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 Table of Contents

1. INTRODUCTION................................................................................................................... 1
1.1 PURPOSE ........................................................................................................................... 1
1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM ................................................................... 1
1.3 SCOPE ............................................................................................................................... 1
1.4 ABSTRACT .......................................................................................................................... 1
1.5 DEFINITIONS AND ACRONYMS .............................................................................................. 2
1.6 DISCLAIMER ........................................................................................................................ 5
1.7 APPROVAL .......................................................................................................................... 5
1.8 REVISIONS .......................................................................................................................... 5
1.9 REPRODUCTION .................................................................................................................. 5
2. DESCRIPTION OF CHLOR-ALKALI CELL EQUIPMENT ................................................... 5
2.1 GENERAL ............................................................................................................................ 6
2.2 DIAPHRAGM CELLS ............................................................................................................. 9
2.3 MERCURY CELLS ................................................................................................................ 9
2.4 MEMBRANE CELLS ............................................................................................................ 10
2.5 RECTIFIERS ...................................................................................................................... 11
3. IDENTIFICATION OF POTENTIAL ELECTRICAL HAZARDS .......................................... 12
3.1 GENERAL .......................................................................................................................... 12
3.2 CELL LINE ATTACHMENTS AND AUXILIARY EQUIPMENT ....................................................... 12
3.3 PIPING .............................................................................................................................. 12
3.4 SYSTEM POTENTIALS AND SHOCKS ................................................................................... 13
3.5 ELECTRICAL FLASH ........................................................................................................... 16
3.6 CUTOUT SWITCHES ........................................................................................................... 17
3.7 EXTERNAL ELECTRICAL SOURCES ..................................................................................... 17
3.8 RECTIFIERS ...................................................................................................................... 17
3.9 INSULATING MATERIAL IN CELL AREAS ............................................................................... 18
3.10 ELECTRICAL CLASSIFICATION OF CELL LINE ................................................................... 18
4. ELECTRICAL HEALTH EFFECTS ON THE HUMAN BODY ............................................ 18
4.1 ACUTE HEALTH EFFECTS .................................................................................................. 18
4.2 CHRONIC HEALTH EFFECTS .............................................................................................. 19
4.3 PACEMAKER AND MEDICAL IMPLANT PRECAUTION.............................................................. 19
5. SAFEGUARDING ............................................................................................................... 23
5.1 ADMINISTRATIVE CONTROLS ............................................................................................. 23
5.2 TRAINING .......................................................................................................................... 23
5.3 PERSONAL PROTECTIVE EQUIPMENT ................................................................................. 25
5.4 SAFE WORK PRACTICES ................................................................................................... 26
5.5 SAFETY IN EQUIPMENT AND DESIGN .................................................................................. 31
5.6 RECOMMENDED SAFETY CHECKLIST.................................................................................. 32
6. FIRST AID........................................................................................................................... 32

i
7. HOUSEKEEPING AND MAINTENANCE ........................................................................... 33
7.1 HOUSEKEEPING AND MAINTENANCE PROGRAM .................................................................. 33
7.2 BASIC CONSIDERATIONS ................................................................................................... 33
7.3 FORMULATING A PROGRAM ............................................................................................... 35
8. REFERENCES.................................................................................................................... 35
8.1 CHLORINE INSTITUTE ........................................................................................................ 35
8.2 OTHER REFERENCES ........................................................................................................ 36
APPENDIX .................................................................................................................................. 37

ii
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 1

1. INTRODUCTION

1.1 PURPOSE

This pamphlet is intended to provide information regarding electrical safety for persons
responsible for operations and maintenance in chlor-alkali facilities. Guidance provided
is based upon common usage experience and is applicable to, and for use by, all
persons who could enter a cell facility including operating personnel, maintenance
personnel and visitors.

1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM

The Chlorine Institute (CI) exists to support the chlor-alkali industry and serve the public
by fostering continuous improvements to safety and the protection of human health and
the environment connected with the production, distribution and use of chlorine, sodium
and potassium hydroxides, and sodium hypochlorite, and the distribution and use of
hydrogen chloride. This support extends to giving continued attention to the security of
chlorine handling operations.

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

1.3 SCOPE

This document describes electrical guidelines, mechanisms, and protective equipment in

common use in the chlor-alkali industry which can provide protection for personnel, and
consequently, a safe workplace.

1.4 ABSTRACT

Voltage or potential difference may exist between various items of equipment and
structure even in some cases when the cell facility is essentially de-energized.
Personnel coming in direct contact with items where a sufficient potential difference
exists can receive an electrical shock and subsequent injury and/or electrical burns as a
result of an electrical current through the body.

Personnel may be protected from electrical hazards in the cell facilities by applying
conventionally used mechanisms such as:

 Isolation - Unauthorized personnel are restricted from the area.

 Guarding - Mechanical isolation of electrical energy sources is installed.

 Use of Protective Equipment - Personnel in the area wear appropriate gloves,

boots, or other similar items. Consideration is given to the flammability,
electrical insulation, thermal protection, and ambient protection of clothing.

 Safe Work Practices or Procedures - Specific procedures are followed to

minimize hazard exposure.
2 PAMPHLET 139

 Training of Personnel - People are trained in identification of potential

hazards and consistent use of safe work practices.

 Acceptable Maintenance and Housekeeping - These programs are operated

at a consistently high level to minimize failures and obstacles that can cause
accidents.

1.5 DEFINITIONS AND ACRONYMS

In this pamphlet, the following meanings apply unless otherwise noted:

ACGIH American Conference of Governmental Industrial Hygienists

Anode A positive electrode of the cell or electrolyzer
ANSI American National Standards Institute
ASTM American Society for Testing and Materials
Battery Effect Electrolytic cells can exhibit characteristics similar to an electrical
storage battery, and thus a hazardous voltage may exist after the
power supply is disconnected from the cell line.
Bipolar Cell An electrolytic cell assembly where paired anode and cathode
components are operated individually to carry the circuit current
without sharing through parallel cells.
Bipolar An electrolyzer stack consisting of electrolytic cells connected in
Electrolyzer series to force identical current through each cell within the stack.
The electrolyzer stack operates at a multiple of single cell voltages.
Bypass Switch See Cutout Switch
Cathode A negative electrode of the cell or electrolyzer
CEC Canadian Electrical Code
Cell (electrolytic) A receptacle or vessel in which electrochemical reactions are
caused by applying DC Power for the purpose of producing chlor-
alkali products.
Cell Line An assembly of electrically interconnected electrolytic cells
supplied by a source of direct current power.

Cell Line Cell line attachments include, but are not limited to: auxiliary
Attachments tanks, process piping, structural supports, exposed cell line
conductors, pumps, positioning equipment, instrumentation, and
cell cutout switches.
Cell Line Auxiliary Cell line auxiliary equipment includes tools, lifts, carts and other
Equipment equipment used for operation and maintenance within the cell line
working zone.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 3

Cell Line Working The cell line working zone is the space envelope wherein operation
Zone or maintenance is normally performed on or in the vicinity of
exposed energized surfaces of the electrolytic cell lines or their
attachments.
CFR U.S. Code of Federal Regulations
Cutout Switch A portable or permanently mounted switch that when connected to
the cell line circuit and closed, carries the cell line current and
allows the physical removal of the electrolytic cell that has been
bypassed.
De-energized Applies to cell lines. A state of having no external source of DC
power to the cell line. (However, the battery effect of the cells may
still be present).
Diaphragm Cell An electrolytic cell constructed with a porous material separating
the anode and cathode compartments from each other.
Discharged A condition of an electrical circuit which is de-energized and
allowed/forced to decay in voltage to a point near zero volts for
safely touching without additional PPE.
Electrical See Voltage
Potential
Electrolyzer An assembly of electrolytic cells used for the production of chlor-
alkali products.
Energized Applies to cell lines. A state of having an external source of DC
power to the cell line.
Gauss The Gauss (G) is the common unit of measure for magnetic fields.
Grounded Connected to earth or to some conducting body that serves in
place of the earth.
Guarded Covered, shielded, fenced, enclosed or otherwise protected by
means of suitable covers, casings, barriers, rails, screens, mats, or
platforms to remove the likelihood of approach or contact by
persons or objects to a point of danger.
High Voltage The source of AC electrical energy to a rectifier system.
Power Source
IEEE Institute of Electrical and Electronics Engineers
IGBT Chopper An electrical DC power supply using isolated gate bipolar
transistors operating as a high frequency switching regulator to
supply controllable DC current through electrolytic circuits.
Institute The Chlorine Institute (CI)
Insulated Separated from other conducting surfaces by a dielectric
substance or air space permanently offering a high resistance to
the passage of current and to disruptive discharge through the
substance or space. Note: When any object is said to be
insulated, it is understood to be insulated in a suitable manner for
the conditions to which it is subjected. Otherwise, it is, within the
purpose of this definition, un-insulated.
4 PAMPHLET 139

Isolated An object not readily accessible to persons unless special means

of access are used.
Jumper Switch See Cutout Switch
Leakage Current Fugitive currents diverted from cells through insulators, electrolyte
piping and streams, instrumentation, etc. through ground or nearby
components energized at different voltages. Leakage currents
provide the driving force for corrosion of components and electrical
paths that can allow sustainable shocks to personnel touching
energized components.

Load break DC A high current switch that can carry the full load of the circuit and
disconnect be operated under the load (current and voltage) of the cell or
electrolyzer line. The switch can be operated manually or
motorized to operate remotely for safety and reliability.
Medical Device A medical machine, contrivance, or implant, that is intended for use
in the diagnosis of disease or other condition or intended to affect
the structure or any function of the body of a person.
Membrane Cell An electrolytic cell having a perm-selective ion separator
membrane between the anode and cathode assemblies.
Mercury Cell An electrolytic cell having mercury cathodes.

Monopolar Cell An electrolytic cell assembly where multiple anode and cathode
components operate in parallel within the same enclosure,
connected to share higher currents at approximately one cell
voltage.
Monopolar An electrolyzer stack consisting of electrolytic cells connected in
Electrolyzer parallel to share currents between multiple cells, operating at a
nominal single cell voltage.
NEC National Electrical Code
NFPA National Fire Protection Association
No load break DC A high current switch that can carry the full load of the circuit and
disconnect not be operated under the load (current and voltage) of the cell
or electrolyzer line. The switch can only be operated with the
rectifiers de-energized. Generally the operation of the switch is
interlocked with the rectifier such that an attempt to operate under
load will result in the tripping of the rectifier. The switch can be
operated manually or motorized to operate remotely for safety and
reliability.
Null Voltage Point The electrically neutral point in a floating electrical system where
the voltage to ground is zero volts.
OSHA Occupational Safety and Health Administration (U.S.A.)
Polarization An auxiliary rectifier used to provide enough voltage at low current
Rectifier that prevents reverse current flow in an electrolyzer when the main
power rectifier is de-energized.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 5

Rectifier An assembly of electrical components used to convert alternating

current to direct current.
Tesla A unit of magnetic flux density in the meter-kilogram-second
system. One tesla is equal to 10,000 gauss.
Voltage The difference between the electrical potential at two points.

1.6 DISCLAIMER

The information in this pamphlet is drawn from sources believed to be reliable. The
Institute and its members, jointly and severally, make no guarantee, and assume no
liability, in connection with any of this information. Moreover, it should not be assumed
that every acceptable procedure is included, or that special circumstances may not
warrant modified or additional procedures. The user should be aware that changing
technology or regulations may require a change in the recommendations herein.
Appropriate steps should be taken to assure that the information is current. These
suggestions should not be confused with federal, state, provincial, or municipal
regulations nor with national safety codes or insurance requirements.

1.7 APPROVAL

The Institute's Health, Environment, Safety and Security Issue Team approved Edition 5
of this publication on November 8, 2012.

1.8 REVISIONS

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

1.8.1 Significant Revisions in Current Edition

Figures 2.1 and 2.2 were updated to show alternative configurations including single
series and parallel. Section 2.5 includes discussion of polarization and rectifier.

Figure 3.3 has been added. New tables have been added for how shock is measured.

1.9 REPRODUCTION

The contents of this document are not to be copied for publication, in whole or in part,
without prior Institute permission.

2. DESCRIPTION OF CHLOR-ALKALI CELL EQUIPMENT

Although other types of cells are in use, the three major ones are diaphragm, mercury
and membrane. Size, shape, capacity and materials vary widely within each type, and
there are many designs, most of them proprietary. In choosing electrolyzers, the
required operating conditions should be carefully considered and detailed information
should be obtained from the manufacturer.

The following sections generically describe cell facilities and the three types of
electrolyzers. There is no attempt to describe a particular manufacturer's equipment.
6 PAMPHLET 139

2.1 GENERAL

Almost all commercial production of chlorine is based on some type of electrolytic

process. Most installations involve the electrolysis of brine, a concentrated aqueous
solution of sodium chloride or occasionally of potassium chloride. Depending on the
type of electrolytic cell and the raw material feed, a variety of products may be co-
produced with the chlorine, such as caustic soda, caustic potash and hydrogen.

Chlorine cell facilities include the cell area, the rectifier system and the high voltage
disconnect. This description of facilities and the identification of electrical hazards is
confined to items pertinent to the subject, i.e., the electrical safety in the operation and
maintenance of chlorine cell facilities.

An electrolytic cell line consists of a number of monopolar cells/electrolyzers that are

electrically connected in series and their associated equipment. Bipolar electrolyzers
are usually operated as individual units with one rectifier. Figures 2.1 and 2.2 illustrate
the elements of a chlorine facility for monopolar and bipolar cells.

Each installation is generally custom designed to suit the particular requirements or

circumstances. The physical size of an installation, cell/electrolyzer design details,
cell/electrolyzer arrangement and electrical characteristics vary widely depending on the
type and number of cells. Cell areas are located indoors and outdoors, in one level or
multi-level structures, in dry or wet environment with conductive or non-conductive floor
surfaces, and with bare or insulated structural steel.

Individual monopolar cells/electrolyzers in series arrangement (a cell line) are

interconnected electrically by exposed conductors of copper or aluminum. The
necessary direct current energy is supplied to the cell line through a copper or aluminum
conductor system from suitable AC-DC rectification equipment. Usually each individual
cell/electrolyzer, the interconnecting conductor, and each of the DC supply conductors
are insulated from ground or grounded surfaces by supports which are of non-
conductive materials. The process piping connections to each cell/electrolyzer utilize an
insulating gap to interrupt the current flow through the process liquids or alternatively
have long resistant paths. Pipe materials can be either metallic or non-metallic
depending on the need for corrosion protection or electrical insulation. Some types of
piping may require insulated supports.
ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 7

Figure 2.1
8 PAMPHLET 139

Figure 2.2 – Bipolar Electrolyzer/Cell Circuit Configuration

 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 9

For individual bipolar electrolyzers, the cells are interconnected on the assembly. The
necessary direct current energy is supplied to the electrolyzer through a copper or
aluminum conductor system from suitable AC-DC rectification equipment. Usually, the
electrolyzer and each of the DC supply conductors are insulated from ground or
grounded surfaces by supports which are of non-conductive materials. The process
piping connections to the electrolyzer are of non-conductive materials with the liquid
having a long path to provide the necessary resistance to current leakage through the
process liquids.

2.2 DIAPHRAGM CELLS

A diaphragm cell is an electrolytic cell that utilizes a porous or permeable membrane to

separate the anode and cathode compartments. The cells can be assembled in
electrolyzers that can be configured either monopolar or bipolar.

2.2.1 Monopolar

A conventional monopolar diaphragm cell has three major parts: the base or anode
assembly, the cathode assembly and the cell top or cover assembly. Electrical
connections, generally copper or aluminum bus bars or flexible connections, are
required. The brine enters the cell, and the chlorine gas, hydrogen gas, and cell liquor
exit through hoses, pipes or tubes.

The usual cell line circuit for monopolar diaphragm cells consist of a number of cells that
are electrically connected in series. The circuit characteristics are usually 30 to 300 kA
DC current and 100 to 1000 volts DC.

Cell renewal is usually performed on individual cells through the use of a portable cutout
switch. The procedure is to connect the cutout switch in parallel with the cell to be
removed, close the switch, remove the cell, install the renewed cell, open the cutout
switch and disconnect the cutout switch from the cell line circuit. During this procedure,
the remaining cells in the circuit continue to operate.

2.2.2 Bipolar

Bipolar diaphragm cell electrolyzers are composed of several cells arranged in a filter
press configuration. Usually the cell line circuit for bipolar diaphragm cells consists of
several bipolar electrolyzers in series. The series characteristics are usually 60 to 200
kA DC current and 100 to 1000 volts DC.

2.3 MERCURY CELLS

A mercury cell has two major compartments, the anode compartment and the
decomposer. They are separate units connected by flowing mercury and piping.

The anode compartment is normally a long, narrow, rectangular box installed at a slight
incline to permit gravity flow of the mercury. Generally, the bottom is steel, the sides are
rubber or plastic-lined steel, and the cover is rubber or rubber-lined steel. At the ends
there are containers designed to allow proper inlet or outlet of the circulating mercury.
10 PAMPHLET 139

The usual cell line circuit for mercury cells consists of a number of cells that are
electrically connected in series. The circuit electrical characteristics are usually 100 to
400 kA DC current and 100 to 800 volts DC. The cells, decomposers and associated
piping are usually electrically isolated from ground.

Cell renewal is usually performed on individual cells through the use of a cutout switch
permanently installed under the cell. The procedure is to close the cutout switch,
complete repairs or replace cell parts, and then open the cutout switch. During this
procedure, the remaining cells in the circuit are kept operating.

2.4 MEMBRANE CELLS

A membrane cell is an electrolytic cell that utilizes a perm-selective ion separator

(membrane) between the anode and cathode. The cells can be assembled in
electrolyzers that can be configured either monopolar or bipolar.

2.4.1 Bipolar

Bipolar designs are most common for new installations requiring lowest installed cost.
Bipolar electrolyzers consist of cells composed of an anode, membrane and cathode
assembled in a frame or stack and electrically connected in series. Cells can be
configured as cell packs individually installed as a cell unit, or configured as elemental
design, where adjacent anodes and cathodes are provided as an element and then
assembled with membranes into the frames.

One or a few electrolyzer stacks can be connected in series or parallel to complete a

circuit.

Cell renewal is performed by shutting down the electrolyzer circuit or bypassing current
from the electrolyzer requiring renewal.

2.4.2 Monopolar

Monopolar electrolyzers consist of cells composed of an anode, membrane, and cathode

assembled in a frame and electrically connected in parallel to achieve high current
operation. Typically, many monopolar electrolyzers are connected in series to complete
a circuit.

Cell renewal is performed on an individual electrolyzer through the use of a portable

cutout switch. The procedure is to connect the open cutout switch in parallel with the
cell to be removed, close the switch to bypass current around the electrolyzer, remove
and install the renewed electrolyzer, then open the switch to restore electrolyzer
production.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 11

2.5 RECTIFIERS

The DC power supply to a cell line or electrolyzer consists of one or more rectifier units
to provide the required direct current and voltage. The DC power supply system
typically includes several elements, such as:

 The high voltage AC disconnect that may include circuit breakers or high
voltage switches.

 The transformer(s) to reduce the incoming high voltage AC power supply to

the level required for the rectifier. Some rectifier systems require a voltage
regulator to control voltage. This may be a separate unit or integral with the
rectifier transformer.

 The rectifier(s) to convert alternating current to direct current.

 The DC disconnect device to electrically isolate the rectifier from the cell line
or electrolyzer. Removable links or removable conductors shall be permitted
to be used as the disconnecting means.

 The DC bus system.

 The rectifier control panel or distributed control system.

Also included are several types of protective relays, instrumentation and meters for the
control of the rectifier system and the DC power flow to the cell line or electrolyzer.
Usually, the DC power supply equipment is indoor or outdoor and adjacent to but
separate from the cell area.

The polarization rectifier is energized immediately when the main power rectifier is de-
energized either under normal or emergency conditions. The polarization rectifier is
generally sized for a DC voltage just above the polarization voltage of the electrolyzer
system.

The purpose of the polarization rectifier is to prevent reverse current flow in the
electrolyzer system when the main power rectifier is de-energized. The reverse current
flow would produce a chemical reaction that can damage the cathode structure or
coating. The polarization rectifier can generally be de-energized after several hours of
operation or when chemical analysis indicates that the chemical reaction is no longer
harmful.

The polarization rectifier typically includes:

 An independent rectifier with the DC output connected to the DC bus system

after any DC disconnect switches that isolate the main power rectifier.

 An independent power source to the polarization rectifier. It is common to

have the power source backed up by a standby generator or UPS system for
reliability.
12 PAMPHLET 139

 The polarization rectifier may be a standalone unit with its own enclosure
remotely located or located in a separate section of the main power rectifier.

 All instrumentation, metering, relays or programmable logic controllers

required to monitor and control the Polarization Rectifier to insure the proper
operation when required.

Note: Operational considerations, including products generated, and handling thereof,

are not addressed in this document.

3. IDENTIFICATION OF POTENTIAL ELECTRICAL HAZARDS

3.1 GENERAL

Electrical hazards associated with a cell area and rectifier system are of three general
types - serious electric shock, fall or injury due to reflex actions from a minor shock, and
flash burns or eye injury from an electrical arc.

The electrical shock hazard can exist for an extended time period after the chlorine cell
line is shut down. Each chlorine cell will function similarly to an electrical storage
battery, and thus an electrical hazard can exist after the DC power supply is
disconnected.

It should be noted there are other hazards within the cell area that are not addressed in
this pamphlet. These include metal corrosion due to electrolysis, burns due to contact
with high temperature equipment or chemicals, chemical explosion hazards, etc.

3.2 CELL LINE ATTACHMENTS AND AUXILIARY EQUIPMENT

Each chlorine cell has attachments and auxiliary equipment that are electrical extensions
of the cell and some of these may be hazardous. Typically, these could include the
supporting steel frame that touches a connected cell, the lifting hook and lifting frame of
an overhead crane, the cutout switch, instrumentation devices or wiring, and possibly
other items including process piping, pumps, motors, safety showers, and eyewash
stations. Each of these cell extensions must be identified and recognized at each plant
so that the hazards are clearly understood.

3.3 PIPING

Piping may be an electrical hazard. Pipe, and its contents connected to a cell, is
typically at the same electrical potential as the cell. However, as the pipeline continues
away from the cell the pipeline changes at some point from cell potential to ground
potential. The pipeline at ground potential and the pipeline at a cell are each a separate
hazard. Some pipelines have an insulator break to isolate the cell potential and the
ground potential pipe surfaces. Other pipelines rely on long distances to achieve
insulation. The manner in which insulation in piping is obtained is different at each
facility.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 13

3.4 SYSTEM POTENTIALS AND SHOCKS

Electrical shock hazard exists because of potential differences between cells and
between cells and ground. Simultaneous contact by a person between two points of
different electrical potential may cause serious electrical shock. To avoid the danger of
electrical shock, simultaneous contact of a cell and ground should be avoided.

Normally, the potential difference between two adjacent cells in series is nominally four
volts. However, the potential difference between adjacent cells in two different rows of
cells may be several hundred volts.

Earth or ground potential is a common base reference to every electrical circuit or

system. A wet concrete floor and structural steel are both examples of a surface at
ground potential.

Each individual cell in a cell line has some leakage current from the cell to ground
through finite resistances in brine feed, hydrogen line, and caustic/cell liquor flows as
well as around cell support insulators that may not be perfectly clean. Leakage currents,
while small in relation to cell line operating currents, are capable of causing serious
injury to the human body.

Theoretically, these resistances will have the effect of locating the electrical center (zero
voltage) of the cell line circuit at about the physical middle of the cell line circuit.
Therefore, at any one point in the cell line circuit, potential to ground will range from one
half total cell line voltage at either end of the circuit to zero at the physical center (See
Figure 3.1).

Variations in individual leakage resistances or accidental grounding will, however, shift

the zero voltage point in the cell line and alter the voltage to ground at all points in the
cell line circuit. The effect is most pronounced at the rectifier terminals at each end of
the line. The extreme situation would be very low or zero resistance to ground at one
end of the cell line resulting in essentially zero voltage to ground at that point and full cell
line voltage to ground at the other end of the cell line. (See Figure 3.2) Ground
detection for the DC cell circuit is recommended in order to detect unintentional grounds
that cause higher than normal voltage potential to grounds. The amount of the zero
voltage point shift due to leakage resistance changes or accidental resistance grounding
will determine the potential to which a person is exposed. Depending on the potential at
the point where a person makes contact to the cell line circuit, substantial current flow
through the body is possible. Reference 8 provides a detailed explanation of this
subject. Excessive low cell leakage resistances or the existence of accidental or
accidental ground shorts also provide an increased current return path to the cell line.
Should a person make contact with the electrically energized equipment and ground, the
greater will be the current passing through the person as this current return path to the
cell line increases.
14 PAMPHLET 139

Figure 3.1
ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 15

Figure 3.2
16 PAMPHLET 139

Figure 3.3

Thus the shock hazard from accidental contact between a cell and ground will vary from
point to point in the cell line and can change in location or severity with time, depending
on the magnitude and variations of cell leakage resistances or accidental ground shorts.
Electrical shock hazards exist because of potential differences between cells and
between cells and ground. Simultaneous contact by a person between two points of
different electrical potential may cause serious electrical shock. To avoid the danger of
electrical shock, simultaneous contact of a cell and ground, from cell to cell, or from an
instrument in the process fluids and ground should be avoided. The magnitude of the
current flowing through the body depends on the voltage difference and the electrical
resistance of the body.

Each surface at ground potential in the cell area may be a hazard. Besides the
previously mentioned grounds, other grounds can be introduced inadvertently into the
cell area and constitute a serious hazard. For example, grounded portable tools,
welding machines, water, steam or air hoses with steel reinforcing or anti-static
construction, cables from an overhead crane and standard grounded electrical plug
outlets can expose workers to handling grounded equipment while in contact with a cell
line.

3.5 ELECTRICAL FLASH

Flash Hazard Analysis Procedure: Each task performed in the electrolytic cell line
working zone shall be analyzed by supervisory management for the injury risk of flash
hazard. If there is risk of personal injury, appropriate measures shall be taken to protect
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 17

persons exposed to flash hazards. These measures shall include one or more of the
following:

 Provide appropriate personal protective equipment (8.2.1, Paragraph 2-5.4.2)

to prevent injury from flash hazard.

 Alter work procedures to eliminate the possibility of flash hazard.

 Schedule task so that work can be performed when cell line is de-energized.

3.6 CUTOUT SWITCHES

A cutout switch is intended to act as a shunting or current transfer device which, in the
closed position, allows cell maintenance procedures to be performed on the cell that is
cutout. The cutout switch should only be opened when it is electrically in parallel with a
cell capable of carrying maximum cell line current.

A serious hazard for a cutout switch failure occurs when its voltage rating is exceeded.
This condition can occur two ways. First, by opening a cutout switch with no cell
electrically in parallel that is capable of carrying maximum cell line current. Second, by
attempting to cutout multiple cells from the cell line. In either of these situations, the
voltage rating of the switch is exceeded resulting in its catastrophic failure and
endangerment to personnel.

It is important to recognize that the cutout switch operates at the same potential as the
cells to which it is connected and assumes this potential as soon as it comes into contact
with an energized cell. Therefore the cutout switch as well as anyone who comes into
contact with it or any attachments, such as the cell room crane, should be insulated from
ground. Cutout switches employ at least one set of insulators and some may have
multiple sets. It is important to inspect, maintain and promptly repair defective or
compromised cutout switch insulators. Since the cutout switch operates at the potential
of the circuit to which it is connected, whether it is open or closed, it should be treated as
part of the circuit.

3.7 EXTERNAL ELECTRICAL SOURCES

Equipment with electrical sources, such as motors and instrumentation, is discouraged

from use within the cell line working zone. Two inherent hazards exist. First, the
external electrical source can come in contact with the cell line and energize the cell line
up to that voltage. Second, the wiring of the external electrical source can carry the cell
line voltage anywhere outside the cell line working zone. If equipment with an electrical
source must be used within the cell line working zone, the equipment must be isolated
and any wired external electrical source must be non-grounded.

3.8 RECTIFIERS

The energy available in the power section of a rectifier presents a serious flash and
explosion hazard, should a failure occur. A rectifier that is not in proper operating
condition can sustain damage and cause unwanted process interruption.
18 PAMPHLET 139

Operationally, the electrical hazards associated with rectifiers are as follows:

 Voltages caused by normal operation or by battery effect can cause electrical

shock.

 Large current magnitudes possible during fault conditions can cause

electrical arcs which radiate enough energy to create a flash hazard and
severe burns can ensue.

The above hazards can exhibit themselves in many different forms depending on facility
design and type of rectifier.

3.9 INSULATING MATERIAL IN CELL AREAS

For permanent installations in cell line working zones it is recommended that FRP (fiber
reinforced plastics) or materials with similar insulating and non-wetting properties be
used whenever possible for structures, platforms, supports and ladders.

For temporary installations such as scaffolding, wood is acceptable. However, it should

be understood that wood, when soaked or wetted, can easily become conductive
especially if the liquid is brine or caustic. For this reason the insulating quality of wood
should not be depended upon as primary protection for personnel or equipment. Metal
(conductive) scaffolding should not be used in the cell line area when the cell line is
energized.

3.10 ELECTRICAL CLASSIFICATION OF CELL LINE

The electrical classification for a cell line should be determined for each installation
(NFPA 497 2012). Normally, cell lines are not electrically classified. The combustible
gas present in a cell line is hydrogen. Being a lighter than air gas and under very little
pressure, it tends to rise and dissipate rapidly when released to the atmosphere.

Most cell lines are in large, well-ventilated buildings or outdoors preventing hydrogen
accumulation in flammable mixtures. Even though open contacts of some cutout
switches could provide an ignition source, operating experience has shown that ignitable
mixtures do not present a hazard in properly ventilated buildings or outdoors.

4. ELECTRICAL HEALTH EFFECTS ON THE HUMAN BODY

4.1 ACUTE HEALTH EFFECTS

It is important to understand how electrical shocks can occur, the factors affecting
severity and why an electric shock occurs when the human body becomes a part of an
electrical circuit. The severity of a shock depends on the magnitude and path of the
current passing through the body, the duration of contact, and whether the current is AC
or DC. Upon contact between two points of different electrical potentials, the quantity of
current that will flow through the body is a function of Ohm's Law. Ohm's Law states that
current (I) equals voltage (V) divided by resistance (R) or I=V/R. The magnitude of the
current that may be flowing through the cell line or a conductor has no bearing on the
possible shock hazard from accidental contact. As the cell line voltage increases more
attention and care should be taken in designing and monitoring for leakage current.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 19

The effect of an electrical shock is potentially most serious when current passes through
the chest area and involves the vital organs. If the current flow is through only parts of
an arm or leg and does not pass through vital organs, then the possible injury may be
limited to electrical burns or falls due to reflex reaction from the shock.

Many studies and technical papers have reported on typical reactions of the healthy
human body to various levels of current flow. Most of the studies have been conducted
and reported on the basis of AC currents. However, it is generally agreed that DC
current requires values several times greater than AC current, to have the same effect.
These effects are shown in Table 4.1.

Flash burns/ thermal burns can have a serious effect on the human body. The degree of
burn will depend on various factors such as the amount of energy released, the proximity
to the flash, etc.

4.2 CHRONIC HEALTH EFFECTS

The American Conference of Governmental Industrial Hygienists (ACGIH) recommends

that personnel exposure not exceed 600 Gauss whole body on a daily, time-weight
average basis (8.2.3). Data provided to the Institute show actual levels of less than 1/3
this value in cell line working zones (8.1 “Static Magnetic Fields in Chlor Alkali Plants”).

4.3 PACEMAKER AND MEDICAL IMPLANT PRECAUTION

The ACGIH (8.2.3, page 142) states the following:

“Safety hazards may exist from the mechanical forces exerted by the magnetic
field upon ferromagnetic tools and medical implants. Cardiac pacemakers and
similar medical electronic device wearers should not be exposed to field levels
exceeding 5G (Gauss). Adverse effects may also be produced at higher flux
densities resulting from forces upon other implanted devices such as suture
staples, aneurism clips, prostheses, etc.”

The Institute recommends that workers with implanted ferromagnetic or electronic

medical devices should not be exposed to static magnetic fields exceeding 5 G (0.5mT).
Personnel with implanted cardiac pacemakers should not enter cell line or rectifier areas
without prior medical approval. It is the facility's responsibility to have a system in
place for managing the issue of electromagnetism and workers, contractors, and
visitors who have implanted ferromagnetic or electronic medical devices and to
identify the 5G exposure protection level. Also ACGIH recognizes that some
pacemakers may be susceptible to interference from extremely low frequency
magnetic flux densities so it is recommended that lacking specific information of
electromagnetic interference from the manufacturer the exposure of persons
wearing cardiac pacemakers or similar medical electronic devices be maintained
at or below 1 G (0.1 mT).
20 PAMPHLET 139

Table 4.1 Effects of Electrical Currents on the Human Body (8.2.6)

Alternating Current
Direct Current (DC)
(AC) in Effects
in Milliamperes
Milliamperes

1 or less 5 or less No sensation, not felt

Shock is felt but not painful.
1 to 8 5 to 50 Individuals can let go at will because
muscular control is not lost.
Painful shock but individual can let go
8 to 15 50 to 100
because muscular control is not lost.
Painful shock and muscular control is
15 to 20 100 to 140
lost. Cannot let go.
Painful, severe muscular contractions
20 to 50 140 to 350
and cannot let go.
Possible ventricular fibrillation,
50 to 200 350 to 1400 muscular contraction and nerve
damage.
Severe burns and muscular
Over 200 Over 1400 contractions. Chest muscles clamp
heart and stop it for duration.

From Table 4.1, it is evident that an electrical current considerably less than one ampere
(1000 milliamperes) can cause serious or possible fatal shock. As noted earlier, when
the body becomes part of an electrical circuit, the actual current flow will depend on the
voltage and body resistance. Cuts or openings in the skin and wet skin can lower this
protective resistance very substantially. Typical resistance of some materials and the
human body are shown in Table 4.2.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 21

Table 4.2 Comparing Wet and Dry Electrical Resistance

100,000 to 100,000,000 ohms per

Dry Wood
centimeter
Wet Wood 1,000 to 50,000 ohms per centimeter
Dry Skin –
100,000 to 500,000 ohms
Measured Hand to Foot
Wet Skin (perspiring) –
Down to 1,000 ohms
Measured Hand to Foot
Submersed in Water –
Down to 150 ohms
Measured Hand to Foot

To prevent or reduce the effects of electrical shock, it is important to maintain the highest
possible resistance in series with the body. From Table 4.2 above, it is clear that the
resistance of wet wood provides very little protection compared to dry wood and should
not be trusted as the only source insulation, fortifying the value of using dielectric gloves.

Assuming, accidental contact through the body, contact resistance to the body surface
controls the impediment of current flow per the How Shock is Measured table (Table
4.3).

Ohms law (I=V/R) is used to predict the current flow available through the body.

An example calculation for contact at 100 volts, touching a dry vs. wet wire, would be as
follows:

Dry: 100V /40,000 Ohms = 2.5 mA

Wet: 100V/4,000 Ohms = 25 mA

As the predictability of contact area of touch and the conditions of the contact point are
uncontrollable, bypassing of dielectric PPE should be avoided.
22 PAMPHLET 139

Table 4.3 How Shock Is Measured

Condition Resistance (ohms)

Dry Wet

Finger Touch 40,000 – 1,000,000 4,000 – 15,000

Hand Holding Wire 15,000 – 50,000 3,000 – 6,000

Finger Thumb Grasp 10,000 – 30,000 2,000 – 5,000

Hand Holding Pliers 5,000 – 10,000 1,000 – 3,000

Palm Touch 3,000 – 8,000 1,000 – 2,000

Hand around 1 ½ pipe 1,000 – 3,000 500 – 1,500

Hand Immersed - 200 – 500

Foot Immersed - 100 - 300

As you can see from this chart, wet, sweaty conditions can be much more dangerous
than dry conditions because water and sweat decrease the resistance to electricity,
allowing more current to flow through the body when someone is shocked or
electrocuted

It always makes good sense to stay away from energized parts, but especially so when
conditions are wet.

This is why electricians are required to wear gloves and use special tools when working
on electrical equipment. The proper clothing and tools keep the resistance through their
body high enough to keep from getting shocked.

Other factors besides water or sweat will determine the resistance of someone being
shocked.

Resistance will often depend on the path of the circuit through the body. A shock from
one finger to another on the same hand will probably provide less resistance than a
shock travelling from one hand to the other or from a hand to the ground through a foot.

In any situation where the circuit has a chance to go through the heart, the dangers can
be life-threatening.

As you look over the chart, notice how the wet situations offer less resistance than the
dry situations. This is because current will flow through dirty water and sweat much
more easily than through air and dry skin.

Also, grabbing a wire would be much more dangerous than just barely touching a wire
because more of your skin would be in contact with the wire.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 23

5. SAFEGUARDING

Safeguards for personnel include the consistent administrative enforcement of safe

practices. Safeguards include training in safe techniques, safe work practices, cell line
design, safety equipment, operating procedures, and work checklists.

5.1 ADMINISTRATIVE CONTROLS

The establishment of work rules along with strict enforcement by management is an

essential requirement for safe cell line operation and maintenance. There are many
management procedures that are commonly used throughout the industry and have
proven effective in promoting safety in cell areas.

5.1.1 Area Security

Only those persons who are qualified and authorized by supervisory personnel should
be permitted to enter the cell or rectifier areas. Permanent signs should clearly mark
these areas. Different rules and security requirements should be enforced for an
energized cell area and de-energized cell area with no battery affect.

5.1.2 Enforcement of Regulations

The establishment of regulations along with consistent enforcement by supervision is

essential for the safeguarding of personnel. Each level of supervision and management
needs to be involved. Each level of supervision and management should make a
personal commitment to create a successful program of safeguards for personnel.

5.2 TRAINING

Personnel working within the cell area should be properly trained in the performance of
their respective duties. It is important that a formal training program be administered.
The program should provide a means which adequately trains the individuals in all facets
of safe cell line operation and maintenance. The training recommendations in CI
Pamphlet #85, Recommendations for Prevention of Personnel Injuries for Chlorine
Producer and User Facilities, should be followed (8.1).

5.2.1 Cell Operating Personnel

All cell operating personnel should be trained to insure that each person has:

 a thorough understanding of the process operation;

 a recognition of problems that are associated with cell line operation;

 a thorough understanding of the electrical characteristics of the cell line;

 a recognition of and the ability to deal with hazards associated with the start-
up, operation and maintenance of the cell lines and rectifiers;

 knowledge of required action to take if a rectifier fails to de-energize as

required;
24 PAMPHLET 139

 knowledge of electrical isolation procedures for maintenance servicing of

equipment; and

 knowledge of appropriate industrial hygiene practices.

5.2.2 Cell Renewal Personnel

Cell renewal personnel are involved with tasks associated with cell renewal and are
usually a separate operating group. The duties of this group involve repairing, rebuilding
and replacing cells that have sustained damage or have become inefficient. Specialized
training is required for the personnel of this work group. These persons, by the nature of
their job, routinely come in contact with the energized parts of the cell line. The training
program should emphasize the specific electrical hazards related to cell renewal work.
The training program should provide the following:

 a thorough understanding of the electrical characteristics and hazards of the

cell line

 a detailed procedure for installing, operating and removing the cutout switch

 an emphasis on the particular hazards of using portable hand tools within the
cell area

 a detailed procedure for removing and installing the inter-cell electrical

connections

 a safe procedure for removal and replacement of cells in the circuit

 detailed procedures for safe operation of overhead cranes and other

equipment within the cell area

 procedures involving proper assembly and disassembly of cells

 a knowledge of cell operating characteristics (in some instances the cell

repair personnel are responsible for the initial operation of a newly installed
cell)

 knowledge of appropriate industrial hygiene practices

5.2.3 Other Personnel

Other personnel, such as maintenance, contractor, and laboratory employees, who by

the nature of their job, are required to work within the cell area require special training.
The training programs for these personnel should, in general, include:

 instruction as to safe (and unsafe) work practices for the cell area

 emphasis on the hazards that may be involved with their specific duties in the
cell area

 instruction as to the requirement and use of personal protective equipment for

the cell area
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 25

 a definition of the specific areas for access to accomplish the assigned tasks

 identification of areas to be avoided in the accomplishment of the assigned

tasks

 knowledge of appropriate industrial hygiene practices

5.2.4 Occasional Visitors

Occasional visitors who have not been trained to recognize cell area hazards should be
personally guided through cell areas by qualified personnel. Such visitors should be
provided with appropriate personal protective equipment and may receive training and
instructions as appropriate.

5.3 PERSONAL PROTECTIVE EQUIPMENT

Each facility should establish appropriate rules to ensure that employees and visitors
use the proper personal protective equipment (PPE). It is essential that such equipment
is periodically inspected properly to insure it is in good working order. Due to
deterioration of equipment (e.g., electrical insulation equipment) from usage and aging,
periodic testing may be necessary to insure that it functions as desired.

A philosophy that has been found to minimize the use of defective personal protective
equipment is one where employees are trained to inspect and test their own equipment
and are responsible for assuring that such equipment is adequate and in good condition.

The following are recommendations for personal protective equipment to protect against
electrical hazards in the cell line working zone. Specific tasks within the cell line working
zone may require additional personal protective equipment.

Such recommendations pertain only to cell line working zone electrical hazards and not
to chemical or thermal hazards.

5.3.1 Footwear

Personnel working in the cell line working zone should wear electrically resistant
footwear appropriate to the electrical hazards present in the specific facility. An example
of such boots suitable for some facilities is described by ASTM F2412-11 (8.2.9). Such
footwear should be tested frequently in accordance with a defined procedure. All such
testing should be documented.

Each facility should establish a policy pertaining to the wearing of electrical boots by
visitors. Such a policy should reflect the electrical hazards presented by that facility and
specify areas where visitor access within the cell line working zone is restricted.

5.3.2 Gloves

Because of the varied nature of the electrical configuration of individual cell circuits and
the varied nature of job assignments performed, each situation should be evaluated for
the possible electrical hazards to determine the requirements for gloves.
26 PAMPHLET 139

Individual facilities should examine site specific factors (e.g. tasks performed, electrical
hazards and dexterity requirements of such tasks, physical layout) and determine
whether there is a need to establish a policy pertaining to dielectrically resistant gloves
(8.2.10 provides some examples). If such a policy is established, it should include
frequent testing and documentation.

5.3.3 Footwear/Glove Testing

To guard against damaged or defective PPE in the cell line working zone, testing of an
individual’s footwear and gloves is recommended to ensure the electrical resistivity is
adequate. This testing should be performed frequently in accordance with a defined
procedure and the test results documented.

One method to accomplish this is by imposing a voltage to the footwear/glove to

determine the resistance. Testing units can be custom fabricated by a facility or
purchased from a supplier with the voltage being supplied by either battery power or a
hand crank. A typical installation is illustrated in Figure 5.1.

It is up to each facility to establish criteria of when equipment is no longer acceptable or

protective for use.

5.4 SAFE WORK PRACTICES

Personnel shall be trained in safe work practices. The use of safe work practices are the
responsibility of each individual worker. Personnel must understand their individual work
assignments and why the work practices in a cell area differ from a similar work situation
in other parts of the plant. Within the United States, the Occupational Safety and Health
Administration has regulations pertaining to electrical safety-related work practices (29
CFR 1910.331 - 1910.335) (8.2.8).
ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 27

Figure 5.1
28 PAMPHLET 139

5.4.1 Body Position

A person should make a practice of mentally noting his/her position when working within
the cell line area. Of special importance is the need to be aware when his/her body is in
contact with energized parts of the cell circuit and when his/her body is in contact with
grounded surfaces. Simultaneous contact with cell circuit parts and ground can cause a
serious electrical shock. The safe work position is standing upright on two feet (with
insulating boots) and having no other parts of the body leaning or pushing against
anything for leverage.

5.4.2 Bypassed Protection

Workers should avoid positioning themselves such that they bypass the protection of
their safety equipment (i.e. kneeling, sitting, or lying on the floor while working in the cell
area). Clothing can at times bypass protective equipment, especially if the clothing is
wet or saturated with brine. Therefore, trouser legs should be kept at appropriate length
above the floor and shirt sleeves should be a good fit so as not to drape while reaching.

Jewelry such as necklace chains, rings, etc. may reduce the effect of personnel
protection. The wearing of such jewelry while working within the cell line working zone
should be avoided.

5.4.3 Insulated Structures

Some supports and steel structures associated with the cell line are insulated with non-
conductive coatings or other non-conductive materials. These insulated structures are
provided to help prevent accidental contact with a grounded surface. It is safe work
practice to consider these items grounded and not rely on the insulation for safety from
electrical shock. This insulation cannot be relied upon because at times salt build-up
may bypass the insulation, or the insulation might have been damaged in some way,
thereby making it unsafe. For this reason, workers should avoid leaning, pushing or
bracing against such insulated supports when working within the cell circuit area.

5.4.4 Insulating Materials

Insulating materials such as rubber blankets should be used whenever a job requires
personnel to be in close proximity to electrical conductors of different potential. Blankets
and temporary insulators should be inspected prior to each application. Worn or
damaged blankets should be replaced.

5.4.5 Unsafe Locations

Insulated, non-magnetic poles or other devices should be used whenever it is necessary

to reach beneath the cells or bus bars for retrieval of dropped parts or tools. These
devices eliminate the need for workers to crawl under a cell, thereby placing themselves
in an unsafe location. Long conductive or magnetic materials such as metal conduit,
pipes, etc. should not be taken into the cell line working zone or rectifier area or
substations.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 29

5.4.6 Cutout Switches

It is a safe work practice to treat the cell “cutout” or “jumper” switch as an energized part
of the cell circuit when it is in use. Switches have various types of safety devices (e.g.
open cell line circuit) for monitoring and providing alarms for abnormal operating
conditions. It is a safe work practice to test the operation of the switch and its safety
devices prior to each use. Appropriate procedures should be in place to prevent switch
operation at the wrong time. Some methods to be considered are mechanical locks,
disconnecting the energy source for switch movement, or disconnecting the cutout
switch operation controls.

Warning: Opening a cutout switch without a connected filled cell in parallel will result in
a violent electrical explosion as the entire circuit current will destroy the opened switch
(See Section 3.6).

Each cutout switch requires its own procedures and checklists.

Additional safe work practices are as follows:

a) Verify switch is open before connecting to cell.

b) After closing the switch, verify that it is carrying most of the current; (check
cell voltage).

c) After closing the switch, take necessary steps to prevent accidental switch
operation.

d) Prior to opening the switch, verify the cell is operational with the proper brine
level.

e) Verify switch is open before disconnecting from cell.

5.4.7 Non-Powered Tools

While working in the cell line working zone, personnel should use non-conductive or
insulated tools when specified by the job rules or when common sense so dictates. If a
metal tool is required, care should be taken to limit the length of the tool so that it cannot
bridge across cells or from a cell to ground. One rule is to limit such tools to a specified
maximum length (e.g., 20 inches) and to prohibit the use of a cheater for a wrench
extension. Maximum tool length would vary depending upon a particular facility's layout.

Non-magnetic tools should be used to avoid losing control of the tool due to the
“magnetic pull”. Metallic ladders should not be permitted in the cell area.

5.4.8 Fixed Equipment

Fixed electric equipment in the cell line working zone should be supplied with an
ungrounded electrical source. Conductive surfaces associated with fixed equipment
should also be ungrounded. Such equipment might include items such as enclosures,
race-ways, motor frames, etc.
30 PAMPHLET 139

5.4.9 Powered Tools

Pneumatic powered tools with non-conductive hoses should be used in the cell area
whenever the job permits. Electrically powered hand tools should be tested periodically
for insulation failure.

Electrically powered hand tools should be connected to ungrounded and isolated

receptacles for use in the cell line working zone. The receptacle circuits within the area
should be clearly identified as being ungrounded and isolated and should have a
distinctive configuration different from standard grounded receptacles. In addition, the
latest edition of IEEE Standard 463 (8.2.1) and the National Electrical Code NFPA - 70
Article 668 (8.2.4) should be consulted. Similar precautions should be taken with electric
powered man lifts.

5.4.10 Cranes and Hoists

Overhead cranes and other hoisting equipment used in the cell area typically have a
lifting hook insulated from ground. It is a safe work practice to periodically test the
insulation on such equipment. Likewise the pendant push button controls and
supporting means should be insulated to prevent grounding the cell circuit and should be
periodically tested.

5.4.11 Welding Machines

Welding machines should be considered energized when welding on cell lines. Care
must be taken not to ground the cell line through the welding machine and its power
supply. Precautions should be taken to prevent personnel from touching the welder and
ground simultaneously. Refer to Section 7.4 of Reference 8.2.1 and Article 668 of
Reference 8.2.4 for details of safeguarding.

5.4.12 Rectifiers

Appropriate precautions should be taken to prevent the exposure of unauthorized

personnel to energized electrical components. Rectifiers should be located inside
barriers or other appropriate isolation means with appropriate personnel warning signs.
Climbing on top of energized rectifiers and transformers should be forbidden. The power
section enclosures of energized (either by the AC side or the DC side) rectifiers should
not be entered.

Qualified personnel should visually inspect inside rectifier cabinets for condensation,
leaks (water or oil), tools, ground cables etc. before energization. Direct contact cooling
water conductivity tests should be performed periodically. All rectifier protective devices
should be operated periodically (“test-tripped”) to trip the high voltage AC disconnect.
Test procedures to ensure that DC disconnects are not closed onto a faulted rectifier to
prevent arc flash of the switch or disconnect bus. Example techniques are open circuit
testing of rectifier with follow up meg-ohmmeter to ground of each bus.

5.4.13 Safe Work Sequence

It is important that a specific safe work sequence be formulated for repetitive jobs in the
cell area. Cell renewal is one typical repetitive job that benefits from a specific work
sequence. The following steps represent the typical procedures for the cell renewal
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 31

process. While such steps would vary depending on each facility's site-specific
conditions, each facility should have a formal cell removal procedure.

a) Test that cutout switch is open and test its safety devices.

b) Check that the correct cell is being bypassed.

c) Install, connect and close cell cutout switch to bypass the cell being removed.

d) Verify that cutout switch is carrying the required current.

e) Lock-Tag-Try the cutout switch.

f) Blank-off and safely disconnect all process connections from the cell.

g) Remove cell interconnecting bus links.

h) Remove the cell from its position with overhead crane or hoisting equipment.

i) Clean or replace insulating supports for the cell.

j) Install renewed cell.

k) Clean and reinstall bus connecting links to new cell.

l) Reestablish proper process connections to new cell.

m) Fill cell with brine.

n) Verify that cell is connected and ready to accept full operating current.

o) Remove lock and tag.

p) Place cell in operation by opening cutout switch.

q) Verify cutout switch is open and disconnect from cell.

5.5 SAFETY IN EQUIPMENT AND DESIGN

Many safeguards are built into the personal safety equipment and into the cell line
design.

5.5.1 Means for Safeguarding

Means for providing the necessary safeguards may be accomplished by the following
items (individual items may not be applicable in all situations):

 Isolation provided for grounded and energized surfaces

 Personal protective equipment including rubber or otherwise insulated gloves,

rubber or otherwise insulated boots, non-conductive safety glasses, face
shield, hat, and welding hood
32 PAMPHLET 139

 Mechanical guards

 Voltage equalization of conductive surfaces

 Isolation of equipment

 Ground detection (zero point) instruments with alarms

 Measurement of stray ground currents

 Physical clearances

 Ungrounded isolation of voltage sources such as power for 120 volt

receptacles and pump motors

 Advisory signs

 Fault current protection for conductors operating at cell circuit potential

 Limitations on maximum circuit voltages

 Bus bar bracing against forces due to high fault currents

 Current interrupters for conductive process streams leaving the cell circuit

 Open cell line circuit detection

 Rectifier reverse current detectors

5.6 RECOMMENDED SAFETY CHECKLIST

Significant items to periodically review in order to ensure proper safeguarding of

personnel are included in the safety checklist found in the Appendix.

6. FIRST AID

An electrical safety program is essential to protect personnel from possible electrical

hazards. Equally important, however, is periodic training in appropriate first aid
response to electrical or flash injury. The ability to react quickly and properly in the
event of an electrical injury is of extreme importance. Many victims have been saved by
the applications of basic standard first aid practices. The key is quick and proper
response.

First aid response for a shock victim has two key components. These are:

 Safe removal of the victim from energized electrical contact

 Knowledgeable application of cardio-pulmonary resuscitation (CPR) as

required and indicated. Trained medical staff or health professional(s) should
be utilized as soon as possible.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 33

The following facts should be recognized in a cell facility:

 A person in direct contact with energized equipment is likely to be paralyzed.

 The person must be freed immediately from the energized electrical contact.
Although immediate shutdown may be recommended for rescuing a person in
a direct contact emergency situation, the rescue should not be delayed due to
the shutdown. Even after a shutdown the energized electrical contact will
continue due to the “battery” action of the cell. Insulated gloves and boots
used by cell facility personnel will normally permit the injured person to be
freed in a safe manner. Each facility should have in place a formalized
procedure for handling this type of situation and have clean, properly
maintained equipment available for immediate use. This equipment might
include such items as gloves, boots, insulating blanket, and rope.

 Immediate application of appropriate first aid procedures at the site of the

accident, after removal from the energized source is essential.

 Check eyes and skin for flash burn and cover as appropriate.

Regular “hands-on” participative training programs will result in an effective electrical

injury response.

7. HOUSEKEEPING AND MAINTENANCE

7.1 HOUSEKEEPING AND MAINTENANCE PROGRAM

For maintenance and housekeeping purposes, a chlor-alkali facility can be looked at in

four parts:

 the basic structural facility or building

 the DC power supply system

 the installed cell circuit equipment

 the installed means for safeguarding

A regular program of preventive and corrective maintenance and housekeeping applied

to each of these parts is essential to electrical safety in a chlor-alkali cell facility.

7.2 BASIC CONSIDERATIONS

The following is a listing of the basic activities and considerations that should be a part of
such a program. The listing is not intended to be complete. A complete list can only be
defined and developed for a specific cell facility.

7.2.1 Basic Structural Facility or Building

a) Maintain floors in a self-draining, non-slippery condition.

b) Keep all drains, trenches and trench covers in good operating condition.
34 PAMPHLET 139

c) Prevent accumulation of debris, solid chemicals, and obstacles presenting

tripping hazards or access barriers.

d) Maintain ventilation and lighting in good condition.

e) Adequately identify and isolate hazards resulting from construction or

improvement work.

f) Provide proper area clean-up throughout and after all jobs and during normal
operating periods.

7.2.2 The DC Power Supply System

a) Maintain rectifier enclosure(s) and transformer tank(s) to prevent

deterioration.

b) Verify and test power equipment and associated protective relays and
controls on a regular basis.

c) Verify the operation of the isolating DC disconnect switch and maintain

adequately.

d) Allow work inside the rectifier power cubicles or on rectifier power

components only when isolated and de-energized.

e) Maintain appropriate barriers and personnel warning signs around rectifiers.

f) Maintain proper seals and fire walls.

7.2.3 Installed Cell Circuit Equipment

a) Maintain cell assemblies in good condition with minimum leakage and

acceptable mechanical tolerances.

b) Maintain good electrical connections between cells.

c) Replace cracked or failed support insulators.

d) Remove any accumulation of salt on cells and insulator surfaces.

e) Provide for regular inspection, testing, and repair of all cutout switches.

f) Periodically test operation of alarms and signals in the cell area.

g) Inspect process piping for mechanical support and electrical isolation where
applicable.

7.2.4 Installed Means for Safeguarding

a) Inspect and maintain insulating and guarding surfaces.

b) Insure that all signs and warning markings are in place and clearly legible.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 35

c) Inspect and test crane hook insulation and controls.

d) Determine regularly that adequate working clearances are available.

e) Verify that tools which are acceptable to management are being used in the
area and that they are in good condition.

f) Verify operation of personal protective equipment testing facilities.

Housekeeping and maintenance are significant parts of the overall plant program to
provide safeguards to personnel from electrical shock. The above remarks are not
complete, but illustrate some typical housekeeping and maintenance practices. In each
facility an acceptable level of housekeeping and maintenance needs to be established
and enforced through consistent practices by supervision.

7.3 FORMULATING A PROGRAM

Two points are of value in formulating a program for housekeeping and maintenance:

 An observation team can identify acceptable levels of housekeeping and

maintenance for electrical safety to personnel. Periodic review and update by
such a team is typically utilized.

 The specific items in each plant that are significant to electrical safety should
be identified. Each plant is different and the deterioration or cleanliness of
those items with significant implications to electrical safety should be
identified.

The basic philosophy described in the above considerations is that a well-maintained,

clean, and orderly facility contributes significantly to a safe work place with minimum
possible hazards.

8. REFERENCES

8.1 CHLORINE INSTITUTE

The following publications are specifically referenced in CI Pamphlet 139. The latest
editions of CI publications may be obtained at http://www.chlorineinstitute.org.

Paper or
Title
Pamphlet #

Electrical Safety in Chlorine Cell Rooms or Cell Shocks - Not

Paper Necessary, A.G. Forster, 16th Chlorine Institute Plant Managers
Proceedings, February 7, 1973, IEEE-1A, Volume 1A-II -No. 6,
November/December, 1975.
The Formulation and Implementation of a Cell Room Electrical
Safety Program, K.W. Sanders and Frank Carelli, 22nd
Paper
Chlorine Institute Plant Managers Proceedings, February 7,
1979.
36 PAMPHLET 139

Paper or
Title
Pamphlet #
Static Magnetic Fields in Chlor Alkali Plants, R.F. Adams, 34th
Paper Chlorine Plant Operations Seminar and Workshop Proceedings,
The Chlorine Institute: Arlington, VA, March, 1991.

Recommendations for Prevention of Personnel Injuries for

85 Chlorine Producer and User Facilities, ed. 5; Pamphlet 85; The
Chlorine Institute: Arlington, VA, 2010

8.2 OTHER REFERENCES

8.2.1 IEEE Standards for Electrical Safety Practices in Electrolytic Cell Line Working Zone,
IEEE Standard 463-2006, The Institute of Electrical and Electronic Engineers, Inc., New
York, N.Y.

8.2.2 Standard for Electrical Safety in the Workplace, NFPA 70E, National Fire Protection
Association, Quincy, MA, 2012.

8.2.3 2012 Threshold Limit Values for Chemical Substances and Physical Agents and
Biological Exposure Agents, American Conference of Governmental Industrial
Hygienists, Cincinnati, Ohio.

8.2.4 National Electrical Code, NFPA 70, Article 668, National Fire Protection Association,
Quincy, MA, 2011.

8.2.5 General Guidelines for Avoiding Shocks in Electrolytic Cell Rooms, T.E. Dye, IEEE PCIC
34th Conference, 1987, Paper No. PCIC 87-53.

8.2.6 How and Why Voltage Kills, S.C. Rothman, Plant and Engineering, February, 1968.

8.2.7 Fault Contribution of Chlor Alkali Cell Line, R.M. Hruda and J.R. Harbaugh, IEEE-IA,
Volume 1A-17, January - February, 1981.

8.2.8 Occupational Safety and Health Act (OSHA), Code of Federal Regulations, 29 CFR
1910.331 - 1910.335.

8.2.9 ASTM F2412-11, Standard Test Methods for Foot Protection, ASTM, Philadelphia, PA.

8.2.10 ASTM D120-09, Standard Specification for Rubber Insulating Gloves, ASTM,
Philadelphia, PA.

8.2.11 ASTM D1051-08, Standard Specification for Rubber Insulating Sleeves, ASTM,
Philadelphia, PA.

8.2.12 ASTM D1048-12, Standard Specification for Rubber Insulating Blankets, ASTM,
Philadelphia, PA.

8.2.13 ASTM D178-01 (2010), Standard Specification for Rubber Insulating Matting, ASTM,
Philadelphia, PA.
 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 37

APPENDIX
PAMPHLET 139 CHECKLIST

This checklist is designed to emphasize major topics for someone who has already read
and understood the pamphlet. Taking recommendations from this list without
understanding related topics can lead to inappropriate conclusions.

Place a check mark () in the appropriate box below:

Yes No N/A
   1. Are cell line attachments identified so the electrical
hazards can be understood? {3.2, 3.3}

   2. Does the DC cell circuit have unintentional ground

detection? {3.4}

   3. Has flash hazard analysis been completed for each

task performed in the cell line working zone? {3.5}

   4. Are cutout switches tested prior to each use? {3.6, 5.4.6}

   5. Are there procedures in place to prevent improper

cutout switch operation? {3.6, 5.4.6}

   6. Is fixed electric equipment in the cell line working

zone supplied from an ungrounded source and their
conductive surfaces ungrounded? {3.7, 5.4.8}

   7. Are rectifiers properly isolated and are warning

signs posted to prevent exposure to energized {3.8,
electrical components? 5.4.12}

   8. Are insulating materials used for structures,

platforms, and ladders in the cell area? {3.9}

   9. Are personnel with medical implants such as

pacemakers informed about the magnetic effects in
cell areas? {4.3}

   10. Are specific safe job procedures formulated for {5.2.2,

repetitive jobs? 5.4.13}

   11. Are signs posted to limit cell area entry to qualified

persons? {5.1.1}

   12. Are unescorted, unqualified persons allowed in the

cell area when cells are de-energized and battery
effect is dissipated? {5.2.4}
38 PAMPHLET 139

Yes No N/A
   13. Are cell operating personnel trained to understand
the hazards of the cell line and are cell operating
personnel trained to follow detailed procedures for
each task? {5.2.1}

   14. Are cell renewal personnel trained in safe cell

renewal procedures? Are cell renewal personnel
trained for installing, operating and removing the
cutout switch? Are cell renewal personnel trained in
procedures for assembling and disassembling
cells? {5.2.2}

   15. Are other qualified personnel trained for safe work

practices in the cell area? {5.2.3}

   16. Are occasional visitors personally guided when in

an energized cell area? {5.2.4}

   17. Do personnel wear footwear appropriate for the

electric hazard in the facility and is there a footwear
policy for visitors? {5.3.1}

   18. Are gloves used appropriate for the electrical,

thermal, and chemical hazards? {5.3.2}

   19. Are footwear and boots tested frequently for

electrical resistivity? {5.3.3}

   20. Are personnel trained in safe work practices, and do

they understand why these practices are different in
cell areas? {5.4}

   21. Are personnel trained in the practice of noting their

body position to avoid electrical hazards? {5.4.1}

   22. Are personnel trained to avoid bypassing

protection? {5.4.2}

   23. Are personnel trained how to use temporary

insulating materials to reduce electrical hazards? {5.4.4}

   24. Are personnel trained to never crawl under an

energized cell? {5.4.5}

   25. Are non-conductive or insulated hand tools used

when specified and is the maximum length of
metallic tools specified? {5.4.7}

   26. Are metallic ladders prohibited from cell areas? {5.4.7}

 ELECTRICAL SAFETY IN CHLOR-ALKALI
CELL FACILITIES 39

Yes No N/A

   27. Are pneumatic tools supplied by non-conductive

hoses? {5.4.9}

   28. Are electrically powered hand tools supplied from

an ungrounded, isolated receptacle of a distinctive
configuration? {5.4.9}

   29. Are methods in place for ground isolation when

using hoisting equipment in the cell line working
zone? {5.4.10}

   30. Is the ground insulation of hoisting equipment

periodically tested and documented? {5.4.10}

   31. Are welding machines used safely in the cell area? {5.4.11}

   32. Are rectifiers inspected prior to energizing? {5.4.12}

   33. Are rectifier protective devices tested periodically? {5.4.12}

   34. Are personnel safeguards adequate for the

conditions? {5.5.1}

   35. Are personnel periodically trained in first aid

response to electrical shock of flash injury? {6}

   36. Is the housekeeping and maintenance program

adequate? {7}

REMINDER:

Users of this checklist should document exceptions

to the recommendations contained in this pamphlet.
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