Chlorine Handling Training Manual

CHLORINE HANDLING TRAINING
FOR TRAINING PURPOSES ONLY

Version: July 2004
PREPARED BY
P. Smit
psmit@watertek.co.za
www.watertek.co.za
Chlorine Handling Training Course
CHLORINE HANDLING TRAINING

TABLE OF CONTENTS
1 MODULE 1 INTRODUCTION...................................................................7
1.1 Why it is important to understand this module.........................................................7
1.2 Objective ......................................................................................................................7
1.3 Learning guide.............................................................................................................7
1.4 A description of chlorine ............................................................................................7
1.5 Harmful effects of chlorine .........................................................................................8
2 MODULE 2 CHLORINE CYLINDERS .....................................................9

2.1 Why it is important to understand this module.........................................................9
2.2 Objective ......................................................................................................................9
2.3 Learning guide.............................................................................................................9
2.4 Introduction .................................................................................................................9
2.5 The Chlorine Cylinder .................................................................................................9
2.6 The standard chlorine valve ..................................................................................... 10
3 MODULE 3 HANDLING AND STORAGE OF CHLORINE

CONTAINERS .......................................................................................... 12
3.1 Why it is important to understand this module....................................................... 12
3.2 Objective ....................................................................................................................12
3.3 Learning guide........................................................................................................... 12
3.4 Introduction ............................................................................................................... 12
3.5 Handling of chlorine cylinders ................................................................................. 13
3.6 Storage of chlorine cylinders ................................................................................... 14
3.7 Transport of chlorine containers by road ................................................................ 15
4 MODULE 4 PLANT LAYOUT ............................................................... 17

4.1 Why it is important to understand this module....................................................... 17
4.2 Objective ....................................................................................................................17
4.3 Learning guide........................................................................................................... 17
4.4 The effect of temperature on chlorine cylinders ..................................................... 17

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4.5 Optimum plant layout................................................................................................ 18
4.6 First Aid Kit and Emergency Equipment ................................................................. 20
5 MODULE 5 SAFETY CLOTHING AND EQUIPMENT.......................... 21

5.1 Why it is important to understand this 21
5.2 Objective ....................................................................................................................21
5.3 Learning guide........................................................................................................... 21
5.4 Introduction ............................................................................................................... 21
5.5 Safety Clothing and Equipment ............................................................................... 21
6 MODULE 6 DETECTING CHLORINE LEAKS ..................................... 24

6.2 Objective ....................................................................................................................24
6.3 Learning guide........................................................................................................... 24
6.4 Introduction ............................................................................................................... 24
6.5 Equipment needed for the detection chlorine leaks ............................................... 24
6.6 The most common places where chlorine appears ................................................ 26
7 MODULE 7 CONNECTING / DISCONNECTING STANDARD

CHLORINE VALVES ................................................................................ 27
7.2 Objective ....................................................................................................................27
7.3 Learning guide........................................................................................................... 27
7.4 Introduction ............................................................................................................... 27
7.5 Disconnecting chlorine containers .......................................................................... 28
7.6 Connecting chlorine cylinders ................................................................................. 29
8 MODULE 8 DEALING WITH PROBLEM LEAKING VALVES AND

SYSTEMS ................................................................................................. 33
8.1 Why it is important to understand this ................................................................... 33
8.2 Objective ....................................................................................................................33
8.3 Learning guide........................................................................................................... 33
8.4 Introduction ............................................................................................................... 33
8.5 Dealing with stuck valves ......................................................................................... 34

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8.6 Dealing with leaking valves ...................................................................................... 35
9 MODULE 9 HANDLING CHLORINE EMERGENCIES ........................ 37

9.2 Objective ....................................................................................................................37
9.3 Learning guide........................................................................................................... 37
9.4 Handling a chlorine incident..................................................................................... 37
9.5 Evacuation procedure ............................................................................................... 38
9.6 Chlorine incident investigation ................................................................................ 38
9.7 Fires............................................................................................................................ 39
10 MODULE 10 FIRST AID..................................................................... 40

10.2 Objective ....................................................................................................................40
10.3 Learning guide........................................................................................................... 40
10.4 Introduction ............................................................................................................... 40
10.5 Rendering First Aid ................................................................................................... 40
11 MODULE 11 EMERGENCY KIT A ................................................. 43

11.2 Objective ....................................................................................................................43
11.3 Learning guide........................................................................................................... 43
11.4 Introduction ............................................................................................................... 43
11.5 Chlorine cylinder leaks ............................................................................................. 43
11.6 Contents of the EMERGENGY KIT A and their uses ........................................... 44
11.7 Procedure to fit the safety hood unit for any type of leak at the cylinder valve ... 45
11.8 Procedure to fit leak patch unit on cylinder with hole in side wall ........................ 46
11.9 Side patch unit parts list ........................................................................................... 47
12 MODULE 12 FITTING THE SAFETY HOOD ..................................... 48

12.2 Objective ....................................................................................................................48
12.3 LEARNING GUIDE ..................................................................................................... 48
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12.4 Introduction ............................................................................................................... 48
12.5 The procedure for fitting the safety hood ................................................................ 50
12.6 Conclusion ................................................................................................................. 51
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List of Diagrams
Diagram 1 - Example of a chlorine cylinder ..............................................................................9
Diagram 2 - Cross section of a chlorine cylinder .................................................................... 10
Diagram 3 - cross section of a standard chlorine valve .......................................................... 10
Diagram 4 - Hand trolley for moving chlorine cylinders .......................................................... 13
Diagram 5 - Suggested storage pattern for chlorine cylinders ................................................ 15
Diagram 6 - Chlorine cylinders correctly secured for road transportation ............................... 16
Diagram 7 - Cylinder mounted chlorinator .............................................................................. 19
Diagram 8 - Manifold mounted chlorination system................................................................ 19
Diagram 9 - Plastic squeeze bottle......................................................................................... 25
Diagram 10 - Side view of valve to flexible connection ........................................................... 30
Diagram 11 - Cross section of the serpentine nut .................................................................. 30
Diagram 12 - Valve Yoke .......................................................................................................31
Diagram 13 - Cross section of a close coupled chlorinator connected via a valve yoke ......... 31
Diagram 14 - Standard Chlorine Valve ................................................................................... 34
Diagram 15 - Universal safety hood (Unit part list) ................................................................. 44
Diagram 16 - Side leak patch unit (parts list).......................................................................... 46
Diagram 17 - Other elements Parts List ................................................................................. 47
Diagram 18 - Safety hood in position ..................................................................................... 50
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1 MODULE 1 INTRODUCTION
1.1 Why it is important to understand this module

Before any staff would be allowed to repair chlorine leaks they would have to have a
very good understanding of chlorine, its properties and how it will react under various
conditions as well as the dangers that it poses.
1.2 Objective
Given A learning guide and assistance of a facilitator.
Action You must be able to:

i. Describe chlorine in both forms (gas and liquid)
ii. Describe the harmful effects of chlorine.
Standard All questions in the Criterion Test must be answered 100% correct.
1.3 Learning guide

The learning guide has been designed to provide you with the knowledge needed to
complete the Criterion test at the end of each module.
1.4 A description of chlorine

Chlorine exists in large quantities combined with sodium in what we know as common
salt. Commercial chlorine is manufactured via the electrolysis of a salt solution. Its
chemical formula is Cl2 and it is used in the manufacturing of a wide range of products
relating to water purification, in the production of disinfectants, insecticides and in the
manufacturing of some plastics.
1.4.1 Chlorine Gas

Chlorine gas is a greenish-yellow coloured gas with a strong and sharp odour. It is
two and a half times heavier than air with the result that it escapes from a container or
system, it will tend to seek the lowest level in the building or area in which the leak
has occurred. Chlorine gas is only slightly soluble in water, but reacts with ammonia
vapour to produce a dense white cloud. This property of chlorine gas is used for the
detection of chlorine leaks.
1.4.2 Chlorine Liquid

Chlorine gas is liquefied by refrigeration and compression during the manufacturing
process. It is then kept under pressure (6 bar) in storage tanks in order to maintain its
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liquid form, before being pumped into cylinders or portable tanks or road tankers.
Chlorine liquid is amber in colour.
Large quantities of chlorine gas can be transported in the liquid form because it takes
only a very small volume of liquid to yield a large volume of chlorine gas. One volume
of chlorine gas yields about 460 volumes of chlorine gas.
When chlorine vaporises the remaining liquid cools and if vaporisation is very rapid,
a freeze line of condensed water will become visible on the outside of the container.
1.5 Harmful effects of chlorine
1.5.1 Chlorine gas is highly toxic (poisonous) and exposure to this gas will result in
shortness of breath and coughing. In its more extreme form, exposure to chlorine gas
can lead to irritation of the throat and chest and in the end lead to death by
suffocation.
1.5.2 Chlorine liquid, if it comes into contact with the skin or eyes, can result in severe skin
irritation, blistering and frost bite. It will attack rubber protective clothing.
1.5.3 Chlorine in its dry form does not corrode metals. However, it reacts with water /
moisture to produce hypochlorous acid which will cause corrosion to most metals.
1.5.4 Chlorine is non-flammable but heating will cause pressure in the containers to rise
and this rise of pressure could result in bursting or an explosion of the container. It is
important to note that steel ignites spontaneously at a temperature of 250 C. In the
presence of chlorine which means that no welding can take place on chlorine
cylinders, or within close proximity of chlorine installations or storage areas.
1.5.5 Chlorine is non explosive but when exposed to turpentine, ether, ammonia,
hydrocarbons and several other flammables, violent explosive reactions will occur. It
is therefore important not to store chlorine (in any form) with any other
hazardous/flammable substances.
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2 MODULE 2 CHLORINE CYLINDERS

Before you will be in a position to repair a chlorine leak it will be important that you
familiarise yourself with the components or parts of portable chlorine tanks and the
standard chlorine valve as wel as the functions of the valve components or parts.
2.2 Objective
Given A learning guide including diagrams of a chlorine cylinder and a
standard chlorine valve, including the assistance of a facilitator.
Action You must be able to:

i. Identify the components of a portable chlorine cylinder
ii. Identify the components of a standard chlorine valve and
describe the functions
Standard All questions in the Criterion Test must be answered 100% correct.
2.3 Learning guide

The learning guide has been designed to provide you with the knowledge needed to
complete the Criterion test at the end of each module.
2.4 Introduction
Chlorine is supplied by suppliers in different sizes of portable containers namely
chlorine cylinders (70kg), the portable chlorine tank (1 ton) and the road tanker /
Isotainer. For the purpose of this programme we will be concentrating on the 70kg
cylinder.
2.5 The Chlorine Cylinder

All chlorine cylinders are made of steel, have either a foot ring at their base or a soiled
base and their only opening is a valve connection at the top. All valves are protected by
a valve protection cap which is screwed onto the top of the cylinder.
Diagram 1 - Example of a chlorine cylinder

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The serial number of the cylinder will always be found on the domed section of the
cylinder near the neck. When filled with 70 kg of chlorine, the total mass or weight of
the cylinder will be between 100 to 130 kg. The diagram provided of the chlorine
cylinder, which is always painted canary yellow, identifies its various components or
parts. Chlorine cylinders must always be transported and stored in a vertical position.
Diagram 2 - Cross section of a chlorine cylinder
2.6 The standard chlorine valve

(used on both chlorine cylinders and portable chlorine tanks)
Diagram 3 - cross section of a standard chlorine valve
All chlorine valves are manufactured from naval brass with a spindle of monel. Monel
is a nickel-copper alloy which is corrosion resistant and very tough over a wide
temperature range. The diagram provided of a chlorine valve identifies its various
components or parts.
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The functions of the various components (or parts) are as follows:

a) The packing nut (1) is used to increase or decrease the pressure of the packing
against the valve stem (5) and the valve body (6) to ensure a tight seal.
b) The packing gland (2) is used to press down on the packing (3) and hold it in place.
c) The packing (3) ensure a tight seal. There are 3 rings of packing in each valve.
d) The packing washer (4) secures the packing (3) and still allows the spindle to move
up and down within the valve.
e) The valve stem or spindle (5) is made of Monel and has a 10mm square top.
f) The valve body (6) is made of naval brass.
g) The lead washer (7) is used to give an adequate seal.
h) The outlet cap or nut (8) is made of brass and has a three-fold purpose. It keeps
moisture out of the valve, safeguards the outlets threads (9) and can be used as a
sealing mechanism if the valve stem seal (10) does not seal properly.
i) The outlet threads (9), to which close coupled chlorinators or flexible hose are
attached.
j) The inlet threads (11) are used to screw the valve into the cylinder itself.
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3 MODULE 3 HANDLING AND STORAGE OF CHLORINE

CONTAINERS

Often chlorine leaks are the result of the incorrect handling and storage of the 70kg
chlorine cylinder and one ton chlorine tanks. Having familiarised yourself with the
contents of this module, you will be able to store and handle chlorine containers in a
safe manner.
3.2 Objective
GIVEN: A learning guide including diagrams, the assistance of a Training
Instructor/designated mentor.
ACTION: You must be able to:

1. Identify the correct methods for handling one ton chlorine
cylinders.
2. Identify the correct methods for storing one ton chlorine cylinders.
STANDARD: All questions in the Criterion Test: Theoretical must be answered

100% correctly within the prescribed time limit.
3.3 Learning guide

This Learning Guide has been designed to provide you with the knowledge needed to
complete the Criterion Test at the end of the module.
3.4 Introduction
Because chlorine is a hazardous or dangerous substance, all chlorine containers, be
they cylinders or tanks, must be handle with extreme care. They must be lifted and
lowered gently and must not under any circumstances be dropped, allowed to fall or be
struck by any object with force.
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3.5 Handling of chlorine cylinders
3.5.1 No cylinder may be moved unless the valve protection cap is in place.
3.5.2 Cylinders must not be lifted by the valve protection cap, (the function of which is to
protect the valve from damage) because the neck ring which the valve protection cap
is attached to is not designed to carry the weight of the cylinder.
3.5.3 Cylinders must be kept in the vertical (upright) position at all times when being moved
or stored.
3.5.4 Cylinders must not be off-loaded by allowing them to fall on a tyre. At least two
people should load and off-load cylinders.
3.5.5 Ideally, a properly balanced hand trolley (see diagram 4) should be used to move
cylinders. This hand trolley should have a clamp or chain at least two-thirds of the
way up the cylinder in place.
3.5.6 If cylinders must be elevated by a hoist, a specially designed cradle or carrier should
be used and not a sling or magnetic device.
3.5.7 If several cylinders are to be off-loaded from a truck, they should be lowered by
means of a platform or by hand.
Diagram 4 - Hand trolley for moving chlorine cylinders
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3.6 Storage of chlorine cylinders and containers
3.6.1 General
3.6.1.1 Chlorine containers must always be used on a first in first out basis and it is
important to note that keeping a container for longer than two years constitutes a
contravention of the law (it is illegal).
3.6.1.2 Chlorine containers must always be stored under cover in a dry, well-ventilated and
readily accessible area. If standing water can collect, it is important that suitable
platforms or supports should be provided to lift chlorine containers above the water
level to prevent corrosion.
3.6.1.3 Chlorine containers should always be stored from any source of heat or potential
source of heat to prevent expansion of the liquid chlorine, a pressure build-up and
possible explosion. Heat sources include direct sunlight, boilers, open-flames,
steam pipes etc.
3.6.1.4 Chlorine containers should not be stored with flammables and other types of
containers, or exposed to corrosive vapours.
3.6.1.5 Chlorine containers should be segregated or kept apart from other compressed gas
containers (e.g. Anhydrous ammonia) and hydrocarbon chemicals to prevent
possible explosive reactions.
3.6.1.6 The storage area should always be kept clean so that accumulated rubbish does
not pose a fire hazard e.g. if an oily rag is left lying around and chlorine gas
escapes, the rag could ignite/catch fire spontaneously.
3.6.1.7 Chlorine containers should not be stored near elevators or ventilating systems so
that if a leak does occur, dangerous concentrations of gas will spread rapidly.
3.6.1.8 Provision must be made for routine inspection of all containers and access to
storage areas by unauthorised persons should be controlled.
3.6.1.9 It is very important that all First Aid and Trouble shooting Kits be housed outside the
storage areas and are readily accessible
3.6.2 Storing Chlorine Cylinders
NB: Empty chlorine cylinders must be stored separately from full cylinders and
the container areas must be clearly marked empty or full. Chlorine cylinders
should be chained at all times.
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3.6.2.1 All full chlorine cylinders must be stored vertically (upright) groups in double rows
with gangways between them or not less than one metre to allow for easy access in
the event of a chlorine leak.
3.6.2.2 Empty chlorine cylinders must be stored vertically (upright) in double rows with
gangways between the rows to allow for easy access. Before storing empty
cylinders it is very important to check that the valves are properly closed and the
valve protection caps in place.
Diagram 5 - Suggested storage pattern for chlorine cylinders
3.7 Transport of chlorine containers by road
3.7.1 All chlorine cylinders must be transported in the vertical (upright) position and all
down portable chlorine tanks in the horizontal (lying down) position, their valve
protection caps/domes in place.
3.7.2 No chlorine container may project beyond the sides or end of the vehicle.
3.7.3 Chlorine containers transported by road must be loaded in such a way that they do
not bounce or strike other objects. There must be no sharp projections on the inside
of the vehicle that could damage a container.
3.7.4 Chlorine cylinders must be securely anchored by strapping or chains so as to prevent

all movement and thus ensuring that they cannot fall of the vehicle.
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Diagram 6 - Chlorine cylinders correctly secured for road transportation
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4 MODULE 4 PLANT LAYOUT

By familiarising yourselves with the Optimum (the best) Plant Layout, you will be in a
position to identify and repair problems quickly.
4.2 Objective
GIVEN: A Learning Guide including a diagram of an Optimum Plant Layout
plus the assistance of a Training Instructor/designated mentor.

1. Describe the effects of temperature on chlorine cylinders.
2. Describe the ideal construction of plant rooms and the materials to
be used.
3. Describe where First Aid Kits and Emergency Equipment should
be stored.

4.3 Learning guide

This Learning Guide has been designed to provide you with the knowledge to complete
the Criterion Test at the end of the module.
4.4 The effect of temperature on chlorine containers

Before we look in detail at the optimum plant layout we need to understand the effect of
temperature on chlorine containers. If they are stored at a temperature of 10 C or less
the supply of chlorine to the system will be sluggish and erratic (changeable). If
containers are exposed to extreme heat, the pressure inside the containers will
increase until they explode. Ideally, they should be stored at 18 C with their comfort
zone extending from 18 C 25 C.
Another important aspect of the effect of temperature on chlorine supply occurs when the
temperature of the contents of the chlorine cylinders is higher than the chlorination
equipment/system through which it passes. In this case the chlorine re-liquefies or condenses
as it passes through the chlorination equipment/system and deposits gunk or ferric in the
system which could clog or block the system
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From the above, it becomes obvious that the design of any plant or system needs to take into
account the fact that chlorine cylinders need to be stored at a lower temperature than the
system through which the chlorine will be passing.
4.5 Optimum plant layout

In order to provide for the above, the ideal plant will consist of two rooms, one for
housing the chlorine one ton tanks and the other for housing the chlorinator
equipment/system.
A - The following construction standards would be ideal:
Building
This should be fireproof and heat resistant and should shade chlorine containers from
direct sunlight at all times. It should protect the containers from rain.
Floors
Should be made of concrete and free from moisture of any kind.
Doors
Should be large enough to wheel a hand trolley into the room in which the chlorine
containers are housed. In addition, they should open outwards and should be kept locked
at all times with strict access (entrance) control. A spare key should be kept in a glassed
frame outside the plant room.
Windows
Should be shaded to deflect direct sunlight.
Ventilation
Because chlorine gas is heavier than air, it will remain at floor level. For this reason,
ventilation outlets and extraction fans should be installed just above floor level. The
ventilation system should ideally allow for a complete change of air every 15 minutes and
it should have the capacity (ability) to get rid of all contaminated air in 3-4 minutes. It is
not necessary to run ventilation continuously and in many cases important not to do so.
Should you have an extraction fan present, please ensure that you have clear operating
procedures on the use of this equipment.
Roof
Ideally the roof should be constructed of asbestos or a similar heat reflective surface. It
should never be constructed of tin which absorbs heat resulting in high temperatures in
the Plant Room.
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Piping Arrangements
These should be as simple as possible with the distance between chlorine cylinders and
chlorinator as short as possible. All parts of a chlorine system should be cleaned and
dried thoroughly before use to prevent possible violent reactions between the chlorine
and oil or grease and to prevent the formation of hypochlorous acid when the chlorine
combines with moisture.
Diagram 7 - Cylinder mounted chlorinator
Diagram 8 - Manifold mounted chlorination system
Ideally the chlorine room which houses the chlorine cylinders, should contain the
following:
At least two chlorine cylinders should be connected to the chlorinator system,, one in
operation (duty) and a full spare one clearly marked standby. In the case of cylinders,
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there should be facilities for securing them upright (chained) so they cannot be knocked
over/fall over.
Scales for weighing the cylinders. This will enable the operator to find out how much
chlorine is left in the cylinder.
A gas pressure gauge for ensuring that the pressure of the supply of chlorine to the
system is correct.
The room which houses the chlorinator equipment/system should be linked to the
other room by means of a flexible connecting-up hose or pipe. As mentioned
before, the distance between the chlorine container and the chlorinator
equipment/system should be as short as possible to reduce (make less) the
opportunity for re-liquefaction. In addition, the floor should slope slightly to a drain
which will allow any water to flow away harmlessly.
4.6 First Aid Kit and Emergency Equipment

Ideally, there should be two large boxes for the storage of the following, outside
the two-roomed structure.
4.6.1 An additional place for storing spare chlorine containers which is under cover and
well-ventilated. (Empty and full containers should be clearly marked). Is this not
covered before?
4.6.2 A lockable box for storing a first aid kit and emergency equipment. These obviously
need to be stored outside the two-roomed structure because in the event of a severe
leak, one would not be able to get at them if they were stored inside. If locked the key
must be immediately available.
4.6.3 In addition to the above, there should also be a glassed in frame outside the plant
room containing a list of standard procedures, emergency contact numbers and spare
keys for the chlorine room. It is very important that only trained authorised personnel
be allowed to enter the chlorine room and that they should be aware always of the
need to pause on opening the plant room where the chlorine containers are stored to
check that no leak has occurred.
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5 MODULE 5 SAFETY CLOTHING AND EQUIPMENT

In order to protect employees while repairing chlorine leaks under dangerous
conditions, it is required to wear safety or protective clothing and wear a B.A.
(Breathing Apparatus) Set. The safety clothing will be needed to protect your skin from
chemical contact, and B.A. Set will allow you to breathe in an atmosphere that would
normally be life-threatening.
5.2 Objective
GIVEN: A learning guide including diagrams of safety clothing and
equipment, a B.A Set plus the assistance of training
instructor/designated mentor.

1. Identify the protective clothing to be worn when repairing
a dangerous chlorine leak.
2. Demonstrate your ability to operate the standard B.A Set.

5.3 Learning guide

This learning guide has been designed to provide you with the knowledge to complete
5.4 Introduction
Because you will be required to work under difficult and sometimes dangerous
conditions to repair chlorine leaks, a detailed knowledge of the safety clothing and
equipment to be used under these circumstances is essential.
5.5 Safety Clothing and Equipment

The following is the safety clothing and equipment to be worn at all times while dealing
with dangerous chlorine leaks.
5.5.1 P.V.C Rubber Gloves
The function of these green PVC Rubber Gloves is to protect your hands and lower
arms from chemical contact. They must be worn at all times despite how
uncomfortable they may seem and how difficult it may be to work with them on.
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5.5.2 Safety Boots
The safety boots have steel toecaps designed to protect your toes from being
crushed in the event of a heavy object falling on your feet. In addition they have
rubber soles that are slip resistant and both soles and uppers are designed to protect
your feet in the event of lightweight chemical spills. All safety boots are made of
leather and are comfortable to wear.
5.5.3 Acid Resistant Overall
The acid resistant overalls are to be worn at all times when working in a chlorine filled
atmosphere. The acid resistant overall will protect the skin from chemical burns.
5.5.4 Full Face Mask
The full face mask protects your eyes and face from liquid chemicals and chemical
fumes and vapours but is only designed to limit the amount of chemical fumes or
vapours entering your lungs. This mask will only allow you to escape from a
dangerous situation or to work in a situation that is non-threatening and where the job
can be completed quickly.
NB: This mask will not allow you to work for any length of time in the presence of
chemical fumes or vapours and is only suitable in an atmosphere where chlorine
content is not more than 15 parts per million.
The apparatus consists of a full face mask with an inner ori-nasal mask to prevent to
main lens from fogging. It has a speech diaphragm just above the nose extension,
which allows you to talk while wearing the face mask. The extension hose is
connected to an activated carbon canister attached to a belt at the waist. Once the
face mask has been donned (put on) and the head harness straps tightened to seal it,
normal breathing through both nose and mouth can take place. (Those with full
beards may struggle to get an air tight fit).
5.5.5 The B.A (Breathing Apparatus )Set
The B.A Set is designed for use when working directly in the vicinity of a spill or
incident where fumes or vapours are very strong, dangerous and life threatening. The
full face piece is designed to seal over your face, and the cylinder mounted on your
back, provides you with fresh air, allowing you to breathe normally for a period of
approximately 30 minutes.
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The B.A set must always be donned (put on) and tested in clean atmosphere before
going into a high risk area. The B.A Set should be inspected and tested regularly by
Fire Department personnel and must always be ready for use in any emergency.
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6 MODULE 6 DETECTING CHLORINE LEAKS

It is essential that you not only know how to detect chlorine leaks, but also the most
common places where chlorine leaks may occur. Only once the chlorine leak has been
properly identified, can work begin on repairing it.
6.2 Objective
GIVEN: A learning guide, equipment for identifying a chlorine leak, and
actual chlorine leak plus the assistance of a training

1. Describe what happens next if chlorine leaks are not detected
quickly.
2. Identify the equipment needed to detect chlorine leaks.
3. Identify the most common places where chlorine leaks may
occur.
4. Detect the chlorine leaks.

6.3 Learning guide

This learning guide has been designed to provide you with the knowledge needed to
complete the Criterion Test at the end of the module.
6.4 Introduction
It is very important to detect chlorine leaks as early as possible and to rectify them at
once. Chlorine flowing out of a leak absorbs moisture from the atmosphere resulting in
the formation of hydrochlorous acid which attacks the metal of the container/valve. It is
possible that the corrosion or rust could eat into the inside of the valve, where it cannot
be seen. When the metal finally gives way, a very bad leak will result. Chlorine leaks
always become worse, they never become small or slower.
6.5 Equipment needed for the detection of chlorine leaks

A gas mask or BA Set must be worn at all times when steps are being taken to identify
a chlorine leak and one of the following two methods can be used:
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6.5.1 Plastic Squeeze Bottle
This method of leak detection is used in all instances where it is possible to physically
reach the area being tested. The plastic squeeze bottle is half filled with cotton-wool
balls and a solution consisting of 50% ammonia and 50% water to form an aqueous
ammonia solution. The dip tube extending through the lid of the squeeze bottle does
not penetrate (go into) the aqueous ammonia solution.
Diagram 9 - Plastic squeeze bottle
When testing for a chlorine leak, the squeeze bottle must be squeezed gently to
release the fumes. When these fumes come into contact with the chlorine gas, a
dense white cloud forms, indicating the position of the leak. It is very important to
make sure that no liquid comes into contact with the leak because this would lead to
the formation of hypochlorous acid severe corrosion (rusting).
6.5.2 Cloth soaked in aqueous ammonia and tied to a long stick
This method of leak detection is used in all instances where it will not be possible to
physically reach the area being tested, or where it is difficult to reach the area being
tested e.g. overhead pipes. etc.
The cloth (normally cotton) is dipped into a strong aqueous ammonia solution and
tied to the end of a long stick. This stick is used to test for the chlorine leaks and a
dense white cloud will form indicating the position of the leak. It is very important
when using this method, to ensure that the cloth does not come into contact with any
part of the system/container etc. as the water content of the aqueous ammonia
solution will mix with any available chlorine, form hypochlorous acid and attack the
metal.
Page 25 of 51
6.6 The most common places where chlorine leaks appear

Chlorine leaks, although they can be smelt, unfortunately is seldom visible to the
human eye. However, should any contamination on chlorine container in the form of
brown spots of liquid be identified, they will indicate a chlorine leak and corrosion in the
process.
The following constitute the most common places where chlorine may occur:
6.6.1 The Valves
Valves may leak at several points including the following:
At the coupling or connection between the container valve and the system. There
may be damage to the outlet threads of the valve or the couple-up nut, or the
lead/Teflon gasket may need replacing.
At the valve spindle as a result of a gland nut that has not been properly
tightened.
Where the valve screws onto the container.
6.6.2 The System
The leak could occur anywhere between the valve connection and the end of the
system.
6.6.3 Holes in the sides of the container
A leak could occur through a hole in the side of a chlorine cylinder or a chlorine tank.
Page 26 of 51
7 MODULE 7 CONNECTING / DISCONNECTING STANDARD

CHLORINE VALVES

It is important that established procedures are followed to connect and disconnect
chlorine containers. There are two types of connections, a close coupled chlorinator
and a wall mounted chlorinator with flexible tubing connected to the cylinder valve.
7.2 Objective
GIVEN: A learning guide, appropriate diagrams, and an opportunity to
connect
and disconnect a chlorine container plus the assistance of a training

1. Describe how to disconnect a chlorine cylinder.
2. Describe how to connect a chlorine cylinder.
3. Demonstrate your ability to disconnect and connect a chlorine
container.

7.3 Learning guide

7.4 Introduction
7.4.1 Before connecting or disconnecting a chlorine container, you must ensure that the
following safety and emergency equipment/other equipment are at hand and operable
(working).
Full face Cl2 gas mask

PVC rubber gloves
Squeeze bottle with aqueous ammonia solution
Appropriate emergency kit, if available
Correct size valve spanner to prevent excessive leverage
New lead washer
Page 27 of 51
Protective clothing
7.4.2 There are two types of connection used:
A close coupled connection where the chlorinator is connected directly to the

container.
A flexible connection where either a suitable copper tubing or approved non-
metallic hose is acceptable and these link the container to the system (a
serpentine)
All connections should be inspected regularly and replaced at intervals of no

less than one year. However, as soon as any sign of deterioration is noticed, the
connection must be replaced immediately.
7.4.3 There are times when the system must remain in operation while containers are
being connected. In these instances auxiliary block valves must be used to isolate
(block) the container from the system and prevent not only a possible escape of gas
from the container, but also the possible entrance of atmosphere moisture into the
container.
7.5 Disconnecting chlorine containers
7.5.1 Preparing to disconnect the container.
7.5.1.1 As soon as the container is empty, the valve should be closed tightly (The gas
supply indicator will then drop to zero).
7.5.1.2 You must then wait for at least five minutes to make sure that there is no pressure
build-up and all the gas is sucked out from the system.
7.5.1.3 You must then check again that the valve is closed tightly before proceeding.
7.5.1.4 Next the ejector must be turned off and you must make sure that the gas supply
indicator stays in the No gas position. If the indicator resets, either gas pressure is
still present or there is an air lock.
7.5.1.5 Do not continue further until the problem has been rectified (fixed).
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7.5.2 Disconnecting the container
7.5.2.1 First the serpentine connector nut must be loosened and the gas feeder removed
from the valve and plugged or covered to prevent moisture ingress.
7.5.2.2 Next the valve outlay cap must be replaced, ensuring that the lead/Teflon washer is
in position in the valve outlet cap.
7.5.2.3 Then you must test for leaks using a squeeze bottle containing aqueous ammonia
solution.
7.5.2.4 Finally the valve protection cap or dome must be replaced.
7.5.2.5 Having disconnected the container, you must check again for chlorine leaks using
the squeeze bottle containing aqueous ammonia solution. If there are no leaks you
can remove the container.
7.6 Connecting chlorine containers
7.6.1 Introduction
It is important that all full containers be given time to acclimatise to their new position
for 24 hours before connecting up takes place. If there are large differences of
temperature between the cylinder and its contents and the system, reliquification
takes place and if moisture is present in the system, gunk can form which could clog
the system. (Refer to the module entitled Plant Layout)
7.6.2 Before connecting the container
7.6.2.1 Before actual connecting can take place, the chlorine container must be secured in
position. (In the case of a portable chlorine tank, the valves must be in a vertical
position).
7.6.2.2 Next, the valve protection cap/dome must be removed carefully.
7.6.2.3 Next, you must check that the valve is properly closed.
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7.6.3 Connecting the container via the outlet threads
7.6.3.1 You must first remove the outlet cap, check visually (with your eyes) that the
threads are not damaged and place a new lead/Teflon washer over the spigot of the
serpentine. All sealing surfaces must be clean and smooth.
7.6.3.2 Next you must line up the serpentine and the equipment absolutely square to each
other before tightening the serpentine nut (check that the thread of the serpentine
nut is not damaged).
7.6.3.3 The serpentine nut must now be tightened onto the valve. This nut must be of the
correct length (25mm) to stop leaks from occurring.
7.6.3.4 Now you must open and close the valve on the container quickly to charge the line.
7.6.3.5 Next you must test for leaks with your squeeze bottle.
7.6.3.6 If all is safe, you may now open the valve. (Do not open the valve fully, two full turns
will be sufficient).
Diagram 10 - Side view of valve to flexible connection
Diagram 11 - Cross section of the serpentine nut

Page 30 of 51
7.6.4 Connecting the cylinder using a valve yoke
The valve yoke can be used under normal circumstances, if the outlet threads are
stripped or if the sealing face is corroded or damaged.
Diagram 12 - Valve Yoke
Diagram 13 - Cross section of a close coupled chlorinator connected via a valve yoke
The following is the procedure for fitting the valve yoke:
Ensure that the valve is properly closed.
Page 31 of 51
7.6.4.1 Remove the outlet cap from the valve outlet. (If the sealing surface is corroded or
damaged, return the container to the supplier).
7.6.4.2 Next, place a new lead washer over the spigot of the connecting-up pipe and place
the spigot in the outlet of the valve.
7.6.4.3 Then slide the connecting-up nut back as it will not be needed and fit the yoke over
the valve so that the connecting-up pipe is resting on the yoke.
7.6.4.4 Next, tighten the yoke bolt to seal the connection.
7.6.4.5 Test for leaks with your squeeze bottle.
7.6.4.6 Finally, open the valve, two full turns.
CONCLUSION
It is very important to note that the valves on chlorine cylinders are not designed to be
regulating devices. This practice damages the valve seat. At all times, valves must
either be fully opened (two full turns) or fully closed.
Page 32 of 51
8 MODULE 8 DEALING WITH PROBLEM LEAKING VALVES

AND SYSTEMS

You will be required from time to time to deal with problems or leaks relating to
standard chlorine valves. As a result they will be required to know the procedures both
for solving problems/repairing leaks and for securing leaks that cannot be repaired.
8.2 Objective
GIVEN: A learning guide, appropriate Emergency Kit, plus the assistance of a
training instructor/designated mentor.

1. Describe how to deal with:
A stuck valve
A leaking valve
2. Describe how to fit a press rod.
3. Demonstrate your ability, practically in all the above areas.
STANDARD: All questions in the Criterion Test: Theoretical must be

answered
8.3 Learning guide

8.4 Introduction
By far, the most common reason for chlorine leaks is as a result of problems relating to
the standard chlorine valves fitted to chlorine cylinders. These valve can either get
stuck (i.e. they will not open or close) or they can leak.
Page 33 of 51
Diagram 14 - Standard Chlorine Valve
8.5 Dealing with stuck valves

When the operator tries to connect up his system to a chlorine container, he sometimes
finds that the valve is stuck. To deal with such a problem, the following procedures
must be followed:
8.5.1.1 First, a full face mask or B A Set must be put on then the chlorine cylinder must be
wheeled into the open using a hand trolley.
8.5.1.2 Next, a new lead/teflon washer must be placed into the valve outlet cap which
should be tightened properly.
8.5.1.3 Now the packing nut must be loosened a half-turn using the appropriate (suitable)
spanner.
8.5.1.4 Next the valve spanner must be placed over the spindle of the valve. Using a
hammer give the side of the valve spanner a sharp tap in an anti-clockwise direction
to loosen it.
8.5.1.5 NOW THE VALVE MUST BE SHUT, THE PACKING NUT TIGHTENED and the
valve outlet cap loosened to release the chlorine trapped inside.
8.5.1.6 After the chlorine has been released the valve outlet cap must be removed
completely and you must test for leaks using the appropriate aqueous ammonia
equipment.
8.5.1.7 If the valve still leaks, then the follow procedures outlined below.
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8.6 Dealing with leaking valves

As mentioned in previous modules there are several points from which standard
chlorine valve leaks can occur, including the following:
Valve packing gland
Valve seat (will not close tightly)
Valve outlet threads
Valve inlet threads
Broken off valve
Valve stem assembly blown out
Valve blown out (due to stripped threads)
Valve body (very Rarely)
NB: At all times when working to repair/stop chlorine leaks, you must wear
appropriate suitable clothing and equipment, and must position the chlorine container
so that the leak is in the gas phase. (Remember, that one volume of chlorine will, on
evaporation, yield 460 volumes of chlorine gas).
The following table outlines the nature of the problem and the actions to be taken to deal
with each problem.
PROBLEM ACTION TO BE TAKEN
Leak through valve packing Tighten the packing nut using the appropriate
A
gland spanner
Gently open and close the valve using the

valve spanner to dislodge a possible scale from
Leak through valve seat (valve
B the valve seat and then close it. If the valve still
will not close tightly)
leaks then apply the Safety Hood. Contact the
supplier to remove the container.
Apply a new lead / Teflon washer to the

outlet cap using the appropriate spanner
Leak through valve outlet
C or
threads
Fit the valve yoke and adaptor if the
threads are stripped
Page 35 of 51
PROBLEM ACTION TO BE TAKEN
Tighten the valve using an appropriate

spanner
Test for continued leaking using an

Leak through valve inlet appropriate aqueous ammonia solution
D
threads
If the above does not solve the problem
then immediately apply the Safety Hood
Drive (hammer) a thin taper into the valve

E Broken valve shank. In the case of a chlorine cylinder apply
the Safety Hood
Drive (hammer) a thin taper into the valve

Valve stem assembly blown
F shank. In the case of a chlorine cylinder apply
out
the Safety Hood
Drive (hammer) a thick taper pin into the valve

Valve blown out (due to
G opening. In the case of a 70 kg chlorine
stripped threads)
cylinder apply the Safety Hood
Page 36 of 51
9 MODULE 9 HANDLING CHLORINE EMERGENCIES
9.1 Why it is important to understand thismodule

It is important to understand this material for you might some day need the skill to
handle a small or large chlorine leak. This module provides guidelines for dealing with
such situations.
9.2 Objective
GIVEN: A learning guide plus assistance of a training instructor/designated
mentor.

1. Describe how to handle a minor chlorine emergency.
2. Describe how to handle a major chlorine emergency.
3. Describe how to handle a fire.

9.3 Learning guide

9.4 Handling a chlorine incident
9.4.1 When chlorine is set free into the atmosphere, it is regarded as a chlorine incident
(leak), this must be prevented at all times .
9.4.2 The following actions are to be taken, step by step to control the chlorine leak and
stop the leak quickly and effectively.
Ensure all personnel are quickly and efficiently removed from the area.
Inform the supervisor of the hazard.
Keep the chlorine room closed to prevent the chlorine gas from contaminating the
surrounding area and evaluate the area up wind from the leak.
Put on safety clothes, chlorine gas mask or B A Set, PVC gloves and an acid
resistant overall.
Have an assistant standby outside the contaminated area.
Page 37 of 51
Close the chlorine cylinder valve to stop the chlorine leak into the atmosphere.
Shut windows and doors. Shut of all air conditioners of building in the vicinity.
This is to prevent chlorine gas from entering such buildings.
When it is safe, extract chlorine gas from the chlorine contaminated room by
means of the extraction fan.
Once this is done and the room is free from chlorine gas then you can go back
and investigate/repair the causes of the leak.
The chlorine supplier should be notified of the incident and the cause thereof.
9.5 Evacuation procedure
9.5.1 The need to evacuate the area will depend on the distance of people from the leak
and the concentration of the leak.
9.5.2 If necessary, people in the vicinity (area) must be evacuated up wind of the leak, (i.e.
in the opposite direction to which the wind is blowing) and should keep moving until
they can no longer smell chlorine gas.
9.5.3 Ideally, they should also be moved to higher ground because chlorine gas is heavier
than air and will collect in the lower areas.
9.5.4 It is important to remember that those inside buildings at a higher level will not be
safe because local air currents will affect the movement of the gas which will in any
event eventually disperse upwards in the atmosphere.
9.5.5 Where chlorine levels are high, those without safety clothing and equipment should
be advised to breathe through wet cloth or handkerchief placed over both nose and
mouth.
9.5.6 Breaths taken should be slow and evacuation should begin immediately.
9.6 Chlorine incident investigation

As a matter of course, all chlorine incidents must be investigated and the relevant
questionnaires/reports compiled. Its objectives will be:
To ensure the avoidance of similar incidents in the future.

A assessment of the effectiveness of the procedures used.
Documentation in the above situation must be carefully completed and filed for future
reference.
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9.7 Fires
Very seldom will you be faced with a situation whereby chlorine containers are
threatened by fire.
Inform the local Fire Brigade immediately

Your function will be to immediately disconnect all containers and remove them
and any other containers from the danger area/fire zone.
Where containers cannot be removed from the fire zone, water must be applied
constantly in order to keep them cool.
In the event that it should become dangerous to personally apply water to
containers in the danger zone and the Fire Department is present.
A monitor can be put in position on its tripod and it will provide a fine spray of water
to the containers.
NB: All unauthorised persons must be kept at a safe distance.
As mentioned in the previous modules, chlorine containers that come into contact with
excessive (great) heat for any period of time will explode. In the case of an explosion, the gas
will burn away immediately but there will be considerable danger to bystanders from metal
shrapnel (splinters).
Finally, if water has to be applied to chlorine containers, you must make sure (if at all
possible) that this water is kept away from chlorine leaks. As mentioned previously, when
chlorine comes into contact with water, hypochlorous acid is formed which will corrode (eat
away) most metals, making any leak worse.
Page 39 of 51
10 MODULE 10 FIRST AID

It may be required from you to render first aid to victims who have been exposed to a
chlorine leak.
10.2 Objective
GIVEN: A learning guide, a first aid kit, plus the assistance of a training
Describe what first aid must be rendered in the event of:

Skin contact
Eye contact
Mild inhalation (breathing in of gas)
Severe inhalation (breathing in of gas)

10.3 Learning guide

10.4 Introduction
In most situations where first aid is necessary as a result of exposure to a chlorine leak,
there will be qualified emergency services personnel available to render this first aid.
However, there may be times that you will have to render first aid and then you should
know what to do and what not to do.
IMPORTANT: In all cases of exposure to chlorine a doctor/qualified medical personnel must

be called immediately to assist.
10.5 Rendering First Aid

You must ensure firstly that you yourself do not become a casualty by wearing the
appropriate (suitable) safety clothing and equipment (either a full face mask or a BA
Set). You must take prompt action to remove the exposed person(s) from the
contaminated (danger) area. Act with firmness and constantly reassure the victims who
Page 40 of 51
will be experiencing high levels of stress and anxiety. It is important that nothing be
given by mouth if the person(s) is unconscious or convulsing (having a fit).
There are four situations which may require treatment.

Skin contact
Eye contact
Mild inhalation (breathing in of gas)
Severe inhalation (breathing in of gas)
We shall look at the procedures to be followed in each situation.
10.5.1 Skin Contact
High concentrations of chlorine gas or liquid will cause blisters and in extreme cases,
frostbite. It is important to remove the victim from the danger area then remove the
victims clothing (preferably under a shower) and to wash the skin for 20 minutes with
water, flushing well. A Vitamin E cream can be applied to exposed skin surfaces
before the victim is either transported to the nearest hospital or a doctor arrives.
10.5.2 Eye Contact
Having removed the victim from the contaminated (danger) area and removed any
clothing that may be contaminated; the eyes must immediately be flushed with
running water (eye bath) for at least 15 minutes. It is important to ensure that all eye
and lid tissues are completed irrigated (flushed with water) by holding the eyes wide
open. In severe cases, the victim should be taken to the nearest hospital or to an eye
specialist.
10.5.3 Mild inhalation (breathing of gas)
The first step is to get the victim(s) out of the contaminated (danger) area reassuring
them constantly by explaining the various procedures to be used etc. The victims
reaction will be to panic because of the sensation or feeling of the closing of the
throat and a feeling of suffocation (not being able to breathe) similar to drowning.
They must be told to breathe shallow and move slowly and to resist the desire to
cough. Contaminated clothing must then be removed slowly and the victim kept
upright in a comfortable position, warm and quiet.
In more severe cases, the victim must lie down with his head and upper body raised
45o 60o to the horizontal plane???
(This semi-sitting position is called the fowlers position). Ventolin spray and propan
gel (anti-acid) should be given to the victim as follows:
2 puffs of Ventolin spray (frequence??)
Page 41 of 51
4 teaspoons of propan gel (frequency???)

Call doctor to examine and assist victim
10.5.4 Severe Inhalation
In severe cases the victim will have stopped breathing and also probably will have
turned blue. Here too, the first step is to remove the victim from contaminated
clothing, secure an open airway and immediately begin artificial respiration. The
victims arms must be placed behind his head to keep his chest cavity open and
artificial respiration must continue until either a doctor or emergency services
personnel arrive.
10.5.5 Conclusion
Chlorine inhalation is fatal (will kill you) at the rate of 1000 parts of chlorine per million
parts air. As far as is known, most victims who have experienced severe gassing do
not experience any serious after effects. However, they do tend to experience anxiety
reactions which could continued for many months.
Page 42 of 51
11 MODULE 11 EMERGENCY KIT A

For problems relating to the chlorine cylinders, it is essential that you familiarise
yourselves with the content of the emergency kit A and their basic uses.
11.2 Objective
GIVEN: A learning guide, appropriate diagrams, an emergency kit A plus
the assistance of a training instructor/designated mentor.

Identify the contents of the emergency kit A
Describe their basic use

11.3 Learning guide

11.4 Introduction
When dealing with problems relating to chlorine cylinders, you will require the
emergency kit A. This kit contains all the equipment needed to repair a leak in the
chlorine cylinder effectively and for this reason you need to familiarise yourself not only
with the contents of the kit, but also with their uses.
11.5 Chlorine cylinder leaks

The following is a summary of the most common places where chlorine cylinders leaks
may occur. You will need to detect the leak using the procedures and the equipment
laid down in the module entitled Detecting Chlorine Leaks.
11.5.1 The valve
The valve inlet threads (i.e. where the valve screws into the cylinder).
The valve outlet threads (i.e. where the valve connects the system).
The valve packing gland (see diagram of a standard packing valve).
The valve seat (see diagram of a standard chlorine valve).
The valve stem assembly blown out (see diagram of standard chlorine valve).
The valve blown out.
Page 43 of 51
A broken off valve.
11.5.2 The side wall of the cylinder
Leaks from the side wall can occur on the chlorine cylinder and will usually be
identifiable (be noticed) by the presence of either a brownish looking stain in the area,
or a gas smell, or a white frost around the hole.
11.6 Contents of the EMERGENGY KIT A and their uses

(NB: Please familiarise yourself thoroughly with the contents of the emergency kit A
and the names of all the parts before you continue with this learning guide).
Diagram 15 - Universal safety hood (Unit part list)
Page 44 of 51
The contents of the emergency kit A allow you to perform the following 3 (functions):
11.6.1 Stopping the valve leak
This can be done by either:
Repairing the valve using the emergency kit A
11.6.2 Applying the safety functions
This equipment is designed to seal off the whole valve area and can be placed over
the valve protection cap if necessary or over a taper pin.
11.6.3 Patching the side leaks
This equipment is designed to seal off any side leaks in a chlorine cylinder.
Having familiarised yourself with the contents of the emergency kit A, you
now need to identify which of these contents are used in which of the above
three functions.
NB: In all the above situations the BA Set must be used. Wherever possible the
chlorine container must be turned so that the leak is uppermost and is
therefore in the gas phase and not the liquid phase.
(Remember that one drop of liquid chlorine expands by 460 times its volume
when it evaporates into a gas form).
11.7 Procedure to fit the safety hood unit for any type of leak at the
cylinder valve
Don BA Set.
Remove the cylinder valve protection dome, if fitted.
Remove the outlet valve cap from safety hood valve and open.
Fit anchor bolts hook around the foot ring.
NOTE: Use anchor bolt attachment on new longer Norris cylinders (currently only
used in Natal)
Fit anchor bolt extension rods to suit cylinder size.

Position rubber gasket over valve boss.
Fit safety hood in position over valve. Allow anchor bolts to protrude through the
holes in safety hood.
Fit nuts to anchor bolts and tighten evenly to ensure a gas tight seal.
Page 45 of 51
Close valve on safety hood and fit end cap with seal.
Check leaks, tighten anchor bolt nuts if required.
NOTE: In certain circumstances it may be very difficult to remove valve protection

dome from cylinder. In such instances, the safety hood can be fitted over valve
protection dome.
11.8 Procedure to fit leak patch unit on cylinder with hole in side wall
Don BA Set.
If the hole in the cylinder is in a position that liquid chlorine is leaking, lay the
cylinder down so that the hole is in an upper most position.
Slip on end of the chain under the cylinder and pull through until it reaches the
hole in the cylinder.
Place gasket and patch over leak.
Adjust cap screw and yoke until point of screw extends only slightly below yoke.
Centralize cap screw in yoke patch depression.
Attach free ends of chain to each side of yoke, keeping chain as short as
possible.
Tighten cap screw.
Test for leaks, tighten cap screw further if necessary.
Diagram 16 - Side leak patch unit (parts list)
Page 46 of 51
11.9 Side patch unit parts list
11.9.1 Never use a valve outlet cap without a blank lead washer (seal).
11.9.2 Use the valve end caps on the valve outlets (with a lead seal).
Diagram 17 - Other elements Parts List
Page 47 of 51
12 MODULE 12 FITTING THE SAFETY HOOD

At the time of the chlorine leak, you will be required in the line of your duty to fit the
safety hood (from the emergency kit A) to the chlorine cylinder. This module outlines
both the procedure for fitting safety hoods and the equipment/parts to be used during
this process.
12.2 Objective
GIVEN: A learning guide, diagrams, the equipment necessary to fit a safety
hood to a standard chlorine cylinder, plus the assistance of training

1. Describe how to fit the safety hood to a standard chlorine
cylinder.
2. Demonstrate your ability to fit the safety hood to a standard
chlorine cylinder.

12.3 LEARNING GUIDE

12.4 Introduction
If all the steps have been taken to repair a leak to a standard chlorine valve on a
chlorine portable tank with no success, e.g. tightening the packing nut, cracking the
valve open and closing it to dislodge a possible scale from the valve seat, etc. then the
safety hood (from the emergency kit B must be applied in order to seal off the leak.
In the event of valves that have broken off, valve stem assemblies that blown out and
valves that have blown out, taper pins will have been driven into the valve
shank/opening. The safety hood must then be fitted over the taper pin to secure it and
prevent any further leaking.
It is essential when fitting safety hoods to wear the standard safety/protective clothing
and either the full face mask or BA Set (in the event of a more serious leak). Care must
Page 48 of 51
always be taken when entering possible danger areas in order to determine the
seriousness of the situation and work must be carried out with the valve pointing away
from you.
Page 49 of 51
12.5 The procedure for fitting the safety hood
12.5.1 The cylinder must be positioned in the vertical or upright position so that the valve is
in the uppermost position and therefore in the gas phase (bearing in mind that one
volume of liquid chlorine will, on evaporation, yield 460 volumes of chlorine gas).
12.5.2 Next the valve protection cap must be removed if it is in position (where it is very
difficult to remove the valve protection cap, the safety hood can be fitted over it).
12.5.3 You are now getting ready to fit the safety hood but must first remove the outlet cap
from the vent valve on the safety hood and open the vent valve.
12.5.4 Before sealing can take place the shoulder of the cylinder must be cleaned and the
scraper must be used to remove any loose or uneven paint.
12.5.5 Now the round neoprene gasket must be placed on the shoulder of the cylinder and
the safety hood must be placed on top of it.
12.5.6 Next, the safety hood must be fixed in position by hooking the anchor bolts under the
base (bottom) of the cylinder and allowing the stays to protrude (poke) through the
holes in the safety hood. These are then tightened in position with anchor bolt nuts to
secure the hood (using the shifting spanner).
12.5.7 Finally, the vent valve on the side of the safety hood must be closed and the outlet
cap replaced before checking for chlorine leaks (using appropriate aqueous ammonia
equipment). If necessary the anchor bolts must be tightened further to stop any
leakage.
Diagram 18 - Safety hood in position
Page 50 of 51
12.6 Conclusion
It is very important to remember that the safety hood is only a temporary measure for
the sealing of a leak. Chlorine cylinders must be returned to the supplier immediately
for emptying and repair and under no circumstances may cylinders be left at the
customers premises for an indefinite period of time. Cylinders with safety hoods fitted
must always be handled gently and with great care. Dangerous and leaking cylinders
are to be transported back to the supplier by the suppliers personnel.
Page 51 of 51

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CHLORINE HANDLING TRAINING

FOR TRAINING PURPOSES ONLY

CHLORINE HANDLING TRAINING

1.2 Objective ......................................................................................................................7

1.3 Learning guide.............................................................................................................7

1.4 A description of chlorine ............................................................................................7

1.5 Harmful effects of chlorine .........................................................................................8

2 MODULE 2 CHLORINE CYLINDERS .....................................................9

2.2 Objective ......................................................................................................................9

2.3 Learning guide.............................................................................................................9

2.4 Introduction .................................................................................................................9

2.5 The Chlorine Cylinder .................................................................................................9

2.6 The standard chlorine valve ..................................................................................... 10

3 MODULE 3 HANDLING AND STORAGE OF CHLORINE

3.2 Objective ....................................................................................................................12

3.3 Learning guide........................................................................................................... 12

3.4 Introduction ............................................................................................................... 12

3.5 Handling of chlorine cylinders ................................................................................. 13

3.6 Storage of chlorine cylinders ................................................................................... 14

3.7 Transport of chlorine containers by road ................................................................ 15

4 MODULE 4 PLANT LAYOUT ............................................................... 17

4.2 Objective ....................................................................................................................17

4.3 Learning guide........................................................................................................... 17

4.4 The effect of temperature on chlorine cylinders ..................................................... 17

4.5 Optimum plant layout................................................................................................ 18

4.6 First Aid Kit and Emergency Equipment ................................................................. 20

5 MODULE 5 SAFETY CLOTHING AND EQUIPMENT.......................... 21

5.2 Objective ....................................................................................................................21

5.3 Learning guide........................................................................................................... 21

5.4 Introduction ............................................................................................................... 21

5.5 Safety Clothing and Equipment ............................................................................... 21

6 MODULE 6 DETECTING CHLORINE LEAKS ..................................... 24

6.2 Objective ....................................................................................................................24

6.3 Learning guide........................................................................................................... 24

6.4 Introduction ............................................................................................................... 24

6.5 Equipment needed for the detection chlorine leaks ............................................... 24

6.6 The most common places where chlorine appears ................................................ 26

7 MODULE 7 CONNECTING / DISCONNECTING STANDARD

7.2 Objective ....................................................................................................................27

7.3 Learning guide........................................................................................................... 27

7.4 Introduction ............................................................................................................... 27

7.5 Disconnecting chlorine containers .......................................................................... 28

7.6 Connecting chlorine cylinders ................................................................................. 29

8 MODULE 8 DEALING WITH PROBLEM LEAKING VALVES AND

8.2 Objective ....................................................................................................................33

8.3 Learning guide........................................................................................................... 33

8.4 Introduction ............................................................................................................... 33

8.5 Dealing with stuck valves ......................................................................................... 34

8.6 Dealing with leaking valves ...................................................................................... 35

9 MODULE 9 HANDLING CHLORINE EMERGENCIES ........................ 37

9.2 Objective ....................................................................................................................37

9.3 Learning guide........................................................................................................... 37

9.4 Handling a chlorine incident..................................................................................... 37

9.5 Evacuation procedure ............................................................................................... 38

9.6 Chlorine incident investigation ................................................................................ 38

10 MODULE 10 FIRST AID..................................................................... 40

10.2 Objective ....................................................................................................................40

10.3 Learning guide........................................................................................................... 40

10.4 Introduction ............................................................................................................... 40

10.5 Rendering First Aid ................................................................................................... 40

11 MODULE 11 EMERGENCY KIT A ................................................. 43

11.2 Objective ....................................................................................................................43

11.3 Learning guide........................................................................................................... 43

11.4 Introduction ............................................................................................................... 43