E85 Equipment Requirements and Specifications

It is important to use the correct equipment with high-blend ethanol (E85) fueling systems. The information below provides an overview of equipment requirements and specifications.

• General Recommendations
• Fill Pipes
• Pumps and Leak Detection Equipment
• Piping
• Fuel Filters
• Hoses
• Nozzles

General Recommendations

Equipment used with E85 should be "listed" according to existing codes. Using incompatible materials or improperly installing or cleaning equipment can lead to fuel contamination, which can result in serious vehicle damage. In general, zinc, brass, lead, and aluminum are sensitive to high-blend alcohol fuels, and fueling system components containing them should be avoided. Plated steel (referred to as "terne-plated," a lead-tin alloy) and lead-based solder are not compatible with E85. Other materials that might degrade in the presence of high-blend alcohol fuels include natural rubber, cork, leather, polyurethane, polyvinyl chloride (PVC), polyamides, methyl-methacrylate plastics, and some types of thermo and thermoset plastics.

Fueling system components that work well with E85 are available. Use the online guide developed and maintained by the Petroleum Equipment Institute to search for ethanol-compatible equipment.

Underwriters Laboratories (UL) published the certification procedure for listing E85 dispensers in 2007 but has not yet listed dispensing-related equipment. For more information and UL-related links, visit the AFDC UL Technology Bulletin. OPW, a well-known fuel equipment manufacturer, issued a memorandum pertaining to common components and their compatibility with E85 (PDF 27 KB). As indicated in the Checklist for Installing or Converting Equipment to dispense E85 (PDF 175 KB), replacing the hanging hardware (connectors, swivels, hose, and nozzle) with the appropriate items is recommended. Download Adobe Reader.

Although ethanol-based fuels have been used for decades, misconceptions persist concerning the impact ethanol has on seals, elastomers, and other components. DuPont, a major elastomer manufacturer, published information in 1993 indicating that concentrated ethanol (e.g., E100) might be less troublesome than other, more common, gasoline additives. See Leak Prevention of Reformulated Fuels and Oxygenates: Sealing Solutions to Protect the Environment and Meet Regulatory Requirements (PDF 874 KB). Download Adobe Reader. Also see the American Auto Manufacturers Association's 1995 document Fuel Ethanol (E85) Compatibility Standards and Dispensing Equipment List for E85 Fuel Vehicles (PDF 345 KB). Download Adobe Reader.

If a fueling site project and selection of its contractor and equipment vendors are subject to a bid process, make certain that bid specifications include all necessary equipment requirements, local codes and standards, and all permit arrangements and costs. Sample costs for a variety of project types and equipment might help in defining project-specific bid details. An experienced contractor or a trusted equipment vendor can assist in gathering bid specifications. A Minnesota Pollution Control Agency fact sheet discusses selecting a certified contractor (PDF 85 KB). Download Adobe Reader.

Fill Pipes

Fuel enters the fueling site dispensing system at the point the fuel is "dropped" from the truck through the storage tank fill pipe. Over the last several years, major component manufacturers, such as OPW and Bartush, have converted many of their gaskets, tubes, adapters, piping, and shear valves to be compatible with ethanol-blended gasoline and E85. Anodized coatings or components made of cast iron or stainless steel are available that are usable with E85.

Pumps and Leak Detection Equipment

Pressurized and suction are the two basic types of fueling systems, and both require different types of leak detection equipment. Suction systems have the pump within the fueling dispenser, whereas pressurized systems use submersible pumps to pump fuel out of the tank to the dispenser. Typically, pressurized systems require continuous and periodic leak detection as well as line tightness testing and other precautions. If a suction system has a check valve solely at the dispenser, leak detection testing might not be required, and line testing requirements might be less.

Piping

New fiberglass pipe should pose no problems when used with E85 systems; however, UL is evaluating ethanol compatibility. As of 2008, flex piping is tested to the same UL standard, but methods might change in the near future. Equipment vendors will want to watch for updated information about flex piping certifications. Flex piping companies, such as Environ Products, have claimed their product can be used with E85.

Fuel Filters

The dispenser filter is the last line of defense before the fuel reaches a vehicle's tank. Typically, a 30-micron filter is used with diesel fuel and a 10-micron filter with gasoline. E85 dispensers should use a 1- or 2-micron filter. The smaller pores will prevent contaminated fuel from causing fuel pump and engine problems. This is especially important with tanks that have been converted to E85. Recently, an improperly cleaned diesel system was found to still have a 30-micron dispenser filter, rather than the 1-micron filter, only after flexible fuel vehicle fuel pumps were damaged by diesel scale contamination of the E85 fuel. The smaller filters cost two to four times as much as the standard gasoline filter, but they are worth the investment.

Hoses

Dispenser hosing for E85, as for gasoline, will vary with the type of vapor recovery system required in the local area. For E85, always use the hose most resistant to alcohol because some amount of E85 always will be in contact with the inside of the hose. Goodyear Tire & Rubber Company is one well-known producer of alcohol-resistant hoses. Any hose material deemed to be "100% methanol compatible" will be safe to use with E85 because methanol can be considerably more corrosive.

Nozzles

Do not use aluminum nozzles with E85 fueling systems. Several companies manufacture stainless steel nozzles or nickel-plated nozzles that are compatible with E85. These might be slightly more expensive (incremental cost of approximately $50) than the more common aluminum variety.

To learn how to prevent equipment failures, see E85 Maintenance Issues.