ICOMIA Global Conformity Guideline for ISO and ABYC Standards. Guideline Number 1 Installed Fuel Systems and Fixed Fuel Tanks

Transcription

1 ICOMIA Global Conformity Guideline for ISO and ABYC Standards sponsored by ABYC, BMF, ICOMIA, IMCI, and NMMA Author: Wieger de Wit Guideline Number 1 Installed Fuel Systems and Fixed Fuel Tanks 1. PURPOSE These documents were created by an international working group for use as a companion to the standards listed below. The creators of these documents assume the users familiarity with either the ABYC or ISO standards. 2. SCOPE The information is presented in two separate yet similar Annexes. The annexes provide additional requirements in order to assess conformity to a parallel standard from another standard system. Access to the parallel standard is required to achieve compliance with that standard. A.1 ABYC + ISO additional requirements = ISO compliance A.2 ISO + ABYC additional requirements = ABYC & USCG compliance

2 A.1.1. Referenced Standards GLOBAL COMPLIANCE APPENDIX A.1 FUEL SYSTEMS ABYC + ISO ADDITIONAL REQUIREMENTS = ISO COMPLIANCE This document shall be used in conjunction with the following standards: International Organization for Standardization (ISO): Small craft - Permanently installed fuel systems and fixed fuel tanks (ISO 10088:2009) This International Standard specifies the requirements for the design, materials, construction, installation and testing of permanently installed fuel systems as installed for internal combustion engines. It applies to all parts of permanently installed diesel and petrol fuel systems as installed, from the fuel fill opening to the point of connection with the propulsion or auxiliary engine on inboard- and outboard-powered small craft of up to 24 m hull length. Requirements for the design, materials, construction and testing of permanently installed fixed fuel tanks are given in ISO Small craft Permanently installed petrol and diesel fuel tanks (ISO 21487:2006) This International Standard establishes requirements for design and test of petrol and diesel fuel tanks for internal combustion engines that are intended to be permanently installed in small craft of up to 24 m length of hull. For installation requirements, ISO applies. American Boat & Yacht Council (ABYC): H-24 GASOLINE FUEL SYSTEMS July SCOPE This standard applies to all parts of permanently installed gasoline fuel systems from the fuel fill opening to the point of connection to the propulsion engine and/or to any auxiliary equipment on all boats with gasoline engines, excluding onboard refuelling systems. H-33 DIESEL FUEL SYSTEMS July 2009 Corrected July SCOPE These standards apply to all parts of permanently installed diesel fuel systems from the fuel fill opening to the point of connection to the propulsion engine and/or to any auxiliary equipment on all boats with diesel engines. A.1.2. Additional Requirement Matrix Subject Heading (ABYC Clause no) CE Marked Components Required in This Topic Ignition Protection & Marking Additional ISO Requirements (ISO Clause no.) 1. Ignition-protected equipment for inboard and stern drive engines (See the included Ignition Protection Standard Comparison Report) 2. Fuel tanks intended for fixed installations 3. Fuel hoses Electrical items in engine compartments or other compartments with gasoline tanks and petrol system connections and/or joints, shall be ignition protected according to ISO 8846 and marked with the CE

3 Fire Testing (H ) (H-33.20) Filters (H-24.10) (H-33.9) Tanks Materials & Thickness (metallic tanks) Tanks Materials & Thickness (non - metallic tanks) (H-33.18) Tanks Testing & Marking (H-33.18) Fuel Hose (H-24.15) (H-33.14) Deck Fill Plate & Marking (H ) (H ) Fill rate (H-24.18) Fuel Tank Installation Gasoline Tank Clearance/Engine mark. ( ) To comply with ISO test all components used in the fuel system according to ISO annex B, or ISO 7840 Small craft-fire- resistant fuel hoses, or purchase the components in the fuel system with an ISO approval or the CE marked fuel hose according to Applies also if the components are used outside the engine compartment. (ISO ) According to ISO fuel filters installed in engine compartments need to be tested and approved using the procedures of ISO 7840 Annex A. ABYC however demands more identification and marking on the filter. It is recommended to purchase ISO compliant filters for the European market and ABYC compliant filters for boats that need to comply with ABYC standards. (ISO ) Metallic tank materials and thicknesses shall be in accordance with ISO Table 1. The ISO requirements are slightly higher then the ABYC requirements (ISO ) Pre-fabricated tanks need to be CE marked. Pre-fabricated tanks need to be CE marked. NOTE: ISO requires the material used for plastic tanks to have a melting point of 150 C. This however is not feasible in practise. On this specific paragraph, the former ISO 10088: 2001 still may be used while it is still harmonized under RCD (ISO , 8) Only tanks carrying the CE mark may be used in boats complying with ISO CFR/ABYC tanks do not fully meet the requirements for CE marking; subsequently CE tanks do not fully meet 33CFR/ABYC requirements. All fuel hose used in a boat must carry the CE mark. ISO 7840 Small craft Fire-resistant fuel hoses covers USCG A1-15 Type hose. ISO 8469 Small craft Non-fire-resistant fuel hoses covers USCG B1-15 Type hose. It is possible to buy both USCG and CE hose. (ISO /5.2.2/5.3.6/5.6.4) To comply with both mark the fuel filling point with the ISO symbol from ISO (ISO ) No blow back of fuel allowed at a flow fill rate of 30 L/min. For tanks < 100 L the fill rate may be 20 L/min (ISO ) To comply with ISO make sure that gasoline tanks have at least 100 mm clearance from the main engine and/or generator, or any other combustion engine.

4 Fuel Tank Installation Clearance/Exhaust Distribution Lines (H ) (H ) (H-33.14) Accessibility Joints/Connections (H-24.12) (H-33.11) Electrically Operated Valves (H-24.9) (H-33.8) Fuel Tank Vent Installation Vent Line & Valves (H-24.14) (H-33.13) Minimum vent diameter (H ) Fuel Tank Vent Installation Spillage (H ) (H ) (ISO ) To comply with ISO provide for a minimum clearance of 250 mm between the petrol tank and any exhaust component, or provide for an equivalent thermal barrier. (ISO ) Any hose inside an engine compartment must meet the ISO 7840 Fire Test. ABYC has the exception for lines outside the compartment and do not drain 5 oz. in 2.5 minutes to be type B. (ISO ) ABYC does not require distribution and return hoses to be accessible over the entire length, only for connections, fittings and joints To comply make the hoses accessible for inspection over the entire length. (ISO ) No other joints in the fuel distribution and return lines other than those required to connect components. To comply in any case only use joints necessary for operation of the fuel system. To comply with both, only an electrically operated valve is allowed in the fuel distribution line, but with a means to be able in emergency to manually shut off the feed. ISO only accepts electrically operated valves in fuel distribution line to the engine. (ISO ) Vent lines shall not have valves, only valves that permit free flow of air and prevent flow of liquid both in and out the tank (ISO ) ISO states a minimum vent cross-sectional area of 95 mm 2 (equivalent to 11 mm diameter). There is no minimum requirement in H-24. H-33 requires a minimum vent diameter of 7/16 inch (11.11 mm) (ISO ) To comply with this requirement, install the vent line termination with sufficient height and take measures to prevent spillage. For monohull sailboats, Spillage is not acceptable to a 30º angle. (ISO )

5 A.2.1. Referenced Standards GLOBAL COMPLIANCE APPENDIX A.2 FUEL SYSTEMS ISO + ABYC ADDITIONAL REQUIREMENTS = ABYC & USCG COMPLIANCE This document shall be used in conjunction with the following standards: International Organization for Standardization (ISO): Small craft - Permanently installed fuel systems and fixed fuel tanks (ISO 10088:2009) This International Standard specifies the requirements for the design, materials, construction, installation and testing of permanently installed fuel systems as installed for internal combustion engines. It applies to all parts of permanently installed diesel and petrol fuel systems as installed, from the fuel fill opening to the point of connection with the propulsion or auxiliary engine on inboard- and outboard-powered small craft of up to 24 m hull length. Requirements for the design, materials, construction and testing of permanently installed fixed fuel tanks are given in ISO Small craft Permanently installed petrol and diesel fuel tanks (ISO 21487:2006) This International Standard establishes requirements for design and test of petrol and diesel fuel tanks for internal combustion engines that are intended to be permanently installed in small craft of up to 24 m length of hull. For installation requirements, ISO applies. American Boat & Yacht Council (ABYC): H-24 GASOLINE FUEL SYSTEMS July SCOPE This standard applies to all parts of permanently installed gasoline fuel systems from the fuel fill opening to the point of connection to the propulsion engine and/or to any auxiliary equipment on all boats with gasoline engines, excluding onboard refueling systems. NOTE: 1) The US EPA has promulgated regulations regarding the emission of hydrocarbons from boat fuel distribution hose and vent systems. The significant changes to ABYC H-24, 2010 includes provisions for these regulations including automotive style nozzle shut-off and carbon canisters or pressure relief systems to meet these regulations. 2) There are many definitions in H-24 that are specific to this ABYC standard. Consult H-24.4 for proper meanings and terms. H-33 DIESEL FUEL SYSTEMS July 2009 Corrected July SCOPE These standards apply to all parts of permanently installed diesel fuel systems from the fuel fill opening to the point of connection to the propulsion engine and/or to any auxiliary equipment on all boats with diesel engines. A.2.2. Additional Requirement Matrix Subject Heading (ISO Clause no.) General requirements Petrol system operating temperature Additional ABYC Requirements (ABYC clause no.) The system and all components shall be capable of operation within an ambient temperature range from

6 (ISO ) General requirements Diesel system operating temperature (ISO ) Tank Vent Systems (Petrol only) Fuel distribution (Petrol only) Pressure relief systems Fuel distribution (Petrol only) Primer bulb Fuel pipes, hoses, connections and accessories Design Fuel pipes, hoses, connections and accessories (Petrol only) Emission Fuel pipes, hoses, connections and accessories (Petrol only) Flow rate fill (ISO ) Fuel pipes, hoses, connections and accessories (Petrol only) Permeation Fuel filters Fuel component labelling (ISO ) Fuel system labeling -40 F (-40 C) to 176 F (80 C) without failure or leakage. (H ) The system and all components shall be capable of operation within an ambient temperature range from -20 F (-29 C) to 176 F (80 C) without failure or leakage. (H ) External fittings: Above the shear line - weathertight. Below the shear line watertight (H ) Pressure relief systems for emission control shall not permit to transfer tank pressure to the distribution line. Pressure control valves shall be located within 40 inches (101.6cm) of the fuel pickup at the tank (H ) A primer bulb if used shall be marked in accordance with 40 CFR The fuel system shall be designed to activate the fuel nozzle s automatic shut off feature when the volume approaches the tank rated capacity (H ) Fuel shall not enter the boat and/or environment while filling or permanent ventilation of the fuel system (H , H ) H includes comprehensive fill tests rates and angles to ensure activation of automatic shut-off feature and protection of emission components. Permeation of hydrocarbon emission of fuel hose and primer bulb is limited to 15 g/m 2 /day. (H ) Additional marking is required for fuel filters, strainers and water pumps, including: date of manufacture, type of unit (filter, strainer or separator), replacement element part designation, direction of flow, suitability for use in a pressurised system, and installation and use instructions. (H ) (H ) A fuel system warning label shall be placed at a readily visible location The symbol and text below meets the requirement: (H-24.17) (H ) If a sight gauge is used for determining fuel quantity, the following label should be placed at a readily visible location:

7 Fuel System tests (Petrol only) Capacity testing Fuel System tests (Petrol only) Automatic shutoff fuel nozzle system testing Fuel System tests (Petrol only) Emission Fuel Tank tests Fuel Tank Labeling Fuel Tank Design & Construction (Diesel only) Diesel outboard boats Diesel outboard boats (H ) Determine the capacity of the fuel system in static floating condition (H ) Test the system for activating the nozzle s automatic shut-off according to the specified test. (H ) Test the watertight or weathertight exterior vent fittings with the specified spray or stream water test (H ) Perform the fire test for both metallic and nonmetallic fuel tanks CE marked non-metallic petrol tanks need an additional fire test according to H for use in ABYC compliant boats; Check H-33 and H-24 for precise requirements. A label according to 40 CFR should be on the tank. If pick-up and/or return tube is not furnished as part of the tank, a detailed construction print is provided (H ) Quick disconnect connection (automatic shut off when disconnected) is provided in the line between the engine and the tank (H ) A fitting is provided at the stern with provision for drainage, unless an electrically operated valve or antisiphon is provided. (H )