SMALL CHLORINE CONTAINERS

CONSTRUCTION AND HANDLING

GEST 88/138
5th Edition
February 2004

EURO CHLOR PUBLICATION

This document can be obtained from:

EURO CHLOR - Avenue E. Van Nieuwenhuyse 4, Box 2 - B-1160 BRUSSELS
Telephone: 32-(0)2-676 72 65 - Telefax : 32-(0)2-676 72 41

GEST 88/138
5th Edition

Euro Chlor

Euro Chlor is the European federation which represents the producers of chlorine
and its primary derivatives.
Euro Chlor is working to:

improve awareness and understanding of the contribution that chlorine

chemistry has made to the thousands of products, which have improved
our health, nutrition, standard of living and quality of life;
maintain open and timely dialogue with regulators, politicians, scientists,
the media and other interested stakeholders in the debate on chlorine;
ensure our industry contributes actively to any public, regulatory or
scientific debate and provides balanced and objective science-based
information to help answer questions about chlorine and its derivatives;
promote the best safety, health and environmental practices in the
manufacture, handling and use of chlor-alkali products in order to assist
our members in achieving continuous improvements (Responsible Care).

***********
This document has been produced by the members of Euro Chlor and should not be reproduced in
whole or in part without the prior written consent of Euro Chlor.
It is intended to give only guidelines and recommendations. The information is provided in good
faith and was based on the best information available at the time of publication. The information is
to be relied upon at the users own risk. Euro Chlor and its members make no guarantee and
assume no liability whatsoever for the use and the interpretation of or the reliance on any of the
information provided.
This document was originally prepared in English by our technical experts. For our members
convenience, it may have been translated into other EU languages by translators / Euro Chlor
members. Although every effort was made to ensure that the translations were accurate, Euro Chlor
shall not be liable for any losses of accuracy or information due to the translation process.
Prior to 1990, Euro Chlors technical activities took place under the name BITC (Bureau
International Technique du Chlore). References to BITC documents may be assumed to be to Euro
Chlor documents.

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RESPONSIBLE CARE IN ACTION

Chlorine is essential in the chemical industry and consequently there is a need for
chlorine to be produced, stored, transported and used. The chlorine industry has
co-operated over many years to ensure the well-being of its employees, local
communities and the wider environment. This document is one in a series which
the European producers, acting through Euro Chlor, have drawn up to promote
continuous improvement in the general standards of health, safety and the
environment associated with chlorine manufacture in the spirit of Responsible
Care.
The voluntary recommendations, techniques and standards presented in these
documents are based on the experiences and best practices adopted by member
companies of Euro Chlor at their date of issue. They can be taken into account in
full or partly, whenever companies decide it individually, in the operation of existing
processes and in the design of new installations. They are in no way intended as a
substitute for the relevant national or international regulations which should be fully
complied with.
It has been assumed in the preparation of these publications that the users will
ensure that the contents are relevant to the application selected and are correctly
applied by appropriately qualified and experienced people for whose guidance they
have been prepared. The contents are based on the most authoritative information
available at the time of writing and on good engineering, medical or technical
practice but it is essential to take account of appropriate subsequent developments
or legislation. As a result, the text may be modified in the future to incorporate
evolution of these and other factors.
This edition of the document has been drawn up by the Equipment Working Group
to whom all suggestions concerning possible revision should be addressed through
the offices of Euro Chlor.

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Summary of the Main Modifications in this version

Section

Nature

7
Appendix 2

New section is added: Respiratory Protective Equipment

List of plant contact in case of accidents was deleted

TABLE OF CONTENTS

INTRODUCTION

TYPES OF CONTAINERS UP TO 4 T CHLORINE

CONSTRUCTION CODE

12

3.1
Vessel Construction
3.1.1 Minimum Design Temperature
3.1.2 Test Pressure
3.1.3 Minimum Wall Thickness
3.1.4 Material of Construction
3.1.5 Welds
3.2
Accessories
3.2.1 Manhole or Handhole (if any)
3.2.2 Valves
3.2.3 Protection against Mechanical Damage during Transport and Storage
3.2.4 Relief Valves and Fusible Plugs
3.2.5 Thermal Insulation
3.2.6 Handling Consideration

12
12
12
12
12
12
13
13
13
18
18
18
18

18

COMMISSIONING AND LOADING

4.1
Initial Commissioning
4.1.1 Vessel
4.1.2 Valves
4.1.3 Drying
4.1.4 Leak Testing
4.2
Maintenance of the Vessel
4.3
Filling
4.3.1 Handling the Containers
4.3.2 Weight Control
4.3.3 Procedure
4.3.4 Safety Measures in the Factory
4.4
Taking out of Service for Maintenance

18
18
19
19
19
19
20
20
20
22
22
22

22

TRANSPORT

5.1
Specific Precautions for Transport
5.1.1 Cylinders
5.1.2 Drums
5.1.3 Spheres
5.1.4 Drums and Spheres Loading and Unloading
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22
22
22
24
24
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6
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8

USE AT THE CONSUMER'S PREMISES

Types of Installation
Location and Design of Storage Area
Leak Detection
Piping and Safety Devices
Pipework
Prevention of Suckback
How to Obtain Chlorine from a Drum
Vaporisers

RESPIRATORY PROTECTIVE EQUIPMENT

24
24
26
28
28
28
30
30
31

31

7.1
Breathing Apparatus with Filter
7.1.1 The Filter
7.1.2 Filter Saturation
7.1.3 Storage of Filters
7.2
Self-Contained Breathing Apparatus - SCBA

32
32
32
33
34

TRAINING OF THE PERSONNEL

34

REPORTING OF ACCIDENTS

35

10 EMERGENCY ORGANISATION

35

11 REFERENCES

35

12 REFERENCES TO EURO CHLOR GEST RECOMMENDATIONS

36

APPENDIX 1: DRYING OUT OF CHLORINE CONTAINERS

37

Principle:
Equipment:
st
1 Example: Air at 0C Saturated with Moisture in the Barrel
nd
2 Example: Air at 20C Saturated with Moisture Contained in the Barrel

37
37
38
39

TABLE OF FIGURES
FIGURE 1: CYLINDER TYPICAL DRAWING
FIGURE 2: DRUM TYPICAL DRAWING FIRST EXAMPLE
FIGURE 3: DRUM TYPICAL DRAWING SECOND EXAMPLE
FIGURE 4: DRUM TYPICAL DRAWING THIRD EXAMPLE
FIGURE 5: CHLORINE CONTAINER - SAFRAP TYPE
FIGURE 6: CHLORINE CONTAINER - SPHERE TYPE
FIGURE 7: SCHEMATIC VIEW OF A VALVE
FIGURE 8: TYPICAL CYLINDER VALVE
FIGURE 9: TYPICAL DRUM VALVE
FIGURE 10: TYPICAL SPHERE VALVE
FIGURE 11: MANUAL ISOLATING VALVE PV)
FIGURE 12: EXAMPLE OF A TYPICAL INSTALLATION

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7
7
8
8
10
11
14
15
16
17
24
25

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1 INTRODUCTION
The recommendations given in this code represent the various measures
taken by the member companies of Euro Chlor for the construction and
handling of liquid chlorine drums, cylinders and spheres.
Study of chlorine accidents shows that small containers contribute to a
relatively frequent number of minor accidents. Euro Chlor, aware of the
continuing necessity to improve safety, has drawn up this guide.
This recommendation does not replace the national or international regulations
in force, such as the ADR, European Agreement concerning the international
carriage of dangerous goods by road, which should be universally respected
as standard practice (See GEST 74/31 - Tank Containers for the Transport
of Liquid Chlorine under Pressure). In general, they reinforce the
international codes and regulations by adding to them the experience gained
by the chlorine producers of the different countries.

2 TYPES OF CONTAINERS UP TO 4 T CHLORINE

A large variety of containers are presently used but most of the
recommendations detailed below apply to all types.
At first, a brief description of the principal types in use is given. The
advantages and disadvantages are compared to aid the choice of container for
a particular application and also to allow for quick reference to the existing
regulations.
The containers are generally classified into cylinders, drums, and spheroid
containers.
Cylinders of various capacities are in use (less than 100 kg). A typical drawing
is given in figure 1. Construction: forged or welded according to 3.1.5.

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Figure 1: Cylinder Typical Drawing

Drums have a capacity between 500 and 3,000 kg. They are horizontal
cylinders. Typical examples are shown in figures 2, 3, and 4. The ends are
either convex or concave. The valves are either protruding or fully protected by
the container itself. In both cases, the valves are protected by a cover.
Figure 2: Drum Typical Drawing First Example

Welded heads, 2 concave ends, 2 separate openings for the valves.

Removable protection cover for the valves. Inspection and cleaning need
particular attention, particularly due to the sharp angles between ends and
cylinder.

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Figure 3: Drum Typical Drawing Second Example

convex ends, 1 cover plate with two openings for the valves, 1 valve protection
cover. Total protection of both ends. Robust construction.
2 welded heads, 2 concave ends, 1 cover plate with 2 openings for the valves, 1
protection cover.
The sharp angles between ends and cylinder need particular attention for cleaning
and drying.
Figure 4: Drum Typical Drawing Third Example

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Totally forged robust construction. Convex ends, removable end plate allowing for
easy inspection, valves on this concave plate protected with a cover; excellent
protection of the valves.

Any new drum will have convex ends.

Typical dimensions
Capacity kg Cl
500
600
850
1000
2100
3000

Tare kg
265
450
650
650
830
1500

Diameter of the
vessel, mm
700 - 712
720
880
750 - 830
1150
1270

Total length
mm
1350 - 1400
1600
1650
2000 - 2200
2160
2500

Spheres
This category includes vertically standing vessels with valves on a manhole at
the top of the container, normally not in contact with liquid chlorine.

Diameter
Total height
Capacity
Tare

Safrap type
1100 mm
1720 mm
1250 dm
750 kg

Sphere type
1900 mm
2300 mm
3600 dm
1300 kg

See figures 5 and 6.

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Figure 5: Chlorine Container - Safrap Type

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Figure 6: Chlorine Container - Sphere Type

550

500

30
2220
2000

560
50

Unit: mm

CHARACTERISTICS OF THE CONTAINER

Gross weight:
Tare:
Capacity:
Maximum load (Cl2 liq.):
Normal load (Cl2 liq.):
Working pressure:
Test pressure

February 2004

5800 kg
1300 kg
3,6 m
4500 kg
4250 kg
15 kg/cm
25 kg/cm

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3 CONSTRUCTION CODE
3.1

Vessel Construction
The transport vessels should be designed according to international
regulations, ADR, and other national regulations as appropriate. The aim of
this text is to indicate the principal usual rules and the further constraints
which are imposed by the chlorine producers by way of additional safety
measures.

3.1.1 Minimum Design Temperature

This has been set at minus 40C.
3.1.2 Test Pressure
The test pressure should be at least 22 bar(g).
3.1.3 Minimum Wall Thickness
For any cylindrical containers, the wall thickness of the ends should not be
less than the thickness of the cylindrical section.
3.1.4 Material of Construction
The steel should be non-alloyed fine grain steel to meet at minus 40C the
requirements laid down by ADR for road tanks (see GEST 79/76 Road
Tank Wagons for the Transport of Liquid Chlorine under Pressure). To
ensure good conditions for welding, as well as to provide a minimum
thickness for mechanical impact resistance, steels with a low ultimate tensile
strength are required. For example, ultimate tensile strength of the steel at
rupture Rm has to be limited to 600 N/mm. The minimum elongation at
fracture has to be greater than 1.000/Rm (recommendation of ADR) and
preferably 20% for 570 N/mm i.e. 1.150/Rm.
3.1.5 Welds
All welds should be 100% examined by radiography, and found free of flaws.
If radiographic examination is not possible, use other methods like
ultrasonic, magnetic or dye penetrant examination.

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3.2

Accessories

3.2.1 Manhole or Handhole (if any)

The hole should be realised by a pad welded directly to the tank. The manlid
should have two openings for the valves. The gasket between manlid and
manhole or handhole should be trapped.
3.2.2 Valves
3.2.2.1 Valves should preferably be made of steel, stainless steel or Monel.
Cylinders are equipped with one valve screwed on the top.
3.2.2.2 Drums are fitted with 2 valves screwed or bolted directly to the drum, or
onto a handhole cover. The valves are fitted with dip-pipes to reach into
the gaseous and liquid phases. The valve outlets should be aligned with
the dip-pipes.
3.2.2.3 Spheres and drums larger than 1 m.
For new large containers, ADR regulations ask that if capacity 1 m, the
valves should consist of two sections:
An internal security disc or ball, situated below the valve plate,
which closes automatically,
A standard valve, fixed to the valve plate above the disc. The valves
should be capable of remote rapid closure. A cap should be fixed on
every valve.
Note: actually, this requirement is difficult to meet because of space
limitation. This has to be carefully examined for new constructions.
All valves should be of a type agreed for the country of origin. Usual types
are represented on figures 7 to 10.
Figure 7: schematic view
Figure 8: typical cylinder valve
Figure 9: typical drum valve
Figure 10: typical sphere valve: to meet ADR regulation, additional
remote closure device should be added.

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Figure 7: Schematic View of a Valve

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Figure 8: Typical Cylinder Valve

Reference
1b
2
3
4
5
6
7
8
9
10
11
12
13
14
15

February 2004

DESCRIPTION
Body
Insert Seat
Stem
Packing Ring
Gland Follower
Handwheel
Cover nut (Outlet cap)
Gasket
Gland Packing
Bush
Stem Nut (Left hand
thread)
Short chain
Split ring
Circlip
Washer

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Figure 9: Typical Drum Valve

Reference
1
2
3
4
5
6

February 2004

DESCRIPTION
Body
Disc
Outside seal
device
Ring
Gasket
Internal screwed
ring

Reference
7
8
9

DESCRIPTION
Screwed bonnet
Hand wheel
Washer

10
11
12

Hand wheel retaining nut

Inlet dip tube
Outlet cap

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Figure 10: Typical Sphere Valve

Reference
1
2
3
4
5
6
7
8
9
10
11

February 2004

DESCRIPTION
Screw stem
Screw key
Bearing
Stop ring
Handwheel
Packing nut
Packing ring
Packing gland
Outlet gasket
Outlet screwed cap
Stem

Reference
12
13
14
15
16
17
18
19
20
21
22

DESCRIPTION
Body
Gasket
Spring washer
Internal check body
Spring
Support nipple
Ball
Inlet dip tube
Bolt
Stud bolt
Nut

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3.2.3 Protection against Mechanical Damage during Transport and Storage

The valve(s) should always be protected by a cover of heavy thickness
strongly fixed to the vessel.
3.2.4 Relief Valves and Fusible Plugs
The installation of relief valves or fusible plugs is emphatically not
recommended.
If this equipment is imposed for transport out of Europe by the IMDG International Maritime Dangerous Goods Code of 1990 completed with the
amendment 26/91, and the Chlorine Institute regulations, during the road or
rail transport within Europe, it should be completely protected by a strong
steel cover tightly fixed on the vessel or manlid.
3.2.5 Thermal Insulation
Thermal insulation of chlorine drums and cylinders is not recommended.
3.2.6 Handling Consideration
Adequate provision should be made for lifting and moving the containers.
Drums may have rolling bands and lifting lugs as shown on figures 2 to 5.
If rolling bands are fitted, they should be designed to collapse on impact
rather than causing damage to the vessel wall.
Similar considerations apply to lifting lugs.
Care should also be taken to prevent corrosion under the rolling bands by
continuous welding of the band.

4 COMMISSIONING AND LOADING

4.1

Initial Commissioning
Chlorine producers receiving a vessel from the manufacturer or from repair
work should carry out a general inspection of the vessel and of the fittings.
These operations can be carried out either by the chlorine producer or by a
specialist organisation acting on their behalf and under their responsibility.
They should proceed to the following inspection:

4.1.1 Vessel
Examination of the internal surfaces. The following should be excluded:

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Areas of rust or scale

Traces of moisture
Traces of grease or oil.
The joint faces and gasket materials should be checked.
4.1.2 Valves
These should be removed to eliminate all traces of moisture or grease
arising from the machining operation. On reinstallation, components which
should be greased must employ a grease compatible with chlorine
(chlorofluorinated grease).
The correct alignment of dip-pipes should be checked.
4.1.3 Drying
After installing fittings on the vessel with new joint rings suitable for chlorine,
the vessel and the accessories should be dried until a dew point minus than
40C at atmospheric pressure has been obtained on the exit gas, after
allowing sufficient delay for mixing off the gas within the vessel.
See Appendix I for recommended drying procedure.
After drying, the vessel should be maintained under a pressure of 0.2 bar(g),
at least, with dry gas to avoid any ingress of moisture. For cylinders, with
only one valve, adequate drying can be accomplished by successive filling
with dry gas and emptying or by using vacuum. Drying can be accelerated
by warming in an oven.
4.1.4 Leak Testing
Before filling, all of the valves and accessories can be tested in a fashion
which will guarantee complete leak tightness in the conditions of service
after drying. The following test methods can be used:
Test pressure of air at more than 4 bar(g) and less than the maximum
operating pressure with detection of leaks by use of soap and water;
A final test with chlorine or a mixture of chlorine and dry gas with the
joints being checked by the use of an ammonia bottle.
4.2

Maintenance of the Vessel

The objective should be to avoid any deterioration of materials due to the
opening or maintenance.
For guidance one should refer to:

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GEST 79/78 Code of Good Practice for the Operations to be Carried

out before and after Maintenance on Road and Rail Tankers and IsoContainers of Liquid Chlorine
GEST 76/53 Code of Good Practice for Installation, Removal and
Maintenance of Pneumatic Valves on Road and Rail Tankers and IsoContainers for Liquid Chlorine.

4.3

Filling
The container should be filled at a filling installation which generally meets the
requirements laid down in chapter 6 of this recommendation.

4.3.1 Handling the Containers

Cylinders should normally be inspected after every trip to check for any
contamination.
For drums and spheres, the necessity of such an inspection depends on the
confidence in the customer's procedure.
Before opening the containers have always to be carefully emptied and
degassed. After opening for internal inspection, the vessels have always to
be cleaned and dried according to 4.1.3.
If the container has not been opened, one must ensure by prior venting
down that the vessel to be filled contains no residual liquid chlorine.
After filling, the plugs or blank flanges on the valves should be put in place
with new joint rings and their leak tightness confirmed.
Before dispatch, one should make:
A final test on leak tightness and good state of the valves,
A check on the labelling.
4.3.2 Weight Control
To improve safety during transport, specific attention is drawn to the control
of the total weight as described below and the total load should normally not
exceed 1.25 kg of chlorine per litre of capacity within the container, except if
local regulations permit a higher figure (a lower figure may be required for
tropical climates).
For the net weight, it is essential that one takes into account the possible
difference between the tare weight at the moment of filling and the original
tare weight of the vessel.
Deviations in tare weight have to be investigated (see logigramme).

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A typical logigram for drums should be:

CONTAINER
ARRIVAL

Not OK
External visual
examination

DEGASSING AND
PURGING

NEUTRALISATION

OK

Ask supervisor

Abnormal

WEIGHING

CLEANING

DEPRESSURIZING

TESTING
Not OK

OK

Normal
WEIGHING

EMPTYING

Yes

>2% OVER
TARE

SCRAP

DRYING

WEIGHING

No
PERIODIC
RETESTING
No
>2% UNDER
TARE
No
FILLING AND
WEIGHING

NH3 LEAK CHECK

CHECK WEIGHING
LABELLING

STORAGE

Note the possible effect of weight of gaseous chlorine. A second check on

weight should be made on a different weighing machine to prevent any risk
of overfilling.

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4.3.3 Procedure
The safety of the filling operation should be ensured by handling of the
returned containers with a written procedure and a check-list which may
easily be controlled.
4.3.4 Safety Measures in the Factory
The chlorine containers should be stored in a location which is isolated and
protected, that is to say sheltered from risks of collision or of fire or
explosion.
4.4

Taking out of Service for Maintenance

All chlorine vessels sent for maintenance to an external non-specialist
workshop should be initially emptied, vented down and neutralised.

5 TRANSPORT
5.1

Specific Precautions for Transport

5.1.1 Cylinders
Care must be taken to ensure that cylinders are securely anchored for
transport.
Vertical loading has the advantage that the valve is in the gaseous phase,
which reduces the emission in case of a gaseous leak. However, because of
the shape of the cylinders, special provisions are necessary for anchoring
them.
Cylinders may be strapped or chained to rings securely attached to the
vehicle. Palletisation of cylinders is also widely used where the proper
loading and unloading equipment is available.
5.1.2 Drums
The preferred methods of securing drums are to use fixed chocks or
purpose made cradles. These can be used where the customer has suitable
lifting equipment or with self-unloading trucks.
If there is a need to roll the container to the rear of the truck for offloading, a
recommended method of containment in transit is to use chains with front
and rear blocking. Straps should be limited to securing individual ton
containers.

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Wooden chocks or wedges should be placed under each container as an

additional safeguard. The front bulkhead should be reinforced. Rear roll-off

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protection must be provided. A reinforced removable guard rail or a contour

fitting steel chock anchored behind the rearmost containers to the truck bed
with pins or chains is an effective restraint.
5.1.3 Spheres
Large spheres should only be transported on dedicated low bed trucks with
special fixing or clamping systems for the spheres on the bed of the trucks.
5.1.4 Drums and Spheres Loading and Unloading
Lifting beams, travelling electric hoists or fork lift trucks are usually
employed by shipper and customer. Proper design of the lifting beam is
essential. Extreme care must be exercised when operating fork lift trucks.
The preferred method is to use a purpose made lifting beam attachment on
the forks.

6 USE AT THE CONSUMER'S PREMISES

6.1

Types of Installation
The containers may be used in various types of application:
a) Single cylinder or drum arranged to deliver gas.
This type of installation is physically capable of only a low steady rate of
supply or very occasional short periods of high supply rate. A manual
isolating (auxiliary) valve mounted very close to the container is
recommended to prevent moisture ingress when disconnected. See figure
11.
Figure 11: Manual Isolating Valve PV)
PV
PI
Point of Use

Air

Flexible Connection

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b) Multiple Cylinders or Drums Arranged to Deliver Gas.

If a higher demand is anticipated than (a) can satisfy, several containers
can be connected to a common manifold. A manual isolating valve may
be sited at the outlet of the manifold. It is important to establish operating
procedures to safeguard against passage of chlorine in significant
quantities between vessels.
c) Drum Arranged to Deliver Liquid.
Unless the liquid chlorine is to be used directly in the process (which is
not recommended in a small installation), this arrangement usually serves
a vaporiser, so as to supply chlorine gas continuously or intermittently at
a higher rate than it is possible from either (a) or (b). The whole system is
more complex, and requires greater safeguarding. On safety grounds, a
system should never be arranged to draw liquid chlorine from more than
one vessel at a time, because of the risk of accidental transfer of liquid
chlorine between vessels, leading potentially to overfilling. Example of a
typical installation is given in figure 12.

Figure 12: Example of a Typical Installation

Expansion chamber
with rupture disc
PI
PDSL

PV

Absorption
unit

Gas
PDSL

PS

Hot
water

Gas under
pressure

PS
PS
E

Air

Liquid
Point of
use

Vaporiser

TI

TA

Separator

Flexible connection

LEGEND
TI

TA

Liquid storage

Temperature
indicator
Temperature alarm

PS

PI

Pressure switch

Pressure indicator

Flexible
connection
PDSL Pressure difference switch low

PV

Pressure valve

To ensure continuity of supply in (b) or (c) above, a changeover panel can be

provided to switch automatically to fresh vessel(s) when the pressure in the
supply vessel falls to a pre-set pressure. This has to be sufficiently high to
prevent suck-back, and a set pressure of 1 bar gauge or more is usual.

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6.2

Location and Design of Storage Area

In practice, most small storage and use areas are indoors so that containers
are exposed to steady temperature. Outdoor storage of drums and cylinders
not in use should be secure and under light cover to keep off rain.
Chlorine should be kept separate from normal working areas and access
should be limited to people working directly with it. The storage area should
be dedicated to the storage of chlorine, immediately associated equipment
and compatible materials and should be clearly identified.
In the open, the storage areas should be at least 5 m away from flammable
materials. Indoor storage areas and rooms in which chlorine containers are
used should be constructed of substantially non-flammable materials and
should provide shielding against radiant heat in case of fire nearby.
Suitable separation of the store and process plant from the site boundary
gives a good measure of protection to people off-site against the
consequences of plant accidents such as pipe failure.
Sizes of such separation distances will depend upon a number of factors
including the number of containers stored and the rate of consumption, the
size and distribution of the surrounding population, and the space available
on site.
The chlorine area should not be closer than 5 m to a roadway used by
vehicles unless adequate barriers (crash barriers or substantial walls) are
provided. If the walls of the store are intended to provide the impact
protection, the structure should be such as not to collapse on to or damage
the installation. Where vehicles have access into a store for loading and
unloading, adequate high kerbs or other fixed wheel stops should be
provided.
Wherever possible, rooms for storage or use of chlorine should be at ground
level and open directly to open air.
Chlorine containers should not normally be stored below ground level or in
the vicinity of basements. Rooms which are below ground level and near a
chlorine store should not be used as workplaces. The storage should not be
such as to allow the chlorine containers to stand in water.
Vessels should be secured in their working position before being connected
up. Drums should be used resting directly on properly designed chocks or
cradles, and should not be double stacked on drums in use. Cylinders should
be secured upright. They should be should be operated on a first-in / first-out
basis.
Care should be taken not to drop containers, and not to drop other loads on
to them. Only properly designed purpose-made lifting gear recommended by
the chlorine supplier should be used. Fork lift trucks without purpose-made

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adapters must not be used. Cylinders should be transported in suitable

purpose-

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made cylinder trolleys or stillages. Hoists should preferably be arranged so

that loads do not pass over chlorine vessels or pipework which is in use.
6.3

Leak Detection
Chlorine detectors and alarms should be provided in unmanned buildings
housing chlorine drums or vaporisers, and should be considered for cylinder
installations.
Their value outdoors depends on the size of the installation and the manning
levels and response times achievable. Recommended alarm actions are a
distinct local audible alarm and a warning light outside the building.
The detector system should activate the alarm at 3-5 ppm chlorine. Lower
settings are liable to activate the system at every cylinder or drum change
and lead to mistrust in the alarm when it gives a real warning of a
malfunction.

6.4

Piping and Safety Devices

At sites taking liquid chlorine from drums or spheres, consideration should be

given to provide remotely-operable valves, in order to minimise the size of a
release. It is desirable that ventilation should go to an absorption system. The
need for an automatic system arranged to shut off the chlorine supply and the
airchange ventilation when a leak is detected will depend on the likelihood
and size of potential leaks and the proximity of any neighbours. If this
arrangement is provided, it must be possible to switch on and lock on the
ventilation before anyone enters the room to work on the chlorine system.
In all installations the pipework between the supply vessels and the point of
use should be as short as practical. Where a relatively long run is
unavoidable, as much as possible of the run should be low-pressure gas.
If remotely operable shut-off valves are used, they should be as close as
practical to the storage containers. Arrangements should be made and
maintained to operate these valves as appropriate from remote manual
operating points outside the chlorine area or, for an unmanned facility, from
chlorine detectors. Care must be taken to avoid trapping liquid between
valves.
6.5

Pipework
Pipework for lines carrying liquid chlorine or gaseous chlorine under pressure
should be constructed generally in accordance with Euro Chlor GEST 79/81
Dry Liquid Chlorine Piping Systems Located Inside Producer's or
Consumer's Plants. Pipe runs should be kept short and protected against
impact. Plastic pipes should not be used.

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As with other parts of the installation, pipework should be subject to routine

inspection and maintenance. All pipework should be kept clean and dry
inside.

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After any exposure to moisture the pipework should be thoroughly dried; the
joint rings should be changed after any hydraulic test.
For gaseous chlorine at atmospheric pressure or slightly below, plastic
pipeworks (preferably reinforced) may be considered when there is a risk of
moisture. Advice should be sought from the chlorine suppliers on suitable
materials.
All packings, gaskets and diaphragms, and all components of pipes, valves
and fittings should be resistant to the action of chlorine between the
foreseeable extremes of operating temperature and pressure. Gaskets should
never be used for liquid chlorine service.
Flexible connector pipes are often made from copper or alloys which are
subject to work hardening. They should be inspected at each cylinder
change, periodically heat treated and replaced if necessary.
6.6

Prevention of Suckback
Precautions must be taken to avoid damage to cylinders and drums due to
suckback of water or other chemicals present in the reaction or absorption
system.

6.7

How to Obtain Chlorine from a Drum

The correct working position of a drum is with the two valves in a vertical
plane so that one dip pipe goes to the bottom of the drum and the other to the
top.
Therefore, the lower valve always delivers liquid chlorine and the upper
gaseous chlorine.
The inflow of heat from the atmosphere limits the amount of chlorine that
vaporises. Therefore, the normal rate of continuous gas withdrawal from a
drum is limited to 5-10 kg/h.
Higher flow rates can be achieved if withdrawal is intermittent.
When the installation is shut down, the valves on the containers have to be
carefully closed.
Before disconnecting the flexibles, it is recommended to purge them with dry
inert gas. Otherwise, one has to wait at least 20 minutes to eliminate the risk
of liquid chlorine spillage. The pipe should be immediately closed with a blank
or plug.

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Where the installation is shut down for a long period, it has to be fully purged
with dry air or dry nitrogen.
Tightness has to be periodically tested with diluted ammonia bottle.
Use always a correct gasket material and never use the same gasket twice.
See GEST 94/216 Experience of Non-Asbestos Gaskets on Chlorine.
If a valve does not open easily, never use too much force.
Do not use too long a key on drums and spheres. Do not use keys for
cylinders. If you cannot open the valve without too much forces, return the
cylinder to the supplier.
Use key recommended by the supplier.
Never use naked flames in the chlorine area.
The valves should always be either full open or closed.
6.8

Vaporisers
Vaporisers (also known as evaporators) are discussed in a separate GEST
75/47 Chlorine Vaporisers.

7 RESPIRATORY PROTECTIVE EQUIPMENT

This section is an extract of GEST 92/171 - Personnel Protective
Equipment for Use with Chlorine.
Chlorine is a toxic substance which can be rapidly fatal in acute exposure.
Work practices and precautions need to be considered carefully when it is
necessary to enter enclosed storage spaces. The most common risk arises
at operations involving the making and breaking of lines.
Breathing apparatus should always be worn when entering an enclosed store
or chlorine room in which a significant leak has been detected.
In such situations, whilst forced ventilation systems may still be operational,
reliance must not be placed on this alone to disperse the chlorine. This is
because the chlorine detector may be some distance from the source of the
leak and consequently concentrations of chlorine at the leak are always
higher than those detected by the alarm system.
For installations with multi-stage alarms the forced ventilation system will
have been switched off on activation of the high level alarm. Entry will be by
means of personnel wearing breathing apparatus whose function will be to
identify and eliminate the source of the leak.

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The user of a breathing apparatus shall be trained and tested for lung
function.
There are two main types of equipment:
breathing apparatus with filters,
self-contained breathing apparatus.
Both groups use a device: the mask (which is different for non-pressurised
and pressurised systems).
7.1

Breathing Apparatus with Filter

They are made up of two elements:
the mask
the filter (cartridge) connected to the mask

7.1.1 The Filter

The filter, or cartridge, absorbs contaminants on active carbon during
inhalation.
With this type of equipment, protection is obtained only if the four following
conditions are met:
filter or cartridge suitable for chlorine
oxygen content at least 19% volume. Make sure oxygen content is
sufficient
chlorine content under 0.5% volume. For higher chlorine or lower
oxygen concentrations or presence of CO or for extended use,
self-contained breathing apparatus should be worn
carbon monoxide (CO), or substances for which filter is inefficient
must not be present at concentration higher than occupational
exposure level.
7.1.2 Filter Saturation
Filter life depends on the concentration of the contaminating gases and of
the breathing rate. It is also influenced by secondary factors such as
humidity or temperature of the inhaled air.
The effective life of a filter can therefore not be specified.
It is strongly recommended that after any significant chlorine exposure, the
cartridge should be changed.
Due to all these limitations, the cartridge mask should only be used for a
quick, easy operation as shutting down a valve or as an escape mask.
Escape masks must never be used for any intervention!

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7.1.3 Storage of Filters

The filter should not be used after expiry date marked on it by the
manufacturer, which usually occurs, according to the type of filter, between
four to six years after delivery.

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Any unused filter which has been opened must be replaced within six
months unless the mask has been stored in an airtight container.
7.2

Self-Contained Breathing Apparatus - SCBA

This equipment enables the user to work in a highly contaminated
atmosphere without using ambient air.
There are two types of self-contained breathing apparatus:
o Closed-circuit apparatus
The expired air is purified of its carbon dioxide, enriched with oxygen
from a bottle contained within the equipment and reinjected into the
breathing circuit.
o Open-circuit apparatus
The expired air is exhausted through a valve into the ambient air.

8 TRAINING OF THE PERSONNEL

See GEST 74/31 Regulations for Tank Containers for the Transport of
Liquid Chlorine under Pressure
Specific training on chlorine should be periodically given to all the personnel
working with chlorine.
This includes the packers at the filling station, the drivers of the vehicles
dedicated to transporting the containers, and the users. The training schedule
should be formally drawn up and should include classroom training as well as
practical instruction during normal work.
The drivers have to know that they transport chlorine, to possess the chlorine
Tremcard and to know what to do in case of incident, for instance to call the
right emergency team immediately.
For all the other concerned people, the training programme should include:
An understanding of the properties and characteristics of chlorine
An understanding of the possible accidents which could arise during
transport, and the precautions which need to be taken.
The precautions to take in the event of an accident - initial procedures.
Training in the use of safety equipment. An understanding of the national
and/or international emergency procedures and the network set up in
order to provide assistance in the event of need.
This training should be under the control of a competent person who is
specifically responsible for this topic. A proper record of the training should be
kept by the company with a copy to the personal.

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9 REPORTING OF ACCIDENTS
Any accident or other incident involving liquid chlorine should be the subject of
a proper report, even when no liquid chlorine leak results. These reports
should be made out on the standard form provided by Euro Chlor for this
purpose (see GST Form

10 EMERGENCY ORGANISATION
The European chlorine producers have set up an international security
organisation to take account of any accident in which liquid chlorine is
involved. Emergency vehicles are permanently available for going out to the
scene of an accident, and personnel specifically trained in dealing with such
emergencies are available at the request of local authorities. The geographical
layout of the emergency system should be listed amongst the documents in
the possession of the driver, as well as the initial steps to be taken in the event
of an accident whilst waiting for assistance.
The driver should be trained in the application of these emergency plans in
order to be able to call for their application by the competent authorities.
The emergency vehicles must be equipped with the special material needed
for all kind of chlorine containers used in their geographic zone. The
emergency team has to be aware of the existence of special devices to isolate
a leaking valve or even to totally enclose a leaking cylinder.

11 REFERENCES
Following documents were largely used for the preparation of present
recommendation
a)
b)
c)
d)

February 2004

Le chlore (October 1996)

Health and Safety Executive - Guidance Note on chlorine from drums
and cylinders (1988)
Chlorine Institute - Pamphlet 76 (August 81)
Dr M. Tyblewski - Umwelttechnik 22 (2) 46 (April 1988).

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12 REFERENCES
TO
RECOMMENDATIONS

EURO

CHLOR

GEST

GEST 74/31 Tank Containers for the Transport of Liquid Chlorine

under Pressure
GEST 75/47 Chlorine Vaporisers
GEST 76/53 Code of Good Practice for Installation, Removal and
Maintenance of Pneumatic Valves on Road and Rail Tankers and IsoContainers for Liquid Chlorine
GEST 79/76 Road Tank Wagons for the Transport of Liquid Chlorine
under Pressure
GEST 79/78 Code of Good Practice for the Operations to be Carried
out before and after Maintenance on Road and Rail Tankers and IsoContainers of Liquid Chlorine
GEST 79/81 Dry Liquid Chlorine Piping Systems Located Inside
Producer's or Consumer's Plants
GEST 92/171 - Personnel Protective Equipment for Use with Chlorine.
GEST 94/216 Experience of Non-Asbestos Gaskets

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GEST 80/84 APPENDIX Page 1 of 3

3rd Draft of the 5h Edition

APPENDIX 1: DRYING OUT OF CHLORINE

CONTAINERS
Principle:
Drying out is carried out by displacing air which is more or less wet contained
within the barrel by means of dry air (dew point less than minus 40C at
atmospheric pressure). It is carried out on the assumption that the barrel no
longer contains liquid water (walls carefully wiped down following the previous
operations of inspection).
Equipment:
The installations comprise:
1. An air compressor, non-lubricated, in order to avoid the contamination of
the air dessiccator with oil or contamination of the barrel itself.
This equipment includes the following accessories:
A water heat exchanger which will keep the air temperature at
approximately 30C before the drier
A water separator and air reservoir
2. An air dryer to provide the dry air required (dew point minus 40C)
including filter.
Operation of the installation
Taking into account the arrangement of pipework within the barrel, it can
appear very difficult to displace all the moist air within the container by a
simple dry air purge. It is, therefore, necessary to carry out a number of
successive complete purgings of the vessel.
The theoretical number of purges required is calculated for an initial air
temperature of 0C or 20C for example, and assuming that the air is
saturated (which is an unfavourable circumstance).
The number of purges which are actually necessary is found to be very little
different from the theoretical requirement, provided that sufficient time is
allowed before each purge for equilibrium conditions to be attained.

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GEST 80/84 APPENDIX Page 2 of 3

3rd Draft of the 5h Edition
1st Example: Air at 0C Saturated with Moisture in the Barrel
Pressure supplied by a compressor at 7 bar(a).
1st purge
For 1 m of air saturated at 0C, i.e. a water content of 4.868 g/m3, 6 Nm of
dry air with a dewpoint of minus 40C (0,86 m3 of air under a pressure of 7
bar(g)), containing 0,117 g of water per Nm, are discharged into the barrel
giving 7 Nm of gas mixture at atmospheric pressure, or 1 m at a pressure of
7 bar(a).
The water content of the mixture is:
1 m * 4,868
6 m * 0,117
Total

=
=

4,868
0,702
5,570

That is: 5,570 / 7 = 0,7957 g/m corresponding to a dewpoint of minus21C.

2nd purge
The calculation can be carried out in the same manner but beginning with a
moisture content of air 0,7957 g of water per m.
The water content of the mixture becomes:
1 m * 0,7957
6 m * 0,117
Total

=
=

0,7957
0,702
1,4977

That is 1,4977 / 7 = 0,2129 g/m corresponding to a dewpoint of minus 34C.

3rd purge
Beginning with air at 0,2129 g/m
The water content of the mixture becomes:
1 m * 0,2129
6 m * 0,117
Total

=
=

0,2129
0,702
0,9149

That is: 0,9149 / 7 = 0,1307 g/m corresponding to a dewpoint of minus 39C.

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GEST 80/84 APPENDIX Page 3 of 3

3rd Draft of the 5h Edition

2nd Example: Air at 20C Saturated with Moisture Contained in the Barrel
Pressure supplied by a compressor at 7 bar(a)
1st purge
For 1 m of air at 20C, i;e; a water content of 17,148 g/m,. 6 Nm of dry air
(0,86 m at 7 bar(a) pressure), with a dewpoint of minus 40C, containing
0,117g of water per Nm are discharged into the barrel giving 7 Nm of gas
mixture at atmospheric pressure , or 1m at a pressure of 7 bar(a).
The water content of the mixture is:
1 m * 17,148
6 m * 0,117
Total

=
=

17,148
0,702
17,850

That is: 17,850 / 7 = 2,55 corresponding to a dewpoint of minus 8C.

2nd purge
1 m * 2,55
6 m * 0,117
Total

=
=

2,55
0,702
3,252

The water content of the mixture is: 3,252 /7 = 0,464 corresponding to a

dewpoint of minus 27C.
3rd purge
1 m * 0,464
6 m * 0,117
Total

=
=

0,464
0,702
1,166

The water content of the mixture is: 1,166 /7 = 0,165 corresponding to a

dewpoint of minus 37C.
It can be seen that in the two cases the approach to a dewpoint of minus 40C
is almost the same with three purges, even if one assumes that the air at the
beginning of the operation was saturated with water vapour which itself is very
rare in Western Europe.
After the 3rd purge, it is necessary to maintain the barrel under a pressure of
air for a minimum of one hour and then, by further venting down, to confirm,
by dew point measurement, that the drying operation has been sufficiently
well carried out.

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Industrial consumers of chlorine, engineering and equipment supply

companies worldwide and chlorine producers outside Europe may establish a
permanent relationship with Euro Chlor by becoming Associate Members or
Technical Correspondents.
Details of membership categories and fees are available from:
Euro Chlor
Avenue E Van Nieuwenhuyse 4
Box 2
B-1160 Brussels
Belgium
Tel:
Fax:
e-mail:
Internet:

February 2004

+32 2 676 7211

+32 2 676 7241
eurochlor@cefic.be
http://www.eurochlor.org

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