Header lines
DN 10 / DN 15
Installation and operating instructions
GRUNDFOS INSTRUCTIONS
English (GB) Installation and operating instructions
Caution
Note
English (GB)
Original installation and operating instructions.
CONTENTS
1. Safety instructions
1.1 Symbols used in this document
1.2 Safety advice for handling chlorine
1.2.1 Hazards of chlorine gas
1.2.2 Hazards of liquid chlorine
1.3 Qualification of the users
1.4 Responsibilities of the owner
1.5 Maintenance and service personnel
1.6 Protective equipment
1.6.1 Personal protective equipment
1.6.2 Obligations of the operating authority
1.6.3 Storage of the protective equipment
1.7 First aid in case of accidents
1.7.1 First aid after inhaling chlorine
1.7.2 First aid after chemical burn of skin
1.7.3 First aid after chemical burn of eyes
1.7.4 First aid after internal chemical burn
1.8 Handling chlorine containers
1.8.1 Steel cylinders
1.8.2 Chlorine drums
1.8.3 Basic rules
1.8.4 Valid regulations
1.9 Chlorine rooms
1.9.1 Regulations for chlorine rooms
1.9.2 Labelling of chlorine rooms
2. Product description
2.1 Correct usage
2.2 Inappropriate usage
2.3 Identification
2.3.1 Nameplate
2.4 Warranty
3. Technical data
3.1 Header line for chlorine gas cylinders
3.1.1 Connections
3.1.2 Weights
3.1.3 Materials
3.2 Header line for chlorine gas drums
3.2.1 Connections
3.2.2 Weights
3.3 Header line for ammonia and sulphur dioxide drums
3.3.1 Connections
3.3.2 Weights
3.4 Dimensions
3.4.1 Header line for 3 cylinders
3.4.2 Header line for 5 drums
3.5 Physical and chemical data of chlorine
4. Construction and function
4.1 Description of the device
4.2 Function
5. Startup
5.1 Installation
5.1.1 Assembling the header line
5.1.2 Tightening the connection valve
5.2 Checking the tightness
5.2.1 Checking the tightness of a large system
5.2.2 Checking the tightness of parts leading chlorine gas or
sulphur dioxide
5.2.3 Checking the tightness of parts leading ammonia
5.3 Start-up
6. Operation
6.1 Container exchange
7. Maintenance
7.1 Replacing the flexible lines
7.1.1 Flexible copper lines for chlorine
7.1.2 Flexible stainless-steel lines for ammonia and sulphur
dioxide
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7.2 Retrofitting old header lines
7.2.1 Assembly with Loctite
7.2.2 Assembly with hemp
7.3 Maintenance of connection valve
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7.4 Maintenance of the shut-off valve
8. Spare parts
9. Fault finding
9.1 Leakage at the connection valve
9.2 Leakage at the shut-off valve
10. Decommissioning
10.1 Short-term decommissioning (up to 2 weeks)
10.2 Long-term decommissioning (more than 2 weeks)
11. Disposal
Warning
Prior to installation, read these installation and
operating instructions. Installation and operation
must comply with local regulations and accepted
codes of good practice.
1. Safety instructions
These installation and operating instructions contain important
information for the user of the product:
• Technical data
• Instructions for commissioning and use
• Safety instructions
If you require further information, or if problems occur that are not
described in detail in this manual, please contact Grundfos.
1.1 Symbols used in this document
This manual contains the following standardised safety
instructions about possible residual risks:
Warning
If these safety instructions are not observed,
it may result in personal injury.
If these safety instructions are not observed,
it may result in malfunction or damage to the
equipment.
Notes or instructions that make the job easier
and ensure safe operation.
1.2 Safety advice for handling chlorine
Country-specific local laws, regulations, and standards apply for
the handling of chlorine.
1.2.1 Hazards of chlorine gas
Warning
Toxic by inhalation.
Irritating to eyes, respiratory system and skin!
• Causes whooping cough, dyspnoea and lacrimation.
• Has a slight paralysing effect to the central nervous system.
• Concentrations of more than 10 ppm chlorine gas in the
respiratory air mean an acute danger to life.
• Inhaling air with a high concentration of chlorine gas for a long
time is lethal.
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1.2.2 Hazards of liquid chlorine
• Causes burns of skin.
• Causes reddening and blistering of skin.
• Rules of conduct
• Change chlorine containers only with gas mask.
• Enter contaminated rooms only with protective suit and
compressed-air respirator.
• In case of flight wear gas mask, if possible. Observe wind
direction.
1.3 Qualification of the users
Based on his professional training and experience, the user must
have a good knowledge of the operation of chlorine gas dosing
systems. He must be so familiar with the relevant laws and
regulations governing safety in the workplace and accident
prevention, and with the recognised standards of good practice,
that he is able to judge the safe working condition of a chlorine
gas dosing system.
The user is responsible for operation and monitoring of the
product at the installation site.
The responsibilities of the user:
• Observe the safety data sheets from the chemicals supplier.
• Be trained by qualified Grundfos personnel in the operation of
the product
• Observe the relevant regulations governing safety in the
workplace and accident prevention
• Wear appropriate protective clothing in accordance with
national regulations for the prevention of accidents when
operating the system and handling chemicals.
1.4 Responsibilities of the owner
The operator of the product is responsible for the following:
• Ensure that this manual is kept clearly accessible in the
immediate vicinity of the system for the entire service life.
• Meet the installation requirements specified by the
manufacturer (environmental conditions, required water
connections and fittings, electrical connection, protective pipe
for dosing line if necessary, audible or optical warning device if
necessary).
• Ensure that water lines and armatures are regularly checked,
serviced and maintained.
• Obtain official approval for storing chemicals, if necessary.
• Train users in the operation of the system.
• Ensure that the regulations for the prevention of accidents are
observed in the installation site.
• Provide all users and service personnel with protective
clothing (e.g. face mask, gloves, protective apron) in
accordance with the national regulations.
1.5 Maintenance and service personnel
The product may only be maintained and serviced by personnel
authorised by Grundfos.
1.6 Protective equipment
1.6.1 Personal protective equipment
The operating authority of a chlorine gas dosing system has to
provide respiratory equipment (full-sight gas mask), personally
fitted, labelled by name, with an effective chlorine filter (B2P3)
and at least 1 spare filter per gas mask, for each operator.
The protective equipment must be stored easily accessible
outside the chlorine rooms.
• For systems with chlorine drums at least 2 protective suits with
compressed-air respirators must be available.
1.6.2 Obligations of the operating authority
• Introducing the operators to handling the protective
equipment.
• The operators must use the personal protective equipment
regularly, or carry out exercises with it at least every 6 months.
• The gas mask filters must be replaced regularly
– after the expiry of the date of durability
– at least 6 months after opening (note the opening date on
the filter)
– after contact with chlorine.
• Observe employing prohibition according to the local laws!
1.6.3 Storage of the protective equipment
• Outside the chlorine rooms
• Well visible
• Easily available at any time
• Protected from dust and moisture.
1.7 First aid in case of accidents
1.7.1 First aid after inhaling chlorine
1. Keep calm.
2. Remove injured persons from the dangerous area.
3. Helpers must pay attention to personal protection.
4. Remove contaminated clothes.
5. Calm down injured persons, and keep them warm with
blankets.
– Supply fresh air, use oxygen respirator, if possible.
– No mouth-to-mouth resuscitation!
6. Call medical aid or transport to hospital
– lying
– sitting in case of difficulty in breathing.
– State chlorine as the cause.
1.7.2 First aid after chemical burn of skin
1. Keep calm.
2. Remove contaminated clothes.
3. Rinse skin with plenty of water.
4. Bandage the wound aseptically.
5. Seek medical aid.
– State chlorine as the cause.
1.7.3 First aid after chemical burn of eyes
1. Keep calm.
– Rinse eyes with plenty of water while the patient is lying.
– Protect healthy eye, if necessary.
– Spread eyelids widely, let the eye move to all sides.
2. Seek ophthalmologist.
– State chlorine as the cause.
1.7.4 First aid after internal chemical burn
1. Keep calm.
2. Drink water in short sips.
– If possible, take medical charcoal.
3. Seek medical aid.
– State chlorine as the cause.
English (GB)
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1.8 Handling chlorine containers
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English (GB)
Chlorine is stored in grey steel cylinders or drums in lockable
chlorine rooms. Due to safety precautions, chlorine containers
are only filled up to 95 % of their capacity.
Kind of gas, weight, owner, producing date and date of the last
testing have to be noted clearly on the container.
Observe the following:
• Store chlorine containers fireproof.
• Protect chlorine containers from heat and sunlight.
• Chlorine containers should not be modified or repaired by the
user.
• Keep full and empty containers closed.
1.8.1 Steel cylinders
• Contents: 50 kg or 65 kg
• Extract chlorine gas from the upright standing cylinder via the
valve.
1.8.3 Basic rules
Warning
Handling of chlorine containers only by
experienced personnel.
Observe safety regulations for chlorine
containers.
• Treat containers carefully, do not throw!
• Protect containers from turning over or rolling away, e.g. with
chains or clips.
• Protect containers from direct sunlight and temperatures over
50 °C.
• Transport containers only with valve protection nut and
protective cap.
Warning
These rules apply for both full and empty
containers, as empty containers still contain
rests of chlorine and therefore are under
pressure.
1.8.4 Valid regulations
Warning
Local laws and regulations for handling,
transport and storage of chlorine must be
observed!
• Regulations for accident prevention with process instructions.
• Regulations concerning places of work
• Technical rules for pressurized gases
• Chlorine gas dosing systems for water treatment
• Chlorine for the treatment of water for the human use (EN 937)
1.9 Chlorine rooms
Chlorine rooms are rooms, where a chlorine gas dosing system
and/or chlorine containers are located. The chlorine in these
TM04 8943 1813
Fig. 1 Design of a cylinder
Pos. Description
1 Protective cap
2Valve
3 Holding clip for securing the cylinder
1.8.2 Chlorine drums
• Contents: 500 kg or 1000 kg
• Extraction of chlorine gas via the riser pipe valve.
• Extraction of liquid chlorine via the dip pipe valve.
Fig. 2 Design of a drum
Pos. Description
1 Riser pipe for chlorine gas extraction
2 Valve for chlorine gas extraction
3 Valve for liquid chlorine extraction
4 Dip pipe for liquid chlorine extraction
5Tyre
6 Mark for adjustment of drum
rooms is under pressure.
1.9.1 Regulations for chlorine rooms
According to the German regulations for accident prevention
"Chlorination of water", chlorine rooms have to meet the following
requirements:
• They should not have connections to other rooms, and must
be separated gas-tight and fire-resistant.
• They must be at ground level, dry and air-conditioned.
The recommended room temperature is 18-20 °C. It should be
neither lower than 0 °C nor higher than 50 °C.
• Overpressure lines of dosing equipment must not end in the
open air.
• Ventilation openings leading into the open air must be limited
to 2 x 20 cm
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• Appropriate exhaust devices with downstream adsorption
systems must be installed.
• Chlorine gas must not get into lower-lying rooms, shafts, pits,
canals or aspirating holes of ventilation systems.
• Chlorine rooms must be equipped with a water sprinkling
system to precipitate the escaping chlorine gas.
– The sprinkling system must have a run-off with air trap.
TM04 8940 1813
– Operation must be possible manually from outside the
chlorine rooms.
• A chlorine gas warning system must be installed
– with optical and acoustical alarm device,
– with connection to the water sprinkling system,
– with a warning system that reactivates automatically after
switch-off (e.g. for container exchange).
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• The floor of a chlorine room must be even, the exit not below
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ground level and not higher than a possible loading ramp.
Fig. 3 Requirements of chlorine rooms
• Chlorine rooms must have a direct exit to the open air.
• Doors must be lockable, open outwards, and it must be
possible to open the doors without a key from inside the room.
• Chlorine rooms must not be dedicated for the permanent stay
of people.
• Eating, drinking, or storing food in chlorine rooms is prohibited
1.9.2 Labelling of chlorine rooms
In Germany, the following warning signs must be installed outside
the entrance of a chlorine room:
Fig. 4 Warning sign and supplementary sign "Chlorination
plant: Access only for instructed persons"
Inside a chlorine room, the mandatory sign "Use the gas mask"
and the "Instruction sheet for first aid in case of chlorine gas
intoxications" must be installed.
2. Product description
2.1 Correct usage
Header lines connect several chlorine gas cylinders or chlorine
gas drums with the components of a gas dosing system.
Header lines must be used exclusively for the applications
described in this manual and with the gas they are approved for.
The usage is limited to industry, water treatment and waste water
treatment.
2.2 Inappropriate usage
Operational safety is only guaranteed, if the product is used
correctly. All operating methods conflicting with correct usage are
not permitted, and lead to the expiry of all liability claims.
TM04 8941 1813
2.3 Identification
The header line can be identified by the connection type of the
T-piece (cemented or welded), and the material of the flexible line
(copper or stainless steel).
Identification of the header line
T-piece
Flexible
line
2.3.1 Nameplate
TM04 8939 1813TM06 1198 4114
The indications on the nameplate are:
• product number
• serial number
2.4 Warranty
A guarantee claim in accordance with our general terms of sale
and delivery is only valid if the following requirements are fulfilled:
• The product is used in accordance with the information within
this manual.
• The installation, startup, operation and maintenance is carried
out by authorised and qualified staff.
Warning
Unauthorised structural modifications to the
product may result in serious damage to
equipment and personal injury.
cemented header line for cylinders
welded header line for drums
copper header line for chlorine gas
stainless
steel
header line for ammonia or sulphur
dioxide gas
English (GB)
Fig. 5 Mandatory sign
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3. Technical data
Caution
English (GB)
The values stated in the technical data must be
adhered to.
3.1 Header line for chlorine gas cylinders
The vacuum regulator is directly connected to the DN 15 header
line. Depending on the chosen header line, up to 8 cylinders can
be connected.
Line pressure max. 16 bar
Ambient temperature 0 °C to +40 °C
Capacity of gaseous chlorine max. 200 kg/h
Capacity of liquid chlorine max. 600 kg/h
3.1.1 Connections
Cylinder connection: 1", G 3/4, G 5/8, 1.03"-14, M 26x3, 1 1/4",
closed yoke (USA), 15/16-8 RH, G 1/2
Vacuum regulator connection: 1", G 3/4, M 26x3
3.1.2 Weights
Number of
cylinders
Weight [kg] 1 3.4 5.1 6.8 8.5 10.2 11.9 13.6
* without collector pipe (only connection valve and copper line)
3.1.3 Materials
Collector pipe
Flexible lines Copper, tin-plated
Valve body Brass, nickel-plated
Valve piston Hastelloy C
Gasket of pressure
connection and gasket of
copper pipe
Packing PTFE
O-rings FKM
1*2345678
Seamless drawn steel pipe,
painted, T-piece screwed in and
cemented
Aramid fibres with NBR
3.2 Header line for chlorine gas drums
DN 15 and DN 25 header lines collect gas or liquid from several
drums. Depending on the chosen header line, up to 8 drums can
be connected.
Line pressure max. 16 bar
Ambient temperature 0 °C to +40 °C
3.2.1 Connections
Drum connection: 1", G 3/4, G 1/2, G 5/8, M26x3, 1 1/4", 1.03"14, closed yoke (USA), 15/16-8 RH
Connection flange of outlet: DN 15 or DN 25
3.2.2 Weights
Materials
Collector pipe
Flexible lines Copper, tin-plated
Body of connection valve Brass, nickel-plated
Body of shut-off valve Grey cast iron, painted
Valve piston Hastelloy C
Connection gaskets Aramid fibres with NBR
Packing PTFE
O-rings FKM
Seamless drawn steel pipe,
painted, connections welded
3.3 Header line for ammonia and sulphur dioxide
drums
DN 15 and DN 25 header lines collect gas or liquid from several
drums. Depending on the chosen header line, up to 8 drums can
be connected.
Line pressure max. 16 bar
Ambient temperature 0 °C to +40 °C
3.3.1 Connections
Pressure connection: 1", G 3/4, G 5/8, W 21.8x1/14
Connection flange of outlet: DN 15 and DN 25
3.3.2 Weights
Number of drums
1* 1.4 1.4
211.5 17.5
3 14.3 21.5
4 18.5 28
522 32
6 24.5 35.5
729 42
832 45.5
* without collector pipe (only connection valve and copper line)
Materials
Collector pipe
Flexible lines
Body of connection valve
Body of shut-off valve Grey cast iron
Valve piston Hastelloy C
Connection gaskets Aramid fibres with NBR
Packing PTFE
O-rings EPDM
DN 15 DN 25
Seamless drawn steel pipe,
painted, connections welded
Stainless steel 1.4571
Weight [kg]
Number of drums
1* 1.3 1.3
211 17
313.8 21
418 27.5
521 31
623.5 34.5
728 41
831 44.5
* without collector pipe (only connection valve and copper line)
DN 15 DN 25
Weight [kg]
6
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