Beruflich Dokumente
Kultur Dokumente
Cylinders
GEST 94/206
2nd Edition
January 2013
GEST 94/206
2nd Edition
Euro Chlor
Euro Chlor is the European federation which represents the producers of chlorine
and its primary derivatives.
Euro Chlor is working to:
***********
This document has been produced by the members of Euro Chlor and should not be reproduced in
whole or in part without the prior 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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Nature
All
All
All
All
All
TABLES OF CONTENTS
1.
INTRODUCTION
1.1.
2.
3.
Types of Installation
1.1.1.
1.1.2.
1.1.3.
1.2.
Risk of Overfill
1.3.
2.1.
2.2.
2.3.
11
2.4.
Order of Consumption
12
12
12
3.1.1.
Fire Risk
12
3.1.2.
Outdoor Storage
13
3.1.3.
13
3.1.4.
13
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3.1.5.
3.2.
14
14
3.2.2.
Access
14
3.2.3.
Ventilation
14
3.2.4.
Temperature
15
3.2.5.
15
3.2.6.
15
3.2.7.
Safety Devices
16
3.2.8.
17
18
3.3.1.
Cylinders
18
3.3.2.
Drums
19
CHLORINATION EQUIPMENT
19
4.1.
20
4.2.
Chlorinator Installation
20
4.2.1.
20
4.2.2.
Securing
21
4.2.3.
Water Supply
21
4.3.
5.
13
3.2.1.
3.3.
4.
Proximity of Access
Chlorinator Operation
21
OPERATING PROCEDURES
21
5.1.
Changeover
22
5.2.
Cylinder Changing
22
5.2.1.
22
5.2.2.
23
5.2.3.
23
5.2.4.
Connection
25
5.3.
27
5.4.
28
5.5.
29
6.
30
7.
EMERGENCIES
30
7.1.
Emergency plan
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7.2.
Coordination
31
7.3.
Plan Details
31
8.
32
9.
TRANSPORT OF CHLORINE
33
10. REFERENCES
33
33
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1. INTRODUCTION
This document describes safe storage and use of liquid chlorine delivered in
drums and cylinders to small and moderate demand consumers such as nondomestic swimming pools, potable water or sewage treatment works, or small
industrial consumers.
The construction, filling and handling of cylinders and drums is covered in GEST
88/138 Small Chlorine Package Construction, Filling and Handling.
This document does not cover bulk liquid chlorine; storage, transport and use of
bulk chlorine are addressed in various other GEST documents (mainly GEST
73/20, GEST 73/25, GEST 78/72, GEST 78/73 and GEST 79/76).
It is not the purpose of this recommendation to address matters such as
swimming pool or water treatment chemistry or the optimum chlorine content
needed to maintain adequate water quality. The objective is to minimise any
risk to the staff or public at the consumers premises due to use of chlorine.
It is expected that chlorine is delivered in liquid phase in cylinders of capacity
typically not exceeding 100 litres or drums with a capacity not exceeding 1000
litres (see definitions in GEST 88/138).
Finally, it is strongly recommended that a sufficient number of operators of the
user site should be periodically trained to ensure the necessary competence in
handling chlorine.
1.1.
Types of Installation
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at a higher rate than is possible from either above options. It is also more
complex and requires greater safeguarding (e.g. chlorine detectors linked
to automatic isolation valves on the drum), because the mass release
rates from a hole in pipework carrying liquid are significantly greater than
those for the same hole in pipework carrying gas. This system should
never be arranged to draw liquid chlorine from more than one drum at a
time (see 1.2).
1.2.
Risk of Overfill
Chlorine packages are delivered with a gas space above the liquid to allow for
expansion. If this space is lost and a package becomes hydraulically full there is
risk of rupture or distortion if the temperature increases.
Whenever packages are connected together via a common manifold, there is risk
of chlorine passing from one vessel to another. This may occur when one vessel
is at a significantly different temperature from the others, for example, when
exposed to a cold wind (causes in-flow from warmer packages) or direct sunlight
(causes out-flow to cooler packages). The risk of significant mass transfer is
much higher in liquid phase and this is why liquid valves should not be connected
in this way.
If you suspect that packages are almost hydraulically full, they should not be
isolated (except in an emergency) until it is possible to reduce the level of liquid
in the vessel and restore the gas space.
1.3.
The gas flow rate from a single chlorine cylinder or drum is sufficient for some
applications. Some installations may require multiple packages in parallel.
The maximum chlorine gas flow rate is dependent on temperature. Based on
experience, typical flow rates are indicated in the following table with some
examples of package sizes:
Temperature, C
15
20
30
40
50 kg cylinder
71 kg cylinder
1.5
980 kg drum
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2.1.
2.2.
2.2.1 Cylinders may be delivered either on vehicle fitted with a tail lift,
or on platform vehicles. An acceptable alternative is to offload
onto a dock at the same height as the platform or tailboard of the
delivery vehicle (see Figure 1). Cylinders must never be dropped off
the vehicle.
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2.2.2 The offloading of both full and "empty" cylinders is the joint
responsibility of the customer and the vehicle driver.
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2.3.
2.3.1 Cylinders should be kept upright at all times, handled with care and
never dropped. Cylinders should always be moved as soon as
possible into the store using specially constructed wheeled carriers
that have a clamp or chain securing the cylinder (see Figure 3 next
page). The protective cap, dome or guard should always be in
position over the valve when the cylinder is being handled. It is
permissible to move the cylinder over short distances in the near
upright position by holding the cylinder shoulder and rotating the
whole cylinder. All cylinders should be secured and never in such a
position that they cause an obstruction. Never use the protective
cap, dome or valve to support the cylinder during handling.
2.3.2 Drums should be moved by forklift truck with a dedicated drum
handling attachment, by bogie, or (for short distances in straight
lines) by rolling if approved by the supplier. The valve cover must
be in place during drum handling. Stored drums should be secured
in cradles or using chocks and not stacked more than two levels
high.
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2.4.
Order of Consumption
It is strongly recommended that the store area and procedures be arranged such
that chlorine packages can be used in the order that they are delivered. This
minimises the risk of packages being left in storage for long periods. Long term
storage by customers increases the risk of valves being found to be stiff when
called upon to operate, and also may mean the packages are not subjected to
statutory testing in a timely manner.
3.1.
The selection of a site and the design of a storage room should take into account
the following potential hazards:
3.1.1. Fire Risk
Although the storage room itself shall be constructed from non-combustible and
low heat conductivity materials, there is still the risk to be considered in respect
of the remainder of the building. Chlorine gas packages are at risk of rupture if
the temperature exceeds 70C and in the event of a fire they will have to be
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kept cool or removed from the premises. Packages should never be stored near a
source of heat.
3.1.2. Outdoor Storage
Outdoor storage of unused drums and cylinders should be secured and under
cover to keep off rain and radiation from the sun. The boundary of an outdoor
storage area should be at least 5 m away from flammable materials.
Packages must not be allowed to stand in water because this will lead to
corrosion of carbon steel vessels. Also, as wet chlorine is extremely corrosive to
most metals, a slight leak may rapidly escalate into a significant one.
3.1.3. Leakage of Gaseous or Liquid Chlorine
Chlorine can be lethal and it follows that storage rooms must be well ventilated
at all times.
To remove packages easily and rapidly, it is strongly recommended that the
storage room be situated at ground floor level. Storage rooms sited below
ground level are not recommended; such installations pose problems in handling
cylinders and dealing with any chlorine leaks (heavy chlorine gas accumulates in
low areas).
It is possible to arrange the storage area to be vented to an absorption unit, but
this is not covered in detail in this document (see GEST 76/52 - Equipment for
the Treatment of Gaseous Effluents Containing Chlorine).
3.1.4. Proximity of Building Ventilation System Intakes
The storage/process room and all other parts of the chlorine system including
the outlet of any exhaust ventilation system should be sited well away from
windows or doors which open onto areas liable to be occupied, and in particular
from air intakes and ventilation systems.
The layout of buildings in the vicinity should not be such as to hinder the
dispersal of any leakage of gas or likely to channel any leakage towards air
intakes or other openings into the buildings.
3.1.5. Proximity of Access
Chlorine should be kept separate from normal working areas and access should
be limited to people working directly with it. The storage area should be
dedicated to the storage of chlorine, immediately associated equipment and
compatible materials and should be clearly identified.
The chlorine area should not be closer than 5 m to a roadway used by vehicles
unless adequate barriers (crash barriers or substantial walls) are provided. If the
walls of the store are intended to provide the impact protection, the structure
should be such as not to collapse onto or damage the installation. Where
vehicles have access into a store for loading and unloading, adequate high kerbs
or other fixed wheel stops should be provided.
The storeroom and the process installation should be sited away from public
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3.2.
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and 0.5 m above ground level. Chlorine gas sensors should be tested regularly in
accordance with the manufacturers instructions to demonstrate that the
detector and its associated circuits are functioning correctly.
Detection systems need to provide a continuous monitoring function when
chlorine is in storage or in use, and be able to operate the alarms in the event of
power loss, sensor failure, or low state of charge of stand-by batteries.
Detector activation concentration levels should be defined after considering
factors such as the size and location of the installation, and the available
equipment (ventilation systems, absorption systems etc.). Small installations
may have a single alarm at low-level concentration, whereas larger installations
may have more sophisticated response systems. An example of activation levels
is described below:
First alarm: chlorine concentration of 1-5 ppm. (Lower settings than this
are liable to activate the system at every drum/cylinder change, unless a
duration requirement is also imposed. For example, some companies set
the first alarm at 0.5 ppm, but require the sensor to register this
concentration for at least 30 seconds) The first alarm should activate the
ventilation fan, open the intake louvres, and activate the local audio and
visual alarms and any remote telemetry alarm.
Second alarm 3-15 ppm,(depending on the duration that the sensor needs
to register this level. Some companies set the second alarm at 2 ppm with
a 30 second duration requirement). On activation of a second alarm the
detector system should shut off the ventilation system and operate the
auto-shutdown system.
The tone of the first and second alarms should be different and operators should
be trained to recognise the difference and how to respond in each case.
If such an automatic system is provided, it must be possible to override it and
lock on the ventilation before anyone enters the room to work on the chlorine
system.
Some sensors can be damaged by high chlorine concentrations, therefore
detector systems should be checked following any high level alarms.
3.2.7. Safety Devices
Consideration should be given especially at larger installations taking liquid
from drums - to provide remotely-operable shutdown valves, in order to
minimise the size of a release. The need for an automatic system arranged to
shut off the chlorine supply when a leak is detected will depend on the
likelihood and size of potential leaks and the proximity of any neighbours.
Some shutdown valves operate by automatically closing the drum or cylinder
valves directly (see Figure 4). It is important to check with the chlorine supplier
the recommended minimum and maximum closure torque for the valves, as this
can vary greatly from one valve type to another (e.g. soft seat versus hard seat).
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3.3.
3.3.1. Cylinders
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Liquid
4. CHLORINATION EQUIPMENT
As described in the introduction, chlorine supplied in drums and cylinders can be
used to supply a wide range of different consumers. The process equipment
connected to the chlorine supply is generally outside the scope of this
document, and reference should be made to the list of Euro Chlor GEST
documents to determine which may be applicable.
One common use however is in simple chlorination equipment for treating water
associated with swimming pools or potable water supplies. An example of a very
simple installation is given in Figure 7 here below, which shows a chlorine
cylinder providing gas to a chlorinator, controlled by a free chlorine analyser.
Recommendations for similar types of installations are covered in this section.
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Water
Treated water
4.1.
4.2.
Chlorinator Installation
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4.3.
Chlorinator Operation
5. OPERATING PROCEDURES
This section gives an example of recommended operating procedures for a small
chlorine installation using chlorine gas from cylinders for water treatment. Such
installations are shown in appendix 3. Many of the points are also applicable to
larger installations and those consuming liquid, but it is expected that such
consumers will develop their own robust procedures after carrying out thorough
risk assessments and discussions with their supplier.
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5.1.
Changeover
If the gas pressure in a cylinder were to fall below atmospheric pressure there is
a danger of water being drawn back into the cylinder, potentially resulting in
severe corrosion damage. In order to prevent this, it is essential that the
pressure in a cylinder is never allowed to fall below 1 barg (approx. 15 psig). At
this point there is no liquid left in the cylinder (gas pressure only) so it is
essentially empty.
To prevent the pressure falling below this value, it is recommended to equip the
cylinder with an automatic shutdown valve. An automatic changeover device, if
fitted, will maintain the supply of gas to the chlorinator by switching to a full
standby cylinder.
There should be a clear indication of which cylinder is online.
5.2.
Cylinder Changing
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ease the union nut and allow the chlorine trapped in the
fittings to escape. Avoid straining the unsupported flexible coil.
Normally the gas should escape in a few seconds. Using the
ammonia- water test bottle (see Figure 8 below), blow
ammonia vapour close (5 cm) and across the connection to
rapidly confirm1 that all the chlorine has escaped. If gas
continues to leak, immediately tighten the union nut and check
with ammonia vapour that the union is gas tight.
Note: to use an ammonia water bottle, squeeze it and direct the ammonia
vapour nearby the connection you want to test, but do not spray liquid on the
connection.
5.2.3.4. If the spindle is stiff, exercise the cylinder valve as per
5.2.1.5.
5.2.3.5. Ease the union nut and test for leaks with the ammonia
water test bottle. If a leak persists follow the instructions given
in Section 5.3 for dealing with stiff valves.
5.2.3.6. When the test with ammonia vapour confirms that the
cylinder valve is closed and all the chlorine has escaped from
the fittings, slowly unscrew the union nut and disconnect the
auxiliary valve.
5.2.3.7. Replace and tighten the cover nut on the cylinder valve and,
if appropriate, fit the protecting dome.
The detection limit of this test is about 30 ppm volume chlorine in air.
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5.2.4.2. Cautiously ease the valve cover nut and test for leaks. If
there is a leak of chlorine, retighten the cover nut, remove the
cylinder and put on the side. Mark the cylinder valve "Faulty",
note the cylinder number and contact the chlorine supplier for
further advice. Even if there is no leakage of gas do not remove
the cover nut at this stage.
5.2.4.3. Where flexible connections are used remove the plug from
the auxiliary valve, remove the used gasket, clean the surfaces,
check that the threads of the union nut are in good condition
and that the valve orifice is clean and free from obstruction.
For a chlorinator unit, which is mounted directly on the
cylinder, remove the used gasket and clean the surfaces of the
connection.
5.2.4.4. Fit a new gasket. Never re-use gaskets. (see GEST 94/216 Experience of gaskets on liquid and dry chlorine gas
service). Do not use any grease except if compatible with
chlorine (e.g. totally chlorofluorinated grease).
5.2.4.5. Remove the cover nut from the cylinder valve, check that
the valve nozzle is clean and is not obstructed by part of the
cover nut joint before fitting the auxiliary valve or vacuum
regulator (in the case of the cylinder mounted unit).
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5.2.4.6. Use two keys to tighten the union nut but do not use
excessive force. Do not allow the valve body to turn. Check
that the auxiliary valve is closed. For cylinder mounted units,
withdraw the clamp bar to its fullest extremity, place the
yoke/regulator unit over the cylinder valve and check that the
gasket is still in position. Carefully tighten the yoke clamp
screw to pull the unit evenly against the cylinder valve union.
Avoid using unnecessary force.
5.2.4.7. Open the cylinder valve shortly approximately one turn by
hand or using the correct valve key to flood the union with
chlorine, then close the valve. Valves fitted with hand wheels
and O-ring or diaphragm seals should only be turned by hand.
These valves do not have gland packing which can be further
tightened. Test for leaks at the union and the valve gland, if it
is a gland type valve. Gently tighten the gland nut if the gland
leaks. If a leak occurs at the union connection it may be
possible to tighten the joint, but if the leak does not stop
immediately when the union is tightened, the joint should be
remade taking all the precautions laid down in Sections 5.2.2
and 5.2.3 dealing with disconnection of cylinders.
5.2.4.8. When remaking the joint it is essential that a new gasket is
used and every effort should be made to find the cause of the
leak. If necessary and applicable, change the auxiliary valve. If
a satisfactory joint cannot be made, refit the cover nut to the
cylinder valve, note the cylinder number and inform the
chlorine supplier. If emergency kits are available secure the
cylinder properly (see 7.1).
5.2.4.9. When a new joint has been made, open the cylinder valve,
close again and retest the union connection (see 5.2.4.7).
5.2.4.10. Repeat the connecting procedure if several cylinders are
connected to a manifold. After finishing the procedure open all
cylinder valves and auxiliary valves fully and turn them back
about half a turn, to enable easy identification of the valve
position.
5.2.4.11. On installations fitted with a changeover panel, open the
auxiliary valve(s), the manifold valve(s), if fitted, and test all
connections for leaks.
5.2.4.12. Operate the changeover panel to check that the pressure at
the chlorinator panel is satisfactory and the flow of chlorine gas
is maintained. On vacuum operated changeover systems, close
the valve on the duty cylinder and observe that the changeover
relay operates and that gas flow is maintained by the new
cylinder.
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5.2.4.13. Change over to the cylinder(s) which were on line or, for the
vacuum operated system, re-open the duty cylinder valve and
close the new cylinder valve to cause the relay to revert to its
previous position. After the relay has changed back to the duty
cylinder supply, re-open the new cylinder valve ready for
subsequent automatic changeover to take place.
5.2.4.14. Where a cylinder or cylinders are connected directly to a
chlorinator, start the chlorinator, open the auxiliary valve(s)
and manifold valve(s), if fitted.
5.2.4.15. Test all connections for leaks, check the chlorinator pressure
gauge reading is satisfactory, and set the flow of chlorine to
the required rate.
5.3.
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5.4.
5.4.1 Chlorine gas is highly corrosive in the presence of moisture and the
use of other than specialised equipment and materials can prove
both dangerous and ineffective.
5.4.2 When new, the flexible copper coil connecting the auxiliary valve
to the manifold and/or the chlorinator can be carefully bent into a
desired position to suit the connections. Once this position is
established and the coil subjected to use, further bending of the
coil may result in fracture as a degree of brittleness in the metal
develops in use, which is not apparent visually. The flexible
connections should be checked regularly to ensure they are in good
condition and changed in accordance with recommendations from
the chlorine supplier (e.g. every year). Each flexible should have a
tag with the date by which it should be changed.
5.4.3 Tools, ammonia-water test bottles should be retained in a store
cupboard or on a storage shelving; the same applies to spare valves
and flexible copper coils, preferably in their original packing. To
prevent the entry of moisture, valves, coils and pipes should retain
their blanking end covers until they are brought into use.
5.4.4 Euro Chlor recommended gaskets (See GEST 94/216 - Experience
of non-asbestos gaskets on liquid and Dry Chlorine Gas Service)
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5.5.
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7. EMERGENCIES
7.1.
Emergency plan
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7.2.
Coordination
The emergency plan shall be discussed with the local authorities and fire
brigade.
7.3.
Plan Details
In planning for possible chlorine leaks, the following checklist can be used:
Conduct a safety audit of the chlorine installation and list the points of
possible chlorine releases.
Train qualified personnel in the proper operation of chlorinator
systems, with particular emphasis on connecting and disconnecting
the packages.
Install in the storage and process rooms chlorine detectors as
described in 3.2.6.
Establish standard response procedures for each possible failure
case. Include a decision tree to determine if outside help is needed
and if evacuation is required.
Post a list of home telephone numbers of personnel to be called in
case of emergency. Also, post a list of emergency telephone numbers
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9. Transport of Chlorine
The transportation of full/empty chlorine bottles or drums runs under the
regulations
of
ADR/RID
(http://www.unece.org/trans/danger/publi/adr/adr2011/11contentse.html)
10. REFERENCES
GEST 73/25 Transport of Dry Chlorine by Pipeline
GEST 75/47 Design and Operation of Chlorine Vaporisers
GEST 76/52 Equipment for the Treatment of Gaseous Effluents
Containing Chlorine
GEST 87/133 Overpressure Relief of Chlorine Installations
GEST 88/138 Small Chlorine Packages Construction, Filling and Handling
GEST 92/171 Personal Protective Equipment for Use with Chlorine
GEST92/175 A Scheme for Safety Visits to Chlorine Customers Plants
GEST 94/216 - Experience of Gaskets on Liquid and Dry Chlorine Gas
Service
UK HSE guide HSG40: Safe handling of chlorine from drums and cylinders
(ISBN 978 0 7176 1646 6)
Additional information can also be found in the publications (freely
downloadable) from the European Industrial Gasses Association (www.eiga.org).
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1. Chlorine cylinder
7. Filter
11. Flowmeter
16. Injector
19. Filter
24.Flowmeter
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Chlorine System
Sprinkler System
A Chlorine cylinders
I Water suppy
1 Water tank
B Safety valves
II Manual valve
2 Flocculent addition
3 Filtration System
D Dosing regulator
IV Sprinkler heads
4 Booster pump
E Injector/chlorinator
V - Drain
5 Gravel filter
F Atmospheric monitor
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Appendix 4 - Headlines for training sessions for people working with chlorine
Part 1: Technical Introduction
1.1 Physical Properties
1.2 Chemical Properties and Important Reactions
1.3 Production of Chlorine
Part 2: Handling with Chlorine
2.1 Chlorine Cylinders, Drums, Valves
2.2 Storage Area
2.3 Dosing equipment
2.4 Importance of residual pressure
2.5 Cylinder and/or drum Changing
2.6 Dealing with stiff valves
2.7 Loading and unloading of cylinders and drums
Part 3: Transport of Chlorine
3.1
3.2
3.3
3.4
Part 4: Emergencies
4.1 Emergency planning - General Rules
4.2 Protective Equipment
4.3 First aid
Part 5: Practical training (package changing)
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Part 6: Introduction into the role of chlorine in society and the Responsible
Care programme
Part 7: Recording of training traceability
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