Portable Fuel T

Portable Fuel T

Testing to EPA Regulat

Presented to Julia Giuliano

U.S. EPA - OTAQ

Mechanical Engineer
EPA Regulation 1060 105(c) (effective Jan 1 20

EPA Regulation 1060.105(c) (effective Jan. 

1 20

(c) Portable marine fuel tanks and associated fuel-system components must meet the following requirements(1) They must be self-sealing (without any manual vents) w

attached to the engines. The tanks may not vent to the attached to the engines. The tanks may not vent to the

atmosphere when attached to an engine.

(2) They must remain sealed up to a positive pressure of 24

(3 5 i ) h th t i i i l t th t (3.5 psig); however, they may contain air inlets th

at open 

there is a vacuum pressure inside the tank. Such fuel tamay not contain air outlets that vent to the atmosphere a

pressures below 34.5 kPa ( p g) 5.0 

psig)
Test Plan Test Plan

• Purpose of Test: To validate whether or not a portable fuel tank attached 

engi ld t t th t h t l l f 34 5kP (5 i 

ine would vent to the atmosphere at a pressure level of 34.5kPa (5psi

At any pressure level, the visual observation of liquid fuel in a catch contairrelevant of the quantity will be considered as a breach of the sealing con

• Test Procedure (Static): Position test unit on engine stand and test the 

full tilt up and full trimmed down positions. Install clear vent hose to catch 

for overflow capture. Fill float bowl completely full. Connect fuel tank to eapp y p p p p ly pressure to fuel tank from 0psi to a maximum of 8psi at 2psi increm

duration of 4 to 5 minutes or until fuel is captured in the overflow containe

• Test Procedure (Dynamic): Place test unit on the boat transom in the tilt 

lock position with the worst case turn pos lock position with the worst case turn position based on float bowl position 

based on float bowl position

clear vent hose to catch container for overflow capture. Fill float bowl comConnect fuel tank to engine and apply constant pressure to fuel tank. Trathe rough road route at 25 mph for 0.5 mile and monitor overflow containe

pressure on fuel tank by 1psi increments from 0 psi to 8 psi or until fuel is pressure on fuel tank by 1psi increments from 0 psi to 8 psi or until fuel is 

the overflow container.
Test Plan vs. Engines Actu

Tested.

Engine Model 

Indicated in Test 

Plan

Engines Model Tested Desc

Static Test Dynamic Test

15 H.P 2-Stroke 10 H.P 2-Stroke 10 H.P 2-Stroke Engines fro

family

8 H.P 4-Stroke 8 H.P 4-Stroke 8 H.P 4-Stroke

15 H.P 4-Stroke 15 H.P 4-Stroke 15 H.P 4-Stroke

4 H.P 2-Stroke 4 H.P 2-Stroke 4 H.P 2-Stroke

40 H.P 2-Stroke 50 H.P 2-Stroke 50 H.P 2-Stroke Engines fro

family

30 H.P 2-Stroke 25 H.P 2-Stroke 25 H.P 2-Stroke Engines fro30 H.P

2 Stroke 25 H.P

2 Stroke 25 H.P

2 Stroke family

30 H.P. 2-Stroke 30 H.P. 2-Stroke 30 H.P. 2-Stroke60 H.P. 2-Stroke 55 H.P. 2-Stroke 40 H.P. 2-Stroke Engines fro

family

90 H P 2 90

H.P. 2-Stroke 90 H P 2 90

H.P. 2-Stroke 90 H P 2 90

H.P. 2-Stroke
Test Procedure (Stat

Test Procedure Ai i r pressure in (Stat

from regulator

Sealed Fuel Cap

Fuel to Outb

Gauge

Scale used to determine 

(0-15 PSIG)Showing 8PSIG in 

Ph t

quantity of fuel leak

Ph

oto
Static Testing Tilt Ang

Static Testing Tilt Ang

and Orientation

N Tilt (0

°

)

and Orientation

•

No-Tilt (0

°

)

• Half-Tilt

–Port–Starboard

• Full-Tilt

–Port

–Starboard
Static Testing Results

Description Tank Pressure (PSIG) 8246886

Kg Start 6.038 5.975 5.975 6.009 6.017 6.017 6.00

Kg Stop 6.038 5.975 5.975 6.008 6.017 6.017 6.00

Time (Minutes) 5555555

Leak rate g/hr 0000000

L k t /h

0

0

0

0

0

0

0

15 H.P 

Carbureted 

F St k

Lea

k rate cc/hour

0

0

0

0

0

0

0

Position (degrees tilt) 0 20 20 20 20 20 30 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

Description Tank Pressure (PSIG) 8246886 

Kg Start 5.997 5.961 5.976 5.984 5.991 5.99 5.98 

Kg Stop 5 996 5 961 5 976 5 984 5 99 5 99 5 98 

Four-Stroke

Kg Stop

5.996

5.961

5.976

5.984

5.99

5.99

5.98

Time (Minutes) 5555555 

Leak rate g/hr 0000000 

Leak rate cc/hour 0000000 

Position (degrees tilt) 0 18 18 18 18 18 35 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

8 H.P 

Carbureted 

Four-Stroke

Description Tank Pressure (PSIG) 82468 6 

Kg Start 4.228 4.184 4.198 4.217 4.224 6.08

Kg Stop 4.227 4.184 4.198 4.22 4.224 6.08

Time (Minutes) 44444 4 

Leak rate g/hr 00000 0 

Leak rate cc/hour 00000 0 

10 H.P 

Carbureted 

Two-Stroke

Position (degrees tilt) 0 20 20 20 20 55 

Orientation (Port or Starboard) Center STB STB STB STB POR

Description Tank Pressure (PSIG) 8246886

Kg Start 5.917 5.875 5.896 5.906 5.913 5.912 5.91

Kg Stop 5.916 5.875 5.896 5.905 5.913 5.912 5.91

Time (Minutes) 4444444

Leak rate g/hr 0000000

Leak rate cc/hour 0000000

Position (degrees tilt) 0 20 20 20 20 20 35 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

25 H.P 

Carbureted 

Two-Stroke
Static Testing Results Con

Description Tank Pressure (PSIG) 8246886

Kg Start 5.928 5.882 5.901 5.915 5.92 5.918 5.909 

Kg Stop 5.927 5.882 5.901 5.915 5.92 5.917 5.909 

Time (Minutes) 4444444

Leak rate g/hr 0000000

Leak rate cc/hour

0

0

0

0

0

0

0

4 H.P 

Carbureted 

Two-Stroke Leak rate cc/hour

0

0

0

0

0

0

0

Position (degrees tilt) 0 25 25 25 25 25 35 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

Description Tank Pressure (PSIG) 8246886

Kg Start 5.847 5.805 5.823 5.834 5.841 5.829 5.83 

K

g Sto

p 5.845 5.804 5.823 5.834 5.84 5.83 5.83 

Two Stroke

g p

Time (Minutes) 4444444

Leak rate g/hr 0000000

Leak rate cc/hour 0000000

Position (degrees tilt) 0 20 20 20 20 20 35 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

50 H.P 

Carbureted 

Two-Stroke

Description Tank Pressure (PSIG) 8246886

Kg Start 5.83 5.785 5.809 5.819 5.825 5.824 5.78

Kg Stop 5.83 5.785 5.809 5.819 5.825 5.824 5.765 

Time (Minutes) 444444 4

Leak rate g/hr 000000 240 

Leak rate cc/hour 000000 324 

P iti (d tilt)

0 15 15 15 15 15 55 

30 H.P 

Direct 

Injection

Position (degrees tilt)

0 15 15 15 15 15 55 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

Description Tank Pressure (PSIG) 8246886

Kg Start 5.467 5.229 5.296 5.315 

Kg Stop 5.466 5.229 5.296 5.314 

55 H P Time (Minutes)

4

4

4

4

Time (Minutes)

4

4

4

4

Leak rate g/hr 0000 

Leak rate cc/hour 0000 

Position (degrees tilt) 0 60 60 60 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

55

H.P

Direct 

Injection
Static Testing Results Co

Static Testing Results Co

Description Tank Pressure (PSIG) 8246886

Kg Start 5.515 5.473 5.491 5.501 5.497 5.493 5.45

Kg Stop 5.514 5.473 5.491 5.5 5.496 5.493 5.45

90 H P Time (Minutes) Time (Minutes)

4

4

4

4

4

4

4

Leak rate g/hr 0000000

Leak rate cc/hour 0000000

Position (degrees tilt) 0 20 20 20 20 20 30 

Orientation (Port or Starboard) Center STB STB STB STB PORT POR

90

H.P

Direct 

Injection
Test Procedure (Dynamic)

Tank Pressure Regulation from Tow Vehicle

Sealed Fuel Cap

Tow Vehicle

Carbureted

Direct Injected

OR

Fuel leak Carbureted 

Trailer on .5 miles of rough road at 25 mph

Vapor Separator Vent
Test Results (Dynamic)

Fuel Tank Pressure

Outboard (Legacy Engines) tilt angle steering angle 1 psi 2 psi 3psi 4psi 5psi 6p

4 hp 2 stroke 4 hp

2-stroke 0° straight straight ok leak na na na na 

4 hp 2-stroke 0° port ok leak na na na na 4 hp 2-stroke 0° starboard ok leak na na na na 4 hp 2-stroke 25° straight ok leak na na na na 4 hp 2-stroke 25° port ok leak na na na na 4 hp 2-stroke 25° starboard ok leak na na na na 8 hp 4 stroke 0° straight ok leak na na na na 8 hp 4 stroke 0° port ok leak na na na na 8 hp 4 stroke 0° starboard ok leak na na na na 8 hp 4 stroke 45° straight leak na na na na na 8 hp 4 stroke 8 hp

4 stroke 45° port leak na na na na na 

8 hp 4 stroke 45° starboard leak na na na na na 

10 hp 2-stroke 0° straight ok ok ok leak na na 

10 hp 2-stroke 0° port ok ok ok leak na na 

10 hp 2-stroke 0° starboard ok ok ok leak na na 

10 hp 2-stroke 55° straight leak leak na na na na 10 hp 2-stroke 55° port leak leak na na na na 10 hp 2-stroke 55° starboard ok leak na na na na 
Test Results (Dynamic) Test Results (Dynamic)

Fuel Tank Pressure

O tb d (L E i ) O

utboar

d (Legacy 

Engines) tilt l ang e sti l eer ng angle 1 i ps 2 i ps 3 i ps 4 i ps 5 i ps 6 

15 hp 4 stroke 0° straight ok ok leak na na n

15 hp 4 stroke 0° port ok ok leak na na n

15 hp 4 stroke 0° starboard ok ok leak na na n

15 hp 4 stroke 60° straight leak na na na na n

15 hp 4 stroke 15 hp

4 stroke 60° port leak na na na na n

15 hp 4 stroke 60° starboard leak na na na na n

25 hp 2 stroke 65° straight leak leak na na na n25 hp 2 stroke 65° port leak leak na na na n25 hp 2 stroke 65° starboard ok leak na na na n

50 hp 2-stroke carbureted 0° straight ok ok ok ok ok o

50 hp 2-stroke carbureted 0° port ok ok ok ok ok o50 hp 2-stroke carbureted 0° starboard ok ok ok ok ok o50 hp 2-stroke carbureted 45° straight leak leak leak leak na n

50 hp 2-stroke carbureted 45° port leak leak leak leak na n50 hp 2-stroke carbureted 50 hp 2-stroke carbureted 45° starboard starboard leak leak leak leak na n
Test Results (Dynamic) Test Results (Dynamic)

Fuel Tank Pressure

Outboard tilt angle steering angle 1 psi 2 psi 3psi 4psi 5psi 6p

30 hp Direct Injection 40° straight ok 2ml 14ml 24ml 50ml na 

30 hp Direct Injection 40° port ok 1ml 15ml 37ml 53ml na 30 hp Direct Injection 40° starboard trace 6ml 15ml 26ml 50ml na 

40 hp Direct Injection 35° straight 7ml 6ml 6ml 8ml 7ml na 40 hp Direct Injection 35° port 7ml 6ml 6ml 8ml 7ml na 40 hp Direct Injection 35° starboard 7ml 6ml 6ml 8ml 7ml na 40 hp Direct Injection 35° straight 15ml 20ml na na na na 40 hp Direct Injection 40 hp Direct Injection 35° port 15ml 20ml na na na na 40 hp Direct Injection 35° starboard 15ml 20ml na na na na 

90 hp Direct Injection 45° straight 3ml 3ml 7ml na na na 90 hp Direct Injection 45° port 5ml na na na na na 

90 hp Direct Injection 45° starboard 3ml na na na na na 
Discussion on the results

• Application of a constant level of pressure to the tank for a given p

time even after the breach of the sealing condition

– Is not replicating what would happened in normal use experience. At th

instant that the sealing condition is breached, the pressure will bleed to allowin

g g the sealin

g condition to re-establish itself

– Therefore causes an extraordinary amount of fuel to be leaked

• Current outboard engine fuel supply control technology (Float, ne

seat valve) cannot provide positive sealing under all conditions

– Tilt angle has an effect on the buoyancy of the float generally reducing t

that the needle exerts on the valve seat 

– When trailered jolting and bouncing of the tilted engine further impacts 

When trailered, jolting and bouncing of the tilted engine further impacts 

pressure between needle and valve seat.