Background
Wawa navigates temporary store closures amid multiple disruptive events.
In 2021, a series of events tested the resilience of the fuel supply chain in the United States. Tropical Storm Elsa ravaged Florida while the Colonial Pipeline suffered a significant cyber attack, both leading to widespread fuel shortages and temporary store closures across the East Coast. Panic buying ensued as consumers scrambled to fill their tanks, exacerbating the already strained logistics of fuel delivery. This tumultuous environment highlighted the critical task of shutting down stores and safely bringing them back online; a process that demands significant resources, time, and technical expertise. Wawa, a well-known convenience store and gas station chain with over 1,000 locations, many of which were in the affected region, recognized the urgent need for a solution to streamline this process.
The Colonial Pipeline Cyber Attack
The Colonial Pipeline cyber attack, which occurred in May 2021, was a major ransomware incident that disrupted the largest fuel pipeline in the United States. The Colonial Pipeline is a critical piece of infrastructure, supplying nearly half of the East Coast’s gasoline, diesel, and jet fuel. The attack forced the company to shut down its entire pipeline system to prevent the spread of the malware.
This shutdown caused a cascade of logistical issues across the southeastern and mid-Atlantic states. The pipeline’s inability to transport fuel led to widespread shortages. Within days, many gas stations reported running out of fuel entirely, forcing shutdowns. In some areas, fuel outages affected over 70% of stations.
Tropical Storm Elsa
Tropical Storm Elsa, which struck in July 2021, was a powerful storm that caused widespread disruption across the Southeastern United States, including Florida. The storm brought heavy rainfall, strong winds, and significant flooding, leading to widespread power outages and infrastructure damage.
As Elsa swept through the region, many fuel stations were forced to shut down operations due to power failures and safety concerns. The aftermath saw logistical challenges as stations worked to restore services amidst equipment failures and disrupted supply chains. In some areas, fuel availability was severely impacted, compounding the strain on an already stretched system.
Challenge
The complex process of bringing a fuel station back online after a shutdown.
Restoring a fuel station after a shutdown – whether caused by a storm, power outage, or fuel supply disruption – is a complex and often delicate process. The equipment used in fuel systems is highly interconnected, requiring precise sequencing during startup to ensure proper functionality and communication between devices. When this sequencing is not followed correctly, it can result in operational delays, equipment malfunctions, or even safety hazards.
At the heart of this process is the need for a communication handshake between key systems. Devices such as fuel site controllers, dispensers, distribution boxes, and price signs must establish a seamless exchange of data to synchronize their operations. Any misstep in this sequence, such as powering on devices out of order, can cause communication failures that interrupt service and necessitate manual on-site troubleshooting.
The challenges of sequencing
Proper sequencing requires that each device powers on in a specific order and within designated time intervals. Without proper sequencing, critical devices may fail to communicate or initialize correctly, requiring additional restarts and prolonging the downtime. Here is an example of a typical sequence to restore fuel dispensing, just one of many similar systems:
Lack of on-site technical expertise
An issue Wawa store managers face during this process is the lack of technical expertise among on-site staff. Fueling systems involve specialized electrical equipment and networked devices, which many store employees may not be familiar to handle. Tasks like resetting circuit breakers, navigating electrical panels, or troubleshooting communication failures can be daunting, particularly in high-pressure situations where customers are waiting, and sales are at a standstill
Implementation
Wawa collaborates with Franklin Electric to develop & deploy the Power Integrity™ Remote Control Solution with OVERSITE™
Recognizing these challenges, Wawa turned to Franklin Electric, a trusted partner in fuel system equipment, to develop a solution that would enhance operational resilience, streamline the power restoration process, and ensure safety for both employees and customers. Franklin Electric’s response was the Remote Control Solution (RCS). The RCS features OVERSITE™ technology, an advanced device networking platform that enables remote visibility, control, and reset capabilities for fuel systems and other critical devices that are vital to Wawa’s daily business operations at each store. At the core of this solution was a vision for the remote resetting of site devices and systems. The RCS allows Wawa’s facilities maintenance personnel to monitor operations from a central location and remotely execute device power cycles or system restarts without deploying a technician to the site. If a system experiences errors, outages, or connectivity issues requiring a reset, the RCS automates the reboot sequence, ensuring that each component powers up in the correct order and at the appropriate time.
"Fuel dispenser related to truck rolls alone amount to 30% of Wawa’s total service requests on yearly basis. A significant amount of these calls are resolved by a simple power cycle of devices at the site."
- Peter Falk, Wawa Fuel Equipment Service Level Manager
EVO™ Series Integration
By leveraging Franklin Electric’s EVO™ Series – already utilized by Wawa for fuel inventory and leak detection monitoring – as the network gateway, the RCS seamlessly integrates into existing systems without requiring additional IT infrastructure. This approach minimizes security concerns associated with validating new network devices. Beyond remote resets, the EVO™ Series opens up additional capabilities like automated response triggers tied to system sensors. For example, sensors detecting fuel leaks, electrical faults, or rising temperatures can automatically shut off power to affected assets, preventing damage and ensuring safety. This proactive approach enhances operational efficiency and provides an added layer of protection.
Turnkey Safety Compliance
The National Electrical Code® (NEC®) and National Fire Protection Association® (NFPA®) requires fuel dispensing facilities to include essential safety devices such as emergency stop disconnects, dispenser hook isolation, and low-voltage dispenser disconnects. Fuel dispensing systems must have clearly identified emergency shutoff devices and disconnects that can simultaneously cut power to all dispenser circuits. This includes all associated dispenser low voltage data, credit card, intercom, and media connections. The RCS combines all of these required safety components into a single, integrated solution with the ability to remotely monitor and control these connections.
Results
The deployment of the Remote Control Solution with OVERSITE™ led to significant improvements.
Reduced Service Truck Rolls:
By leveraging remote power cycling and sequencing capabilities, Wawa can significantly decrease the need for service truck rolls, leading to substantial cost savings and faster recovery times.
Increased Site Uptime:
Remote power cycling and sequencing reduce recovery times during outages by eliminating the wait for a technician’s travel time, minimizing downtime and improving operational resilience.
Remote Emergency Shutdown:
E-stop integration and power status monitoring allows Wawa to verify sites are properly powered down or execute the shutdown remotely ahead of emergencies.
Centralized Monitoring:
Wawa is now notified of power-related outages in near real-time allowing them to proactively diagnose and resolve remotely, allowing for quicker response to site-specific issues and enhanced efficiency.
Sequential Power Restoration:
Following a power outage, sequential power-up streamlines the process of safely bringing sites back online, ensuring proper communication between systems and minimizing the involvement of on-site staff.
Streamlined Technician Deployment:
The facility maintenance team can now better allocate technicians to more time-consuming issues, maximizing workforce efficiency and response times.
Conclusion
In the short time after implementation, not only has the RCS started solving the challenges of streamlining power restoration, but Wawa is also leveraging OVERSITE™ remote power cycling to resolve common occurrences of offline equipment or communication issues that affect daily operations across their entire network. Overall, their objective is to shift problem resolution and support from onsite contractors to a remote central helpdesk, thus providing cost savings and increased equipment uptime.
