Client’s task🔍
The client approached us with the task of automating a gas station where the existing system did not provide reliable control over fuel dispensing.
A solution was needed that would eliminate unauthorized transactions, improve accounting accuracy, and enhance the transparency of all processes.
Project Objectives
- Automate the fuel dispensing process and control access to it.
- Eliminate human error in accounting for fueling operations.
- Ensure precise correspondence between fuel volumes and reporting data.
- Improve the reliability and resilience of the existing infrastructure.
Baseline
- The gas station had been in operation for over 10 years and showed signs of unsuccessful integrations.
- The system exhibited discrepancies in fuel dispensing, with an error rate of up to 750 ml per 10 liters.
- A complete equipment inspection, repair, and implementation were required.
Solution and Implementation
1. Integration of New Control Logic
Fuel dispensing remains the standard operating principle through the gas station management system, but now permission to dispense is controlled by the terminal, which:
- receives a signal only after the user has authorized the dispensing with an RFID card;
- blocks dispensing of fuel without confirmed permission, even when requested by the management system;
- keeps an accurate count of the dispensed fuel volume for each driver and vehicle.
2. Two-Level Control System
Each refueling operation is now accompanied by:
- identification of the fuel truck driver;
- authorization of the driver of the vehicle being refueled;
- reading data from the fuel level sensor (FLS) installed on the vehicle.
This approach ensures full tracking of fuel movement from the tanker to the final vehicle’s tank.
3. Equipment Repair and Calibration
Fuel station maintenance was performed, damaged components were repaired, eliminating accumulated errors and restoring fuel metering accuracy.
Implementation Results
- Full control of fuel dispensing at all stages—from receipt to final filling.
- Unauthorized fuel dispensing was eliminated and metering errors were eliminated.
- Detailed accounting was possible: which vehicle, which driver, when, and how much fuel was dispensed.
- Improved staff discipline and reporting transparency.
Economic Impact
Four months after implementation, the system demonstrated sustainable results:
- Monthly savings ranged from 4,800 to 10,000 liters of diesel fuel;
- Maintenance and process control costs were reduced;
- Leaks and inaccuracies present in the old system were eliminated.
Thanks to the implemented system, the company now has a fully functional tool for automated fuel control, integrated with equipment and internal reporting.
The solution became part of a comprehensive monitoring platform, ensuring reliable and transparent accounting of all fuel operations.