SANS10298
SANS10298
SANS10298
ISBN 978-0-626-22842-2
SANS 10298:2009
Edition 1.2
SANS 10298:2009
Edition 1.2
Table of changes
Change No. Date Scope
Amdt 1 2005 Amended to change the designation of SABS standards to SANS
standards and to update the referenced standards.
Amdt 2 2009 Amended to update a referenced standard and to move reference
to legislation to the foreword.
Foreword
This South African standard was approved by National Committee SABS TC 138, Water and
sanitation – Equipment and systems, in accordance with procedures of the SABS Standards
Division, in compliance with annex 3 of the WTO/TBT agreement.
A vertical line in the margin shows where the text has been technically modified by amendment
No. 2.
A reference is made in 5.1.1.1, 6.2.5 and in the NOTE to 6.2.5 to “relevant safety legislation”. In
South Africa this means the Occupational Health and Safety Act, 1993 (Act No. 85 of 1993).
A reference is made in 5.1.1.1 to “relevant legislation”. In South Africa this means the Mines and
Works Act, 1956 (Act No. 27 of 1956).
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Contents
Page
Foreword
1 Scope ..................................................................................................................................... 3
3 Definitions .............................................................................................................................. 3
7 Maintenance ........................................................................................................................... 22
8 Training .................................................................................................................................. 24
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1 Scope
This standard gives recommendations in respect of the selection of equipment, installation practice
and the maintenance of small to medium-sized chlorine gas installations. It gives recommendations
for vacuum type systems with up to six cylinders or a single "ton" container of nominal capacity
1 000 kg. It lays down procedures to be followed to minimize risks to the safety of persons and the
environment in terms of exposure to chlorine. General guidelines regarding medical treatment of
persons exposed to chlorine are included.
2 Normative references
The following standards contain provisions which, through reference in this text, constitute
provisions of this standard. All standards are subject to revision and, since any reference to a
standard is deemed to be a reference to the latest edition of that standard, parties to agreements
based on this standard are encouraged to take steps to ensure the use of the most recent editions
of the standards indicated below. Information on currently valid national and international standards
can be obtained from the SABS Standards Division.
SANS 9956-3/ISO 9956-3 (SABS ISO 9956-3), Specification and approval of welding procedures
for metallic materials Part 3: Welding procedure tests for the arc welding of steels. Amdt 1; Amdt 2
SANS 10019, Transportable containers for compressed, dissolved and liquefied gases – Basic
design, manufacture, use and maintenance. Amdt 1
SANS 15614-1/ISO 15614, Specification and qualification of welding procedures for metallic
materials – Welding procedure test – Part 1: Arc and gas welding of steels and arc welding of nickel
and nickel alloys. Amdt 2
3 Definitions
For the purposes of this standard, the following definitions apply:
3.1
approved inspection authority
organization that is approved by the regulatory authority
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3.2
bronchospasm
spasmodic constriction of the bronchial tubes
3.3
chlorination
use of chlorine to disinfect water
3.4
chlorinator
composite device that regulates the flow of gaseous chlorine into a water system
3.5
chlorine detector
sensing device that detects the presence of chlorine gas in the atmosphere, activates an alarm or
shuts off the system, and starts a safety procedure
3.6
chlorine filter
device installed in a chlorination system to remove particulate matter
3.7
chlorine gas; gaseous chlorine
element chlorine in the gaseous state
3.8
chlorine solution
solution of chlorine in water
3.9
container
container manufactured in accordance with SANS 10019 that is used for the transportation or
storage (or both) of chlorine
3.10
corticosteroid
any of the hormones of the adrenal cortex or any synthetic substitute
3.11
cylinder
portable chlorine container of maximum (filled) mass 70 kg that is used only in the vertical position
and that supplies only gaseous chlorine
3.12
dermatitis
inflamation of the skin
3.13
diffuser
device that disperses chlorine gas before exposure of the gas to water in order to maximize its
absorption
3.14
dosing unit
device that indicates chlorine flow rate
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3.15
dry chlorine
liquid or gaseous chlorine product that contains no more than 150 µg of water per gram of product
NOTE The dry compound used in swimming pool sanitation is not dry chlorine.
3.16
emesis
vomiting
3.17
evaporator
vaporizer
device in which liquid chlorine is converted to gaseous chlorine by the addition of heat and that is
mainly used in high-rate chlorination systems
3.18
flow regulator
device that controls the flow of chlorine to a water system at a constant rate
3.19
injector
vacuum injector that allows chlorine gas to be drawn into a water solution under operating
conditions only
3.20
lacrimation
formation of tears in the eyes
3.21
liquid chlorine catchpot
device that is installed in chlorine supply piping from chlorine containers, upstream of all regulating
and control devices, to prevent liquid chlorine carry-over
3.22
moist chlorine
wet chlorine
chlorine product, liquid or gaseous, that contains more than 150 µg of water per gram of product
3.23
pharynx
musculomembranous cavity located behind the nasal cavities, mouth and larynx
3.24
portable tank
portable chlorine container of maximum (filled) mass 1 000 kg that is used only in the horizontal
position and that can supply both liquid or gaseous chlorine
3.25
pulmonary
relating to the lungs
3.26
rhinorrhea
profuse watery nasal discharge
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3.27
substernal
situated beneath the breastbone
3.28
syncope
brief loss of consciousness; a faint
3.29
vacuum pressure regulator
device that reduces unregulated chlorine gas pressure from a chlorine gas supply system to a
constant supply under vacuum
A vacuum system is one in which an injector unit is used to create a negative pressure such that
chlorine is only drawn into and mixed with a water supply when the water is flowing, i.e. being
pumped. In the event of a fault condition the vacuum is interrupted and the chlorine feed stops
operating.
a) chlorine supply,
c) injector,
A pressure system feeds pressurized gaseous chlorine direct into the water supply. The use of a
pressure system is also known as direct chlorination. This involves great risk as the built-in safety
aspect of a vacuum system is not present in this type of system. Direct injection systems therefore
require careful design and operation.
4.2.1 Classification
small systems (up to 5 kg), medium systems (5 to 10 kg), and large systems (over 10 kg).
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1 2 3 4
Gas capacity per
Chlorine installation type Discerning feature Comment
container at 20 °C
Single-cylinder installation Cylinder-mounted
Up to 800 g/h Limited supply
(see figure 1) chlorinator
Single-cylinder installation(see Wall-mounted
Up to 800 g/h Limited supply
figure 2) chlorinator
Multiple-cylinder installation Cylinder-mounted Up to 800 g/h
Continuous supply
(see figure 3) auto changeover per cylinder
Multiple-cylinder installation Up to 800 g/h
Manifold Continuous supply
(see figure 4) per cylinder
Single portable container
Gas supply 6,8 kg/h Limited supply
installation
Multiple portable container Gas supply 6,8 kg/h
Continuous supply
(see figure 5) manifold per tank
Portable container installation, Liquid supply Above
Continuous supply
single or multiple container(s) using evaporator 40 kg/h
In order to minimize the dangers (such as the risk of exposure of the eyes, skin and mucous
membranes to chlorine) inherent in small to medium chlorination systems, the following components
or fittings (or a combination of them) should be used, if practicable:
Large systems usually source chlorine in liquid form. In these layouts the continuous supply of
chlorine is critical. However, these systems are not covered by this standard.
4.3 Materials
All the component parts of a chlorination system, such as membranes, springs, valve seats and
casings, that are in direct contact with chlorine gas (or liquid), shall be manufactured from high-
quality fully resistant materials as indicated in table 2.
All materials that are used, including for non-metallic parts for joints, seals, diaphragms, hoses, etc.,
shall be resistant to the action of chlorine, its impurities and other substances that are present under
the relevant operating conditions of temperature, pressure and corrosion.
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1 2 3 4
Liquid Dry chlorine gas Wet chlorine gas
Material Room temp. Max. temp. Room temp.
Chlorine
°C °C °C
1) 2) 3) 3)
Atlac X S 104 S (up to 140 °C)
Brass (60-90 percent copper) S S 180 X
Bronze (aluminium-silicon grade Corrosion rate
S S 180
– without Zn) 0,25 mm/year
Cast iron S S 100 X
Copper S S 100 X
2)
Duracor 6000 (FRP) X S 100 S (up to 82 °C)
Glass X S 204 S
1) 2)
UNS No 10276, Hastelloy C S S 510 X
1) 2)
UNS No 6600, Inconel S S 540 X
2)
PVDF, e.g. Kynar X S 100 X
Lead (gaskets only) S S 100 X
1) 2)
UNS No 4400, Monel S S 320 X
1)
UNS No 2201, nickel S S 250 X
Platinum S S 250 S
Polyethylene (high-density) X X – X
Polyethylene (low-density) X X – X
2)
PTFE, e.g. Teflon S S 250 S
PVC-u X S X S
Rubber (hard-cured) X S 150 S
2)
PVC, e.g. Saran X S 80 S
Silver S S 425 S
Steel (suitable grades) S S 100 X
Stainless steel (suitable grades) S S 180 X
Tantalum S S 150 S (up to 150 °C)
Titanium X X – S
1) The above table only takes corrosion resistance properties of the materials into account. The
effects of any fabrication and welding procedures used should also be considered.
2) The trade names referred to are registered and commonly used. However, this information is
given only for the convenience of users of this standard. This in no way constitutes
endorsement of the products referred to. Equivalent products may be used if they can be
shown to produce the same results.
3) The letter S indicates that the material might be usable, but does not necessarily indicate
complete freedom from corrosion. X indicates that the material is unsuitable. When selecting a
material for a particular application, care should be taken to comply with statutory regulations. It
should also be borne in mind that some metals may not be used at pressures above
atmospheric.
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NOTES
1 As chlorine is an extremely dangerous substance it is advisable that each individual chlorine application be
studied in detail and that specialists on chlorine be consulted before the selection of materials.
2 The user shall ensure that material thicknesses comply with the requirements of this standard and shall
take into account pressure and temperature conditions together with all safety factors.
CAUTION – Moist chlorine is extremely corrosive to all the common construction metals and
its use in conjunction with such metals shall be avoided.
At low pressures hard rubber, unplasticized polyvinylchloride, glass-fibre reinforced polyester, poly-
vinylidene chloride or polyvinylidene fluoride can be used for either the components of the system
or for the lining of the parts. Fully halogenated fluorocarbon resins of a suitably chemical resistant
grade may be used, depending on the specific application. All of these materials should be selected
with great care. For higher pressures, common metals shall be used in combination with resistant
lining materials for strength.
4.3.2.1 Titanium may be used with moist chlorine but shall not be used with dry chlorine under any
circumstances as it burns spontaneously on contact. Tantalum is inert to moist and dry chlorine at
temperatures of up to 149° C. High-alloyed nickel steels and Monel are widely used. Platinum and
silver have special applications. In general, operations that involve moist chlorine require individual
study. Chlorine and equipment suppliers can make recommendations only after careful study of all
the factors involved.
4.3.2.2 For chlorine under vacuum, PVC, copper and brass piping may be used. Plastic piping shall
never be used on the pressure side.
All piping and fittings shall have pressure and temperature ratings suited to their application.
4.3.3.1.1 Seamless heavy-duty carbon steel piping shall be used together with forged 20 MPa1)
rating screwed or socket welded fittings. Unions shall also have the required 20 MPa rating and
shall be manufactured from carbon steel and shall be used in conjunction with lead gaskets.
4.3.3.1.2 Piping systems shall have screwed, welded or screwed-and-welded joints. Screwed joints
shall be fitted with chlorine resistant tape or jointing paste. If flanged valves or other equipment are
used, the flanges shall be manufactured of compatible material and shall have the required
pressure rating.
Vacuum piping and fittings shall be of class 16 PVC or other applicable material(s) (see table 2).
Joints shall be solvent or solvent-and-seal welded or, if necessary, flanged to accommodate special
valves or pieces of equipment. Provisions shall be made for expansion and contraction in the
system.
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4.3.3.3 Valves
4.3.3.3.1 Valves shall be either manually or automatically operated. If automatically operated, the
actuators shall be either electrically or pneumatically actuated.
4.3.3.3.2 The suitability of valves for particular applications should always be discussed with
manufacturers and suppliers. Valves shall be constructed from the materials listed in table 2.
Pressure and temperature ratings shall suit the conditions of the proposed system. The valve ends
shall be screwed, flanged, or socket welded.
4.3.3.3.3 Valves for chlorine under pressure should be manufactured from forged steel, cast steel
or aluminium-silicon bronze. Valves shall be able to withstand the effects of ferric chloride build-up.
To this end, ball valves shall have a port that links the upstream side and the downstream side of
the valve to prevent liquid chlorine from being trapped when the valve is stuck in the closed
position.
4.3.3.3.4 The following types of valves may be used in conjunction with dry chlorine:
a) Ball valves
Ball valves shall have forged carbon steel bodies with Monel balls and stems, together with
PTFE seats and seals. Their design shall be such that the trapping of liquid chlorine below the
ball is not possible.
b) Plug valves
Plug valves shall have forged carbon steel bodies with either forged steel or cast iron plugs and
covers. The bodies shall be PTFE-lined and the seals shall be manufactured from PTFE. The
plugs shall be made of Monel and the valve ends shall be flanged or screwed.
If a plug valve is used for a liquid chlorine application a Monel seal plug shall be used that has a
hole drilled through it on the downstream side. The body shall be PTFE-lined and the gland seal
arrangement shall be designed with the specific application of the valve in mind.
c) Diaphragm valves
Diaphragm valves shall have either forged steel or cast iron bodies suitable for dry chlorine
applications. They shall be fitted with a PTFE diaphragm that houses a polyvinylidene fluoride
(PVDF) membrane between the diaphragm and the rubber lining.
d) Globe valves
Globe valves shall have bodies and bonnets of cast iron or steel and have either bellows or
packed gland seals. In addition the valves shall have components manufactured from high-
quality steel forgings. If bellows seals are used, a back seat shall be fitted. The stems and globes
shall be forged steel and the seats shall be manufactured from Monel. If gland type seals are
used, the length of packing shall be twice the stroke length.
These valves shall have a back seat to prevent any emission in the event of gland or bellows
failure. Valves shall also have hard stellite seats of conical design in order to reduce the emission
of impurities.
4.4 Containers
All containers shall be designed and manufactured in accordance with SANS 10019 or other
approved standards.
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4.4.1 Cylinders
1 2 3 4 5
Net mass Avg tare mass Gross mass Length Diameter
kg kg kg mm mm
70 32 102 930 300
70 45 115 860 325
70 56 126 1 224 254
70 33 101 980 302
Portable tanks shall be welded tanks of capacity 915 kg to 990 kg and of gross mass up to 1 665 kg
(see figure 7). Approximate dimensions and masses are shown in table 4. The ends of portable
tanks are concave and shall be welded to the barrel. The sides shall be crimped inward at each end
to form chimes that provide a substantial grip for lifting beams. The valves of portable tanks shall be
protected by a removable steel protective housing.
1 2 3 4 5
Net mass Avg tare mass Gross mass Length Diameter
kg kg kg mm mm
915 736 1 651 1 880 873
940 671 1 610 2 090 784
940 615 1 555 2 090 765
990 675 1 665 2 090 784
990 644 1 643 2 044 908
4.4.3 Marking
The number of the relevant standard (i.e. SANS 10019), serial number, identifying symbol,
inspector's official mark and date of hydrostatic test shall be stamped on the metal near the neck of
the cylinder.
All permanent markings on portable tanks shall be made in accordance with SANS 10019 and shall
be stamped into the chime at the valve end.
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5.1.1 Piping
5.1.1.1 General
The construction of chlorine pipelines shall be in accordance with general techniques for gases
under pressure and shall comply with the relevant safety legislation (see foreword) and the relevant
legislation (see foreword). Amdt 2
Piping arrangements shall be as short and simple as possible, accessible above ground and clearly
visible. The number of flanged joints shall be minimized. The piping systems should be well
supported and have a slope towards the chlorine container(s) or liquid trap to allow drainage. Low
spots that can trap liquid shall be avoided. Suitable allowance shall be made for pipe expansion due
to changes in temperature.
Chlorine pipes shall run through zones of increasing temperature up to the chlorinator. Where this is
not possible, the pipes shall be heated by means of self-regulating heating tape. Pressure reduction
can aid this system.
Flexible connectors of header piping shall be manufactured from cadmium-plated or from nickel-
plated copper and shall preferably be fitted with an auxiliary isolating valve. Connection to the
manifold valve (header valve) shall be achieved using a union nut, which shall be fitted with lead
washers. These washers shall be replaced each time the joint is broken.
5.1.2 Valves
Where necessary, appropriate pressure reducing valves shall be fitted in a system to ensure that
reliquefaction does not occur within the system. In addition sufficient accessible, permanently
identified isolation valves shall be provided to separate any section of the pipeline for maintenance,
repair or emergency.
5.1.3 Evaporators
5.1.3.1 If chlorine gas is sourced from the liquid phase in a portable tank such as in large
installations (i.e. over 75 kg/h) an evaporator shall be used. The evaporator shall vaporize the
chlorine gas by the following means:
b) steam; or
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5.1.4 Separators
If an evaporator is used, a liquid chlorine separator (trap) shall be fitted to the downstream side of
the evaporator together with a filter and a chlorine pressure reducing safety valve of appropriate
capacity.
If liquid chlorine is used or if any possibility exists that liquid chlorine might be formed, expansion of
the liquid shall be catered for by one or by a combination of
b) a pressure relief valve or rupture disc that discharges to a receiver or to an agreed safe area.
Pressure limiting devices shall not discharge to the atmosphere and they shall be effectively
contained for disposal purposes.
5.1.6.1 Suck-back (see 5.4.4) shall be prevented at all times, and to this end consideration shall be
given to the use of an additional check valve that shall be placed between the ejector and the
vacuum regulator. However, where suck-back is a possibility the installation shall be protected by
any one or by a combination of
a) non-return valves,
b) flow interlocks,
d) barometric loops.
5.1.6.2 A barometric loop is useful only when the chlorination vessel is at atmospheric pressure
and the loop can extend more than 11 m above the surface of the liquid.
5.2.1 Joints in chlorine piping shall be flanged, screwed or welded. Flange connections on the
chlorine lines shall have suitable gaskets and shall be of the correct temperature and pressure
rating.
5.2.2 The following items (or proven functioning equivalents) shall be used as gaskets and sealing
materials and shall be replaced at regular intervals or when components are renewed (also when
cylinders and drums are changed):
a) fibre seals;
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5.3.1 The chlorine gas storage room and the instrumentation room shall have solid walls to
prevent direct access to any other rooms and shall be gas-tight.
5.3.2 Exits shall lead direct to the open air. Doors shall open to the outside, and it shall be possible
to fasten them in the open position.
5.3.3 Sight glasses (i.e. door viewers) shall be fitted to doors to allow checking of the inside of a
room from outside.
5.3.4 Chlorine gas rooms shall be of solid construction and shall be fire resistant. These rooms
shall also be safeguarded against unauthorized entry.
5.3.5 The room(s) shall be so constructed that unobstructed escape is possible. In addition, the
switch for the ventilating arrangement (if not automatically operated), shall be located outside and
close to the door of the room.
5.3.6 A chlorine room shall be so designed that sunlight cannot shine direct through windows and
doors onto chlorine tanks and cylinders.
Liquid chlorine has a high coefficient of thermal expansion. If liquid chlorine (containing no gas
bubbles) is trapped between two valves, extremely high hydrostatic pressure can develop if the
temperature of the chlorine increases. The pressure can lead to rupture of the line. The effects of
possible rupture must be considered in the design of any piping system and safety margins against
excessive pressure must be provided, i.e. bursting discs and expansion tanks shall be placed at
strategically sensitive areas.
5.4.2.1 If chlorine installations have been competently designed, condensation of chlorine will
normally not take place.
5.4.2.2 However, condensation or liquefaction of chlorine can occur in chlorine gas lines that pass
through areas where the temperature is below the temperature-pressure equilibrium point indicated
by the vapour pressure curve. Condensation can usually be prevented by reducing the pressure by
means of a pressure reducing valve.
5.4.2.3 If all other measures fail it might be necessary to insulate the lines and perhaps to heat-
trace them. Heat-tracing chlorine lines is potentially hazardous and shall be approached with great
caution to preclude ignition of steel, which will ignite spontaneously at approximately 250 °C in a
chlorine environment. (Chlorine should always flow from an environment of lower temperature to
one of higher temperature, to keep the chlorine in the gaseous phase). A liquid chlorine catchpot,
preferably heated and installed at the correct place, will overcome reliquefaction problems.
5.4.2.4 Piping shall, wherever possible, be open in order to facilitate immediate visual inspection.
The frosting up of pipes and containers is possible if large quantities of gaseous chlorine are
removed from them over long periods. In normal use the rates of withdrawal from bottles and tanks
shall not exceed 1 % of the contents over a period of 1 h (at ambient temperatures of 18 °C to
20 °C).
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5.4.4 Suck-back
5.4.4.1 If chlorine gas is being injected into a liquid, the liquid can be sucked back into the chlorine
line and into the container from which the chlorine is being fed. This happens when chlorine flow
ceases, for example when
5.4.4.2 Suck-back has caused serious accidents and severe corrosion. The design of the system
shall be such that suck-back is prevented.
5.5.1.1 Before the introduction of chlorine into new fittings and pipelines, the complete system shall
be thoroughly cleaned (see 5.5.1.2) and dried. New valves or other equipment received in an oily
condition shall be dismantled and cleaned before use.
WARNING: Chlorine can react violently with cutting oil, grease, and other organic materials.
5.5.1.2 Only fully hydrogenated hydrocarbons shall be used for cleaning purposes.
CAUTION: Exposure to chlorinated solvents presents a toxic risk. In order to keep risk levels to a
minimum and to ensure the least exposure to such solvents, the most effective combination of
controls, work practice and personnel protective equipment shall be used.
5.5.2.1 All newly built chlorine piping systems shall be pressure tested before being used as
described below. Depending on the pressure ratings of the components used (see below), nitrogen
or air pressure testing shall be performed at a maximum of 1,5 times design pressure.
5.5.2.2 Before installation all components comprising the system shall be pressure tested to their
maximum test pressure. If possible, the entire system shall then be tested to the highest pressure
rating of the lowest-rated pressure component in the system.
5.5.2.3 Hydrostatic pressure testing may be performed (where compressed air is not available),
although this method is not recommended. If performed, it is essential that the system be
thoroughly dried (see 5.5.3) before the system is put into service.
5.5.3 Drying
5.5.3.1 During construction, moisture can enter the system from the atmosphere or from other
sources. For this reason piping shall always be dried before use.
5.5.3.2 Except in the case of plastics components, drying shall be effected by passing superheated
steam through from the high end of the sloping lines until they are thoroughly heated. While
steaming, condensate and foreign matter shall be drained out. After steaming the steam supply
shall be disconnected and all the lutes, pockets and low spots in the line drained, and thereafter dry
air or non-reactive gas (e.g. nitrogen) that has a dew point of –40 °C or lower shall be blown
through the line until it is dry (while the line is still hot).
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5.5.3.3 If steam and dry air are not available, particular care shall be taken when sections of pipe
and other equipment are cleared before assembly, and careful inspection is necessary as
construction proceeds. The final system shall be purged with dry air or nitrogen to remove as much
moisture as possible from the system.
After the system has been dried, it should be pressurized with dry air or non-reactive gas and tested
for leaks by the application of soapy water to the outside of joints. Chlorine gas may then be
gradually introduced and the system again tested for leaks (see 7.2).
6 Operational safety
6.1 Responsibilities in the event of an emergency
It shall be the duty of the person in charge of any premises where a chlorine system is installed, to
display conspicuously instructions for the operation of the system and the precautions to be
observed in case of breakdown or leakage, as follows:
c) the name, address and day and night telephone numbers for obtaining service from the chlorine
suppliers and other relevant authorities;
d) the name, address and telephone numbers of the municipal inspection department that has
jurisdiction; and
e) instructions to notify the local emergency services immediately in the event of an emergency.
6.2.1 All chlorine facilities shall have an ongoing safety programme in place, which shall comprise
regular safety inspections (documented) and ongoing user (personnel) training programmes.
6.2.2 The equipment shall be inspected and serviced at regular intervals by suitably qualified and
experienced personnel at least once a year.
6.2.3 All chlorine handling systems shall be designed and erected by persons who are suitably
trained and experienced in the chlorine field.
6.2.4 All facilities that are situated near strategically sensitive areas (e.g. places inhabited by
people or animals), shall have an early-warning gas detection system.
6.2.5 With the above in mind, users of this code of practice shall ensure that the relevant safety
legislation (see foreword) is adhered to at all times with regard to the design, maintenance and
ongoing usage of chlorine facilities. Amdt 2
NOTE It is strongly recommended that in the case of all installations near strategically sensitive areas (e.g.
places inhabited by people or animals), the necessary risk assessments in terms of the draft major hazard
installation regulations linked to the above relevant safety legislation (see foreword), be carried out in order to
ensure that such installations comply with legal requirements. Amdt 2
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c) the first-aid procedures to be followed when personnel are exposed to chlorine gas.
6.4.1 The applicable National Occupational Safety Association (NOSA) signs and emergency
procedures as well as South African Chlor-Alkali Manufacturers' Association (SACAMA) wall charts
shall be appropriately displayed. (This shall include a first-aid information sheet for chlorine-gas
poisoning.)
6.4.3 At least two self-contained breathing sets shall be mounted in the foreman's or
superintendent's office or near (but not inside) the chlorine room.
6.4.4 Appropriate signage indicating that lone entry into the chlorine room is inadvisable while
containers are being changed or when leaks are detected shall be appropriately displayed.
Respirators and breathing apparatus shall be selected, used, inspected and maintained in
accordance with the applicable regulations. In particular
2) when the seal has been broken for any reason, and
NOTES
1 It is important that all personnel who might have to use these respirators be given practice in fitting and
using them.
2 Canister type respirators are not suitable for high concentrations of gases or for prolonged periods.
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6.5.2.1 Personal protective equipment shall be kept in an easily accessible, locked cabinet in the
immediate vicinity of the plant. The cabinet shall not be situated in any room that contains chlorine.
The cabinet shall be reserved exclusively for such equipment and shall be clearly and suitably
marked.
6.5.2.2 Protective equipment shall be located outside the area of possible contamination.
A record shall be kept of the serial numbers of containers received and the dates on which they
were received and dispatched. It is also recommended that containers be used in the order in which
they are received (first in, first out).
6.6.3.1 Containers shall be handled with care and shall not be subjected to shock. Any damage to
the container and valve shall be avoided.
6.6.3.2 The valve outlet protection cap and valve protection dome shall always be secured when
containers are not in use.
6.6.3.4 Filled (or partially filled) cylinders shall always be handled, transported and used in a
secured upright position.
6.6.3.5 Filled (or partially filled) tanks shall always be handled, transported and used in a secured
horizontal position. Tanks shall always be fixed in position such that at least one of the valves is
above the level of the liquid.
6.6.3.6 Containers shall not be dropped (for example from truck tailboards), dragged or rolled on
their sides or be allowed to skid. Cylinders that cannot be handled by hand shall be transported by
hand trolley. Portable tanks shall be lifted and placed in position by crane or hoist, using a suitable
lifting beam or chains.
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6.6.3.7 Containers shall be lifted and lowered gently and not be allowed to strike any sharp objects.
No object shall be allowed to strike a container with force.
6.6.3.8 Before connecting or disconnecting a container the operator shall make sure that all safety
and emergency equipment are available and operable.
CAUTION: To prevent unequal pressure build-up within the system when cylinders or tanks from
different temperature environments are connected, ensure that the units are temperature equalized
before installation.
6.6.3.9 Leak tests shall be carried out every 12 h (i.e. in the morning and afternoon), even on
"empty" cylinders.
6.6.3.10 To avoid the possibility of dangerous concentrations of gas spreading in the event of a
leak, containers shall never be stored near elevators or ventilation systems.
6.6.3.11 Containers shall never be exposed to flame or to any form of intense radiant heat. (The
fusible plug begins melting at 70 °C.)
6.6.3.12 The storage area shall be well ventilated to provide a free flow of air and to assist in gas
dissipation in the event of leakage.
6.7.1.1 Chlorine is irritating and can be corrosive to the eyes, skin and mucous membranes.
6.7.1.2 Target organs are the eyes, skin and respiratory tract organs and in the case of ingestion,
the oesophagus.
6.7.1.3 Contact with escaping compressed liquid can cause frostbite of the skin and freezing of the
eye tissues.
a) burning sensation;
b) lacrimation;
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The respiratory system is the most important system to be affected. Chlorine can have the following
effects on the respiratory tract:
a) Symptoms and signs include coughing, choking, substernal pain, hypoxemia, chemical
pneumonia, bronchospasm, pulmonary oedema and respiratory collapse. Symptoms can be
intermediate or delayed.
c) Other symptoms and signs that can occur include burning of the eyes, nose and mouth, and
lacrimation, rhinorrhoea, nausea and vomiting, headache, dizziness and syncope and dermatitis.
6.7.2.4 Ingestion
a) corrosive damage to mouth, pharynx and oesophagus and even perforation of the oesophagus;
and
b) If the tissue is not frozen, flush eyes immediately with copious amounts of water under low
pressure for 15 min to 20 min. Hold eyelids apart to ensure complete irrigation of all eye and lid
tissues. Do not attempt chemical neutralization of any kind.
a) If frostbite has not occurred, flush contaminated skin with copious amounts of running water
under low pressure for 15 min to 20 min. Remove clothes and shower to ensure irrigation of all
contaminated skin. Do not attempt chemical neutralization and do not apply ointment to damaged
skin.
c) If frostbite has occurred, seek medical attention immediately. Do not rub the affected areas or
flush them with water. In order to prevent further tissue damage, do not attempt to remove frozen
clothing from frostbitten areas.
d) Treat skin (dermal) irritation or burns with standard topical therapy. Patients who develop dermal
hypersensitivity reactions might need treatment with corticosteroids or antihistamines.
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1) placing the patient in a comfortable position in a chair or, alternatively, lying down with the
head and trunk elevated to between 45° to 60° in severe cases,
6.7.3.4 Ingestion
b) Give the patient water or milk to drink (to dilute the swallowed substance).
6.8.1 Overexposure
All individuals who have developed symptoms as a result of an acute overexposure to chlorine
substances shall be placed under the supervision of competent medical personnel.
6.8.2 Antidote
There is no known specific antidote for acute chlorine exposure. Prompt supportive measures shall
be implemented to obtain good therapeutic results.
6.8.3 Anxiety
Alleviate anxiety by describing to the patient the various procedures to be applied and by eliciting
his co-operation, especially in breathing exercises.
6.8.4 Respiration
6.8.5.1 Position the patient in a chair; in severe cases have the patient lie down with the head and
trunk elevated to a 45° to 60° position.
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6.8.5.5 Monitor respiratory function for 24 h because pulmonary oedema might be delayed.
6.8.6.1 Maintain oxygenation with arterial blood gas monitoring (if available).
6.8.6.2 Early use of positive end-expiratory pressure (PEEP) and mechanical ventilation might be
needed to maintain optimal partial pressure of oxygen (PO2).
6.8.6.3 Intermittent positive pressure breathing apparatus may be used to reduce the risk of
developing oedema.
6.8.6.4 Corticosteroid therapy, given early, might be effective in preventing or alleviating pulmonary
oedema. If steroids are used, a loading dose should be given promptly and the dose should then
gradually be tapered off over a one to two week period, in accordance with clinical findings.
6.8.6.5 The use of antibiotics should be considered to protect against secondary pulmonary
infection.
6.8.7 Bronchospasm
6.8.7.1 Bronchodilators nebulized into the respiratory air might be beneficial when spasm is
present. Inhaled beta 2 stimulants (for example, salbutamol) are usually effective.
6.8.8 Ingestion
6.8.8.3 Observe the patient for symptoms and signs of oesophageal and gastro-intestinal corrosion
and give symptomatic and supportive treatment as indicated.
6.8.9 Recommendations
It is further recommended that an emergency shower, an eye wash facility and emergency oxygen
resuscitation equipment be installed at a suitable location to facilitate immediate first-aid application
in the event of an accident.
In larger installations ventilation systems of appropriate size shall be installed for the emergency
removal of chlorine gas.
7 Maintenance
7.1 General
7.1.1 To avoid damage to equipment and danger to persons, it is essential that chlorine plants be
carefully maintained by the personnel (or concern) to whom this duty is assigned. Automatic
protective devices shall be checked regularly, and leakages and other faults shall be attended to
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immediately. When a dangerous leakage of chlorine has occurred, the area concerned shall be
enclosed and personnel shall not be permitted to enter the enclosed area until it has been cleared
by purging or ventilating. In addition, personnel who enter the contaminated area shall be provided
with, and shall use, suitable breathing apparatus. In all cases at least one person shall remain in
attendance outside, and next to, the entrance to the contaminated area. This person shall also be
wearing the required breathing apparatus for rescue purposes.
7.1.2 Procedures covering routine daily maintenance and preventative maintenance shall be
formally documented. Maintenance of the installation shall be carried out by competent, well-trained
personnel.
7.1.3 Chlorine gas dosing equipment and apparatus, chlorine gas warning systems and sprinkler
apparatus shall be serviced at least once a year and also each time faulty operation is detected.
This shall only be done by a competent person, who shall preferably be authorized by the
manufacturer or importer of the product.
7.1.4 On completion of any work on a chlorine system, a report on the work done and the parts
replaced as well as on the result of the pressure or vacuum tests performed shall be provided and
shall certify that the system is in proper working order.
7.1.5 Chlorine gas warning systems shall be subjected to an in-house check for chemical function
at least once a month in accordance with the manufacturer's instructions. Proper records shall be
kept.
7.2 Leaks
7.2.1 The system shall be leak tested before it is commissioned; in the event of leakage the
chlorine supply shall be shut off, the pressure shall be relieved and necessary repairs shall be
made. Leak testing shall be done using a suitable leak detection fluid, e.g. ammonia (NH3).
7.2.2 If welding is needed, the system shall be purged with dry air or non-reactive gas, e.g.
nitrogen. All welding shall be grade A welds to SANS 15614-1 and shall be completed under the
supervision of an approved inspection authority. Amdt 1; amdt 2
7.2.3 Leaks shall never be repaired by welding until all chlorine has been purged from the system
with nitrogen or air. When detectable leaks have been repaired, the line shall be retested.
a) all changes (including the removal and addition of components) are made in accordance with this
standard,
b) there is no leakage (with particular attention to valves, joints of all types, connections and areas
of corrosion),
c) filters are in good condition and are not blocked (clean where necessary),
d) valves to be used in normal operation or in cases of emergency are accessible and are easy to
operate (the applicable valves are to be checked for leak tightness),
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f) relief valves are checked for leakproof closure and proper working condition,
h) the external finish of the system and protection against corrosion are present and functioning as
intended, and
i) the piping and associated equipment are free from damage and are in working order.
NOTE Steam or hot water rapidly dissolves ferric chloride. Lines or equipment so cleaned should be carefully
dried before they are put back in service. Steam should not be used on plastic equipment unless it is known
that the specific plastics material can withstand the temperature.
7.4.1 If any work or repairs or modification that requires the use of arc-producing or flame-
producing apparatus (such as welding and brazing equipment) is to be done indoors, the work shall
not be started until the room(s) have been thoroughly ventilated. Where necessary, the workman
shall have a second person in attendance.
7.4.2 The necessary protective equipment shall be available and should be used. In addition, fire-
extinguishing apparatus shall be readily accessible.
8 Training
8.1 Users of chlorine and chlorine apparatus shall
a) be educated in the required procedures, and
8.2 All personnel involved in the operation and maintenance of chlorine installations shall have
been instructed in the functioning of the installation, to ensure that they are fully conversant with the
equipment concerned.
8.3 Depending on the complexity of the plant, it might be advantageous for the personnel or
people involved in the operation and maintenance to be present during the erection, testing and
setting-up of the plant.
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Annex A
(informative)
Additional information
Dry chlorine gas or liquid does not react with (corrode) many metals, but it is strongly corrosive
when moisture is present. This is because chlorine reacts with water to form hypochlorous acid and
hydrochloric acid, which causes the corrosion. It is therefore imperative to keep moisture out of
chlorine containers and chlorine piping.
Chlorine gas is heavier than air. If it escapes from a container or system, it will accumulate in the
lowest level in the building or area in which the leak occurs. (Extraction fans should be fitted low
down in the chlorine room.)
Chlorine is only slightly soluble in water. Chlorine gas reacts with ammonia gas (vapour) to produce
a dense white cloud of ammonium chloride. This property is used to detect chlorine leaks. Only
ammonia vapour shall be used when testing for chlorine leaks.
At atmospheric pressure liquid chlorine boils at −34 °C. To maintain chlorine in the liquid form, it
therefore has to be kept under pressure. One volume of liquid chlorine yields about 460 volumes of
gas when it vaporizes. When chlorine vaporizes, the residual liquid cools and if vaporization is too
rapid, a freeze line of condensed water will become visible on the outside of the container.
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A.5.2 Take a plastic bottle similar to a dish washing soap bottle that can be squeezed and that
has a dip tube attached. Fill the bottle with a 20 % aqueous ammonia solution. Direct the ammonia
vapour at the suspected leak. If chlorine gas is present, a white cloud of ammonium chloride will
form.
The kits operate on the principle of containing minor leaks in cylinders, tanks and valves, by
applying hoods or gaskets (or both) to the area(s) of leakage. To this end, patches are provided for
sealing off small holes in the side walls of cylinders and tanks, and gaskets for the repairing of valve
leakages. The kits also contain the necessary tools and step-by-step instructions to effect the
necessary repairs.
It is strongly recommended that chlorine consumers incorporate training in the use of these kits in
their emergency preparedness programmes.
© SABS
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