Installing New Equipment

Use the information on this page as a general guide to help you install new E85 fueling equipment. This page intends to provide a step-by-step guide to the process, but be certain to consult your own professionals that are familiar with local conditions and regulations. Every fueling location is unique and there may be some additional steps that should be taken based on your individual location requirements. Another option is converting existing equipment to be E85 compatible.

Become Familiar with E85 and E85 Infrastructure Requirements

Start by learning about the fuel and fueling requirements and consider hiring a professional to assist you. You are also encouraged to contact your state's energy office, Clean Cities coalitions and industry associations like the National Ethanol Vehicle Coalition. Review the Getting Started section of this toolkit to learn more and be sure to visit all the navigational elements located on the left-side of this site.

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 company is responsible for project oversight and successful completion of the project.

It is important for the fleet operator to estimate the amount of onsite fuel storage that will be needed. Although it may be possible to have too much capacity, it will be much easier and cost-effective to install a tank that will allow for future growth. It would be unfortunate to be forced to re-enter a site and disturb operations a second time simply 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 other nearby fleet operations to share your 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.'

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 period of 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 to complete. Locations involving new concrete will 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 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 both fleet and retail fueling site projects. Since 'listed' equipment is not yet available, a variance must be obtained from the Authorities Having Jurisdiction in order to receive the permits. Projects using aboveground tanks will likely involve additional local fire marshal and state requirements. Some municipalities no longer allow aboveground fuel storage tanks. Underground storage tank requirements may require a different set of issues; however, their use must also meet all state guidelines and electrical codes. The contractor will register storage tanks with the state environmental agency that will, in turn, register new tanks with the U.S. Environmental Protection Agency. If a petroleum fuel tank is converted to an E85 operation, the state environmental agency is notified of the change in status. The Underwriters Laboratories (UL) is currently evaluating E85 dispensing equipment for certification. For more information and UL related links, go to the AFDC UL Technology Bulletin.

Order Equipment and Prepare the Site

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 fuel ordered and loaded at the time of backfilling. Typically, the fuel load must be 90% of the tank capacity in order to secure the tank in place. Aboveground tanks can be loaded with fuel at the discretion of the site operator.

Install Equipment and Conduct Testing

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. Following the wiring and plumbing of the system, minor dirt work and concrete finishing is done. Typically, 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. Since 'listed' equipment is not yet available a variance must be obtained from the Authorities Having Jurisdiction in order to receive the permits.

Ensure Final Walk Through Meets Expectations

A final walk-through is conducted between the contractor and client to ensure the completed project meets with expectations.