Storage of Liquid Chlorine

GEST 73/17
7th Edition
January 2014

EURO CHLOR PUBLICATION

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

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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 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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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 Equipment working
group 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

Merge with GEST 72/10 on pressure storage of liquid chlorine

and adapt the terminology (refrigerated and non-refrigerated)

All

Clarification on double-jacketed storage tanks

3.2.5.

Updated thermal insulation paragraph

3.4.

Precision that stress relief is done after welding

4.2.

Precision added for cases where chlorine withdraw is from the

bottom of the tank

4.5.1.

Removal of chlorinated fluorocarbons as example, as there is no

practical experience mentioned

5.8.

Added paragraph on inspection (after washing)

5.10.

Addition of paragraph on fighting a big leak

Table of Contents
1.

GENERAL POINTS
1.1. The Choice between Storage with or without Refrigeration
1.2. Unit Capacities
1.3. Number of Storage Tanks

2.

BASIC DESIGN AND LOCATION OF THE STORAGE SYSTEM

2.1. Design and Permits
2.2. Principle
2.3. Location
2.3.1. Outside or Inside Location
2.3.2. Protection from External Damage
2.3.3. Distance from Rails and Roads
2.3.4. Distance from Another Operating Process
2.3.5. Distance from the Boundary of the Factory
2.3.6. Distance between two Adjacent Storage Tanks
2.4. Bunding
2.5. Emergency Capacity

3.

CONSTRUCTION OF STORAGE TANKS

3.1. Basis of Design
3.1.1. Design Pressure
3.1.2. Design Temperature
3.1.3. Corrosion Allowance
3.1.4. Thermal Insulation
3.2. Materials of Construction
3.2.1. Steel
3.2.2. Branches, Flanges, Nuts and Bolts

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3.2.3. Pipework
3.2.4. Quality of Jointing Materials
3.2.5. Thermal Insulation
3.3. Foundations and Supports
3.3.1. Foundations
3.3.2. Supports
3.4. Stress Relief
3.5. Inspection and Testing
3.5.1. Inspection of Construction Materials
3.5.2. Inspection during Fabrication

4.

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ACCESSORIES

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4.1.
4.2.
4.3.
4.4.
4.5.

Branches
Valves and Isolation
Pipework
Measuring Equipment
Safety Equipment
4.5.1. Over and Under-Pressure
4.5.2. Protection of the External Shell
4.6. Filling Ratio
4.7. Thermal Expansion Bellows for Double-Jacketed Tanks
4.8. Filling, Emptying and Venting Equipment
4.8.1. Filling
4.8.2. Emptying
4.8.3. Venting

5.

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OPERATION
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.

19

Cleaning and Drying before Chlorine can be Admitted

Leak Testing
Commissioning
Total Emptying
Reactive Materials
Filling and Emptying in Normal Operation
5.6.1. Quality of Chlorine Introduced
5.6.2. Temperature and Pressure of the Liquid Chlorine Introduced
5.6.3. Emptying the Tank
5.7. Venting and Isolated Systems (Cold Chlorine Storage)
5.8. Periodic Inspection and Testing
5.8.1. External inspection
5.8.2. Internal inspection
5.9. Methods of Protection and Alarm
5.10. Response to a significant loss of primary containment - Methods and Equipment

6.

REFERENCES

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DEFINITIONS
This recommendation concerns storage systems provided by fixed liquid chlorine
storage tanks constructed to operate with or without refrigeration.

1.

GENERAL POINTS
1.1. The Choice
Refrigeration

between

Storage

with

or

without

Ambient temperature chlorine storage means storage at high pressure. The

advantages of ambient temperature storage are:

Simplicity of operation

Easy visual external inspection (no thermal insulation)

Lower investment cost

Refrigerated chlorine storage means storage at lower pressure, in some cases at

atmospheric pressure. The advantages of refrigerated storage are:

Lower initial emission in case of loss of containment if at atmospheric

pressure (lower initial flash of chlorine gas due to the fact that liquid
chlorine is at lower temperatures compared to pressurized storage)

The complexities of refrigerated storage and its associated systems mean it is

unsuitable for small chlorine users.

1.2. Unit Capacities

In order to minimise hazard, the inventory should be limited to the minimum
strictly necessary. The unit capacity is chosen taking into account:

The process requirements (operation continuity, maintenance/inspections

works),

The loading/off-loading requirements; the tank must normally be larger

than the contents of one mobile tanker.

Based on practical long term field experience, the probability of a total tank
failure can be assumed as negligible.
The most important safety feature depends primarily on the design, operation
and inspection of the storage system.

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1.3. Number of Storage Tanks

In order to provide the desired storage capacity and the continuity of the
supply, a compromise may be required between the individual unit capacities
and the number of storage tanks.
It should be noted that increasing the number of tanks leads to a proportional
increase in the number of accessories, with the related various risks of maloperation and mal-functioning. It is therefore desirable to limit the number of
tanks, without forgetting the necessity of an available safety capacity (see point
2.5.).

2.

BASIC DESIGN AND LOCATION OF THE STORAGE

SYSTEM
2.1. Design and Permits

A careful risk assessment study, periodically updated, is necessary to ensure

that the required level of safety is attained.
The methods used should be agreed with the relevant national/local authorities.
In some countries scenarios and models are required.
Some consideration is given below to the choice of the worst case scenario (see
paragraph 2.2. Principles).
Simple models are usually sufficient to evaluate the physical effects. However,
relevant expertise is always needed to define the scenarios, to use and to
interpret the results of such models correctly. To assess the effect on people
(workers and neighbouring population) recognised toxicity probit function1
will be used. The study must show that the risk is acceptable and that adequate
measures have been taken to protect people and the environment.
In some cases, storage tanks may be designed with double jacket; Usually,
double jacket means that the outer wall is designed to resist a lower pressure
than the inner wall as it is primarily used to monitor possible small leaks of the
chlorine inner storage tank (for example PN 10). The space inside the double
jacket should be monitored, e.g. by a permanent flow of dry air or nitrogen with
a chlorine detector at the outlet of the flushing gas with alarm; alternatively
the space can be kept under nitrogen pressure with alarm.

1 The probit function is a statistical function describing the range of susceptibility in a population to
a harmful consequence; it uses a criterion in the form of an equation which expresses the
percentage of a defined population which will suffer a defined level of harm (normally death) when
exposed to a specified dangerous load (time and intensity/concentration)..
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In some cases, the outer wall is also used as bunding and its design conditions
will then be identical to those of the inner wall.

2.2. Principle
Liquid chlorine bulk storage could be the potential source of the worst case of
loss of primary containment. However, a chlorine storage system can be
designed and operated safely so that the risk of complete tank failure and
release of much of its contents can be assumed negligible.
The principles which must be followed to achieve this are discussed in the
following chapters.
It is also recommended to use GEST 87/130 - Hazard Analysis for Chlorine
Plant' for the design of the storage system.

2.3. Location
2.3.1.

Outside or Inside Location

Storage system can be located in the open air or in a closed building.

The decision on this matter must be based on a careful risk assessment taking
into account the advantages and disadvantages of each alternative listed in the
Position paper XII - Memorandum on Confinement of Liquid Chlorine Plants.
2.3.2.

Protection from External Damage

Chlorine storage must be located in an area with protective barriers so that it is

fully protected from external damage from vehicle impact.
The location and design of a storage tank has to be chosen to minimise the
possible effects resulting from traffic (see 2.3.3), flooding, subsidence,
earthquake, fire or explosion in a neighbouring plant.
2.3.3.

Distance from Rails and Roads

Installations should be located at least 25 m from public roads and railway lines
to minimise the risk of damage to the storage in the event of an accident. This
distance has to be defined taking into account the local conditions, rules and
regulations.
2.3.4.

Distance from Another Operating Process

If a neighbouring unit does not present risk of fire or explosion, the minimum
recommended separation is 10 m taking into account the local situation.

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If a fire or explosion risk exists, greater distances or means of protection will be

required. These must be established for each individual case, based on a risk
assessment and taking any national and local rules and regulations into account.
2.3.5.

Distance from the Boundary of the Factory

The minimum recommended separation is 10 m taking into account the local

situation and the size of the storage.
In all cases, suitable fences, together with adequate security supervision, should
be provided to prevent unauthorised access (see also GEST 05/316 Guideline
for site security of chlorine production facilities).
2.3.6.

Distance between two Adjacent Storage Tanks

It is recommended that sufficient distance should be provided between adjacent

storage tanks, to give good access to the tanks for operation, maintenance and
inspection, and to permit the passage of personnel equipped with self-contained
breathing apparatus in case of incident.

2.4. Bunding
All above ground storage tanks should be placed in a liquid tight bund.
The volume of the bund should be calculated to receive at least the full
contents of the worst realistic case scenario. A retention capacity of one storage
tank is generally considered adequate. As a single bund may contain more than
one storage tank, its capacity shall be based on the largest tank contained.
The bund should be designed to limit the surface area in order to reduce the
rate of evaporation of liquid chlorine in the event of a leakage, but without
restricting access (see sections 5.9 and 5.10.
The bund shall never be directly connected to a drain. Collected water (rain )
shall be removed by a pump or an ejector which shall be manually operated only
after checks on the bund contents.
In case of double-jacketed tank, the outer wall can be designed to provide such
a bunding facility.

2.5. Emergency Capacity

It is essential that a damaged storage tank can be emptied rapidly into a spare
capacity, preferably a spare tank.
If the emergency capacity is in the form of an empty tank, there should be a
means to maintain it at low pressure, e.g. a system of degassing to an

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absorption system or a chlorine consuming unit, or a large liquefaction set, the

reliable operation of which should be assured.
The use of a double-jacketed storage tank with the external wall designed as
bunding facility means that any chlorine leakage will be contained and will not
affect the external environment. In this case it is therefore not necessary to
provide spare capacity to which the contents of a leaking tank can be
immediately transferred.

3.

CONSTRUCTION OF STORAGE TANKS

3.1. Basis of Design
3.1.1.

Design Pressure

The design pressure should be chosen on the basis of detailed consideration of

all circumstances which will arise during operation of the storage system. The
principal factor to be taken into account is the vapour pressure of chlorine at
the maximum temperature to which the storage system can be subjected.
Allowance must also be made for the maximum pressure resulting from the
presence of any padding gas.
Once the design pressure has been chosen, all reasonable measures must be
taken to ensure that it is not exceeded in the course of subsequent operations.
It is also necessary to consider a minimum design pressure.
In case of double-jacketed tank, these minimum and maximum design pressures
have to be determined both for the internal and the external shells.
Storage tank (inner shell in case of double-jacketed tank)
The minimum design pressure should be calculated taking into account:

the minimum temperature of the chlorine introduced

the means of emptying and venting chlorine (connection to absorption

unit or suction of a compressor)

the maximum venting rate, even under accidental circumstances

the pressure from any purge gas between the two walls of doublejacketed tanks

the possible accidental presence of some chlorine between the two walls
of double-jacketed tanks.

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The maximum pressure should be calculated as a function of:

the vapour pressure of chlorine at the maximum temperature to which

the storage tank can be subjected, including a margin for the presence of
inert gasses

the internal conditions within the storage tank when it is isolated (for
example roll over of the liquid chlorine)

the hydrostatic pressure due to the height of liquid chlorine

any transient conditions during filling and emptying.

External Shell (if double-jacketed tank)

The weight of the external thermal insulation, if present, shall be taken into
account.
If the external wall is designed as bunding facility, the minimum and maximum
pressures should be identical to the inner wall to account for the extreme
conditions in case of failure.
3.1.2.

Design Temperature

The minimum design temperature is minus 40C (considering that an excess of

inert gasses can lower the vaporisation temperature of the chlorine).
The maximum design temperature can be calculated from possible solar heating,
taking into account of any insulation.
In case of a double-jacketed tank, the choice of minimum design temperature
for the external shell depends on its extended purpose. As it is intended to
provide secure containment in the event of a leak from the internal tank, it
should be designed for minus 40C. If it is only intended to monitor possible
small leak of the internal wall, it may be designed for ambient temperatures.
The overall construction must take account of differential thermal expansion
between the internal tank and the external shell, particularly in relation to
supports, branches and other equipment; the maximum allowed differential
temperature should be defined during the design.
3.1.3.

Corrosion Allowance

A corrosion allowance of 1 mm is considered a minimum for the tank (also for

the external shell if it is designed to act as a bund in the event of a leak). This
value will be added to the calculated thickness before choosing the schedule
just above the resulting total thickness.
Thermally insulated or not, the external surface of the equipment will be
painted with a corrosion protective coating.

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3.1.4.

Thermal Insulation

For chlorine storage tanks, insulation may be required for different reasons:

avoid water condensation or ice formation on equipment

protection of personnel for cold temperature

protection from possible external heating

If installed, the thermal insulation should be based on the minimum chlorine

temperature and the maximum external temperature appropriate for the
geographical location. The thickness is determined by, amongst others, the
capabilities of the facilities to handle the evaporated chlorine gas due to the
heat input (liquefaction unit, absorption unit or refrigeration unit) see section
5.7.
Care will be taken to avoid any accumulation of moisture between the insulation
layer and the equipment surface in order to prevent corrosion under insulation
(CUI).
Proper painting or coating of the equipment or piping is strongly recommended
to prevent external surface corrosion, as well as good insulation surveillance,
inspection and repair programs.
Operating discipline must be applied to ensure that insulation stripped or
removed for maintenance or inspection purposes is replaced and sealed in a
timely manner.
The quality of installation is important for the corrosion protection of the
pipe/equipment and the tightness of the jacketing can be improved by tapes or
mastic sealing; particular attention shall be paid at branching points.

3.2. Materials of Construction

3.2.1.

Steel

The plate chosen for the construction of storage tanks should be made of fine
grain steel with good welding properties and which has satisfactory impact
strength at minus 40C after welding (see also GEST 79/82 - Choice of
Materials of Construction for Use in Contact with Chlorine).
These tests are particularly important concerning the impact strength of the
metal before and after welding.
If double-jacketed tank, the quality of the steel can be different for the internal
tank and the external shell, to take into account of the minimum design
temperature chosen for each.

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3.2.2.

Branches, Flanges, Nuts and Bolts

The metal used for flanges and branches should have the same quality as the
material used in the construction of the storage tank itself. Bolting equipment
should conform to GEST 88/134 - Stud Bolts, Hexagon Head Bolts and Nuts for
Liquid Chlorine.
The overall arrangement of flanges and jointing material should prevent the
gasket being expelled by excess pressure.
3.2.3.

Pipework

Pipework used for handling chlorine should be designed to have an adequate

wall thickness and should use a quality of steel suitable for the temperature and
pressure of the operation.
As far as possible, l00% radiography of the welds should be carried out. In
circumstances where radiography is not possible welds should be inspected by a
dye penetrant test, ultrasonic or magnetic inspection. For further information,
refer to GEST 73/25 - Transport of Dry Chlorine by Pipeline.
3.2.4.

Quality of Jointing Materials

The jointing material used must be an asbestos free material. See GEST 94/216
- Experience of Non-Asbestos Gaskets on Liquid and Dry Chlorine Gas
Service.
3.2.5.

Thermal Insulation

The material used for thermal insulation needs to be:

inert in presence of chlorine

not flammable or combustible, or at least self-extinguishing

For cold liquid chlorine, there is no predominant insulation material but the
following are satisfactorily used:

polyurethane foams

foam glass

mineral wool

Other materials are sometimes used (phenolic resins ).

Vapour barriers must be utilised to prevent the ingress of moisture on any
insulated pipe/equipment that operates at temperatures below ambient
temperature).
For the cladding used to protect externally the insulation layer and to prevent
as far as possible ingress of water, several materials can be used, according to

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the local environment (aluminium, stainless steel, coated carbon steel, plastic,
resin, fibre reinforced resin ).
For double-jacketed tanks, no insulation will be installed in the inner space.

3.3. Foundations and Supports

3.3.1.

Foundations

The design of the foundation will take into account the wind and seismic loads.
3.3.2.

Supports

Supports should be designed in accordance with a recognised standard and in

such a manner that they provide overall mechanical stability for the storage
tank and do not lead to any abnormal stresses on its walls. They must permit
thermal expansion and contraction due to variations in temperature which can
occur. They must limit local thermal losses by conduction.
The design of the supports will take into account the wind and seismic loads.
Special consideration may be necessary where load cells or balances are used in
determining the contents of the tank.

3.4. Stress Relief

Stress relieving is recommended and should be carried out, after welding, in
accordance with the quality of steel used and with the method of welding. It is
specifically recommended for the support legs and branches and especially for
areas of greater wall thickness.

3.5. Inspection and Testing

3.5.1.

Inspection of Construction Materials

The steel plate supplied for the tank should be tested mechanically and
chemically in order to confirm the material is in compliance with the
specifications (in addition to checking the certificates).
These tests are particularly important to establish the impact strength of the
metal at the proposed design temperature.
The metal used for flanges, blanks, nuts, bolts, welding rods etc. should also be
subject to acceptance tests to meet a specification compatible with the above
requirements.

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3.5.2.

Inspection during Fabrication

The inspection procedures during the construction of the liquid chlorine storage
system should conform to the codes being applied, particularly regarding (not
exhaustive and not in chronological order):

qualification of the welders and the welding procedures

100% radiography of welds

tensile strength, bending, hardness and impact strength tests on test

pieces of the welds

thickness measurement and detection of cracks or laminations by

ultrasonic means

pressure test

Additionally, inspection to determine gas tightness by halogen or helium testing

could be realised.
Conformance to the relevant codes should be confirmed by an independent third
party.
The objective is to guarantee a fault free construction. The quality of the
construction is considered to be an essential requirement for the safety of
future operation.

4.

ACCESSORIES
4.1. Branches

The wall thickness should be according to GEST 73/25 Transport of Dry

Chlorine by Pipeline. The number and sizes of branches should be limited to
the minimum necessary for the installation of equipment required in the gas or
liquid phase.
For mechanical robustness, the recommended minimum diameter of the
branches should be 40 mm.
Except for the liquid chlorine extraction connection, if realised on the bottom
of the tank, all branches should be installed on manhole covers.
Top connection is preferred. In the case of a bottom connection it should be
limited to one connection and the construction must be strong enough to
withstand accidental mechanical loads.
A dimension of 150 mm is considered as a maximum for the liquid phase.
Larger branches such as those required for manholes, introduction of pumps etc.
should be located in the gaseous phase of the storage tank.
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There should not be bi-directional connections between the gas phase of the
tank and the gaseous chlorine network that could contain some hydrogen (see
also GEST 08/360).

4.2. Valves and Isolation

It is necessary to provide valves on each branch of the storage tank which
enable it to be isolated. It is recommended that remotely operable valves be
fitted at least on liquid chlorine inlet and outlet connections. All manually
operated valves should be installed in a way allowing easy access.
All valves installed on the storage tank should be of a design specifically
developed for liquid chlorine duty. The materials of construction of these valves
should correspond to the intended operating temperature and pressures. GEST
06/318 Valves Requirements and Design for Use on Liquid Chlorine and
GEST 94/204 Pneumatically Operated Valves for Use on fixed Storage
Tanks, Rail and Road Tankers and ISO-Containers for Liquid Chlorine provide
specifications for valve types suitable for use on storage tanks. Other valves may
be suitable but should be assessed carefully to ensure they deliver equivalent
safety.
When the storage tank is fitted with a bottom connection, it is normally
recommended that a secondary internal globe valve is provided, capable of
isolating the branch in the event of failure of the external isolation valve or of
the associated joint. This internal globe valve should also be remotely operable,
independently of the external valve.
As an alternative to the secondary internal valve for both bottom liquid
connections, the storage tank may be located in a closed and sealed building
(secondary containment) connected to an absorption unit with sufficient
absorption capacity to process possible chlorine leak (see 2.3.2 regarding indoor
tanks). In any case, the number of connections/valves should be strictly limited.
On connections to storage tanks used to withdraw liquid chlorine from the top,
dip tubes will be installed.

4.3. Pipework
All pipework connections to the storage tank should be designed to suit the
temperature and pressure of the chlorine and should be of an adequate wall
thickness (See GEST 73/25 Transport of Dry Chlorine by Pipeline).
100% radiography of welds on this pipework is recommended. In circumstances
where radiography is not possible welds should be tested by dye penetrant test
ultrasonic or magnetic inspection.
The specific connections between the storage system and loading or off-loading
installations should conform to the recommended guideline GEST 78/73 January 2014

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Design Principles and Operational Procedures for Loading/Off-Loading Liquid

Chlorine Road and Rail Tankers and ISO-Containers.

4.4. Measuring Equipment

The following instrumentation is recommended to check the status of the tanks
from the control room:

an indication of level (weighbridge, load cells, radioactive measuring

system or other adapted for chlorine duty)

high level alarm

pressure indicator with alarm

The high level alarm should be provided by a separate device to that used for
normal measurement of level and should ensure that the filling ratio indicated
in section 4.6 below is not exceeded.
Any hydraulic fluids or oils used in the instrumentation should be compatible
with chlorine (chloro-fluorinated oil).
Additionally, double-jacketed tanks should be provided with:

maximum, minimum and differential pressure alarm for the annular space

flow rate of annular purge air

humidity of the purge gas

chlorine content of the purge gas leaving the space between the inner
and outer tanks

temperature measurement on the walls of the internal tank.

Temperature measurement is important to avoid thermal shock or stresses. At

least four measurement points should be provided on the wall of the internal
tank. The indication given by these measurements is particularly important
during the commissioning of the tank to avoid the maximum temperature
differential used in the differential expansion calculation for the tank, being
exceeded.

4.5. Safety Equipment

4.5.1.

Over and Under-Pressure

The internal tank (and the external shell) should be fitted with means to protect
them against over-pressure (relief valves, hydraulic guards, etc.). Bursting discs
may be used to prevent small leaks at safety valves. In those cases the space
between the valve and the disc has to be monitored closely and leaks (pressure
rise) is to be alarmed. The application of bursting discs without safety valves is
not recommended because chlorine flow would not stop when the pressure
returns to normal value.
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If the tank is not designed for the maximum under-pressure that can occur,
additional protective measures may be required (e.g. hydraulic guards,
blanketing ).
These systems should be capable of isolation for maintenance or after
operation, by means which provide an adequate level of safety such as, for
example, the use of valves which are locked open or the use of a double
inter-connected valve system.
Relief valves should conform to the recommended guideline GEST 87/133
Overpressure Relief of Chlorine Installations.
Where a hydraulic guard can be used, the liquid chosen should be suitable for
operating in an atmosphere of chlorine, for example sulphuric acid of 92-95%
strength.
The operating pressure of the relief systems should be consistent with the design
pressure and operating pressure chosen. The design of the relief systems should
take all possible scenarios into account.
The vent from a relief stream should be retained in a suitable installation - a
compression and liquefaction system or an absorption system. To cope with
potential pressure surges, and to avoid liquid entrainment in a system designed
for gas, a large enough buffer tank must be installed downstream of the relief
system.
4.5.2.

Protection of the External Shell

The annular space between the two shells should be permanently purged by dry
air or nitrogen. This compensates for the effect of breathing between the two
shells, and allows also confirming the absence of humidity or chlorine.

4.6. Filling Ratio

The total load should not exceed the filling ratio multiplied by the volume of the
chlorine tank. The filling ratio used shall comply with the applicable national or
international legislation.
The filling ratio usually considered within Europe is 1.25 t/m.

4.7. Thermal Expansion Bellows for Double-Jacketed Tanks

As the internal and external shells can be at very different temperature, it is
essential to allow for the differential thermal expansion which may occur
between the walls of the internal tank and the external shell. This should be
calculated for the extreme conditions of service, including those arising during
commissioning or total emptying of the storage system (with possible liquid
chlorine cooled down by partial vaporisation). To do this, all branches should be
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designed to take the full variation in temperature into account. This may be
achieved by use of expansion bellows.
The expansion bellows should generally be constructed of high nickel alloy,
without any corrosion allowance. Expansion bellows are an important feature of
the construction which should be given careful study. Radiographic examination
should be carried out on all welds. In addition, particular care should be taken
during installation.

4.8. Filling, Emptying and Venting Equipment

4.8.1.

Filling

The transfer of chlorine into the tank is generally done through a dip pipe.
4.8.2.

Emptying

Empting by means of nitrogen or dry air pressure is often applied.

Alternatively, vertical submerged pumps can be installed inside the tank or in an
individual duct connected to the tank or canned pumps can be located below
the storage tank.
4.8.3.

Venting

The chlorine vent gas should be retained in a suitable installation - a

compression and liquefaction system or an absorption system. In either case, the
chosen system must be designed to be permanently available.

5.

OPERATION
5.1. Cleaning and Drying before Chlorine can be Admitted

Before chlorine is admitted, the tank and all its accessories should be rigorously
degreased, cleaned and dried (see also GEST 80/84 Commissioning and
Decommissioning of Installations for Dry Chlorine Gas and Liquid). The drying
should be carried out to achieve and confirm a dew point of minus 40C on the
purge gas at the exit of the system. For all internal equipment which requires to
be greased, and where there is a risk of it coming in contact with chlorine, only
grease which is compatible with chlorine may be used (chloro-fluorinated
greases).

5.2. Leak Testing

Before commissioning, all valves and accessories should be tested to guarantee
their gas tightness under the conditions of operation.
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The following methods may be used:

1. a helium test in a calm and non-ventilated atmosphere
2. testing with a chlorine/dry gas mixture with the various joints etc.
checked by the use of ammonia
3. a pneumatic test using soap and water to detect leaks.

5.3. Commissioning
The procedure given in GEST 80/84 - Code of Good Practice for the
Commissioning of Installations for Dry Chlorine Gas and Liquid should be
strictly observed.
A number of precautions need to be taken before commissioning:

confirmation of the quality of the chlorine introduced

o moisture content below 20 mg/kg (see GEST 10/362)
o nitrogen trichloride (see GEST 76/55 - Maximum Levels of
Nitrogen Trichloride in Liquid Chlorine)

check on the temperature differential from top to bottom of the tank (for
double-jacketed tanks, see paragraph 3.1.2).

One method of commissioning consists of filling the tank in batches, and waiting
between each introduction of liquid until thermal equilibrium has been
established. It is desirable to take the system up to the maximum operating
pressure for each of these introductions of liquid. It is desirable to limit the rate
at which chlorine is introduced to limit the vent rate and the temperature
differential between the different points of the tank (for double-jacketed
tanks).

5.4. Total Emptying

A number of precautions need to be taken before total emptying:

removal of the maximum amount of chlorine in the liquid phase

final dilution of the residual chlorine contained in the tank by chlorine

known to have a low nitrogen trichloride level

check on the quality of chlorine remaining in the tank in order to ensure

that it contains an acceptable level of nitrogen trichloride for total
vaporisation

purging with dry air or an inert gas (dew point minus 40C at atmospheric
pressure), using a connection to the tank which is only made immediately
before its time of use; alternatively, a permanent connection can be
installed with backflow protection and double block and bleed.

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5.5. Reactive Materials

All precautions must be taken to avoid the entry of humidity, reactive materials,
or hydrogen into the storage tank.
In addition, if inert gas is being used for the transfer or purging of chlorine, this
should not be source of contamination by reactive materials (see 5.6.3).

5.6. Filling and Emptying in Normal Operation

5.6.1.

Quality of Chlorine Introduced

The chlorine introduced into a storage system should be periodically tested in

particular to meet the following points:

moisture content (lower than 20 mg/kg)

nitrogen trichloride (for values see GEST 76/55 - Maximum Levels of

Nitrogen Trichloride in Liquid Chlorine)

All precautions must be taken to avoid accumulating hydrogen in the gas phase
of the tank.
5.6.2.

Temperature and Pressure of the Liquid Chlorine Introduced

For refrigerated liquid storage, the temperature of the liquid chlorine

introduced should be sufficiently close to that of the chlorine already contained
in the tank to ensure the evaporation rate in the tank does not exceed the
design conditions of the system. This point is particularly important when
chlorine is being imported directly from mobile containers.
During the operation of filling and emptying, the connections between the cold
liquid storage tank, and all other external equipment, should be carefully
checked and supervised to avoid any scenario which could unintentionally
connect high pressure gas (chlorine or inert gas) to the tank gas phase.
To avoid thermal shock on the steel shell, it is preferable to cool down the tank
prior to the first liquid introduction (using for example a cool gas).
5.6.3.

Emptying the Tank

The liquid chlorine can be extracted from the tank with the help of a pump or
with padding with uncontaminated dry inert gas having a dew point below minus
40C at atmospheric pressure.
The volume of liquid removed can be compensated with dry gaseous chlorine
exempt of hydrogen or with dry air or inert gas (a dew point lower than minus
40C at atmospheric pressure).

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To prevent possible backflow, the pressure of the inert gas should be at least 1
bar greater than the operating pressure of the tank and this differential pressure
must be permanently maintained. The total pressure should not exceed the
design pressure.

5.7. Venting and Isolated Systems (Cold Chlorine Storage)

The vent rates depend on the level of liquid chlorine (variation in surface area),
the pressure of the vent system and possibly external atmospheric conditions
(temperature, rain, etc).
The autonomy of the storage system (the time for which it can remain totally
isolated) depends on:

the ratio of surface to volume of the tank

the filling ratio

the thermal insulation chosen

the difference between the pressure at the time of the tank isolation and
the maximum operating pressure.

Two days should be considered a minimum for an isolated system to be

sustained.

5.8. Periodic Inspection and Testing

Periodic inspection of the whole storage system is necessary. This includes the
inner tank, the shell, pipework, valves, pressure relief devices, instruments,
safety loops, etc.
The internal inspections are done after having completely emptied, vented and
washed the tanks to avoid the potential risk coming from residual chlorine.
5.8.1.

External inspection

The first inspection is recommended two years after the first commissioning.
The periodicity of inspection will be determined by local regulations but should
not exceed 6 years.
Inspection should include the following aspects:

visual examination, particularly of the welds

(ultrasonic) thickness testing of walls, flanges and branches

verification of all accessories

inspection of lagging and painted surfaces (including under the lagging).

As a general rule, all equipment should be replaced systematically before there

is any risk of it becoming defective.
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5.8.2.

Internal inspection

Here also the inspection frequencies will depend on the requirements of the
authorities. Based on the inspections history with consecutive good results and
other control measures in place to avoid corrosion, it is advised to discuss with
the authorities an extension of the inspection interval as long as appropriate
because the procedure itself introduces the risk of corrosion.
Inspection should include the following aspects:

visual examination, particularly of the welds, the bottom line and around
gas-liquid interface level

(ultrasonic) thickness testing of walls

verification of all internal accessories

Where a storage tank has been washed out or where a hydraulic test is imposed
by local regulations, specific procedures need to be laid down in order to reduce
to a minimum the effects of corrosion (see GEST 80/84 - Code of Good Practice
for the Commissioning of Installations for Dry Chlorine Gas and Liquid). Too
frequent hydraulic retesting is not recommended because of the risk of
corrosion which is associated with it.

5.9. Methods of Protection and Alarm

The following precautions should be taken:

an emergency plan, giving the detailed instructions to be followed in the

event of emergency, should be permanently available and understood by
plant personnel; this emergency plan should contain detailed instructions
for transferring the content of a leaking storage tank into another tank

chlorine leak detectors should be provided to warn the operators of the

existence of a leak; see also GEST 94/213 - Guidelines for the Selection
and use of Fixed Chlorine Detection Systems in Chlorine Plants

the operator should be able to use a fixed water spray curtain or the site
fire brigade should be able to rapidly use a mobile water spray curtain to
control the spread of any chlorine gas cloud; this operation should avoid,
as far as possible, any direct contact between the water and the liquid
chlorine

for small leaks, a funnel connected with flexible hoses to an absorption

system can be applied to the leak

if the storage system is installed within a bund, measures should be taken

to reduce the rate of evaporation of any chlorine contained within the
bund e.g. walls of the bund with a low thermal conductivity, slope in the
bund which allows the liquid chlorine to accumulate in a small area, or
use of a protein foam or a plastic sheet to form an insulating layer on the
liquid chlorine pool

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if the chlorine cloud comes from a leakage in liquid phase, an alternative

method with an emergency funnel can be used; the funnel is connected
at the leakage and reduces the access of air to droplets of chlorine (less
energy available and fewer droplets evaporated). The droplets coalesce
to liquid chlorine in the funnel and can be collected in a (temporary)
emergency tank at the outlet of the funnel, reducing the chlorine cloud

self-contained breathing sets and protective clothing suitable for dealing

with a chlorine leak should be always available in various locations in the
vicinity of the storage system and always accessible in case of emergency
(cartridge respirators should not be used for intervention and particularly
when there is any risk of a high concentration of chlorine)

a means of indicating the wind direction should be installed to tell the

operator of the possible direction of dispersion of gas that will occur in
the event of an accident; it is important to remember that heavy chlorine
gas clouds behave like liquid and will tend to flow to the deepest area

all operators and maintenance personnel should be trained to deal with

leaks of chlorine, and periodic exercises should be organised to ensure
that this standard of training is maintained.

5.10. Response to a significant loss of primary containment Methods and Equipment

Depending on local circumstances, several solutions are possible to respond to a
significant liquid chlorine leak. Some practical examples are given below:

spread foam (medium expansion protein foam, e.g. FP 70) on the

containment bund

spray water curtains around the area (do not spray into the bundle)

start air aspiration above the containment bund, and send it to the
absorption unit

connect the containment bund to an underground tank to minimise the

evaporation area and allow localised connection to the absorption unit
(avoid sending liquid chlorine to the absorption unit)

transfer the liquid chlorine from the leaking tank into an empty spare
tank; this one is vented to the absorption unit to neutralise progressively
all the chlorine. This transfer can be achieved by the pressure difference
between the leaking tank and the relatively depressurised spare tank or
by means of a pump. Those transfer capabilities are preferably remotely
controlled.

Remarks:

the foam is effective to drastically reduce the chlorine evaporation,

giving time to organise the collection of the liquid chlorine, but a

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temporary increase of chlorine vaporisation occurs when the foam is

sprayed

6.

the water curtains have only a local impact; by creating a significant air
mixing, they reduce the chlorine concentration behind the curtain, but
have no long distance impact; precautions must be taken to avoid
increased corrosion by spraying water on the leak, and to increase the
vaporisation by adding water into the containment bund.

REFERENCES
GEST 73/25 - Transport of Dry Chlorine by Pipeline
GEST 76/55 - Maximum Levels of Nitrogen Trichloride in Liquid
Chlorine
GEST 78/73 - Design Principles and Operational Procedures for
Loading/Off-Loading Liquid Chlorine Road and Rail Tankers and ISOContainers
GEST 80/84 - Code of Good Practice for the Commissioning of
Installations for Dry Chlorine Gas and Liquid
GEST 87/133 Overpressure Relief of Chlorine Installations
GEST 88/134 - Stud Bolts, Hexagon Head Bolts and Nuts for Liquid
Chlorine
GEST 94/204 Pneumatically Operated Valves for Use on fixed
Storage Tanks, Rail and Road Tankers and ISO-Containers for Liquid
Chlorine
GEST 94/213 - Guidelines for the Selection and use of Fixed Chlorine
Detection Systems in Chlorine Plants
GEST 94/216 - Experience of Non-Asbestos Gaskets on Liquid and Dry
Chlorine Gas Service
GEST 05/316 Guideline for site security of chlorine production
facilities
GEST 06/318 Valves Requirements and Design for Use on Liquid
Chlorine
Position Paper XII - Memorandum on Confinement of Liquid Chlorine
Plants
TSEM 90/161 - Quantitative Risk Assessment

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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

January 2014

Tel:

+32 2 676 7211

Fax:

+32 2 676 7241

e-mail:

eurochlor@cefic.be

Internet:

http://www.eurochlor.org

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