p.1 

OAR Box 1147 

Prepped by Ollie Stewart 

Document Number: 

203) IV-E-77 

Docket Number: 

A-87-11 

Printed 4/22/2008 2:42:58 PM Sheet 203 of 242 
P.2 

ussy 

%**< / 

jK-s-77 

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY 

A N N ARBOR. MICHIGA N 48105 

OFFICE OF 

AIR AND RADIATION 

OCT 2 5 !988 

MEMORANDUM 

SUBJECT: Briefing to Ford on EPA work on a Ford Taurus Fuel 

Tank 

FROM: 

TO: 

John F. Anderson, Senior Project Manager 

Standards Development and Support Branch 

Docket A-87-11 

/>u_ 

On October 21, 1988 a meeting was held to brief 

representatives of Ford on recent work we have done to evaluate 

difficulties Ford was having in applying the simplified onboard 

refueling control concept to its vehicles. Our work found the 

same system as used on the GM fuel tank to be applicable to the 

Ford Taurus tank. Copies of the briefing material and 

attendance list are attached. 

Attachments 

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•c',-'cS ''Azfy.Zy-'""' 

r.*MW 

-7 \OP'r-
P.3 

Charles L. Gray, Jr. EPA 313/668-4404 

Chester J. France EPA 313/668-4338 

John F. Anderson EPA 313/668-4496 

John Polasek EPA 313/668-4223 

Rick Rykowski EPA 313/668-4339 

Lee Jones EPA 313/668-4356 

Carl Fuller EPA 313/668-4418 

Kelly Brown Ford 313/322-0033 

E. Ellsworth Ford 313/337-8569 

Tom Rolewicz Ford 313/845-8076 

390-2361 

Walt Kreucher Ford 313/845-8247 
P.4 

Application Of Simplified Refueling 

Controls To A Ford Taurus Fuel Tank 

Briefing to Ford 

October 21, 1988 
P.5 

Initial Tank Configuration 

Ford Production Fuel Tank (16 gal) 

Carbon Canister 2.5L 

Fuel Filler Pipe 

Rollover/Vapor Vent Valve with Large Diameter (0,350") 

Orifice to Allow Passage of Refueling Vapor 

5/8 I.D. Vapor Vent Line 

Removed Existing External Vent Line 
P.6 

Results of Initial Configuration Testing 

With Blue Rollover/Vapor Valve 

Filled at 10 gpm 

Satisfactory liquid seal 

Spitback at end of fill 

Dispensed 20.8 gals 

With White Rollover/Vapor Valve 

Filled at 10 gpm 

Satisfactory liquid seal 

Spitback at end of fill 

Dispensed 16.5 gals 
P.7 

Modifications to Initial Configuration 

Spitback Valve Added 

Spitback problem eliminated 

Near zero emissions at 10 gpm 

However, Testing at Low Flow Rates Indicated Inadequate 

Liquid Seal 
P.8 

Further Modifications 

Several Fill Pipe Restrictors Were Evaluated 

GM 1.050 dia restrictor with a tube 

Restrictors with tubes 

Dia ranging from 1.050" to .800" 

Various inlet face shapes 

Hardware display 

Restrictors without tubes 

Dia ranging from 1.000" to .800" 

Various inlet face shapes 

Hardware display 

Possible to get a liquid seal at low flow rates with 

several difference restrictors 

Smaller restrictors tended to cause premature 

shutoff at high dispensing rates 

. 
P.9 

Summary - Liquid Seals at Low Flow Rates 

Function of Restrictor Diameter and Shape 

Smaller Diameters Give Better Seals 

Function of Back Pressure 

Several Restrictors Showed Excellent Liquid Sealing 

Largest Restrictor Selected to Maximize Performance at 

High Flow Rates 
P.10 

Other Changes Evaluated 

Rollover/vent Valve Location 

Obtain appropriate fill height 

One location had splash interference 

Canister Back Pressure 

-

N Acceptable performance over wide range of canister 

back pressure (0.5-3" H20 at 10 gpm dispensing rate) 
P.11 

Final Configuration for Testing 

0 Ford Production Fuel Tank 

(16 gal-capacity) 

0 Fuel Filler Pipe 

0 Restrictor (1.050" dia restrictor as used on GM tank) 

0 Rollover/Vapor Vent Valve with Large Diameter (.350") 

Orifice to Allow Passage of Refueling Vapors 

0 5/8" I.D. Vapor Vent Line 

0 Anti-Spitback Check Valve 

0 2.5L or 4.0L Canister 
Test 

No. 

1 

2 

3 

80-1 

80-2 

81 

82 

83 

84 

85 

86 

IkrT 

(Vmf iaruration 

Valve Color 

and Location Restrictor 

Blue stock none 

White stock none 

White stock none 

Blue Center (C) none 

White Center (C) none 

Blue Center (C) 1.050 GM 

rest. & tube 

White Center (C) 1.050 GM 

rest. & tube 

White Center (C) 1.050 GM 

rest. & tube 

White Center (C) 1.050 GM 

rest. & tube 

White Front (B) 1.050 GM 

rest. & tube 

White Front (B) 1-050 GM 

rest. & tube 

linealibrated data. Use for es 

Spitback 

Valve 

No 

No 

No 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

timating 

Canister 

2.5L 

inside 

2.5L 

inside 

4.0L 

inside 

4.0L 

inside 

2.5L 

inside 

2.5L 

inside 

2.5L 

inside 

2.5L 

outside 

4.0L 

outside 

4.0L 

outside 

2.5L 

outside 

only. 

GPM 

10 

10 

10 

10 

5 

5 

5 

5 

10 

10 

10 

g/gal 

— 

— 

— 

.02 

.12 

.02 

.09 

.01 

.02 

.02 

Gal 

Disp. 

20.8 

16.5 

16.4 

19.7 

15.6 

18.2 

13.8 

13.8 

14.3 

14.5 

Pressure 

~ Ave. Peak 

(in H20) (in H20) 

— 

— 

— — 

5>5** 8.7** 

.9** 4.9** 

.7** 4.2** 

.1** 5.2** 

1.1** 5.3** 

7.8** 

6.0** 8.5** 

4.0** 8.6** 

Comments 

\ 

Stock tank 

1/2 cup spitback 

Stock tank 

1/4 cup spitback 

i 

Stock tank

 ! 

1/4 cup spitback 

Slight spitback 

Nozzle wasn't in 

all the way 

Kickoff 3X — 

Valve was being 

splashed on 

Valve moved to 

stop interference 
Test 

No. Configuration 

Valve Color 

and Location Restrictor 

Gal 

G

pM g/gal Disp. Pressure 

Spitback Ave. Peak 

Valve Canister (in H2O) (in H2O) 

Yes 2.5L 3 .08 16.7 .3 6.6 

outside 

Yes 4.0L 10 .02 14.3 4.2 8.3 

outside 

Yes 4.0L 3 

outside 

Yes 4.0L 10 .01 16.5 4.2 8.3 

Yes 4.0L 3 

Yes 2.5L 3 — 

Yes 2.5L 3 .07 13.6 .3 6.5 

outside 

Yes 2.5L 3 — 

outside 

Comments 

89-1 White Front (B) 

89-2 White Front (B) 

89-3 White Front (B) 

A4 White Front (B) 

A5 White Front (B) 

87 White Front (B) 

90 White Front (B) 

91-3 Blue Front (B) 

1.050 GM 

rest. & tube 

1.050 GM 

rest. & tube 

1.050 GM 

rest. _ tube 

1.050 GM 

rest. & tube 

1.050 rest. 

1.000 

modified 

rest, with 

GM tube 

1.000 

modified 

rest, with a 

lip. &' GM tube 

1.000 

modified rest, 

with lip. and 

GM tube 

Liquid seal did 

not form 

No seal 

No seal 

No seal formed 

using blue valve. 

91-4 White Front (B) 

93 White Front (B) 

1.000 

modified rest, 

with lip. and 

GM tube 

1.000 

rest, tube 

Yes 

Yes 

2.5L 

outside 

2.5L 

outside 

.07 17.1 

.08 16.8 

3.9 

.35 6.2 
Test 

No. 

91-2 

101 

112 

113 

97-1 

97-2 

102 

103 

92 

B2 

Valve Color 

and Location 

White Front (B) 

White Front (B) 

White Front(B) 

White Front(B) 

White Front (B) 

White Front 

White Front (B) 

White Front (B) 

White Front (B) 

White Front (B) 

Spitback 

Restrictor Valve 

1.000 

modified rest, 

with a lip. 

No tube. 

.99 rest, tube 

with a lip 

.99 rest, tube 

45° 

.99 rest, tube 

45° 

.950 plug 

no tube 

.950 plug 

no tube 

.95 plug 

no tube 

.95 plug 

no tube 

.95 plug with 

GM tube 

.95 rest, 

no tube 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Canister 

2.5L 

outside 

4.0L 

outside 

4.0L 

outside 

4.0L 

outside 

2.5L 

outside 

2.5L 

outside 

4.0L 

outside 

4.0L 

outside 

2.5L 

outside 

2.5L 

GPM 

3 

3 

3 

10 

3 

10 

3 

10 

3 

10 

g/gal 

.07 

.01 

.06 

.015 

.06 

.04 

.05 

.01 

Gal 

Disp. 

16.7 

15.5 

17.2 

16.4 

16.9 

14.8 

17.1 

15.3 

Pressure 

Ave. Peak 

(in H20) (in H20) 

.4 5.9 

4.2 7.9 

.28 5.5 

3.0 6.7 

.30 6.7 

4.7 6.5 

.3 4.9 

4.0 7.5 

Comments 

No seal 

No seal 

Premature shutoff 

at 3 gal & 13.2 ge 

Repeated once 
Test 

No. Configuration 

Gal 

GPM g/gal Disp. 

Valve Color 

and Location Restrictor 

Spitback 

Valve Canister 

Pressure 

Ave. Peak 

(in H20) (in H20) 

Comments 

B3 White Front (B) 

Cl White Front (B) 

95-2 White Front (B) 

96 White Front (B) 

.95 rest, 

no tube 

.95 rest, 

no tube 

.930 

rest, tube 

.930 

rest, tube 

Yes 2.5L 

Yes 2.5L 

Yes 

Yes 

104 White Front (B) -93 rest, tube Yes 

105 White Front (B) -93 rest, tube Yes 

Al White Front (B) -925 restrictor Yes 

A2 White Front (B) -925 rest. Yes 

110 White Front(B) 

111 White Front(B) 

.900 modified Yes 

rest, no tube 

.900 modified Yes 

rest, no tube 

4.0L 

outside 

4.0L 

outside 

.06 16.3 5.1 

10 .01 18.5 3.9 7.5 

2.5L 

outside 

2. 5L 

outside 

4.0L 

outside 

4.0L 

outside 

4.0L 

4.0L 

10 

3 

10 

3 

3 

10 

.02 

.07 

.007 

.07 

.05 

.04 

14.6 

17.1 

14.9 

16.3 

18.1 

17 

3.2 

.3 

4.5 

.3 

.3 

4.0 

6.8 

6.8 

5.7 

7.0 

5.8 

7.7 

10 -01 15.5 3.7 6.7 

,06 16.9 -33 5.6 

11 1/2 RVP, Temp 

of 10% - 95° F 

1 Premature shutoff 

Nozzle was not in 

all the way 
Test 

No. 

Configuration 

Gal 

GPM g/gal Disp. 

Valve Color 

and Location Restrictor 

Spitback 

Valve Canister 

4. #n\ qnn rest, tube Yes 4-OL 10 106 White Front (B) -900 rest. uu_ outside 

Pressure 

Ave Peak 

(in H20) (in H20) 

.01 14-8 3.2 4.5 

Comments 

Premature shutoff 

at 13.2 gal 

Repeated test and 

kicked off at 3.0 

gal 

108 White Front(B) .850 modified 

rest, no tube 

109 White Front(B) .850 modified 

rest, no tube 

98-1 White Front (B) -800 modified 

rest, no tube 

98-2 White Front (B) -800 modified 

rest, no tube 

107 White Front(B) -800 modified 

rest, no tube 

94 White Front (B) .800 

* rest, tube 

95-1 White Front (B) -800 

* rest, tube 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

Yes 

4.0L 

outside 

4.0L 

outside 

2.5L 

outside 

2.5L 

outside 

4.0L 

outside 

2.5L 

outside 

2.5L 

outside 

10 -05 15.8 

10 

.059 17.2 

10 .02 15.1 

.06 19.8 

3 -05 17-1 

10 

2.7 8.4 

.29 5.3 

3.0 7.0 

.28 5.0 

4.0 

.30 6.1 

Kickoff at .6 and 

1.6 gal 

Kickoff 3X 

6484W