Pamphlet 168 - Ed 2 - July 2015 PDF

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Table of Contents
1. INTRODUCTION................................................................................................................... 1
1.1 PURPOSE AND SCOPE ......................................................................................................... 1
1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM .................................................................. 1
1.3 BACKGROUND ..................................................................................................................... 1
1.4 DEFINITIONS AND ACRONYMS .............................................................................................. 1
1.5 DISCLAIMER ........................................................................................................................ 2
1.6 APPROVALS ........................................................................................................................ 2
1.7 REVISION ............................................................................................................................ 3
1.8 REPRODUCTION .................................................................................................................. 3
2. REGULATORY REQUIREMENTS AND INTERCHANGE STANDARDS ........................... 3
2.1 DOT REGULATIONS ............................................................................................................ 3
2.2 CANADIAN REGULATIONS .................................................................................................... 3
2.3 MEXICAN REGULATIONS ...................................................................................................... 3
2.4 AAR STANDARDS ............................................................................................................... 4
3. GENERAL INFORMATION .................................................................................................. 4
3.1 QUALITY ............................................................................................................................. 4
3.2 TESTING/INSPECTION .......................................................................................................... 4
3.3 RELIABILITY ........................................................................................................................ 4
4. VALVE DESIGN AND MATERIALS OF CONSTRUCTION ................................................. 5
4.1 VALVE DESIGN .................................................................................................................... 5
4.2 MATERIALS OF CONSTRUCTION ........................................................................................... 5
5. LIQUID AND VAPOR VALVES ............................................................................................ 6
5.1 VALVE TYPES ..................................................................................................................... 6
5.2 VALVE PAIRING ................................................................................................................... 7
5.3 FLOW ................................................................................................................................. 7
5.4 VALVE CONNECTION ........................................................................................................... 7
5.5 TESTING ............................................................................................................................. 7
5.6 KEY COMPONENTS.............................................................................................................. 7
5.7 MAINTENANCE .................................................................................................................... 8
6. PRESSURE RELIEF SYSTEM ............................................................................................. 8
6.1 GENERAL ............................................................................................................................ 8
6.2 DESIGN AND TESTING REQUIREMENTS................................................................................. 9
6.3 KEY COMPONENTS.............................................................................................................. 9
6.4 MAINTENANCE .................................................................................................................... 9
7. VALVE MARKING ................................................................................................................ 9
7.1 RUPTURE DISC HOLDER ASSEMBLY..................................................................................... 9
7.2 PRESSURE RELIEF VALVE ................................................................................................. 10
7.3 LIQUID AND VAPOR VALVES ............................................................................................... 10
8. OPERATION AND INSTALLATION CONSIDERATIONS ................................................. 10
8.1 GENERAL .......................................................................................................................... 10
8.2 LOADING CONDITIONS ....................................................................................................... 10
8.3 VALVE INSTALLATION ........................................................................................................ 11
9. REFERENCE ...................................................................................................................... 12
9.1 CHLORINE INSTITUTE PUBLICATIONS.................................................................................. 12
9.2 DOT REGULATIONS .......................................................................................................... 13
9.3 TRANSPORT CANADA REGULATIONS .................................................................................. 13
9.4 AAR PUBLICATIONS .......................................................................................................... 13
9.5 ASME STANDARDS ........................................................................................................... 13
9.6 OTHER CHLORINE INSTITUTE PUBLICATIONS ...................................................................... 13
APPENDIX A – RECOMMENDED CHLORINE TANK CAR...................................................... 15
APPENDIX B – VALVE INFORMATION .................................................................................... 16
DRAWINGS ................................................................................................................................ 31
ii
GUIDELINES FOR DUAL VALVE SYSTEMS
FOR BULK CHLORINE TRANSPORT 1
1. INTRODUCTION
1.1 PURPOSE AND SCOPE
The purpose of this pamphlet is to set forth performance/selection criteria that should be
utilized in identifying dual valve systems for bulk chlorine transportation applications (i.e.
tank cars, cargo tanks and barges). These criteria are intended to meet U.S. Department
of Transportation (DOT) and Transport Canada (TC) performance requirements. This
pamphlet contains information pertaining to standardization, performance and design
criteria as well as an appendix that includes information on valves/fittings and
arrangements that meet these criteria.
1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM
The Chlorine Institute 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 sustaining the attention already placed on
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 improvements. For more information on the Institute’s
stewardship program, visit CI’s website at www.chlorineinstitute.org.
1.3 BACKGROUND
For over 50 years the Chlorine Institute has used a standard manway cover plate
assembly with standard valves (see CI Drawing 103D), also referred to as the traditional
valves, which have effectively served the needs of bulk chlorine shippers throughout
North America, helping to ensure safe and efficient transportation of chlorine from the
producer to the end user. Nevertheless, over this period of time significant changes in
valve and fitting technology have been brought to the marketplace.
For this reason, the Institute has determined that it is best to identify new valves and
fittings for bulk chlorine transportation equipment. The goal is to develop a
performance/selection criteria to assist users in selecting valves that meet their needs,
while remaining confident that the Institute’s collective knowledge and experience
supports their choice. Hence the development of this pamphlet.
1.4 DEFINITIONS AND ACRONYMS
In this pamphlet the following meanings apply unless otherwise noted:
AAR Association of American Railroads
ASME American Society of Mechanical Engineers

2 PAMPHLET 168
ASTM American Society for Testing and Materials
cfm Cubic feet per minute (air)
CFR Code of Federal Regulations
Chlorine Dry chlorine (either gas or liquid)
DOT Department of Transportation (U.S.)
Globe valve A linear motion valve (raising or lowering stem) with a

globe shaped body having a plug shaped seat.
Institute The Chlorine Institute
kPa Kilopascal(s)
psia Pounds per square inch absolute
psig Pounds per square inch gauge
PTFE Polytetrafluoroethylene
TC Transport Canada
1.5 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 procedure. The user should be aware that changing
technology or regulations may require a change in the recommendations herein.
Appropriate steps should be taken to insure that the information is current when used.
These suggestions should not be confused with federal, state, provincial, municipal or
insurance requirements, nor with national safety codes.
1.6 APPROVALS
1.6.1 Valves
The Association of American Railroads’ (AAR) Tank Car Committee has approved
various globe valves, which are compliant with current U.S. Department of
Transportation (DOT) regulations and Transport Canada (TC) regulations, for use on
chlorine tank cars.
1.6.2 Pamphlet
The Institute’s Transportation Issue Team approved Edition 2 of this pamphlet on July
21, 2015.
1.7 REVISION
Suggestions for revision of the contents of this pamphlet should be directed to the
Secretary of the Institute.
1.7.1 Significant Revisions in Current Edition
Significant revisions in Edition 2 of this pamphlet include the addition of Section 8, which
provides operational and installation considerations, the addition of Appendix A, which
provides recommended fittings arrangement criteria, and various updates to valve
manufacturers’ information in Appendix B.
1.8 REPRODUCTION
The contents of this pamphlet are not to be copied for publication, in whole or in part,
without Institute permission.
2. REGULATORY REQUIREMENTS AND INTERCHANGE STANDARDS
2.1 DOT REGULATIONS
The DOT regulates the packaging and transportation of hazardous materials in the
United States. DOT's Pipeline and Hazardous Materials Safety Administration (PHMSA)
regulates the transportation of chlorine in the U.S. PHMSA's Hazardous Materials
Regulations (also referred to as the HMR) are found in Title 49 CFR Parts 171-180 (9.2).
Because chlorine is a hazardous material, personnel involved in any aspect of handling,
packaging and transportation of chlorine should be knowledgeable of the relevant
regulatory requirements.
2.2 CANADIAN REGULATIONS
Canadian regulations are covered by Transport Canada (TC) in the Transportation of

Dangerous Goods (TDG) Act and Regulations, which parallel the DOT requirements in
most respects. There are 16 parts to the regulations which cover such items as
Interpretations, General Provisions, Classification, Documentation, Dangerous Goods
Safety Marks, Means of Containment, Training, Emergency Response Plan and
Accident Release and Imminent Accidental Release Report Requirements. These
regulations include, by reference, various standards published by agencies such as the
Canadian Standards Association (CSA) and the Canadian General Standards Board
(CGSB) (9.3).
2.3 MEXICAN REGULATIONS
The Normas Officiales de Mexico (Official Mexican Standards) often referred to as

Normas or NOMs, support the Mexican Hazardous Materials Land Transportation
Regulation. The Mexican Secretariat for Communications and Transport is responsible
for publishing and applying the NOMs. The Mexican NOMs are fairly consistent with
those of the United Nations Recommendations on the Transport of Dangerous Goods
(UN Recommendations), as well as Transport Canada and DOT regulations.
4 PAMPHLET 168
2.4 AAR STANDARDS
The AAR establishes standards for the design, inspection, maintenance, marking and
registration of tank car tanks. This is primarily done through its standard Manual of
Standards and Recommended Practices, M-1002, Section C, Part III, Specifications for
Tank Cars (also referred to as M-1002) (9.4.1). Tank car valves and fittings
requirements are covered in Appendix A of M-1002. Each valve design must pass a
regulatory review, which shall include a service trial.
This standard also establishes requirements for certification of tank car facilities. Much of
M-1002 is incorporated by reference into DOT and Transport Canada regulations. The
AAR Tank Car Committee oversees changes to this specification. Other aspects of car
design, maintenance, inspection, as well as quality systems are managed through a
series of additional AAR standards and manuals.
3. GENERAL INFORMATION
3.1 QUALITY
All AAR tank car facilities, including valve manufacturers and valve rebuilders, shall have
a quality system that complies with AAR requirements. Upon request, valve
manufacturers shall provide documents demonstrating the results of the tests required
by ASTM, the valve manufacturer’s quality assurance program and user requirements.
3.2 TESTING/INSPECTION
Chlorine tank car service equipment, including the pressure relief device, must be
qualified at least once every ten years, or at a shorter interval, if necessary, to ensure
reliability of the devices. Refer to CI Pamphlet 66 (9.1) for more information.
3.3 RELIABILITY
Each valve shall be designed to remain operable in chlorine service over its service
cycle. Operable is defined as follows:
• no product leak to atmosphere through all leak paths using aqua ammonia
vapor test
• no product leak through the stem seat area during post loading inspection
using aqua ammonia vapor test
• be operable by hand without the use of wrenches
• maintain integrity of exterior finish

4. VALVE DESIGN AND MATERIALS OF CONSTRUCTION
4.1 VALVE DESIGN
4.1.1 Design Pressure
Each valve shall meet or exceed the required test pressures stated in this pamphlet.
4.1.2 Design Temperature
Valves shall be rated for a minimum process temperature of -40°F (-40°C).
4.1.3 Dimensions
Chlorine globe/check valves shall have a common set of key dimensions to assure
compatibility with common flange and commonality of emergency procedures. Pressure
relief valves shall also have a common set of key dimensions to assure
interchangeability and commonality of emergency procedures.
All valves must fit to manway covers as defined by Chlorine Institute Drawings 103A, B,
or C, included in Appendix C. Attaching hardware shall be consistent with specifications
outlined in Chlorine Institute Drawing 102 which can be found in CI Pamphlet 66 (9.1).
Stud lengths may vary depending on valve design. The protective housing and its ports
shall be designed to accommodate the valves’ maximum height and outlets according to
the manufacturer’s drawings.
4.1.4 Emergency Kit Application
The protective housing and valve configuration must be designed to be compatible with
any one of the hoods in the Chlorine Institute’s Emergency Kit C. Refer to CI Pamphlet
IB/C and C-DVD for more details (9.1).
4.1.5 Security
The protective housing shall be designed to provide for the seal security feature
described in CI Pamphlet 66 (9.1).
4.1.6 Criteria for Future Tank Car Builds
For chlorine tank cars built after June 12, 2015, see Appendix A of this pamphlet for
valve arrangement criteria.
4.2 MATERIALS OF CONSTRUCTION
The following table lists materials which have been successfully used in chlorine valve
service. Choice of specific materials depends on a combination of factors, including
chemical resistance, mechanical strength, manufacturing experience and economics.
6 PAMPHLET 168
Table 4.4. Materials of Construction Successfully Used in Chlorine Valve Service
Part Material
Body* Low temperature carbon steel ASTM A352, Gr LCC or ASTM A350,
Grade LF2 or Monel® casting ASTM A494, M35.1 or ASTM A105
normalized
Bonnet Low temperature carbon steel ASTM A352, Gr LCC or ASTM A350,
Grade LF2 or Monel® casting ASTM A494, M35.1 or ASTM A105
normalized
Disk Hastelloy® C-276, Monel® 500, fluorocarbon insert
Bellows Hastelloy® C-276
Stem Hastelloy® C-276, Monel® 500
Metallic Seat Monel® 400, Stellite facing, Hastelloy® C-276
Soft PTFE
Spring, PRV Alloy Steel
Spring, Check Valve Inconel®
Packing Fluorocarbon
O-rings Viton®
Nuts ASTM A194 Grade 4, Monel®
Bolts/studs ASTM A320 Grade L7, Monel®
Gaskets See CI Pamphlet 95 (9.1)
* All body castings must meet the quality requirements contained in the AAR’s M-1002,
Appendix M, Section 4.9 (9.4.1).
5. LIQUID AND VAPOR VALVES
5.1 VALVE TYPES
5.1.1 Globe Angle Valve
Angle valves shall be hand actuated globe type. Closure sealing can be either soft
seated or metal seated. Soft seated valves shall be designed so that the valves will
provide substantial closure, even if the soft seat is damaged or displaced. Stem seals
can utilize bellows or packing/O-rings. In either case, backup packing or O-rings are
required.
5.1.2 Check Valve
The check valve is a spring-loaded valve that is either soft seated or metal seated. The
check valve is mounted below the globe valve and remains closed until it is pushed open
by the globe valve. The check valve shall provide a positive seal in case the globe valve
is broken off or removed.
5.2 VALVE PAIRING
Globe valves and check valves are designed to operate as a pair. Individual
manufacturers’ paired globe and check valves have been designed and tested to
operate together.
5.3 FLOW
The valve flow passages shall be designed so that in a typical chlorine tank car
unloading situation, with a differential pressure (tank car pressure - valve outlet
pressure) of approximately 20 psig, a minimum unloading rate of 20,000 pounds per
hour can be achieved. Valves shall have a minimum flow coefficient (Cv) of 12.
5.4 VALVE CONNECTION
The valve outlet connection may be a one-inch female NPT or a one-inch ANSI Class
300 flanged connection. The outlet connection can be an integral part of the body or
built as a replaceable assembly.
5.5 TESTING
A minimum pressure of 500 psig shall be utilized for the required shell and closure
testing.
5.6 KEY COMPONENTS
5.6.1 Handwheel
Handwheel designs, as shown in Figure 5.1, should accommodate adapters for remote
actuators.
8 PAMPHLET 168
Figure 5.1. Typical Handwheel Design
5.6.2 Closing/Turning Torque
All valves shall have a method for determining the direction to open and close the valve.
Valve designs shall ensure that overtorquing will not result in a failure that allows a
chlorine release. Normal and maximum closing/turning torque shall be stated by the
manufacturer.
5.6.3 Lubrication
Lubrication shall be provided for bearing surfaces. Use only non-reactive lubricants for
parts in contact with chlorine. See CI Pamphlet 164 (9.1), for more information on
reactivity and compatibility with various materials.
5.7 MAINTENANCE
A valve service interval shall be defined for each valve design. It is recognized that this
service interval will be influenced by the process conditions present at loading and
unloading sites. Car owners must determine the proper maintenance interval for their
fleets within federal guidelines to prevent service failures. A valve rebuilt per the
manufacturer’s instructions will be leak tight at 500 psig.
6. PRESSURE RELIEF SYSTEM
6.1 GENERAL
The pressure relief system recommended in this pamphlet is considered a combination

system, consisting of a pressure relief valve and a rupture disc.
The pressure relief valve (PRV) is a spring-loaded valve with either metal-to-metal or
elastomeric seat seals. During an overpressure event, the rupture disc mounted below
the valve will burst and the valve will open fully, discharging chlorine to the atmosphere
until the pressure in the tank is reduced to a level below the PRV start-to-discharge
pressure. At that time, the valve is designed to reseat and function as a pressure relief
valve.
The rupture disc shall be mounted under the pressure relief valve to provide a positive
seal in case the pressure relief valve is broken off or removed. A non-fragmenting
rupture disc is required for this combination system assembly.
6.2 DESIGN AND TESTING REQUIREMENTS
Pressure relief valves shall meet the following design and testing requirements:
• Flow requirements per AAR M-1002 Appendix A (9.4.1);
• Pressure relief device requirements per 49 CFR 179.15;
• Start-to-discharge requirements per 49 CFR 173.314(k); and
• Thermal protection systems and analysis per 49 CFR 179.18 (9.2.1).
6.3 KEY COMPONENTS
The needle valve tell-tale indicator or port must be incorporated between the rupture disc
and reclosing portion of the pressure relief device.
6.4 MAINTENANCE
A pressure relief device service interval shall be defined for each valve design. It is
recognized that this service interval will be influenced by the process conditions present
at the loading and unloading sites. Car owners must determine the proper maintenance
interval for their fleets within federal guidelines to prevent service failures.
7. VALVE MARKING
Tank car valves must be approved by the AAR Tank Car Committee in accord with AAR
M-1002 tank car specification requirements. Valves and rupture disc holders on tank
cars must be permanently marked or tagged per AAR M-1002, Appendices A, C and D
(9.4.1).
7.1 RUPTURE DISC HOLDER ASSEMBLY
The rupture disc or a metal tab attached to the pressure relief valve must be marked to
indicate the following:
• The name or identifying mark of the manufacturer

10 PAMPHLET 168
• Burst pressure, psi (or psi and kPa)
• The lot number
7.2 PRESSURE RELIEF VALVE
The marking may be placed on the valve or plate(s) securely fastened to the valve.
Markings must include the following and be maintained for the life of the valve:
• Manufacturer's design or type number
• Serial number
• Set pressure, psi (or psi and kPa)
• Official flow capacity, cubic feet per minute (or cubic feet per minute and
cubic meters per second) of air at standard conditions
• Flow rating pressure, psig (or psig and kPa)
7.3 LIQUID AND VAPOR VALVES
All valves with a net free flow area of more than ½ square inch (323 square millimeters)
must be marked to indicate the following:
• Manufacturer's design or type number
• Serial number (effective for valves built after July 1, 2013)
• Type of trim
• Pressure-temperature limitations
8. OPERATION AND INSTALLATION CONSIDERATIONS
8.1 GENERAL
The design and functionality of dual valve systems are different than the traditional
valves (angle and excess flow valves) that have been in service for many years, so they
require special operation and installation considerations that may not have been given
with other designs.
8.2 LOADING CONDITIONS
With regard to chlorine loading operations, dual valve systems should be evaluated on a
case-by-case basis before implementing them into service. Loading conditions vary
significantly throughout the chlor-alkali industry, some of which may impact the
performance of the dual valve systems. Maintaining the integrity of valve components,
with respect to flow, primarily depends on the differential pressure and velocity of
chlorine through the valve.
Because of the properties of chlorine, more extreme loading conditions (i.e. high flow
rates and/or large differential pressure) can create dual phase flow, which is the
simultaneous flow of chlorine gas and liquid through the valve. The drastic effect of dual
phase flow can cause flashing and cavitation of the chlorine which can result in
damaging effects, such as erosion, accelerated corrosion and fatigue, to the internal
components of the valves. This issue requires more consideration for dual valves
system because the spring-loaded check valve is in the flow path, whereas in other
designs the excess flow valve is more forgiving with these effects.
Some shippers have commonly loaded through gas valves only, or through a
combination of gas and liquid valves. In a traditional chlorine valve system, there are no
excess flow valves under the gas valves. When transitioning to the use of dual valves,
caution should be taken when considering loading only through the gas valves, or gas
and liquid valves at the same time. The design of the dual valves has a check valve in
the flow path of all the valves, which can create a disturbance in the thermodynamic flow
of chlorine through the valves at higher flow rates, creating a risk of flashing inside the
dual valves during loading. The fact that eduction pipes are not installed under the gas
valves causes an even higher risk of flashing inside the gas valve during loading.
Therefore, shippers should be cautious of loading at high rates through either the gas or
liquid valves.
For the reasons discussed above, it is imperative that tank car owners work with the dual
valve manufacturers to evaluate the loading conditions, to which the valves will be
exposed, before implementing them into their tank car fleet. This process will help
owners determine if the valves will maintain integrity through its life cycle at those
conditions or if parameters should be changed in their loading operation to meet that
goal.
8.3 VALVE INSTALLATION
Because of the change in design of the liquid and vapor valves and the pressure relief
device, care must be taken to ensure that errors are not made during installation that
can impact the functionality of the valves.
Liquid and Vapor Valves
In dual valve systems, the globe valve and check valve are designed to function as a
pair. To ensure this functionality, the manway plate must be machined within the exact
tolerances provided by the valve manufacturer. If these tolerances are not precise,
opening/closing of the valve can cause damage and result in the valve not functioning
properly, which can potentially cause a chlorine release during operation or transit.
Pressure Relief Devices
The combination pressure relief device design covered by this pamphlet has changed
the way the rupture disc is attached to the relief valve and manway plate compared to
12 PAMPHLET 168
previous designs. When removing pressure relief devices for inspection/repair, it is

crucial that the same design device is reinstalled on the manway plate. Reinstalling an
older design pressure relief device (see CI Pamphlet 66 (9.1)) where a current design
pressure relief device was installed can result in two rupture discs in series, which
impacts the devices ability to relieve pressure as designed. This scenario can potentially
cause a dangerous situation, so tank car owners must ensure the correct pressure relief
device is installed.
9. REFERENCES
9.1 CHLORINE INSTITUTE REFERENCES
The following publications are specifically referenced in CI Pamphlet 168. The latest
editions of CI publications may be obtained at http://www.chlorineinstitute.org.
Pamphlet & DVD # Title
66 Recommended Practices for Handling Chlorine Tank Cars; Ed.

5, Pamphlet 66; The Chlorine Institute: Arlington, VA 2015.
95 Gaskets for Chlorine Service; Ed. 5, Pamphlet 95; The

Chlorine Institute: Arlington, VA 2014.
164 Reactivity and Compatibility of Chlorine and Sodium

Hydroxide with Various Materials; Ed. 2-R1, Pamphlet 164;
The Chlorine Institute: Arlington, VA 2007.
IB/C Instruction Booklet: Chlorine Institute Emergency Kit "C" for

Chlorine Tank Cars and Tank Trucks; Ed. 10, Pamphlet IB/C;
C-DVD How to Use the Chlorine Institute Emergency Kit "C" for
Chlorine Tank Cars and Tank Trucks, Ed. 2, Video; C-DVD;
DWG 103A-3 Typical Dimensions for 20” Manway Cover Plate (with 4
valves and center PRD), Drawing; DWG 103A-3; The Chlorine
Institute: Arlington, VA 2015.
DWG 103B-3 Typical Dimensions for 18” Manway Cover Plate (with 3
valves and off center PRD), Drawing; DWG 103B-3; The
Chlorine Institute: Arlington, VA, 2015.
DWG 103C-4 Typical Dimensions for 20” Manway Cover Plate (with 3
valves and off center PRD), Drawing; DWG 103C-3; The
Chlorine Institute: Arlington, VA 2015.
DWG 167-8 Chlorine Tank Car Marking, Drawing; DWG 167-6; The
Chlorine Institute: Arlington, VA, 2015.
9.2 DOT REGULATIONS
9.2.1 Code of Federal Regulations. Title 49. Parts 100-185. Office of the Federal Register
National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).
9.3 TRANSPORT CANADA REGULATIONS
9.3.1 Canadian Transportation of Dangerous Goods Act and Regulations; Transport Canada:
Ottawa, Ontario, 2009. Website: http://tc.gc.ca/tdg.
9.3.2 Containers for Transport of Dangerous Goods by Rail, a Transport Canada Standard
(TP14877E); Transport Canada: Ottawa, Ontario, 2013.
9.4 AAR PUBLICATIONS
9.4.1 Manual of Standards and Recommended Practices, M-1002, Section C, Part III,
Specifications for Tank Cars; Association of American Railroads: Washington, DC, 2014.
9.5 ASME STANDARDS
9.5.1 Valves - Flanged, Threaded and Welding End, ASME B16.34, an ANSI standard; The
American Society of Mechanical Engineers: New York, NY, 2013.
9.5.2 Process Piping, ANSI/ASME Code for Pressure Piping; ASME B31.3, an ANSI standard;
The American Society of Mechanical Engineers: New York, NY, 2014.
9.6 OTHER CHLORINE INSTITUTE PUBLICATIONS
The following publications provide useful information in addition to the publications

referenced herein. The latest editions of CI publications may be obtained at
http://www.chlorineinstitute.org.
Pamphlet # Title
1 Chlorine Basics; Ed. 8, Pamphlet 1; The Chlorine Institute:
Arlington, VA 2014.
6 Piping Systems for Dry Chlorine; Ed. 16, Pamphlet 6; The

Chlorine Institute: Arlington VA 2013.
49 Recommended Practices for Handling Chlorine Bulk

Highway Transports; Ed. 9, Pamphlet 49; The Chlorine
Institute: Arlington, VA 2009.
57 Emergency Shut-Off Systems for Bulk Transfer of Chlorine;

Ed. 6, Pamphlet 57; The Chlorine Institute: Arlington, VA
2015.
14 PAMPHLET 168
For further assistance and information on items referenced, contact:
Association of American Railroads American Chemistry Council

425 Third Street, S.W. 700 Second St., NE
Washington, D.C. 20024 Washington, DC 20002
202-639-2100 202-249-7000
www.aar.org 202-249-6100 (Fax)
http://www.AmericanChemistry.com
Superintendent of Documents
Government Printing Office American Society of Mechanical Engineers
732 N. Capitol Street, N.W. United Engineering Center
Washington, DC 20402 345 East 47th Street
202-512-1800 (Sales) New York, NY 10017
http://www.access.gpo.gov 212-705-7740
1-800-843-2763 (publications)
U.S. Department of Transportation
1200 New Jersey Ave., S.E. Transport Canada
Washington, D.C. 20590 330 Sparks Street
202-366-4000 Ottawa, ON K1A 0N5
www.dot.gov 866-996-9737 (toll free)
613-990-2309 (direct)
Association of American Railroads (AAR)
Transportation Technology Center, Inc. The Chlorine Institute
(TTCI) 1300 Wilson Boulevard, Ste. 525
5500 DOT Road Arlington, VA 22209
Pueblo, CO 81001 703-894-4140
877-999-8824 703-894-4130 (Fax)
719-584-7157 (Fax) http://www.chlorineinstitute.org
http://www.aar.org
APPENDIX A – RECOMMENDED CHLORINE TANK CAR

FITTINGS ARRANGEMENT CRITERIA
For chlorine tank cars built after June 12, 2015, the fittings and manway plate
arrangement are recommended to meet the following performance criteria.
1. Number of Product Valves
Fittings arrangements should include 4 product valves and one pressure relief device
in the center.
2. Manway Size
A 20-inch manway should be installed and should be equipped with grab iron bar
assemblies to accommodate C-Kit application.
3. Valve Mounting
It is recommended that pressure plates be designed with a common mounting

interface that would accommodate any manufacturers’ valves, if possible. See CI
Drawings 103A, B and C.
4. Valve Interchangeability
Valves should not allow for interchangeability between manufacturers’ components.
5. C-Kit Application
Valves should be designed to accommodate the 6A or 24A hood without requiring

removal of any valve parts except the outlet plug. In addition, tank cars should have
a decal that indicates when a 24A C-Kit hood is required. See CI Drawing 167.
6. Excess Flow Valve
An excess flow valve is not required to be designed as part of a dual valve system, if
installed.
16 PAMPHLET 168
APPENDIX B – VALVE INFORMATION
This appendix contains information on valves that meet these guidelines and are approved for
use on chlorine bulk transportation in North America. The information has been provided by the
valve manufacturer. Questions on the content should be sent to the appropriate company.
Valve information included herein:
Crosby Pressure Relief Valve and Salco Products Rupture Disc Assembly
1. Pressure Relief Valve for Chlorine Service, JQ-RD-375
2. Pressure Relief Combination System Layout
3. Rupture Disc Holder
descote SAS
1. 1” Standard Angle Valve (Bellows Sealed) + Internal Ball Check for Chlorine
Railroad Tank Cars, Model 922
2. One Inch Pneumatically Operated Valve for Chlorine Tank Car, Model 925
Midland Manufacturing Corp.

1. 1” Angle Valve
2. 1” Check Valve
3. Top Style Safety Valve with Rupture Disc Holder
PRESSURE RELIEF DEVICE FOR CHLORINE SERVICE
1. Manufacturer Name: Pentair Valves & Controls

Address: 55 Cabot Blvd., Mansfield, MA
Phone No.: (508) 594-4490
2. Valve Type/Name: Crosby 1-1/2” 1-1/2” JQ-RD-375
3. Valve Drawing: DS-139-1004 (JQ-RD-375)
4. Key Dimensions: 12.125’ height
5. Materials of Construction: See drawings on pages 18-20
6. Rated Capacity: 4,132 SCFM air (JQ-RD-375)
7. Special Features (seat type, operation, etc.):

• Available with metal-to-metal or elastomer O-ring seat configuration
• To be used with Salco rupture disc holder RD-375 w/ non fragmenting rupture disc
8. Approvals (AAR, DOT, USCG, etc.): SRD-099013
9. Quality Assurance Program: In accordance with Anderson Greenwood Crosby QAM
10. Torque Requirements, Limitations:

• Refer to Instruction Manual PRV application
• For Salco RD-375
• 2 ft. lbs. to secure rupture disc in holder device
• 14 ft. lbs. for disc holder to pressure plate
18 PAMPHLET 168
20 PAMPHLET 168
1” ANGLE VALVE (BELLOWS SEALED)
1. Manufacturer Name: descote SAS

Address: 9 Avenue Jean-Jaures Feyzin, France 69320
Master distributor-USA and Canada: FC Tech,
17546 N. Airline Hwy, Prairieville, LA 70769
Phone No.: (225) 744-3788
Web: www.fctechusa.com
2. Name: descote model 922/926
3. Valve Drawing: 110659 D
4. Key Dimensions: See drawing on page 22
5. Materials of Construction: See bill of materials on drawing
6. Rated Capacity: Cv=16
7. Special Features:
• Bellows seal
• C-Kit Hood 24A compatible
• Hard faced seat soft seated disc
• Handwheel can accommodate Powell or Midland pneumatic closure devices
8. Approvals (AAR, DOT, USCG, etc.): E-079010 attached
9. Quality Assurance Program: ISO and AAR M1002

• Valve closing torque Min. 18.4 ft. lbs. Max. 22.1 ft. lbs.
22 PAMPHLET 168
1” PNEUMATICALLY OPERATED VALVE FOR CHLORINE TANK CAR
1. Manufacturer Name: descote SAS

Address: 9 Avenue Jean-Jaures Feyzin, France 69320
Master distributor-USA and Canada: FC Tech,
17546 N. Airline Hwy, Prairieville, LA 70769
Phone No.: (225) 744-3788
Web: www.fctechusa.com
2. Name: descote model 925/926
3. Valve Drawing: 110519 D
5. Materials of Construction: See bill of materials on drawing
6. Rated Capacity: Cv=16
• Bellows seal
• C-Kit Hood 6A compatible
• Hard faced seat soft seated disc
• Air to open spring fail close with manual override
8. Approvals (AAR, DOT, USCG, etc.): E-079010 attached
9. Quality Assurance Program: ISO and AAR M1002
10. Air/Pneumatic Requirements, Limitations:

• Valve closing Minimum air supply is 60 PSIG and Maximum is 110 PSIG
24 PAMPHLET 168
1” ANGLE VALVE
1. Manufacturer Name: Midland Manufacturing Corp.

Address: 7733 Gross Point Road
Skokie, IL 60077
Phone No.: (847) 677-0333
(847) 677-0138 (fax)
2. Valve Type/Name: 1” Angle Valve
3. Valve Drawing: A-718
5. Materials of Construction: Monel & Hastelloy C for wetted components
6. Flow Coefficient: Cv=20.3 when tested in tandem with the A-180 check
valve
• Seals are mainly elastomers and PTFE sealing against Hastelloy C
• Handwheel moves downward to open
• Handwheel action is counterclockwise to open and clockwise to close
8. Approvals (AAR, DOT, USCG, etc.): AAR E132004
9. Quality Assurance Program: ISO 9001 and AAR M-1002

• Handwheel torque to close the valve should be about 20-25 ft. lbs.
• Minimum torque failure threshold of handwheel – 80 ft. lbs.
11. Maximum Operating Pressure: 500 psig
12. Maximum Operating Temperature: 350°F (limited by elastomer seals)

26 PAMPHLET 168
1” CHECK VALVE

Skokie, IL 60077
Phone No.: (847) 677-0333
(847) 677-0138 (fax)
2. Valve Type/Name: 1” Check Valve
3. Valve Drawing: A-180
6. Flow Coefficient: Cv=20.3 when tested in tandem with the A-718 Angle
Valve

• Seals are mainly elastomers and PTFE sealing against Hastelloy C
• Valve utilizes a spring to maintain a constant seal until activated by the A-718
angle valve
• Monel, Hastelloy C, Inconel x750 and Stellite components for better corrosion
resistance
• All components can be serviced through the top of the plate
• Special tool required to remove components, T-A-180
8. Approvals (AAR, DOT, USCG, etc.): AAR E082001

• Torque required to compress the PTFE seal in the plug is 55 ft-lbs.
11. Maximum Operating Pressure: 500 psig
12. Maximum Operating Temperature: 350°F (limited by elastomer seals)

28 PAMPHLET 168
TOP STYLE SAFETY VALVE WITH RUPTURE DISC HOLDER

Skokie, IL 60077
Phone No.: (847) 677-0333
(847) 677-0138 (fax)
2. Valve Type/Name: Top Style Pressure Relief Valve with Rupture Disc
3. Valve Drawing: A-14378-ML
6. Flow Rate: 7299 scfm

•
• Soft seated valve for a more consistent seal
• Tantalum rupture disc
• Independent mounting of rupture disc holder to pressure plate
8. Approvals (AAR, DOT, USCG, etc.): AAR PRD 082006

• Torque required to tighten rupture disc flange components is 12 ft-lbs.
• Torque required to tighten rupture disc holder to pressure plate is 25 ft-lbs.
30 PAMPHLET 168
DRAWINGS
(Full versions of CI drawings can be obtained upon request).
32 PAMPHLET 168
34 PAMPHLET 168
36 PAMPHLET 168
1300 Wilson Boulevard « Suite 525 « Arlington, VA 22209
Telephone: (703) 894-4140 « Fax: (703) 894-4130
Email: pubs@CL2.com « Website: www.chlorineinstitute.org
THE CHLORINE INSTITUTE Technical inquiries: techsvc@cl2.com
©The Chlorine Institute all rights reserved.

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1.1 PURPOSE AND SCOPE

1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM

1.4 DEFINITIONS AND ACRONYMS

In this pamphlet the following meanings apply unless otherwise noted:

AAR Association of American Railroads

ASME American Society of Mechanical Engineers

ASTM American Society for Testing and Materials

cfm Cubic feet per minute (air)

CFR Code of Federal Regulations

Chlorine Dry chlorine (either gas or liquid)

DOT Department of Transportation (U.S.)

Globe valve A linear motion valve (raising or lowering stem) with a

Institute The Chlorine Institute

psia Pounds per square inch absolute

psig Pounds per square inch gauge

1.7.1 Significant Revisions in Current Edition

2. REGULATORY REQUIREMENTS AND INTERCHANGE STANDARDS

2.1 DOT REGULATIONS

2.2 CANADIAN REGULATIONS

Canadian regulations are covered by Transport Canada (TC) in the Transportation of

2.3 MEXICAN REGULATIONS

The Normas Officiales de Mexico (Official Mexican Standards) often referred to as

2.4 AAR STANDARDS

• be operable by hand without the use of wrenches

• maintain integrity of exterior finish

4. VALVE DESIGN AND MATERIALS OF CONSTRUCTION

4.1 VALVE DESIGN

4.1.1 Design Pressure

4.1.2 Design Temperature

Valves shall be rated for a minimum process temperature of -40°F (-40°C).

4.1.4 Emergency Kit Application

4.1.6 Criteria for Future Tank Car Builds

4.2 MATERIALS OF CONSTRUCTION

Table 4.4. Materials of Construction Successfully Used in Chlorine Valve Service

5. LIQUID AND VAPOR VALVES

5.1 VALVE TYPES

5.1.1 Globe Angle Valve

5.1.2 Check Valve

5.2 VALVE PAIRING

5.4 VALVE CONNECTION

5.6 KEY COMPONENTS

Figure 5.1. Typical Handwheel Design

5.6.2 Closing/Turning Torque

6. PRESSURE RELIEF SYSTEM

The pressure relief system recommended in this pamphlet is considered a combination

6.2 DESIGN AND TESTING REQUIREMENTS

• Flow requirements per AAR M-1002 Appendix A (9.4.1);

• Pressure relief device requirements per 49 CFR 179.15;

• Start-to-discharge requirements per 49 CFR 173.314(k); and

• Thermal protection systems and analysis per 49 CFR 179.18 (9.2.1).

6.3 KEY COMPONENTS

7.1 RUPTURE DISC HOLDER ASSEMBLY

• The name or identifying mark of the manufacturer

• Burst pressure, psi (or psi and kPa)

• The lot number

7.2 PRESSURE RELIEF VALVE

• The name or identifying mark of the manufacturer

• Manufacturer's design or type number

• Set pressure, psi (or psi and kPa)

• Flow rating pressure, psig (or psig and kPa)

7.3 LIQUID AND VAPOR VALVES

• The name or identifying mark of the manufacturer