Cl2safehandling

Aditya Birla Chemicals (India) Limited

SAFE
HANDLING OF
CHLORINE
1

1


CHLORINE

1

2


Safe Use of Chlorine

CHLORINE

1

3


Use of Chlorine

CHLORINE

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Water purification.
Bleaching of textiles.
Pulp & Paper
Crop Protection (As pesticides & insecticides)
Pharmaceuticals and medical equipments.
PVC and plastics.
Refrigerants (F11, F12, F21, F22).
Industrial solvents : (CTC, MCB, and TCE)
Treatment of Cooling Water.
Rocket fuel (Chlorine Trifluride).

Chlorine is involved in over 50% of all commercial chemistry
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4


Unsafe use of Chlorine

CHLORINE

1 1 Vol. Liquid Chlorine =

457.6 Volumes of5
Chlorine gas.


Properties of Chlorine
Physical state
Colour

:
:

Odour
Taste
Corrosivity
Water solubility
Stability during transportation
Boiling point
Melting point
Specific gravity
Threshold limit

:
:
:
:
:
:
:
:
:

1

Gas or liquid
Greenish Yellow (gas)
Clear amber (Liquid)
Pungent, suffocating.
Bitter
Corrosive.
Slightly soluble
Stable
-34.5oC (1 atm)
-100.98oC (1 atm)
1.4 at 20oC.
1PPM (3mg/m3)
7


What is Threshold Limit ?

TLV is average concentration of the substance in
ambient air for a normal 8 Hours working or 40 Hrs
work week to which nearly all workers may be
repeatedly exposed, day after day without adverse
effects:
Fatal dose

1

:

1000 ppm (1 ppm = 3 gm/m3)

8


Chlorine Hazard at atmospheric
condition
Sl.
No.
1
2

Chlorine concentration in
air (PPM)
3.5
15.10

3

30.20

Sl.
No.
1

Chlorine concentration in
air (PPM)
1

2

4.00

3
4

40 to 60
1000

1

Degree of hazards
Least detectable odour.
Least amount required
imitation of throat
Least amount required
coughing.

to

cause

to

cause

Degree of hazards
TLV-Least amount which can be
inhaled safely – shown workdays for
a life time.
Maximum amount that can be
breathed for one hour without serious
effect.
Amount dangerous in ½-1 hour.
Amount likely to be fatal after a few
deep breathes.

9


Volume - Temperature relation in a
container of Chlorine
110
100

70

90

60

80

50

70

40

60

30

50

20

40

10

30

0

20

-10

10

-20

0

V
o
l
u
m
e
%

80

-30
8.8

83

85

Temperature (oC) -25

-15

-5

Volume %

T
e
m
p
e
r
a
t
u
r
e

87.2 89.3 90.3 92.2 95.5 97.8 99.8 101
5

15

25

35

45

55

65

70

With increase of temperature of container the volume of liquid increased rapidly
and at 70oC it crosses the capacity of container and damage of container is possible
causing SERIOUS HAZARDS.

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10


Temperature – vapour pressure
relationship of liquid chlorine
50

110
100
90

40

80

Vapour

70

30

60

Pressure

50

20

40
30

10

20
10

0

0

Vap. Pre Kg/cm2
Temperature (oC)

1

6.84
20

T
e
m
p
e
r
a
t
u
r
e

8.95 11.51 14.51 18.16 22.38 27.25 32.84 39.23
30

40

50

60

70

80

90

100

Vapour pressure of Liquid Chlorine increases rapidly with increase of
temperature and bursting of container is always possible at higher temp.
creating SERIOUS HAZARDS.

11

Chlorine Cylinder Internals
Gas Eduction Pipe
Chlorine Gas

Upper
Valve (Gas)
Lower Valve
(Liquid)
Liquid Chlorine
Liquid Eduction Pipe
Valve Bonnet

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12


Detection of Chlorine Leakage Point

Take a stick with a cloth bulb at one end. Soak the cloth bulb with aqua
ammonia and hold it close to the area of suspected leak. A white cloud will
indicate if there is any Chlorine leakage and the source thereof.

Note :
• Avoid contact of ammonia with brass parts.
• Use commercial 26oC Baume aqua ammonia.

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Procedure to be followed for safe handling of
Chlorine Containers
UNLOADING OF FILLED CONTAINERS:
Safe procedure to be
Precautions to be taken
What can happen if precautions are
followed
not taken
a) Unload
chlorine a) Do not remove valve a) If valve hoods are not firmly kept
containers
with
protection hoods before
in position, any accidental impact
mechanical
or
unloading.
on valves may damage the valves.
electrical hoist.
Liquid Chlorine will start coming
out which cannot be controlled.
b) If the above is not b) Do not drop containers b) Container wall will get dented
available
unload
on to hard ground
and become weak or may get
containers manually
where pebbles or any
punctured.
on to a slanted Ramp
iron rods or beaks are
from the truck.
lying.
c) After unloading check c) White fumes indicate c) Any Chlorine leakage will
the container
leakage of Chlorine gas.
increase with time if it is not
In case any such leakage
corrected in time.
is found, take suitable
action.

N.B. –DO NOT DROP CONTAINERS ON HARD SURFACE. DO NOT REMOVE
1 VALVE HOOD UNTIL CONTAINER IS TO BE DISCHARGED.
16


Chlorine Containers
UNLOADING OF FILLED CONTAINERS:

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Chlorine Containers
STORAGE:

1

What can happen if precautions
followed
are not taken
a) Store the containers in a) Keep containers away from a) Excessive
heating
may
a covered shed only.
heat or sun or any other
tremendously increase the
source of heat like hot
Chlorine pressure inside the
water, steam, direct flame
container resulting in its
and furnace.
bursting.
1) Do not load or store
Chlorine container with
explosives, acids and
articles of inflammable
nature.
2) Do not store containers It will spoil the container paint
in wet and muddy areas. and start corrosion of container
wall.
b) Use of containers
b) Use containers in the order
of their receipt i.e. FIFO
(First In First Out)
C) Chlorine Cylinders
a) Above two layers there will
should not be stored
danger of falling of cylinders.
above two layers
b) If leakage is found, then it will
be difficult to attend

19


Chlorine Containers
STORAGE:

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Chlorine Containers
WHILE CONNECTING CONTAINER TO LIVE SYSTEM
Safe procedure to be followed


a) Connect Chlorine container a) It is very much
only to a process piping
essential to avoid
where
an
appropriate
back flow of any
inverted U-type barometric
liquid
from
the
leg is provided. The height
process
into
the
of barometric leg should be
container
by
h=34÷d ft. where d is the
siphoning, when the
density of process liquid in
latter is emptied out.
gm/cu cm (lowest in case of
change during process)

What can happen if
precautions are not taken
a) There is every possibility
of an explosion taking
place
inside
the
container.
A Unwanted corrosion
of the container will take
place.

b) Remove valve protection b) In this way Chlorine b) If this is not followed,
hood.
Keep container on
gas can be taken out
only liquid Chlorine will
horizontal place in such a
from upper valve
come out from both the
way that the two valves are in
and liquid chlorine
valves.
a vertical plane.
from lower valve.

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21

Chlorine Cylinder Internals
Gas Eduction Pipe
Chlorine Gas

Upper
Valve (Gas)
Lower Valve
(Liquid)
Liquid Chlorine
Liquid Eduction Pipe
Valve Bonnet

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22


Chlorine Containers
WHILE CONNECTING CONTAINER TO LIVE SYSTEM
followed
C) For proper and leak
proof connection, use:
- seamless copper tube
OD-12mm, 10mm or
6mm.
- OS Nipple
- CS Clamp
- Lead washer.


Tighten the clamp properly on
the container valve and the
connecting nipple to make a leak
proof joint.
1) Use lead washers. Do not
use rubber washers or
steam gasket washers.
2) Do not use rubber hose for
Chlorine gas transfer. Use
seamless copper tube and
C.S. Piping.
D) Check the connection Open the container valve and
with dilute ammonia close it immediately for checking
solution
for
any leakage. If leakage is observed
leakage.
tighten the clamp and leakage
will stop.

Note :

1

not taken
Any leakage of Chlorine will corrode
the valve outlet which may be
damaged the valve outlet and
become uncontrollable.
1) Rubber or other washers get
damaged
easily
causing
Chlorine leakage.
2) Rubber hose in cold Chlorine
gas gets hardened and cracks.
It may burst any time resulting
in an accident.
If leakage is not checked before
hand, then after opening the valve
fully, there will be a lot of gas
nuisance from the joint, if the same
is leaking.

1) DO NOT USE RUBBER HOSE FOR LIQUID CHLORINE SERVICE.
2) USE SEAMLESS COPPER TUBE OR C.S. PIPING ONLY.
24
3) USE LEAD WASHERS.


Chlorine Containers
CHLORINE GAS TRANSFER


not taken
a) Use Chlorine container as a) Do not keep container valve a) In such a case due to high velocity
a storage vessel. Operate
in slightly open position for
of Chlorine gas, the valve seat
container valve to full
Chlorine gas flow control.
may get damaged by erosion.
open or full closed
Valve will leak even in closed
position.
position.
b) Use proper size of valve b) Do not use loose spanner or
spindle spanner.
pipe wrench.
1. Do not apply too much
force while operating the
valve.
2. Keep one spindle spanner
always fitted on the valve
on which connection has
been given.
c) Provide regulating valve Appropriate control valves
for Chlorine gas flow should be fitted to the
control
process pipe lines.

1

Spindle head may get rounded
causing
inconvenience
while
operating, specially when there is
some leakage.
1. It may twist and damage the
spindle.
2. It is quite helpful to close the
valve immediately in case a
sudden leakage develops.
Uncontrolled
quantity
of
Chlorine will enter your
process
which may create
problems.

25


Chlorine Containers
CHLORINE GAS TRANSFER


d) Provide a pressure gauge of It should be provided between
range 0 to 25.0 Kg/cm2 with the Chlorine container valve
one isolation valve.
and the regulating valve. It is
necessary to establish that the
container is being emptied
properly
when
pressure
comes down to zero.
A
Chlorine gas pressure of 0-0.5
Kg/cm2 should be left inside
the
container
before
disconnecting.
e) Do not heat Chlorine
container with hot water,
steam or direct flame, to
take out Chlorine gas.

Chlorine will come out
automatically
under
the
normal
atmospheric
temperature in gaseous form.

not taken
If the container is emptied out
completely
but
still
remains
connected to a system, a temporary
vacuum is created inside the
container due to lowering of
atmospheric temperature and liquid
from the process may get sucked into
the container if a barometric leg is
not provided.

Due to excessive heating pressure of
Chlorine gas inside the container will
increase tremendously which may
become very dangerous.
Container paint will get spoiled and
cylinder wall will get corroded.

Note 1.
2.

1

DO NOT USE CHLORINE CONTAINER VALVE FOR FLOW CONTROL.
DO NOT HEAT CHLORINE CONTAINER FOR TAKING OUT CHLORINE
GAS.

27


Chlorine Containers
DISCONNECTION AND RETURN OF EMPTY CONTAINERS
What can happen if
followed
precautions are not taken.
a) As soon as Chlorine a) See that pressure in the gauge has a) Any other liquid coming
has been consumed,
reduced to 0.0.5 Kg/cm2. It shows that
inside the container may
disconnect
the
Chlorine has been consumed.
cause explosion or chocking
2
container from the a1) Leave pressure of 0-0.5
Kg/cm of
of the container.
process.
Chlorine gas in the cylinder to avoid
back flow of any liquid from the
system.
a2) Close the container valve fully. Then
close the flow regulating valve. Loosen
the clamp to release Chlorine gas
pressure inside the connecting tube.
b) Fix the valve outlet b) Valve outlet nuts and protection hoods b) Due to loose fittings these
nuts and the valve
are to be fitted firmly. Make a check parts may fall apart during
protection hood and
chart of material for each container transportation and valves
remove
the
and fill it up while returning.
will be unprotected and
container.
under unsafe condition.
c) Make
proper c) Give correct serial number of c) If correct serial numbers are
challan of the empty
containers being returned.
not mentioned it becomes
containers
being c1) Mention that valve outlet nuts and difficult to maintain proper
hoods are fitted on the containers.
records.
1returned.
28


Chlorine Containers

NOTE :
1. LEAVE A PRESSURE OF 0-0.5 Kg/CM2 OF
CHLORINE GAS INSIDE THE CONTAINER WHEN
IT HAS BEEN CONSUMED.
•

1

VALVE HOODS SHOULD ALWAYS REMAIN IN
POSITION EXCEPT WHEN CONTAINER IS
BEING USED.

29


Chlorine Containers

LOADING OF TONNERS ON TRUCKS


What can happen if
precautions are not taken.

a) Load chlorine container on
truck with mechanical or
electrical hoist.
b) If above is not available People loading containers Containers may slip causing
load manually through manually should use safety accident and injury to people
slanted ramp.
shoes. Loading should be handing containers.
done carefully.

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Chlorine Leakage

As soon as there is any indication of the presence of chlorine in
the air immediate action should be taken to locate the leak. This
is best done with the help of acqua ammonia. Tie a cloth to the
end of a stick, soak the cloth with aqua ammonia and hold it
close to the suspected area. A dense white smoke of Ammonium
Chloride develops which will reveal the point from which the
Chlorine is escaping.

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Chlorine Leakage Management

•
•

1

Take immediate steps to mitigate the situation as soon as
there is any indication of presence of Chlorine in the air.
Chlorine leaks always get worse, if not attended promptly.
If the leak is major one, all persons in the path of the gas
must be warned to leave the area and asked to keep on
the wind ward side of the leak and higher than the leak.
Since gaseous Chlorine is 2½ times heavier than air, it
tends to lie close to the ground.

32


•

WATER SHOULD NEVER BE SPRAYED ON A
CHLORINE LEAK. If it is done, will make the leak worse
because of corrosive action of wet chlorine. Moreover heat
from water increases evaporation rate of Chlorine.

•

If a container is leaking in such a position that chlorine is
escaping as a liquid, the container should be turned so that
Chlorine gas escapes.
This reduces the hazards
tremendously due to the following reasons:

•

The quantity of the gas escaping from a gas leak is about
1/15th of the amount that escapes a liquid leak through the
same size hole.
11 Vol. Liquid Chlorine =

457.6 Volumes of 33
Chlorine gas.


•

The severity of a Chlorine leak may be mitigated by reducing
the pressure of the leaking container. This may be done by
absorbing Chlorine gas (not the liquid) in a solution of
caustic soda or soda ash or Hydrated lime slurry. Caustic
soda is recommended as it absorbs chlorine more readily. If
Hydrated lime is used, the slurry must be continuously
agitated for chlorine absorption.

•

Availability of Safety kit for tonner/cylinder at site is also
very helpful.

1

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LEAKAGE FROM CHLORINE CYLINDER VALVE
Valve gland: Leakage around valve stem can generally be stopped by turning the
packing nut clockwise about half turn. If once repeated, this does not help,
or if the leak is of really serious nature, the container should be removed
outside. It is desirable that the chlorine leaves the cylinder in gaseous rather
than liquid form, since the natural chilling by evaporation will soon
substantially reduce the escape of chlorine. Therefore cylinders should be
stood up right and the tonne container be scrolled that the valves are in a
vertical plane with the leaking valve upward.
.
Valve seat
:
Fix valve cap. If this is not possible due to
excessive pressure then apply valve clamp.
.Valve inlet threads
.Valve seat

1

: Use Valve cover and tie rod assembly from
tonner safety kit.
: Use chain and yoke assembly from tonner
safety kit.

35



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First Aid

Contact with liquid chlorine or with a strong concentration of
gaseous chlorine can cause injury to eyes, skin and mucous
membranes.
Liquid chlorine causes severe irritation and blistering of the
skin. Clothing contaminated with liquid chlorine continues to
give off chlorine gas and irritate the body until all the liquid has
evaporated.
Therefore, contaminated clothing should be
removed immediately and the exposed parts of the body washed
with a large amount of water.
Inhalation of gaseous Chlorine can cause respiratory injury
ranging from irritation to death.
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First Aid

Treatment:
In all cases, Immediately remove the patient from the contaminated area,
immediately begin appropriate treatment. Never give anything by mouth to
an unconscious patient.

Inhalation:
If the patient is breathing, place him in comfortable position, keep him warm
and at rest until a physician arrives. It breathing is difficult, administer
oxygen if equipment and trained personnel are available.
Automatic artificial respiration is considered preferable to manual, but only
when administered by an experienced operator.

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First Aid

Eyes:
If even small quantities of Chlorine have entered in the eyes, flush eyes
immediately with copious amounts of lukewarm running water for atleast 15
minutes. Hold the eyelids apart forcibly to insure complete irritation of all
eye and lid tissues.
Never attempt chemical neutralization. Do not give any medication except
under specific intimation from a physician.

Skin:
Get patient under a shower immediately remove clothes while the shower is
running wash the skin with large quantities of soap and water.
Do not attempt to neutralize Chlorine with chemicals. Do not apply salves or
ointment except as directed by a physician.

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First Aid

Throat Irritation:
Drinking milk may help relieve the discomforts of throat irritation from
Chlorine exposure.

Coughing:
A mild stimulant such a hot coffee or hot tea is often used for relief.

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First Aid

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43


TIPS FOR TRUCK DRIVERS

• Do not park the vehicle in the sun.
• Avoid driving the vehicle through thickly populated areas.
• Chlorine tonners transported in vehicle shall be blocked or braced and be so secured
to prevent movement, striking each other or falling down.
• Do not carry any other article of highly flammable or corrosive nature with Chlorine
Tonners.
• In case of any emergency, inform the Police/Fire Brigade/Chlorine supplier.
• If the emergency cannot be tackled then drive the vehicle to an isolated open place so
that damage to life and property will be minimum.

1

44


TIPS FOR PUBLIC

• Do not panic. Chlorine does not burn or explodes.
• Avoid deep breathing when Chlorine is present in the atmosphere.
• Go indoors and close the doors and windows of the house and switch off the
ventilation system.
• Move to the upper floor if in a multi storey building.
• Cover the face with a wet towel for additional protection.

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45


TIPS FOR CHLORINE CONSUMERS
• Use tonners on “first come first used” basis.
• Do not heat the Chlorine Containers. This may lead to serious accidents and
even rupture of containers.
• Use tonner key for operating the tonner valves.
• Never use plastic tubing for Chlorine service. Use copper tubing with stand
fittings.
• Install a BAROMETRIC LEG in the system.
• Keep a solution of Caustic Soda/Soda Ash/Hydrated Lime Slurry in a tank
ready for neutralization of Chlorine in emergency,
• Keep a tonner/cylinder safety kit always handy.
• Pressure in a Chlorine Container is not a measure of quantity in the container.
At a given temperature, the pressure in a container will be the same whether
the quantity is 1 Kg. Or 900 Kgs.

1
• Send your operators for training at your supplier’s works.46


TIPS FOR CHLORINE CONSUMERS

Chlorine
Caustic Water
Soda
Water
container
Soda Volume
Ash
Volume
capacity (Kg) Weight
Ltr
Weight
Ltr
(Kg)
(Kg)
45
58
182
136
450

Hydrated
Lime
Weight
(Kg)
58

Water
Volume
Ltr
566

68

90

270

220

680

82

815

900

1160

3680

2720

9050

1160

11350

• A suitable tank to hold the solution should be provided in a convenient
location.
• Chlorine should be passed into the solution through a suitable piping
with a perforated distributer at the end and appropritely weighted to hold
it submerged under the surface.
• The container should not be immersed in the tank.

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EDUCATE ON CHLORINE SAFETY

1

48

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