Portable Fuel TankPortableFuelTankTesting to EPA RegulationsPresented to Julia GiulianoU.S. EPA - OTAQMechanical EngineerEPA Regulation 1060 105(c) (effective Jan 1 2010)EPARegulation1060.105(c)(effectiveJan.12010)(c) Portable marine fuel tanks and associated fuel-systemcomponents must meet the following requirements(1) They must be self-sealing (without any manual vents) when notattached to the engines. The tanks may not vent to theattachedtotheengines.Thetanksmaynotventtotheatmosphere when attached to an engine.(2) They must remain sealed up to a positive pressure of 24.5 kPa(3 5 i ) h th t i i i l t th t h(3.5psig);however,they may contain airinletsthatopen whenthere is a vacuum pressure inside the tank. Such fuel tanksmay not contain air outlets thatvent to the atmosphere atpressures below 34.5 kPa(5.0psig)p g)2Test PlanTestPlan•Purpose of Test: To validate whether or not aportable fuel tank attached to ani ld t t th t h t l l f 34 5kP (5 i ) b lengine wouldventtothe atmosphere ata pressurelevelof34.5kPa(5psig)orbelow.At any pressure level, the visual observation of liquid fuel in a catch containerirrelevant of the quantity will be considered as a breach of the sealing condition.•Test Procedure (Static): Position test unit on engine stand and test the unit in thefull tilt up and full trimmed down positions. Install clear vent hose to catch containerfor overflow capture. Fill float bowl completely full. Connect fuel tank to engine andapplypressure to fuel tank from 0psi to a maximum of 8psi at 2psi increments for ay p p p pduration of 4 to 5 minutes or until fuelis captured in the overflow container.•Test Procedure (Dynamic): Place test unit on the boat transom in the tilt up trailedlock position with the worst case turn posbased on float bowl position Installlockpositionwiththeworstcaseturnpositionbasedonfloatbowlposition.Installclear vent hose to catch container for overflow capture. Fill float bowl completely full.Connect fuel tank to engine and apply constantpressure to fuel tank. Trailer boat onthe rough road route at 25 mph for 0.5 mileand monitor overflow container, increasepressure on fuel tank by 1psi increments from 0 psi to 8 psi or until fuel is captured inpressureonfueltankby1psiincrementsfrom0psito8psioruntilfueliscapturedinthe overflow container.3Test Plan vs. Engines ActuallyTested.Engine ModelIndicated in TestPlanEngines Model Tested DescriptionStatic Test Dynamic Test15 H.P 2-Stroke 10 H.P 2-Stroke 10 H.P 2-StrokeEngines from the samefamily8 H.P 4-Stroke 8 H.P 4-Stroke 8 H.P 4-Stroke15 H.P 4-Stroke 15 H.P 4-Stroke 15 H.P 4-Stroke4 H.P 2-Stroke 4 H.P 2-Stroke 4 H.P 2-Stroke40 H.P 2-Stroke 50 H.P 2-Stroke 50 H.P 2-StrokeEngines from the samefamily30 H.P 2-Stroke25 H.P 2-Stroke25 H.P 2-StrokeEngines from the samefamily30H.P2Stroke25H.P2Stroke25H.P2Stroke30 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-StrokeEngines from the samefamily90 H P 2-Stroke90 H P 2-Stroke90 H P 2-Stroke90H.P.290H.P.290H.P.24Test Procedure (Static)Ai iTestProcedure(Static)r pressureinfrom regulatorSealed FuelCapFuel to OutboardGaugeScale used to determine(0-15 PSIG)Showing8PSIG inPh tquantity of fuel leakPhoto5Static Testing Tilt AngleStaticTestingTiltAngleand OrientationNTilt (0°)andOrientation•No-Tilt(0°)• Half-Tilt–Port–Starboard• Full-Tilt–Port–Starboard6Static Testing ResultsDescription Tank Pressure (PSIG)824688688Kg Start6.038 5.975 5.975 6.009 6.017 6.017 6.006 6.014 6.013Kg Stop6.038 5.975 5.975 6.008 6.017 6.017 6.005 6.013 6.012Time (Minutes)555555555Leak rate g/hr000000000L k t /h00000000015 H.PCarburetedF St kLeakrate cc/hour000000000Position (degrees tilt)0 20 20 20 20 20 30 30 30Orientation (Port or Starboard)Center STB STB STB STB PORT PORT PORT STBDescription Tank Pressure (PSIG)82468868 8Kg Start5.997 5.961 5.976 5.984 5.991 5.99 5.985.983 5.975Kg Stop5 9965 9615 9765 9845 995 995 985 9665 968Four-StrokeKgStop5.9965.9615.9765.9845.995.995.985.9665.968Time (Minutes)55555555 5Leak rate g/hr0000000204 84Leak rate cc/hour0000000275 113Position (degrees tilt)0 18 18 18 18 18 3535 35Orientation (Port or Starboard)Center STB STB STB STB PORT PORTPORT STB8 H.PCarburetedFour-StrokeDescription Tank Pressure (PSIG)82468 68 8Kg Start4.228 4.184 4.198 4.217 4.224 6.0894.224 6.086Kg Stop4.227 4.184 4.198 4.22 4.224 6.0894.173 6.045Time (Minutes)44444 44 4Leak rate g/hr00000 0765 615Leak rate cc/hour00000 01032 82910 H.PCarburetedTwo-StrokePosition (degrees tilt)0 20 20 20 20 5555 55Orientation (Port or Starboard)Center STB STB STB STB PORTPORT STBDescription Tank Pressure (PSIG)824688688Kg Start5.917 5.875 5.896 5.906 5.913 5.912 5.914 5.92 5.918Kg Stop5.916 5.875 5.896 5.905 5.913 5.912 5.914 5.92 5.9187Time (Minutes)444444444Leak rate g/hr000000000Leak rate cc/hour000000000Position (degrees tilt)0 20 20 20 20 20 35 35 35Orientation (Port or Starboard)Center STB STB STB STB PORT PORT PORT STB25 H.PCarburetedTwo-StrokeStatic Testing Results Cont:Description Tank Pressure (PSIG)824688688Kg Start5.928 5.882 5.901 5.915 5.92 5.918 5.909 5.918 5.917Kg Stop5.927 5.882 5.901 5.915 5.92 5.917 5.909 5.917 5.917Time (Minutes)444444444Leak rate g/hr000000000Leak rate cc/hour0000000004 H.PCarburetedTwo-StrokeLeakratecc/hour000000000Position (degrees tilt)0 25 25 25 25 25 35 35 35Orientation (Port or Starboard)Center STB STB STB STB PORT PORT PORT STBDescription Tank Pressure (PSIG)824688688Kg Start5.847 5.805 5.823 5.834 5.841 5.829 5.83 5.837 5.838KgStop5.845 5.804 5.823 5.834 5.84 5.83 5.83 5.836 5.838Two Strokeg pTime (Minutes)444444444Leak rate g/hr000000000Leak rate cc/hour000000000Position (degrees tilt)0 20 20 20 20 20 35 35 35Orientation (Port or Starboard)Center STB STB STB STB PORT PORT PORT STB50 H.PCarburetedTwo-StrokeDescription Tank Pressure (PSIG)824688688Kg Start5.83 5.785 5.809 5.819 5.825 5.8245.781 5.764 5.656Kg Stop5.83 5.785 5.809 5.819 5.825 5.8245.765 5.663 5.623Time (Minutes)444444444Leak rate g/hr000000240 1515 495Leak rate cc/hour000000324 2045 668P iti (d tilt)0151515151555555530 H.PDirectInjectionPosition(degreestilt)01515151515555555Orientation (Port or Starboard)Center STB STB STB STB PORTPORT PORT STBDescription Tank Pressure (PSIG)824688688Kg Start5.467 5.229 5.296 5.315 5.327 5.327Kg Stop5.466 5.229 5.296 5.314 5.327 5.328Time (Minutes)44444455 H P8Time(Minutes)444444Leak rate g/hr0000 00Leak rate cc/hour0000 00Position (degrees tilt)0 60 60 60 60 60Orientation (Port or Starboard)Center STB STB STB STB PORT PORT PORT STB55H.PDirectInjectionStatic Testing Results Cont:StaticTestingResultsCont:Description Tank Pressure (PSIG)824688688Kg Start5.515 5.473 5.491 5.501 5.497 5.493 5.451 5.457 5.457Kg Stop5.514 5.473 5.491 5.5 5.496 5.493 5.452 5.457 5.456Time (Minutes)44444444490 H PTime(Minutes)Leak rate g/hr000000000Leak rate cc/hour000000000Position (degrees tilt)0 20 20 20 20 20 30 30 30Orientation (Port or Starboard)Center STB STB STB STB PORT PORT PORT STB90H.PDirectInjection9Test Procedure (Dynamic)Tank PressureRegulation fromTow VehicleSealedFuel CapTilt AngleTowVehicleCarburetedDirect InjectedORFuel leakCarburetedCollectionBeakerTrailer on .5 miles ofrough road at 25 mphVapor SeparatorVent10Test Results (Dynamic)Fuel Tank PressureOutboard (Legacy Engines) tilt angle steering angle 1 psi 2 psi 3psi 4psi 5psi 6psi 7psi 8psi4 hp 2 stroke0°straightokleaknananananana4hp2-strokestraight4 hp 2-stroke 0° portokleakna na na na na na4 hp 2-stroke 0° starboardokleakna na na na na na4 hp 2-stroke 25° straightokleakna na na na na na4 hp 2-stroke 25° portokleakna na na na na na4 hp2-stroke 25° starboardokleakna na na na na na8 hp 4 stroke 0° straightokleakna na na na na na8 hp 4 stroke 0° portokleakna na na na na na8 hp 4 stroke 0° starboardokleakna na na na na na8 hp 4 stroke 45° straightleakna na na na na na na8 hp 4 stroke45°portleaknanananananana8hp4stroke8 hp 4 stroke 45° starboardleakna na na na na na na10 hp 2-stroke 0° straightok ok okleakna na na na10 hp 2-stroke 0° portok ok okleakna na na na10 hp 2-stroke 0° starboardok ok okleakna na na na10 hp 2-stroke 55° straightleak leakna na na na na na10 hp 2-stroke 55° portleak leakna na na na na na10 hp 2-stroke 55° starboardokleakna na na na na na11Test Results (Dynamic)TestResults(Dynamic)Fuel Tank PressureO tb d (L E i )tilt lti l1 i2 i3 i4 i5 i6 i7 i8 iOutboard(LegacyEngines)ange seerng anglepspspspspspspsps15 hp 4 stroke 0° straightok okleakna na na na na15 hp 4 stroke 0° portok okleakna na na na na15 hp 4 stroke 0° starboardok okleakna na na na na15 hp 4 stroke 60° straightleakna na na na na na na15 hp 4 stroke60°portleaknanananananana15hp4stroke15 hp 4 stroke 60° starboardleakna na na na na na na25 hp 2 stroke 65° straightleak leakna na na na na na25 hp 2 stroke 65° portleak leakna na na na na na25 hp 2 stroke 65° starboardokleakna na na na na na50 hp 2-stroke carbureted 0° straightok ok ok ok ok okleak leak50 hp 2-stroke carbureted 0° portok ok ok ok ok okleak leak50 hp 2-stroke carbureted 0° starboardok ok ok ok ok okleak leak50 hp 2-stroke carbureted 45° straightleak leak leak leakna na na na50 hp 2-stroke carbureted 45° portleak leak leak leakna na na na50 hp 2-stroke carbureted45°starboardleakleakleakleaknananana50hp2-strokecarburetedstarboard12Test Results (Dynamic)TestResults(Dynamic)Fuel Tank PressureOutboard tilt angle steering angle 1 psi 2 psi 3psi 4psi 5psi 6psi 7psi 8psi30 hp Direct Injection 40° straightok2ml 14ml 24ml 50mlna na na30 hp Direct Injection 40° portok1ml 15ml 37ml 53mlna na na30 hp Direct Injection 40° starboard trace6ml 15ml 26ml 50mlna na na40 hp Direct Injection 35° straight7ml 6ml 6ml 8ml 7mlna na na40 hp Direct Injection 35° port7ml 6ml 6ml 8ml 7mlna na na40 hp Direct Injection 35° starboard7ml 6ml 6ml 8ml 7mlna na na40 hp Direct Injection 35° straight15ml 20mlna na na na na na40 hp Direct Injection35°port15ml20mlnananananana40hpDirectInjection40 hp Direct Injection 35° starboard15ml 20mlna na na na na na90 hp Direct Injection 45° straight3ml 3ml 7mlna na na na na90 hp Direct Injection 45° port5mlna na na na na na na90 hp Direct Injection 45° starboard3mlna na na na na na na13Discussion on the results• Application of a constant level of pressure to the tank for a given period oftime even after the breach of the sealing condition– Is not replicating what would happened innormal use experience. At the veryinstant that the sealing condition is breached,the pressure will bleed to a lower levelallowingthe sealingcondition to re-establish itselfg– Therefore causes an extraordinary amount of fuel to be leaked• Current outboard engine fuel supply control technology (Float, needle andseat valve) cannot provide positive sealing under all conditions– Tilt angle has an effect on the buoyancy ofthe float generally reducing the pressurethat the needle exerts on the valve seat–When trailered jolting and bouncing of the tilted engine further impacts the contactWhentrailered,joltingandbouncingofthetiltedenginefurtherimpactsthecontactpressure between needle and valve seat.14