Chlorine Safety

A 5-Minute Safety Training Aid HS04-076C (12-21)

Many industrial and household products

contain chlorine, including bleaches, cleaning
products, and water purification tablets.
Exposure to chlorine can irritate the skin, eyes,
nose, and mucous membranes. If swallowed
or inhaled, a chlorine-based product is toxic
and can create a medical emergency. However,
chlorine is safe when properly handled.

Chlorine Chlorine is sometimes in the form of poisonous gas. Chlorine gas

can be pressurized and cooled to change it into a liquid so that
it can be shipped and stored. When liquid chlorine is released,
it quickly turns into a gas that stays close to the ground and
spreads rapidly.1 Chlorine gas weighs about 2.5 times more than
air and settles in low-lying areas unless sufficient wind disperses
it.2
Chlorine gas is greenish-yellow at room temperature and the
liquid is clear amber. Both have the distinctive smell of bleach. It
is highly corrosive and reacts violently with petroleum products
such as gasoline, diesel, oil, solvents, and turpentine. Chlorine can
also react with carbon monoxide and other combustion products
to make highly toxic and corrosive gases.
Chlorine gas is typically supplied in 150-pound or ton
(2000-pound) containers. Liquid chlorine comes typically in
100-pound or 150-pound cylinders. Chlorine cylinders contain
a fusible plug, located on the rear of the cylinder valve, which is
designed to melt and release pressure should the temperature
reach 158-165°F (70-74°C).

These guidelines can help prevent injury and illness when

Safe Handling handling chlorine:
• Provide training
If a worker must handle chlorine, the worker needs
training and supervision on chlorine safety. (See OSHA
Standards 1910.1200 and 1910.119.)

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HS04-076C
HS01-014E(12-21)
(08-2 1
 Safe Handling • Use respiratory protection.
(continued) Ensure that workers wear an approved self-contained
breathing apparatus in areas where chlorine is stored or
used. (See OSHA Standard 1910.134.)
• Store respiratory protection away from chlorine.
Keep all breathing apparatus stored outside the chlorine
area.
• Prepare an escape plan.
Have an emergency strategy in place should there be a
chlorine emission. Remember to move uphill and upwind.
• Never store chlorine near flammable materials.
Chlorine is especially dangerous to place next to gasoline
or other combustibles. It can spontaneously explode and
create a toxic fire.
• Never apply heat directly to a chlorine container.
Chlorine plugs will melt at temperatures between 158°-
165° F, resulting in a chlorine leak.3
• Purge chlorine pipelines before welding.
Chlorine reacts with many substances, usually as heat
increases. For example, iron and steel ignites in chlorine at
about 450°-500° F.4 To avoid combustion, never weld an
empty chlorine pipeline without purging it with air first.
• Install safety wash stations nearby.
Ensure emergency showers and eyewash stations are
located near chlorine equipment.
• Use at least two people when handling chlorine.
It is wise to use a buddy system when changing or
handling chlorine. If one operator falls victim to hazardous
vapors, the other can call for help. Do not work alone!
• Avoid spraying water on leaking chlorine containers.
Water and chlorine can create hydrochloric and
hypochlorous acids.5 This mixture is corrosive and
potentially oxidizing, which can make the leak worse.
• Take shallow breaths.
When entering an equipment area, breathe shallow
breaths around the containers until sure a chlorine leak is
not present.

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Texas Department
of Insurance,
of Insurance,
Division of
Division
Workers’
of Workers’
Compensation
Compensation
Compensation www.txsafetyatwork.com
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2 HS20-002A
HS04-076C (05-20)
HS01-014E(12-21)
(08-20)
Safe Handling • Never drop or knock over a cylinder.
(continued) Move chlorine cylinders with care using a hand truck that
has restraint chains to secure the cylinder. Avoid contact
between cylinders. Once the cylinder is in place, secure it
with chains, chocks, or trunnions to prevent the cylinder
from falling.
• Check the weight rating on moving equipment.
Do not move filled containers with equipment designed to
handle less than two tons.
• Avoid connecting more than two cylinders or
containers to a common, non-automatic manifold.
Non-automatic manifolds cannot mechanically open
and close the valves to correct pressure. Therefore,
placing more than two cylinders on a common manifold
or connecting the valves of two or more containers to a
non-automatic manifold can overload the capacity of the
manifold, increasing the chances for accidental leaks.
• Never tamper with a fusible plug.
Fusible plugs (also called melt plugs) are activated by
temperature, not pressure. If not tampered with, they
can with relative safety, release gas before a hazardous
reaction can begin.
• Never lift cylinders by the hood.
Always keep the hood in place, except when the cylinder is
being used.

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Texas Department
of Insurance,
of Insurance,
Division of
Compensation Division
Workers’
of Workers’
Compensation
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HS04-076C (12-21) 3
 Personal
Protective Use chlorine in well-ventilated areas. Eyewashes, showers, and
Equipment oxygen should be available and nearby. Self-contained breathing
apparatus or canister-type respirators should be accessible. In
addition, the following personal protective clothing should be
worn:
• full face shield and non-ventilated chemical goggles;
• chemically-resistant rubber gloves;
• apron or jacket;
• long sleeves;
• long pants; and
• closed-toe shoes.

Safe Storage It is important to have a separate room for chlorine. Chlorine

storage and feed rooms should be:
• enclosed, sealed, and separated from other operating
areas;
• on the downwind side of the building away from
entrances, windows, walkways, and other occupied areas;
and
• at least 60°F, but protected from extreme heat or direct
sunlight.
In addition, the storage room should have:
• a shatter-resistant inspection window mounted in an
interior wall of the plant;
• doors equipped with panic hardware that provide an easy
escape by opening outward to the building exterior;
• a ventilating fan (that runs whenever the room is
occupied) that exchanges the air at least once a minute;
• an air intake near the ceiling that exhausts to the outside;
• motorized louvers that provide airtight closure;
• individual vandal-proof switches for the fan and lights
located both outside the chlorine room and at the
inspection window; and
• a nonslip floor without a floor drain that could connect to
other internal or external drainage systems.
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4 HS04-076C (12-21)
Health Effects • A low concentration of chlorine can result in burning eyes,
nose, and throat; sneezing and coughing; and redness in
the face.
• High concentrations of chlorine can result in tightness in
the throat and difficulty breathing:
 1,000 parts per million (ppm) is fatal after a few
breaths and
 35-51 ppm can be fatal even an hour later.6

Changing Post the following instructions near the chlorinator. (These are generic
Cylinders7 instructions. Customize these instructions as needed.)
1. Turn the chlorine cylinder valve off (clockwise). BE SURE THE
CHLORINE CYLINDER VALVE IS CLOSED AND NOT STUCK IN AN
OPEN POSITION.
2. The chlorinator rate valve should be open about three turns.
3. Turn on the ejector water to produce a vacuum. The ball in the
meter tube should drop to the bottom. The indicator should
show red if the cylinder valve is closed tight.
4. Turn off the ejector water supply and wait five minutes until
the indicator flag drops to show red. If the flag does not drop
to show red, the likely cause is that the cylinder valve is not
closed enough to create a vacuum-tight system.
5. VERIFY that the chlorine cylinder valve is closed before
removing the chlorinator. Slowly turn the yoke screw loose to
carefully remove the chlorinator from the cylinder valve. Place
the cap and hood on the empty cylinder.
6. Secure a new full cylinder using a chain. Remove the hood and
slowly remove the cap to be sure the new cylinder was closed
properly.
7. Remove the masking tape from the chlorinator inlet (on new
units only). Be careful not to let filter material and the Teflon
disc and screen drop out of the inlet assembly.
8. Remove the old lead gasket and install a NEW lead gasket on
the chlorinator inlet. Reusing the lead gasket will cause leaks!
9. With the new lead gasket in place, put the chlorinator on the
cylinder and tighten the yoke screw with the provided wrench.
(Do not use excessive force.)

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HS04-076C (12-21) 5
 Changing 10. Open the chlorine cylinder valve ¼ turn and CLOSE
Cylinders IMMEDIATELY. Check for leaks with ammonia using a plastic
(Continued)
squeeze bottle to direct ammonia fumes around the lead
gasket, cylinder valve, and two fittings on the chlorinator. If
a leak is present, the ammonia will create white smoke. To
repair a leak, connect the tubing from the ejector to the top
fitting on the chlorinator. Then, turn on the ejector so the
chlorine can be pulled through the ejector to the process
water. CORRECT LEAKS BEFORE PROCEEDING:
a. Hook up the vacuum tubing from the ejector to the top
chlorinator fitting.
b. Hook up the vacuum tubing from the chlorinator bottom
fitting to vent to a safe outside location (not near walkways
or ventilation intakes).
11. If no leaks are detected, open the chlorine cylinder valve 1/4
turn and recheck for leaks (keeping the wrench on the cylinder
valve).
12. Turn on the water supply to the ejector. The chlorinator meter
should indicate chlorine flow. (It may be necessary to break
the vacuum by removing the poly tubing from the top fitting
on the chlorinator and reconnecting it.)
13. Adjust the feed rate using the rate valve on top of the
chlorinator and test for free or total chlorine.
Changing Ton Post the following instructions near ton containers. (It is not necessary
Containers8 to remove the regulator from the ton adapter when changing ton
containers. If it is removed, a new lead gasket must be used on the
regulator inlet adapter every time it is reinstalled on the ton adapter.)
1. Using a cylinder wrench, turn the ton container valve stem
clockwise to close it. Be certain the valve is closed before
removing the regulator/ton adapter combination.
2. With the water supply set to ejector (vacuum to regulator),
ensure that the rotameter ball drops to zero, meaning there is
no residual gas flowing through the regulator.
3. If no gas flow exists, remove the regulator/ton adapter
assembly by loosening the ton adapter yoke handle and lifting
the assembly from the ton container valve. Turn off the water
supply to the ejector.
4. Replace the empty ton container with a full one. Remove the
protective hood and MAKE SURE the container valves are
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6 HS04-076C (12-21)
 Changing Ton aligned vertically. VERIFY the upper (gas) valve is closed and
Containers remove the valve cap. Make sure the valve outlet is clean and
(Continued)
free of dirt and residue.
5. REMOVE THE OLD LEAD GASKET FROM THE TON ADAPTER
INLET AND DISCARD IT. Replace it with a new lead gasket.
NEVER re-use an old lead gasket.
6. Position the regulator/ton adapter assembly on the gas
(upper) valve making sure the lead gasket is in place. Tighten
the ton adapter yoke handle until secure and the lead gasket is
slightly compressed.
7. Open the cylinder valve slightly and quickly re-close it.
8. Test for gas leaks using accepted procedures.
9. If a leak is detected MAKE SURE the gas valve is closed and
repeat steps #2 and #3 of this procedure. Then remove the
regulator/inlet adapter assembly and correct the problem
causing the leak. Once the problem is corrected, start with
step #5 of this procedure and continue through the remaining
steps.
10. After ensuring no leaks exist and the regulator/inlet adapter
assembly is properly installed, open the ton container valve
approximately 1/4 turn. Always keep the cylinder wrench on
the container valve when in use.
11. Turn on the ejector water supply and set the proper feed rate
on the regulator.

Inhalation
First Aid9
• Remove the victim from the contaminated area.
• Keep the victim warm and in a reclined position with
head and shoulders elevated.
• Give artificial respiration if needed.
• Give oxygen as soon as possible.
• Call emergency personnel or a physician immediately.
Skin Contact
• Shower victim, removing all contaminated clothing.
• Wash the affected area with soap and water.

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HS04-076C (12-21) 7
 First Aid Eye Contact
(Continued)
• Irrigate eyes with water for 15 minutes, holding eyelids
wide apart.
• Call emergency personnel or a physician immediately.
• Irrigate for a second 15 minutes if emergency personnel
or a physician is not immediately available.

Emergency Post emergency contact numbers at several locations in the

Numbers plant and office. Include contact information for the local fire
department, police, and County Emergency Management Office.
To report the release of a hazardous substance, contact the Texas
Emergency Oil Spill and Hazardous Substance 24-Hour Reporting
Service at 800-832-8224. This phone number is supported by
several Texas emergency reporting agencies including the Texas
General Land Office, Texas Commission on Environmental
Quality, and Railroad Commission of Texas.

For additional resources on chemical or hazard communications

safety, download or stream any of DWC’s free publications or
workplace safety videos.

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8 HS04-076C (12-21)
 References
1
Centers for Disease Control and Preventions, “Facts about Chlorine,” Webpage. https://emergency.cdc.gov/agent/chlorine/
basics/facts.asp. Accessed December 21, 2021.
2
Washington State Department of Health, Division of Environmental Health, Office of Drinking Water, “How to Handle
Chlorine Gas Safely,” PDF. https://www.doh.wa.gov/portals/1/Documents/pubs/331-364.pdf. Accessed December 21, 2021.
3
Hydro Instruments, “Chlorine Handling Manual,” p. 9, PDF. http://www.hydroinstruments.com/files/Chlorine%20
Handling%20Manual%202016%2005%2006.pdf. Accessed December 21, 2021.
4
Workers Compensation Board, WorkSafeBC, “Safe Work Practices for Chlorine,” p. 21, PDF. https://www.worksafebc.com/en/
resources/health-safety/books-guides/safe-work-practices-chlorine?lang=en&direct. Accessed December 21, 2021.
5
CAMEO Chemicals, “Chlorine,” Website. https://cameochemicals.noaa.gov/chemical/2862. Accessed December 21, 2021.
6
Washington State Department of Health, Division of Environmental Health, Office of Drinking Water, “How to Handle
Chlorine Gas Safely,” PDF. https://www.doh.wa.gov/portals/1/Documents/pubs/331-364.pdf. Accessed December 22, 2021.
7
Hydro Instruments, Changing Cylinders Safely,” PDF. http://www.hydroinstruments.com/files/Changing%20Cylinders.pdf.
Accessed December 22, 2021.
8
Chlorinators Incorporated, “Ton Container Changing Procedure for Chlorinators,” PDF. https://d2fjjl0fhjuhkd.cloudfront.net/
regal/pdfs/ton_cont_changing.pdf. Accessed December 22, 2021.
9
Washington State Department of Health, Division of Environmental Health, Office of Drinking Water, “How to Handle
Chlorine Gas Safely,” PDF. https://www.doh.wa.gov/portals/1/Documents/pubs/331-364.pdf. Accessed December 22, 2021.

www.txsafetyatwork.com
1-800-252-7031, Option 2

The Texas Department of Insurance,

Division of Workers’ Compensation (DWC)-Workplace Safety
P.O. Box 12050
Austin, TX 78711-2050

Disclaimer: Unless otherwise noted, this document was produced by the Texas Department of Insurance, Division of Workers’ Compensation
using information from staff subject specialists, government entities, or other authoritative sources. Information contained in this fact sheet
is considered accurate at the time of publication. For more free publications and other occupational safety and health resources, visit www.
txsafetyatwork.com, call 800-252-7031, option 2, or email resourcecenter@ tdi.texas.gov.

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HS04-076C (12-21) 9