Download as PPT, PDF, TXT or read online from Scribd
Download as ppt, pdf, or txt
You are on page 1/ 46
Energy Limited
AWARENESS PROGRAM 1 THEME Energy Limited 1. Introduction to Chlorine. 2. Properties of Chlorine 3. Chlorination System in our Plant. 4. Hazards of Chlorine 5. Design Safety Measures. 6. Safety Precautions while Operation and Maintenance 7. First aid 8. Emergency Preparedness 9. Emergency Leak Arresting Kit 2 Energy Limited INTRODUCTION
Chlorine gas is used in Power Plant as a Biocide in Open Loop
Water Circulating System where the quantity of water involved is large. Hence usage of chlorine reduces the algae and other biological growth in the water. The danger with chlorine is when it leaks in to atmosphere. As little as 3PPM can cause severe effect if exposed for long duration. Chlorine leaks in large quantity if there is break down of valves or any puncture of wall of tonner.Other leaks from the chlorine pipelines can be easily controlled by isolating the tonner. Hence Chlorine system is designed taking in to consideration all these points. 3 PROPERTIES OF CHLORINE Energy Limited Physical Properties Colour : Greenish Yellow Gas Odour : Pungent Suffocating Odour Density : Heavier than Air • Toxic properties Threshold Limit Value (TLV) : 1 PPM Short Term Exposure Limit (STEL) : 3 PPM Immediately Dangerous to Life & Health : 10 PPM • Compatibility with Chemicals Solubility in Water: 0.7 % Water: Reacts with water to form corrosive solution of hyperchlorous acid which decomposes on standing to chlorine,oxygen & chloric acid Explosive Mixture with following Chemicals: Alcohols, Acetylene etc.. 4 Energy Limited CHLORINATION SYSTEM IN OUR PLANT
5 Copper Tube Energy Limited Pressure Relief Valve Tonner
01 6 Energy Limited Non Return Valve 01 Drain Valve
Injector
Water from Side
Stream Filtration. Supplied by Booster Pumps Diffuser
7 CHLORINE TONNER Energy Limited
8 CHLORINE GAS HEADEREnergy Limited
9 Energy Limited CHLORINE GAS STREAM A & B
10 CHLORINATION CABINET Energy Limited
11 PRESSURE RELIEF VALVE Energy Limited
12 Energy Limited DIFFERENTIAL PRESSURE REGULATOR
13 VACCUM RELIEF VALVE Energy Limited
14 Energy Limited VACCUM CREATING SYSTEM
15 Energy Limited INJECTORS
16 Energy Limited CONECTION TO DIFFUSERS
17 Energy Limited
18 HEALTH HAZARD Energy Limited
- Chlorine is Toxic if inhaled.
Threshold Limit Value (TLV): 1PPM Short Term Exposure Limit (STEL): 3PPM Immediately Dangerous to Life & Health (IDLH) : 10 PPM
- Signs and symptoms of Acute Chlorine Exposure: Rapid
Heart rate, hypertension followed by hypotension, and cardiovascular collapse. Pulmonary edema and pneumonia are often seen. The eyes, nose, throat and chest may sting or burn following exposure to chlorine. Cough with bloody sputum, a feeling of suffocation, dizziness, anxiety, nausea, and vomiting are common. Dermal exposure may result in sweating, pain, irritation and blisters. 19 DESIGN SAFETY MEASURES Energy Limited
A) Chlorination system is maintained at a pressure below
atmosphere. This prevents the leakage of chlorine outside in case of leakage at the PVC joints. B) PVC pipe is being used where chlorine gets dissolved in water. This prevents corrosion in pipelines. C) FRP hood is provided to chlorine tonner which in turn is connected to blower and neutralisation pit. This hood prevents chlorine already leaked out from tonner to come into atmosphere. The blower has two modes auto & manual. In auto mode the blower starts automatically after it gets the start signal from
20 DESIGN SAFETY MEASURES Energy Limited
D. A chlorine sensor is placed in
chlorination area to detect any chlorine leaks. This sensor will sound local hooter, alarm to control room in DCS and start blower for evacuation of chlorine from hood. E. Chlorination room is a semi shed and well ventilated F. Towards the most predominant wind direction plantation is made which will prevent the spread of chlorine in case of leak. 21 Energy Limited SAFETY PRECAUTIONS FOR OPERATION - Chlorination system checks before start up. • Check whether the chlorine sensor is in service and concentration displayed in the panel. • Check the chlorine tonner weight to identify whether the tonner is full or empty. • Check the level of caustic solution in neutralisation pit. • Check whether the supply for blower is turned on and the blower is in auto mode. • Have a general check of PVC pipelines and valve fittings for any damage. • Check for leakage in the tonner isolation valve before opening tonner valve with ammonia torch. 22 Energy Limited SAFETY PRECAUTIONS FOR OPERATION - Chlorination system start up procedure. • Charge the injector water side by opening the outlet and inlet valves. • Open the injector vacuum isolation valve. • Check vacuum in the gauge.(400 – 450mm of Hg). Open flow valve to required. • Open stream isolation valve. • Open chlorine header valve and then open manifold valve (3/4 turn). In case any drop • Open chlorine tonner valve (1/4 turn). Wear chlorine canister mask. • Check for leakage in the line with ammonia torch. 23 Energy Limited SAFETY PRECAUTIONS FOR OPERATION - Chlorination system shut down procedure. • Close the tonner isolation valve wearing chlorine escape mask. • Watch the pressure gauge of header and after PRV. These should read zero. Also rota meter should indicate zero flow. • Close the manifold valve and the header isolation valve. • Close the stream isolation valve. • Close the injector vacuum isolation valve. • Close the inlet and outlet isolation valves of injector simultaneously and slowly.
Note: Chlorination system to be shutdown during plant trip
or CW pump trip. 24 Energy Limited SAFETY PRECAUTIONS FOR MAINTENANCE
- PM for chlorine sensor.
• Take valid permit and inform control room before starting the job. • Use chlorine canister mask while opening the calibration gas and during calibration. • Calibration to be carried by two persons. They should stay upwind while doing calibration. • Isolate the blower before carrying calibration. • In case the sensor fails to respond, kindly inform safety department.
25 Energy Limited SAFETY PRECAUTIONS FOR MAINTENANCE
- Chlorine Tonner Changing.
• Inform safety department before starting the job. • Shut down chlorination system and ensure that no chlorine is left in the pipeline. • Disconnect the tonner in service and check for any passing in the tonner isolation valve. The valve to be plugged with cap after checking. • Tonners should be handled with suitable lifting clamp in combination with a hoist. Tonners should not be lifted with rope slings, chains or magnetic devices. Lifting clamp should be either rubber lined or wooden/rubber block should be used between lifting hook and tonner to avoid dent marks on the tonner surface. 26 Energy Limited SAFETY PRECAUTIONS FOR MAINTENANCE
- Chlorine Tonner Changing.
• Replace lead washers after opening the copper tube ferrule. • Never force connections that do not fit. Use only approved equipment to effect a valve opening or closure. Never use a hammer for this purpose, nor apply excessive force than what is required for opening or closing a valve/adapter. • Choke the vehicle before shifting or unloading tonner from vehicle. Ensure parking brake is put for vehicle. • Tonners should not be dropped under any circumsatnces and no object should be allowed to strike them with force. • Tonners while being transported by trucks or by any other vehicle should be carefully chocked to prevent shifting and 27 rolling during transportation. Energy Limited SAFETY PRECAUTIONS FOR MAINTENANCE - Any maintenance work which require opening of Chlorine Line. • Chlorine tonner to be isolated and pipeline to be purged under vacuum. • If possible, vacuum to be maintained in the pipeline while carrying out maintenance. Wear chlorine canister mask while opening flanges or union in pipeline. • Cutting oil, grease and other foreign material should be removed with trichloroethylene or other suitable chlorinated solvents. Hydrocarbons or alcohol not to be used. • Special type of gasket (acid resistant) to be used for flanges. Ordinary gasket can fail. • Check for leakage in the system after taking into service. 28 FIRST AID Energy Limited - Inhalation of Chlorine. • Wear PVC suit and SCBA. • Move victims to fresh air. • Evaluate vital signs including pulse and respiratory rate and note any trauma. If no pulse is detected provide CPR. If breathing is labored, administer oxygen or other respiratory support. • Immediately transport to a health care facility.
- Dermal / Eye exposure of chlorine.
• Same as 3 steps above. • Remove contaminated clothing as soon as possible. • If eye exposure has happened, eye must be flushed with lukewarm water for at least 15min. • Wash exposed areas of skin for at least 15min with soap and water. 29 • Immediately transport to a health care facility. EMERGENCY PREPAREDNESS Energy Limited - Personnel Protective Equipments • Wear Self contained Breathing apparatus. • Wear Full Body PVC suit with gloves and head cover. - The objective of emergency responder is to : - 1. Rescue any casualty. 2. Identify the leak. 3. Arrest the leakage or contain the leak. 4. Avoid a disaster. - Handling Emergencies • Incase the leak is from tonner which is in service an attempt shall be made to close the tonner isolation valve. Otherwise the leak absorption system shall be put into service and continue till the gas gets emptied. While carrying out this ensure that caustic soda is added into neutralisation pit and the pH is maintained alkaline to enable maximum absorption of chlorine. 30 EMERGENCY PREPAREDNESS Energy Limited - Handling Emergencies
• In case the leak is from any flanges or from vacuum side the chlorination plant can be shutdown and the leak can be attended. • Incase the leak cannot be contained by the leak absorption system. The hood has to be removed and the type of leak to be identified. • If leak is from isolation valve which is passing, a suitable adaptor to be used from leak arresting kit. Before attempting to put adaptor the tonner should be rolled till valves are in vertical plane. The leaking valve should be in the top to ensure that chlorine leaks out only in the gas from and not as liquid. • There are adaptors in the leak arresting kit for attending leak from plug and as well as from puncture on the chlorine tonner. 31 CASE STUDY Energy Limited - A CASE OF Chlorine Leak.
32 EMERGENCY PREPAREDNESS Energy Limited - Handling Emergencies
• Leaks around the valve stems can be stopped by tightening the
packing nut or gland. • Tonner should not be attempted to immerse in water or caustic solution in case of leakage. • Water should not be applied to point of leakage as this can aggravate the leak. • Apply water spray or mist to knock down vapours. Vapour knock down water is corrosive or toxic and should be diked for containment. • Absorb bulk liquid with fly ash or cement powder. Neutralize with dilute caustic soda or soda ash. 33 LEAK ARRESTING KIT Energy Limited
