Keeping bulk fuel tanks free of water is essential to protect your equipment, maintain fuel quality, and ensure compliance. Water contamination can cause corrosion, microbial growth, filter blockages, and even lead to costly downtime. Our professional water removal services are designed for service stations and commercial fuel sites across Australia, delivering safe and effective results.
Why Water Gets Into Tanks
Water can enter tanks in many ways. Damaged fill caps, cracked lids, faulty vent caps, or worn gaskets can allow rainwater and groundwater to seep in. Storm surges and flooding can introduce large volumes of water. Even when tanks are properly sealed, condensation builds up inside when fuel tanks are not kept full. Over time, these small amounts of water accumulate, causing major problems like phase separation in ethanol fuels, microbial contamination in diesel, and corrosion of tanks and lines.
Damaged Dip Cap Seal
The Risks of Water in Fuel
When water is present, fuel quality deteriorates quickly. Diesel tanks often develop microbial growth, forming sludge and slime that clogs filters and damages injectors. Petrol tanks with ethanol blends can undergo phase separation, where ethanol and water mix, reducing octane and creating unsafe fuel. Corrosion in tanks and lines leads to leaks and costly repairs. Customers may complain about poor engine performance, while operators face increased maintenance costs and potential regulatory penalties.
How to Recognise Water Problems
Water issues are often identified by ATG alarms, high water floats, or frequent filter changes. Operators may notice cloudy or hazy fuel, or see visible water when taking a bottom sample. Customer complaints such as drivability issues or poor dispenser flow are common signs. In diesel tanks, black particulates or microbial sludge are red flags. Acting early prevents costly escalation and protects customer trust.
Our Step-by-Step Water Removal Process
We use a proven process to remove water and restore tanks safely:
Site Safety and Isolation
Our technicians make the site safe, isolate affected tanks or dispensers, and complete a Job Safety Analysis before starting work.
Testing and Diagnosis
We confirm water levels using certified bottom sampling, water paste, and ATG readings. If necessary, we test for ethanol phase separation and microbial activity.
Precise Extraction
Water is extracted from the lowest point of the tank using dedicated equipment. For tanks with heavy contamination, we perform a controlled clean to remove sludge and settled material.
Fuel Recovery and Polishing
Where possible, fuel is filtered and polished to restore clarity and quality. Waste that cannot be salvaged is disposed of through licensed waste handlers.
Additive and Biocide Treatment
Diesel tanks may be treated with biocide and corrosion inhibitors to kill microbes and prevent regrowth. Treatment is carefully calculated based on tank volume.
Verification and Return to Service
We provide clear jar samples, confirm ATG water-free readings, and reset alarms. Dispenser flow and filter condition are tested before tanks are recommissioned.
Full Documentation
A detailed service report with photos, ATG screenshots, disposal certificates, and recommendations is provided for your compliance and records.
View our process here: Tank Cleaning & Fuel Restoration Process
Emergency Response
If you detect significant water ingress, phase separation, or repeated alarms, immediate action is needed. Stop dispensing fuel from the affected tank and contact us. We provide same-day response in most metropolitan areas and rapid deployment to regional sites to prevent further contamination.
Preventing Water Issues
Proactive maintenance helps avoid future water contamination. Regularly replace fill cap gaskets and cracked lids, and keep spill buckets clean and dry. Inspect vent caps and risers for signs of leaks. Ensure fuel delivery contractors follow tight-fill procedures. Keep tanks topped up to reduce condensation. Calibrate and check ATG water floats regularly to ensure alarms are accurate.
Compliance and Safety
Our work is carried out in line with Australian standards and state-based Underground Petroleum Storage Systems (UPSS) requirements. We maintain full chain of custody for all waste removed from site, with licensed disposal and tracking documentation supplied.
Why Choose Flowco
When you choose Flowco, you get fast response times, professional service, and complete documentation. We deliver before-and-after photos, retain sample jars on request, and provide ATG trend reviews. Our technicians ensure tanks return to service quickly and safely with minimal disruption to your operations.
Real-World Example
At a coastal service station, heavy rain caused stormwater ingress into a premium petrol tank. The site experienced repeated alarms and slow dispenser flow. Flowco removed 420 litres of water and sludge, filtered 42000 litres of fuel, replaced the fill cap gasket, and restored the tank to service the same day. No further issues were reported.
Frequently Asked Questions
How quickly can you attend my site?
In areas we can attend the same day. For regional areas, we provide rapid mobilisation with clear timelines confirmed at booking.
Will the tank need to be emptied?
No. Free water and contamination can be extracted and the fuel polished without draining the tank.
Can you recover contaminated fuel?
Yes, we filter and polish fuel to meet standards. Any unrecoverable product is disposed of responsibly.
What if microbial contamination is found?
We remove sludge and water, then treat diesel with biocide and inhibitor to eliminate microbes and stop them returning.
How do I know the issue is resolved?
We provide sample jars, photos, ATG screenshots, and a detailed report. Post-service monitoring ensures the problem does not recur.
Will my site be disrupted?
We isolate only the affected tank and dispensers, ensuring the rest of the site remains operational while we complete the service.
Related Services
We also provide precision tank testing, full tank cleaning and fuel polishing, line and leak testing, dispenser repairs, ATG servicing, vent and containment upgrades, and meter calibration.
Take Action
If you suspect water in your tanks, act quickly before it damages equipment or fuel quality. Contact Flowco today for immediate water removal and fuel recovery. Visit our Contact Us page or call our team to schedule fast, reliable service.
