Fuel leakage through a fill limit vent valve (FLVV) inside a fuel tank is an important factor to consider during the design of a new tank. The performance of the carbon canister which absorbs the hydrocarbon can be compromised if fuel manages to escape through the valve, so called Liquid Carry Over (LCO) and thus not fulfilling the fuel emission requirements. As of today this is not thoroughly investigated using experiments nor Computational Fluid Dynamics.

The main focus of this study was to develop a method to simulate the behaviour of the FLVV during various driving conditions at an early design stage and if this gives rise to fuel escaping through the FLVV. This method was later to be validated with an experimental set-up and later used to perform some simulations to investigate LCO by varying different parameters such as fuel level and different types of driving. What happens when the canister is purging was also investigated to see if it has a pronounced effect on LCO. Purging is when hydrocarbons, absorbed by the canister, are sent to the engine and giving rise to an under pressure in the tank.The method was developed to run on a cluster utilizing 200 Central Processing Unit Cores where each simulated physical second required an average of 3 hours of simulation time.The flow inside the tank was simulated using a Volume Of Fluid (VOF) multiphase model and the dynamic behaviour of the floater inside the FLVV was simulated using an overset mesh with a Dynamic Fluid Body Interaction.The movement of the simulated dynamic floater was validated with an experimental set-up specifically developed for the overset mesh validation and the motion of the floater was captured at a fairly accurate level.A prototype for an experimental tank was also developed and produced to validate the VOF set-up used for sloshing inside the tank which was utilized on the real tank but due to time limitation the experiments were not performed.

The results from the parameter investigation showed that LCO was present in cases with high fuel level inside the tank 95 % and that an aggressive driving gives rise to a higher level of LCO compared to normal driving. Simulations with a fuel level of 85 % and lower showed no evidence of LCO for this particular tank model. The purging of the tank induced a pumping effect giving rise to a higher level of LCO pumped through by the floater.