CHLORINE INSTITUTE

EMERGENCY KIT “A”

FOR 100-LB. & 150-LB.
CHLORINE CYLINDERS
Edition 13
January 2021

Kits manufactured after Jan. 1, 2013 Kits manufactured before Dec. 31, 2012

TH E CH LOR I N E I NSTITUTE INSTRUCTION BOOKLET

 Table of Contents

1. INTRODUCTION ................................................................................................................ 1
1.1 SCOPE ............................................................................................................................ 1
1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM ................................................................. 1
1.3 DISCLAIMER ..................................................................................................................... 1
1.4 APPROVAL ....................................................................................................................... 1
1.5 REVISIONS ....................................................................................................................... 2
1.6 REPRODUCTION ............................................................................................................... 2
1.7 REVISION HISTORY AND COMPATIBILITY ............................................................................ 2
2. GENERAL DESCRIPTION ................................................................................................ 3
2.1 TRAINING AND SAFETY ..................................................................................................... 3
2.2 RESPIRATORY EQUIPMENT ............................................................................................... 4
2.3 CHLORINE CYLINDER INSPECTION ..................................................................................... 4
2.4 VALVE APPLICABILITY ....................................................................................................... 4
2.5 GASKET REPLACEMENT .................................................................................................... 4
2.6 LEAK DETECTION ............................................................................................................. 4
2.7 ASSISTANCE .................................................................................................................... 5
2.8 REPORTING REQUIREMENTS ............................................................................................. 5
2.9 EMERGENCY PLAN ........................................................................................................... 5
3. IDENTIFYING AND STOPPING LEAKS............................................................................ 5
3.1 LEAK: VALVE STEM PACKING (FIGURE 3.1) ...................................................................... 6
3.2 LEAK: THROUGH VALVE SEAT (WILL NOT COMPLETELY CLOSE) (FIGURE 3.2) ................... 6
3.3 LEAK: VALVE INLET THREADS (FIGURE 3.3) ..................................................................... 6
3.4 LEAK: VALVE STEM ASSEMBLY BLOWN OUT (FIGURE 3.4) ................................................ 7
3.5 LEAK: VALVE BROKEN OFF (FIGURE 3.5) ......................................................................... 7
3.6 LEAK: VALVE BLOWN OUT (DUE TO STRIPPED THREADS) (FIGURE 3.6) ............................. 7
3.7 LEAK: FUSIBLE PLUG THREADS ....................................................................................... 8
3.8 LEAK: FUSIBLE METAL OF PLUG OR POURED FUSIBLE PLUG (FIGURE 3.8) ......................... 9
3.9 LEAK: SIDE WALL OF CYLINDER (FIGURE 3.9) .................................................................. 9
4. EMERGENCY KIT “A” MANUFACTURED AFTER 1/1/2013 ...........................................10
4.1 HOOD ASSEMBLY FOR VALVE – DEVICE 1 .........................................................................10
4.2 CLAMP FOR FUSIBLE PLUG – DEVICE 2 .............................................................................12
4.3 PATCH FOR SIDE LEAKS – DEVICE 8 .................................................................................14
5. EMERGENCY KIT “A” MANUFACTURED BEFORE 12/31/2012 ....................................16
5.1 HOOD ASSEMBLY FOR VALVE – DEVICE 1 .........................................................................16
5.2 CLAMP FOR FUSIBLE PLUG – DEVICE 2 ............................................................................18
5.3 PATCH FOR SIDE LEAKS – DEVICE 8 ................................................................................20
6. HANDLING OF CHLORINE REMAINING IN CYLINDER .................................................22
7. KIT MAINTENANCE .........................................................................................................22
7.1 AFTER USE .....................................................................................................................22
7.2 ROUTINE ........................................................................................................................22
7.3 SPARE PARTS .................................................................................................................22

i
8. KIT LIMITATIONS.............................................................................................................23
8.1 CYLINDER DESIGN...........................................................................................................23
8.2 OTHER COMPRESSED GASES ..........................................................................................23
9. REFERENCES ..................................................................................................................23
9.1 INSTITUTE PUBLICATIONS ................................................................................................23
9.2 REGULATIONS .................................................................................................................24
APPENDIX A: PARTS LIST .....................................................................................................26
APPENDIX B: OPTIONAL EQUIPMENT..................................................................................30
APPENDIX C: EMERGENCY CONTACTS ..............................................................................31

ii
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 1

1. INTRODUCTION
Leaks in chlorine cylinders rarely occur. When they do occur, however, prompt corrective
action is required by trained, competent personnel with special equipment. The Chlorine
Institute Emergency Kit “A” and this instruction booklet are made available by The Chlorine
Institute (CI or the Institute) in the belief that they will be helpful in handling such
emergencies.

1.1 SCOPE

This instruction booklet provides information on the design and use of the Chlorine
Institute Emergency Kit “A”.

1.1.1 Two Generations of Emergency Kit “A”

On January 1, 2013, the design of Emergency Kit “A” was modified for ease of use. This
booklet includes instructions on how to apply both the current and previous versions of the
tools and devices in Emergency Kit “A”. Previous generations of the Emergency Kit “A”
kit will still fit most chlorine cylinders. Section 1.7 details which cylinders will fit the kits.

1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM

The Chlorine Institute exists to support the chlor-alkali industry in advancing safe, secure,
environmentally compatible, and sustainable production, distribution, and use of its
mission chemicals 1.

Chlorine Institute members are committed to adopting CI’s safety and stewardship
initiatives, including pamphlets, checklists, and incident sharing, that will assist members
in achieving measurable improvement. For more information on the Institute’s
stewardship program, visit CI’s website at www.chlorineinstitute.org.

1.3 DISCLAIMER

The information in this booklet is drawn from sources believed to be reliable. The Institute
and its members, jointly and severally, make no guarantee, and assume no liability, in
connection with any of this information. Moreover, it should not be assumed that every
acceptable procedure is included, or that special circumstances may not warrant modified
or additional procedures. The user should be aware that changing technology or
regulations may require changes in the recommendations contained herein. Appropriate
steps should be taken to ensure that the information is current when used. These
recommendations should not be confused with federal, state, provincial, municipal, or
insurance requirements, or with national safety codes.

1.4 APPROVAL

The Institute’s Emergency Preparedness Issue Team approved Edition 13 of this

instruction booklet on January 12, 2021.

1
CI’s mission chemicals: chlorine, sodium and potassium hydroxides, sodium hypochlorite, the
distribution of vinyl chloride monomer (VCM), and the distribution and use of hydrogen chloride.
2 IB/A

1.5 REVISIONS

Suggestions for revisions should be directed to the Secretary of the Institute in writing.

1.5.1 Significant Revisions

Significant revisions in Edition 13 of this instruction booklet include:

• New section to emphasize instructions’ applicability on the standard chlorine

valves (Section 2.4);

• New section to further emphasize importance of Viton® gasket replacement

(Section 2.5);

• Updated guidance on using aqua ammonia for leak detection (Section 2.6);

• Revised preferred instruction for leaks on valve inlet threads (Section 3.3);

• Revised preferred instruction for leaks on fusible plug threads (Section 3.7);

• Enhanced instruction cautions related to tightening of kit equipment (Sections

4 and 5);

• Enhanced guidance on handling chlorine remaining in containers (Section 6);

• Enhanced guidance on cleaning kit equipment after use (Section 7.1);

• New section providing caution if using kits for compressed gases other than
chlorine (Section 8.2);

• New reference section (Section 9);

• Enhanced quality of various images throughout; and

• Minor editorial and formatting updates throughout.

1.6 REPRODUCTION

The contents of this instruction booklet are not to be copied for publication, in whole or in
part, without prior permission from the Secretary of the Chlorine Institute.

1.7 REVISION HISTORY AND COMPATIBILITY

The Chlorine Institute has published an instruction booklet for the Emergency Kit “A”
beginning in 1969. Since then, the kit and booklet have gone through a series of changes.
The table below details the updates through the years and device compatibility with current
equipment.
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 3

Instruction Compatible
Booklet Date Revision Summary with Current
Edition Cylinders?
Ed. 13 Jan. 2021 No Kit design change, Booklet updated Yes
Ed.12, Rev. 2 July 2014 Added Device 400A in the “Optional Equipment”
Yes
section, which replaced Device 400
Ed.12, Rev. 1 Sept. 2013 Added Revision History and Compatibility Summary Yes
Ed.12 Jan. 2013 Modified Device 1 for valve leaks, Modified Device 8 Yes
for sidewall leaks
Ed. 11 Jan. 2009 No Kit design change, Booklet updated Yes
Ed. 10 June 2003 No Kit design change, Booklet updated Yes
Ed. 9 June 2000 No Kit design change, Booklet updated Yes
Ed. 8 June 1996 No Kit design change, Booklet updated Yes
Modified Device 1 to fit over cylinders with oversized
Ed. 7 March 1993 neck-rings, radius gasket 1BRV added, adjustable
base assembly 1EFP included Yes

Ed. 6, Rev.1 Feb. 1992 Gasket 1FVG included in kit as temporary fix until kit
is modified permanently to address cylinders with Yes
oversized neck-rings.
Ed. 6 April 1986 Modified Part 1C1 to 4 bolt design, Booklet updated Yes (std. cyl.
Ed. 5 May 1983 No Kit design change, Booklet updated Yes (std. cyl.
Ed. 4 July 1978 ® Yes (std. cyl.
Included Molded Viton gaskets 1BMV & 8EV
l )*
Ed. 3 1976 No Kit design change, Booklet updated Yes (std. cyl.
l )*
Ed. 2 1975 No Kit design change, Booklet updated Yes (std. cyl.
Ed. 1 1969 Booklet created Yes (std. cyl.
*Some cylinders have oversized neck-rings. Standard Cylinder (Std. cyl.) neck-rings have a maximum
outside diameter of 4’ 3/8”

2. GENERAL DESCRIPTION

The CI Emergency Kit “A” is designed for use with the standard DOT 3A480 or 3AA480,
100- and 150-pound capacity cylinders in chlorine service only. The cylinders have outside
diameters between 8¼ and 10¾ inches and overall height from 39½ to 59 inches. The kit
is designed for use with all configurations of standard chlorine cylinders. This kit should
not be applied to a cylinder that is liquid full.

2.1 TRAINING AND SAFETY

Emergency response and other personnel must be trained in the use of the devices and
tools within the CI Emergency Kit “A”. Training must include the use of respiratory
equipment and all other safety equipment. Knowledge of the properties of chlorine is a
must.

Personnel safety is of primary importance. Emergency response should only be performed

by authorized personnel who are trained in the procedures and are equipped with suitable
respiratory and personal protective equipment. See the current edition of CI Pamphlet 65
for guidance on appropriate personal protective equipment (9.1).
4 IB/A

2.2 RESPIRATORY EQUIPMENT

The type of respiratory equipment required will be determined by the severity of the leak
and the potential for exposure to chlorine. For further details, see the current edition of CI
Pamphlet 65 (9.1).

2.3 CHLORINE CYLINDER INSPECTION

Daily inspection of full cylinders is recommended whether or not they are connected to
unloading lines. Through these means a leak usually can be detected in an early stage
when it can be corrected or controlled by appropriate procedures. Inspection guidance
can be found in CI Pamphlet 17 (9.1).

2.4 VALVE APPLICABILITY

The instructions included in this booklet are applicable to cylinders having a standard
chlorine cylinder valve installed (CGA 820). If another type of valve is installed, consult
your supplier or the kit manufacturer for additional instruction details.

2.5 GASKET REPLACEMENT

All Viton® gaskets for the emergency kit are stamped with the date of manufacture and
should be removed and replaced every four years (see Section 7 for more details). For
further guidelines concerning the Viton® gaskets, consult the manufacturer or The Chlorine
Institute.

2.6 LEAK DETECTION

As soon as there is an indication of the presence of chlorine in the air, authorized, trained
personnel equipped with suitable personal protective equipment should investigate
promptly. All other persons should be kept away from the affected area.

The location of a leak in a chlorine-containing system can usually be detected by the

reaction of ammonia vapor with the escaping chlorine. The reaction is a dense white cloud.
The most convenient way is to use 5-30% aqua ammonia (10.3 – 61.7% ammonium
hydroxide solution) in a squeeze bottle. Direct the vapors at the suspected leak. To avoid
corrosion, the ammonia solution (liquid) should not be directly sprayed onto the cylinder
or its connections. Efforts to detect the source of any leak should be carried out with an
awareness of the potential hazards and use of necessary personal protective equipment.
Note, a weaker solution such as household ammonia, which is typically 5%, may not be
concentrated enough to detect minor leaks because the solution may degrade over time.

Once the leak is found and you can safely maneuver the
container, rotate the container, if needed, so that the leak is
coming out from the top of the container. Liquid will be on the
CAUTION bottom of the container and gas will be on top. Because chlorine
liquid vaporizes and expands into gas by 460 times its volume,
it is more manageable to have gas leaking from the cylinder
instead of liquid.
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 5

2.7 ASSISTANCE

Chlorine emergencies should be handled only by trained personnel at the use site. If
assistance is required, promptly notify your supplier. If the supplier cannot be reached or
respond immediately, then summon help by activating CHLOREP (The Chlorine
Emergency Plan), an emergency response mutual aid network that can be accessed 24/7
for assistance. CHLOREP can be activated by calling CHEMTREC in the U.S. 1-800-424-
9300 or CANUTEC in Canada 1-613-996-6666.

2.8 REPORTING REQUIREMENTS

There are federal, state and local requirements for the reporting of chlorine releases that
must be met.

2.9 EMERGENCY PLAN

It is recommended that users have an emergency plan that complies with federal, state
and local government requirements. For further detail on emergency response plans, refer
to CI Pamphlet 155 (9.1).

3. IDENTIFYING AND STOPPING LEAKS

WEAR PERSONAL
PROTECTION

Figures 3.1, 3.2, and 3.3

6 IB/A

3.1 LEAK: VALVE STEM PACKING (FIGURE 3.1)

ACTION:

1. Ensure valve stem is closed with WRENCH 200A.

2. Tighten packing nut with WRENCH 200A.

3. Test for leaks.

3.2 LEAK: THROUGH VALVE SEAT (WILL NOT COMPLETELY CLOSE) (FIGURE 3.2)
ACTION:

1. If disconnecting from a process, reconnect and firmly open and close valve
stem to dislodge foreign matter from seat with WRENCH 200A, then
disconnect and apply outlet cap and GASKET 2B with WRENCH 200A.

- or -

If the leak is from an unconnected cylinder, apply outlet cap and GASKET 2B,
then tighten with WRENCH 200A.

2. Test for leaks.

3.3 LEAK: VALVE INLET THREADS (FIGURE 3.3)

ACTION:

1. Apply DEVICE 1 (Hood Assembly) (See Section 4 or 5 for instructions).

2. Test for leaks.

Kit “A” contains WRENCH 201 that can be used to tighten the
valve back into the cylinder to address this type of leak. Extreme
NOTE caution should be used when attempting this to avoid making
the leak worse by dislodging the valve. Only trained and
knowledgeable personnel should ever attempt this procedure.
Otherwise, use DEVICE 1.
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 7

Figure 3.4 Figure 3.5 Figure 3.6

3.4 LEAK: VALVE STEM ASSEMBLY BLOWN OUT (FIGURE 3.4)

ACTION:

1. Drive small DRIFT PIN A-3 into valve body.

2. Test for leaks.

DEVICE 1 (Hood Assembly) will probably not fit over the DRIFT PIN
NOTE A-3. Secure the cylinder in an isolated area and call your chlorine
supplier. If the supplier is not immediately available, activate
CHLOREP (see Section 2.7).

3.5 LEAK: VALVE BROKEN OFF (FIGURE 3.5)

ACTION:

1. Drive small DRIFT PIN A-3 into valve shank and apply DEVICE 1 (Hood
Assembly) (See Section 4 or 5 for instructions).

2. Test for leaks.

3.6 LEAK: VALVE BLOWN OUT (DUE TO STRIPPED THREADS) (FIGURE 3.6)

ACTION:

1. Drive large DRIFT PIN A-4 into valve opening and apply DEVICE 1 (Hood
Assembly) (See Section 4 or 5 for instructions).

2. Test for leaks.

8 IB/A

Figure 3.7 Figure 3.8

3.7 LEAK: FUSIBLE PLUG THREADS

ACTION:

1. Apply DEVICE 1 (Hood Assembly) (See Section 4 or 5 for instructions);

- or -

Saw off fusible plug flush with valve body, file the surface smooth and apply
DEVICE 2 (Clamp Assembly, Figure 3.8) (See Section 4 or 5 for instructions).

2. Test for leaks.

Kit “A” contains WRENCH 203 that can be used to tighten the
fusible plug back into the valve to address this type of leak
NOTE (Figure 3.7). Extreme caution should be used when attempting
this to avoid making the leak worse by dislodging the fusible plug.
Only trained and knowledgeable personnel should ever attempt
this procedure. Otherwise, use DEVICE 1 or 2.
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 9

3.8 LEAK: FUSIBLE METAL OF PLUG OR POURED FUSIBLE PLUG (FIGURE 3.8)

ACTION:

1. Apply DEVICE 2 (Clamp Assembly) (See Section 4 or 5 for instructions).

2. Test for leaks.

NOTE The abovementioned leaks can also be corrected by applying

DEVICE 1 (Hood Assembly) (See Section 4 or 5 for instructions).

Figure 3.9

3.9 LEAK: SIDE WALL OF CYLINDER (FIGURE 3.9)

ACTION: Apply DEVICE 8 (Patch Assembly) (See Section 4 or 5 for instructions).

At all times, before and after application of emergency devices,

NOTE position cylinder so that the source of the leak is in the gas phase
(See Section 4 or 5).
10 IB/A

4. EMERGENCY KIT “A” MANUFACTURED AFTER 1/1/2013

4.1 HOOD ASSEMBLY FOR VALVE – DEVICE 1

STEPS – See Figure 4.1 Equipment

1. Position cylinder so that the valve is in the uppermost position. Remove valve
protective housing if in place.
- If unable to remove valve protective housing, the HOOD (1A3) should fit over it.
2. Remove outlet cap from VENT VALVE (1V) on HOOD (1A3) and open VALVE. WRENCH 200A
3. Prepare BASE ASSEMBLY (1EFP1) with CHAINS (1F1) set in outer most position. BASE ASSY. 1EFP1

4. Roll upright cylinder and center in position on BASE ASSEMBLY (1EFP1).

5. Clean shoulder of cylinder: Use SCRAPER (A-8) if paint is loose or uneven. SCRAPER A-8
6. Inspect condition of GASKET (1BRV). Place GASKET (1BRV) on HOOD (1A3). HOOD 1A3
Center HOOD (1A3) with GASKET (1BRV) over leaking valve. GASKET 1BRV

7. Attach chains from base (1EFP1) to corresponding hooks on HOOD (1A3). Hooks HOOD 1A3 inc. CAP
should be in lowest position by turning CAP SCREWS (1K2). Ensure that CHAINS SCREWS (3) 1K2,
(1F1) are straight and not twisted. Attach CHAINS (1F1) to hook with appropriate link CHAINS (3), BASE
to avoid slack in chains. Base of CHAINS (1F1) should be flush with bottom of ASSY 1EFP1
cylinder.
8. Hand tighten CAP SCREWS (1K2). Tighten CAP SCREWS (1K2) equally, forcing WRENCH 201
the HOOD (1A3) and GASKET (1BRV) against the shoulder of cylinder.
CAUTION: Tighten only enough to stop the leak. Overtightening may damage
gasket. Wait a short amount of time (allowing cylinder to come back ambient
temperature/pressure) to ensure the leak has stopped and the cap screws do
not need additional tightening.
If leak persists, tighten CAP SCREW (1K2) further in area of leak.
CAUTION: Check the foot-ring on base of cylinder for possible deterioration under
extreme pressure conditions. Ensure that CHAINS (1F1) are against side of cylinder
at base.
9. Close VENT VALVE (1V) on HOOD (1A3). WRENCH 200A
10. Test for leaks around GASKET (1BRV). Tighten CAP SCREW(s) (1K2) if necessary. WRENCH 201

DEVICE 1 INCLUDES:
HOOD 1A3 including (3) CAP SCREW SCREWS – 1K2 WEAR PERSONAL
GASKET – 1BRV PROTECTION
BASE ASSEMBLY – 1EFP1
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 11

HOOD1A3

CAP SCREWS D
E
1K2 (3 pcs)

HOOK

VENT VALVE
1V V
GASKET
1BRV I
C
~CHAIN
1F1

BASE ASSEMBLY
1EFP1
1
(2013 version)
DEVICE 1
INSTALLATION
VIDEO

Figure 4.1
12 IB/A

4.2 CLAMP FOR FUSIBLE PLUG – DEVICE 2

STEPS - See Figure 4.2 Equipment

1. Position cylinder so that the valve is in the uppermost position.

Remove valve protective housing if in place.
NOTE: If face of fusible plug is badly pitted or corroded, or HACKSAW A-2
if the leak is at the threads of the fusible plug, saw off FILE A-14
fusible plug flush with valve body, filing the surface
smooth.
2. Loosen SET SCREW (2D) and place CLAMP (2C) over leaking WRENCH 200A &
valve. CLAMP 2C
NOTE: It is not necessary to remove valve outlet cap.
3. Place GASKET (2BB) between leaking fusible plug and BLOCK GASKET 2BB
(2A).
4. Tighten SET SCREW (2D) until leak stops. WRENCH 200A
CAUTION: Tighten only enough to stop the leak.
Overtightening may damage gasket. Wait a short amount
of time (allowing cylinder to come back ambient
temperature/pressure) to ensure the leak has stopped and
the cap screws do not need additional tightening.
5. Test for leaks. Tighten SET SCREW (2D) further if necessary. WRENCH 200A
NOTE: Some valves have the fusible metal poured directly into
the valve body. In such cases, be sure gasket seating surface
is clean and free from pitting.
NOTE: The abovementioned leaks can also be corrected by
applying DEVICE 1 (HOOD ASSEMBLY) (See Section 4.1 for
instructions).

DEVICE 2 INCLUDES:
BLOCK - 2A WEAR PERSONAL
CLAMP - 2C PROTECTION
SCREW - 2D
GASKET - 2BB
EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 13

WRENCH 200A

GASKET D
E
28B

V
SET SC
I
2D
C
E

2
(2013 version)
DEVICE 2
INSTALLATION
VIDEO

Figure 4.2
14 IB/A

4.3 PATCH FOR SIDE LEAKS – DEVICE 8

STEPS - See Figure 4.3 EQUIPMENT

1. Roll cylinder so that leak is in uppermost position. Be sure cylinder wall

around leak is sound before proceeding with application of device.
2. Adjust CAP SCREW (8C1) in YOKE (8B) until point of screw extends slightly YOKE 8B &
below YOKE (8B). CAP SCREW 8C1
3. Slip one end of STRAP (8S) under cylinder and pull it through until it STRAP 8S
reaches the approximate area of leak. Note: inspect strap after each use
for wear and replace as necessary.
4. Place BUTTON GASKET (8GV) inside of PATCH (8D1). Ensure THUMB CAP SCREW 8C1,
SCREWS (8F) are fully retracted into PATCH (8D1). Center CAP SCREW BUTTON GASKET 8GV &
(8C1) in YOKE (8B) and then into PATCH (8D1) depression. PATCH 8D1
5. Hook free ends of STRAP (8S) to ears on each side of YOKE (8B).
6. Use SCRAPER (A-8) if paint is loose or uneven. Slide PATCH (8D1) with PATCH 8D1, STRAP 8S &
GASKET (8GV) and STRAP (8S) over leak. SCRAPER A-8
7. Hand tighten CAP SCREW (8C1) until leak stops. Tighten THUMB
SCREWS (8F) until touching cylinder – do not over tighten.
CAUTION: Tighten only enough to stop the leak. Overtightening may
damage gasket. Wait a short amount of time (allowing cylinder to come
back ambient temperature/pressure) to ensure the leak has stopped and
the cap screws do not need additional tightening.

CAUTION: If there is any evidence of weakening of the cylinder wall,

immediately discontinue tightening CAP SCREW (8C1).

8. Test for leaks. Tighten CAP SCREW (8C1) further, if necessary.

NOTE: THUMB SCREWS (8F) can be adjusted independently to apply
pressure on the opposite sides of gasket to stop leak.

DEVICE 8 INCLUDES:
YOKE - 8B
CAP SCREW - 8C1 WEAR PERSONAL
PATCH - 8D1 PROTECTION
THUMB SCREWS - 8F
GASKET – 8GV
STRAP – 8S
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 15

CAP/ D
E
SCREW8C1 YOKE SB
✓

THUMB~ ....________ THUMB

V
I
SCREW SF SCREW SF

/
C
PATCH 8D1 "'GASKET8GV

CAP SCREW 8C1

8
(2013 version)

DEVICE 8
INSTALLATION
VIDEO

Figure 4.3
16 IB/A

5. EMERGENCY KIT “A” MANUFACTURED BEFORE 12/31/2012

5.1 HOOD ASSEMBLY FOR VALVE – DEVICE 1

STEPS - See Figure 5.1 Equipment

1. Remove valve protective housing if in place. Position cylinder so that the valve is in the
uppermost position.
- If unable to remove valve protective housing, the HOOD (1A2) should fit over it.
2. Remove outlet cap from VENT VALVE (1V) on HOOD (1A2) and open VALVE. WRENCH 200A
3. Prepare BASE ASSEMBLY (1EFP) to insure proper position and stability of base BASE ASSY. 1EFP
segments. Secure RAMP (1R) between two base segments by means of hook attached RAMP 1R
to center spacer slot to prevent sliding of BASE ASSEMBLY while cylinder is being
positioned.
4. Roll upright cylinder up RAMP (1R) and center in position on BASE ASSEMBLY (1EFP).
5. Clean shoulder of cylinder: Use SCRAPER (A-8) if paint is loose or uneven. SCRAPER A-8
6. Inspect condition of GASKET (1BRV). (See Section 8, Kit Maintenance). Place GASKET HOOD 1A2 &
(1BRV) on HOOD (1A2). Place HOOD (1A2) with GASKET (1BRV) over leaking valve. GASKET 1BRV
7. Adjust CAP SCREWS (1D1) and (1K1) in YOKE (1C1) so that the points of the screws CAP SCREWS
extend only slightly below YOKE (1C1). (1)1D1, (3)1K1,
YOKE 1C1
8. Place YOKE (1C1) in position on top of HOOD (1A2), with screw positioned in the CHAINS IF
dimples on top of HOOD (1A2). Ensure that CHAINS (1F) are straight and not twisted. WRENCH 201,
Hook CHAINS (1F) over ears of YOKE (1C1) using appropriate link to avoid slack in (WITH 1EFP ASSY)
CHAINS (1F). HOOD 1A2
YOKE 1C1
9. Hand tighten CAP SCREWS (1D1) and (1K1). Tighten CAP SCREWS (1K1) equally WRENCH 201
forcing the HOOD (1A2) and GASKET (1BRV) against the shoulder of cylinder. Keep
CAP SCREW (1D1) hand tightened against center of HOOD (1A2). If leak persists,
tighten CAP SCREW (1K1) further in area of leak.
CAUTION: Check the foot-ring on base of cylinder for possible deterioration under
extreme pressure conditions. Ensure that CHAINS (1F) are against side of cylinder
at base.
CAUTION: Tighten only enough to stop the leak. Overtightening may damage
gasket. Wait a short amount of time (allowing cylinder to come back ambient
temperature/pressure) to ensure the leak has stopped and the cap screws do not
need additional tightening.
WRENCH NCH
10. Close VENT VALVE (1V) on HOOD (1A2). 200A
11. Test for leaks around GASKET (1BRV). Tighten CAP SCREW(s) (1K1) if necessary. WRENCH 201
DEVICE 1 INCLUDES: WEAR
HOOD 1A2 & GASKET 1BRV PERSONAL
YOKE ASSEMBLY 1C1 with BOLTS 1K1 (3) & 1D1 (1) PROTECTION
CHAIN AND BASE ASSEMBLY 1 EFP & RAMP 1R
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 17

D
YOKE - --------
lCl

CAP SCREW ---...

lDl E
V
DO NOT OVER -
TIGHTEN. MAY VENT
DAMAGEG~~~ , ~ VALVE
1/ lV

I
CAP SCREW
lKl

HOOD - ---

C
1A2

GASKET - ~

E
lBRV

CHAIN - --
lF

BASEASSY. / RAMP
1
lEFP I lR (pre-2013 version)

Figure 5.1
18 IB/A

5.2 CLAMP FOR FUSIBLE PLUG – DEVICE 2

STEPS - See Figure 5.2 Equipment

NOTE: Remove valve protective housing if in place. Position cylinder so

that the valve is in the uppermost position.

If leak is at threads of fusible plug:

1. Saw off fusible plug flush with valve body, filing the surface smooth. HACKSAW A-2
FILE A-14
2. Loosen SET SCREW (2D) and place CLAMP (2C) over leaking valve. WRENCH 200A &
CLAMP 2C

NOTE: It is not necessary to remove valve outlet cap.

3. Place GASKET (2BB) between leaking fusible plug and BLOCK (2A). GASKET 2BB
4. Tighten SET SCREW (2D) until leak stops. WRENCH 200A
5. Test for leaks. Tighten SET SCREW (2D) further if necessary. WRENCH 200A
If leak is in fusible material:
1. If face of fusible plug is badly pitted or corroded, saw off fusible plug flush HACKSAW A-2
with valve body, filing the surface smooth. FILE A-14
NOTE: Some valves have the fusible metal poured directly into the valve
body. In such cases, be sure gasket seating surface is clean and free
from pitting.
2. Loosen SET SCREW (2D) and place CLAMP (2C) over leaking valve. WRENCH 200A &
CLAMP 2C
NOTE: It is not necessary to remove valve outlet cap.
3. Place GASKET (2BB) between leaking fusible plug and BLOCK (2A). GASKET 2BB
4. Tighten SET SCREW (2D) until leak stops. WRENCH 200A
5. Test for leaks. Tighten SET SCREW (2D) further if necessary. WRENCH 200A
NOTE: The abovementioned leaks can also be corrected by applying
DEVICE 1 (HOOD ASSEMBLY) (See Section 5.1 for instructions).

DEVICE 2 INCLUDES:
BLOCK - 2A
WEAR PERSONAL
CLAMP - 2C
PROTECTION
SCREW - 2D
GASKET - 2BB
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 19

D
E
\VRENCH
200A

V
ASKET
2BB

\
\
. I
C
\

SETSCREW
E
2D

CLAMP
2C 2
(pre-2013 version)
BLOCK
2A

Figure 5.2
20 IB/A

5.3 PATCH FOR SIDE LEAKS – DEVICE 8

STEPS - See Figure 5.3 EQUIPMENT

1. Roll cylinder so that leak is in uppermost position. Be sure cylinder wall

around leak is sound before proceeding with application of device.
2. Adjust CAP SCREW (8C) in YOKE (8B) until point of screw extends only YOKE 8B &
slightly below YOKE (8B). CAP SCREW 8C
3. Slip one end of CHAIN (8A) under cylinder and pull it through until it reaches CHAIN 8A
the approximate area of leak.
NOTE: Ensure CHAIN (8A) is straight and not twisted.
4. Center CAP SCREW (8C) in YOKE (8B) in PATCH (8D) depression. YOKE 8B
CAP SCREW 8C &
PATCH 8D
5. Hook free ends of CHAIN (8A) to ears on each side of YOKE (8B), keeping
CHAIN (8A) as short as possible.
6. Use SCRAPER (A-8) if paint is loose or uneven. Place GASKET (8EV) and GASKET 8EV
PATCH (8D) over leak. PATCH 8D &
SCRAPER A-8
NOTE: Two GASKETS (8EV) may be required on slender cylinders
(about 8 inches in diameter).

7. Tighten CAP SCREW (8C). CAUTION: Use extreme caution if leak is due WRENCH 201
to internal corrosion.
CAUTION: If there is any evidence of weakening of the cylinder wall,
immediately discontinue tightening CAP SCREW (8C).

8. Test for leaks. Tighten CAP SCREW (8C) further, if necessary.

DEVICE 8 INCLUDES:
CHAIN - 8A
YOKE - 8B WEAR PERSONAL
CAP SCREW - 8C PROTECTION
PATCH - 8D
GASKET - 8EV
 EMERGENCY KIT “A” FOR 100 LB AND 150 LB CHLORINE CYLINDERS 21

D
E
YOKE - - - - -
8B ----

PATCH- - - -

V
8D

GASKET - - - - ~4~~-~
I
BEV

CHAfN

C
8A

8
(pre-2013 version)

Figure 5.3
22 IB/A

6. HANDLING OF CHLORINE REMAINING IN CYLINDER

The containment of leaks by the CI Emergency Kit “A” devices is only an interim measure.

If the leaking cylinder is located at a consuming plant, the cylinder can be connected to the
consuming process to eliminate the remaining chlorine prior to disposition of the damaged cylinder.
The leaking cylinder may also be connected to vent lines for disposal into the scrubbing system.
VALVE YOKE (A-9) AND VALVE ADAPTER (A-10) are included in this kit for use in these
processes. These procedures should be attempted by experienced personnel only.

CONSULT WITH THE CHLORINE SUPPLIER IMMEDIATELY AND ARRANGE FOR

ULTIMATE DISPOSAL.

If the supplier is unknown, see Section 2.5 for instructions to contact CHLOREP for immediate
assistance.

If the cylinder requires transport to another facility for disposal, it is important to be familiar with
applicable transportation regulations. If the cylinder is safe for transport, it may be transported in
the U.S. with Kit “A” devices applied (see 49 CFR §173.3(e)(1)). However, in Canada, transport
requires an approved Temporary Certificate from Transport Canada (9.2).

7. KIT MAINTENANCE

All parts of the CI Emergency Kit “A” should be maintained in a ready-to-use

NOTE
condition.

7.1 AFTER USE

Inspect all parts for damage, wear and corrosion. Wash all parts used with approximately 5%
solution of caustic soda or soda ash to neutralize any residual chlorine. After washing, rinse parts
with water until they are free of cleaning solution. Dry all parts once free of cleaning solution.
Lubricate moveable parts with a lubricant that is non-reactive to chlorine. Refer to CI Pamphlet 164
for information on lubricant materials that are compatible with chlorine (9.1).
Replace all gaskets used. Inspect side patch strap after use for wear and replace as necessary.

7.2 ROUTINE
The kit should be frequently inspected by the person responsible for the equipment and checked
with the contents list to ensure that equipment is complete and ready for use. The box should be
sealed after each inspection and such seals should be broken only by authorized persons or in
case of accidents. Many owners coordinate routine inspection with training drills.

All Viton® gaskets are stamped with the date of manufacture and should be removed from
emergency use after a four-year shelf life. For further guidelines concerning the Viton® gaskets,
consult the manufacturer or The Chlorine Institute.

7.3 SPARE PARTS

Spare parts may be purchased by owners of this kit from the manufacturer. For information on
ordering procedures consult the manufacturer or The Chlorine Institute.
 EMERGENCY KIT “A” FOR 100-LB AND 150-LB CHLORINE CYLINDERS 23

8. KIT LIMITATIONS

8.1 CYLINDER DESIGN

Some 100-lb. and 150-lb. chlorine cylinders in current use are of such design that application of
the CI Emergency Kit “A” devices might be difficult or impossible. Among these are those having
oversize neck-rings (precluding proper placement of DEVICE 1). The kit devices also are
unsuitable for stopping leaks around the cylinder neck, base and foot-ring areas. In these cases,
the Chlorine Institute Recovery Vessel may be used.

8.2 OTHER COMPRESSED GASES

The CI Emergency Kit “A” is designed for use on chlorine cylinders. Contact the kit manufacturer
before considering applying on other compressed gas cylinders.

Using Emergency Kit “A” for other compressed gas cylinders can result
CAUTION
in a worsening incident due to incompatibility of materials provided in the
kit.

Different gasket materials may be required for other compressed gases. When used with
compressed gases other than chlorine, the Viton® gasket included with this kit may result in rapid
deterioration and continued release.

9. REFERENCES

9.1 INSTITUTE PUBLICATIONS

The following publications are specifically referenced in the CHLOREP Handbook. The latest
editions of CI publications may be obtained at www.chlorineinstitute.org.
Pamphlet # Title

1 Chlorine Basics (Formerly The Chlorine Manual), ed. 8; Pamphlet

1; The Chlorine Institute: Arlington, VA, 2014.

17 Packaging Plant Safety and Operational Guidelines, ed. 5;

Pamphlet 17; The Chlorine Institute: Arlington, VA, 2017.

65 Personal Protective Equipment for Chlor-Alkali Chemicals, ed. 6;

Pamphlet 65; The Chlorine Institute: Arlington, VA, 2015.

155 Water and Wastewater Operators Chlorine Handbook, ed. 3;

Pamphlet 155; The Chlorine Institute: Arlington, VA, 2014.

164 Reactivity and Compatibility of Chlorine and Sodium Hydroxide

with Various Materials, ed. 3; Pamphlet 164; The Chlorine
Institute: Arlington, VA, 2017.
24 IB/A

9.2 REGULATIONS

9.2.1 Code of Federal Regulations. Title 49. Chapter 1. Parts 190-192 & 195. Office of the Federal
Register National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).

9.2.2 Canadian Transportation of Dangerous Goods Act and Regulations; Transport Canada: Ottawa,
Ontario, 2009. Website: http://www.tc.gc.ca/tdg.
 EMERGENCY KIT “A” FOR 100-LB AND 150-LB CHLORINE CYLINDERS 25

APPENDICES

Appendix A: Parts List

Appendix B: Optional
Equipment

Appendix C: Emergency
Contacts
26 IB/A

APPENDIX A: PARTS LIST

Chlorine Institute Emergency Kit “A”

Kits Manufactured After 1/1/2013

Part Number Description Quantity Per Kit

1A3 Hood Assembly (with Vent Valve 1V) 1

1BRV Gasket, Molded Viton® 2
1K2 Cap Screw 3
1EFP1 Chain and Base Assembly 1
2 Clamping Device (with Block 2A, Yoke 2C, Set Screw 2D) 1
2B Gasket, 15/16” diameter x 1/16” thick 5
2BB Gasket, 1” x 3” x 1/16” thick 5
8B Yoke 1
8C1 Cap Screw 1
8D1 Side Patch (with 8F thumb screws) 1
8GV Gasket, Viton® 1 7/16” diameter ¾” thick 2
8S Strap and Buckle Assembly 1
200A Wrench, 3/8” sq. box, 1 1/4” open end x 7 1/4” long 1
201 Wrench, straight open end, 1 1/4” x 1 1/8” x 12 3/8” long 1
203 Wrench, combination, 7/16” open end, 6pt. box end 1
A-1 Hammer, machinist, 48 oz. 1
A-2 Hacksaw, 10” and 3 blades 1
A-3 Drift Pin, 9/64” x ½” x 6” long 2
A-4 Drift Pin, 7/8” x 1 1/4” x 8” long 2
A-5 Ring, vent valve packing, 7/8” OD x 15/32” ID x ¼” thick 5
A-6 Kit Box Seal 15
A-7 Gasket Sack 1
A-8 Paint Scraper, 1 1/4” blade 1
A-9 Valve Yoke 1
A-10 Valve Yoke Adapter (820 - Hose) 1
A-12 Washer, valve outlet, 9/16” ID x 15/16” OD x 1/16” thick 5
A-13 Plastic Gasket Box 1
A-14 File 1
144 Tool Roll 1
151A Kit Box, 34” L x 16 1/4” W x 16 1/2” H 1

Instruction Booklet 2
CI Pamphlet 1, Chlorine Basics 1

Viton® is a registered trademark of The Chemours Company.

EMERGENCY KIT “A” FOR 100-LB AND 150-LB CHLORINE CYLINDERS 27

CHLORINE INSTITUTE EMERGENCY KIT “A”

Kits Manufactured after 1/1/2013
Figure A-1
28 IB/A

Chlorine Institute Emergency Kit “A”

Kits Manufactured Before 12/31/2012

Part Number Description Quantity Per Kit

1A2 Hood Assembly (with Vent Valve 1V) 1

1BRV Gasket, Molded Viton® 2
1C1 Yoke 1
1D1 Cap Screw 1
1K1 Cap Screw 3
1EFP Chain and Base Assembly 1
1R Ramp 1
2 Clamping Device (with Block 2A, Yoke 2C, Set Screw 2D) 1
2B Gasket, 15/16” dia x 1/16” thick 5
2BB Gasket, 1” x 3” x 1/16” thick 5
8A Side Chain 1
8B Yoke 1
8C Cap Screw 1
8D Side Patch 1
8EV Gasket, Viton® 2 1/2” square x 1/8” thick 2
200A Wrench, 3/8” sq. box, 1 1/4” open end x 7 1/4” long 1
201 Wrench, straight open end, 1-1/4” x 1-1/8” x 12-3/8” long 1
203 Wrench, combination, 7/16” open end, 6pt. Box End 1
A-1 Hammer, machinist, 48 oz. 1
A-2 Hacksaw, 10” and 3 blades 1
A-3 Drift Pin, 9/64” x ½” x 6” long 2
A-4 Drift Pin, 7/8” x 1 1/4” x 8” long 2
A-5 Ring, vent valve packing, 7/8” OD x 15/32” ID x ¼” thick 5
A-6 Kit Box Seal 15
A-7 Gasket Sack 1
A-8 Paint Scraper, 1 1/4” blade 1
A-9 Valve Yoke 1
A-10 Valve Yoke Adapter (820 - Hose) 1
A-12 Washer, valve outlet, 9/16” ID x 15/16” OD x 1/16” thick 5
A-13 Plastic Gasket Box 1
A-14 File 1
144 Tool Roll 1
151A Kit Box, 34” L x 16 1/4” W x 16 1/2” H 1

Instruction Booklet 2
CI Pamphlet 1, Chlorine Basics 1

Viton® is a registered trademark of The Chemours Company.

EMERGENCY KIT “A” FOR 100-LB AND 150-LB CHLORINE CYLINDERS 29

CHLORINE INSTITUTE EMERGENCY KIT “A”

Kits Manufactured before 12/31/2012

Figure A-2
30 IB/A

APPENDIX B: OPTIONAL EQUIPMENT

If the optional equipment shown here is used, consult the kit manufacturer for instruction details.

Device Part #400A Device Part #405

Stripped Valve Stem Clamping Device: Valve Plugging Device:

Designed to close cylinder and ton valves with Designed to seal leaks in valves with stripped
stripped valve stem threads. outlet threads or corroded outlet face.
 EMERGENCY KIT “A” FOR 100-LB AND 150-LB CHLORINE CYLINDERS 31

APPENDIX C: EMERGENCY CONTACTS

Chlorine Supplier:
Address:
Phone:
CHEMTREC* 800-424-9300

CANUTEC** 613-996-6666

Nearest Chlorine
Producer or
Packager:
Address:
Phone:
Police Department:
Fire Department:
First Aid:

* In the UNITED STATES, summon help through CHEMTREC, the Chemical

Transportation Emergency Center at the American Chemistry Council in Arlington, VA.

(Toll Free) 800-424-9300

** In CANADA, summon help through CANUTEC, the Canadian Transport Emergency

Centre in Ottawa.

CANADA, All provinces (Call Collect) 613-996-6666

 1300 Wilson Boulevard • Suite 525 • Arlington, VA 22209
Telephone: (703) 894-4140
Email: pubs@Cl2.com
Website: www.chlorineinstitute.org
THE CHLORINE INSTITUTE Technical Inquiries: TechSvc@CL2.com

The Chlorine Institute all rights reserved.