1. EPA Compliant Fuel Systems IBEX Sep 28, 2010 George Bellwoar

2. Who should do your design? o Boat builders themselves o Tank builders o Component suppliers o System integrators o All of the above Who is responsible? o Suppliers & designers o Boat builders – your name is on the boat Just how hard is this? o Large number of details o Many design options o It isn’t rocket science Getting started

3. Boat builders and system integrators need new information o Collecting data first can save time & money Each model boat should be evaluated on a stand-alone basis o Evaluate needs independently o Potential for commonality of design What are the steps in the design process? o Collect data o Evaluate options o Build test boat o Test and certify

4. Collect Data on… o The boat itself o The fuel tank(s) o Fuel tank location and positioning in the boat o The area immediately above the fuel tank(s) o Access to installed tanks & components o The availability of space for new components (like canisters & ullage tanks) o The fuel and vent line routing

5. Organize & collect model specific data o Pictures o Hand sketches o Specification sheets o Measurements Focus on o Current & potential fill & vent locations o The areas around your fuel tank o Possible locations for new components Unique characteristics such as o Whether a boat will normally be refueled on the water or on a trailer o Length & beam Boat details

6. Dimensionally locate all existing tank components o Incoming fill pipe(s) and/or dog house(s) o Tank vent(s) o Connection(s) to engine(s) & generator(s) o Level sender o Hold down straps o Fuel pumps Note any other unique tank features 2D drawings and especially 3D files are useful Tank details

7. Accurately identify tank positioning relative to… o The hull for venting calculations at static rest o Fills & vents to begin evaluating fill quality Know how your customer’s use can affect tank position o While on a trailer o While in storage Fuel tank location & positioning in the boat

8. Note all tank clearances o Consider potential for tank expansion During pressure testing During refueling From diurnal changes Anticipate component placement o Recognize changing clearances o Pay particular attention to the center of the tank The area immediately above the tank

9. Marine o Passive purge o Remote fuel pump o Fill above fuel level o Fittings on top most level of tank o Refueling vapors vented to atmosphere o Tank & fittings subject to fire test o USCG requires access to our connections Automotive vs. marine systems Automotive o Active purge o Fuel pump in tank o Fill below fuel level o Fittings below top most level of tank o Refueling vapors captured at pump or on-board Automotive Marine

10. Access to installed tanks & components Access requirements affect component placement US Coast Guard regulations require access to…  Tank connections o Valves o Senders o All tank penetrations  Hose connections o Valves o Canisters o Ullage tanks o Fills o Vents

11. This configuration will affect fill quality Problem configurations include those with… o Long runs o Gentle slopes o Hard angles o Dips Collect details on current system including… o Overall run length & drop from fill & vent to tank o All slopes individually and as a system o Any dips o Any hard curves or bends (>45  ) Fill & vent line routing

12. Canisters Function Installation Positioning Supporting Potential failure modes Cracked housing or fittings Carbon breakdown Flooded (water or fuel) PERKO DELPHI ATTWOOD STANT

13. Protecting canisters From water o Gravity o Inverted loops o P-trap type devices A-24 (i.e. A-16) requirements o Above the shear line o Below the shear line From fuel o Automotive style fuel system valves o Gravity - Alternate system approaches Sebek Technology Enviro-Fill by Ameri-Kart Air/fuel separators

14. Ullage tanks… o Are vent-line devices containing airspace outside of the fuel tank o Must be located above the fuel tank o Must meet fuel tank requirements including fire resistance & permeation o Are sized at approximately 6% of fuel tank volume o May still require a valve to protect canisters from fuel Advantages o Eliminates or reduces access problems o Allows for complete tank filling & greater range o May be the best solution for extremely long, shallow tanks Ullage tanks

15. When to start o As soon as possible…this will take time System design help & components are available now This is practical The tools exists There are vendors ready & able to help How to start o Meet with & select vendors/partners o Collect data o Evaluate options o Build test boat o Test and certify Getting started

17. Sample Design Worksheets