Frequently Asked Questions

ELAFLEX is a global brand producing high-performance solutions for the safe transfer of hazardous and sensitive liquids. It serves fuel station forecourts, industrial facilities, the chemical industry, cryogenic applications and specialty chemical transport with hoses, nozzles, couplings and expansion joints. All products are manufactured to international safety and environmental standards.

ELAFLEX hoses are compatible with petrol, diesel, ethanol-petrol blends (E10/E25/E85), biodiesel, jet fuel, kerosene, AdBlue/DEF and a wide range of chemicals. The inner tube and outer cover are produced from NBR, EPDM or fluoroelastomer compounds selected to suit each fuel type, providing high chemical resistance and a long service life.

ELAFLEX manual and automatic nozzles stand out with precise flow control, vapor recovery compatibility, automatic shut-off safety and ergonomic grip. High-flow ZVA nozzles save time on truck and fleet refuelling while fully complying with EN 13012 and TRbF standards.

The ELAFLEX ERV series of rubber compensators is designed to absorb vibration in piping, accommodate thermal expansion and extend the life of the piping system. They isolate sound and vibration in pump stations, cooling towers, HVAC plants and industrial water/fuel lines, preventing line failures.

ELAFLEX hose reels are designed for ergonomic use, space saving, safe winding/unwinding and long service life. The automatic rewind mechanism prevents the hose from dragging on the ground, increasing operator safety while minimising hose wear. They are widely used in industrial workshops, marine refuelling and bus/truck depots.

ELAFLEX products comply with EN 1360, EN 13483, EN 13012, ATEX directives and TRbF norms. ATEX-certified models are available for explosive atmospheres, and Stage I and Stage II vapor recovery solutions are also offered. These certifications guarantee that products can be used legally on the European and global markets.

ELAFLEX dry-break couplings and fittings deliver zero-drip, fast and safe connections during fuel transfer. They prevent fuel spills during tank filling, eliminate the risk of environmental contamination and reduce operating time. They also enable a single connection standard across mobile and fixed installations.

A Submersible Turbine Pump (STP) is an electric pump installed inside the underground fuel tank that delivers fuel to dispensers under pressure. The motor runs submerged in the fuel and the turbine impeller moves fuel to the surface at high flow and stable pressure. Compared to suction systems, STPs offer faster filling, longer-distance delivery and the ability to feed multiple dispensers from one tank.

FE Petro STPs are produced in five HP options: 1/3 HP, 3/4 HP, 1 1/2 HP, 2 HP and 4 HP. This range covers everything from small single-dispenser sites to large multi-dispenser forecourts and high-flow truck fuelling lanes. Choosing the correct HP maximises flow rate while optimising energy consumption.

Yes. FE Petro STPs are built with biofuel-compatible materials and run reliably on ethanol blends (E10, E15, E25, E85) and biodiesel blends (B5, B20, B100). Corrosion-resistant components and fuel-resistant seals deliver a long service life despite the high water-absorbing and aggressive chemical behaviour of alternative fuels.

Modern stations require one tank to feed several dispensers, fuel to be transported over distances exceeding 100 metres, and high service flow rates. Suction pumps cannot deliver this performance. Submersible turbine pumps provide fast filling, lossless delivery, long-line performance and multi-dispenser support — modern forecourt architecture cannot operate without them.

The FE Petro Variable Speed STP automatically adjusts motor speed to fuel demand. It runs quietly and energy-efficiently at low demand, then ramps up to maximum flow during peak hours to reduce customer waiting time. This means lower electricity bills, less mechanical wear and higher customer satisfaction.

MagShell® is FE Petro's patented motor canister technology. Its enhanced magnetic design increases motor efficiency, raises turbine flow and delivers a higher flow rate at the same HP rating. In high-traffic stations this technology shortens fill times and increases daily fuel throughput.

FE Petro STPs are equipped with a corrosion-resistant coated body, active air elimination, an inlet filter screen, a pressure relief valve and safe service disconnects. Active air elimination prevents fuel/air mixtures from causing dispenser meter errors, while the inlet filter stops sediment and metal particles from damaging the pump. These features can roughly double service life.

A composite manhole cover is a one-piece glass-reinforced resin cover, a modern alternative to cast iron or steel covers. It is light enough to be opened by a single person, does not corrode, does not rust, has no scrap value (so it isn't stolen) and lasts decades. It is used at fuel stations, in wastewater networks, telecom infrastructure and electrical pits.

Fibrelite covers are produced under EN 124 in load classes from B125 (12.5 t) up to F900 (90 t). The most common ratings are C250 (25 t, slow traffic) and D400/HS25 (40 t, heavy wheel traffic — diesel islands, truck stops, bus depots). E600 and F900 classes are also available for specialised projects.

Cast iron covers rust over time, are very heavy and are stolen for scrap. Fibrelite composite covers do not corrode, are up to 70% lighter, have no scrap value, offer a non-slip surface, are unaffected by underground gases and chemicals and can be made in any colour. Their total cost of ownership is far below cast iron.

On forecourts, manhole covers are opened and closed frequently for tank filling, gauging and maintenance. Fibrelite covers are watertight, bolt-free and ergonomic enough for one person to open, which speeds up these operations. Multi-port and single-port configurations provide a single-piece solution for tank gauge tubes. Major oil companies such as BP, Shell and TotalEnergies have made Fibrelite a global specification standard.

Yes. Fibrelite covers contain no metal, so their scrap value is zero and stealing them is economically pointless. Optional locking and bolt-down systems are available for high-security locations. This protects the underground infrastructure and eliminates the public-safety risk of open chambers caused by stolen covers.

Yes. Fibrelite covers are available in any colour using UV-stable pigments, and corporate logos, brand marks or directional symbols can be moulded into the upper face. This strengthens brand identity for fuel chains and makes it easy to visually identify which cover belongs to which tank or product.

Fibrelite covers contain no mechanical hinges or moving parts, so they don't seize, don't corrode and don't need painting. In practice maintenance cost is essentially zero, and the light weight also reduces user injury claims. Over the long term the total cost of ownership is far lower than for traditional covers.

Fuel polishing is a maintenance process that removes water, microbial contamination (bacteria and fungi), sludge and solid particulates from stored diesel using multi-stage filtration and water-separation techniques. The fuel is circulated through a closed loop, cleaned and returned to the tank in a reusable state. The process restores the fuel to near-original quality without disposing of or replacing it.

Diesel oxidises with exposure to oxygen, moisture, temperature swings and storage time, and absorbs water and dust. Microorganisms — bacteria and fungi — grow at the fuel/water interface and form a biological mass known as "diesel bug". Diesel bug clogs filters, damages injectors, causes corrosion in fuel lines and is the most common cause of generator and vehicle failures.

It depends on usage profile and storage conditions. Critical standby generator tanks (hospitals, data centres, airports) should receive a full polish at least once a year. Fleet tanks in regular use should be inspected every 6–12 months and polished as required. Immediate intervention is needed if the ISO 4406 cleanliness code exceeds the limit or water content rises above 200 ppm.

Polishing improves the ISO 4406 particulate cleanliness code, reduces water content to ppm levels, halts bacterial and fungal growth, prevents oxidation and acid formation, eliminates injector and generator failures, ensures critical power systems are emergency-ready and avoids the cost of disposing of contaminated fuel.

ISO 4406 is an international standard expressing particulate contamination in hydraulic fluids and fuels using a three-number code (e.g. 18/16/13). The numbers represent particle counts above 4, 6 and 14 microns respectively. Modern diesel generators and common-rail injection systems typically target 18/16/13 or better — fuel polishing is the most reliable way to reach this target.

Clean fuel eliminates injector wear, fuel pump failures, filter clogging and combustion-quality issues. As a result engine life is extended, maintenance intervals widen, unexpected breakdown costs fall and fuel consumption is optimised. For standby generators that must be ready year-round, fuel polishing acts as cheap insurance.

Preventive measures include fitting moisture-trap filters on tank vents, using special inlet filters on the filling line, keeping the tank topped up to reduce condensation from daily expansion/contraction, periodic water draining, and adding a fuel microbiocide. Once contamination has set in, fuel polishing is the only lasting solution.

OPW FlexWorks® is an integrated underground fuel transfer and containment system developed by OPW Fueling Containment Systems, the leading manufacturer of forecourt equipment. Pipe, sumps, fittings and accessories are designed to work together as a single system — delivering long service life, leak tightness and fast installation.

Mixing pipe, sumps and fittings from different manufacturers creates compatibility, leakage and warranty problems. Integrated systems such as FlexWorks provide a single-supplier warranty, certified compatibility, proven leak tightness and fast installation — minimising the risk of soil and groundwater contamination over the system's lifetime.

FlexWorks flexible pipe runs long distances with very few fittings thanks to its bendable construction, reducing excavation and labour cost. It is resilient to ground movement and seismic activity, and the coaxial (double-wall) versions provide environmental containment. Installation time can be reduced by up to 50% compared to traditional steel pipework.

Yes. The FlexWorks DEF Loop System™ is engineered specifically for AdBlue®/DEF (Diesel Exhaust Fluid). DEF is highly sensitive to freezing, contamination and contact with certain metals. The system uses DEF-compatible materials, optional insulation and a dedicated sump design to preserve fluid quality all the way to the dispense point.

A tank sump is a sealed enclosure mounted on top of the underground tank to surround its connection points. A dispenser sump sits beneath the dispenser and houses the pipe connections. Both act as secondary containment that captures any leak before fuel reaches the soil and provides a clean, accessible workspace for maintenance.

FlexWorks delivers multi-layer protection through coaxial pipe, sealed sumps, sump entry fittings and test boots. Interstitial monitoring is possible at each connection, and annual tightness tests confirm the integrity of the system. The architecture exceeds the secondary containment requirements of EN 14125 and EPA UST regulations.

Thanks to flexible pipe, push-fit fittings and certified sump-entry components, a FlexWorks system typically installs 30–50% faster than an equivalent steel-pipe system. A typical 4-dispenser station can be commissioned in 3–5 working days, depending on excavation and site complexity.

A pump automation system is a control platform that manages every dispenser at a fuel station or fleet refuelling site from a single central application, automatically logging each sale and preventing unauthorised refuels. Shift, attendant ID, plate, fuel type, volume and amount are streamed in real time to the central fuel-management system.

The system blocks fuel deliveries to unauthorised personnel or vehicles, eliminates manual logging errors, prevents staff misuse, stops fuel-type mix-ups (wrong fuel into the wrong vehicle) and detects stock-vs-sales discrepancies in real time. Typical losses are reduced from 2–5% down to under 0.1%.

An RFID reader mounted on each dispenser refuses to start dispensing until a valid RFID key (attendant or customer card) is presented. At the vehicle-identification (DTS) level, an antenna integrated into the nozzle reads an RFID ring inside the vehicle filler neck — if it doesn't match, no fuel is dispensed. This guarantees fuel only flows into a registered vehicle.

Modern pump automation systems are compatible with a wide range of dispensers, including Gilbarco / Veeder-Root, Wayne Dresser / Autocourt, Tokheim, Tatsuno (Sunny / Neo / Ultra), Schlumberger (IVPE / M3000), Nuovo Pignone, Mepsan / Mekser / Meksan, Petposan / Petrotec, Bennett, Scheidt & Bachmann, Koppens, Logitron Pumalan, Larsen & Toubro, Adast Easycall, AG Walker-Prowalco and Autotank. The IFSF, EMR3, Gascomm, Midco, Nara, Novotec, Satam and Z-Line protocols are supported.

When the internet connection is up, all transactions are streamed to the central server in real time. If the link is lost, transactions are stored in local device memory and synchronised automatically when connectivity is restored. This uninterrupted architecture means station operations never stop and no data is lost.

DTS is a system that uniquely identifies each vehicle and ensures fuel is only dispensed to that specific vehicle. Plate, fuel type, tank capacity and daily/monthly limits can be set per vehicle. It eliminates wrong-fuel delivery, prevents misuse and provides fleet managers with per-vehicle consumption reports — critical for municipalities, public agencies, logistics and construction fleets.

For fleet operators, automation reports fuel use by driver, plate and assignment, raises alerts on abnormal consumption, feeds maintenance planning, blocks fake receipts and reduces costs by 15–25%. It also integrates with ERP and accounting systems, eliminating manual data entry.

A tank automation system — Automatic Tank Gauge (ATG) — is an electronic monitoring platform that continuously measures level, temperature, water content and volume inside underground fuel tanks. It provides accurate stock tracking, validates deliveries, detects leaks and contamination early and produces reports for legal compliance. The EVO™ 200 and EVO™ 400 are modern solutions in this category.

The EVO™ 200 is a compact console designed for small to mid-size stations (typically up to 4–6 tanks). The EVO™ 400 is intended for medium-to-large stations that need more tanks, more sensors and extended software modules. Both deliver precise inventory management, containment monitoring, remote access and C-store integration — the main difference is capacity and modularity.

Without an ATG, you can't accurately know how much fuel is actually in the tank — manual dipsticks are unsafe and inaccurate. An ATG provides millimetre-level accuracy, water-bottom detection, leak alarms, delivery confirmation and temperature compensation, showing the true sellable volume. ATGs are also a legal requirement in many jurisdictions.

The ATG records pre- and post-delivery levels automatically, so the volume actually delivered by the supplier is verified. Daily Statistical Inventory Reconciliation (SIR) compares sales and stock; any shortfall or surplus is reported instantly. Stock confidence increases, ordering is optimised and the risk of running a tank dry is eliminated.

EVO systems combine static leak detection with continuous monitoring. The tank is isolated during quiet periods (typically overnight); volume and temperature changes are analysed and leaks of 0.1–0.2 gallons per hour (0.38–0.76 L/h) can be detected. Interstitial sensors also alarm immediately on any leak between the tank walls.

Through a web-based or cloud platform you can access real-time tank levels, sales data, alarm history, delivery reports, leak-test results and compliance reports. Multiple stations can be managed from a single console — providing centralised operational control for chains and distribution companies.

In Turkey, EPDK regulations; in EU member states, EN 13160 / EN 13352; and in the US, EPA Title 40 CFR Part 280 all require leak detection and level monitoring on underground fuel tanks. Certified ATG systems such as the EVO™ family meet these obligations automatically and produce the records needed during inspections.

Tank bottom cleaning is the process of pulling sludge, sediment, water and microbial mass (diesel bug) from the bottom of underground or above-ground fuel tanks, filtering it and recovering the fuel. Left untreated, this build-up clogs pump filters, slows dispenser flow, can damage customer vehicle injectors and creates compliance problems.

A certified technician first verifies area safety with a portable LEL gas meter, then runs the machine. A specialised snake hose is lowered into the tank to draw contaminated fuel from the bottom; the fluid passes through 8 filtration stages before the cleaned fuel is returned to the tank. The system operates at 30 L/min transfer and 16 L/min recovery flow.

No. The Forecourt Engineering system works on a single dispenser line while the others continue to sell. There is no need to empty the tank or perform a gas-free procedure. As a result, station operations are barely interrupted and revenue loss is avoided.

Sediment and water create the perfect environment for microbial growth, accelerate acid formation, cause corrosion and lower the cetane number and lubricity of the fuel. The result, in customer vehicles, is filter clogging, injector failure and combustion problems — leading to complaints and legal exposure.

General guidance: every 2–3 years for underground fuel tanks, and once a year for standby generator tanks. If routine gauging shows a water layer above 5 cm, the microbial test is positive, or filter-change frequency rises above normal, cleaning should be scheduled immediately. Frequency should be increased in high-humidity regions.

The system has 8 filtration stages — particulate, water-separation and final fuel-polishing filters — that separate sediment and water from the fuel with minimum waste. It operates between –10 °C and +60 °C, with fuel line pressure up to 2 bar and air line pressure up to 4 bar, keeping the volume of contaminated fuel discarded to a minimum.

Traditional methods require draining the tank and disposing of the fuel as waste — a heavy financial loss. The Forecourt Engineering system pumps fuel out, filters it and returns it to the tank, leaving only a small amount of contaminated fuel as waste. Initial and final samples are compared visually to document a successful clean.

Tank drilling is the process of cutting a new hole and tapping a thread on top of an existing underground fuel tank to install an automation sensor, manual dip pipe, overfill prevention valve or additional fitting. The Forecourt Engineering Tank Drilling Machine performs this operation "live" — without emptying the tank — using a patented system.

The machine keeps the tank-internal LEL (Lower Explosive Limit) level at zero with a nitrogen feed, holds the cutter tip at a maximum of 112 °C with continuous coolant supply, and uses a dedicated capture mechanism that prevents metal swarf from falling into the tank. The system is ATEX Zone 0 certified, allowing safe operation in explosive atmospheres without any risk of sparking.

ATEX Zone 0 is the highest hazard category — areas where an explosive gas, vapour or mist atmosphere is present "continuously, for long periods or frequently". Equipment for this zone must under no circumstances generate sparks or hot surfaces. The Forecourt Engineering Tank Drilling machine is ATEX Zone 0 certified, allowing it to work inside live, fuel-filled tanks at the highest safety category.

No. Traditional methods require draining the tank, gas-freeing it, disconnecting all piping and waiting for certified atmosphere checks — a process that costs days of lost sales. With Forecourt Engineering's system the tank stays full, sales continue and only the few dispensers connected to that tank need to be paused briefly. The technique has been used on more than 20,000 tanks for BP, Shell, Total and others over 20 years.

The Forecourt Engineering Tank Drilling machine can cut and tap 2", 3" and 4" diameters in metal flange thicknesses up to 5 cm. The hydraulic motor delivers up to 360 Nm of torque at 75 rpm and operates between –30 °C and +90 °C, so it performs reliably even in the most demanding site conditions.

The integrated swarf-capture mechanism collects every metal chip and shaving generated during cutting; nothing falls into the tank. A closed-loop coolant circuit keeps the cooling fluid from mixing with the fuel, so fuel quality is unaffected. A subsequent tank cleaning is generally not required.

Adding an ATG, manual dip pipe or overfill valve to an existing station means re-opening the tank. The classic approach involves weeks of work, major revenue loss and high service cost. The Forecourt Engineering live-drilling solution completes these jobs in a few hours, with no sales interruption and the highest level of environmental safety.

UPP™ is the world's first electrofusion pipe system designed specifically for fuel applications. For more than 30 years it has been the global standard of the fuel industry. It is a semi-rigid, leak-tight, corrosion-resistant polyethylene pipe family that is welded together with electrofusion technology to behave as a single, monolithic line.

Electrofusion fittings have resistance wires embedded in their inner surface. Once the pipe is inserted into the fitting, the control unit applies a defined voltage for a defined time. The wires heat up, melting the fitting and the inner surface of the pipe at the molecular level, and after cooling the joint becomes a single piece. Mechanical-joint leak paths simply disappear.

Mechanical joints rely on gaskets, threads and clamping elements that fatigue over time and react to temperature and pressure swings, creating leak risk. The UPP electrofusion joint fuses pipe and fitting at the molecular level, so the joint is no longer the weak point — the system behaves as a single piece, and long-term leak tightness is guaranteed.

UPP pipe is used in underground fuel station piping, commercial fleet refuelling lines, industrial generator feed lines, marina and port applications, above-ground fuel transfer lines and underground storage tank (UST) connections. Its semi-rigid construction tolerates ground movement and routes complex paths with very few fittings.

More than 30 years of field service, millions of metres installed worldwide, inclusion in the specifications of major oil companies (Shell, BP, Total, Chevron, etc.) and certifications such as EN 14125 have made UPP the accepted global standard. Its leak tightness, ease of installation and long service life are backed by an unmatched reference list.

Yes. UPP pipe is highly UV resistant, so above-ground installations are not damaged by sunlight. It is also produced from materials that withstand fuels, ethanol/biodiesel blends and aggressive soil chemistry. It does not corrode, rust or degrade, and retains original performance for decades.

Yes. With its flexibility, UV resistance and light weight, UPP is ideal for marina, port and ship-bunkering fuel lines. It eliminates the corrosion problem that affects steel pipe in salt-laden marine air. It is also widely used on above-ground industrial fuel transfer lines.

Wayne®, with more than 250 years of heritage, is a global manufacturer of fuel dispensers. Developed under Dover Fueling Solutions (DFS), Wayne dispensers offer high-precision metering, advanced payment integration, modular design and remote management — giving station owners a reliable, future-ready forecourt.

The Wayne Helix® 6000 II uses advanced IoT technology to connect to the DFS DX Cloud platform. It provides remote diagnostics, real-time performance monitoring, over-the-air (OTA) software updates, predictive maintenance and centralised reporting. Faults are detected before they become breakdowns, service costs drop and station downtime is minimised.

The Wayne Helix® Additive Dispenser is a unique model that injects an additive into a base fuel at the point of dispense, producing premium fuel on demand. Station owners can offer different octane / additised grades without installing an additional underground tank, lowering capital expenditure while expanding product variety.

For AdBlue®/DEF dispensing the Wayne range includes dedicated models: the Helix® 6000 II AdBlue® Dispenser for modern diesel vehicles and the Wayne Century® 3 AdBlue® Dispenser for compact forecourts. The Wayne Reliance® E-123 ARLA32/DEF model adds real-time remote monitoring and is a cost-effective option for fleet use.

The Wayne Century® 3 series is a modular, robust, hydraulically proven platform. Variants for standard fuel, ultra-high-speed truck refuelling, AdBlue® and even windshield washer fluid serve both retail forecourts and heavy-duty fleet refuelling sites. The windshield washer dispenser also reduces plastic-bottle waste, providing an environmental advantage.

The Wayne Global Vista™ 3 holds ATEX (Europe), IEC (international) and INMETRO (Brazil) certifications, meeting approval requirements worldwide. Corrosion-resistant materials and ease of maintenance let it operate reliably in different climates and regulatory environments — providing global standardisation for multinational chains.

For heavy-vehicle fleets where wait time is critical, the Wayne Century® 3 Fuel Dispenser ultra-high-speed variants deliver a high litre-per-minute flow rate. The Wayne Reliance® E-123 Fleet Fuel adds economies of scale, smart authorisation and detailed reporting for fleet managers, making it the ideal choice for professional fleet fuel management.