CODE OF GOOD PRACTICE

FOR INSTALLATION, REMOVAL AND MAINTENANCE

OF MANUALLY OPERATED CHLORINE VALVES

GEST 80/85

4th Edition

September 2002

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 user’s 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 Chlor’s 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 GEST 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 sections Wording
4 New title for this section (the old one was: Inspection and
Repairs)
4.1 New title for this section (the old one was: Removal)
4.2.2 Remove of the bellows
4.3 New title for this section (the old one was: Reinstallation)

TABLE OF CONTENTS

1. DEFINITION 5
2. GENERAL PRINCIPALS 5
3. REMOVAL OF VALVES 5
4. REPAIRS 6
4.1. Disassembly 6
4.2. Work to be Carried out 6
4.2.1. Valves with a Packed Gland 6
4.2.2. Bellows Valves 7
4.3. Reassembly 7
5. INSPECTION 7
5.1. Pneumatic Leak Testing 7
5.2. Leak Testing of the Sealing Arrangements (Disc/Seat) 7
5.3. Valves with a Packed Gland - Leak Testing of the Back Seating Arrangement 8
5.3.1. Leak Testing of the Back Seating Facilities 8
5.3.2. Leak Testing of the Packed Gland 8
5.4. Bellows Valves - Leak Testing of the Bellows 8
6. PREPARATION FOR SERVICE 8
7. STORAGE 9
8. CERTIFICATION 9
9. INSTALLATION 9
10. COMMISSIONING 10
11. REFERENCES 10

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1. DEFINITION

Practical experience has shown that the installation of dry gaseous and
liquid chlorine valves necessitates specific precautions to avoid their
deterioration and consequent loss of gas tightness. This recommendation
has been written to provide a number of simple rules that will help avoid
deterioration of such valves; the guidance is applicable:

 During initial installation or following replacement on an operating

installation.
 In the course of maintenance to or inspection of the installation.
 During repairs to or overhaul of such types of valve.

2. GENERAL PRINCIPALS

1. A chlorine valve should not come into contact with water after it has been
installed, because subsequent complete drying out with dry air is virtually
impossible.

2. A valve removed from an installation which has contained chlorine should

be immediately neutralised (see Section 3 below), because of the very
rapid corrosion which will take place on all the surfaces which have been
in contact with chlorine.

3. A valve should not be put back into service without having been checked,
repaired, tested, degreased, dried and confirmed as a chlorine valve
suitable for the required service.

3. REMOVAL OF VALVES

If the installation is to be vented down (see GEST 80/84 – Code of Good

Practice for the Commissioning of Installations for Dry Chlorine Gas and
Liquid), the valve should be removed and immediately neutralised by
soaking in an alkaline solution (e.g. sodium carbonate), followed by
rinsing with water and drying. The flanges should be protected to avoid
any deterioration during subsequent handling. All valves should be fitted
with a label indicating that they have been used for chlorine. The valve
should then be dispatched to the workshop for inspection or repair.

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4. REPAIRS

The following rules should be followed when overhauling chlorine valves.

4.1. Disassembly

The valves should be dismantled into all its components parts. All
consumable parts such as joint rings and gland packing should be
discarded.

4.2. Work to be Carried out

After suitable derusting, such as sand or shot blasting, passivation and

washing all the components, each component shall be rigorously
examined and dried. Any defective component may be repaired by
machining so long as their dimensions after machining are within
specified tolerances and compatible with proper operation of the valve.
To this effect, thicknesses shall be compatible with the standards
indicated on the valve (PN, ASA). If not, the component should be
rejected.

The valve seat should be made good by welding and then re-machined.

The disc should be overhauled and if necessary made good by welding.

The sealing faces (flanges, valve head) shall be machined if necessary.

The state of the spindle surface shall be checked. If inadequate, it shall

be replaced.

Any new component used should be either in the same material of

construction as the original component, or of a quality recommended in
the recommendations GEST 89/140 - Specification for Flanged Steel
Globe Valves-Bellows Sealed -for Use on Liquid Chlorine and GEST
90/150 - Specification for Flanged Steel Globe Valves - Packed
Gland - for Use on Liquid Chlorine.

4.2.1. Valves with a Packed Gland

The back seating arrangement used to obtain a gas seal when the
valve is fully opened should be checked, and if necessary, made good
by welding and then re-machining.

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4.2.2. Bellows Valves

. It is preferable to change the bellows and especially when it is in

stainless steel. Bellows made from noble metals: hastelloy, monel, may
be reused. If the bellows are welded to the spindle, this operation of
welding shall only be carried out in an approved workshop specially
equipped for this work.

4.3. Reassembly

One shall ensure that all components used are the correct materials and
dimensions for the duties envisaged. The reinstallation of the valve shall
be carried out with new joint rings and gland packing. Lubrication of
components which may come into contact with chlorine shall be carried
out with a special grease, compatible with chlorine (chlorofluorinated
greases). All components and the fully reassembled valve shall be dried.
Components which should be greased, notably the thread and the
operating spindle, shall exclusively be treated with a grease which is
compatible with chlorine (chlorofluorinated greases).

5. INSPECTION
The following inspection and tests should be carried out. As a preliminary,
the satisfactory operation of the fully reassembled valve shall be
confirmed.

5.1. Pneumatic Leak Testing

Pressure test: of 6 bars

Test fluid: dry air or nitrogen
Method: the test shall be carried out with the valve partially
opened. The gland follower on the packed gland shall be
tightened such that it has not taken up more than half its
travel.
Standards: with a test duration of two minutes and no leakage being
tolerated.

5.2. Leak Testing of the Sealing Arrangements (Disc/Seat)

Test pressure: 6 bars

Test fluid: dry air or nitrogen
Method: with the valve closed with normal hand pressure and with the
gland packing partially slackened off.
Standard: duration two minutes, no leakage being tolerated.

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5.3. Valves with a Packed Gland - Leak Testing of the Back

Seating Arrangement

5.3.1. Leak Testing of the Back Seating Facilities

Test pressure: 6 bars

Test fluid: dry air or nitrogen
Method: the valve should be completely opened and the packed gland
shall be slackened off.
Standard: duration two minutes with no leakage being tolerated. In
practice, this operation can be carried out first before
installation of the gland follower.

5.3.2. Leak Testing of the Packed Gland

Test pressure: 6 bars

Test fluid: dry air or nitrogen
Method: the valve shall be half-open, and the gland follower should be
tightened to the extent that it is not compressed more than
half way.
Standard: duration two minutes with no leakage being tolerated. In
practical terms, this operation can be combined with that of
paragraph 5.1.

5.4. Bellows Valves - Leak Testing of the Bellows

Test pressure: 6 bars
Test fluid: dry air or nitrogen
Method: with the valve partially opened and with gland packing
partially slackened off.
Standard: duration two minutes, no leakage should be tolerated.

6. PREPARATION FOR SERVICE

Valves delivered new or being returned from maintenance shall be completely

dry (for example by drying in a vacuum oven). All traces of grease, oil and
solvent used during their manufacture, testing or inspection, and likely to
cause reaction with chlorine, shall be removed. External non-machined
surfaces should be treated with a layer of antirust paint.

Machined surfaces, such as flange faces and particularly joint bearing areas
and threaded surfaces, shall avoid any trace of paint. These surfaces should
be coated with a protective layer which is easily removed or with a layer of
grease compatible with chlorine. The valve orifices shall be blanked off and

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protected with plastic plugs. The diameter of the plugs shall be such that the
joint surfaces are completely protected.

A plate shall be attached which indicates the name of the valve repairer, the
month and year the repair was carried out, or some identification number
(fixed to the flanges of the bonnet or the valve flanges).

7. STORAGE

To avoid any subsequent confusion, all chlorine valves once assembled shall
be identified specifically for this duty. All precautions must be taken to
maintain valves in an area where they will be protected from moisture. To this
effect, they should be stored in a location which is maintained if possible at a
reasonable temperature. It is a good precaution to keep them in a gas-tight
plastic bag containing a drying aid such as silica gel. For valves which are
waiting installation, another possibility consists of putting them in a cupboard
which is purged by dry gas. The same precautions shall be taken for
removable components, which if they need to be greased, shall be treated
with a chlorofluorinated grease.

8. CERTIFICATION

If the maintenance of the valves is sub-contracted to an external organisation,

the workshop carrying out valve maintenance shall provide for each batch, a
certificate confirming that the tests and preparation of the valve have been
carried out in conformity with the requirements laid down in paragraphs 5 and
6.

9. INSTALLATION

The installation of valves in their subsequent location after selection of the

correct valve, should only be done when all of the activities associated with
maintenance, inspection, cleaning and drying of the installation, have been
completed. The valve should be withdrawn from the store just before its
installation. If the storage conditions do not provide a guarantee that the valve
will be kept away from moisture, there needs to be prior drying of the valve.
The valve shall be taken to its point of installation, either maintained within its
protective seal, or fitted with plastic or magnetic plugs which shall not be
removed until just before installation. Except for special circumstances, the
valve should be installed in such a way that the direction of fluid flow will be in
the direction indicated on the arrow (liquid entering from below the disc).

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10. COMMISSIONING

After installation, the valve shall be subjected to a final operation of drying out
and leak testing as laid down in paragraph 5 of GEST 80/84 – Code of Good
Practice for the Commissioning of Installations for Dry Chlorine Gas and
Liquid.

11. REFERENCES

 GEST 80/84 - Code of Good Practice for the Commissioning of

Installations for Dry Chlorine Gas and Liquid
 GEST 89/140 - Specification for Flanged Steel Globe Valves-Bellows
Sealed -for Use on Liquid Chlorine
 GEST 90/150 - Specification for Flanged Steel Globe Valves - Packed
Gland - for Use on Liquid Chlorine.

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Industrial consumers of chlorine, engineering and equipment supply

companies worldwide and chlorine producers outside Europe may establish a
permanent relationship with Euro Chlor by becoming Associate Members or
Technical Correspondents.

Details of membership categories and fees are available from:

Euro Chlor
Avenue E Van Nieuwenhuyse 4
Box 2
B-1160 Brussels
Belgium

Tel: +32 2 676 7211

Fax: +32 2 676 7241
e-mail: eurochlor@cefic.be
Internet: http://www.eurochlor.org

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