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9. Thermal expansion of liquid chlorine. Protect equipment and piping from over-
pressure where chlorine can be trapped between closed valves. Liquid chlorine
has an unusually high coefficient of thermal expansion that can cause rupture as
temperature increases, unless the system is protected with items such as
expansion chambers or relief devices.
2.2 MATERIALS
See Tables 2-1 and 2-2 for a list of common materials and their compatibility in chlorine
service and for recommended materials of construction for primary element components.
Materials are listed in the tables in general terms. Users should investigate and select
the appropriate grade or alloy for each specific application. See Section 4 for
information on materials in final control elements.
For an exact definition of dry and wet chlorine see CI Pamphlet 100 (7.1). Carbon steel
is commonly used in dry chlorine service but should not be used where process
temperatures are expected to exceed 300°F (149°C) due to increased corrosion rates
and possible ignition at higher temperatures.
Many carbon steels are susceptible to brittle fracture at temperatures below -20°F
(-29°C). Special low temperature steels (e.g. ASTM A333 carbon steel) or Monel® can
be used for these applications. Additional information can be found in CI Pamphlet 6
(7.1).
Some stainless steels of the 300 series have useful properties at low temperatures but
can fail due to chloride stress corrosion cracking in the presence of moisture.
Aluminum, titanium and tin must never be used in dry chlorine because they will react
violently at room temperatures. CI Pamphlet 167 (7.1) details an incident and the
negative results where titanium came in contact with dry chlorine. Aluminum is often
used in instrument housings, where it is not in direct contact with chlorine, but the
exterior should be painted or coated to prevent corrosion.
Plastics are often used as liners, seals and ancillaries such as tubing and fittings.
Fluoropolymers are the most common lining material; PTFE, FEP, ECTFE, PVDF and
PFA are all used as liners. Chlorine will permeate all fluoropolymers to a degree. The
rate of permeation is dependent on the compound, material density, temperature,
pressure, and other factors, and should be considered when selecting liner material and
the underlying material behind the liner material. Plastics should be used only as
specified by a designer or equipment manufacturer who is experienced in handling
chlorine. Reference is made to CI Pamphlet 6 (7.1). Typical limitations on the use of
plastics in chlorine service are shown in Table 2-1.
6 PAMPHLET 165
Nonferrous metal piping or tubing is generally used for flexible instrument connections.
Because of the reaction between chlorine and tin, no tin should be used in brazing alloys
for flexible connection fittings. Therefore, silver brazing alloys must contain no tin and
should contain at least 44% silver.
Gasket type connections are preferred where they are disconnected frequently. Flared
type fittings are not recommended.
Table 2-1 identifies some commonly used nonferrous materials. Consideration should
be given to the mechanical protection of tubing systems from external damage.
Please see CI Pamphlet 100 (7.1) for an exact definition of dry and wet chlorine.
Wet chlorine is corrosive to many of the materials commonly used for dry chlorine
service. Plastics including PVC, CPVC, FRP, dual laminates and fluoropolymers are
commonly used because of their resistance to wet chlorine gas. However, use of plastic
pressure-containing components should be carefully reviewed to ensure they do not
mechanically fail in pressurized gas service (i.e., rupture, loss of strength with increasing
temperature, brittleness, UV attack). For higher pressures, titanium or fluoropolymer
lined metallic systems can be used.
Plastics are often used as liners, seals and ancillaries such as tubing and fittings.
Fluoropolymers are the most common lining material; PTFE, FEP, ECTFE, PVDF and
PFA are all used as liners. Chlorine will permeate all fluoropolymers to a degree. The
rate of permeation is dependent on the compound, material density, temperature,
pressure, and other factors, and should be considered when selecting liner material and
the underlying material behind the liner material. Polypropylene and polyethylene are
susceptible to cracking and are generally not used in wet chlorine systems.
Titanium is suitable for wet chlorine service where there is a substantial amount of
moisture in the chlorine such as before the drying towers in a producer’s plant. Care
must be taken to ensure that titanium does not come into contact with dry chlorine under
any circumstances, as it will spontaneously burn on contact. Refer to CI Pamphlet 100
(7.1) for the determination of wet chlorine. Moisture content at saturated conditions in
the gas phase is a function of the temperature and pressure. Figure 2-1 allows the
determination of the safe use of titanium at a given temperature and pressure. The
location of the point on the graph will show whether or not this is a safe operating region
for the titanium. The possibility of backflow of dry chlorine into a wet chlorine system
should be considered when titanium is used.
Tantalum and titanium are preferred for instrument components that are in contact with
wet chlorine. Hastelloy® C has also been used successfully in some applications.
TABLE 2-1. FOR DRY CHLORINE SERVICE
Low
Temperature Class I, II, IV and V Only Not Used Used Not Used Not Used Not Used Not used
Carbon Steel
Stainless Steel Not Recommended
Hastelloy® C Class I through VI Not Used Used Used Used Used Used
Titanium reacts with dry
Titanium Not Acceptable
chlorine.
Monel® Class I, II, IV and V Only Used Used Used Used Used Used
Tantalum Class I through VI Not Used Used Used Used Not Used Not Used
Frequent stressing will
Copper Class I and IV Only Not Used Not Used Not Used Not Used Used Not Used
cause embrittlement.
Leaded
Commercial Class I and IV Only Not Used Not Used Not Used Not Used Not Used Used
Bronze
Silver Class I and IV Only Not Used Not Used Used Used Not Used Not Used
Aluminum Not Acceptable
Tin Silver brazing alloys
Not Acceptable
should not contain tin.
Pressures below 6 psig at
PVC Not Used Not Used Not Used Not Used Not Used Used
0oF (-18oC) to 140oF (60oC)
Pressures below 6 psig at
CPVC Not Used Not Used Not Used Not Used Not Used Used
0oF (-18oC) to 160oF (71oC)
PFA Class I, II, III Only Not Used Not Used Used Not Used Used Used
Used when Used when
PTFE Class I, II, III Only Not Used Not Used Used Used pressure is pressure is
<10 psig <10 psig
FEP Class I, II, III Only Not Used Not Used Used Not Used Not Used Not Used
ECTFE Class I and II Only Not Used Not Used Used Not Used Not Used Not Used
ETFE Class I and II Only Not Used Not Used Not Used Not Used Not Used Not Used
PVDF Class I Only Not Used Not Used Used Not Used Not Used Not Used
Polypropylene Not Recommended
Polyethylene Not Recommended
(1)
Footnote: For description of Service Classes, see Table 2-3. Used - Materials commonly used in the industry
(2)
For bourdon tube use, see Section 5. Not Used - Materials technically acceptable but not commonly used in the industry
Not Recommended - Industry experience suggests materials are not suitable
Not Acceptable - Materials should not be used due to known compatibility problems with chlorine
TABLE 2-2. FOR WET CHLORINE GAS SERVICE
(1)
Footnote: For bourdon tube use, see Section 5. Used - Materials commonly used in the industry
Not Used - Materials technically acceptable but not commonly used in the industry
Not Recommended - Industry experience suggests materials are not suitable
Not Acceptable - Materials should not be used due to known compatibility problems with chlorine
INSTRUMENTATION FOR CHLORINE SERVICE 9
90
85
80
Safe
Zone
Temperature (Deg. F)
75 Zone of Uncertainty
70
65
60
55
50 Reaction Zone
45
40
-2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Pressure (PSIG)
2.3 GASKETS
Gaskets used for the installation of instrumentation are typically the same as used for
the rest of the piping system. CI Pamphlet 95 (7.1) contains recommendations for
gaskets used in chlorine service.
Chlorine can react violently with hydrocarbon based oils, grease, and other seal fluids.
For this reason, fluorocarbon based greases and seal fluids are used in chlorine service.
CI Pamphlet 164 (7.1) contains information on the reactivity and compatibility of chlorine
and sodium hydroxide with various materials, including lubricants.
I Gas only vacuum to 150 psig (1034 kPa) and -20°F to 300°F (-29°C to 149°C)
II Gas only vacuum to 150 psig (1034 kPa) and -50°F to 300°F (-46°C to 149°C)
III Gas only vacuum to 150 psig (1034 kPa) and -150°F to 300°F (-101°C to 149°C)
IV Gas or liquid vacuum to 300 psig (2068 kPa) and -20°F to 300°F (-29°C to 149°C)
V Gas or liquid vacuum to 300 psig (2068 kPa) and -50°F to 300°F (-46°C to 149°C)
VI Gas or liquid vacuum to 300 psig (2068 kPa) and -150°F to 300°F (-101°C to 149°C)
Pressure sensing elements may be protected from the chlorine by a liquid-filled seal or
isolating diaphragm, filled with a fluorocarbon that is not reactive with chlorine. Types of
pressure sensing elements commonly used are:
Type Comments
Usually used on select applications involving very small pressure
drops, such as on electrolytic cells. Devices are vulnerable to
Manometer
process upsets and may require surveillance to avoid an
environmental incident.
Inexpensive device but moving parts may be susceptible to
Bourdon Tube
corrosion.
Diaphragm or
Variety of materials available, many different installation options.
Capsule Type
Usually used on select applications involving very small pressure
Bellows drops. Used in low pressure applications and differential pressure
applications.
INSTRUMENTATION FOR CHLORINE SERVICE 11
Type Comments
Resistance
Common sensing element is paired with a transmitter or field
Temperature Device
indicator.
(RTD)
Thermometer Bi-metallic field indications are very common.
Thermocouple metals should be selected for resistance to
Thermocouple corrosion in ambient conditions, i.e., Type J should not be
used.
Infrared Portable handheld unit
Type Comments
Additional information is available in CI Pamphlet 5 (7.1). Plain gauge
Visual Level
glass systems should not be installed for any chlorine application.
Indication
Armored refractive type with forged steel body are recommended.
Liquid Flow
Type Comments
High rangeability, excellent accuracy, flanged connections are a
standard option, high cost. The best overall metering principle for
Coriolis (Mass) liquid chlorine. Ensure pressure drop across meter does not introduce
cavitation/flashing within the meter or downstream piping. Include
dissolved gases (i.e. nitrogen) in the calculations.
The differential pressure required by the measuring device usually results
Differential in downstream cavitation/flashing. Many potential leak points are
Pressure introduced into the system by tubing and valves normally associated with
this measurement principle.
Positive Meters contain many moving parts and seals. Proper metallurgy of
Displacement internal components is usually an issue.
Must consider the temperature of the liquid and its effects on the
Sonic transducers. Connections at the transducers must be sealed to prevent
ambient moisture from condensing and interfering with electrical signals.
Thermal energy introduced by meter may cause evaporation and result in
Thermal (Mass)
cavitation/flashing at the measurement RTD.
Typically requires line size reductions to produce sufficient measurement
Vortex
velocities which may in turn exceed the recommended pipe velocities.
Gas Flow
NOTE: For all chlorine gas applications the gas must be superheated. If the gas is not
superheated the possibility of two-phase flow exists. If any liquid is present in the
metering system, accuracy is affected.
Type Comments
High rangeability, excellent accuracy, flanged connections are a
Coriolis (Mass) standard option, high cost. Ensure system can handle high pressure
drop required by Coriolis meters in gas applications.
Differential
Low cost, numerous materials available, easily understood system.
Pressure
Positive Meters contain many moving parts and seals. Proper metallurgy of
Displacement internal components is usually an issue.
Materials of construction should be carefully considered. In addition,
since chlorine gas is very attenuating at pressures under 100 psig (689
Sonic
kPa), careful analysis should be performed before utilizing this
technology.
Thermal (Mass) Thermal energy introduced by meter may be above system specifications.
Relatively high rangeability and accuracy, flanged connections are a
Vortex
standard option.
INSTRUMENTATION FOR CHLORINE SERVICE 13
Control valves are devices that automatically manipulate the flow rate of the process
fluid. They consist of a valve sometimes combined with a positioner and actuator that
change the position of the closure member as a function of an input signal. The
functionality and special design of control valves and their use in chlorine service
requires particular attention to valve specifics that are not covered in this pamphlet.
Materials for use in chlorine service must be chosen carefully to suit the conditions of the
intended application in terms of moisture, fluid state, temperature, and pressure. For
materials in contact with dry liquid and dry gaseous chlorine the recommendations and
guidelines in CI Pamphlet 6 (7.1) should be considered.
Several standards such as the international standard IEC 534-1(7.2) cover terminology,
sizing, and noise considerations of industrial process control valves. Throttling control
continuously cycles the stem/shaft of a control valve in order to obtain the desired
process condition. Due to the cycling particular attention should be paid to the stem/shaft
guiding and the stem/shaft sealing. A variety of special seals are available such as
bellows seals, live loaded stem seals or lantern ring design. Stem and sleeve material
must be resistant to wet chlorine corrosion. If a bellows seal is used, ensure the seal
has adequate cycle life for the intended use.
Control valves are usually not required to provide a tight shutoff. Guidance for control
valve leakage rates can be taken from standard ANSI FCI 70-2 or IEC 534-4 (7.2).
14 PAMPHLET 165
5. INSTALLATION GUIDELINES
Installation Consideration
Good installation practices should be used and should take into account the following
considerations:
• Thread sealants should contain only materials that do not react with chlorine,
see CI Pamphlet 164 (7.1).
ANSI/ISA-84 (7.2) is recognized as good engineering practice for instrument and control
design, installation, and maintenance requirements. The following are examples of a
program that would meet the requirements of ANSI/ISA-84 as of the publication date of
this document. [(ANSI/ISA-84.00.01-2004 Parts 1-3 (IEC 61511 Mod))].