSE S A CORROSIO N RIS KAN D IC E FORMATIO N COUL D CU TTH E BLADDE R
•AL L O F TH E HARDWAR E REQUIRE D FO R A MECHANICA L NOZZL E SEA L SYSTE M WIL L B E REQUIRE D
•NE WFUE L TAN KMANUFACTURIN G PROCESSE S MUS TB E DEVELOPE D
•REQUIRE S NE WCONCEP TFUE L PIC KU P AN D FUE L GAG E SENDE RSlide:X16531-l l Opid : Job#: C 15 3 DDS-.600 0 Size:75 2 Tu e Au g 1 1 21:38:2 3 1987 ' . 

# SUMMAR YO F HARDWAR E EVALUATIO N

•EAC H SYSTE M HAS ADVANTAGE S AN D DISADVANTAGE S
•EAC H SYSTE M ADD S COMPLEXIT YAN D ADDITIONA L SOURCE S FO R POTENTIA L IGNITIO N
•EAC H SYSTE M REQUIRES :

- FURTHE R DESIG N WOR KT O RESOLV E KNOW N SHORTFALL S

- TESTIN G T O EVALUAT E CONFORMANC E T O STANDARD S AN D DISCOVE R ADDITIONA L POTENTIA L FAILUR E MODE S

- REDESIG N AN D RETES TT O VERIF YTHA TTHES E INVENTION S MEE TAN D EXCEE D AL L STANDARD S

i

# LEADTIM E

DU E T O COMPRESSE D LEADTIM E REQUIREMENT S ASSUME D B

YEP A MANUFACTURERS AR E FORCE D T O INTRODUC E COMPROMISE S
IDEALL YAL L MECHANICA L MECHANISM S SHOUL D B E CONTAINE D A TTH E FUE L TAN K FUE L TAN K

REDESIG N LEADTIM E I S 5 2 MONTH S MINIMU M ASSUMIN G AL L DESIGN S CAN B E PHASE D I NP.2 3
COLLAPSIBL E BLADDE RFUE L TANK S EPA Position : A s state di nthe Marc h198 7 Draf t repor t entitle d"Safety Implication s o f Onboar dRefuelin g Vapo r Recover y Systems" , EP

A con clude s tha t a "collapsibl e bladde r tank coul dbe use dt o mee t th e onboar drequirement " addin g tha t " a bladde r tan k coul deliminat e essen tiall y al l o f the safet y concern s raise dregardin g contro l o f refueling emissions . Thi s i s becaus e a vapo r spac e woul dno t be presen t ina bladde r tank , an dwithou t a vapo r space , refuelin g emission s woul dno t occur. "
Genera l Comments : The EP A positio ni s incomplet e i ntha t i t fail s t o recogniz e the limitation s andunresolve ddesig nissue s associate dwit hthi s emergin g technology . A s anyon e wh o ha s eve r fille da swimmin g poo l equippe dwit ha poo l line r ca nattest , i t i s nearl y impossibl e t o completel y remov e wrinkle s fro m a liner , wrinkle s tha t i na fue l syste m ca naccumulat e t o decreas e preciou s tank capacit y

an dpotentiall y bloc k the critica l openings . Thu s whil e desig nwor k i s continuin g i nthi s are a ther e i s no immediat e hope tha t the many unresolve d ope nissue s wil l permi t productio nusag e o f thi s potentia l technology . Som e o f the ope nissue s include :

MATERIAL S COMPATIBILIT Y The bladde r mus t b e compatibl e wit hal l fue l an dfue l blends , an d alcoho l fuel s currentl y availabl e o r expecte dt o b e available . Thi s include s sou r fuel , aftermarke t additive s andentrappe dmoisture . Th e materia l mus t als o remai nflexibl e unde r al l conditions , b e abrasio n resisten t andhav e littl e i f an y weight . ENVIRONMENTA L COMPATIBILIT Y Th e bladde r must remai n flexibl e andabrasio n resisten t unde r al l temperatur e condition s fro m extreme col d(minu s 5 0 F an dbelow ) t o extrem e hot . FUE L SYSTE M SHUTOF F Th e seale d syste mmus t b e capabl e o f bein g fille dunde r al l environmenta l condition s an d unde r condition s o f fue l dispensin g nozzl e failure . Fue l shutof f mus t resul t i nconstan t fue l 'full ' leve l unde r al l condition s withou t fue l spitback . CONDENSATIO N Becaus e o f th e potentia l temperatur e differentia l betwee n th e bladde r an d th e tank , consideratio n mus t b e give n t o moistur e condensation . Provision s mus t b e mad e t o evacuat e th e moisture . Thi s tas k i s complicate d b

yth e fac t tha t th e bladde r b ydesig n wil l sea l al l opening s i n ch e surroundin g tan k an d wil l collaps e an d expan d differentl yeac h rirr e th e syste mi s filled . Thi s coul d caus e moistur e t o becom e permanent]." / trappe d whic h i n tur n coul d limi t capacity , freeze , whic h coul d formic e dagger s tha t potentiall ycoul d punctur e th e bladder , o r caus e o r contribut e t o othe r hazards .P.2 4
FUE L TAN

KBLADDE ROPEN

ISSUE S - FIL L RAT E LIMITATION S Consideratio nmus t be give nt o insur e tha t the syste m wil l fil l a t a n acceptabl e rat e unde r al l environmenta l conditions . Col dtemperature s coul dstiffe nth e bladder s thereb y increasin g th e pressur e require dto fil l anddecreasin g the fil l rate . Consideratio nmus t b e give nto how t o shutof f fil l t o avoi doverpressurization . ELECTROSTATI C BUILDU P Th e complete dsyste m mus t preven t the buildu po f electrostati c charges . PRESSUR E BUILDU P Th e complete dsyste m mus t b e abl e t o readil y andsafel y

stabiliz e an

y pressure buildu presultin g fro m the interna l fue l temperature s o r durin g fill . FUE L LEVE L SENSIN G Ne w technolog y

mus t b e develope dt o accuratel y andsafel y

sens e th

e fue l leve l i nthe tank . PERMEABILIT Y Material s mus t no t be permeabl e t o fue l whic hcoul dbecome trappe d betwee nthe bladde r an d the tank liner . MANUFACTURINGPROCES S Entirel y

ne w processe s mus t b e develope dt o manufacture r th e bladde r o n a mas s productio nbasi s andt o assembl e the component s i na hig h qualit y

fashio ns o a s t o preclud e leak s an dothe r defects . Curren t bladde r tank s ar e mad e on e a t a time , b y hand . FUE L RESERVOI R Alternativ e technolog y fo r handlin g the uniqu e issue s tha t occu r durin g lo w fue l condition s nee dt o b e explored . SHAP E DEPENDENC Y Expecte dtan k configuration s wil l com e i na variet y o f shape s t o conform

t o availabl e spac e limitations . Th e bladde r mus t b e sufficientl y

flexibl e t o confor m t o a variet y

o f contours . VAPO R ENTRAPMEN T Current fuel s begi n t o boi l (i.e . evaporate ) a t abou t 8 0 F an d significant amount s o f fue l wil l boi l a t typica l vehicl e operatin g temperatures . Th e vapo r generate d mus t b e remove d i f th e bladde r i s t o resea l itsel f agains t th e fuel . Increasin g fue l volatility , o f course , exacerbate s thi s problem . An ypressur e buildu p i n th e tan k mus t b e relieve d o r a t a minimu mcontrolle d i n orde r t o preclud e balloonin g o f th e tan k o r fue l expulsio n upo n ca p removal .