Background
A major oil company based in the United Arab Emirates (UAE) operates an extensive network of fueling stations, serving both everyday motorists and commercial transport fleets. With over 800 service stations in the UAE, Saudi Arabia, and Egypt, the company plays a critical role in fueling the Middle East’s transportation and logistics sectors. To maintain its market leadership, the company continuously seeks ways to enhance operational efficiency, reduce environmental impact, and improve customer service.
For a large fuel retailer, even small inefficiencies can lead to significant costs. High energy consumption per station adds up across the network, increasing operational expenses. Inefficient fuel dispensing slows service, reducing throughput and revenue potential. Excess energy use also raises carbon emissions, challenging sustainability goals. Optimizing efficiency helps lower costs, improve profitability, and support long-term competitiveness.
Challenge
The oil company relied on 2 Hp fixed speed submersible pumps to supply dispensers designed to consistently deliver 30+ LPM (8+ GPM). However, their existing fixed speed pumps struggled to maintain these flow rates under varying demand conditions. Additionally, the oil company sought to explore power consumption across its vast network to identify potential efficiencies. By evaluating how its fixed speed pumps operated under varying demand conditions, it aimed to determine whether adjustments could reduce operating costs and enhance overall performance.
Implementation
To address this issue, the oil company partnered with a local distributor/contractor to test the FE PETRO® 2 Hp Variable Speed Submersible Pump and Variable Frequency Controller. Over a 45-day evaluation period at a test site, data on power consumption and fuel flow rates was collected to analyze system performance.
Power Consumption Analysis
| 2 Hp System | Average Daily Power |
| Fixed Speed | 21.7 kW |
| Variable Speed | 18.5 kW |
A calibrated power meter was installed in the electrical cabinet allowing the measurement of the power consumption.
15% Energy Savings
Flow Rate Analysis
| 2 Hp System | Achieved Flow Rate (LPM) |
Achieved Flow Rate (GPM) |
| Fixed Speed | 25 - 34 LPM | 6.6 - 9.0 GPM |
| Variable Speed | 30 - 34 LPM | 8.0 - 9.0 GPM |
Testing was conducted at the 4-dispenser, 8-nozzle site. Nozzles were lifted sequentially starting with one. Flow rates were recorded for each nozzle as they were gradually increased to all eight, ensuring precise data collection and accurate performance measurement.
Station Throughput Analysis
| 2 Hp System | Achieved Flow Rate (LPM) |
Achieved Flow Rate (GPM) |
| Fixed Speed | 29.0 LPM | 7.7 GPM |
| Variable Speed | 31.1 LPM | 8.2 GPM |
7% Increase
The deployment of FE PETRO® variable speed pumps and controllers led to significant improvements:
Energy Savings:
Energy consumption was reduced by 15% compared to the fixed speed alternative, which could lead to considerable costs savings if applied across their entire network of 800+ sites.
Minimized Equipment Wear:
By reducing sudden pressure changes, the variable speed system helps prevent wear and tear on fuel system components, extending equipment lifespan and reducing maintenance costs.
Increased Flow Rates:
By switching to an FE PETRO® Variable Speed Pump, the oil company experienced increased and more consistent flow rates, significantly improving fueling efficiency.
Consistent Customer Experience:
Faster fueling times reduced wait times at the dispensers, enhancing customer satisfaction and increasing station throughput by 7%.
Conclusion
By adopting Franklin Electric’s FE PETRO® Variable Speed Pump with a Variable Speed Controller, this UAE-based oil company successfully enhanced fuel station performance, reduced energy costs, and improved the customer experience. The transition to variable speed technology provided a cost-effective solution for optimizing fueling operations while supporting sustainability initiatives.
