Turnkey projects involve the complete construction, production or installation of facilities that can be immediately used. Owners of private real estate often choose this method of installation of new gas equipment.
Ordering a turnkey gas tank in one organization is much easier than entering into agreements with several companies. In any case, the installation is carried out strictly in accordance with the requirements and regulations.
In this material we will understand the stages of installation of gas turn-key.
The content of the article:
- Benefits of a turnkey project
- Requirements for installation of a gas tank
- Contract Options with the Executive
The main stages of the installation of a gas tank turnkey
- Drafting and reservoir selection
- Preparation of the pit and trench
- Installation of gas tank to the pit
- The organization of the base entry into the house
- Connecting gas equipment
- Commissioning and backfilling
- Agreement for the maintenance of the gas supply system
- Conclusions and useful video on the topic
Benefits of a turnkey project
Owners of private housing, wanting to save money, sometimes they try to do some of the work themselves. And it is advisable if there is experience in the installation or connection and there are no legal barriers.
However, in the case of the organization of independent gas supply, there is practically no way for independent intervention of the “loopholes”:
- all installation, additional equipment, connection, commissioning should be carried out by an organization having a special license;
- development of the TU and the drafting of the project are also engaged in the company’s permission;
- before concluding a contract with installers, the owner collects a package of documents (TU for gasification of the house, documents of title to the land, a plot plan, coordination with multiple authorities, etc.), which takes a lot of time.
If the owner of the house for the first time encounters with the design and installation of an autonomous gas system and at the same time is busy man, it is better to immediately contact a private company that has been successfully installing gas-holders for a long time and successfully servicing gas systems.
The company, which has 10-15 years of experience in autonomous gasification, is provided with a staff of skilled workers who thoroughly know all the rules and regulations for the installation of equipment
Representatives of a private company, as a rule, have the necessary connections in various related instances, so the process of coordination of documentation will be much faster.
The advantages of the “full package” also include on-the-fly installation of a gas-holder, including land works, transportation and installation, connection and pressure testing.
Specialists of the company are fully responsible for the implementation of all installation works, which are carried out in accordance with the rules of safety regulations, construction norms and regulations, GOST and the joint venture.
If errors occur during the installation process, they are corrected free of charge. The conclusion of a maintenance contract (maintenance, gas injection) with the gas-holder installation company facilitates the repair or replacement of equipment. You can read more about the cost of installing a gas-holder in a private house in this material.
Requirements for installation of a gas tank
An autonomous gas storage, as well as a gas pipeline, is a construction of a high degree of danger; therefore, a number of requirements are imposed on the installation and connection of gas equipment.
They are set forth in regulatory documents: for example, in PB 03-576-03 You can find out about the installation conditions for pressure vessels, and in SP 62.13330.201 - about the general provisions of the construction of gas distribution systems.
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The minimum distance for installing horizontal models from a gas-holder to a residential building is 10 m, to the foundations of technical constructions - 8 m
Installation in the ground is subject to the provision of electrochemical corrosion protection and with mandatory access to the valve (pressure gauge, safety valve, gas supply valve)
After the tank is installed, backfilled is connected, the area allocated for its installation should not be covered with asphalt or concrete, planted with shrubs and trees
It is necessary to provide access to the tank fittings, for which a technical hatch with a tight-fitting lid is equipped
For regular (1-2 times per year) filling of the tank with gas, it is necessary to equip the approach to the tank or to ensure the supply of the hose (up to 30-40 m in length)
The basis for the smooth installation of the tank is a concrete slab of 0.16 m in thickness. The gas holder is mounted on metal supports, which are part of the structure, with the help of anchors and belts
The installed reservoir is filled with river sand, which has the necessary thermal conductivity parameters and performs the function of drainage and a protective barrier.
The installation of the basement input is performed by representatives of the installation company. The device is welded and covered with protection in the factory, homemade for use is prohibited
The distance from the gas holder to objects on the site
Installation requirements for buried tanks
Territory with installed gas tank
Conditions for further maintenance of the tank
Conditions for filling the gas tank
Requirements for installation on a concrete slab
Capacity Backfill Rules
Socle entry of the pipeline into the building
Similar requirements are imposed on the gas pipeline, through which fuel flows from the tank to the building:
- trench depth for polyethylene (steel used extremely rarely) pipes - not less than 1.7 m;
- obligatory installation of a condensate collector;
- pipe slope to the condensate collector - 1 cm by 1 m;
- pipes are connected in one piece;
- distance to parallel pipelines - not less than 1 m.
When backfilling trenches, the gas pipeline installation zone is marked with a wide signal tape, which is stretched all over the pipe and sprinkled with soil.
Contract Options with the Executive
If the owner of the house is interested in installing the turnkey gas tank, then he will have to choose from several different nuances of options. To expand the circle of customers, companies offer 3-4 solutions. Usually they are called "Economy", "Standard", "Optima", "Premium", "Suite" and similar names.
One of the options for installing a turnkey gas tank for a house of up to 150 m². The main package includes design, the tank itself with valves, transportation, installation, connection, commissioning and commissioning. Extra paid earthworks and gas filling
The choice is good because you can choose the optimal package, saving on the same earthworks or signing a gas supply agreement with another organization.
The main stages of the installation of a gas tank turnkey
Turnkey installation implies execution of all stages of autonomous gasification by the company with which the contract is concluded. However, some control by home owners over the activities of installers will not interfere.
Drafting and reservoir selection
Project documentation is issued only after the specialist leaves the site. The size of the site, the location of the house and highways, the composition of the underlying rocks, the level of groundwater depends on the choice of the gas tank and the mounting nuances.
It is decided on site how much volume of the tank is optimal. This parameter is tied to the floor space of the house, so even professionals often use matching tables.
Horizontal gas-holder of the Czech brand Kadatec. Calculation of the volume of the building area: up to 150 m² - reservoir for 2400 l, up to 250 m² - 4300 l, up to 400 m² - 6200 l, etc.
Having experience in installation, representatives of the contractor can advise on the choice of the manufacturer of gas equipment. However, in practice, they, as a rule, are distributors of one or several companies that produce gas-holders, therefore, they will recommend their products.
It is logical to assume that it is unprofitable for them to offer tanks of poor quality, because they bear full responsibility for the safety of the facility.
Read more about the types of gas-holders read Further.
Variations of gas holders for cottages:
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The Antonio Merloni brand tanks are known for their vertical models. The advantage of vertical vessels is a low depth, therefore, a higher temperature. They operate up to -40ºС
The Polish Chemet plant is known for having permission to produce tanks for the storage of highly hazardous substances. This means that Chemet gas tanks are manufactured with high quality requirements and are distinguished by reliability.
Deltagaz is a Czech company that is a subsidiary of G.A.M. from Germany, so the quality of gas tanks really German: made on modern equipment and processed according to the latest technologies, the tanks are free from any defects
FASKHIMMASH produces gas-holders for the implementation of government gasification programs, as well as for equipping gas stations. Lukoil, Gazpromneft stations, etc., therefore it is possible to draw conclusions about a sufficiently high product quality for autonomous gas supply
Antonio Merloni - vertical gas holders
Products of the Polish company Chemet
Deltagaz - Czech gas tanks of German quality
Faskhimmash - high and low pressure tanks
After inspecting the territory and picking a complete set, a detailed action plan is drawn up and an estimate is compiled taking into account what exactly is included in the concept of "turnkey".
If any work must be paid additionally, it is agreed before the start of work. Project documentation is provided along with documents from the customer for obtaining permission to install an autonomous gas system.
Preparation of the pit and trench
Some companies offering autonomous gasification services for village houses and country cottages do not include land works in a turnkey complex service or include, but only in “Lux” type packages, that is, the costly.
Consequently, at the stage of digging the pit and trench, you can save 15-20 thousand rubles. and do the earthwork yourself.
What you need to do:
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The pit (pit) is pulled out on the territory designated in the project. The place is chosen taking into account many factors, therefore, it is not recommended to go beyond the boundaries of the area specified in the plan. For horizontal models - at least 10 m from the building
The dimensions of the pit are also defined in the project, and more specifically, attached to the installation instructions for the tank. Usually the depth of the pit is not less than 1.9 m, and the length / width depends on the dimensions of the tank. The bottom is closed with a sand and gravel pad.
The installation of the concrete base is an indispensable part of the installation work. It provides an even, horizontal location of the tank, stability, prevents the settling of the bottom. The plate must have holes or hinges for fastening the gas tank.
Given the level of soil freezing, the trench is dug at a depth of at least 1.7 m. The width is about 0.6 m. Finish the earthworks at the foundation of the house - in the place where the basement gas pipeline will be put into building
Step 1 - plot layout
Step 2 - Digging
Step 3 - Install the Concrete Slab
Step 4 - digging a trench to the house
Backfilling is performed after installation of the gas tank and valves, connection and testing. River sand is used for backfilling, and only for the upper layer (20% of the entire backfill) native soil is allowed to be used.
Installation of gas tank to the pit
Gas tank is transported by special equipment. Mini-tanks can be delivered on their own transport, but for cottages, as a rule, use large containers from 2000 liters. If there is an entrance to the pit, then the best option is a truck with a manipulator.
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In order not to damage the walls of the gasholder, install it onto the base smoothly and precisely, several pairs of hands will be required for unloading operations
Before fixing the gas tank to anchors or belts, it must be leveled relative to the concrete base and the ground surface. If the depth of the pit does not match the height of the tank, it will have to be reached, and the pit will deepen / reduce
There are several ways to mount the tank to the concrete slab, but you need to choose the one recommended by the manufacturer. Anchors, brackets, belts, cables or other fixation devices are supplied with the container.
This stage is carried out at the end of the strapping, connecting the stop and safety fittings, installing the condensate trap, etc. In the process of backfilling use tamping, but not concreting
Step 1 - Installation of the tank on the concrete slab
Step 2 - Tank Leveling
Step 3 - Mount the gas tank to the stove
Step 4 - Backfill Sand
Installation is carried out by an organization licensed to work with gas equipment. It is strictly forbidden to install a gas tank on your own, to connect a gas pipeline and other equipment to it.
The organization of the base entry into the house
Low-pressure gas is introduced into the building by a special technology called “basement entry”. At its core, this is the transition of a polyethylene pipe that goes from a gas-holder to a steel pipe that goes inside the house.
For installation input usually choose the shortest path. During installation, ensure that gas pipes do not overlap with other communications.
Three options for the arrangement of basement input: a - steel; b - polyethylene with a free bend of the pipe; в - polyethylene with tap ZN. Legend: 1 - section made of steel pipe; 2 - transition from steel pipe to polyethylene; 3 - polyethylene pipe; 4 - protective case; 5 - flexible polyethylene case; 6 - withdrawal from SN
Socle taps produced by the factory according to SNiP 42-103-2003. Parts dimensions may vary depending on installation conditions.
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In case of steel CV, the transition from the polyethylene pipe to the steel pipe should be underground, on a horizontal section, at a distance of at least 0.3 m from the ground
The section of the steel riser, located outside the building, is treated with zinc after welding works in the factory. To prevent the formation of cold bridges, the pipe is insulated
The hole in the wall of the building is performed according to the parameters of the pipe according to the project documentation. To enter the gas pipeline, a metal sleeve is laid from a section of steel pipe that is 0.5–1 cm in diameter
A mandatory element of the basement input is a ball valve, which can manually shut off the flow of gas during repairs or in the event of an accident.
Transition from polyethylene to steel
Protection of the steel input section
Metal sleeve in the wall
Ball valve to shut off
Two types of ground inlet should not be confused - for liquefied and wet or dried gas. If they are used improperly, the supply of fuel may be disrupted during frost.
We also recommend reading the article on how to install a gas-holder at a distance. Read more - go to reference.
Connecting gas equipment
After installing the tank on the stove, the devices are being installed, without which the gas supply cannot be made:
- electrochemical corrosion protection (anodic-cathodic);
- bellows compensator to ensure linear expansion and contraction during the period of ground movements;
- condensate trap to prevent ice jams in the frosty time (mounted at the lowest point of the pipeline);
- ground loop and lightning protection system.
On the throat panel, which protrudes above the ground, all valves and valves must be in good condition. This applies to the safety valve and charging valve, pressure gauge with tap, adjusting gearbox, gravity valves, etc.
From the tank to the ground water pave the gas pipeline from the HDPE. Low-pressure polyethylene is not in vain as a material for pipes: it is durable, flexible, not enters into a chemical reaction with the fuel, easily transfers the pressure of the soil, has a long life service.
After the gas pipeline is laid, it is covered with a layer of sand of at least 20 cm, on top of which a bright yellow tape with a prohibition sign is pulled. It is necessary that in the course of subsequent land works not damage the highway
Unlike the external gas pipeline, the internal one is assembled from steel pipes. They are interconnected by detachable connections and left open to be able to repair or connect additional equipment.
When installing a turn-key gas tank, the internal connection of stoves or boilers is often not taken into account, except in the most expensive package of services. This question is negotiated separately.
Commissioning and backfilling
Commissioning is carried out before backfilling, in order to correct possible errors, tighten connections, make additional protection of the pipeline at the joints.
First, pressure testing and purging of the reservoir and pipes are carried out using pneumatic equipment under a pressure of 50 kg / h, after which leakage is monitored. If everything is normal, the tank is filled with gas and once again check all connections in order to detect leaks.
Installers check the status of the valves at the inlet and at the outlet, check and adjust the pressure in the system at test points - at the regulator outlet and at the inlet to consumers
All data are logged in the commissioning log, gas sensors are mounted (optional), a thermal shut-off valve. And only after the completion of the commissioning works, the tank is filled with sand.
If the installation package includes installation of internal equipment, you can immediately check the operation of the gas boiler, stove, fireplace, etc. On installation works, as well as on all devices, the guarantee is given.
Agreement for the maintenance of the gas supply system
Servicing and refueling of an autonomous gas station are mandatory points, so a contract for further maintenance is concluded with or with organization that installed the gas tank or with another company (for example, which is closer or offers lower prices for refueling).
The call of tankers is carried out as the tank is empty, about 1-2 times a year, but with active gas consumption, the intervals between refueling can be reduced
Payment for gas is made in cash at the time of service (according to the meter installed on the gas carrier) or by bank transfer.
System maintenance is divided into planned, unscheduled (repair) and emergency (emergency). Planned includes the inspection of equipment, check the operation of all devices, the determination of gas pressure, if necessary, the setting.
According to the schedule, the safety valve is replaced. The reservoir is checked for integrity at intervals of 4-5 years.
If there are any doubts whether it is worth installing a gas tank on the site, we suggest reading the article where we compared the installation of a gas tank and the main gas. Read more here.
Conclusions and useful video on the topic
How the gas holders look and work, how they are installed and filled, you can find out from the following videos shot by professional installers.
About the nuances of using liquefied gas and autonomous gasification:
Informative about mounting and fittings:
Example of improper installation of a gas tank:
The use of gas in domestic conditions makes life outside the city comfortable, but subject to absolute security. Professional installation of equipment by a company that has a license and extensive experience is the only option to properly and legally connect a gas tank. Turnkey installation in this case looks practical and expedient.
If you have experience installing a turn-key gas-holder, share it with our readers. Leave comments in the box below the article. You can also ask questions about the topic of the article.