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This document can be obtained from: EURO CHLOR - Avenue E. Van Nieuwenhuyse 4, Box 2 - B-1160 BRUSSELS Telephone: 32-(0)2-676 72 65 - Telefax: 32-(0)2-676 72 41
Euro Chlor
Euro Chlor is the European federation which represents the producers of chlorine and its primary derivatives. Euro Chlor is working to:
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This document has been produced by the members of Euro Chlor and should not be reproduced in whole or in part without the prior written consent of Euro Chlor. It is intended to give only guidelines and recommendations. The information is provided in good faith and was based on the best information available at the time of publication. The information is to be relied upon at the users own risk. Euro Chlor and its members make no guarantee and assume no liability whatsoever for the use and the interpretation of or the reliance on any of the information provided. This document was originally prepared in English by our technical experts. For our members convenience, it may have been translated into other EU languages by translators / Euro Chlor members. Although every effort was made to ensure that the translations were accurate, Euro Chlor shall not be liable for any losses of accuracy or information due to the translation process. Prior to 1990, Euro Chlors technical activities took place under the name BITC (Bureau International Technique du Chlore). References to BITC documents may be assumed to be to Euro Chlor documents.
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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 GEST Working Group to whom all suggestions concerning possible revision should be addressed through the offices of Euro Chlor.
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TABLE OF CONTENTS
1 2 DEFINITIONS......................................................................................................... 6 GENERAL STATEMENTS .................................................................................. 6 2.1 2.2 2.3 3 4 LIQUID PHASE ..................................................................................... 6 GASEOUS PHASE ................................................................................. 7 CHOICE OF PHASE .............................................................................. 7
BASIC DESIGN AND INSTALLATION ............................................................. 7 CONSTRUCTION AND DESIGN ....................................................................... 8 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 DESIGN PRESSURE ............................................................................. 8 DESIGN TEMPERATURE .................................................................... 8 FLUID VELOCITIES ............................................................................. 9 CORROSION ALLOWANCE ............................................................... 9 RADIUS OF CURVATURE .................................................................. 9 THERMAL INSULATION .................................................................... 9 TRACE HEATING OF CHLORINE GAS PIPELINE .......................... 9 MATERIALS OF CONSTRUCTION .................................................. 10 Piping 10 Flanges, nuts and bolts 10 Gaskets 11 Thermal insulation 11 SUPPORTS ........................................................................................... 11 Buried pipeline 11 Pipelines above-ground or in trenches 11 INSPECTION OF PIPING MATERIALS ............................................ 12 INSPECTION PROCEDURES DURING CONSTRUCTION ............ 12
ACCESSORIES ................................................................................................... 12 6.1 FLANGES, BRANCHES AND ANCILLARY EQUIPMENT ............ 12 6.2 END CONNECTION VALVES ........................................................... 13 6.3 ISOLATION VALVES ......................................................................... 13 6.4 EMPTYING, VENTING AND PURGING .......................................... 13 6.5 TRANSFER EQUIPMENT .................................................................. 14 6.6 PROTECTION AGAINST OVERPRESSURE AND THERMAL EXPANSION ...................................................................................................... 14 6.7 PROTECTION AGAINST SURGE FOR LIQUID CHLORINE......... 15 6.8 PROTECTION AGAINST CORROSION ........................................... 15
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6.9 EQUIPMENT FOR MEASUREMENT AND MONITORING THE CONDITION OF THE PIPELINE ...................................................................... 16 6.10 MALOPERATION MEASURES/PROCEDURES .............................. 16 7 OPERATION ........................................................................................................ 16 7.1 CLEANING AND DRYING BEFORE PUTTING INTO SERVICE.. 16 7.2 LEAK TESTING................................................................................... 17 7.3 COMMISSIONING AND TESTING BEFORE PUTTING INTO SERVICE ............................................................................................................ 17 7.4 TAKING THE PIPELINE OUT OF SERVICE ................................... 17 7.5 QUALITY OF THE CHLORINE INTRODUCED .............................. 18 7.6 PRECAUTIONS AGAINST INGRESS OF MOISTURE OR OTHER REACTIVE MATERIALS ................................................................................. 19 7.7 PRECAUTIONS IN THE EVENT OF FAILURE OF THE TRACE HEATING (FOR GAS PIPELINE)..................................................................... 19 7.8 PERIODICAL INSPECTION AND TESTING ................................... 19 7.9 EMERGENCY PROCEDURES AND TRAINING ............................. 20 8 REFERENCES .................................................................................................... 21
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1 DEFINITIONS
This code of practice concerns the transfer of dry gaseous or liquid chlorine by long distance pipelines. These are defined as pipelines which pass outside of the limits of a chlorine producer or consumer site boundary.
2 GENERAL STATEMENTS
Chlorine can be transported safely by a long pipeline, either in the gas or liquid phase, provided the appropriate design and operating conditions are satisfied. All precautions should be taken such that, in a pipeline designed to carry only liquid chlorine, vaporisation cannot occur, and in a pipeline designed for the transport of only chlorine gas, nothing should lead to the formation of liquid. In each case, specific precautions are required. These are described for both states within this recommendation. I some exceptional circumstances gaseous chlorine pipelines have been designed to accept some partial liquefaction in function of the physical conditions; in this case the construction and the operation procedures have to take all necessary precautions to cope with the phenomena, and especially: Minimum design temperature and material of piping, Thermal expansion of trapped liquid chlorine, Drain tank for rapid emptying of the chlorine, Maximum velocity of the fluid. This very specific case is not considered in this recommendation.
The above will determine the length and throughput of a particular pipeline system, as pumping stations outside the confines of a chlorine-producing or
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consuming factory are not recommended. In Europe, there are many years experience of liquid phase pipelines up to a length of about 8 km with inlet pressures up to about 30 bars (a).
In Europe, there are many years experience with gas phase pipelines up to a length of 4 km and with inlet pressures up to 6 bars absolute.
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Where the pipeline is buried, the route of the pipeline should be well indicated at the surface, and it should be protected against any unauthorised excavation, by some form of below ground indicator (for example concrete slabs marked "buried pipeline"). Dividing a liquid chlorine pipeline into smaller segments with automatic isolation valves, in order to improve safety, is not recommended. For gaseous chlorine, the need for rapidly closing (automatic or remotely controlled) isolation valves along the length of the pipeline is related to its length and to the quantity of chlorine held up in the pipeline. For safety considerations, the maximum quantity of chlorine accepted between two isolation valves should be related to the location of the pipeline (safety study). In both cases, such valves represent a weak point in the construction of the pipeline, adding the supplementary risk, for liquid chlorine, of trapping liquid between two closed valves with possible thermal expansion thereafter (necessity to install special protection and possibility to connect to absorption system for each section). Therefore, it is recommanded to avoid such isolation valves outside the confines of industrial premises. The in- and outlet of the pipeline will be equipped with isolation valves (taking into account the risk of surge for liquid chlorine), and at least one of the extremities will be connected, via remotely operated valve, to a degassing system (with surge tank for liquid chlorine) and chlorine absorption facility. This will allow safe depressurisation of the pipeline in case of an incident.
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For gaseous chlorine, the complete system should be designed for the maximum temperature capable of being attained and for the lowest temperature that can occur.
heating system and to avoid any localised overheating to prevent local corrosion or chlorine/iron fire. Such overheating can be prevented on the basis of suitable calculation of the heating density, so that at no point the metal temperature should not exceed 120C. Electrical trace heating by means of quality resistance elements (self limiting in temperature) attached to, the chlorine pipeline is preferred, The resistance elements should preferably be armoured externally and protected against corrosion and the ingress of moisture. The capacity should be calculated as a function of the thermal losses, and not as a function of the heat input required for the revaporisation of the liquid chlorine. Spirally wound trace heating should be avoided except over short distances. Resistance heating using the pipe itself shall not be used. Trace heating with steam, using tubing attached to the chlorine pipeline can also be used as an alternative. Steam can be replaced by any other heating fluid (i.e. hot water). Steam pressure must be low enough to ensure that temperature does not exceed 120C. Desuperheating devices may be required if the steam is not saturated. If steam trace heating is applied all connections should be outside the insulation to prevent corrosion (water in insulation resulting from possible leaks).
The steel chosen for the construction of the pipework should be of a certified quality, fine grain steel and readily weldable. For liquid chlorine, it will have a satisfactory impact strength, according to the standards being used, at minus 40C after welding. The metal used in branches and other pieces welded to the pipe should be of a quality compatible with the base metal chosen for the pipe itself. It is advisable to choose a quality of steel which avoids the need for stress relief after welding. Seamless pipe is preferred. Flanges, nuts and bolts
The pipeline should be completely welded with only flanges at the beginning and the end. The metal used for flanges, nuts and bolts should possess the same characteristics as that of the piping. Weld neck flanges should be used for all
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flange connections. The flanges should be designed to avoid a possible expulsion of the gasket (e.g. male/female or tongue and groove type), and taking into consideration the continuity of the cathodic protection (if present). Gaskets
The gasket used should be made in a material with positive experience on chlorine, see GEST 94/216 - Experience of Non-Asbestos Gaskets on Liquid and Dry Chlorine Gas Service for further information. Thermal insulation
If the installation of thermal insulation is necessary, the materials to be applied should meet the following criteria: Non-flammability Chemically inert to chlorine Totally sealed against the ingress of moisture Protected against mechanical damage.
The most appropriate materials corresponding to these criteria are, for example, foam glass and vapour seal polyurethane (non-flammable or auto-extinguishing) ... Preventing the ingress of atmospheric moisture necessitates the choice of a closed pore structure material, or provision of a high quality external gas-tight wrapping. Note: the bare pipeline (carbon steel) should be coated before the insulation is applied, to prevent corrosion by moist air. Aluminum shall not be used for insulation cladding due to reactivity concerns.
4.9 Supports
Buried pipeline
If the terrain to be crossed is unstable or susceptible to movement, a pipeline should not be buried in the ground. Pipelines above-ground or in trenches
The supports should be fixed on foundations, which provide adequate rigidity (taking account surge effects for liquid chlorine). If necessary, they should be insulated from the pipe with a mechanically robust material, which also provides adequate thermal insulation to avoid frosting on the support (leading to external corrosion). The supports should permit the thermal expansion of the pipeline due to any likely variations in temperature, and should also deal with any possible earth movement. The support system should be designed to avoid any ingress of moisture under the thermal insulation.
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Valve operation should be guaranteed at the pipeline design temperature (minus 40C for liquid chlorine). If the pipeline is to be cleaned or inspected with a "pig", the valves should be of the full bore type in order to permit passage.
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possible, the pipeline will be emptied by gravity. It is also possible to empty the pipeline by gas pressure or by the use of a "pig". The design must be such that chlorine gas can be vented into a suitable installation (absorption unit or compression and liquefaction of adequate capacity). In the case of liquid chlorine, it should be noted that this venting will take place at low temperature. All equipment associated with the operation, therefore, should be suitable for the actual temperatures which will arise.
Purging: Inert dry gas (dew point less than minus 40C at 1 bar (a)) of adequate quantity and pressure should be permanently available. Purged gas should be passed through a suitable absorption installation to remove chlorine, before being vented to atmosphere.
For gaseous chlorine, the choice of compressor for feeding the pipeline system is a function of the characteristics required (throughput, operating pressure, maximum pressure). A non return system should be installed on the down stream side of the compressor and particular attention must be paid to its reliability (the choice of an automatic valve is recommended). If the gas supply comes from vaporisation of liquid chlorine, and if the working pressure is high enough, it is possible to work without any additional transfer equipment.
Where isolation valves are provided along the length of the pipeline, provision must be made to allow for thermal expansion of any trapped liquid chlorine. Such provision should preferably be provided at least at one of the extremities of the pipeline and situated inside the confines of an industrial location. This can be achieved by either of the following methods:
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Closed expansion tanks, in which it is necessary to verify the permanent presence of a gaseous phase. This gas phase can be obtained either by vaporised chlorine, or by the use of an inert gas. Bursting discs or relief valves discharging into a vessel or a collection system. In controlled circumstances, it should be possible to isolate these relief devices for maintenance. The bursting of the disc or the functioning of the relief valve should be alarmed.
If the compressor is capable of overpressuring the pipeline, a relief device must be installed at the outlet of the compressor. These relief devices should always be connected to an absorption system or a point of use in the liquefaction. They should be capable of being isolated from the pipeline for maintenance. Steel pipe thermal expansion The thermal expansion and contraction of the pipe should be carefully studied and all precautions should be taken to avoid any unacceptable consequences. The design basis for thermal expansion of the pipeline should take into account the maximum and minimum achievable temperatures. In case of liquid chlorine, the minimum temperature to consider should be minus 40C. For above ground pipelines, it is preferable to use large radius expansion loops. Expansion bellows must not be used because they are weak points in the construction. For straight lines, where free expansion cannot take place, account must be taken of the longitudinal stresses which will result from the maximum variation in temperature.
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6.9 Equipment for Measurement and Monitoring the Condition of the Pipeline
All pipelines should include as a minimum the following equipment: Measurement and recording of the pressure and temperature at the inlet and outlet. Maximum and minimum pressure (and temperature for chlorine gas) alarms and, if appropriate, means for relaying their signals to both ends of the pipeline. Flow measurement at both ends with differential alarms or, for liquid chlorine, .measurement of the weight of the feed or discharge tanks,
The personnel at both ends of the pipeline should be provided with appropriate methods for monitoring the functioning and status of the safety measures indicated above, i.e.: Remotely operated isolation valves at the two ends. Remotely operated isolation valves along the length of the pipeline, if any. Bursting discs and relief devices (if presents). Connections to the venting system (and drain tank for liquid chlorine).
If the pipeline is completely or partly double walled for a specific reason, a leak detector should be installed (e.g. pressure alarm or chlorine detector on the purge gas of the dubble wall). Permanent connections by telephone and/or computer connection between the two ends of the pipeline shall be provided.
Drying should be carried out with the aid of a dry inert gas to obtain a stable dew point of less than minus 40C at 1bar (a) at the exit of the pipeline. Drying by the use of methanol or hydrocarbons, which could cause a risk of explosion in the presence of chlorine, should be done only in well controlled circumstances where perfect draining of the pipe can be ensured with additional purging with nitrogen, not forgetting the branches. If possible, vacuum drying may be used. For greasing internal equipment which can possibly come into contact with the chlorine, only greases compatible with chorine can be used (chlorofluorinated grease).
possible to remove the liquid chlorine with the aid of nitrogen, dry compressed air or with a pig. In the case of removal by inert gas, care must be taken to remove first as much liquid chlorine as possible before injecting the inert gas (chlorine vaporisation could then lead to a quite low temperature). For a few hours shutdown of a gaseous chlorine pipeline the thermal tracing, if any, will be turned off to avoid the risk of hot spots, and the pressure lowered; the pressure may not fall below atmosphere to avoid air ingress but, whenever possible, stay below the chlorine vapour pressure corresponding to the pipeline temperature, to prevent the risk of liquefaction; before restart, all efforts must be made to confirm the absence of any liquid phase chlorine. If works have to be performed on the pipeline, or if the duration of the shut down is too long to guarantee a correct continuous surveillance, the thermal tracing, if any, will be kept off, and the chlorine in the pipeline will be replaced by dry inert gas (dew point lower than minus 40 C) by depressurisation, venting and purging towards an appropriate installation (liquefaction, absorption, etc). This operation should be continued until the residual chlorine content within the system permits its opening or dismantling without risk of corrosion or gassing of personnel. For all maintenance operations the pipeline shall be isolated upstream and downstream by the installation of blank flanges, or the removal of a spool piece provided for this purpose.
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The influence of the initial pressure is relatively small between 0.25 and 11.5 bara. It is recommended that experimental measurements are undertaken if operating at higher pressure. The practical operating conditions in the production lines and equipments will be chosen to work with a suitable safety margin with respect to these limits, taking into account the fact that pressure increase widens the flammability zone and that the concentration will increase either as a result of condensation in a pipeline operating under high pressure in cold weather. In-line analysers will be used to check that one always remains below the low limit of the table. The quality of chlorine introduced in the pipeline should be checked periodically.
7.7 Precautions in the Event of Failure of the Trace Heating (for Gas Pipeline)
In the event of failure of the trace heating system, for which the operating personnel should be aware, it is preferable to reduce the pressure in the pipeline and to vent it down to avoid chlorine liquefaction. If accidental liquefaction does take place, it is essential to reduce the pressure in the pipeline and to allow it to vent down before putting it back into service.
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A visual inspection at least once per week of the pipeline and its surroundings should be carried out. Particular attention should be paid to the following aspects: Areas of frosting or deterioration of the thermal insulation. Circumstances arising in the vicinity of the pipeline which could present any risk to it, e.g. crane activity. A check that the warning devices (flow - and pressure measurements) and communication systems are functioning correctly. Buried pipelines A visual inspection of the route, from the air and/or on foot, at least once per week, with: A check that the confines of the pipeline are as specified. A check that the warning devices (flow - and pressure measurements) and communication systems are functioning correctly.
A check on the cathodic protection (At least once per year). Inspection and test Periodic inspection and testing of the system is required, with an interval never exceeding 5 years. It should take into account the following aspects: Thickness testing of the pipe walls in specific areas as specified at the time of construction (ultrasonic). Visual inspection of the protective coating of the buried pipeline. A check on all equipment. As a general rule, all accessories should be replaced in a systematic manner before there is any risk of them becoming defective. Inspection of the supports for above ground pipeline systems.
Re-testing
If a re-test is required, a pneumatic test is preferred. A hydraulic re-test of the pipeline is not advisable, because of the subsequent risk of internal corrosion to the piping system which could occur in a potentially uncontrolled manner.
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Self-contained breathing equipments and protective clothing suitable for dealing with a chlorine leak (liquid if it is the case) should be available in lockers located near to the ends of the pipeline, and accessible at all times in case of emergency. A means of indicating the wind direction should be installed in order to inform the operators of the direction of gaseous dispersion that might occur in the event of a leak. During the periodic check of the pipeline, as indicated above in 3.5.6, the personnel carrying out the inspection should be provided with checklists covering the principal points to be controlled. These checklists and, if necessary, additional remarks, are collected in a logbook. Bearing in mind the specific hazards associated with chlorine-iron fire, a study should be carried out of the means of dealing with a fire in the vicinity of the pipeline. Common routing of the pipeline with electric cables or flammable fluids should be avoided.
8 REFERENCES
GEST 72/10 - Pressure Storage of Liquid Chlorine GEST 76/55 - Maximum Levels of Nitrogen Trichloride in Liquid Chlorine GEST 79/81 - Dry Liquid and Gaseous Chlorine Piping Systems Located Inside Producer's or Consumer's Plants GEST 79/82 - Materials of Construction for Use in Contact with Chlorine (General Information) GEST 79/82A - Choice of Materials of Construction for Use in Contact with Chlorine (Spreadsheet) GEST 89/140 - Specification for Flanged Steel Globe Valves (Bellows Sealed) for Use with Liquid Chlorine GEST 90/150 - Specification for Flanged Steel Globe Valves (Packed Gland) for Use with Liquid Chlorine GEST 93/180 - Specification for Flanged Steel Ball Valves (Packed Gland) for Use with Liquid Chlorine GEST 99/252 - Specification for Flanged Steel Ball Valves for Use with Dry Gaseous Chlorine
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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.
Euro Chlor Avenue E Van Nieuwenhuyse 4 Box 2 B-1160 Brussels Belgium Tel: Fax: e-mail: Internet: +32 2 676 7211 +32 2 676 7241 eurochlor@cefic.be http://www.eurochlor.org
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