Installing New E85 Equipment

This page provides a general step-by-step guide to installing new E85 (85% ethanol, 15% gasoline) fueling equipment. Professionals familiar with local conditions and regulations should be consulted before a project begins. Every fueling location is unique, and additional steps might be required. Another option is converting existing equipment to be E85 compatible.

Become Familiar with E85 and Infrastructure Requirements

Start by learning about the fuel and fueling requirements; this AFDC Ethanol Web site is a good place to begin. Consider hiring a professional with experience in E85 projects. Also consider contacting the state energy office, the local Clean Cities coalition, and industry associations.

Determine Fueling Specifications

It is important for the fleet operator to estimate the amount of onsite fuel storage needed. Although it might be possible to have too much capacity, it will be much easier and more cost effective to install a tank that enables future growth. It is unfortunate to be forced to reenter a site and disturb operations a second time to add more capacity. This is especially true if the cost of a slightly larger tank is minimal. Allow room for future growth, and consider allowing nearby fleet operations to share the fueling site.

Additionally, the fleet operator will need to balance the inventory of fuel to store over the typical 30- to 60-day period. Note that extra per gallon costs will be incurred if you order small or partial loads. In areas with several E85 retailers, it may be possible to share transport loads (8000 gallons) with other fleet or retail E85 stations in what is referred to as a 'milk run.'

Decide on Hiring a Project Contractor

In most cases, the fleet operation wishing to alter its onsite fueling system will hire the services of a project contractor. This is often done through a bid process, especially if it is a fueling site operated by a government entity. The contractor is responsible for project oversight and successful project completion.

Review Bid Proposals and Select a Contractor

If a bid selection is used, it is likely that firms planning to bid on the job will be asked to help provide site- and fuel-specific details and equipment needs for preparing the official bid. This bid is then advertised for a time before it is awarded to the company that best meets the criteria of the bid.

Create a Project Timeline

Once the contractor is selected and the agreements are signed, that company's plan for the site is set in motion. Equipment ordering—as well as scheduling excavation, concrete, and electrical work—can be the biggest factors in determining how long a project will take. Locations involving new concrete require one to two weeks for proper curing before vehicles can be driven on them. Also, it is not unusual for storage tank and dispenser orders to be delayed at certain times of the year and in certain areas of the country. Poor weather can also delay a project. An experienced contractor will be able to plan a reasonable project timeline.

Secure Permits and Adhere to State Requirements

The contractor is responsible for ensuring that all permits are secured for the project. A city or county permit, usually obtained through the building inspector's office, will be necessary for fleet and retail fueling site projects. Because "listed" equipment is not yet available, a variance must be obtained from the authorities having jurisdiction to receive the permits. Projects using aboveground tanks likely will involve additional local fire marshal and state requirements. Some municipalities no longer allow aboveground fuel storage tanks. Underground storage tank requirements might have different requirements; however, their use must also meet all state guidelines and electrical codes. The contractor will register storage tanks with the state environmental agency, which will register the new tanks with the U.S. Environmental Protection Agency. If a petroleum fuel tank is converted to E85 operation, the state environmental agency is notified of the change in status. Underwriters Laboratories (UL) is currently evaluating E85 dispensing equipment for certification. For more information and UL-related links, visit the AFDC UL Technology Bulletin.

Install Equipment, Prepare the Site, and Conduct Testing

Once the storage tank and associated equipment are procured, excavation and other site preparations can begin. Projects involving underground storage tanks will need to have the tank set into the hole and the fuel loaded into the tank at the time of backfilling. Typically this practice involves loading the tank to 90% of capacity to ensure the tank does not shift during backfilling. Aboveground tanks can be loaded with fuel at the discretion of the site operator. Following the wiring and plumbing of the system, minor dirt work and concrete finishing is done. After a few days, or when the dispenser can be delivered to the site, the dispenser is set on its concrete pedestal and undergoes wiring and plumbing to the system. Once the dispenser is set, the system can be tested for leakage (tightness test), proper working order, and dispensing accuracy. At about this time, the necessary labeling, decaling, and signage are completed.

Complete Inspection Process

It is the contractor's responsibility to notify all involved, including the client, of developments and to ensure the completed project passes standards and codes set by the city building inspector, state or local fire marshals, and/or state electrical inspector.

Ensure Final Walkthrough Meets Expectations

A final walkthrough is conducted between the contractor and client to ensure the completed project meets expectations.