Retail Fuel Station Refurbishment Process

Retail Fuel Station refurbishment, like any other asset, must be upgraded at times to keep up with modern safety standards and changing customer requirements.

Upgrading an existing, established retail fuel station presents different challenges than developing a new (or so-called “greenfields”) station. You must contend with an established layout and flow of vehicles and people and adapt the old infrastructure for new customer requirements.

This article will highlight some challenges we have faced and solutions developed/proposed for our Retail Fuel Station Upgrade projects. These could assist the reader in making their refurbishment project a success.

1.  The process

1.1 Retail Fuel Station Refurbishment: Owner Consultation

When planning a fuel retail refurbishment project, it is crucial to engage the station’s owners and assess what currently works, does not work, and what they envisage after the project is completed. In many cases, the owners are unsure themselves as to what they require. In this case, you would need to guide them in understanding what it would take to operate their station efficiently.

1.2 Placement of Tanks

With regard to the infrastructure, one of the first things to consider is where to place new tanks. From the ease of construction perspective, it would be beneficial to place them in the location of the current tanks, as removing the current tanks and the void that is created will assist with a reduction in construction time and cost to place the new tanks.

One often underestimates the size of the tanks that are placed in a fuel retail station. A 30m3 tank excavation will be at the absolute limit of what a normal TLB would be able to achieve. Keep in mind that adequate drainage is needed around the tanks. These tanks also sit on a bed of soft soil to aid in compaction and protect the tank’s integrity. Once the tanks are in the ground, it is crucial to fill them with water. These tanks often tend to pop out of the ground if they are empty and the backfilling process begins. Backfilling of the soil should be done in layers of approximately 300mm and compacted throughout. Many fittings, piping, and sump material are attached to the tank, so consider that when determining the excavation depth.

Newer tank manufacturing processes involve making the tank utilizing fibreglass and special plastics. These tanks are double-walled and quite easy to handle. Throughout America and Europe, these tanks have become the gold standard. They are also secured in place, employing special foundation beams on each side and straps holding the tank down.

1.3 Retail Fuel Station Refurbishment: Excavation of Pipe Trenches

When the tanks are excavated, the piping trenches should start. One thing to note is that the piping from the tanks to the first dispenser should be free of any bends or unnecessary loops. This ensures that adequate fuel flow is always maintained. The piping trenches between dispensers should be the shortest minimal distance. These trenches also have to be wide enough to accommodate the piping as well as cable sleeving.

1.4 The Positioning of Dispenser Sumps

At the site of the dispensers, it is advisable to first place the dispenser sumps into the excavation and then align them. The sumps should be properly secured, as there will be a lot of tugging and pulling to get the final pipework in. Be sure about the specific retailers’ requirements for how the final island should look and what position the dispensers should be in. Once your piping is secured and welded together, it is challenging to change positions.

1.5 Retail Fuel Station Refurbishment: Connecting The Tanks and Sumps

At this stage, the tanks and sumps are in position, and they need to be connected.

It is advisable to install a shutoff valve on each line leading from the tanks. This will facilitate maintenance and fault finding with minimal spillage and increase safety.

The industry standard is to use HDPE piping which will be electrofusion welded. These pipes can be in a single or double-walled variety. The double-walled pipes are usually used between sumps and the single walls on internal piping. The welding process itself is quite easy, but the welder needs to be trained and competent to set up every weld. On every weld, the welder must indicate the following details: the number of welds in sequence, the date, the time, and the welder’s name. This ensures that the welder is cognisant of the time the weld is executed and if the weld has soaked enough. These welds are strong, but the key to them is preparation and leaving enough time to soak and dry. Welding all the pipes, including the ones going into the dispenser, is strongly recommended. It is usually at this point where the system is prone to leaks.

1.6 Pressure Testing the System

You must pressure test the system before backfilling. If not done, you run the risk of fault-finding later by excavating all piping and dealing with fuel while searching for the problem.

1.7 Retail Fuel Station Refurbishment: Tanks Flange

There are four main points on the tank flange that you need to take care of:

1. The pumping point – Where the STP (Submersible Tank Pump) sits. All your piping going to the dispensers connected to it.
2. The filling point – This is where the fuel truck connects to fill the tank
3. The dip hatch – This is where daily dips are done to track fuel levels.
4. The vent point.

1.8 Vent Stacks

If you are refurbishing a fuel station, you might want to use the old vent stacks. This is only advisable if they comply with current regulations. The main problem is that the vents need to be high and far enough to release vapour safely from any electrical supply or human interaction. We have found on occasion that these older vents are blocked or partially blocked. This will cause the overall system pressure to rise and could cause a leak on hotter days.

You can simply attach a compressor on one end and blow them out to clean these vents. For more stubborn blockages, connect a nitrogen cylinder to the piping and blow out any debris that is stuck.

1.9 Cable Sleeving

Before backfilling the excavations, ensure the cable sleeving is in place. The electricians connect all the cabling last. The piping and cable sleeving require a layer of soft sand around the equipment to protect them from damage.

The area over the excavations can now be concreted or paved as specified by the client.

1.10 Fuel Station Aesthetics/ Branding

Usually, the fuel stations require an aesthetic upgrade as well. This will include painting the canopy, installing new lights and upgrading the branding of the overall site. This is the final item the client and the public will see, so it pays to keep a close eye on the finishing.

1.11 Fuel Station Licensing

Once all the hardware is in and the branding is done, it is just a matter of getting the license to operate from the fire department and welcoming customers to your new station.

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