Product Improvement Test of Nonmetallic Fuel Tanks for Trucks
30
Transcript of Product Improvement Test of Nonmetallic Fuel Tanks for Trucks
RDTE PROJECT NO./FSN
TEST AGENCY PRaJECT NO.
TEST SPONSOR Ys - nd
TEST SPONSOR PROJECT-.NO,
TRADOC AC NO.
U S m m T a dOah:t a
PRODUCT IMPROVEMENT TEST OF NONMETALLIC FUEL TANKS
FOR - TRUCKS, M151 AND M715 SERIES
(PHASE I ) I
FIRST LlX"l'ER REPORT DUGWAY PROVING GROUW
BY T ~ H N L C A L LIBRARY -0 a: JUAN A. SUAREZ
JUNE 1 9 7 4
DISTRIBUTION LIMITED TO US GOVERNMENT AGENCIES ONLY; TEST AND EVALUATION; JUNE 1 9 7 4 . OTHER REQUESTS FOR THIS DOCUMENT MUST BE REFERRED TO US ARMY TANK-AUTOMOTIVE COMMAND, WARREN, MICHIGAN 4 8 0 9 0 .
U. S. ARMY YUMA PROVING GROUND
Dootroy t h i r roport when no longer needed. Do not nt* it to tho oris;inator.
Tho findin80 i n t h i r report are not t o be conrtruad u an o f f i c i a l Dapartmont of the Army posit ion unless ro doaiyutod by othor authorlawid documento.
Tho tam of trade namem i n t h i s report does not con- r t i t u t e an o f f i c i a l endorsement o r approval of the w o of ruch comorcial hardware o r roftware. This n p o r r u y not be c i ted fo r purpose of advertisement.
DISCLAIMER NOTICE This document may contain
pages which do not reproduce legibly.
Inconsistent page numbers are due to omittance of blank
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Unclassif ied LCURITY CLASSIFICATION O? TMIS r r o c F a n D r . Entor*@
Tanks f o r Trucks, M151 and M715 Se r i e s (Phase I )
b RePORTDOCUMENTATtONPAGE . REPORT NUMBER 2. OOVT A C C I U I O N NO.
USAYPG Report 193 1 . T I T L E ( m d Sublltle)
Product Improvement Test of Nonmetallic Fuel
READ MM'RUCTIONS BEFO- COYPL-Q FORM
3. R L C I P I L N T ' ~ CATALOQ NUMIER
S. TYPE O? RePORT 6 CLAOO C O V L M O
F i r s t Le t t e r Report, 17 April
'. AUTHOR(a)
ATTN: STEYP-MTM I
8. CONTRACT OR GRANT N U M I L W ~ )
JUAN A. SUAREZ I. PERFORMING ORGANIZATION NAME AND ADDRESS
US Army Y u m a Proving Ground 10. PROORAM ELEMENT PR JECT, TASK
AREA * WORK UNIT * N ~ M ~ I M
US Army Tank-Automotive Command ATTN: AMSTA-RHT
Y u m a , Arizona 85364 1. CONTROLLING OFFICE NAME AND ADDRESS
J u 1974 13. NUMBER OF PAGES
12. REPORT DATE
Warren, Michigan 48090 I 14. MONITORING AGENCY NAME 13 ADDRESS(1f dlfforent from Controlling Offlc*) I 15. SECURITY CLASS. (of thle t.poH)
US Army Test and Evaluation Command ATTN: AMSTE-BB US Army Aberdeen Proving Ground, Maryland 21005
I NA 6. DISTRIBUTION STATEMENT (of L i e Roporl)
Dis t r ibu t ion l imi ted t o US Government Agencies only; Test and Evaluation; June 1974. Other reques t s f o r t h i s document must be re fe r red t o US Army Tank-Automotive Command, Warren, Michigan 48090
7. DlSTRleUTlON STATEMENT (of th* abalract .nt*red I n Block 10, 11 dlll*rent from Roport)
8. SUPPLEMENTARY NOTES
9. KEY WORDS (Continuo on raveroe d d o I f necoaauy and Identlfy by block number)
0. ABSTRACT (Contlnu* on rovorae aide I f nec*ae.ry m d Id*ntlfy by block number)
A Product Improvement Test of Nonmetallic Fuel Tanks f o r Trucks, M151 and M715 Se r i e s was conducted by US Army Yuma Proving Ground during the period 17 Apr i l 1973 through 10 May 1974. The purpose of t he test was t o determine the s u i t a b i l i t y of t h e nylon f u e l tanks f o r N151 and M715 s e r i e s t rucks un- der deser t environmental conditions. The t e s t items were i n s t a l l e d i n M151 and M715 s e r i e s t rucks. These t rucks were operated under rou t ine , adminis- t r a t i v e operation on gravel , paved and cross-country t e r r a i n a t US Army Yuma
EDITION OF 1 NOV 65 IS OBSOLETE
SECURITY CLASSIFICATION OF THIS PAGE ( m e n D.1. Enlered)
I 'the nylon f u e l tanks are sui table f o r use i n the M715 and M151 s e r i e s truck
It was recammended tha t :
(1) To preclude fur ther f u e l tank support bands slippage, one of the followSng act ions must be implemented: ( a ) Change the nylon f u e l tank design t o provide molded depressions, o r (b) join the support bands by in- s t a l l i n g two metal banding s t raps between them.
(2 ) Incorporate the operational procedure of grounding the f u e l pump and the f u e l sending uni t i n pertinent technical manuals.
Unclassified SKCURITY CLASSIFICATION OF THIS PAGE(Whrr Data k t -
DEPARTMENT OF THE ARMY M r . J . A . Suarez/mjt/899-2929 US Army Yuma Proving Ground
Yuma, Arizona 85364
STEYP-MTM
SUBJECT: F i r s t L e t t e r Report on Product Improvement Tes t o f Nonmetallic Fuel Tanks f o r Trucks, MI51 and M715 S e r i e s , TECOM P r o j e c t No. 1-VG-123-000-001 (Phase I )
Commander US Army Tank-Automotive Command ATTN: AMSTA-RHT Warren, Michigan 48090
Dates of Tes t : 17 Apr i l 1973 through 10 May 1974
1. REFERENCES
a. L e t t e r , Headquarters, US Army Tes t and Evaluat ion Command, AMSTE-BB, da ted 1 3 A p r i l 1972, s u b j e c t : Customer Tes t D i rec t ive : Product Improvement Test of Non-Metallic Fuel Tanks f o r Trucks, M151 and M715. -
b . Customer Test D i rec t ive , AMSTA-RPT, dated 28 March 1972, p l u s inc lo- s u r e l e t t e r , dated 14 March 1972, s u b j e c t : Tes t Program of Non-Metallic Fuel Tanks.
c . L e t t e r , US Army Tank-Automotive Command, AMSTA-RPT, dated 1 5 November 1 9 7 2 , s u b j e c t : Product Improvement Test of Non-Metallic Fuel Tanks.
d . I , e t t e r , Headquarters, US Army Tes t and Evaluat ion Command, AMSTE-BB, dilted 1 5 December 1972, s u b j e c t : Product Improvement Test o f Non-Metallic l 'ucl Tanks f o r Trucks, M151 and M715.
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e . Customer Test D i rec t ive , AMSTA-RPT, da ted 4 December 1972, p l u s i n c l o s u r e l e t t e r , dated 1 6 November 1972, s u b j e c t : Revised Tes t Program for Non-Metallic Fuel 'iaa?ks.
f L e t t e r , US Army Test and Evaluat ion Command, AMSTE-BB, da ted 23 February 1973, s u b j e c t : Rescheduling of Non-Metallic Fuel Tank Tes ts .
C
STEYP-MTM SUBJECT: F i r s t L e t t e r Report on Product Improvement Tes t of Nonmetallic
Fuel Tanks f o r Trucks, M151 and M715 Ser ie s , TECOM Pro jec t No. 1-VG-123-000-001 (Phase I )
g. L e t t e r , US Army Tank-Automotive Command, AMSTA-RHT, dated 6 Novem- be r 1973, sub jec t : Product Improvement Test of Non-Metallic Fuel Tanks.
2. BACKGROUND
Nonmetallic f u e l tanks have c e r t a i n advantages over m e t a l l i c tanks i n s o far as they a r e not prone t o corros ion, a r e l i g h t weight and are somewhat l e s s expensive than metal f u e l tanks. US Army Tank-Automotive Connnand has been i n t h e process of securing from p r i v a t e indust ry , under c o n t r a c t , a quant i ty of nylon, high dens i ty polyethylene,and cross-l inked polyethylene f u e l tanks. Since t h i s ma te r i a l is r e l a t i v e l y new, t h e Army has e s t ab l i shed a program t o f i e l d t e s t them i n a l l environments ( h o t , co ld , dry , humid) f o r a t least 1 year t o determine t h e i r s u i t a b i l i t y t o m i l i t a r y app l i ca t ion . A t e s t program, Reference b , was i n i t i a t e d and its genera l plan was t o test a quan t i ty of nonmetallic f u e l tanks a t t h e arctic, d e s e r t , and t r o p i c test s i t e s . Due t o unresponsive bidding from manufacturers, and, later, t o de lay i n obta in ing t h e necessary t o o l i n g requi red i n manufacturing t h e t e s t i tems, t h e o r i g i n a l t e s t program was rev i sed and rescheduled by Referencesc through g. I n i ts rev i s ion , Reference e a l s o includes t e s t - ing t h e items a t t h e temperate test s i t e . Because t h e test items could - not a r r i v e a t t h e d i f f e r e n t test sites a t t h e same time, TACOM decided t o d iv ide t h e progran. i n t o two phases. Phase I of t h e test (nylon f u e l tanks) was t o start between March and Apr i l 1973 a t t h e arctic, d e s e r t and temperate test s i t e s ; Phase I1 of t h e t e s t (high dens i ty polyethylene and cross-l inked polyethylene f u e l tanks) was t o s t a r t between January and Apr i l 1974 a t a l l four of t h e previously mentioned t e s t sites.
This r e p o r t is based on t h e r e s u l t s obtained during Phase I o f t h e t e s t ( r o u t i n e , adminis t ra t ive opera t ion of t h e M151 and M715 s e r i e s with t h e i n s t a l l e d nylon f u e l tanks on g rave l , paved and cross-country t e r r a i n ) a t US Army Yuma Proving Ground.
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3. OBJECTIVE
To determine the s u i t a b i l i t y of t h e nylon f u e l tanks f o r t h e M151 and M715 s e r i e s t r u c k s under d e s e r t environmental condit ions.
4. PROCEDURES AND RESULTS
Sixteen nylon f u e l tanks (one each f o r e igh t M715 and one each f o r e igh t M151 series t rucks ) were received f o r t e s t . Each t e s t item was inspected;
STEYP-MTM SUBJECT: F i r s t L e t t e r Report on Product Improvement Test of Nonmetallic
Fuel Tanks f o r Trucks, M151 and M715 Ser ie s , TECOM Projec t No. 1-VG-123-000-001 (Phase I)
no damage o r i r r e g u l a r i t i e s were found. The conventional t e r n e p l a t e tank was removed from each of t h e f a c i l i t y t rucks and s to red f o r f u t u r e r e in - s t a l l a t i o n . The t e s t i tems were i n s t a l l e d i n t h e above f a c i l i t y t rucks i n accordance with t h e i n s t a l l a t i o n and s a f e t y procedures out l ined i n TM 9-2320-218-20 (Organizat ional Maintenance Manual f o r M151 s e r i e s t rucks ) and TM 9-2320-244-20 (Organizat ional Maintenance Manual f o r M715 s e r i e s t r u c k s ) . Since t h e M151A1 t ruck conta ins a self-grounded submerged f u e l pump i n t h e t e r n e p l a t e f u e l tank, t h e f u e l pump i n t h e nylon f u e l tank a s we l l a s t h e f u e l sending u n i t had t o be grounded. The mileage of each t ruck was then recorded. The 16 t rucks were operated f o r 1 year under rou t ine , adminis t ra t ive operat ion on gravel , paved and cross-country t e r r a i n . During t h e 1-year period, a s circumstances permitted, t h e f u e l tanks were checked f o r f u e l leakage, cracking, bulging, e t c . When a problem developed, it was inves t iga ted and then temporari ly correc ted by USAYPG t o expedite t e s t i n g . Af ter the one-year t e s t period was completed, t h e mileage of each t ruck was recorded again t o e s t a b l i s h t o t a l t e s t miles on each nylon f u e l tank. The nylon f u e l tanks were inspected before and a f t e r removal from the t rucks . No damage o r i r r e g u l a r i t i e s were found i n t h e t e s t items ex- cept f o r some thermal expansion of t h e f u e l tanks which was expected of t h i s mater ia l . No co lo r changes, cracking o r craz ing were found during t h i s inspect ion .
Date of i n s t a l l a t i o n and removal of each t e s t item, i d e n t i f i c a t i o n of each t r u c k , t o t a l t e s t miles accumulated on each t e s t i tem, and p e r t i - nent remarks can be found i n Inclosure 1. Photographs i l l u s t r a t i n g t h e nylon f u e l tank a s i n s t a l l e d on t h e t ruck can be found i n Inclosure 2. I
Meteorological da ta a t USAYPG from Apri l 1973 through Apr i l 1974 a r e in- cluded f o r information purposes i n Inclosure 3.
'The following inc idents occurred with the M715's nylon f u e l tanks during t h e 1 year of t e s t :
I a. After 116 days of operat ion and 2087 accumulated t e s t miles on t h e nylon f u e l tank which was i n s t a l l e d i n t ruck USA Reg No. 03B00469, the sup- p o r t bands were found t o have s l ipped o f f (due t o road v ib ra t ions ) allowing the f u e l tank t o f a l l t o t h e ground. The f u e l l i n e s and t h e gage wire were r ipped loose. The f u e l tank i t s e l f sus ta ined minor scra tches but d id not rupture. The f u e l tank was then r e i n s t a l l e d . A t t h i s time, two metal band- ing s t r a p s were i n s t a l l e d joining t h e two support bands t o keep them from separa t ing .
P STEYP-MTM SUBJECT: F i r s t Letter Report on Product Improvement Test of Nonmetallic
Fuel Tanks f o r Trucks, M151 and M715 Ser ie s , TECOM Projec t No. 1-VG-123-000-001 (Phase I )
b. Another inc ident similar t o t h e one mentioned i n t h e above para- graph occurred with t r u c k USA Reg No. 03543568 a f t e r 119 days of operat ion and 1652 accumulated t e s t miles. Two metal banding s t r a p s were then i n s t a l l e d jo in ing t h e two support bands.
c . A last inc ident similar t o t h e ones i n t h e above paragraphs occurred with t ruck USA Reg No. 03E92768 a f t e r 125 days of operat ion and 761 accumu- l a t e d t e s t miles. However, t h e inc ident was noticed before t h e f u e l tank could f a l l o f f , preventing poss ib le damage t o t h e f u e l tank o r any of its components. Metal banding s t r a p s were i n s t a l l e d a s explained above.
During t h e inspect ion o f a l l t h e above inc iden t s , it was found t h a t t h e nu t s on t h e end of t h e support bands could not be t ightened fu r the r . However, t h e r e was an inc ident with M715 t ruck USA Reg No. 03M41668 where one of t h e n u t s on t h e end o f a support band loosened and f e l l o f f , allowing t h e support band t o loosen and t h e tank t o near ly f a l l o f f , The support bands were put back i n place and t h e nut was t ightened.
Af ter t h e support band s l ippage inc ident occurred i n t h r e e separa te t rucks , two metal banding s t r a p s were i n s t a l l e d on each of t h e nylon f u e l tanks on t h e r e s t of t h e M715 s e r i e s t rucks .
I l l u s t r a t i o n s of t h i s modification can be found i n Figures 3 and 4, Inclosure 2.
5. CONCLUSIONS
The nylon f u e l tanks a r e s u i t a b l e f o r use i n t h e M715 and M151 s e r i e s t rucks under d e s e r t environmental condit ions.
6. RECOMMENDATIONS
. To preclude f u r t h e r f u e l tank support bands s l ippage , one of the following a c t i o n s must be implemented:
(1) Change t h e nylon f u e l tank design t o provide molded depres- s ions , o r
( 2 ) Jo in t h e support bands by i n s t a l l i n g two metal banding s t r a p s between them (See Fig 3 and 4 of I n c l 2 ) .
STEW-MTM SUBJECT: First Letter Report on Product Improvement Test of Nonmetallic
Fuel Tanka for Trucks, MI51 and M715 Series, TECOM Proj~ect No. 1-VG-123-000-001 (Phaae I)
b. Incorporate the operational procedure of grounding the fuel pump and the fuel rending unit in pertinent technical manula.
FOR THE COMMANDER:
4 Incl 1. Test Data 2. Photographs 3. Meteorological Data 4. Distribution List
BAElON J. HEICK Acting Director of Materiel Teat
TEST DATA NYLON FUEL TANKS
1 Dates I Truck USA pns ta l la t ion I Removal ( Reg No.
18 Apr 73 6 May 74 03E92768
20 Apr 73 7 May 74 03F50668
23 Apr 73 6 May 74 3D67368
24 Apr 73 29 Apr 74 03543568
25 Apr 73 30 Apr 74 03502260
26 Apr 73 7 Hay 74 03B00469
Type of Truck
U5lA1, %-Ton 415lA1, %- on TI. 5 lAl . 36- Ton
I'otal Tesi Miles Remarks
The submerged f u e l pump and f u e l sending uni t must be grounded. Incorporation of t h i s opera- t iona l procedure i n the per t inent technical manuals is required.
(1) After 127 days of operation and 1101 accu- mulated t e s t miles, the nut on the end of a support band loosened and f e l l o f f . The supporl band loosened and the tank nearly f e l l off . (2) Two metal banding s t r aps were added on 23 --- - -
Aug 73 a f t e r 1169 ac&nula&d test miles. (1 ) After 125 days of operatior, and 761 accu- mulated t e s t miles, t he support bands began t o s l i p o f f . The f u e l tank d id not f a l l off . (2) Two metal banding s t raps were added on 21 August 1973 a f t e r 761 accumulated t e s t miles. (1) Two metal banding s t r aps were added (no - .- - record of date and mileage). (2) Vehicle remained parked s ince 29 Jan 74 waiting f o r power t r a i n r e p a i r par ts . Two metal banding s t r aps were added on 27 AunB - a f t e r 3343 accumulated t e s t m i l e s . Two metal banding s t raps were added on 23 AugZ - a f t e r 432 accumulated t e s t m i l e s . (1) After 119 days of operation and 1652 accu- mulated t e s t miles, t h e support bands slipped o f f . The f u e l tank f e l l o f f . (2 ) Two metal banding s t r aps were added on 23 Aug 73 a f t e r 1652 ac&ulated t e s t miles. Two metal banding s t r aps were added on 22 AUR 7 - a f t e r 991 accumulated test miles. (1) After 116 days of operation and 2087 accu- mulated t e s t miles, t he support bands slipped of f . The f u e l tank fel l of f . (2) Two metal banding s t r aps were added on 17 Aug 73 a f t e r 2687 accumulated t e s t miles.
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METEOROLOGICAL SUMMARY FOR APRIL 1973
AVERAGE DAILY SKY CONDITION C - CLEAR P - PARTLY CLOUDY & CLOUDY
r i l l -
I ~ I I I I I I I I I I I ~ I I I I I I I I I I I C C C C C C C C P P C e c C P c C C C . P C C C C C C C C P
60 *
AV6RAbC HOURLY SOLAR RADIATION (OM CAI./CMJ *
50
1
40 I
Incl 3 Page 1 of 14
v I
3 0
20. 6 -
N
2 0
15
10
5
0
I AVERAGE HOURLY S O U R RADIATION (QM CAL / C M ~
I
DAILY Pl?EVAlLING WIND SpEEO [ M P ~ , AND DIRECTION
AVERAGE DAILY SKY CONDITION C-CLEAR P-PARTLY CLOUDY & CLOUDY
C I I I ~ I I I I I I I I I I I I I I I I . I I I I . I I I I I I C C C O C C C C C C C P C C C C C C C C C . ' C C C C P C P . P C C Incl 3
METEOROLOGICAL SUMMARY FOR JUNE 1973
Incl 3 Page 3 of' 1 4
METEOROLOGKAL SUMMARY- FOR JULY 1973
MAXIMUM AND M I N I M U M DAILY AMBIENT
TEMPERATURE (OF)
AVERAGE HOURLY S O U R RADlATlO
1
AVERAGE DAILY SKY CONDITION C - CLEAR, P S A R T L Y CLOUDY & CLOUDY
U C P C C C C C C
Incl 3 Page 4 of 14
I
METEROLOGICAL SUMMARY FOR AUGUST 1973
N
20 DAILY PREVAILING W I ~ D (SPEED ( M P N AND DIRECTION)
I
15
10 - I -1
AVERAGE DAILY SKY CONDI'IION C - CLEAR P - PARTLY CLOUDY & CLOUDY
~ I I I I I I I I I I I I I I I I I I I I I I I I . I I I I ~ ~ C P P P C C C C c C C c P P P P P P c P c C C C C c c C C P C
Incl 3 Page 5 of' 14
JOD ,DPCt
