Emergency Intervention in Case of

Chlorine Leaks

GEST 93/179
9th Edition
December 2015

EURO CHLOR PUBLICATION

This document can be obtained from:

EURO CHLOR - Avenue E. Van Nieuwenhuyse 4, Box 2 - B-1160 BRUSSELS

E-mail: eurochlor@cefic.be Internet: http://www.eurochlor.org
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Euro Chlor

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

Euro Chlor is working to:

 improve awareness and understanding of the contribution that

chlorine chemistry has made to the thousands of products, which
have improved our health, nutrition, standard of living and
quality of life;

 maintain open and timely dialogue with regulators, politicians,

scientists, the media and other interested stakeholders in the
debate on chlorine;

 ensure our industry contributes actively to any public, regulatory

or scientific debate and provides balanced and objective science-
based information to help answer questions about chlorine and its
derivatives;

 promote the best safety, health and environmental practices in

the manufacture, handling and use of chlor-alkali products in
order to assist our members in achieving continuous
improvements (Responsible Care).

***********

This document has been produced by the members of Euro Chlor and should not be reproduced in
whole or in part without the prior written consent of Euro Chlor.

It is intended to give only guidelines and recommendations. The information is provided in good
faith and was based on the best information available at the time of publication. The
information is to be relied upon at the user’s own risk. Euro Chlor and its members make no
guarantee and assume no liability whatsoever for the use and the interpretation of or the
reliance on any of the information provided.

This document was originally prepared in English by our technical experts. For our members’
convenience, it may have been translated into other EU languages by translators / Euro Chlor
members. Although every effort was made to ensure that the translations were accurate, Euro
Chlor shall not be liable for any losses of accuracy or information due to the translation process.

Prior to 1990, Euro Chlor’s technical activities took place under the name BITC (Bureau
International Technique du Chlore). References to BITC documents may be assumed to be to
Euro Chlor documents.

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RESPONSIBLE CARE IN ACTION

Chlorine is essential in the chemical industry and consequently there

is a need for chlorine to be produced, stored, transported and used.
The chlorine industry has co-operated over many years to ensure the
well-being of its employees, local communities and the wider
environment. This document is one in a series which the European
producers, acting through Euro Chlor, have drawn up to promote
continuous improvement in the general standards of health, safety
and the environment associated with chlorine manufacture in the
spirit of Responsible Care.

The voluntary recommendations, techniques and standards presented

in these documents are based on the experiences and best practices
adopted by member companies of Euro Chlor at their date of issue.
They can be taken into account in full or partly, whenever companies
decide it individually, in the operation of existing processes and in
the design of new installations. They are in no way intended as a
substitute for the relevant national or international regulations which
should be fully complied with.

It has been assumed in the preparation of these publications that the

users will ensure that the contents are relevant to the application
selected and are correctly applied by appropriately qualified and
experienced people for whose guidance they have been prepared.
The contents are based on the most authoritative information
available at the time of writing and on good engineering, medical or
technical practice but it is essential to take account of appropriate
subsequent developments or legislation. As a result, the text may be
modified in the future to incorporate evolution of these and other
factors.

This edition of the document has been drawn up by the Storage,

Transport and Safety Working Group (GEST) to whom all suggestions
concerning possible revision should be addressed through the offices
of Euro Chlor.

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Summary of the Main Modifications in this version

Section Nature

All Review and update of references

TABLE OF CONTENTS
INTRODUCTION 5

1. FIRST MEASURES 5

1.1. Emergency Plan 5

1.2. Initial Precautions 5

1.3. Locating the Leak 6

1.4. Actions to Avoid 6

1.5. Possibilities for Isolation 6

2. MEANS OF LIMITING A CHLORINE LEAK OR ITS CONSEQUENCES 6

2.1. Venting and Purging of Equipment 6

2.2. Water Curtain 7

2.3. Converting a Liquid Leak into a Gas Leak 7

2.4. Limiting the Gas Leak 7

3. STOPPING A LEAK 7

3.1. Leak from a Cylindrical or Convex Wall 8

3.2. Leak from a Small Diameter Hole 8

3.3. Leak from a Weld on a Pipe 8

3.4. Leak from a Valve 8

4. USING A SEALED CONTAINER 8

5. MEANS OF SLOWING DOWN THE VAPORIZATION OF A LIQUID

CHLORINE POOL 8

6. REFERENCES 9

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INTRODUCTION

The aim of this document is to offer practical guidelines for measures to be

taken in case of chlorine leak.

Typical equipment, procedures and other safety considerations are listed. These
are given only as examples.

It must be borne in mind that a small leak will always become worse, sometimes
very rapidly. It is therefore important to intervene without delay to resolve it.

Remark: any defective equipment which has to be sent back to the supplier should be
accompanied with a document describing the anomaly

1. FIRST MEASURES

1.1. Emergency Plan

The first step should be to initiate the emergency plan.

Depending on the size of the leak, it may be necessary to restrict or prohibit

access to the contaminated area and to scale up the emergency level to include
the whole site or even the surrounding offsite areas.

1.2. Initial Precautions

When approaching chlorine leaking equipment, the following precautions should
be taken.

 Use self-contained breathing apparatus and in case of liquid chlorine,

full protective clothing is recommended. In all cases, make sure that a
colleague is ready for help and back-up.

 In the case of a minor leak or for a very quick check of the situation
where the chlorine content in the air is very low (less than 10 ppmV,
monitored with a portable detector), a panoramic cartridge mask may
be used during a short period. Cover the face with a correctly fitting,
sealed mask and remember that gaseous chlorine, which is denser than
air, will accumulate close to the ground. On Personal Protective
Equipment refer to GEST 92/171 - Personnel Protective Equipment
in the Chlorine Industry.

 If the leak is situated in the open air, try to approach the leak from an
upwind direction, taking into account the above mentioned
precautions.

 If the leak is situated inside a building, except in the case of a small

chlorine emission, the use of self-contained breathing apparatus is
mandatory. The operator should keep visual and/or radio contact with
a colleague in a safe area, ready to intervene in case of need. In some
cases it is advisable for the operator to wear a safety harness to
facilitate his recovery if immobilised. Preliminary ventilation of the

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building may be necessary, especially if the visibility is poor due to a

high chlorine concentration. In any case, two people at least must be
present for such actions.

1.3. Locating the Leak

Options to detect a (small) not visible leak are:

 a mobile, portable detector with a sensitivity of 1 ppmV

 an ammonia sniff bottle or a pad moistened with 10% ammonia solution

fixed to the end of a long handle. The leak will be indicated by the
appearance of white fumes of ammonium chloride, which become
thicker and whiter the greater the concentration of chlorine in the air.
Bear in mind that ammonium chloride only becomes visible with
chlorine concentrations above 30 ppmV. Do not spray ammonia
solution on the leak.

1.4. Actions to Avoid

Never spray a chlorine leak from steel equipment with water as this would
aggravate the leak by corrosion.

In case of liquid chlorine leak, never spray water on the chlorine because it
increases the evaporation rate.

1.5. Possibilities for Isolation

Provision for isolation of leaking part of the installation via (remotely operated)
shut-off valves should be considered, depending on the results of the risk
assessment study.

Be aware of the risk of trapped chlorine between two closed valves.

High-flow indicators, low pressure signal, chlorine monitors … are some options
for activating shut-off systems.

2. MEANS OF LIMITING A CHLORINE LEAK OR ITS

CONSEQUENCES

2.1. Venting and Purging of Equipment

Vent valves should be provided to allow quick depressurisation of a leaking part
of the installation. All venting lines, including the relief valves exit, should go to
an absorption unit.

Whenever possible for liquid containing systems, drain-piping with remotely

activated valves enabling rapid draining under gravity to a receiving vessel are
also recommended.

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After venting/draining is completed (fully depressurised), the lines and

equipment should be purged with dry air or nitrogen to the absorption unit.

2.2. Water Curtain

Spraying with water on the leak is strongly advised against due to corrosion
effect in case of steel as construction material.

Spraying water to create a curtain at some distance downwind of the emergency

area may be considered, to create air turbulence, dilute the gaseous chlorine
cloud and steer the cloud away from populated areas.

2.3. Converting a Liquid Leak into a Gas Leak

For the same opening, the amount of gaseous chlorine released is, on average,
fifteen times less than that which escapes in the liquid state; whenever possible,
a leak of liquid chlorine should be converted into a leak of gaseous chlorine.

Should a leak from a drum or a cylinder be found in a position such that the
chlorine is escaping in liquid form, the package should be moved as quickly as
possible so that the source of the leak is situated in the gaseous phase.

2.4. Limiting the Gas Leak

A mobile funnel with a flexible hose connected to an absorption system may be
used (if adequate piping is provided near the leak).

The leaking equipment can be connected to an absorption system and

depressurised as quickly as possible, ideally to below atmospheric pressure.

The evaporation of chlorine from a vessel causes it to be cooled; if the flow rate
is significant, the cooling will cause the internal pressure to drop and the leak-
rate will decrease.

In the case of small containers, use of a cooling agent can be quite effective. As
cooling agents, dry ice (solid carbon dioxide) is recommended. Liquid nitrogen is
probably easier to obtain and to handle than carbon dioxide, but the effect of a
very low temperature on the vessel (risk of brittleness) may be dangerous.

3. STOPPING A LEAK

This section is not intended to be an exhaustive inventory of all the means of

stopping a leak but suggests some simple means of sealing which can be
employed. For further details, refer to appendix for the various types of leaks
encountered on a vessel and the measures to be taken in each of these cases.

Methods for sealing leaks differ according to the type of leak, its size and the
position at which it occurs.

All these repairs shall be considered temporary.

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3.1. Leak from a Cylindrical or Convex Wall

If a leak is located on a cylindrical or convex wall (body of a vessel), pipeline,
etc. a small sheet of thick rubber can be applied over the leak, or alternatively a
cushion which can be inflated to sufficient pressure (clamp fitting, wire ligature,
etc.).

3.2. Leak from a Small Diameter Hole

If the source of the leak is circular in shape with a small diameter, it may be
stopped with a wooden, copper, lead or brass pin. Before driving the pin into the
hole, check that the metal surrounding the hole is sufficiently sound (no
generalised corrosion) so that the size of the leak is not aggravated. The pin
should be fixed in position, if possible.

Alternatively, a leak sealing lance can be introduced through the hole, inflating
a cushion inside.

In some cases it may be possible to seal the leak with special mastic, Teflon
strips, quick setting cement, etc. (see appendix 2 for cements, resins and
mastics).

3.3. Leak from a Weld on a Pipe

If possible, gently tighten the crack using clamps. Additionally, a Teflon strip or
mastic may be compressed by means of a pipe clip. A worm-gear clamp and
rubber stoppers may be used to stop leaks on welds or when the leak is in a spot
that a normal clamp cannot fit.

3.4. Leak from a Valve

See Appendix 1

4. USING A SEALED CONTAINER

In order to transport a leaking cylinder or drum, a gas-tight container (salvage

vessel, "coffin") should be used.

These containers are custom made and thus are particularly suitable for this use.
Several companies have such containers.

5. MEANS OF SLOWING DOWN THE VAPORIZATION OF A

LIQUID CHLORINE POOL

Covering the chlorine pool with a plastic sheet is the primary recommendation.

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The use of a medium density, chlorine compatible foam may be recommended.

It must be noted that the first effect of the high water content spray is
increasing the vaporisation rate of the liquid chlorine.

The best practice is to use protein based foam, with low drainage rate (ideally
greater than 15 minutes 25% drain down time), produced and applied on the pool
with an appropriate system of foam generator to avoid mixture of chlorine with
foam, for example:

- MOUSSOL APS made by Dr. STHAMER

Dr. SthamerHamburg
Liebigstrasse 5, D - 22113 Hamburg, Germany
Phone: +49 40 73 61 68-0
Fax: +49 40 73 61 68-60
http://www.sthamer.com
E-Mail: info@sthamer.com
- POLYPETROFILM made by EAU et FEU
Eau et Feu
ZI Sud Est, Rue Aloys Senefelder, BP 1008, 51683 Reims, France
Phone: +33 3 26 50 64 10
Fax: +33 3 26 09 64 38
http://www.eauetfeu.fr
E-mail: contact@eauetfeu.fr

Spraying of carbon dioxide may be a good mean to reduce the vaporisation of

liquid chlorine.

Liquid nitrogen is not recommended because its rapid evaporation could carry
over too much chlorine.

6. REFERENCES

 GEST 90/162 - Emergency Transfer of Liquid Chlorine

 GEST 92/171 - Personnel Protective Equipment in the Chlorine Industry

 GEST 94/206 – Safe Use of Chlorine from Drums and cylinders

 GEST 76/55 - Maximum Levels of Nitrogen Trichloride in Liquid Chlorine

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APPENDIX 1 - INTERVENTIONS

1. ON CHLORINE CYLINDERS AND DRUMS

1.1. Specialised Teams

PROBLEMS / LEAKS ACTIONS

CYLINDERS  Close valve if possible

 Leak from the valve  Cover with a safety hood

 Put the cylinder in a sealed container if
available
 Transfer content to an absorption unit.
DRUMS  Close valve if possible

 Leak from the valve  Reduce the leak (cap)

 Rupture of the valve  Cover with a safety hood

 Place the tank in a sealed container if
available
 Transfer content to an absorption unit.
DRUMS  Reduce the size of the leak (see chapter 3)

 Leak from the upper end  Place the drum in a sealed container if
available
 Leak from the main body
 Transfer content to an absorption unit.

1.2. Users
The following intervention instructions are intended for people handling
cylinders and drums on sites where chlorine is used (water treatment stations,
swimming pools, etc.). In each case the supplier will be informed as soon as
possible.

They consist of actions to be performed before external emergency teams arrive

on site.

Please remember that any intervention must be carried out using protection
means which are correctly suited to the hazards involved (see GEST 92/171 -
Personnel Protective Equipment in the Chlorine Industry):

A basic principle: Whenever possible, turn a liquid phase leak into a gas phase
leak. The container should be placed in such a way that the leak is in the gas
phase of the container. If possible, try to continue consuming the chlorine in
the downstream process or absorption unit.

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1.2.1. Intervention on Cylinders

PROBLEMS ACTIONS

1.1. Close the valve and disconnect the consumer equipment

1.2. If the leak persists, attach the safety cap with gasket

1.3. If leak from the gland follower = Tighten up the gland follower nut.
If the leak still persists :

1. Leak from the valve or on the thread  Tap the upper part of the valve spindle slightly with a rubber or wooden hammer and try to
close the valve.
1.4. If the leak still persists :
 Apply a vented valve cover or place the cylinder in a sealed container.
 If there is no such equipment (within a reasonable time), the following can be done: vent
using a valve and hose into a 20% solution of caustic soda (500 kg of 20% caustic soda for 50
kg chlorine), or immerse the cylinder in such a solution.

2.1. Stand the cylinder upright (valve in gaseous phase)

2.2. Plug up the hole with a wooden, lead or copper plug.

2. Broken valve 2.3. Apply a vented valve cover or place the cylinder in a sealed container, if available.

2.4. If there is no such equipment (within a reasonable time), the following can be done: vent
using a valve and hose into a 20% solution of caustic soda (500 kg of 20% caustic soda for 50
kg chlorine), or immerse the cylinder in such a solution.

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PROBLEMS ACTIONS

3.1. Position the cylinder so that the leak is in the gaseous phase.

3.2. Fill in the hole either with :

 plug (wood or other),
3. Leak from the main body of the cylinder
 device made from a rubber sheet, metal (no titanium!) plate and wire (strapping)
 Inflatable cushion, VETTER* type.
3.3. Notify the supplier for the transfer of the cylinder (container)

Any defective cylinder which has to be sent back to the supplier should be accompanied with a
REMARK
document describing the anomaly.

* Manfred Vetter GmbH

http://www.vetter.de

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1.2.2. Intervention on Drums

PROBLEMS ACTIONS

1.1. Close the valve and disconnect the consumer equipment.

1.2. Rotate the drum to have the leaking valve in the gas phase, if possible.

1.3. If the leak persists, attach the safety cap with gasket.

1. Leak from the valve 1.4. If there is a leak from the gland follower: tighten the gland follower nut.

1.5. If the leak persists, depending on the availability of equipment or the installation :
 either place a safety hood over it or place the drum in a sealed container,
 or vent the drum to an absorption unit (10 000 kg 20% caustic soda for 1000 kg chlorine) or
even in a tank.

2.1. Try to tighten up the joint slightly.

2. Leak from the valve flange gasket
2.2. If the leak persists, identical actions as in section 1.5 here above

3. Rupture of the valve 3.1. Position the drum to have a gaseous phase leak, if possible.

or 3.2. Plug the hole with a wooden, copper or lead plug.

Rupture of the stud 3.3. If the leak persists, identical actions as in section 1.5 here above

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PROBLEMS ACTIONS

4.1. Position the drum to have the leak in the gaseous phase, if possible.

4. Leak from the hand hole cover gasket 4.2. Use a screw-clamp or carefully try to tighten the joint (reasonable force).

4.3. If the leak persists, identical actions as in section 1.5 above.

5.1.Position the drum to have the leak in gaseous phase.

5.2. Fill in the hole, using either :

 a plug,
5. Leak from the main body of the drum
 a device consisting of a rubber sheet, metal plate (no titanium!) and wire (strapping)
 an inflatable cushion, VETTER type.
5.3 If the leak persists, identical actions as in section 1.5 above

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2. ON RAIL AND ROAD TANKERS OR ISO-CONTAINERS

If a problem is detected, the consumers or hauliers should inform the supplier and request advice and support.

PROBLEMS ACTIONS

1.1. Open the actuator vent cap (if this has not already been done)

1.2. If still impossible to open, try the other liquid valve if available

1.3. If still impossible, open the valve by direct action on the spindle using the manual safety
1. Impossible to open the liquid chlorine
system.
valve(s)
1.4. Offload the wagon

1.5. If not possible to open any liquid phase valve, vent the tanker in the gas phase taking into
account the NCl3 concentration increase (see GEST 55)

2.1. Tighten up the flange bolts or safety cap

2. Leak from the blank flange or cap
2.2. Change the gaskets, nuts and bolts (only if primary isolation is present).

3.1. Close valve if possible

3. Valve bellows pierced + leak through the 3.2. Attach or tighten up the relief cap
relief cap
3.3. If the leak persists, clean the threat of the cap, re-thread or attach a plug and tighten with a
fixation system, clamp, etc.

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PROBLEMS ACTIONS

4. Bellows pierced + membrane pierced (or 4.1.Proceed as in 3 here above

piston seal leaking) + leak on control air
intake 4.2.Screw a cap in the place of the air supply connection

5. Bellows pierced + membrane pierced (or 5.1. Process as in 3 here aboved

piston seal leaking) + leak through the
spindle 5.2. Fix a gasket on the valve blocking cap or Teflon on the spindle thread

6.1. Process as in 3 here above

6. Bellows pierced + defective seal on
external membrane
6.2. Tighten the nuts at the valve head

7.1. A cover or funnel covering the valve and connected to an absorption unit is helpful to reduce
7. Any valve leaks
emission of chlorine

8.1. Close the valve

8.2. Carefully tighten up the fixation nuts on the valve

8. Leak between the external and internal
valves (very uncommon)
8.3. If the leak persists, unload the tank by using the other liquid valve, if present
8.4. If the leak persists, and only for the gaseous phase valve,
 empty the tank with dry air or nitrogen
 try if possible to remove the outer valve after testing the seal of the internal valve by
slightly opening the outer valve without opening the inner valve (use the manual spindle).
Replace with a blank flange or another valve.

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PROBLEMS ACTIONS

9.1. Tighten up the nuts

9. Leak from the manhole cover of the 9.2. Try to caulk the leak with lead wires
tanker
9.3. If the leak is at the gaseous phase level (tanker in upright position), empty the tank with dry
air or nitrogen

10.1. Attach a blank flange or another outer valve, if possible (no damaged parts)
10. Outer valve torn off
10.2. If impossible, empty the tanker into another tank at the scene of the incident

11.1. Close the valve

11. Leak from the valve unit downstream of
the outer seat
11.2. Seal using a plug or tightening device

12.1. Fill in the hole with either :

 a plug
 a device consisting of a rubber sheet, metal plate and strapping
12. Leak from the body of the tanker  an inflatable cushion, VETTER type
12.2. A cover or funnel covering the leak and connected to an absorption unit is helpful to reduce
emission of chlorine

12.3. Unload the tanker into another tank

12.4. Degas the tanker

REMARK: If transfer into an empty tank is considered, see GEST 90/162 - Emergency Transfer of Liquid Chlorine.

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APPENDIX 2 - CEMENTS, RESINS AND MASTICS

Each company seems to have own recipes to seal chlorine leaks but the practical
experience is too limited to offer a specific recommendation.

Available information can be summarised as follows:

1. Normal practice for dealing with leaks is to use plugs, pipe clamps, sheets of
rubber, Viton, Teflon, lead pressed over the leak and steel or lead caulking
as described in the recommendation.

2. In some cases, injection of binding material into prefabricated cover or

clamps is considered.

Products used are:

PTFE brand FSC 5C PUTTY

Furmanite International Ltd - UK MIDWAY MANUFACTURING, Inc.
Furman House P.O. Box 251
Shap Road, Kendal Kinsley, KS 67547
Cumbria LA9 6RU USA
www.furmanite.co.uk www.midwaymfg.com

Compound TT1 Metalock Resin Sikadur 43

Metalock Engineering UK Ltd SIKA S.A
Unit H5 Pilgrims Walk, Prologis Park 101 rue de Tolbiac
Coventry CV6 4QG 75013 Paris
England France
www.metalock.co.uk www.sika.fr
sales@metalock.uk hotline@fr.sika.com

WAPEX 201
Akzo Nobel Decorative Coatings B.V.
Rijksstraatweg 31
The Netherlands
www.sikkens.nl
info@sikkens.nl
Service company to place clamps:
Team Industrial Services Netherlands
Postbus 37
4380 AA Vlissingen
www.teamindustrialservices.nl/team_contacts_mechanical_services.htm
infoNL@Teaminc.com
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3. For piping under slight pressure temporary sealing is possible by using quick
acting cement in combination with a cover from steel sheet or plastic.

Neurofix

HASIT Trockenmörtel GmbH

Landshuter Straße 30

D - 85356 Freising

Germany
www.hasit.de

MC-Emfix
MCBauchemie Müller GmbH & Co. KG
Am Kruppwald 1-8
D - 46238 Bottrop
Germany
www.mc-bauchemie.de
info@mc-bauchemie.de
4. For wet chlorine below atmospheric pressure, GRP pipes can be tightened
with compatible resins.

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Industrial consumers of chlorine, engineering and equipment supply companies

worldwide and chlorine producers outside Europe may establish a permanent
relationship with Euro Chlor by becoming Associate Members or Technical
Correspondents.

Details of membership categories and fees are available from:

Euro Chlor

Avenue E Van Nieuwenhuyse 4

Box 2

B-1160 Brussels

Belgium

Tel: +32 2 676 7211

Fax: +32 2 676 7241

e-mail: eurochlor@cefic.be

Internet: http://www.eurochlor.org

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