Project Report on Chloro Caustic Group

Project Report on Chloro Caustic Group

Tata Chemicals Ltd. Mithapur

Gujrat India

Submitted to:- Submitted by:-

Mr. Rajnish Vadgama (HOD) Pintu Jain

Mr. Anil Modi (Deputy Manager) 3rd year chemical engineering

MNIT Jaipur

Email id- [email protected]

PREFACE Theory on any subject is very important but without knowing and witnessing its practical application it becomes useless. The principle activity of plant training is to get details about unit operations unit processes which are carried out in chemical industry and also about the equipment used in industry. Another attractive feature to learn about industrial management and discipline which are equally important in life. During the period of training students get acclimatized to the industry atmosphere and also come face to face with the various problems occurring and ways to solve them, this helps him tremendously to face, the different challenges when he actually becomes an employee of industry. Thus, industry exposure is really mandatory for every technical student.

ACKNOWLEDGEMENT

It will be a great experience to be part of this organization. I have received

encouragement and support from various persons who have directly or

indirectly contributed towards the completion of this project.

I am thankful to the management of Tata Chemical Limited who permitted me

for doing the project training within an exposure of functioning of big

corporate for the period of 45 days.

I would like to show my greatest appreciation to Mr. PARAG BADIYANI SIR

& Mr. UPENDRA BHAYANI who gave me a golden chance to become part

of Tata chemicals. I feel motivated and encouraged every time I met them.

I would also like to specially thank Mr. RAJNISH VADGAMA SIR Mr. ANIL

MODI SIR and entire CHLORO AND CAUSTIC Department for their

constant help and critical evaluation.

Last but not least, I would like to thank the whole staffs of Tata Chemical Ltd.,

Who support me in my research and data collection.

Index

S. no. Content

History

CHLORO –CAUSTIC GROUP • Product of C. C. Group • CCG management

HISTORICAL EVALUATION of PROCESS • Non - Electrolytic Process • Electrolytic Process • Review of Technology

INTRODUCTION TO C. C. Group • Process Flow Chart of the CC Group

PRIMARY BRINE REFINING • Flow sheet • Material balance

SECONDARY BRINE REFINING • Process Flow Chart for Filtration • Filtration • Process flow chart for resin tower • Resin tower • Equipment details

CELL HOUSE • Theory regarding the electrolysis • Brief Description of Plant • Brine Dechlorination & Chlorate decomposition • Chlorine Cooling & Blowing • Electrolysis PROCESS • Equipment deatils • Material balance and energy balance

HYDROCHLORIC ACID PLANT • HCl Plant flow sheet • Process • Hydrogen handling before processing in HCL Plant

• Handling of equipment’s • M.O.C. of Equipment • Safety & Good House keeping

CHLORINE PLANT

Chlorine Drying

Plant flow sheet

Chlorine Compression

Plant flow sheet

Liquefaction and storage of chlorine gas

Filling of liquid chlorine cylinder

CL2 neutralizer Hypo plant

Equipment details

Properties of Chlorine

Degree of Hazards and their Effects

First Aid

DO’S & DON’T For Chlorine

Safe Handling of Liquid chlorine Tonner:

Receipt of Empty Tonner Returned From The Party:

Filling operation NICKLE BRINE BODY EVAPORATOR

Brief Description of Plant

Plant flow sheet

Material balance and energy balance

M.O.C. Of Equipment UTILITY SECTION

Cooling Water System

Chilled Water System

Raw Water System

D. M. Water System CRITICAL PROCESS PARAMETERS IN THE CC GROUP PLANT

GENERAL SAFETY INFORMATION

Lab Safety Equipment:

Chemical Hazards and Symbols

Chemical Hazard Symbols and Definitions

Selection of PPE According To Body Part

Selection of Material of Construction of PPE

Material Safety Data Sheet

Safety data for different chemicals WORK PERMIT PROCEDURE

Purpose

Scope

Work Permit

Procedure for obtaining the Work Permit

History

Mithapur is located in the Dwarka Taluka of the Jamnagar District of

Gujarat state on the western coast of India. Started as a small trading firm

by Jamsedji Nusserwanji Tata in 1868, from a small private trading firm to

one of the largest conglomerates in India; the Tata Group has come a long

way Starting in 1939 with a capacity of 33,000 tons per annum of Soda

Ash, the plant at Mithapur has since grown into a chemicals behemoth

with an installed capacity of 8,75,000 Tons Per Annum, about 34 per cent

of the country’s capacity, making it one of the largest producers of

synthetic soda ash in the world.

The Mithapur plant is the largest integrated salt works and inorganic

chemicals complex in this part of the world. Its salt works are spread over

60 sq km and can produce over 2 million tones of solar salt, the base raw

material for almost all the 27 basic chemicals that the company produces.

Beginning with a soda ash capacity of 80 Tones per day, the chemical

complex has grown into a vast operations site manufacturing 2,400 Tones

per day of Soda Ash, 1500 Tonnes per day of vacuum evaporated salt and

33 other products. Tata Chemicals pioneered the production and marketing

of high-quality iodized salt from Mithapur. With the turnover of Rs.4107

cores (2006-07), Tata Chemicals Limited was India's leading manufacturer

and marketer of inorganic chemicals and fertilizers.

Tata Chemicals is also one of India's leading manufacturers of urea and

phosphatic fertilizers. The urea plant, located at Babrala in the state of

Uttar Pradesh in Northern India, is the country's most energy efficient

fertilizer unit, and produces 12% of the country's urea output in the private

sector.

TCL is also a pioneer and market leader in the branded, iodized salt

segment. Its salt has a purity percentage of 99.8 per cent, the highest in the

country. In 2006, TCL introduced i-shakti, a high iodine based salt for

growing kids.

Headquartered in Mumbai, TCL has a regional presence in Ahmadabad,

Mumbai, Chennai, Kolkata and Noida. TCL offices are also located at

Chandigarh, Agra, Bareilly and Lucknow.

An ISO-9001/14001 certified company, TCL has a varied user industry

base comprising glass, paper, textiles, food additives, petroleum, refining,

chemicals, dyes, pesticides, direct farm application etc. With an export

presence in South and Southeast Asia, the Middle East and Africa, it has

set itself the objective of achieving global cost competitiveness in soda ash.

The Company has outperformed its competitors to maintain

leadership not only in the market share but also in providing

innovative product and service offerings. The Company, the first

synthetic soda ash manufacturer in the country, has been the market

leader since its inception. Tata Chemicals pioneered the sale of

packaged iodized edible branded salt in India. The Tata Kisan

Kendras are at the forefront of transforming the face of rural India.

CHLORO –CAUSTIC GROUP

• Product of C. C. Group

50 % Caustic Soda Lye

Liquid Chlorine

Hydrochloric Acid

Sodium Hypo Chlorite

• CCG management

HISTORICAL EVALUATION of PROCESS

• Non - Electrolytic Process

The production of caustic soda by non - electrolytic process ( i.e. Lime

Soda process - Solvay Process ) dates back to early years of the chemical

industry.

• Electrolytic Process

1) 1800 : First ever electrochemical production of caustic soda & chlorine

by CRUICK-SHANK.

2) 1885 : Introduction of Diaphragm Technology - the Grieshem cell. 1930

: Mercury - Amalgam cell process gained importance as rapid growth of

Rayon industry increased the demand for pure chloride free caustic soda.

Actually this technology was introduced by Castner Kellner in 1892.

3) 1928 : Kenneth Stewart of Hooker Chemicals of U.S.A. introduced

deposited diaphragm cell.

4) 1930 : Mercury - Amalgam cell process gained importance as rapid

growth of Rayon industry increased the demand for pure chloride free

caustic soda. Actually this technology was introduced by Castner Kellner in

1892.

5) 1970 : Du Pont - USA and Asahi - Japan, developed Bi - layer

membrane , which had higher conversion efficiency and had prolonged life.

6) 1970 : Introduction of membrane cell .

7) 1971 : Oxy Tech developed the Modified Diaphragm. Modified

Diaphragm is a mixture of asbestos and fibrous fluorocarbon polymer.

Review of Technology:

1. Diaphragm Technology

• Advantages:

Use of well brine.

Lower Power consumption.

• Disadvantages:

Use of Asbestos.

Lower purity of Caustic & chlorine

Cell outlet caustic is of only 15%.

2. Mercury Amalgam Technology

Advantages:

Cell outlet caustic is of direct 50%.

High Purity of Caustic & Chlorine

Brine Purification is simple.

Disadvantages:

Use of Mercury, a lethal pollutant.

Large floor space. High power consumption

Costly environmental protection.

3. Membrane cell Technology

Advantages:

Lower power consumption.

High Purity of Caustic & Chlorine.

High concentration of Caustic i.e 32%

Environment friendly

Disadvantages:

Brine processing cost is high.

Sensitive to Shut Down.

Spare replacement is highly costly.

INTRODUCTION TO C. C. Group:

• We have Switched over from DIAPHRAGM CELL technology to

MEMBRANE CELL technology in July - 1995.

• Capacity enhancement done from 30 TPD to 100 TPD production rate

of Caustic Soda.

Process Flow Chart of the CC Group

BRINE REFINING

PRIMARY BRINE REFINING

To remove brine impurities

PROCESS:

The saturated brine from SSD is coming to the reaction tan where

soda solution and caustic is added to it. And finally it goes to the

thickener.

The impurities like Ca++ & Mg++ are precipitates in the form of

Calcium carbonate (CaCO3) & Magnesium Hydroxide (Mg (OH)2)

using soda solution (Na2CO3) & caustic solution (NaOH).

The precipitates are settled in clarifier. The precipitates which are

settled in clarifier (sludge) are sending to S.B.R.

CHEMICAL REACTIONS:

• Ca++ + Na2CO3 = CaCO3 + 2Na+

• Mg++ + 2 NaOH = Mg (OH)2 + 2Na+

PRIMARY BRINE REFINING FLOW SHEET

MATERIAL BALANCE

• Ca++ + Na2CO3 = CaCO3 + 2Na+

• Mg++ + 2 NaOH = Mg (OH)2 + 2Na+

Inlet brine composition

Ca+2=2.5 gpl

Mg+2=0.5gpl

Equivalent mole of Ca+2 = 2.5/40=0.0625 mole/l

Equivalent mole of Mg+2= 0.5/23=0.0217 mole/l

Output Brine composition

Ca+2= 2 ppm

Mg+2=3 ppm

Equivalent mole of Ca+2 = 2/40=0.5*10^-4 mole/l

Equivalent mole of Mg+2= 3/23=1.2295*10^-4 mole/l

Required weight of Na2Co3 = (0.0625-0.5*10^-4)*96= 5.9952 g/l

Required weight of NaOH= 2*(0.0217-1.2295*10^-4)*40=1.726 g/l

SECONDARY BRINE REFINING

• OBJECTIVE:

To produce ultra-pure brine produced in two steps.

SECONDARY BRINE REFINIERY FLOW SHEET

FILTRATION:

• Using three precoat type leaf filter (Pressure Filters) having 16 leaf in each

unit. Which removes the fine sludge particles, which are not settled in the

Clarifier?

• Material used, as a precoat is cellulose When filter reaches the maximum

operating pressure (2.5 Kg / cm2) or outlet brine to filter laboratory

analysis exceeds 1 N.T.U., the filter must be cleaned. Before going to

storage tank brine passed through Safety filter, which stops the cellulose

fibers eventually released by pressure leaf filters. To E - 507 (heat

exchanger) low pressure steam & cooling water connection are provided to

warm or cooled the brine temperature in order to control Resin Operating

Temperature & thermic balance of electrolysis.

RESIN TOWER:

• Before entering in the electrolyzer brine passes through two ion -

exchange resin tower placed in series in order to absorb Calcium,

Magnesium & Strontium ions contained in the brine.

• The resin utilized has a very high selectivity for metal ions so that

Calcium and Magnesium content can be reduced to below 20 ppb.

• When the resin in a tower reaches the maximum absorbing capacity the

resin must be regenerated

• Absorption capacity - 6 gms / liters of resin.

• The resin volume in the towers is 4000 liters. Washing the resin with

demiwater, 4% hydrochloric acid solution, 5 % caustic solution & brine

performs the regeneration.

• The operation and regeneration of the resin tower is completely atomized

and controlled by DCS.

Process Flow Chart for Resin tower

EQUIPMENTS DETAILS

TAG NO. EQUIPMENT CAPACITY MOC

P-536 PUMP 15M3/Hr,3.7kw SS-316

P-537 “ 40m3/hr,3.75kw SS-316

P-538 Sludge pump “ “ P-504 “ “ “ P-525 “ 3 “ 5.5 “ Pp

P-506 Pump 55m3/hr,18.5 Kw Titanium

p-507 “ “ “

P-508 “ 60” PP

p-509 “ 42” Pp

p-510 “ 30”11kw Pp

p-511 “ 0.11m3/hr.0.38kw SS-410

p-515 “ 5m3/hr,5.5kw PP

D-536 Soda solution tank 21m3 Ms

D-537 “ 22m3 “

D_537 Reactor 36m3 MSRL

D-504 Clarified brine tank 24m3 “

D-525 A Na2So3 5m3 MSRL

D-526 NaoH 1m3 “

D-527 A Flocculent tank 7m3 MS

D-527 B “ 0.56m3 “

D-535 Stand pipe 7m3 MSRL

p-516 Pump 55m3/hr,18.5kw Titanium

P-505 “ 5m3/hr, 5.5kw “

D-511 Agitators 0.75kw

D-506 Clarified brine tank 55m3 MSRL

D-507 Filtered brine tank 55m3 “

D-510 Alpha cellulose tank 2m3 “

D-515 Effluent tank 100m3 “

D-516 B Pure brine tank 55m3 “

CELL HOUSE

Theory regarding the electrolysis

Electrolysis process is characteristic quqntatily by laws established by

M.FARADAY

FARADAY’S LAW OF ELECTROLYSIS

1). the mass of a substance formed in electrolysis is proportional to the

amount of electricity that has passed through the electrode.

2) In the electrolysis of different chemical components equal amount of

electricity result in the electrochemical transformation of equivalent

amounts of substance.

The following equation expresses faraday’s law:

M= Meq I*t/F

Where,

M=mass of substance that has been formed or transfer

I=current

T=time

F=96500C/mol

There are two types of membrane available for cation exchange

1. Sulfonate base

- A thin cathodes side carboxylic layer

- A thick core sulphonic layer with embedded reinforcement cloth

2. Carboxyl ate base

-A very thin layer of anodic sulphonic

-A thick core carboxylic layer with embedded reinforcement cloth

-A thin cathodic side carboxylic layer

CELL VOLTAGE

- Current density is defined the electrical load per unit of membrane area

- A minimum theoretical D.C. potential must (2.3 v) be impressed between

the anode and the cathode to run the reaction.

VCR= Vm +voltage drop

CURRENT EFFICIENCY

• Theoretical caustic production in Mton NaOH (100%) =0.0358*I (kA)

• Cathodic current effin. = Real caustic production/theoretical production

• The.CL2 production=0.0318*I

• As a cathodic current efficiency we can calculate the cathodic current

efficiency.

• Power in KWh/Mtcs =670.1*Vc/C.E *100

• Power in KWH / Mtcl2=756*Vc/A.E. *100


32% Caustic soda is used as a R.M. in CCG, it is also supplied to

Marine Chemicals & rest is evaporated to 50% Caustic Soda.

Cl2 gas is cooled and further processed in Chlorine Processing Plant

(CPP).

H2 gas is cooled and then used in HBR plant of Marine Chemicals &

HCl plant of CCG.

Depleted Brine free-chlorine content is removed in Cell House section &

sent to DeMag pant of Soda Ash.

Brine Dechlorination & Chlorate decomposition

Depleted Brine coming out from Electrolyser contains dissolved

chlorine of 1.5 to 3 gpl & Chlorate of 1.5 to 3 gpl that must be

removed in the brine dechlorination section.

Depleted brine is bifurcated into two streams, approximately 30%

quantity is diverted to chlorate decomposer & 70% quantity is

diverted to vacuum dechlorination tower.

The chlorate decomposition is done with the help of HCl addition.

The overall reaction for chlorate & hypochlorite ion decomposition

takes place is :

NaClO3 + 6HCl = NaCl + 3Cl2 + 3H2O

HOCl + HCl = Cl2 + H2O

In chlorate decomposer steam is diffused through the brine to strip

out the Cl2 & to maintain the temperature about 90° C for chlorate

decomposition.

The brine leaving the Electrolyser contains some available / free Cl2,

i.e. Chlorine molecules physically absorbed in brine & in the form of

Hypo-chlorous ions.

Hypo-chlorous ions are converted to Cl2 by HCl addition.

Brine dechlorination is done by passing the brine through packed

tower where vacuum is created with help of steam jet ejector.

If it required, sometime brine dechlorination is done by addition of

Na2SO3.

Cl2 + Na2SO3 + H2O = 2HCl + Na2SO4.

The available / free chlorine contents reduced from 3 gpl to 0.5 gpl

level.

After dechlorination, dechlorinated brine is sent to DeMag plant of

Soda Ash.

Cl2 gas comes out from Electrolyser is having temperature of

about 85 - 90 ° C , it is saturated with water vapors and it carries

NaCl mist.

In this section Cl2 gas is cooled to 20 °C temperature by passing

through 3 nos. of shell & tube type Cl2 cooler so water vapor is

condensed & moisture content is Cl2 gas is reduced.

This cool Cl2 gas is supplied to HCl & Chlorine Processing plant

by chlorine Blower.

Chlorine Cooling & Blowing

Cl2 leaves from electrolyser has a very high temperature (< 75 oC)

This Cl2 first passes counter current with Feed Brine from P-516

delivery through heat exchanger E-518 where brine heights up & Cl2

Cooled down.

Then Cl2 goes to E-601 where cooling water cooled it up to 30 oC

Then it goes to Cl2 blower suction, where blower blow it in such a

way that header suction always remain -50 mmwc & discharge

pressure ~ 1300 to 2300 mmwc.

From Cl2 blower it goes to Z-601 which is a desuperhighter & from

here it goes to E-602 where chilled water cooled it to 20 oC

And from E-602 Cl2 goes to CPP section.

PROCESS

• There are 8 nos. of ELECTROLYSER. Each Electrolyser is having 30

nos. of elementary membrane cell.

• Each elementary cell is made up of two compartments, Anodic and

Cathodic, separated by cation exchange membrane The specially designed

cation exchange membrane, separating the Anodic & Cathodic

compartments, in electric field, permits the passage of sodium ion & water

from Anodic to Cathodic side and strongly rejects the passage of anions.

By passing the Direct Current through the Electrolyser fed with ultra pure

brine, as an outcome of electrochemical reaction it gives three products

(1) 32% Caustic Soda

(2) Cl2 gas

(3) H2 gas and the following overall reaction take place:

• DM water is fed to the cathodic compartment in order to keep the

concentration of caustic soda allowed by membrane (30% to 33%).32%

Caustic soda is used as a R.M. in CCG, it is also supplied to Marine

Chemicals & rest is evaporated to 50% Caustic Soda.

• Cl2 gas is cooled and further processed in Chlorine Processing Plant

(CPP).

• H2 gas is cooled and then used in HBR plant of Marine Chemicals & HCl

plant of CCG.

• Depleted Brine free-chlorine content is removed in Cell House section &

sent to DeMag pant of Soda ash depleted Brine coming out from

Electrolyser contains dissolved chlorine of 1.5 to 3 gpl & Chlorate of 1.5 to

3 gpl that must be removed in the brine dechlorination section.

• Depleted brine is bifurcated into two streams, approximately 30%

quantity is • diverted to chlorate decomposer & 70% quantity is diverted to

vacuum dechlorination tower.

The chlorate decomposition is done with the help of HCl addition.

• In chlorate decomposer steam is diffused through the brine to strip out

the Cl2 & to maintain the temperature about 90° C for chlorate

decomposition

• De Nora electrolyser 30 DD 350 consists of 30 elementary membrane

cells with 84 sqmt of total membrane area. (3.5sqmt / elementary

cell.)Electrolyser is made of 29 intermediate bipolar elements (with an

anodic & cathodic side) and 30 membrane sheets assembled in a typical

filter press (zero gaps) configuration.

• The elementary cell of electrolyser is in a series electrical connection.

Current is carried by copper bus-bar to the end elements of of each

electrolyser & reaches sequentially all the elementary cell passing through

the metallic body of bipolar element Pure brine feed in to Decarbonisation

tower C - 507 through a heat exchanger E - 518.

Heat exchanger exchange heat with the produced chlorine, in order to

preheat the brine, recovering some heat from chlorine, by its partial cooling

and dehumidification. From C - 507 pure brine is feed directly by gravity to

each electrolyser.

• For filling and startup of single electrolyser brine goes through E- 517

heat exchanger In the electrolysis room the electrolysis of NaCl (Brine) is

operated by 8 electrolyser De-Nora, type 30 DD 350 at a rated load of 12.5

kA.

Effect of different impurity ions on membrane Components Effect on membrane Control

Acidity Neutralize the carboxylic

group so increase

electrical resists &so cell

voltage &over heating to

membrane &may cause

permemanent demage to

membrane

PH is controlled

Sulphate Depress the solubility &

difficult to maintain the

desired salt concentration.

Decrease hydroxyl ion

rejection capability

Sulphate con. Must be

taken in the range of the

specification limit

Calcium Physical disruption of

membrane

Brine specification limit

Sr,ba,fe,I,Al,Si All these element cause

the any way cause the

precipitate and increase in

current

Weekly checked at a out

let f resin tower

CHEMICAL REACTION

The overall reaction takes place is:

2NaCl + 2H2O = 2NaOH + Cl2 + H2

The overall reaction for chlorate & hypochlorite ion decomposition takes

place is

NaClO3 + 6HCl = NaCl + 3Cl2 + 3H2O

HOCl + HCl = Cl2 + H2

EQUIPMENTS DETAILS TAGNO. EQUIPMENT CAPACITY MOC

P-201 Pump 25m3/hr,7.5kw Cf-8m

P-202 “ 15”5.5kw Cf-8m

P-501 “ 55”15kw Ti

P-502 “ 55”,15kw “

k-601 “ 1900”,55kw “

D-501 32%caustic tank 15m3 SS-316-l

d-202 “ 6m3 MSRL

D-402 DM water tank 2m3 PP/FRP

D-501 Depleted brine

tank

55m3 FRP

D-502 “ 55m3 FRP

D-505 C Na2 SO3 1m3 MSRL

DM-505 Acidic brine tank 0.6m3 FRP

DM-506 “ 1.4m3 “

E-501 Heat exchanger 295744kcal/hr

no.tubes-109

Shell-MSRL

Tubes-SB-338 GR-2

E-518 “ 252746Kcal/hr

no. of tubes -217

Shell-SB-265 GR-2

Tube SB –338 GR-2

E-601 Heat exchanger 266421 k.cal/hr

no.tubes=343

Shell-MSRL

Tube-SB-338 GR-2

E-602 CL2 COOLER 90278 kcal/hr

no.of tubes=157,

shell-chilled water

Shell SS 516 GR-60

TUBE-SB-338 GR-2

E-2101 H2 COOLER 199012 kcal/hr

no.of tubes-232

shell-H2

Shell-SA-516 GR-60

Tube- SA-312 TP-

316

E-201 32%NaOHcooler,

plate heat

exchanger

456901kcal/hr Plate hast-c-276

Gasket –EPDM

E-202 “ 476784 kcal/hr “

E-516 Pure brine heater 1127136kcal/hr Plate- titanium

Gasket –EPDM

E-517 Start up brine

heater

188100kcal/hr Plate-titanium

Gasket –EPDM

MATERIAL AND ENERGY BALANCE

Let Basic brine flowrate is 59m3/hr.

Assuming 100% yield.

Input brine solution composition:-

Nacl= 300gpl

Na2So4=5.5 gpl

Output depleted brine composition:-

Nacl= 230 gpl

Na2So4=6.5 gpl

Here Na2So4 is not taking part in reaction so its mass will remain same in

both streams input and output.

Now Na2So4 mass flowrate in brine=5.5*59000=324.5 kg/hr

Therefore depleted brine flowrate=324.5*1000/6.5=49.923 m3/hr

Nacl in inlet brine=300*59000=17700kg/hr

Nacl in depleted brine=230*49923.077=11482.31kg/hr

Nacl reacted=17700-11482.31=6217.69kg/hr

Overall reaction around the cell

2NaCl + 2H2O = 2NaOH + Cl2 + H2

117 36 80 71 2

117 kg Nacl 80 kg Naoh

6217.69 kg Nacl 80*6217.69/117=4250.41 kg/hr NaOh

NaOh product rate= 4250.41 kg/hr= 102.033 ton/day

DM water requirement

6217.69 kg 2Nacl react with 2H2O=6217.69*36/117=1913.13 kg/hr

H2O required for reaction=1913.13 kg/hr

S.g. of brine at 80.7oc=1.181

Density of water at 80.7oc=974.8 kg/m3

Density of brine=1151.24 kg/m3

Density of depleted brine by same manner= 1094.46 kg/m3

Mass flowrate of brine= 59*1151.24=67923.16 kg/hr

Mass flowrate of water in brine= mass flow rate of brine-(mass flow rate of

Nacl + mass flowrate of Na2So4

=67923.16-(17700+324.3)

=49898.66 kg/hr

Mass flow rate of depleted brine=49.923*1094.46=54638.73 kg/hr

Mass flow rate of water in depleted brine=54638.73-(11452.31+324.5)

= 42831.91 kg/hr

Mass flow rate of water will go with products=47898.66-42831.91

=7066.74 kg/hr

Now NaOH produced from the cell is 32% w/w

Total NaOH solution= 4250.41/0.32= 13285.66 kg/hr

Water in NaOH=13285.66-4251.41=9034.25 kg/hr

Assuming H2 and Cl2 having 0% moisture content

Additional water required to 32% NaOH solution=9034.55-7066.74

= 1967.61 kg/hr

Total water required= additional + Water required for rxn

= 1967.61+1913.13=3880.74 kg/hr

Volume floe rate of DM water=3880.79/974.8=3.9810 m3/hr

H2 and Cl2 product rate

6217.69 kg Nacl- ? H2? Cl2

H2 produced=6217.69*2/117=106.28 kg/hr=2.55 ton/day

Cl2 produced= 3217*71/117=90.55 ton/day

ENERGY BALANCE:-

Electric current supplied = 12 kA =12000 coulomb per second.

Now according to, Faraday’s 2nd law of electrolysis,

“For a given quantity of electricity (electric charge), the mass of an

elemental material altered at an electrode is directly proportional to the

equivalent weight of elemental material.”

“The Equivalent weight of a substance is its molar mass divided by an

integer that depends on reaction undergone by the material.”

So,

m = e ×q ; production of 1 ton of 100% NaOH.

1000= 40×q

96500

So, q =2912500 coloumb

Now,

q = I×t

2912500=12000×t

So,

t =210.041 second.

Cell voltage =3.412 volt.

To calculate ton per hour of 100% caustic per cell:-

M =z×i = (40×12000) kg/sec

96500

M = (40×12000×3600) ton/ hr

96500×1000

M = 17.906 Tonnes/ hr .

η = (Tones/hour of NaOH produced per cell) ×100

1.651 × Circuit current

Here, tones /hr of 100% NaOH produced per cell = 17.906 ton

η = 17.906×100

1.651 × 12000

η = 90.33%

nsumption in kw/hr per ton of 100% = 608×volt×100

Caustic produced % current efficiency

= 608×3.412×100

90.

Power consumption in kw/hr per ton of 100% = 2297.3 kw/hr

Caustic produced

HYDROCHLORIC ACID PLANT

HCl Plant flow sheet

Sample Point

( For Analysis )

Vent Gas Blower

D.M.Water I/L

Chlorine I/L

HCl Recycle to

chamber

Hydrogen I/L

HCL

32%

Unabsorbed

HCl

vapour to tail

tower

Vent Line to Scrubber

Acid Circulation Pump

Combustion

Chamber

Cooler

TAIL

TOWER

Acid

circulati

on

Tank

(P900A/B)D900A

CT-2779

FI911A

PC911A

K902A/B

FC915A

TT913A

Moist.

Separ.HC912A

PI918A

FC918A

Moist.

Separ.

F601

FC919A

PI919A

PL9123

HV911A

HV912

F2101

7101

PI922 PC923

N2

PROCESS

Hydrogen handling before processing in HCL Plant

The scope of Hydrogen handling section are:-

To maintain positive hydrogen pressure in cell house header

To increase hydrogen pressure for suitable use in HCL plant.

To cool the hydrogen gas from 85 to 20 deg. C

To remove excess moisture ( NaOH mist )

Hydrogen handling section consist two shell & tube heat exchanger , two

mist eliminators, two hydrogen blower and seal pots.

Startup Operation of Hydrogen Handling

As rectifier load reaches to 2 -2.5 KA, HCL operator will Open H2

blower suction filter inlet valves per instruction of CCR

HCL operator shall check following valves are open.

Suction & Delivery v/v of blower

Hydrogen chiller’s chilled water I/L & O/L v/v

Hydrogen line I/L & O/L valve.

Isolation v/v of all control valves

D.M. water I/L valve to suction & discharge filter & main D.M.

water valve.

Suction & delivery filter drain valve.

Make up water I/L valve to H2 seal pot

HCL operator will inform CCR that H2 blower at field

is ready for startup.

CCR operator will open H2 blower suction pressure control

Valve 100 % on manual mode.

As rectifier current reaches to > 4 KA, CCR operator will

Start H2 blower & make announcement that H2 blower is

Started

CCR operator shall put H2 blower vent pressure cont.r on

‘Auto mode’ with fully shut position ( PC - 2102 ) & slowly

Closing suction pressure cont.r on manual mode.( PC- 2101)

As H2 blower suction pressure becomes 80 - 200 mmwc, CCR

Operator shall put suction pressure controller on ‘Auto mode’

by giving set point of 80 - 200 mmwc.

Startup Operation of HCL Furnace

First of all HCL operator make ready the cooling water circuit of

individual furnace in which

start cooling water fan

open cooling water i/l & o/l v/v of cooler absorber & combustion

chamber

start cooling water pump p - 276

open i/l valve of sea water to cooling tower

Cooling water flow to cooler absorber shall be more than 150 m3/hr

unless furnace will be tripped.

HCL operator shall open CL2 & H2 moisture separator i/l valve

Make ready the D.M. water circuit in which

open i/l D.M water v/v to D- 906 ( D.M. water storae tank )

put D- 906 level controller on auto mode

start P- 906 to fill overhead tank

HCL operator shall check D.M. water flow contr. isolation v/v open

& fill the acid circulation tank D – 900

Start P - 900 acid circulation pump

HCL operator open acid circulation v/v,isolation v/v of tank D -900

level controller & acid production v/v to HCL storage tank D - 902

Start vent blower K - 902 after ensuring that chamber suction

control v/v is open from CCR.

Chamber suction should be > 150 mmwc

CCR operator shall make all condition ready to start furnace such

as

make furnace interlock healthy

H2 safety v/v 25 % open,H2 flow controller 6-20 % open CL2 flow

controller 20-30 % open & chamber suction controller on auto mode

to maintain -50 to -90 mmwc suction

As furnace is ready for start-up Shift Engineer shall inform CCR

operator to make announcement of plant start up condition.

HCl operator shall open N2 purging valve manually for

approximately one minute.

HCl operator shall light up pilot burner after opening pilot burner H2

valve and operator shall put pilot burner with H2 flame into the

combustion chamber through pilot window, Shift Engineer shall

observe flame through chamber sight glass.

HCl operator shall manually open hydrogen valve (after the hydrogen

control valve).

Shift Engineer shall first open 1 “Ø H2 line valve fully and open 1”

Ø control valve slowly till H2 flame is visible through combustion

chamber burner block by keeping furnace under suction.

After assuring stable H2 flame through burner, Shift Engineer shall

ask HCl operator to close pilot burner valve.

Now operator shall remove pilot burner & close pilot window

properly.

HCl operator shall open 1” Ø H2 valve till H2 flow reaches to 8 - 20

Kg/hr. by keeping chamber under suction.

Shift Engineer shall ask HCl operator to open Cl2 wheel valve slowly.

As H2 flame colour changes to whitish Shift Engineer shall ask

operator to close air intake valve to Cl2 line.

Operator shall open more 1” Ø H2 wheel valve to increase H2 flow.

As this valve gets fully open operator shall start slowly opening valve

before H2 flow control valve.

As valve in H2 line before H2 flow control valve gets fully opened,

operator shall close H2 line both 1” Ø valve completely.

As H2 flow reaches to 22 - 25 kg/hr. and Cl2 flow reaches to 330 -

380 kg/hr. Shift Engineer shall ask C.C.R operator to put H2 flow

controller and D.M. water flow on “ CASCADE MODE “ and to

give chamber suction set pilot – 30 to - 90 MMWC.

After observing plant condition, Shift Engineer shall instruct CCR

and HCl operator to increase Cl2 flow if it is required.

HAND OVER OF EQUIPMENT TO MAINTENANCE DEPT.

Any equipment shall be handed over to maintenance dept. by issuing

safety work permit ( QSF-730-12-01 / QSF-730-12-02 ).

Before issuing safety work permit shift engineer shall check that

equipment is isolated as mentioned below.

Tank like D-203, D- 900 & D-902 shall be completely emptied out /

drained, isolated from all inlet & out let pipeline. Washed with water.

Pump shall be isolated by closing suction, delivery & sealing valve.

EED shall be asked to remove its motor fuse.

Heat Exchanger shall be isolated by closing its all inlet & out let

valves.

M.O.C. of Equipment

P- 900 • Capacity of pump 44

m3/hr • M.O.C of pump PP • KW of pump 7.5

P - 901 • Capacity of pump 20

m3/hr • M.O.C of pump PP • KW OF pump 7.5

P – 902 • Capacity of pump 15

m3/hr • M.O.C of pump PP • KW of pump 2.2

P – 906 • Capacity of pump 7

m3/hr • M.O.C of pump SS-316 • KW OF pump 2.2

P - 276 • Capacity of pump 200

m3/hr • M.O.C of pump CF-8M • KW of pump 37

P – 904 • Capacity of pump 44 m3/hr • M.O.C. of pump PP • KW of pump 7.5

K - 2101 • Capacity of pump 1697

m3/hr • M.O.C of pump • KW of pump 22.5

D- 906 • DM water storage tank

Capacity 5 m3 • M.O.C. of tank MSRL

D - 900 • Acid circulation tank • Capacity 3.5 m3 • M.O.C of tank FRP

D - 902 • Acid storage tank • Capacity 150 m3 • M.O.C. of tank FRP

Safety & Good House keeping

Always insured Nitrogen purging before starting & shut down the

plant.

Use safety equipment such as hand gloves, gogles etc whenever

work with HCl acid leakage at plant.

Always ensure sufficient overflow of sea water at H2/Cl2 seal to

prevent any harmful effect of Cl2/H2 prss.

Always maintain N2 cylinder ready to use with proper connection.

Use plenty of sea water & soda powder at leakage of Hcl acid for

neutralization.

CHLORINE PLANT

This section mainly comprises of

1) Drying of Chlorine gas.

2) Compression of Chlorine gas.

3) Liquefaction of Chlorine gas & Storage.

4) Filling of Liquid Chlorine toners / cylinder.

5) Cl2 neutralization (Hypo) Plant.

Chlorine Drying

As Cl2 gas having a small amount of water is highly corrosive, in this

section Wet Cl2 received from C/H is passed through packed tower

having H2SO4 circulation in counter current direction.

As Cl2 gas comes in contact with Concentrated H2SO4, H2SO4

absorbs the moisture from Cl2 gas to give Dry Cl2 as a product.

Dilute waste H2SO4 is discharged to malara effluent.

PROCESS FLOW DIAGRAM

Chlorine Compression

Dry Cl2 is compressed to 3 - 5 Kg. / Cm2 pressure by liquid ring

type compressor & then supplied to Marine Chemicals and Liquid

Chlorine Plant.

Here H2SO4 is used as liquid for formation of ring in Chlorine

compressor.


LIQUEFACTION AND STORAGE OF CHLORINE GAS

The chlorine gas coming from cells which after cooling, drying and

compression enters the tubes of the chlorine condenser, where it is

cooled down and liquefied by means of Freon - 22 evaporation.

Liquid chlorine flows by gravity into the storage tanks.

All the sniff gas, uncondensed chlorine & incondensable gases leaves

the liquefier tube side and goes to the either in HCl plant or Cold

process plant of Marine chemicals dept.

The liquefaction section is composed by :-

Freon compressors

Freon condenser, shell & tube heat exchanger, with chilled water as

cooling medium circulating in the tubes.

Condensed Freon receiver.

Chlorine condenser – shell & tube heat exchanger, where chlorine is

condensed by means of evaporating Freon.

Freon compressor:-Compressor, compressed the refrigerant at high

pressure, thereby increasing temperature. This high pressure &

temperature convert vapor into liquid.

FILLING OF LIQUID CHLORINE CYLINDER

There are four nos. of Liquid Cl2 storage tank, each having the storage

capacity of 76.0 T.

As per statutory requirement one storage tank always remains empty

for any emergency use.

As one storage tank gets filled it is isolated from liquifier &

pressurized to 170# psig.

At 170psig. Pressure liquid Cl2 is transferred from storage tank to

Tonner / Cylinder.

Tonners / Cylinders are stored in Godown & then dispatched.

CL2 NEUTRALIZATION (HYPO) PLANT

All section Cl2 equipments / pipelines are connected to “Cl2

Neutralization Section”.

During any emergency (i.e. leakages of any Cl2 carrying pipeline /

equipment) Cl2 gas from any section is released to this section.

In this section Cl2 gas is absorbed in 16% Caustic Soda in packed tower.

As a result of chemical reaction it gives Sodium Hypochlorite as a product.

Sodium Hypochlorite is supplied to internal as well as external customer by

road truck.

EQUIPMENTS DETAILS

Tag no. Equipments Capacity MOC

D-602 98%H2so4 tank 20m3 Cs

D-603 Dil.h2so4 tank 3.5m3

D-605 98%H2so4 tank 2m3 Ms

D-801-A/B Hypo tower tak 55 m3 Pvc/frp

D-802 “ “ “

Cl2 ST1 Cl2 storage

tank

76T MS

Cl2 ST2 " “ “

CL2 ST3 “ “ “

CL2 ST4 “ “ “

Properties of Chlorine:

Threshold Limit Value:

Definition:

TLV is average concentration of substance in ambient air for a normal 8

hours working or 40 hours work week to which nearly all workers may be

repeatedly exposed, dry after day without adverse effects:

Degree of Hazards and their Effects

Sr. No Chlorine Concentration

In Air (PPM)

Degree of Hazards

1 3.5 Least detectable odor.

2 15.1 Least amount required to

cause imitation of throat.

3 30.2 Least amount required to

cause coughing.

4 1.0 TLV-Least amount which

can be in haled safely –

shown workdays for a life

time.

5 4.0 Maximum amount that can

be breathed for one hour

without serious effect.

6 40 to 60 Amount dangerous in ½-1

hour.

7 1000 Amount likely to be fatal

after a few deep breathes.

First Aid

Treatment:

In all cases, immediately remove the patient from the contaminated

area, immediately begin appropriate treatment. Never give anything

by mouth to an unconscious patient.

Inhalation:

If the patient is breathing, place him in comfortable position, keep

him warm and at rest until a physician arrives. It breathing is difficult,

administer oxygen if equipment and trained personnel are available.

Automatic artificial respiration is considered preferable to manual, but only

when administered by an experienced operator.

1) Eyes: If even small quantities of Chlorine have entered in the eyes, flush

eyes immediately with copious amounts of lukewarm running water for at

least 15 minutes. Hold the eyelids apart forcibly to insure complete

irritation of all eye and lid tissues.

Never attempt chemical neutralization. Do not give any medication except

under specific I intimation from a physician.

2) Skin: Get patient under a shower immediately remove clothes while the

shower is running wash the skin with large quantities of soap and water.

Do not attempt to neutralize Chlorine with chemicals. Do not apply salves

or ointment except as directed by a physician.

3) Throat Irritation: Drinking milk may help relieve the discomforts of

throat irritation from Chlorine exposure.

4) Coughing: A mild stimulant such a hot coffee or hot tea is often used

for relief.

DO’S & DON’T For Chlorine

DO’S:

Use required PPE’s during Chlorine handling.

Chlorine is 1.8 times heavier than air so, when Chlorine will leak you

should leave place perpendicular or opposite direction of air in

respect of working place.

One liter liquid Chlorine = 456.8 liter Chlorine gas so, when liquid

Chlorine will leak

You must immediately arrest leakage.

Keep away flammable material from Chlorine

When Chlorine will spillage Chlorine should neutralize with Caustic

soda after it should wash with water

When Chlorine will spray on any parts of body you have to wash

with water up to minimum 15 minute

When Chlorine come in respiratory system then affected person shift

toward open place and give artificial respiratory

On above situation immediately give medical treatment.

DON’T:

Flammable material should not burnt near to Chlorine.

When liquid Chlorine will spray on any parts of body then skin will affect with cold burn so, you must not direct contact with liquid Chlorine.

Wet Chlorine is highly corrosive so, dry chlorine never keep in contact with water.

Chlorine and Petroleum product can form some compound with Hydrogen, Turpentine, Alcohol, Acetylene, Ammonia and Sulphur etc. and by this compound it can blast so, it must always keep away from chemicals.

Effect of Temperature on Volume:

• With increase of temperature of container the volume of liquid increased

rapidly and at 70oC it crosses the capacity of container and damage of

container is possible causing SERIOUS HAZARDS.

Effect of Temperature On Vapor pressure:

Safe Handling of Liquid chlorine Tonner:

Caustic soda and chlorine - one of the most important inorganic chemicals

- are used by almost all industries for one thing or the other. The

consumption of liquid chlorine in various sectors is increasing day by day.

Although chlorine is highly toxic and hazardous in nature, at the same time

it is very useful to mankind and has become indispensable. There are many

hazards inherent in the manufacture, handling and use of chlorine like

many other industrial chemicals. But with proper design and sound

operating practices, costly injuries and damage can be reduced and in many

cases eliminated.

For safer handling of chlorine, it is either transported by pipe lines or by

big tanker. In India, tonners are widely used for transportation of liquid

chlorine.

Handling of chlorine needs experience and skill staff as well as it also

requires to be managed by proper design of plant for handling due to its

hazardous nature.

One should know the physical and chemical properties of gaseous and

liquid chlorine before handling it. Before going in detail about the handling

of chlorine, knowledge of following top ten hazards is highly useful while

handling the chlorine tonner.

Contamination of chlorine tonner with other chemical.

Exposure of chlorine tonner / storage to high temperature or fire

Lifting of the chlorine tonner by its valve protection hood.

Chlorine tonner valve leakage

Transportation of chlorine tonners without valve cap.

Keeping the tonners in stack (More than one layer).

Using chlorine tonners as pressure vessel or intermediate tank.

Using other method for loading and unloading tonners other than

EOT crane / mobile crane.

Moisture in chlorine will cause corrosion in the storage and tonner.

Hence chlorine drying and padding air quality is important

keeping the tonner in wet & muddy surface

Apart from the knowledge of long list of physical and chemicals

properties of chlorine, understanding of following properties of

chlorine, helps to handle the liquid chlorine tonner in a safer way.

The vapor pressure of liquid chlorine rises steeply with respect to

increase of temperature. At 200C., the vapor pressure is 5.6 atm.. So

chlorine tonner should always be kept away from heat source.

Also, the liquid chlorine has high coefficient of thermal expansion

leading to rapid increase in volume, with rising in temperature. Due

to this property, no container is completely filled completely.

The solubility of chlorine in water is very less. It is about 1% at

9.40C. It forms below crystalline chlorine hydrate when it is cooled

below 9.40C. This property is utilized by spilling the chilled water

below 9.40C while the chlorine is heavily leaking.

AT 00C and 1 atm. 1 volume of liquid chlorine = 457.6 volume of

gaseous chlorine. This property is utilized in case of leakage of liquid

chlorine through lower valve of the tonner. In this case, the tonner is

rolled immediately in order to position the leakage valve at top side

to allow only the gas leakage. This is also because the quantity of

chlorine that escape from gas leak is only about 1/15 th of what

would escape from a liquid leak through a hole of the same size.

Knowledge of following point is preferable to avoid any emergency

situation in chlorine handling area.

Manually operated chain pulley block as a standby for EOT crane

during power failure for lifting leaky chlorine tonners.

DG set power supply, as an alternative should be given to hypo

system and EOT carne.

Padding air compressor auto tripping and restarting at 180 - 150 psig

pressure to avoid over pressurizing the chlorine storage.

Always one liquid chlorine storage tank should be kept empty as a

“dump tank” for any emergency. This is also a statutory requirement.

Cl2 leak detectors should be installed at Chlorine storage and tonner

filling area. It is to be monitored on continuous basis and periodical

testing of sensors to be carried out.

Monitor compressed dry air quality - Dew Point to assure the dryness

of padding air (- 400C).

NRVs are to be provided in padding airline to liquid chlorine storage

to prevent the back flow. The NRV should be checked periodically.

Handling of chlorine tonner is done with utmost care with a

systematic procedure. At our site in Tata Chemicals Ltd, the entire

processes are divided into three steps in order to explain each activity

for safer operation.

Handling of liquid chlorine in tonner is done in three stages a)

Receipt of empty tonner returned from the party b) Filling operation

c) Storing the tonner and finally dispatching to the end user.

Receipt of Empty Tonner Returned From The Party:

On receipt of the tonner, its identification No, it’s physical condition,

valve condition, valve cap, and valve guard and hydraulic test date are

checked.

In case of tonner own by the party, evidence of paper for CCE

approval, manufacturer’s certificate and last hydraulic test is required

before unloading the tonner at site.

Proper segregation of tonners is necessary with display board in order

to avoid any confusion. Toner which is due for hydraulic test ,

tonners which is ready for filling, tonners which is kept for washing

etc – all are properly segregated.

All the tonners are checked and verified by the Engineer/Supervisor

for giving green signal for filling the liquid chlorine. The checklist

include following.

Test date.

Valve condition.

Checking of foreign materials- Checking of empty chlorine tonner

for possibility of any foreign chemicals is really a big and challenging

task. So following measures are taken

Information about all the chemicals used by the end users are

kept in our record. It is essential to have a knowledge of what

type of chemicals, the end user is using in the reactor or vessel

where the chlorine from the toner is emptied out and whether

it can form an explosive reaction or not.

Visit is done to the user end to check the methods of emptying

out the tonner.

Knowledge sharing with the user is encouraged for creating

awareness of possible consequence. Apart from the above

measure, it is also recommended to check the empty tonner by

inserting small bulb with camera by removing the plug from the

tonner.

If tonner does not contain any foreign matter, air pressure inside the

tonner is taken to check the valve and plug leakage with ammonia

torch.

If any foreign matter is found or suspected, tonner is shifted to

washing area for inspection.

In order to check the brass valve threads, seat and gland, air pressure

of 170Psig is taken inside the empty tonner. The leakage is detected

with the help of soap solution.

Stickers are affixed on the tonner’s duly signed, in order to ensure

that the tonner’s are checked by a responsible person to ensure ready

for filling.

FILLING OPERATION

Every day, the weighing machines are calibrated by standard weight

and recorded.

The tare weight are checked and are compared with the last record in

order to get the trend for loss of weight for analyzing. It is required

to find out the reason of major loss of weight.

During the tonner filling, the initial filling rate is kept low enough to

check any rise of temperature on the surface of tonner. A pyrometer

(a temperature measuring device) has been installed to monitor the

surface temperature of the tonner continuously. The temperature is

displayed on the DCS control room and in case of sudden rise of

temperature; immediate announcement is done for stopping the

filling operation. Recently, we have put interlock system for closing

the auto-filling valve when the temperature rises beyond a certain

limit.

In case of any rise in temperature is observed, following actions are

taken a) Filling operation is stopped immediately. b) Release the

chlorine gas from the tonner to hypo system. c) All senior staff is to

be informed. d) After releasing, the tonner is to be shifted for

washing. e) It is very-very important to get the name of the party who

has returned this tonner. This helps to find out the root cause

analysis for the reason of rise of temperature.

The weight of the liquid chlorine being filled in the tonner is

displayed at site. An auto filling system has been provided which

allows the auto filling valve, mounted in the chlorine filling line,

immediately shut off when net weight of liquid chlorine in the tonner

reaches to 900 Kg. Hooter starts buzzing to draw the attention of the

operator.

Sometimes, icing is observed on the vent line of the copper tube

connected to the tonner during filling operation. At this point, filling

operation is stopped immediately. Although it is very rare case but it

indicates either overfilling or any puncture on gas reduction pipe.

The filling line filter is clean in every fifteen days to ensure no

escaping of foreign particles with the liquid chlorine.

After filling is completed, the copper tubes are disconnected and

brass valve is covered with guard

The filled tonner / cylinder should be kept in the storage area (kept

under shade).

Storing the tonner and finally dispatching to the end user:

The filled tonners are kept under the shade.

Time and date of filling are be recorded and written on the tonner so

as to dispatch the tonner 24-hours after filling. This is required to

check any abnormal rise of temperature in 24 hrs. For this, the

operator checks the surface temperature of the tonner in every 4 hrs

and record the temperature in logbook for every tonner. The tonner

is dispatched after 24 hrs, after ensuring that there is no rise of

temperature in last 24 hrs.

Keep enough space between the tonners so that it can be accessed

easily.

Filled chlorine tonners should not be exposed to sunlight.

Chlorine tonners should not be stacked one above the other

Following necessary care are taken during the transportation.

Valid License / Certificate of fitness of driver.

Roadworthiness checks prior to loading.

Routes are properly identified and explained.

Drivers are made aware of the bad weather condition.

Drivers are trained for Emergency procedures.

Material Safety Data Sheet are provided to the drivers.

Apart from the above mentioned practices at our site, it is also ensured to

follow following practices by the end use for safe handling of chlorine

toner. All the following information are shared with them during customer

visit.

The Tonner or Cylinders should not be used as intermediate or

process vessel.

The Tonner or Cylinder valve should not be used for controlling the

flow of chlorine. A separate regulating valve on the process side

should be used for purpose of controlling the flow. Avoid frequent

operations as it can damage the valve.

Tonner should not be heated with hot water, steam or direct flame.

Increase in temperature will increase vapor pressure of the chlorine

inside the tonner which may lead to bursting of container.

A pressure gauge between the chlorine container valve and regulating

valve should be provided. Withdrawal of Chlorine must be stopped

when the gas pressure inside the container drops to 0.5 Kg/cm2.

Emergency absorption system should be provided to neutralize

chlorine from a tonner in case of emergency.

Consumer must provide an inverted barometric loop for connecting

the chlorine tonner to the process piping, particularly one containing

process liquid. This will prevent the back flow of liquid from process

to the tonner.

Emergency kit should be available at nearby location for arresting

leakage from the valve.

Do not spray water on leak chlorine tonner as it will make situation

worse due to corrosive action of chlorine and water.

In case of fire at nearby area it is allowed to spray cold water on the

surface of the tonner to keep them cool.

In case of the chlorine leakage, roll the tonners and bring the leaky

point up to prevent liquid chlorine from escaping as leak rate of

liquid chlorine is much higher than the leak rate of gas chlorine.

Roller type arrangement can be made for the usage of chlorine

tonners.

Tonners should not be unloaded directly throwing from road truck.

It is recommended that customer should send operators to the

supplier’s works for taking training on handling the tonners.

As it is mentioned above that handling of liquid chlorine in tonner requires

experience and trained personnel, but at the same time, there should not be

any gap while following the procedure. In spite of documented procedure,

people sometime bypassed the procedure which leads to the disastrous

incidence. So it is also necessary to have a frequent training to the same

experience personnel and conducting a mock drill at a regular interval. It

helps to keep them ready all the time.

Various safety measures related to CL2 Tonner Design & usage:

900 Kg liquid Cl2 filling in tonner the quantity of liquid CL2 to be

filled in a tonner is dependent on its water capacity.

Qty. of Liquid Cl2 = Water capacity * Filling ratio (1.19).

Generally water capacity in our country is 760 Liters corresponding

to 915 kg or more Liquid Cl2.

Both Cl2 Cylinder & tonner valves are conforming to IS 3224

approved by chief controller of explosives.

Barometric Leg: With emptying of container, the pressure inside

steadily drops & vacuum develops. Consequently there is a possibility

of suck-back into container from process line. This suck in back of

liquid results in internal corrosion of tonner. This can be prevented

by installing a suitably designed barometric leg. In system working at

atm pressure, the height of barometric leg should be:

H = 34/D ft

Where D is density of liquid in g/cc.

Protective Equipment’s For Cl2 Leak:

Air Line continuous respirator

Self-contained breathing apparatus

Industrial canister type gas mask

Emergency escape breathing apparatus: EEBA from ISI is a proven

line of emergency escape breathing devices. These are not used for

use as emergency response SCBA but as a means for personnel to

escape hazardous environments in workplace.

Tips To Get Protection Against Chlorine:

Tips for Public:

Do not panic. Chlorine does not burn or explodes.

Avoid deep breathing when Chlorine is present in the atmosphere.

Go indoors and close the doors and windows of the house and

switch off the ventilation system.

Move to the upper floor if in a multi store building.

Cover the face with a wet towel for additional protection.

Tips for Chlorine Consumers:

Use tonners on “first come first used” basis.

Do not heat the Chlorine Containers. This may lead to serious

accidents and even rupture of containers.

Use tonner key for operating the tonner valves.

Never use plastic tubing for Chlorine service. Use copper tubing with stand fittings.

Install a BAROMETRIC LEG in the system.

Keep a solution of Caustic Soda/Soda Ash/Hydrated Lime Slurry in a tank ready for neutralization of Chlorine in emergency,

Keep a tonner/cylinder safety kit always handy.

Pressure in a Chlorine Container is not a measure of quantity in the container. At a given temperature, the pressure in a container will be the same whether the quantity is 1 Kg. Or 900 Kgs.

Send your operators for training at your supplier’s works.

Education on Chlorine Safety:

NICKLE BRINE BODY EVAPORATOR


Scope of this section is production of Pure Salt Slurry & 50%

Caustic Soda.

In this section there are two evaporator bodies. Body no. 1 is used

for production of Pure Salt Slurry & Body no. 2 is used for

production of 50% Caustic Soda.

As per requirement & facility available we can run both the bodies

as either single effect or double effect.

Pure Brine received from SABR is evaporated with help of 50#

steam in BODY NO. - 1 & gives Pure Salt Slurry as a product

which is supplied to MUW plant.

32% Caustic Soda received from C/H is evaporated with help of

50# steam in BODY NO. - 2 & gives 32% Caustic Soda as a

product.

50 % Caustic Soda is supplied to customer by Road Tanker.


MATERIAL BALANCE AND ENERGY BALANCE FOR NBE2

Let we are producing 1 ton 50% caustic

L=F+1000

Caustic balance

L*0.32=1000*0.5

L=1.562 ton

Water balance

L*(1-0.32)=F+500

F=562.5kg=0.562 ton

Energy balance

stream Caustic(kg/sec) Water(kg/sec) Total kg/sec

feed 0.1388 0.2951 0.4339

product 0.1388 0.1388 0.2776

Water vapor -------- 0.15625 0.15625

Data

Feed temperature of 32% caustic=358k=85oc

Steam pressure=50 psig

Latent heat of saturated steam=2118 KJ/kg

Outlet temperature of 50% caustic and water vapor=368k

Specific heat of feed=3.68 KJ/kg K

Specific heat of outlet 50% caustic=3.22 KJ/kg K

Heat entering at feed=mcpdt

=0.4339*3.68*(358-298)

=95.805 kW

Heat leaving at product=0.276*3.22*(368-298)

=62.2104 KW

Heat leaving at Product from water vapor

=Latent heat of vaporization + mcpdt

=0.15625*[2260+4.18*(373-298)]

=402.109 KW

Total heat Balance

Heat supplied by superheated steam= Output-input

M*lf=468.109+62.201-95.805

M=368.514/2079.21

M=0.177 kg/sec steam will be required for 1 ton/hr 50% caustic

M.O.C. Of Equipment

P -1400 :- • Capacity of this pump is 3578

M3/Hr • M.O.C. of this pump is Ni. +

Cr. • Power consumed is 75 kW

P -1401:- • Capacity of this pump is 60

M3/Hr • M.O.C. of this pump is SS-

316 • Power consumed is 15 kW



316 • Power consumed is 9.5 kW

P -1403 :- • M.O.C. of this pump is SS-



M3/Hr



316. • Power consumed is 7.5 kW

P -1407:- • Capacity of this pump is 16









• M.O.C. of this pump is SS-316

• Power consumed is 22.5 kW P - 2701 :-

• Capacity of this pump is 550 M3/Hr

• Power consumed is 75 kW K - 2701:-

• Power consumed is 22 kW P - 203 :-


• Power consumed is 5.5 kW P -1305 :-


• Power consumed is 2.2 kW

P/BRINE P :- • Power consumed is 22.5 kW • D-1401(RAW WAETR

TANK):-Capacity of this tank is 21.2 M3

• M.O.C. of this tank is SS-316 D-1403(RAW WAETR TANK)

• Capacity of this tank is 9.42 M3

• M.O.C. of this tank is MSRL • D-1404 (SLURRY TANK) :-

Capacity of this TANK is 21.2 M3

• M.O.C. of this tank is SS-3016

If rubber lined vassal is not used, then there is a possibility that Slurry carry over Iron content.

UTILITY SECTION

Sub sections

Low Pressure Steam (1.0 Kg / Cm2)

Cooling Water (Sea Water of 5.5 pH)

Raw Water

Chilled Water (NH3 Refrigeration System)

D. M. Water

Cooling Water System

Sea water comes from Talao header is fed to Mixing Tank where HCl

addition is being done to reduce pH up to 5.5 to 6.0.

The reaction takes place is:

CaCO3 + 2HCl = CaCl2 + CO2 + H2O

CO2 is liberated by Air Stripping in Degasifier.

By this way CaCO3 content in sea water is reduced to prevent any scaling

in any process equipment.

Chilled Water System

In this section Raw Water temperature is reduced to 8 - 15 ° C by NH3

refrigeration system.

There three nos. of (150 TR capacity for each) NH3 compressors in this

system.

Chilled water is supplied to various sub section of CCG & to Br2 plant.

Raw Water System

Raw Water is received from Water Softening plant to CCG - Utility section

& then supplied to various sub section of CCG.

D. M. Water System

D. M. Water is received from Water Softening plant to CCG - Utility

section & then supplied to various sub section of CCG.

CRITICAL PROCESS PARAMETERS IN THE CC GROUP

PLANT

SECTION PARAMETERS VALUES

PBR Brine density

NaCl Concentration in

clarified Brine

Ca+Mg ions

Concentration in clarified

brine

Free chlorine in clarified

brine

Clarity

Net Flow Turbidity Units

(NTU)

Racker load (For more

sludge settling)

23 Baume

300 -305gpl

(4-6) ppm

0.36 ppm

36 inches

12

1.5 Amp

Soda solution

Concentration (Soda

ash)

Sodium Sulphite

concentration in the

clarified Brine

170 gpl

2.8 gpl

SBR 3 Vertical

Leaf type

Pressure filters

are provided

-- Pressure

Drop

depends on

the thickness

of the filter

cake formed

inside

Pressure drop Across

each filter

Solids ratio

Quantity of Cellulose

used per square meter of

filtering surface

Pre-coat

Concentration

Outlet pressure for Safety

Filter

HCl Concentration

Temperature Control of

Filtered

Brine to Resin Tower

Calcium+ Magnesium

ions

NaCl (Gpl)

PH

Free- Chlorine(To Resin

Tower)

Pressure Drop across

Resin bed

(Ca+Mg) ions

Concentration

Caustic: DMWRatio

HCl: DMWRatio

0.55Kg/sq.cm

1:1

0.6 kg

20 gpl

0.15 kg/sq.cm

32%

60-65. C

6 ppm

(306-308)

(8.3 - 8.5)

Suitable for resin towers Nil

0.6

16-17 ppb

6.2

5.6

Cell house Composition of inlet brine

Temp.

Cl2 header pressure

NaOH con.

Rectifier load

Depleted brine

concentration

Individual cell voltage

306-308 gpl

65-75c

-40 to -80 mmwc

29.5 to 32 %

6.0 KA

210 - 250 GPL

2.5 - 4.5 volt

CCD Cl2 pressure at outlet of

compressor

Hypo

concentration(NaOH)

4 - 5 Kg. / Cm2

10-18 % of NaOH.

NaOH concentration reduced to

0.5 to 2% & F – Cl2 becomes > 110

gpl then iso late hypo tank

HCL Chamber suction

H2 safety

H2 flow controller

CL2 flow controller

chamber suction

H2 flow

Cl2 flow

should be > 150 mmwc

v/v 25 % open,

6-20 % open

20-30 % open &

-50 to -90 mmwc

8 - 20 Kg/hr

330 - 380 kg/hr

GENERAL SAFETY INFORMATION

Lab Safety Equipment:

Chemical Hazards and Symbols:

Chemical Hazard Symbols and Definitions:

Selection of PPE According To Body Part:

Body Part Hazard PPE Necessary

Head Falling object, shock,

chemical spurting

Safety helmet, hard hats,

safety caps, headgear

Eye Chemical splash, dust

flying, particles, gas

welding ,radiation

Spectacles, lenses & goggles

for chemical welding,

grinding, furnace, dust etc

Ear High level noise( more

than 90 db-A)

Earplugs, plugs, inserts

Nose Dust, Toxic gases Dust masks, cloth mask,

rubber mask, fume mask,

respirator for dust, gas,&

vapor, breathing apparatus,

Canister gas mask, air line

respirators,

chemical/mechanical filters

Selection of Material of Construction of PPE:

No Material For the protection from

1 Metal Flying particles, falling

body, sharp edge,

abrasion

2 Fiber Metal Sparks, falling body, flying

particles, sharp edge,

abrasion, machinery

3 Metal Screen Sharp edge & abrasion

4 Plastic, PVC Hot liquid, moisture, water,

petroleum product, acid

,alkali, spark, falling body,

flying particles, electric

shock, sharp edge,

abrasion, skin protection

5 Rubber Hot liquid, moisture, water,

acid, alkali, electric shock,

machinery, skin protection

6 Conductive Rubber Explosive Substance

CHLORINE, HYDROGEN, CAUSTIC are comes into hazard

product so we have to care for safety especially human safety and

equipment’s safety. Here different plant wise required safety

provisions taken to be mention below.

PBR SECTION

In this section there are no particular hazard apart from Na2CO3 and

CAUSTIC solution.

Here we should avoid soda ash spillage.

SBR SECTION

We have to take care of alpha -cellouse powder and alkali, HCL used for

regeneration of resin bed.

CELL HOUSE, CCD, Chlorine storage

In cell house we have to take care from the DC current .avoid touch

to the bus bar. Hydrogen line always should be in pressure which

ensures that air cannot enter and make explosive mixture.

Chlorine line always should be in pressure, which avoid the chlorine

gas to the atmospheric.

Time to time we should check the all joints and line of cl2 by

ammonia

We have to know the properties of chlorine, hydrogen, HCL, caustic

to avoid any danger regarding safety.

Apart from all this breakage glass alarm provided at several point in

plant and emergency shower is also provided with 24-hr water

facility. cell house and ccd is equipped with chlorine detector

alarm.(23 cl2 dectors)

All chlorine gas vent line is opened in the hypo tower so at the

changeover in hypo tower and storage tank we have to take care.

In chlorine storage area without gas mask no one should enter. And

in other area especially like NaOH storage, H2SO4 handling all the

PPE must be used. Like goggles with radiation shield, PVC coat, gum

boot, gloves etc.

Here from safety data sheet of chlorine, bromine and hydrogen gas

we can have a proper idea of the properties of same.

Material Safety Data Sheet

It is the best source of information the industrial hygienist can have

regarding any chemical hazards.

Manufacturers, Importers, Exporters, Users, Employers, workers

must have a copy of M.S.D.S. for each hazardous chemical.

M.S.D.S. should contain following information:-

Identity of the chemical --- common and chemical name of the

substance.

Physical & chemical characteristic of the substance. e.g. vapor

pressure , flash point etc.

Physical hazards. e.g. reactivity for explosion , potential extinguishing

data .

Health hazards with signs & symptoms of exposure, route of entry,

toxicity etc.

O.S.H.A. --- PEL & ACGIH – T.L.V, STEL etc.

Disclosure of information of any carcinogenic property.

Safe handling procedures, precautions, procedures for safe clearing

up on spills & leakages.

Emergency First Aid measures with possible Antidotes if available.

Revision of data of M.S.D.S. & Date of its preparation

Name, Address, emergency contact numbers of chemical

manufacturers, importers, distributors, who can provide additional

information on chemical.

Reactivity data – stability, incompatibility, corrosiveness, avoidable

conditions etc.

Waste disposal --- storage handling, transfer, transport precautions.

• Under the “ Right to Information “ Act , every worker involved in a

factory , has fundamental right to know actual potential exposure to

Hazards , it’s consequences and hence use of M.S.D.S. has become familiar

along with Specific Hazard Communication Specific employee training

program is required .

Important Points for F.M.O. & Hygienist Regarding M.S.D.S.

Potential risk from hazard exposure.

Practicable control measures e.g. elimination, substitution, enclosure

etc.

Compare effectiveness of different control measures.

Relative cost of implementation.

Maintenance & testing procedures for control.

User acceptability for long periods.

Social impact of implementation. ( Work force orientation)

Safety data for different chemicals:-

CHLORINE

General

Synonyms: berth lite, Molecular formula: Cl2

Physical data

Appearance:

Light greenish-yellow gas with an irritating odor

Melting point: -101 °C

Boiling point: -34 °C

Vapor density: 2.98 g/l

Vapor pressure: 5.8 bar at 20 ˚C

Specific gravity: 1.47 g/ml at 0 ˚C

Critical temperature: 144 ˚C

Auto ignition temperature: n/a

Stability

Stable. Incompatible with reducing agents, alcohols.

Toxicology

Toxic by inhalation, ingestion and through skin contact. Inhalation can

cause serious lung damage and may be fatal. 1000ppm (0.1%) is likely to be

fatal after a few deep breaths, and half that concentration fatal after a few

minutes. May irritate or burn skin. OEL (8hr TWA) 1 ppm.

Environmental information

Very toxic to aquatic organisms.

Personal protection

Safety glasses, gloves and good ventilation.

Sodium Hydroxide:

General

Synonyms:

caustic soda, soda lye, lye, white caustic, aetznatron, ascarite, Collo-

Grillrein, Collo-Tapetta, sodium hydrate, fotofoil etchant, NAOH, STCC

4935235, sodium hydroxide pellets, Lewis red devil lye, stamperprep, tosoh

pearl

Molecular formula: NaOH

Physical data

Appearance: odor less white solid (often sold as pellets)

Melting point: 318 ˚C

Boiling point: 1390 ˚C

Vapor density:

Vapor pressure: 1 mm Hg at 739 C

Specific gravity: 2.12

Flash point: n/a

Explosion limits: n/a

Water solubility: High (Note: dissolution in water is highly exothermic)

Stability

Stable. Incompatible with a wide variety of materials including many

metals, ammonium compounds, cyanides, acids, nitro compounds,

phenols, combustible organics. Hygroscopic. Heat of solution is very high

and may lead to a dangerously hot solution if small amounts of water are

used. Absorbs carbon dioxide from the air.

Toxicology

Very corrosive. Causes severe burns. May cause serious permanent eye

damage. Very harmful by ingestion. Harmful by skin contact or by

inhalation of dust. Typical STEL 2 mg m-1.

Hydrochloric acid

GENERAL

Synonyms: muriatic acid, chlorohydric acid. [Data for dilute Hydrochloric

acid can be found here.] Molecular formula: HCl

PHYSICAL DATA

Appearance: clear colorless or slightly yellow liquid with pungent odor.

Concentrated acid is fuming.

Melting point: -25 C

Boiling point: 109 C

Specific gravity: 1.19

STABILITY

Stable. Avoid heat, flames. Incompatible with most common metals,

amines, metal oxides, acetic anhydride, propiolactone, vinyl acetate,

mercuric sulfate, calcium phosphate, formaldehyde, alkalis, carbonates,

strong bases, sulfuric acid, chloro sulfonic acid.

TOXICOLOGY

Extremely corrosive. Inhalation of vapor can cause serious injury.

Ingestion may be fatal. Liquid can cause severe damage to skin and eyes.

TLV 5 PPM.

ENVIRONMENTAL INFORMATION

Lethal to fish from 25 mg/l up. Toxic for aquatic organisms due to pH

shift.

PERSONAL PROTECTION

Safety glasses or face mask, gloves. Effective ventilation.

WORK PERMIT PROCEDURE

Purpose:

The permit to work procedure is a formal written system used to

control certain types of potentially hazardous work. It is also a means

of establishing an effective means of communication and

understanding between personnel requiring the work to be done and

the personnel or contractors who are going to do the work.

• The issue of a permit does not in itself make a job safe. It also does not

constitute permission to do dangerous work and therefore should not be

seen as an easy way of eliminating a hazard or reducing risk.

• This procedure has been written for the benefit of all parties involved in

the Production, maintenance and services, and closure of a Permit to Work

for the Isolation or Interruption of Systems or Services or specific

Hazardous Activities.

• Safe working permit systems enable employees to enhance safety

procedures provides information on the requirements associated with safe

work permit systems including:

The authority to issue safe work permits

The situations where a permit is required

Things to be considered prior to the issue of a permit

The conduct of the work in accordance with the permit

The closure of the permit.

Scope:

• This procedural guidance applies to all work permit procedure in the

complex and complies with Gujarat Factory Rules. This procedure covers

provisions to prevent loss of life and property from incident, fire or

explosion as a result of cold /hot work in complex.

• The permit-to-work system covers all on-site including Routine non-

routine work, which may create potential hazards.

• Non-routine is that work normally requiring initiation of work orders

such as maintenance work on equipment, installation or modification of

equipment, painting, repair, working on a moving equipment of machinery

and equipment.

• This procedure includes Lockout/Tag out of equipment’s, piping and

valve etc.

Work Permit Procedure:

Five Categories of work permits are existing for the entire complex as

1. Category-1

2. Category-II

3. Category-III

4. Category-IV

Category-1

Each permit will have work permit No. and Book No. printed on it

• The work permit book will be available in the control room and custody

owner of the plant area.

• The issuer shall be a person in the grade of G from the operation Dept.

• If the job is to be carried out from the same dept. the issuer will be the

dept./section head to the job in charge of the area and the acceptor shall

be a person in the Grade G.

In normal circumstances the acceptor shall be a person from the

maintenance department not less than the G level.

Category – I permit will be applicable for

• Welding, cutting, grinding, drilling, soldering activity in the atmosphere of

Hydrogen, NH3, Cl2, Br2, CH3OH, C2H5OH, Kerosene, Diesel, Lignite

(Bag filter, crusher, vibrator, bin and ESP) and Highly flammable

chemicals. Other Hazardous jobs where the high risk are involved as

working on chimneys, lifting and shifting of heavy objects more than (05

tons) inside plant, Working at a height of more than 20ft, arresting of

steam leakage from running line where the steam pressure is more than

450#.

• Vessel entry, Entry of personnel into confined spaces for the purpose of

maintenance / inspection works containing or having contaminated gas,

hydrocarbons or toxic / corrosive chemicals or which is or has been

deficient in oxygen for normal breathing.


This permit will be prepared in three copies.

First Copy - The acceptor & display at site

Second copy - Electrical Dept.

Third copy - As the book copy of the issuer.

Appropriate marking has also been done on top left of each copy about the

distribution pattern as mentioned above

Explanatory Notes to Work Permit Forms

The check-listed items in the work permit forms are elaborated

below to amplify the underlying concepts and highlight their

significance.

Issuer:

The person shall be from operation / owner of the area not below the

‘Management’ cadre.

Authorization:

Only ‘F’ level staffs / Dept. Heads are the ‘Authorized Person’ to sign in

the work permits. In case the F level staff is not available / absent, the

person immediately below him can be the ‘Authorized Person’

Acceptor:

An engineer from the maintenance / service department shall accept the

permit. In case the permit is to be issued within the process/ operations

department itself (say for inspection of a vessel) the issuer shall be one

engineer and the acceptor shall be a different engineer.

Permit Receiver:

The person who is directly responsible for doing the job at site.

Department:

The name of the issuing department / section.

Location:

Exact location of the job (Area / floor / equipment name Description of

the job:

The actual work like cutting, welding, cleaning of vessel etc to be carried

out at site.

In case emergency alarm is sounded after permit is issued, the permit

becomes void.

Category I Work Permit – Work Flow:

Category-II

General

This is applicable for all activities other than those, which does not cover in

class I permit and will cover the following activities

Hot work which are not flammable in nature

Maintenance of pumps, equipments, vessels and structural jobs.

Civil and construction in running plants.

Laying and rerouting of piping.

Insulation, whitewashing and painting jobs.

Braking and opening of pipelines containing ammonia, sulphuric acid

steam, Hydrochloric acid, caustic soda and chlorine.

Vessel entry where toxic and flammable chemicals are not involved.

Cutting and welding near belt conveyors.

Any other specific activity as decided by the issuing authority

No permit is required for routine welding/cutting and similar jobs carried

out in the main fabrication shops and central workshops as well as for

torches, furnaces, sparking equipment etc. located in designated locations

of central laboratory. These jobs shall be done as per their work

instructions for respective activities.

Each permit will have work permit No. and Book No. printed on it

The work permit book will be available in the control room and

custody owner of the plant area.

The issuer shall be a person in the grade of G or Any authorized

person from the operation Dept.

If the job is to be carried out from the same dept. the issuer will be

the dept./section head to the job in charge of the area and the

acceptor shall be a person in the Grade G or any authorized person


This permit will be prepared in triplicate.

First Copy - The acceptor & display at site.

Second copy - Electrical Dept.

Third copy- as the book copy of the issuer.

Each copy is duly marked on top left as per the above distribution pattern.

All permits must be issued only from the respective control room

and shall be received by the concerned plant engineer or authorized

person.

On completion of the jobs the permits should be handed over by the

permit issuer after certifying the completion of job and the issuing

authority will accept the permit back and file the same in the control

room.

After completion of the job, the display copy shall be returned to the

issuer duly signed by the acceptor and shall be retained for one

month.

Explanatory Notes to Work Permit Forms

The check-listed items in the work permit forms are elaborated below to

appraise the underlying concepts and highlight their significance.

Issuer:

The person shall be from operation / owner of the area not below the

supervisory grade.

Acceptor:

An engineer / supervisor from the maintenance / service department shall

accept the permit. In case the permit is to be issued within the process/

operations department itself (say for cleaning/ inspection of a vessel) the

issuer shall be one of the engineers controlling the activity and the acceptor

another engineer in charge of job execution.

Department:

The departments issuing or accepting the work permits.

Location:

Exact location of the job (Area / floor / equipment name)

Description of the job:

The actual work like cutting, welding, cleaning of vessel etc to be carried

out at site.

Documents

Project Report on Chloro Caustic Group