9 - GEST 17 492 Edition 2 - Specifications and Approval Procedure For Valves To Be Used in Liquid Cl2...

Specifications and Approval Procedure
for Valves to be Used in Liquid Chlorine

or Dry Chlorine Gas
GEST 17/492
January 2021
2nd Edition
EURO CHLOR PUBLICATION

This document can be obtained from:
EURO CHLOR – Rue Belliard 40, Box 15 – 1040 Brussels
E-mail: eurochlor@cefic.be Internet: http://www.eurochlor.org
GEST 17/492
2nd edition
Euro Chlor
Euro Chlor is the European Federation which represents the producers of chlorine and its
primary derivatives.
Euro Chlor is working to:
• Improve awareness and understanding of the contribution that chlorine

chemistry has made to the thousands of products, which have improved our
health, nutrition, standard of living and quality of life;
• Maintain open and timely dialogue with regulators, politicians, scientists,

the media and other interested stakeholders in the debate on chlorine;
• Ensure our industry contributes actively to any public, regulatory or

scientific debate and provides balanced and objective science-based
information to help answer questions about chlorine and its derivatives;
• Promote the best safety, health and environmental practices in the

manufacture, handling and use of chlor-alkali products in order to assist
our members in achieving continuous improvements (Responsible Care).
***********
This document has been produced by the members of Euro Chlor and should not be reproduced in
whole or in part without the prior written consent of Euro Chlor.
In this document, the requirements to get the Euro Chlor Approval are defined. The information is
provided in good faith and was based on the best information available at the time of publication.
The information is to be relied upon at the user’s own risk. Euro Chlor and its members make no
guarantee and assume no liability whatsoever for the use and the interpretation of or the reliance on
any of the information provided.
This document was originally prepared in English by our technical experts. For our members’
convenience, it may have been translated into other EU languages by translators / Euro Chlor
members. Although every effort was made to ensure that the translations were accurate, Euro Chlor
shall not be liable for any losses of accuracy or information due to the translation process.
Prior to 1990, Euro Chlor’s technical activities took place under the name BITC (Bureau International
Technique du Chlore). References to BITC documents may be assumed to be to Euro Chlor
documents.
January 2021 Page 2 of 84

GEST 17/492
2nd edition
RESPONSIBLE CARE IN ACTION
Chlorine is essential in the chemical industry and consequently there is a need for chlorine to
be produced, stored, transported and used. The chlorine industry has co-operated over many
years to ensure the well-being of its employees, local communities and the wider
environment. This document is one in a series which the European producers, acting through
Euro Chlor, have drawn up to promote continuous improvement in the general standards of
health, safety and the environment associated with chlorine manufacture in the spirit of
Responsible Care.
The voluntary recommendations, techniques and standards presented in these documents are
based on the experiences and best practices adopted by member companies of Euro Chlor at
their date of issue. They can be taken into account in full or partially, whenever companies
decide it individually, in the operation of existing processes and in the design of new
installations. They are in no way intended as a substitute for the relevant national or
international regulations which should be fully complied with.
It has been assumed in the preparation of these publications that the users will ensure that
the contents are relevant to the application selected and are correctly applied by
appropriately qualified and experienced people for whose guidance they have been prepared.
The contents are based on the most authoritative information available at the time of writing
and on good engineering, medical or technical practice but it is essential to take account of
appropriate subsequent developments or legislation. As a result, the text may be modified in
the future to incorporate evolution of these and other factors.
This edition of the document has been drawn up by the Euro Chlor Equipment working Group
to whom all suggestions concerning possible revision should be addressed through the offices
of Euro Chlor.

GEST 17/492
2nd edition
Table of Contents
1 Foreword .......................................................................... 7
2 Scope .............................................................................. 7
3 Valve selection ................................................................... 8
3.1 Globe valves ................................................................................. 8
3.2 Ball valves .................................................................................... 8
3.3 Valves for transport containers and storage tanks ..................................... 9
4 Construction ...................................................................... 9
4.1 Pressure and temperature design ........................................................ 9
4.2 Corrosion and erosion allowance ........................................................ 10
4.3 Stem sealing ................................................................................ 10
4.4 Drain tapping ............................................................................... 10
4.5 End flanges and the body to bonnet flange ............................................ 11
4.6 Bolting ....................................................................................... 11
4.7 Indicator..................................................................................... 11
4.8 Anti-static design .......................................................................... 12
5 Materials and manufacturing ................................................ 12
5.1 General ...................................................................................... 12
5.2 Restrictions on chemical analysis and physical properties of steel ................. 12
5.3 Impact requirements ...................................................................... 12
5.4 Castings...................................................................................... 12
5.5 Forgings ..................................................................................... 15
5.6 Packing and gaskets ....................................................................... 16
5.7 Finishing welding ........................................................................... 16
5.8 Welding (including armouring and hard facing overlay) .............................. 18
6 Examination .................................................................... 18
7 Pressure testing ................................................................ 19
7.1 General ...................................................................................... 19
7.2 Hydrostatic pressure testing of components ........................................... 19
7.3 Pneumatic testing of assembled valves ................................................. 20
8 Other tests...................................................................... 21
8.1 Functional testing .......................................................................... 21
8.2 Leak test for valves without bellow seals .............................................. 21
9 Test and material certificates ............................................... 21
9.1 Test certificates............................................................................ 21
9.2 Material certificates ....................................................................... 22
10 Marking .......................................................................... 22
10.1 General ...................................................................................... 22
10.2 Body marking ............................................................................... 22
10.3 Identification plate marking.............................................................. 22
10.4 Additional body marking and identification plate marking .......................... 23
11 Preparation for dispatch...................................................... 23
11.1 General ...................................................................................... 23
11.2 Painting...................................................................................... 23
11.3 Final drying and blanking ................................................................. 23
12 Design requirements for flanged steel globe valves ...................... 24
12.1 Description .................................................................................. 24
12.2 Nominal sizes ............................................................................... 24
12.3 Body.......................................................................................... 24

GEST 17/492
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12.4 Bonnet ....................................................................................... 25

12.5 Stem ......................................................................................... 26
12.6 Yoke/Bridge and pillars ................................................................... 26
12.7 Yoke bush/Stem nut ....................................................................... 26
12.8 Bellows seal ................................................................................. 26
12.9 Auxiliary packed gland .................................................................... 27
12.10 Bellows leakage detection tappings ..................................................... 27
12.11 Disc and disc nut ........................................................................... 28
12.12 Operation and actuation .................................................................. 29
12.13 Mechanical strength ....................................................................... 31
13 Design requirements for flanged steel ball valves ........................ 32
13.1 Description .................................................................................. 32
13.2 Nominal sizes ............................................................................... 32
13.3 Body.......................................................................................... 32
13.4 Bonnet ....................................................................................... 35
13.5 Ball and seat ................................................................................ 36
13.6 Stem ......................................................................................... 36
13.7 Gland housing .............................................................................. 37
13.8 Operation and actuation .................................................................. 38
14 Design requirements for valves for storage- and transport containers 40
14.1 Operating conditions ...................................................................... 40
14.2 Basic functions ............................................................................. 41
14.3 Accessories / Design principles .......................................................... 41
14.4 Valve operation ............................................................................ 43
14.5 External valve design ...................................................................... 44
14.6 Internal valve design ...................................................................... 45
14.7 Pneumatic actuator........................................................................ 46
14.8 Manual override (not for valves on transport containers) ............................ 47
14.9 Materials of construction ................................................................. 47
14.10 Production testing ......................................................................... 48
15 Enquiry and ordering information ........................................... 51
16 Maintenance instructions ..................................................... 51
16.1 Definition.................................................................................... 51
16.2 General principals ......................................................................... 52
16.3 Removal of valves .......................................................................... 52
16.4 Repairs....................................................................................... 52
16.5 Inspection ................................................................................... 53
16.6 Preparation for service.................................................................... 54
16.7 Storage ...................................................................................... 54
16.8 Certification ................................................................................ 55
16.9 Installation .................................................................................. 55
16.10 Commissioning .............................................................................. 55
17 Approval of the valves specified under this document .................. 55
17.1 General ...................................................................................... 55
17.2 Application by valve manufacturer ...................................................... 56
17.3 Receipt of application by Euro Chlor .................................................... 56
17.4 Production quality assurance............................................................. 56
17.5 Technical specification approval ........................................................ 57
17.6 Valve testing ................................................................................ 57
17.7 Operating experience ..................................................................... 57

GEST 17/492
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17.8 Review by Euro Chlor ...................................................................... 58

17.9 Issuing of certificate....................................................................... 58
17.10 Modification of approved/verified valve ............................................... 58
17.11 Periodic review ............................................................................. 59
18 Procedure to be used by the inspection body ............................. 59
18.1 Quality assurance .......................................................................... 59
18.2 Technical specification evaluation ...................................................... 61
18.3 Production examination ................................................................... 63
18.4 Mechanical strength test .................................................................. 65
18.5 Inspection report ........................................................................... 66
18.6 Documents for the Euro Chlor master file .............................................. 66
19 References ...................................................................... 66
Appendix 1: Standards ....................................................................... 67
Appendix 2: Examples of statistical casting inspection of production batches ...... 70
Appendix 3: Approval diagram & requirements for independent inspection body .. 71
Appendix 4: Field test report ............................................................... 71
Appendix 5: Mechanical strength test procedure for globe valves .................... 72
Appendix 6: Globe valve and part list ..................................................... 73
Appendix 7: Ball valve and part List ....................................................... 78
Appendix 8: Assembly of a pneumatically operated storage tank valve .............. 80
Appendix 9: Assembly of a pneumatic operated transport container valve .......... 81
Appendix 10: Removal and Decontamination Procedure ................................. 82

GEST 17/492
2nd edition
1 Foreword
This new document replaces all Euro Chlor documents of valves in liquid chlorine and dry
gaseous chlorine. With this new document there is one document taking care of the design
principles, specification, maintenance requirements and the approval process for globe
valves, ball valves and double lock valves (with internal/external valves) to be used on storage
tanks and transport containers. All described valves can be used in liquid chlorine and gaseous
dry chlorine gas. Other types of valves are used in chlorine application (e.g. butterfly valves
in dry gaseous chlorine) but so far Euro Chlor does not have specifications for the type of
valves.
With this document the following documents are no longer valid: GEST 06/318, GEST 75/46,
GEST 76/53, GEST 80/85, GEST 86/128, GEST 86/129, GEST 93/180, GEST 96/220, GEST
94/201 and GEST 94/204.
Where specific standards are cited in this document it is generally accepted that an
equivalent recognized standard may be used at the preference of the manufacturer. When
choosing to take advantage of this option it is the manufacturer’s responsibility to
demonstrate the equivalence of the proposed standard. This option has to be agreed between
the valve manufacturer and the buyer
Notes: Where this document uses the word "agreed", this means "agreed in writing" between
the valve manufacturer and the buyer.
2 Scope
This document covers the flanged valves types listed in Table 1 below:
Valve Temperature Nominal sizes

Valve type
material range From To
Flanged globe manual valves with
bellow seal and auxiliary packed gland
Flanged globe control valves with
bellow seal and auxiliary packed gland
- 40 oC + 120 oC DN 25 DN 150
Forged or cast steel
Flanged globe remotely operated shut-

off valves with bellow seal and
auxiliary packed gland
Flanged manual ball valves with
packed gland
-40 oC + 120 oC DN 15 DN 50
Flanged remotely operated ball valves
with packed gland
Valves for chlorine transport
containers and storage tanks -40 oC + 50 oC DN 25 DN 150
containing an internal and an external
valve
Table 1 - Valve type and service range
Use of valves outside these nominal sizes is generally not recommended for liquid chlorine.
However, in certain well documented, correctly engineered circumstances, this may be
acceptable.

GEST 17/492
2nd edition
The Chapters 3 to 11 of this document cover the general requirements for all valves types.
Chapter 12 covers the specifics for flanged globe valves, Chapter 13 covers the flanged ball
valves and Chapter 14 valves used on transport containers and storage tanks.
Chapter 15 contains information that should be specified on enquiries and orders for valves
meeting the requirements of this specification.
Chapter 16 contains information on the maintenance of the valves.
Chapters 17 and 18 contain the information on how to get Euro Chlor approval for the valves.
3 Valve selection
3.1 Globe Valves
Flanged steel globe valves are strongly recommended for liquid chlorine and are also used in
dry chlorine gas applications.
Globe valves are recommended to be used for primary isolation, i.e. on all chlorine
connections to fixed chlorine storage tanks and in all pipework systems.
The requirements here defined relate specifically to standard bore, outside screw-and-yoke
(or pillars and bridge) globe valves, straight and angle patterns, with bolted bonnet and
packed gland.
3.2 Ball valves

Ball valves are used in dry chlorine gas applications but in some specific situations, ball valves
can be used on liquid chlorine where they offer some advantages:
➢ Locations such as loading points for drums and cylinders, vent points and purge points,
where their ease of operation can be helpful;
➢ In dual-stream relief systems, which can benefit from their low pressure drop;
➢ At the end of the filling connections for road and rail tankers, to prevent ingress of
wet air;
➢ Where their line size opening is helpful in situations where a pig may need to be used
for pipeline cleaning.
Requirements are given here for full bore and reduced bore straight through ball valves of
one-piece body with top entry or two-piece split body, quarter turn and packed gland. The
ball may be seat supported (floating ball) or trunnion mounted.
However, when ball valves are used, it is essential that globe valves in accordance with this
recommendation should be used as means of primary isolation i.e. on all chlorine connections
to fixed chlorine storage tanks and in all pipework systems.
Remarks for ball valves:
➢ Ball valves are not recommended to be used under operating conditions which involve
exposure to frequent or large variations in temperature;
➢ Due to the high coefficient of expansion of chlorine in the liquid state, reliable means
for relieving hydraulic expansion pressure should be provided for the liquid trapped in
the valve;

GEST 17/492
2nd edition
➢ The tightness of the valve depends on the surface condition of the ball. Therefore,
ball valves are not intended to be used in any situation where impurities in the chlorine
could cause corrosion or erosion;
➢ Use of ball valves on mobile containers is forbidden;
➢ Fitting of actuators is very straightforward with ball valves, but the speed of opening
or closing must be carefully checked to avoid any possibility of pipework damage as a
result of liquid hammer.
3.3 Valves for transport containers and storage tanks

This are pneumatically operated valves for use on fixed storage tanks or mobile transport
tankers for liquid chlorine and directly mounted on the tank. It comprises an assembly of an
internal valve, an external valve (double lock), a pneumatic actuator, a manual override and
accessories.
4 Construction
Valve design shall fit the requirements of the European Pressure Equipment Directive
2014/68/EU respectively of the European Transportable Pressure Equipment Directive
2010/35/EU.
4.1 Pressure and temperature design

PN 40 (according to EN 1092-1) or class 300 (according to EN 1759-1) will be used for valves
in liquid chlorine applications and PN25, PN 16 or class 150 for valves in dry gaseous chlorine
when the design pressure for the system allows these lower pressures.
PN 16 valves are only allowed when the (gas) operating pressure is below 6 bar(g).
It is generally recommended that the maximum operating pressure of valves in liquid or
gaseous chlorine service should not exceed approximately 80% of the maximum allowable
pressure of the valve (see example in the graph 1).
Graph 1 - Maximum allowable/operating pressure for valves
The minimum pressure shall take into account the possibility of full vacuum when drying the
piping or equipment.

GEST 17/492
2nd edition
The pressure-temperature ratings of valves to this specification shall be in accordance with

the relevant specification for the valve pressure designation and the materials concerned. All
valve components will meet the pressure-temperature rating of the body.
The requirements of pressure-temperature rating for ball valves are indicated in Chapter 13
(this does not apply for the globe valves as they have hard faced seats).
The lower temperature limit of minus 40°C takes into account the possible undercooling due
to chlorine vaporisation slightly below atmospheric pressure.
The upper temperature limit of 120°C is the recommended maximum temperature for the
use of carbon steel on chlorine duties.
4.2 Corrosion and erosion allowance

The valve body wall thickness will be calculated/selected according to the EN 12516 -1 to
12516-3 for EN-Valves and ASME B16.34 for ANSI-valves. To allow for corrosion/erosion the
calculated value has to be increased with a safety margin. This safety margin is:
• For di ≤ 50 mm → C = 1,5 mm;

• For 50 mm < di ≤ 250 mm → C = 0,0175·di + 0,625 mm;
• For di > 250 mm → C = 5 mm
di is the DN size of the valve (see also the graph and table below).
DN-size Corrosion &

of the erosion
valve allowance
in mm
25 1.50
40 1.50
50 1.50
80 2.03
100 2.38
150 3.25
Graph 2: Relation between valve size and corrosion+ erosion Table with corrosion
allowance to be used. and erosion allowance
4.3 Stem sealing

The stem sealing of globe valves for liquid chlorine application will be realised with a bellow
plus an auxiliary gland packing.
For ball valves, the stem sealing can only be realised by gland packing.
4.4 Drain tapping

Drain tappings in the body are not permitted.

GEST 17/492
2nd edition
4.5 End flanges and the body to bonnet flange

End flanges and flange facings for PN 40 valves shall comply with the requirements of EN
1092-1 and end flanges for Class 300 valves shall comply with the requirements of ASME B16.5
or EN 1759-1.
The user shall specify the type of flange face required. The flange face finishing is defined in
the previous mentioned standards; it will be B1.
For raised flanges, the gasket contact surface shall have either a serrated concentric or
serrated spiral finish.
4.6 Bolting
Bolting shall be in accordance with Unified inch or ISO metric standards. All stud bolts etc.
shall extend fully through their nuts with full effective thread engagement, not including the
chamfered threads, when tightened.
Tapped holes for studs shall be of sufficient depth that the thread engagement is at least
equal to the nominal thread diameter.
The bolting of the bonnet shall be composed of at least four stud bolts/studs of the following
minimum sizes (first row specific for ball valves, two last rows specific for globe valves):
Valve nominal size Minimum nominal size of stud bolt/stud

DN NPS Metric UNC (inch)
15, 20 1/2, 3/4 M10 3/8
25, 40 & 50 1,1½ & 2 M 12 1/2
80 & 100 3&4 M 16 5/8
150 6 M 20 3/4
Table 2 - Stud bolt/stud minimum nominal size
Remark: bolts of a smaller diameter may be accepted if sufficient dimensioning is proved.

The length of the body to bonnet bolts should be reduced to the minimum necessary for the
flange thicknesses and gasket spaces. This arrangement is to limit the risks of differential
thermal expansion between the bolts and the internal parts of the valve and hence the risk
of a leak from the body to bonnet joint.
The bonnet flange bolting should use stud bolts passing through plain holes in the flange, with
a nut at each end.
Stud bolts/studs shall comply with the requirements as specified in GEST 88/134 - Stud Bolts,
Hexagon Head Bolts and Nuts for Liquid Chlorine.
4.7 Indicator
Each valve shall be fitted with an indicator which clearly indicates the fully open and fully
closed positions of the valve.
Where the lever is used to indicate the position of the ball port of ball valves, the method of
fitting the lever shall not permit incorrect assembly and be arranged so that the lever lies
parallel to the line of flow/the ball port when the valve is in the open position.

GEST 17/492
2nd edition
4.8 Anti-static design

Where specified by the user, valves shall incorporate anti-static devices ensuring electrical
continuity between the valve stem and valve body of nominal size DN50, NPS2 or smaller.
Where a larger valve is designed using the principles of this specification, it should have
electrical continuity between the valve body, stem and disk/ball. The design shall be agreed.
Anti-static devices shall be protected against external contamination.
The anti-static valves shall have electrical continuity across the discharge path with a
resistance not exceeding 10 ohms from a power source not exceeding 12 volts DC in
accordance with ISO 7121.
5 Materials and manufacturing

5.1 General
Materials shall be suitable for use with liquid and gaseous chlorine (see GEST 79/82 -
Materials of Construction for Use in Contact with Chlorine). The use of alternative
materials shall be agreed. Material proposed for gland components other than virgin PTFE
shall be resistant to an atmosphere containing wet chlorine.
Cast iron shall not be used.
Stainless steel bolting shall not be used (risk of stress corrosion cracking) (see GEST 88/134
- Stud Bolts, Hexagon Head Bolts and Nuts for Liquid Chlorine).
5.2 Restrictions on chemical analysis and physical properties of steel

Notwithstanding anything to the contrary in the material specification for steel, the following
restrictions shall apply to forgings and castings (minimise the risk of hydrogen cracking
associated with welding):
1) The carbon content shall not exceed 0.25 per cent.
2) The carbon equivalent (CE) shall not exceed 0.43 per cent on heat analysis and 0.45 per
cent on product analysis, when calculated with the full formula:
Mn Cr + Mo +V Ni + Cu
(CE ) = C + + +
6 5 15
where C, Mn, Cr, Mo, V, Ni, Cu are expressed as % composition of steel.
3) They shall be in the normalised condition or annealed and tempered condition.
4) The actual maximum tensile strength of any component shall not exceed the lesser of:
• The minimum required by the relevant material specification plus 155 N/mm2,
• 725 N/mm2.
5.3 Impact requirements

Impact testing is required as described in the GEST 79/82 - Materials of Construction for
Use in Contact with Chlorine.
5.4 Castings
Good casting design is critical to enable the foundries to achieve high and repeatable casting
quality, especially around large changes in thickness.
Body and bonnet castings shall comply with the requirements as specified in Paragraph 5.2.
Castings shall not be peened, plugged or impregnated.

GEST 17/492
2nd edition
Each manufacturer will appoint body and bonnet casting manufacturers for their valves with
whom they will work to ensure the necessary quality levels are delivered on a repeatable
basis. The appointed producers shall be notified to Euro Chlor at the time of application for
homologation.
In case of new casting design, casting design changes, casting process change or any change
of casting manufacturer, prototype testing of the affected casting is required. The quality
acceptance level for the prototype testing shall be conforming to Table 3.
Euro Chlor shall be notified in advance of any prototype testing.
Each manufacturer shall comply with the follow requirements:
5.4.1 Pilot batch testing
Following the completion of successful prototype castings, and prior to casting of full-scale
production batches, pilot batches shall be completed for the following cases:
a) any new valve design,
b) any existing valve design where castings are modified,
c) any existing casting design when manufactured at a new foundry for the first time,
d) any change in foundry casting process.
The pilot batch shall consist of at least 5 parts from each casting type.
Radiographic and surface testing (See 5.4.2 and 5.4.3) shall be completed for 100% of all cast
parts from the pilot batch.
The quality acceptance level for the prototype and the pilot batch shall be conforming to
Table 3 prior to any weld repair.
5.4.2 Radiographic examination
Radiographic examination of each tested part shall cover 100% volumetric coverage of the
casting The radiography plan, including positions of films and sources, shall be approved by a
third-party non-destructive testing practitioner of EN 473 level 3 or equivalent. All
radiography and interpretation of radiographs shall be completed by non-destructive testing
practitioners of EN 473 level 2 or equivalent.
All pilot and production castings subjected to radiographic examination must meet the
required quality levels as documented in Table 3; the radiographic inspection will be
performed according to EN 12681 or equivalent.
Discontinuity type Category Acceptable comparative plate

ASTM E446 level 2
Prototype, pilot batch and production

testing
Gas porosity A A2
Sand and slag inclusions B B2
Shrinkage: type 1 C CA2
type 2 C CB2
type 3 C CC2
type 4 C CD2

GEST 17/492
2nd edition
Cracks D None
Hot tears E None
Inserts (chills, chaplets) F None
Mottling G None
Table 3 - Casting quality assurance procedures acceptance levels
5.4.3 Surface testing
All casting surfaces are 100% tested by magnetic particle (as defined in ISO 4986) or dye
penetrant examination at the foundry (as defined in ISO 4987). For both types of examination,
acceptance criteria are severity levels SM2, LM2 (AM2) and SP2, LP2 as given in the standards
ISO 4986 and ISO 4987. If unacceptable defects are found they shall be rejected or repaired
(see paragraph 5.7).
5.4.4 Batch Size
The production melt batch size shall be limited to 2 tonnes unless agreed otherwise.
The temperature shall be controlled between the beginning and end of pouring to avoid
generating unacceptable defects.
A batch can be composed of different patterns (a pattern refers to a particular part -bonnet
or body- of a particular size). The number of castings which constitute a batch shall be agreed
at the time of homologation (Euro Chlor valve type approval process), but the following are
typical examples for batches of single valve size:
DN50 NPS 2 Number of castings <50

Table 4 - Number of castings per batch
5.4.5 Production batch testing
Two approaches may be taken to testing of casting production batches:

i. 100% of each production casting shall be subjected to complete radiographic and surface
examination as described above. Each casting is then accepted, repaired or rejected.
This may be an economical approach for larger castings in particular.
ii. If a pilot batch and 5 additional production casting batches with minimum 5 castings per
batch for a particular casting pattern has been produced that were fully compliant with
the acceptance levels set out above, then a statistical procedure may be applied as
follows.
The method of statistical casting inspection shall be agreed with the valve manufacturer
at the time of homologation (Euro Chlor valve type approval process) but shall as a
minimum include the 100% radiographic and surface testing of one casting from each
pattern in the batch and amounting to a total of at least 10% or 3 pieces per batch
(whichever is greater), applying the acceptance criteria of Table 3 in Paragraph 5.4.2
without any repair, except for those detected by surface testing (see examples in
Appendix 2).

GEST 17/492
2nd edition
If any of the castings selected for testing contain unacceptable defects the whole batch
shall be rejected, or all the other castings in the batch shall be similarly tested and
repaired if necessary.
5.5 Forgings
Note that the requirements for forgings detailed below make reference to standard EN 10222-
1, which nominally applies to “open-die” type forgings only. However, for the purposes of
this recommendation document, the criteria shall be applied as stated to closed-die forgings.
Body and bonnet forgings shall be of a “closed die” type. Materials shall comply with the
requirements of EN 10222-1 or equivalent national standards and with the stipulations given
in GEST 79/82 - Materials of Construction for Use in Contact with Chlorine.
Well-designed forging tooling and process should ensure high quality repeatable forgings. The
following qualification and inspection processes shall be used to control forging quality.
5.5.1 Pilot batch testing of forgings
Pilot batches shall be completed for the following cases:

a) any new forging design,
b) any existing design where forging tooling is modified,
c) any existing forging design when manufactured at a new forge for the first time,
d) any other change in forging process.
The pilot batch shall consist of at least 5 parts for each forging.
100% of pilot forgings shall be subjected to non-destructive testing in accordance with the
requirements of Paragraphs 5.5.1.1 and 5.5.1.2. No repair is permitted prior to the non-
destructive testing but the forging surface may be prepared for inspection in accordance with
EN 10228-1 and -2. All forgings from a pilot batch shall successfully conform to the required
standards before the forging design is considered fit for production forging. All non-
destructive testing shall be completed by practitioners of EN 473 level 2 or equivalent.
5.5.1.1 Surface examination
Surface examination of 100% of the external surfaces of every forging shall be carried out in
line with EN 10222-1 option A6 (magnetic particle to EN 10228-1). Acceptance criteria shall
be according to EN 10228-1 quality class 3.
5.5.1.2 Ultrasonic examination
Volumetric examination of 100% of forgings from the pilot batch shall be carried out in line
with EN 10222-1 option A5 (ultrasonic examination to EN 10228-3). Acceptance criteria shall
be according to EN 10228-3 quality class 3.
5.5.2 Production forgings
Following successful documented completion of pilot batches of forgings, production forging

can commence. The following testing shall be carried out for production forgings (no
volumetric testing of production forgings is required given successful pilot batch testing).
5.5.2.1 Ultrasonic examination of bar stock
100% of the raw bar stock intended for use in forgings shall be subjected to ultrasonic
examination in accordance with EN 10308 (this may be completed by the supplying steel mill).
Acceptance criteria shall be according to EN 10308 quality class 3.

GEST 17/492
2nd edition
5.5.2.2 Surface examination of production forgings

Following forging and necessary surface preparation, surface examination of 100% of the
external surfaces of every forging shall be carried out in line with EN10222-1 option A6.
Acceptance criteria shall be according to EN 10228-1 quality class 3. Indications outside of
this acceptance level may be repaired as described in EN 10228-1, followed by a repeat of
the examination.
5.6 Packing and gaskets

Material for the auxiliary gland packing and for gaskets shall be suitable for continuous use
on chlorine at the pressure designation over the temperature range minus 40°C to +120°C,
and resistant to moist chlorine atmosphere.
Gland packing made in rings or chevrons of solid PTFE or unfilled PTFE from virgin material
(free of reclaimed processed material) is recommended. Alternative materials may be
proposed with supporting information.
The gasket between the valve body, the valve bonnet and the split body flange (ball valves)
shall be of a PTFE based material that minimises cold flow or PTFE with a metal insert of a
type suitable for use with dry chlorine. Other non-asbestos gasket materials already used with
satisfactory results on similar applications by Euro Chlor members are also accepted (See also
GEST 94/216 - Experience of Gaskets on Liquid and Dry Chlorine Gas Service).
5.7 Finishing welding

Production weld repairs refers to the repair by welding of valves to be used for dry gaseous
or liquid chlorine duty, during the casting, and subsequent machining procedures, prior to
assembling of the finished product.
The basic principle is that any non-conformity detected prior the assembly of the valve
components should be reported to a responsible as defined in the quality system of the valve
manufacturer with a repair proposal submitted to his approval.
5.7.1 Allowable areas for welding
Repairs to critical areas are not allowed. Critical areas are areas where homogeneity of
material properties is required. Typical critical areas are bridges, flange necks and areas
adjacent to valve seats.
5.7.2 Allowable defects for welding repairs
Defects in allowable areas may be repaired in accordance with the following policy:
➢ Surface defects of up to 20% of wall thickness may be removed by grinding subject to
the remaining wall thickness being greater than that specified in the relevant Euro Chlor
recommendations. No welding required;
➢ Surface defects of up to 40% of the wall thickness may be repaired by grinding and
welding, subject to the wall thickness after grinding being of greater than 3 mm, and
the original thickness being restored by welding;
➢ In all other cases the component shall be rejected.
In the case of casting defects detected by foundry statistical process control, only this rough
casting may be repaired. If the foundry or valve manufacturer wishes to use all of the rough
castings from the batch, each casting shall be inspected and repaired or rejected as
appropriate.

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5.7.3 Repair specifications
The valve manufacturer shall clearly identify where the expertise for production weld repairs
lies, with themselves, or the foundry.
5.7.3.1 Welding process
The welding process and consumables used shall be demonstrated to be suitable for welding
to the substrate valve material.
The deposited weld metal shall have mechanical and metallurgical properties compatible
with the valve material, including tensile strength and impact toughness, at the design
conditions (minimum allowable temperature (tS) according to EN 764-1).
Where welding is necessary, a low heat input welding procedure is recommended: Welding
processes GTAW (141), GMAW (131) or small diameter SMAW (111) according to ASME Section
IX / ISO 4063 standard can be used.
5.7.3.2 Welding procedure
Repair welding procedure specifications shall be written in accordance with EN 288-1 or an
agreed equivalent which shall be identified, e.g. ASME IX.
5.7.3.3 Welding procedure approval
The welding procedure approval shall be approved by a notified body or an authorised third
party in accordance with EN 288-3.
5.7.3.4 Welder approval
The welder, working to an approved welding procedure shall be qualified in accordance with
ISO 9606-1.
5.7.3.5 Weld finishing
The weld should be ground back to reinstate the original component profile.
5.7.4 Inspection of repairs
It is essential that weld repairs are subject to inspection to ensure that they are free of
cracks. Inclusions and defects shall be within the limits defined in the relevant welding
standards.
Inspection methods and acceptance standards shall be agreed in writing between the valve
manufacturer and the user.
Inspection methods as specified in the European standards may include the following:
➢ For surface defects:
• Visual testing (VT)
• Penetration testing (PT)
• Magnetic testing (MT)
➢ For sub-surface defects:
• Radiographic testing (RT)
• Ultrasonic testing (UT)

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5.7.5 Repair map
The valve manufacturer shall maintain records for a period of at least ten years from the date
of despatch of the order. available to the user, of production weld details for each valve, as
described in this specification.
In addition, each valve shall carry with it a drawing, displaying the location and size, and
depth of production weld repairs, which have involved grinding and welding clearly marked
on the drawing.
The “typical” valve drawings contained in this specification, may be considered as bases for
the repair map drawing, although the valve manufacturer/foundry may prefer to use their
own drawings for the purpose.
5.8 Welding (including armouring and hard facing overlay)

The welding, armouring and hard facing overlay procedures will be developed and qualified
in accordance with the ISO 15607 standard and with EN 13480-4 Paragraph 9. The impact
properties shall have been met in qualifying the welding procedures with the exception of:
➢ hard facing;
➢ all bellows welds, including longitudinal weld and welds to end-rings and valve
bonnet/stem.
Adjustment and repair shall be in accordance with EN 13480-4 Paragraph 10.
In process inspection and testing shall be in accordance with EN 13480-5 Paragraph 7.
Non-destructive testing shall be in accordance with EN 13480-5 Paragraph 8.
Following documents shall be made available to the user for a period of at least ten years
from the date of despatch of the order:
➢ WPS (Welding procedure specifications);
➢ WPQR (Welding procedure qualification records);
➢ Welder Qualification (including welder identification);
➢ Reports of adjustments, repairs and hard facing overlay;
➢ In process inspection and test reports/results;
➢ Non-destructive testing reports/results.
The welding procedure adopted shall be submitted to Euro Chlor for approval.
6 Examination
This paragraph provides a summary of requirements for examination; additional details are
to be found in the referenced Chapters.
1) Castings shall be examined according to the requirements of Paragraph 5.4.;
2) Forgings shall be examined in accordance with Paragraph 5.5.;
3) All components shall be examined to ensure conformity with the manufacturing
drawings. The examination shall include a check on wall thickness;
4) During manufacture, all machined seating surfaces and prepared weld areas shall be
examined using dye penetrant to prove that there are no evident imperfections;
5) Each bellow assembly shall have a visual examination, dye penetrant examination and
gas porosity examination;

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6) Examination, 100% by radiography, of butt welds on pressure retaining parts. This shall
follow any heat treatment of the welds, see also Chapter 7;
7) Examination of all completed welds using a dye penetrant technique. There shall be no
evident imperfections;
8) Any additional non-destructive examination specified in the purchase order;
9) Early leak and hydrostatic tests may be carried out for pressure retaining valve parts,
e.g. castings and bellows;
10) All assembled valves shall be visually examined;
11) All completed valves shall be pressure tested, see Chapter 7;
12) All anti-static valves shall have electrical continuity as specified in Paragraph 4.8 when
tested in accordance with EN12266-2 (F21/F22).
The valve manufacturer shall maintain suitable records for a period of at least ten years from
the date of despatch of the order in order to demonstrate that all the examination
requirements have been met.
7 Pressure testing
7.1 General
Each valve shall be tested in accordance with:
➢ EN 12266-1
• P10 (body strength), P11 (body tightness), P12 (seat tightness only for shut-off
valves);
• Except that for P11 the test fluid shall be a gas and the pressure shall be 1.1 x
allowable pressure at room temperature;
• Except that for P12 the test fluid shall be a gas and the pressure shall be 1.1 x
design pressure at room temperature;
• Acceptance criteria: Rate A (no visual detectable leakage during test).
➢ Paragraphs 7.2 and 7.3 of this specification (similar to EN 12266-1 with different
conditions)
Obturator test according to EN 12266-2, P20, can be required according to the purchase
order.
Note: the obturator test in EN 12266-2, P20, can only be performed if the surface of the
obturator can be observed, as the acceptance criterion is leakage from the surface of the
obturator; it is almost impossible to perform this test on small bore globe valves (this test
was originally developed for butterfly valves or end of line valves).
7.2 Hydrostatic pressure testing of components

Early hydrostatic tests parts may be carried out for pressure retaining valve parts, e.g.
castings and bellows. A pressure test with (dry) gas as a test medium is allowed when there
is an agreement on this between the buyer and manufacturer.
After completion of all machining each valve shall be hydrostatically pressure tested. The
test pressure shall be according to EN 12266-1, P10.
Visible leakage shall be cause for rejection.

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After testing, all parts shall be dried (3 hours at 120oC) prior to assembly and new gaskets
shall be used.
7.3 Pneumatic testing of assembled valves

7.3.1 General
Before the pneumatic testing of assembled valves is undertaken, each component shall have
previously successfully withstood the hydrostatic pressure test as specified in Paragraph 7.2.
All valves, prior to painting or coating, shall be pneumatically tested in accordance with
Paragraph 7.3.2 and 7.3.3. The test gas shall be oil free and the dryness shall be equivalent
to that at a dew point of minus 40°C. No part of any assembled valve shall be immersed in
water.
7.3.2 Body test
Each assembled valve shall be pneumatically pressure tested as follows:

1) The body ends shall be blanked so that the valve is not constrained;
2) The valve shall be in the partly open position (all body cavity pressurised);
3) For cast bodies and bonnets, a low-pressure test to 4 barg to highlight wall casting
defects that could be missed in the following high-pressure test. This test pressure shall
be maintained for at least one minute;
4) The test pressure shall be 1.1 times the design pressure of the valve at 20°C, appropriate
to the pressure designation. The pressure shall be maintained for at least two minutes;
5) Bellow sealed valves shall be tested without the (auxiliary) gland packing.
Visible leakage testing using a bubble forming solution shall be cause for rejection on both
the low pressure and high-pressure tests.
The auxiliary stuffing box of globe valves shall be thoroughly dried before fitting the auxiliary
gland packing.
7.3.3 Seat test
Each completely assembled valve shall have a pneumatic seat test according to EN 12266-1
P12, as follows:
1) The valve shall be closed in the normal manner respect the maximum force;
2) The test pressure shall be applied from the inlet end of the body (underside of the disc
for globe valves), with the outlet blanked and having a connecting pipe to a bubble test
rig;
3) The test pressure shall be 1.1 times the design pressure of the valve at 20° C,
appropriate to the pressure designation. The test pressure shall be maintained for at
least two minutes.
The acceptance rate will be “A” in the case of manual and automatic shut-off valves and in
the case of control valves (globe valves) see chapter 12.11.2.

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8 Other tests
8.1 Functional testing
Each valve shall be tested in accordance with EN 12266-2 F20, confirming the valve operates
over its design range of travel and that open and shut indicators are correctly positioned.
The mechanical strength shall also be examined after testing the shut off-of the valve and
shall include checks for:
➢ Premature wear or damage to the spindle assembly;
➢ Damage to the seat or plug.
8.2 Leak test for valves without bellow seals

For all kind of valves only equipped with stuffing box (and not with bellow seal with additional
stuffing box) a leak test according to ISO 15848-1 shall be carried out in the scope of the
homologation process (Euro Chlor approval) This test shall be carried out for each two of the
three valves selected according to Paragraph 18.3.2 (Inspection and tests by the independent
inspection body). The independent inspection body shall examine the related reports (look at
Paragraph 18.3.3).
The test gas shall be helium.
The tightness class BH shall be achieved.
If not specified by the buyer, all kind of shut-off valves shall achieve strength class CO1 (N =
205 mechanical load cycles) and all kind of control valves shall achieve strength class CC1 (N
= 20.000 mechanical load cycles).
If not specified by the buyer, the temperature class shall cover the range from -40°C up to
120°C.
The leak test shall be carried out with the specified mounting parameters of the stuffing box,
given in the operating manual of the valve.
9 Test and material certificates

9.1 Test certificates
The valve manufacturer shall provide with each order (also for valves with sizes outside this
specification):
➢ A certificate that contains:
o A confirmation that each valve has been manufactured and tested in
accordance with the requirements of this specification and the purchase order,
o The test pressures and the fluids used;
➢ Impact test certificates of pressure retaining part materials.
The valve manufacturer will retain all tests results (including non-destructive ones like
radiographic films made at the foundry…) for a period of at least ten years from the date of
despatch of the order.

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9.2 Material certificates

Type 3.1 material certificates shall be provided for all the following valves components
according to EN 10204: body, bonnet, bellow, stem, disc/ball, seat and disc hard facing. For
the bolting (bolts and nuts), type 2.2 material certificate shall be provided.
The documentation shall also list the references of the material certificates provided with
the raw materials used in the manufacture of the body, bonnet, stem, bellow, disc seating,
body seat and bolting (Valve trim materials are to be considered as primary pressure
boundary, because the valves must be suitable as isolation valves).
The original material certificates shall be retained by the valve manufacturer for a period of
at least ten years from the date of despatch of the order.
10 Marking
10.1 General
Marking shall be in accordance with EN 19.
Each valve shall be legibly marked with the body marking and identification plate marking
specified in 10.2 and 10.3 respectively.
10.2 Body marking

Body marking shall be integral with the body. As required by EN 19 Table 1, the marking shall
include at least the following:
1) Nominal size designation (DN xx, NPS yy etc. as appropriate);
2) Pressure designation (for example PN xx or Class yyy as appropriate);
3) Body material identification;
4) Valve manufacturer's name or trademark;
5) An arrow indicating the preferred direction of flow (the tail indicating the high
pressure of the valve);
Note: for globe valves, the preferred direction of flow is from under the disc.
6) The melt identification for castings, as well as foundry trade mark or symbol (as
required by EN 12569).
10.3 Identification plate marking

The identification plate shall be securely fixed to the valve body and/or bonnet (or in case
of valves on transport containers on the flange). The marking shall include (based on EN 19
Table 1) the following:
1) Allowable operating temperature (= minus 40°C to 120°C unless otherwise specified
by the user);
2) Allowable operating pressure (with indication “GAS ONLY” if pressure rating below
PN40/class 300, cf. chapter 15);
3) Valve trim identification of stem, disc seating and body seat material (globe valves)
or ball and body seat materials (ball valves);
4) Valve type number;
5) Design construction standard (and reference to this Euro Chlor GEST 17/492
recommendation); Euro Chlor homologation reference;
6) Valve manufacturer's serial number (the number that identifies the valve in all
respects);

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7) The words "bellow seal" and the bellow material for globe valves; at the option of the
manufacturer this may be on a separate plate; the word “stem seal” and the stem
seal material for ball valves;
8) Year of Production;
9) CE MARK (with Notified Body No) where applicable; at the option of the manufacturer
this may be on a separate plate;
10) “Anti-static” for valves with anti-static design.
10.4 Additional body marking and identification plate marking

Additional body marking and identification plate marking may be used providing they do not
conflict with the requirements as specified in Paragraphs 10.2 and 10.3.
If there is only one identification plate (as indicated in Paragraph 10.3), the manufacturer's
serial number shall be marked on the body (body connector if any) and bonnet.
11 Preparation for dispatch

11.1 General
Each valve shall be clean, dry and free from all hydrocarbon grease, oil or solvents.
Components which require to be lubricated (even if not in direct contact with chlorine, such
as the thread on a globe valve stem) shall be treated with chlorine compatible chloro-
fluorinated grease.
Machined and threaded surfaces shall be coated with chlorine compatible chloro-fluorinated
rust inhibitor and the ends of the valve blanked.
11.2 Painting
Prior to priming, all external surfaces shall be suitably cleaned to remove all traces of grease
or dirt (mask first the ends of valve and part to be protected). This may be done by mechanical
or chemical means. In the case of cast or forged materials this shall ensure the complete
removal of sand, rust or scale.
One coat of anti-rust primer and an agreed top-coat system shall be applied to all external
un-machined surfaces not made from a "stainless steel", with intermediate air drying as
required. The final paint shall then be applied.
The stem and gland follower shall be free from primer/paint.
11.3 Final drying and blanking

Each valve shall be dried with air and then in an oven at 120°C for at least three hours. After
drying, but before blanking, the valve shall be stored for cooling in a way which prevents
moisture condensation, e.g. in the oven or other chamber, with a dry gas purge (dew point
lower than minus 40 °C), or under sealed vacuum.
After the valve is removed from the oven and before the temperature of the valve body falls
below 35°C, both the inlet and outlet flanges shall be fitted with suitable gaskets and metal
blank flanges having silica gel sachets or an agreed alternative attached to their inner faces.
The blank flanges shall be securely bolted to the valve flanges and shall be watertight and
airtight.

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12 Design requirements for flanged steel globe valves

12.1 Description
This chapter details the design requirements for three types of valves:
➢ Flanged steel globe valves, bellow sealed;
➢ Process control valves, bellow sealed;
➢ Remotely operable shut off valves, bellow sealed.
These high integrity valves with standard bore and rising stem can be in forged or cast steel,
with straight or angle pattern, with screw and yoke or pillar and bridge.
12.2 Nominal sizes

the range of nominal sizes shall be as follows:
➢ DN25, DN40, DN50, DN80, DN100 and DN150;
➢ NPS1, NPS1½, NPS2, NPS3, NPS4 and NPS6;
➢ Where nominal sizes outside this range are necessary, the philosophy of this
specification shall be adopted.
The minimum nominal size of DN25 (NPS1) is specified for reasons of mechanical strength.
Small diameter globe valves (DN15 (NPS½) and DN20 (NPS¾)) shall only be used for
instrumentation and for filling cylinders/drums but separated from the process line by a DN25
(NPS1) valve.
In general, valves larger than DN150 are not recommended for use on liquid chlorine due to
the risks associated with large volumes.
12.3 Body
12.3.1 Body construction
The body shall be a flanged one-piece forging or casting. For control valves it is allowed to
create additional space for the bellow via a separate piece
Forged components are recommended for nominal sizes equal to or less than DN50 / NPS2
due to the higher quality components that can be achieved using this method of production.
12.3.2 Body end ports and seat bore
The body end ports and the seat bore shall be circular and not less than the dimensions given
in Table 6 below. The flow-way area between the body end ports shall be not less than the
body end port area.

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Nominal size Body end port inside diameter Nominal packing width
and seat bore ± 5% (Packing Gland)
NPS DN (mm) (mm)
1 25 25 5.0
1½ 40 40 6.0
2 50 50 6.0
3 80 80 6.0
4 100 100 8.0
6 150 150 8.0
Table 6 - Body end port inside diameters and nominal packing width
12.3.3 Face-to-face and centre-to-face dimensions
The preferred face-to-face dimensions for straight pattern valves and the centre-to-face
dimensions for angle valves shall comply with the following:
Pressure Straight valves face-to-face Angle valves centre-to-face

designation
PN40 EN 558 EN 558
Basic Series 1 Basic Series 8
ASME Class 300 EN 558 EN 558
Table 7 - Face to face and centre to face dimension standard
Valves with different face to face dimensions can also be approved under the condition that
they also fulfil all other specifications and requirements of this document.
12.4 Bonnet
The minimum wall thickness of the bonnet shall comply with the principle as presented in
Paragraph 4.2.
The body to bonnet connection shall be of circular form and flanged with male and female
and fully trapped gasket or with tongue and groove facings.
Where a back seat is provided in the bonnet, a means of preventing trapping liquid chlorine
in the bellow chamber shall be provided.
Welding is permitted in order to assemble the bellows into the bonnet. Weld quality shall be
inspected and demonstrated to be satisfactory, see Paragraph 12.8.
The bonnet shall incorporate an auxiliary packed gland seal external to the bellows (and the
bellows weld) to prevent leakage to atmosphere if the bellows should fail, see Paragraph
12.9.
Welding is permitted in the construction of the bonnet and stuffing box, but any weld that
directly separates chlorine from atmosphere must be a full penetration butt weld subjected
to 100% radiography. This requirement does not concern the case where there is a secondary
sealing after or before the weld.

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All welding is to be carried out in accordance with Paragraph 5.8.
12.5 Stem
The stem in the packing area shall be of the rising, non-rotating type which shall be prevented
from rotating by provision of a spline or similar arrangement. The quality of other proposed
solutions has to be demonstrated.
A single piece stem is recommended when external corrosion of the coupling can be a
concern. In the case of two-piece stems, the manufacturer shall prove that the strength of
the coupling can withstand at least 3 times the maximum operating load in the opening
direction in accordance with Paragraph 12.13.2. A forged coupling is recommended.
The surface of the stem that moves within the packing shall have a surface finish of 0.4 µm
Ra or smoother.
The out of roundness of the stem (the difference between the maximum diameter and the
minimum diameter measured at the same cross section) shall not exceed 0.01 mm.
Prior to assembly the stem shall not deviate from straightness by more than 0.005% of the
length of the stem.
The transmission threads shall be of a profile type not sensitive to dust or sand and preventing
galling and stress concentration (for example ACME trapezoidal type).
12.6 Yoke/Bridge and pillars

The yoke may be integral with, or separate from, the bonnet or in the form of a bridge
mounted on pillars. The pillars shall be through bolted and securely held in place with
hexagon nuts. For valves with nominal sizes up to and including DN50, pillars may be screwed
into the bonnet if this is accepted during the homologation.
The pillars shall not be used for the body to bonnet flange joint fastenings.
12.7 Yoke bush/Stem nut

The yoke bush/stem nut shall be threaded to suit the stem and designed to withstand the
maximum opening and closing forces defined in Paragraph 12.13.2. The transition between
the outside diameter of the barrel of the yoke bush/stem nut and its collar shall be by a
radius of at least 0.4 mm.
12.8 Bellows seal

The construction should be high nickel base alloy (for example Hastelloy C276®) bellow
welded to high nickel alloy supporting rings, reducing corrosion to a minimum.
A list of approved producers for the bellow shall be provided by the manufacturer at the time
of application for approval. Euro Chlor shall be notified in advance of any change of supplier.
The bellows seal arrangement shall prevent leakage past the stem to atmosphere.
The bellows shall have a minimum of two plies.
The bellows of manual or actuated on-off valves shall have a guaranteed minimum life of
10,000 cycles (fully open - fully close- fully open) at the maximum allowable operating
pressure of the valve at 20°C. For control valves, the bellows have to be guaranteed for at
least 100,000 cycles (fully open -fully close- fully open) at the maximum allowable operating
pressure of the valve at 20°C.

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The bellows ends shall be welded. The weld procedures (including preparation and
examination), welder approval and testing shall be agreed between the valve manufacturer
and the Euro Chlor working group.
A number of options for welding the bellows to its supporting components exist. It is
recommended that the supporting components and the bellows are of the same material. The
drawing shall clearly identify the materials of the bellows and supporting component
separately.
The bellows shall not protrude into the main area of flow.
12.9 Auxiliary packed gland

An auxiliary packed gland seal shall be included. This shall be external to the bellows (and
the bellows weld) to prevent leakage to atmosphere if the bellows should fail. The gland shall
be externally adjustable.
12.9.1 Stuffing box
Where the stuffing box is a separate component, the connection and sealing of the stuffing
box to the bonnet must comply with the requirements and restrictions on welding set out in
Paragraph 12.4.
The stuffing box shall be flat bottomed and have a minimum depth of five rings of packing.
Other designs are possible if proven that at least a similar performance can be guaranteed.
The inner surface of the stuffing box shall have a surface finish of 3.2 µm Ra or smoother.
12.9.2 Gland follower
The packing gland should be of a one piece or a two-piece self-aligning design (i.e. gland
flange with gland follower). Vertically split gland followers are not permitted. The gland
flange shall have holes (not slots) for two bolts. The gland follower shall have a shoulder at
its outer end to prevent complete entry into the stuffing box.
There shall be an O ring or similar seal to prevent ingress of water between the gland follower
and the stem. A second seal should prevent ingress of water between the gland follower and
the auxiliary stuffing box. These are to prevent water ingress into the packing and gland area
and possible holing of the bellow due to water freezing and expanding inside the bellow. This
design ensures water cannot enter the gland in the event of the packing becoming loose.
12.9.3 Gland bolting
Gland bolting shall be one of the following:

a) Stud bolts passing through plain holes in the flange of the bonnet neck. Each stud bolt
shall be secured to the flange by two nuts (one on either side of the flange).
b) For diameters up to 50 mm, the use of studs may also be accepted.
12.10 Bellows leakage detection tappings

Tappings to the interspace between the bellows seal and the auxiliary packed gland shall not
be provided unless specifically requested by the customer user.

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When a tapping is requested, it shall be sealed by a suitable plug. The plug shall be designed
for the design pressure of the valve over the temperature range minus 40°C to +120°C. The
material of the plug shall be suitable for use with chlorine.
12.11 Disc and disc nut

The plug/disc on globe valves shall have a bevelled seating surface and be securely attached
to the stem, independent of the valve assembly, whilst permitting correct alignment and
proper seating. Flat seating is not allowed due to bad experiences in the past due to ferric
trapped between the seats on the flat designs.
The plug/disc nut shall be securely locked in place to prevent loosening in service. The seating
surfaces of plug/disc and seat shall be designed to give line, or very narrow area contact.
Any contact between the bonnet and the disc or disc nut shall not allow the trapping of fluid.
If present, the back seat should not trap liquid chlorine.
12.11.1 Manual and shut-off valves
The minimum radial clearance between the outside diameter of the disc and the inside
surface of the body shall be as indicated in the Table 8 here below:
Valve nominal size Minimum radial clearance
DN NPS (mm)
25 1 1.0
40 1½ 1.25
50 and above 2 and above 1.5
Table 8 - Minimum radial disc-body clearance
When the disc is in the fully open position, the minimum flow area between the disc and the
seat shall be not less than the area of the body end ports.
Hard seats (for example cobalt base alloys, e.g. Stellite™) are required due to their longer
life. Corrosion and mechanical properties of armouring or plating material have to be suitable.
The body seat shall have a minimum hardness value of 300 HB.
12.11.2 Process control valves
The plug/disc and seat shall be renewable to allow the flow rate coefficient Cv to be changed.
The calculation of the dimensions of the plug and seat for flow rate estimation shall be in
accordance with IEC 60534-2-1.
Different types of seal may be used to meet the control requirements. If the valve in the
closed position will normally has a sealing performance with the requirements of EN 12266-1
P12, leakage rate “B” if the customer requires that the control valve also has the function of
tight shut off the leak rate “A” should be specified.
A welded deposit of cobalt base alloy, e.g. Stellite™, hard facing or equivalent weld deposit
material on the valve body seat and plug may be considered if a valve tight in the closed
position is required. Corrosion and mechanical properties of armouring or plating material
have to be suitable.
For special requirements, the user may specify an alternative sealing standard.

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12.12 Operation and actuation

12.12.1 Manual globe valves
12.12.1.1 Method of operation

Unless otherwise specified by the user, valves shall be direct hand wheel operated and each
valve shall be closed by turning the hand wheel in a clockwise direction when facing the top
of the valve.
12.12.1.2 Hand wheel
The hand wheel shall be of the spoke and rim, or closed disc design. Pressed steel hand wheels
are not permitted.
The hand wheel shall be fitted such that it may be replaced, when necessary, but secured so
as to preclude loosening in service.
The valve shall be designed to be operated without the use of a wheel key; use EN 12570
Industrial valves. Method for sizing the operating element
The maximum torque for hand wheel design is defined in Paragraph 12.13.2.
12.12.2 Actuated valves
For the electric parts, the ATEX directive requirements (protection in explosive ambiance)
will be taken into account.
12.12.2.1 Actuator type
12.12.2.1.1 Process control valves
The pneumatic actuator shall be either:
➢ a single acting diaphragm type with an internal return mechanism;
➢ a double acting diaphragm type;
➢ a single acting piston type with an internal return mechanism;
➢ double acting piston type.
Pneumatic pressure when applied to one side of the diaphragm/piston shall cause linear
movement of the pneumatic actuator stem. For single acting actuator the mechanism shall
give a positive return action of the stem when pressure on the diaphragm/piston is released.
A spring return as fail safe function due to the loss of pneumatic pressure shall be used if the
valve has a safety function.
12.12.2.1.2 Shut-off valves
The user shall define the action taken by the valve in the event of control air failure
depending on the specific plant requirements, either:
➢ The valve shall close (fail closed);
➢ The valve shall open (fail open);
➢ The valve shall remain in its position.
For fail open and fail closed valves, the pneumatic actuator shall be either a single acting
diaphragm type with an internal return mechanism or a single acting piston type with an
internal return mechanism. The mechanism shall give a positive return action of the stem
when pressure on the diaphragm/piston is released.

GEST 17/492
2nd edition
If the valve is required to stay in position in the event of a loss of control air the valve shall
be a double acting piston type with an appropriate system to prevent valve movement in the
event of motive fluid failure. Pneumatic pressure when applied to one side of the
diaphragm/piston shall cause linear movement of the pneumatic actuator stem.
12.12.2.1.3 Actuator design
The pneumatic actuator shall be operated at the minimum motive fluid supply pressure and
design pressure specified by the user.
The user should consider variations in these pressures and it is recommended to specify a
motive fluid pressure 30% lower than the minimum available.
The actuator body shall have a minimum ingress protection level of IP55 as defined in EN
60529.
The actuator mechanism shall be suitably lubricated to ensure continued reliable operation
and to prevent corrosion of both the assembly and the local stems.
The actuator housing shall not be vented directly to atmosphere. Any vent hole shall be either
plugged or vented via a moisture removing device. The non-pressure side of the actuator
diaphragm shall be designed in such a way that any trapped gas shall not affect the valve
operation adversely.
The dimensions of the operating mechanism, particularly for the conditions of closing of the
valve, shall be such that it can resist any mechanical stress resulting from the operating
conditions of the valve.
The operating mechanism shall also be designed so that any frost formation due to the liquid
chlorine being transported does not obstruct the movement of the spindle.
The use of a process fluid driven actuator is not permitted for liquid chlorine.
The sizing of the actuator shall be such that it ensures the correct operation of the valve over
the whole of the travel of the stem and for the range of differential pressure which results
across the plug.
The actuator body shall have connections for attachment to both the actuated process valve
bonnet/cover and the manual override and be capable of complying with Paragraph 12.13.2.
O-rings shall be fitted to the stem.
12.12.2.1.4 Process control valves
The safe position of the valve, open or closed, in the case of loss of motive fluid should be
assured by a mechanism which gives sufficient guarantee of reliability (multiple spring, air
reservoir, etc.). This should ensure correct positioning of the valve even under the maximum
operating pressures likely to occur at the plug.
The use of control valves with a manual over-ride is not recommended. Such a mechanism, if
not in the neutral position, can limit the travel of the valve and possibly prevent full closure.
12.12.2.1.5 Shut-off valves
The safe position of the valve, open or closed, in the case of loss of motive fluid should be
assured by a mechanism which gives sufficient guarantee of reliability (multiple spring, air
reservoir, etc.).

GEST 17/492
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If appropriate, this should ensure total closure of the valve even under the maximum
operating pressures likely to occur under the plug.
It shall also permit opening of the valve with the full pressure applied on the plug. Where fail
open or fail closed positioning of the valve has a safety implication, the valve positioning
should be ensured by a spring.
12.12.2.2 Actuator attachment
The attachment of the actuator to the valve shall be by dedicated pillars / bolting. This
bolting shall not be shared with the body to bonnet bolting. Hence it shall be possible to
remove the actuator without affecting the integrity of the valve.
The attachment shall be designed so that there is no confusion regarding which bolting retains
the actuator. This is to ensure that there is minimal risk of undoing the wrong bolting when
removing the actuator.
There shall be a suitable number of pillars to properly support the actuator and associated
possible external forces, e.g. pressure shocks or pipe vibration. Any pillar shall be through
bolted and securely held in place with hexagon nuts. For valve nominal sizes up to and
including DN50, pillars can be screwed into the bonnet. The actuator mounting flange should
be in accordance with ISO 5210.
12.13 Mechanical strength

12.13.1 Control valves not requiring to provide a tight shut off
It is usually the case that control valves are not required to provide tight shut off (normally
rate “B” closure and are used solely to control flow rates. When submitting an application for
Euro Chlor approval, the manufacturer shall propose suitable type testing to demonstrate
adequate mechanical strength of the valve during normal operations.
12.13.2 Shut-off valves (and control valves requiring tight shut off)
Normally control valves do not require tight shut off.

The valve and hand wheel or actuator assembly shall be designed and type tested to withstand
3 times the “normal” load which can be applied to the system by the hand wheel or actuator
or the actuator manual override, whichever is the greater, without the material of any part
yielding and without the operability of the valve and the leak tightness of the gland being
affected.
The maximum hand wheel load during "normal" operation shall be taken as 300 N applied by
each hand. The equivalent torque is therefore (300)*(d) Nm, where "d" is the hand wheel
diameter in metres. See EN 12570
Past experience has shown the value and importance of this requirement. It ensures materials
and components are sufficiently strong to withstand a valve key being used to seal a valve
whose seat was passing.
Examination after testing shall include checks for:
➢ Premature wear or damage to the spindle assembly.
➢ Damage to the seat or plug.

GEST 17/492
2nd edition
13 Design requirements for flanged steel ball valves

13.1 Description
This chapter details the design requirements for high integrity flanged straight through
quester turn ball valves, with packed gland, for use on liquid chlorine. These requirements
are given for full bore and reduced bore ball valves of one-piece body with top entry or two-
piece split body.
It covers straight through valves of PN 40 in nominal sizes DN15 to DN50 inclusive and Class
300 in nominal sizes NPS1/2 to NPS2 inclusive; they can be manually operated or remotely
operable shut off valves.
13.2 Nominal sizes

For ball valves (full and reduced bore), the range of nominal sizes shall be as follows:
➢ DN15, DN20, DN25, DN40, DN50;
➢ NPS1/2, NPS3/4, NPS1, NPS1½, NPS2.
13.3 Body
13.3.1 Body construction
The body shall be either one-piece with top entry or two-piece split construction complying
with the following sections (see Figures 3 and 4 below). Three-piece split body valves and
valves having end (axial) inserts are not permitted.
The valve body shall be a one-piece forging or casting having body end flanges and a bonnet
flange. The gland housing shall form part of a separate flanged bonnet.
The valve body shall comprise two flanged, forged or cast components (body and body
connector) each having an integral body end flange and an integral split body connecting
flange. The gland housing shall form an integral part of the body.
The split body connecting flanges (if any) shall have a minimum design strength equivalent to
that of the body end flanges and shall meet the body end flange pressure-temperature
requirements. The flanges shall have bolt holes. The stud bolts shall be equally spaced on the
bolt circle diameter and shall be located off-centre. The use of studs shall be agreed.
The split body connecting flange facings shall be male and female or tongue and groove in
order to trap/constrain the body gasket.

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2nd edition
Figure 3: Ball valve, one-piece top entry body
Figure 4: Ball valve, two pieces split body
The velocity of the chlorine in the bore shall be limited to 2 m/s.
13.3.2 Pressure-temperature rating
The pressure-temperature rating of the valve shall not be less than values in Tables 12 and
13 here below. The ratings are based on the use of unfilled virgin PTFE.

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2nd edition
The body seats shall also be suitable for full vacuum at the specified minimum temperature
of the valve.
Nominal size of valve / Minimum pressure (bar g) for a temperature (°C) of:
Nominal size of Minimum pressure (bar g) for a temperature

valve (°C) of:
Min temp
DN NPS 50 75 90 100 120
to +40
15 1/2 69 66 56 51 47 40
20 3/4 69 66 56 51 47 40
25 1 50 49 48 48 47 40
40 1½ 50 49 48 48 47 40
50 2 50 49 48 48 47 40
Table 12 - Minimum Pressure-Temperature Body Seat Ratings
Unless otherwise agreed, the material used for the body seats shall be unfilled PTFE from
virgin material, free of reclaimed processed material. The body seat pressure-temperature
capability shall comply with the tables here above.
13.3.3 Bolting
For split body flange joint, stud bolts with a nut at each end shall be used, unless otherwise
agreed for small diameters. The diameter, number and material shall ensure that the split
body flanged joint pressure-temperature rating is equivalent to that of the body end flanges.
The stud bolts shall not be less than M12 or ½ inch UNC.
Where a gland flange is used, gland bolting shall be stud bolts passing through plain-holes in
the flange of the bonnet neck. Each stud bolt shall be secured to the flange by two nuts (one
on either side of the flange).
13.3.4 Body end ports and seat bore
The body end ports and the body throat port shall be circular and not less than the dimensions
given in Table 14 below.
Nominal size Body end port inside diameter and Reduced bore ball port minimum
full ball port minimum diameter diameter (mm)
(mm) ± 5% (*)
NPS DN (mm) (mm)
1/2 15 12.5 9
3/4 20 17 12.5
1 25 24 17
11/2 40 37 28
2 50 49 36
(*) on forged bodies, due to machining constraints, this tolerance can go up to ± 10%, in
order to respect the dimension of the raised face gasket surface at the flange
Table 14 - Body end port inside diameters and reduced bore ball port minimum

GEST 17/492
2nd edition
In the case of reduced bore valves there shall be a gradual transition between the body end
ports and the body throat ports.
The flow-way area between the body end ports shall be not less than the body end port area.
13.3.5 Face-to-face and centre-to-face dimensions
The face-to-face dimensions for straight pattern valves and the centre-to-face dimensions for
angle valves shall comply with the following:
Pressure designation Straight valves Angle valves

face-to-face centre-to-face
PN 40 EN 558 EN 558
ASME Class 300 EN 558 NA
Basic Series 4
Table 15 - Face to face and centre to face dimension standard
Valves with face to face dimensions can also be approved under the condition that they also
fulfil all specifications and requirements of this document.
13.3.6 Body cavity relief
Over-pressurisation of the body cavity shall be prevented by relieving the excessive pressure
to the upstream side of the valve. This may be achieved either by:
a) a hole/passage in the body connecting the body cavity to the upstream side of the valve.
This ensures continuous provision of pressure relief, or
b) a hole of at least 3 mm diameter, provided in the ball to connect the body cavity to the
upstream side of the valve. This ensures hydraulic pressure relief of all internal cavities
and of the ball part when the valve is in the closed position and also ensures pressure
relief of the cavity when the valve is in open position.
These provisions make the valve unidirectional; and the direction of the sealing will be
indicated by an arrow. It must be noted that they are only valid for floating ball valve.
There are two types of vented ball valve in use, the directional ball valve with a drilling hole
in the ball and the floating ball valve which is not held in place by a trunnion, it is self-
relieving and bi-directional.
In case of the drilled valve it is important to install it in the proper direction. If it is installed
in the wrong direction it will not seal properly.
Trunnion mounted ball valves must have self-relieving seats and relief hole is forbidden.
The design of the valve shall be such that the valve can only be assembled with the vent hole
in the ball located on the high-pressure side of the valve.
13.4 Bonnet
Integral bonnet/stuffing boxes with no welds directly separating the process fluid from the
atmosphere are required.

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The bonnet shall be a flanged one-piece forging or casting. It shall contain the machined
gland housing which shall be in accordance with the requirements of Chapter 13.7.1. The
bonnet shall be of the extended type.
Welding may be used in manufacture of the bonnet/gland housing assembly only where
existing valve design prevents a single piece bonnet with a machined gland housing, provided
it does not conflict with Paragraph 13.3.
The body to bonnet connection shall be flanged with male and female or tongue and groove
facings (of circular form) in order to trap/constrain the gasket.
The minimum wall thickness of the bonnet shall comply the specified values in Paragraph
13.3.4 here above.
Stud bolts/studs shall comply with the requirements of Chapter 4.6.
13.5 Ball and seat

Only “solid ball” will be allowed. “Sealed cavity ball”, “cored cavity ball” and “hollow ball”
(acc. EN 1983) will not be allowed.
The ball shall be spherical of solid construction having a through cylindrical bore and may be
seat supported or trunnion supported.
Unless otherwise agreed, the spherical surface shall have a polished surface finish in the range
0.08 µm Ra to 0.13 µm Ra.
Plated or coated surfaces are not permitted.
Where a body cavity vent is not provided in the body (Chapter 12.3.6), a 3 mm diameter hole
shall be provided in the ball so as to connect the body cavity to the upstream side of the
valve when the ball is in the closed position.
The clearance between the ball and the inside surface of the body shall be not less than the
minimum values shown in Table 16.
Valve nominal size Minimum clearance

DN NPS (mm)
15 1/2 1.0
20 3/4 1.0
25 1 1.0
40 1½ 1.25
50 2 1.5
Table 16 - Minimum clearance between ball and body
Body seats (seat rings, seat ring assemblies) shall be designed so that they are renewable.
The method of retaining the body seats in the body shall ensure that the turning of the ball
does not cause deformation, scoring or rotation of the body seats due to the operation of the
valve.
Stops shall be provided for both the fully open and the fully closed positions of the valve.
13.6 Stem
The stem shall be either of one-piece design, preferably forged, or integral with the ball.

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2nd edition
The stem shall be sized so that the minimum cross section and connection to the ball can
withstand satisfactorily the minimum lever forces given in Table 17 of Chapter 13.8.1
In the case of the stem not being integral with the ball, the design of the body and the stem
shall ensure that the stem cannot be blown out of the body in the event of the gland retainer
being removed whilst the valve is under pressure.
The surface of the stem that moves within the packing shall have a surface finish of 0.4 µm
Ra or smoother.
The out of roundness of the stem (the difference between the maximum and minimum
diameters measured at the same cross-section) shall not exceed 0.01 mm. Prior to assembly
the stem shall not deviate from straightness by more than 0.005% of the length of the stem.
The stem shall have a double D lever connection (two flat faces, where the lever connects to
the stem, see Figure 5).
Figure 5
13.7 Gland housing

13.7.1 General
The stem sealing will be realised by gland packing externally adjustable.

Where gland compression is by a single nut on the valve stem, the valve stem shall be
threaded so that the stem nut has engagement over the whole circumference of the stem.
The minimum thread engagement shall be at least equal to 0.5 times the nominal thread
diameter of the stem. The nut shall be lockable and made from a material not subject to
attack by a moist chlorine atmosphere.
The inner surface of the gland housing shall have a surface finish of 3.2 µm Ra or smoother.
Where live loaded packing is used the material of the spring washers shall be resistant both
to wet and dry chlorine and to stress corrosion cracking i.e. a high nickel base alloy.
The gland housing shall be integral with the body or bonnet and be flat bottomed.
The body design and bonnet design shall ensure that the travel stop and gland adjustment
are outside the valve insulation and that stem leakage is readily detectable assuming an
insulation thickness of 50 mm or more.

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2nd edition
13.7.2 Sealing device
Where a bolted type of gland is used, the packing gland shall be of two-piece self-aligning
design, i.e. gland flange with gland follower. Vertically split gland followers are not
permitted. The gland flange shall have holes (not slots) for two gland bolts. The gland follower
shall have a shoulder at its outer end to prevent complete entry into the stuffing box.
The gland housing shall be fitted with a double stem seal comprising a primary (lower) stem
seal and a secondary (upper) stem seal. The design may permit detection of leakage of the
primary stem seal.
Primary and secondary stem seals shall have a depth greater than the diameter of the stem
and the total height of the seals shall be greater than twice the diameter of the stem.
the auxiliary stuffing box. These are to prevent water ingress into the packing and gland area.
This design ensures water cannot enter the gland in the event of the packing becoming loose.
13.7.3 Leakage detection / Purge tapping
Tappings to permit purging or testing of the space between the primary and secondary stem
seals, which enables detection of primary stem seal leakage, shall not be provided unless
specified by the buyer.
When tappings are specified they shall be fitted with suitable plugs. The plug and the method
of fitting shall be designed for the design pressure of the valve over the temperature range –
40°C to +120°C. The material of the plug shall be suitable for use with chlorine.
13.7.4 Gland bolting
Gland bolting shall be one of the following:
• Stud bolts passing through plain-holes in the flange of the bonnet neck. Each stud
bolt shall be secured to the flange by two nuts (one on either side of the flange).
• For diameters up to 50 mm, the use of studs may also be accepted.
13.8 Operation and actuation

13.8.1 Manual ball valves
13.8.1.1 Method of operation

Unless otherwise specified by the buyer, valves shall be lever/hand wheel (hand lever)
operated and each valve shall be closed by turning the lever/hand wheel in a clockwise
direction when facing the top of the valve.
The lever/hand wheel shall be fitted so that it may be replaced, when necessary, but secured
to preclude loosening in service
13.8.1.2 Lever/Hand wheel
Each valve shall be capable of withstanding a force applied at the end of the lever/hand
wheel, with the ball held stationary, not less than twice the force given in Table 17 without
the material of any part yielding or significant distortion and without the operability of the
valve and the leak tightness of the ball being affected.

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2nd edition
The length of the lever or diameter of the hand wheel shall be such that a force not exceeding
350 N, when applied to the lever/hand wheel, moves the ball from the open position and
closed position when subject to the maximum differential pressure of the valve.
Nominal size of valve Force

DN NPS (N)
15 1/2 350
20 3/4 350
25 1 450
40 1½ 600
50 2 700
Table 17 - Lever/Hand wheel force
For ball valves with diameters up to 2”, an oval wheel can be used:
➢ to avoid unintentional operation of the valve (due to its low actuating torque).
➢ to avoid slanting of the stem, which allows leaking through stem packing during
operation.
13.8.2 Actuated ball valves
For the electric parts, the ATEX directive requirements (protection in explosive ambiance)
will be taken into account.
13.8.2.1 Actuator type
13.8.2.1.1 Shut-off valve
The buyer shall define the action taken by the valve in the event of control air failure
depending on the specific plant requirements, either:
➢ The valve shall close (fail closed);
➢ The valve shall open (fail open);
➢ The valve shall remain in its position.
For fail open and fail closed valves, the pneumatic actuator shall be either a single acting
diaphragm type with an internal return mechanism or a single acting piston type with an
internal return mechanism. The mechanism shall give a positive return action of the stem
when pressure on the diaphragm/piston is released.
The safe position of the valve should be assured by a mechanism which gives sufficient
guarantee of reliability (multiple spring, air reservoir, etc.) in the case of loss of motive fluid.
If appropriate, this should ensure total closure of the valve even under the maximum
operating pressures likely to occur in the body. It shall also permit opening of the valve with
the full pressure applied on the plug.
If the valve is required to stay in position in the event of a loss of control air the valve shall
be a double acting piston type with an appropriate system to prevent valve movement in the
event of motive fluid failure.
13.8.2.1.2 Actuator design
The pneumatic actuator shall be operated at the minimum motive fluid supply pressure and
design pressure specified by the buyer.

GEST 17/492
2nd edition
The buyer should consider variations in these pressures and it is recommended to specify a
motive fluid pressure 30% lower than the minimum available.
60529.
plugged or vented via a moisture removing device. The non-pressure side of the actuator shall
be designed in such a way that any trapped gas shall not affect the valve operation adversely.
The dimensions of the operating mechanism, particularly for the conditions of closing of the
valve, shall be such that it can resist any mechanical stress resulting from the operating
conditions of the valve.
The operating mechanism shall also be designed so that any frost formation due to the liquid
chlorine being transported does not obstruct the movement of the spindle.
The use of a process fluid driven actuator is not permitted for liquid chlorine.
The sizing of the actuator shall be such that it ensures the correct operation of the valve over
the whole of the travel of the stem and for the range of differential pressure which results
across the plug.
The actuator body shall have connections for attachment to both the external valve
bonnet/cover and the manual override.
O-rings shall be fitted to the stem which shall be suitable for connection to the stem of the
external valve.
13.8.2.1.3 Actuator attachment
The attachment of the actuator to the valve shall be by dedicated pillars/bolting. This bolting
shall not be shared with the body to bonnet bolting. Hence it shall be possible to remove the
actuator without affecting the integrity of the valve.
The attachment shall be designed so that there is no confusion regarding which bolting retains
the actuator. This is to ensure that there is minimal risk of undoing the wrong bolting when
removing the actuator.
There shall be a suitable number of pillars to properly support the actuator and associated
possible external forces. Any pillar shall be through bolted and securely held in place with
hexagon nuts. For valve nominal sizes up to and including DN50, pillars can be screwed into
the bonnet. The actuator mounting flange should be in accordance with ISO 5211.
14 Design requirements for valves for storage- and

transport containers
14.1 Operating conditions
Pneumatically operated valves used on mobile containers for liquid chlorine should be capable
of resisting the static and dynamic forces which may be exerted on them without leading to
any measurable leakage rate in the closed position. The nominal pressure for these valves is

GEST 17/492
2nd edition
PN 25 and the temperature range is from – 40oC to 50oC with the remark that the valves should
be resistant to 120oC for drying conditions.
For fixed storage tanks the nominal pressure will be PN 25 (or class 150) for valves in systems
for gaseous medium and PN 40 (or class 300) for valves in systems for liquid medium.
14.2 Basic functions

The pneumatically operated valve shall fulfil five basic functions:
• Allow safe transfer of liquid chlorine into and out of the tank;
• Provide an external valve capable of a tight seal against the passage of gas or liquid;
• Provide, within the tank, a tight seal in the event of failure of the external valve body
(double lock);
• Provide remote operation;
• Close rapidly.
These functions shall be achieved by the use of:
• Internal valve;
• External valve;
• Actuator;
• Manual override.
14.3 Accessories / Design principles

The functions mentioned here above can be obtained by the use of the items described below.
Appendix 8 shows a typical pneumatically operated valve for fixed storage tank and identifies
the various parts of the valve using the definitions given in this chapter; Appendix 9 shows a
similar drawing for a typical transport container valve.
14.3.1 Internal valve
A spring-loaded check valve located within the tank, opened by the inward movement of the
stem of the external valve when this is opened. It shall be operable remotely, close rapidly
and ensure a gas-tight seal within the storage tank.
For mobile containers, the location and attachment of the internal valve should follow the
dimensions laid down in the UIC 573 document of October 2007.
14.3.2 External valve
A globe type angle valve located outside the tank and directly mounted on the flange of the
internal valve. The external valve shall be leak free, designed and located in such a way that,
in the event of impact, the internal valve will not be damaged. This may be achieved by, for
example, the inclusion of a breaking zone or designed failure point.
For mobile tankers, the overall dimensions of the pneumatically operated external valves
shall be such that they can be completely installed within the normal design of the
tanker/container valve dome taking into account the various design standards for liquid
chlorine tankers (UIC 573 document of October 2007).
The external valve shall have a stem and disc which is directly in line with the internal valve
ball/disc.

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2nd edition
The external valve and internal valve shall be completely independent of each other except
that the external valve stem shall contact and open the internal valve disc/ball during
opening.
14.3.3 Actuator
A valve operator, pneumatically operated, which is of a spring opposed diaphragm or piston

type, giving linear movement of the actuator stem.
For mobile tankers, the usual motive fluid recommended pressure is between 5.5 and 7 barg.
For fixed tanks, the design of the pneumatic actuator shall be such that the stem will operate
with the minimum motive fluid pressure of the user site taking into consideration a maximum
tank pressure of 14.5 barg, unless otherwise agreed by the user.
The pneumatic actuator shall withstand a motive fluid maximum pressure of 10 barg.
The remote rapid closure of the valves shall always be possible to ensure the safety of the
operations.
In the case of failure of the motive fluid to the pneumatic actuator, both external and internal
valves shall close automatically.
Stem Lubrication: if required a lubricator (grease nipple) shall be provided in order to
lubricate the threaded portion of the stem (use only greases compatible with chlorine).
14.3.4 Manual operation facility (manual override)
A device, manually operated, which is fitted to the body of the pneumatic actuator and which
allows manual operation of the external valve stem.
For mobile tankers, the possibility of remote closure must be retained (see Paragraph 14.7).
A security device should be fitted to the manual override so to prevent any unauthorised
operation of the valve for mobile tankers.
14.3.5 Accessories
Devices such as position indicators, micro switches, bellows leakage detectors, etc. are
usually installed on valves for fixed tankers.
For valves mounted on transport containers, the flange of the external valve side branch
should be fitted with a gasket and blank flange and securely bolted after loading or off-
loading; a security device (transport cap) should be fitted so that the external valve remains
gas tight in the event of general vibration during transport and should also hinder any
unauthorised opening of the external valve.
14.3.6 Mounting on the Tank
The pneumatically operated valve shall be capable of being mounted on a special connection,
on the tank, with the internal valve protruding into the storage tank and securely bolted to
the special connection independently of the external valve. For this bolting a maximum tank
pressure of 14.5 barg has to be considered too, unless otherwise agreed by the user. The
external valve shall be mounted in contact with and directly above the internal valve using
studs that pass through holes in the flange of the internal valve and secured to the same
special connection.

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2nd edition
The attachment and gas tightness of the pneumatically operated valve flanged connections
to the storage tank should be studied with particular care. Crevices in which there is a risk
of dirt or moisture accumulating shall, if at all possible, be avoided. Those which are
unavoidable shall be adequately protected against the ingress of moisture by use of suitable
sealing products with an adequate level of permanent elasticity.
14.3.7 Nominal sizes
For fixed tanks, the designation of the pneumatically operated valve nominal size shall be
that of the external valve branch nominal size. The range of nominal sizes shall be as follows:
a) PN pressure valves: DN 25 – DN150
b) Class pressure valves: NPS 1 - 6
For mobile containers, the flange will be DN 80 for the internal valve and DN 40 for the side
branch.
14.3.8 Provisions for inspection and maintenance
The design of the pneumatically operated valve shall allow the following individual
components to be adequately inspected and readily maintained:
a) The internal valve;
b) The external valve;
c) The bellows;
d) The pneumatic actuator, manual override and emergency closing device.
14.4 Valve operation

14.4.1 Normal operation
With no pneumatic pressure acting on the diaphragm the actuator springs shall maintain the
external valve in the closed position. At the same time the internal valve spring shall maintain
the internal valve in the closed position.
The application of pneumatic pressure to the diaphragm shall cause compression of the
actuator springs and move the actuator stem (see appendices 7 and 8). Initial movement of
the stem shall move the external valve disc from contact with its seat. Further movement of
the stem shall result in the external valve stem contacting the internal valve ball/disc.
Still further movement of the stem shall move the internal valve ball/disc from contact with
the seat and compress valve spring. Finally, at full stroke both the external valve and the
internal valve shall be open and the actuator spring(s) and internal valve spring subject to
compressive forces of such magnitude as to cause, upon release of pneumatic pressure from
the diaphragm:
a) The automatic and rapid retraction of the actuator stem;
b) Closure of the internal valve, before closure of the external valve;
c) Closure of the external valve.
14.4.2 Failure of pneumatic pressure
Upon failure of pneumatic pressure to the diaphragm, the pneumatically operated valve shall
respond in the same way as release of pneumatic pressure (see 15.4.1).

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14.4.3 Manual control
The manual override shall permit the manual control of the actuator stem and the external
valve stem.
14.4.4 Emergency closure
In the case of unintentional loss of pneumatic pressure on the actuator diaphragm or

mechanical damage to the external valve the internal valve shall close automatically.
14.4.5 Removal and decontamination
To avoid damaging the equipment, the removal and decontamination of the valve before
control or repair shall be carefully performed. Best practices are described in appendix 10.
14.5 External valve design

14.5.1 Pneumatic actuator mounting
For the fixed tank valves, the mounting for the pneumatic actuator is described in chapter
12.
For mobile container valves, the pneumatic actuator shall be mounted directly on the valve
body.
14.5.2 Body seat and disc seat
The internal valves will always have a soft seat while the external valve can have a soft or
metallic seat.
In case of metal to metal sealing for the external valve, the contact surfaces should be as
narrow as possible and there shall be a welded deposit of cobalt base alloy, e.g. Stellite™,
hard facing or equivalent weld deposited material on the valve body seat and disc seat (flat
face to face contact surface are not recommended). Corrosion and mechanical properties of
armouring or plating material have to be suitable.
14.5.3 Bellows seal
The bellows seal arrangement shall prevent leakage past the stem to atmosphere.
The bellows shall have a minimum of two plies.
The bellows of manual or actuated on-off valves shall have a guaranteed minimum life of
10,000 cycles (fully open to fully close) at the maximum allowable operating pressure of the
valve at 20°C.
It will also be able to resist any permanent deformation as a result of the static and dynamic
stresses to which it will be subjected, as well as the hydrostatic test pressure of the valve.
14.5.4 Auxiliary stuffing box (for fixed tank valves only)
The external valve shall have an auxiliary packed gland external to the bellows to prevent
leakage to atmosphere should the bellows fail. The gland shall be externally adjustable.
Details see chapter 12.

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the auxiliary stuffing box.
Rail road and ISO Containers have a direct mounted pneumatic actuator in a closed housing
with a leakage control. Therefore, this valve type does not need an auxiliary stuffing box.
14.5.5 Bellows leakage detection tappings (for fixed tank valves only)
Tappings to the interspace between the bellows seal and the auxiliary packed gland shall not
be provided unless specifically requested on the order.
When a tapping is requested, it shall be sealed by a suitable plug. The plug shall be designed
for the design pressure of the valve over the temperature range minus 40°C to +120°C,
appropriate to the pressure designation. The material of the plug shall be suitable for use
with chlorine.
14.5.6 Soft seal ring
Where a soft seal ring is fitted at the obturator seating, it shall be designed to compress down
to the level of the metal seat when the disc is in the fully closed position and to give a metal
seal even if the soft seal ring is damaged or displaced.
14.6 Internal valve design

14.6.1 General
The internal valve shall have a spring-loaded disc/ball which seals against the internal valve
seat. It shall have a flange suitable for both connections to the storage tank and for the direct
mounting of the external valve. The other end shall be preferably prepared for welding
threaded or.
The normal opening of the internal valve shall be carried out by the application of pneumatic
pressure to the pneumatic actuator, and the closing by the internal valve spring after the
release of the pneumatic pressure.
14.6.2 Body
The total valve consists out of 2 separate bodies. Each of these bodies shall be a one-piece
forging or casting.
The minimum wall thickness of the valve body shall comply with the valve manufacturer's
standard, appropriate to the pressure designation, body material and the nominal size of the
flange.
14.6.3 End connections
The internal valve shall have a flanged end suitable for connecting to both the tank and the
external valve. It shall be prepared for butt welding or socket welding or have an internal
thread so that a dip pipe may be attached.
The flange shall be of a nominal size and dimensions compatible with the flange of the
external valve and be capable of meeting the pressure-temperature rating appropriate to the
pressure designation and material. For PN designated valves the flange and facings should be
based on the requirements of EN 1092-1 and for class designated valves on ASME B16.5. The

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flange should have a female or groove on the front of the flange for connection to the external
valve and a male or tongue on the back of the flange for connection to the storage tank.
The ball/disc shall be held on the seat by the internal valve spring, which shall maintain a
tight shut-off until the downward movement of the external valve stem pushes the ball/disc
from the seat. The seat may be of a hard-facing material deposited directly on the body or a
soft seating material securely attached to the body.
Both ends of the spring shall be closed and ground, properly located and guided.
14.7 Pneumatic actuator

14.7.1 General
The pneumatic actuator shall be either a single acting diaphragm type with spring return or
a single acting piston type with spring return. Pneumatic pressure when applied to one side
of the diaphragm/piston shall compress the spring(s) and cause linear movement of the
pneumatic actuator stem. The spring(s) shall give a positive return action of the stem when
pressure on the diaphragm/piston is released.
The system will be of the type “fail close”.
For the fixed tanks, the actuator body shall have connections for attachment to both the
external valve bonnet/cover and the manual override; for mobile containers the actuator
shall be directly attached to the body of the valve.
Air connections shall be provided in the actuator body above the diaphragm/piston. A
threaded plug shall be provided in the body below the diaphragm/piston so that the integrity
of the bellows can be checked; this plug shall be normally closed.
60529 (protection against dust and water jets).
plugged or vented via a moisture removing device. The non-pressure side of the actuator
diaphragm shall be designed in such a way that any trapped gas shall not affect the valve
operation adversely.
A manual override shall be fitted to the actuator body (see Chapter 14.8).
14.7.2 Diaphragm type with spring return
The securing of the diaphragm by the actuator body and cover shall ensure that the joint does
not leak when subjected to:
a) A motive fluid maximum pressure of 8 barg;
b) A test pressure of 10.5 barg;
c) Forces developed during manual operation.
14.7.3 Piston type with spring return (fixed tank valves only)
The internal surface of the external valve body on which the piston seal slides should be
machined with a smooth finish and protected against corrosion. This internal surface shall be
designed to allow assembly without a risk of damage to the piston seal.

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14.8 Manual override (not for valves on transport containers)

Each valve shall be provided with a manual override in order to operate the valve in the case
of lack of or failure of the motive fluid to the pneumatic actuator.
The manual override shall be securely fastened to the cover of the pneumatic actuator and
connected to the pneumatic actuator stem.
The design shall prevent pneumatic operation while the manual override is being used.
For transport containers’ valves, the manual override will be operated using a lever (removed
or repositioned for transport to allow full closure of the tank dome). In the case of an
emergency, it will permit rapid closing of the internal valve, by pulling a release cable/cord
which is of adequate strength and securely attached to the device; the length of the
cable/cord should allow operation from a safe distance.
14.9 Materials of construction

14.9.1 Disc seating and seat
14.9.1.1 Metal to metal

If a metal to metal disk seating is used, the disk seating and seat of the external valve must
be resistant to gaseous chlorine with traces of moisture.
14.9.1.2 Soft seal ring
The internal valve is equipped with a soft seat.
Material for the soft seal ring shall be suitable for continuous use on chlorine at the
pressure designation (PN 25, PN 40 or ANSI Class 150 and Class 300) over the temperature
range specified in chapter 4.
14.9.2 Bellows
Nickel base alloys (for example Hastelloy C276®) shall be used. Preference should be given
to high nickel base alloy.
The bellows specification and supplier shall be agreed between the valve manufacturer and
the buyer. Each ply shall be made preferably from high nickel alloy. The material selection
shall be agreed between the valve manufacturer and the user.
14.9.3 Actuators
The housing should be made of steel suitable for the design minimum temperature.
It is essential that the material of the pneumatic actuator diaphragm or piston seals shall be
resistant to chlorine and retain a tight seal to ensure there is no risk of chlorine coming into
contact with the motive fluid even in the event of failure of the bellows. If included in the
drying they shall also withstand the drying procedure without degradation.
The sealing component (such as shaft sealing) shall be resistant to chlorine.
The use of aluminium parts shall not be used.

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14.9.4 Bolting
Bolting shall be in accordance with Unified inch or ISO metric standards. All stud bolts etc.
shall extend fully through their nuts with full effective thread engagement, not including the
chamfered threads, when tightened.
Stud bolts, studs, nuts etc. should be manufactured from materials that have suitable
mechanical characteristics, impact strength and hardness. (see GEST 88/134 - Stud Bolts
Hexagon Head Bolts and Nuts for Liquid Chlorine).
14.10 Production testing

14.10.1 General
Basically, the products will be tested as described in the Chapter 7, considering this chapter
is dealing here with automatic shut-off valves and taking into account, when necessary the
particularities (absence of stuffing box for mobile containers valves …).
This applies particularly for the hydrostatic pressure tests of the components and the
pneumatic body tests of the assembled valves.
For the seats of the assembled valves, the following specific pneumatic tests will be
performed.
14.10.2 Pneumatic seat test
14.10.2.1 Pneumatic seat test of internal valve

Each completely assembled internal valve shall be pneumatically seat tested as follows:
a) The body ends shall be blanked so that the body is not constrained;
b) The disc/ball shall be closed by the internal valve spring force;
c) The test pressure shall be applied to the underside of the disc/ball from the dip
pipe end of the body, with the outlet flange blanked and having a connecting pipe
to a bubble test rig;
d) The test pressure shall be as follows:
• Test 1: Low pressure test, using 1 barg air pressure,
• Test 2: High pressure test, using 1.1 times the design pressure of the valve at
20°C, appropriate to the pressure designation of the tank.
e) The test pressure shall be maintained for at least 2 minutes.
Visible leakage (bubble) shall be cause for rejection.
When a soft seat is fitted, following the high pressure test the seat shall be checked for
damage.
14.10.2.2 Pneumatic seat test of external valve
14.10.2.2.1 External valve operated by the pneumatic actuator
Each external valve assembled with the pneumatic actuator shall be pneumatically seat
tested as follows:
a) The body flanges shall be blanked so that the body is not constrained;
b) The valve shall be closed by the pneumatic actuator spring force (fail close
position);
c) The two blanking flanges shall have connecting pipes to a bubble test rig;
d) The test pressures, given in (e), shall be applied alternatively on each side of the
disc;

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e) The test pressures shall be as follows:

• Test 1: A pressure equal to 1.1 times the design pressure of the valve at 20°C.
• Test 2: A pressure of 1 barg.
f) Each test pressure shall be maintained for at least 2 minutes.
Visible leakage (bubble) of the seat shall be cause for rejection.
• Premature wear or damage to the spindle assembly,
• Damage to the seat or plug.
14.10.2.2.2 External valve operated by the manual override

Each external valve, assembled with the pneumatic actuator and the manual override, shall
be pneumatically seat tested as follows:
a) the valve shall be closed using the manual override;
b) the test pressure shall be applied to the underside of the disc with the outlet
branch blanked and having a connecting pipe to a bubble test rig;
c) the test pressure shall be 1.1 times the design pressure of the valve at 20°C;
d) the test pressure shall be maintained for at least two minutes.
Visible leakage (bubble) of the seat shall be cause for rejection.
• Premature wear or damage to the spindle assembly,
• Damage to the seat or plug.
14.10.2.3 Minimum pneumatic pressure to open the valve
The following test shall be conducted to determine the lowest motive fluid pressure which
allows the full stroke of the valve.
a) A pressure equal to the design pressure shall be applied under the valve disc;
b) The disc/seat shall be checked for bubble tightness;
c) A progressive motive fluid pressure shall be applied, until the valve starts
leaking;
d) The motive fluid pressure shall be recorded.
This pressure shall be lower than 80% of the minimum pneumatic supply pressure which is
given in the purchase order.
14.10.2.4 Testing of the assembled equipment
The complete pneumatically operated valve shall be assembled on a special bench testing
arrangement, using gaskets specified by the user.
The testing procedure shall comply with 14.10.2.4.1 and 14.10.2.4.2.
14.10.2.4.1 Operating test without pressure
With no pressure being applied to the underside of the internal valve disc/ball, the valve shall
be subjected to a minimum of 5 full strokes (opening and closing), by using the nominal motive
fluid pressure.
The actual stroke of the pneumatic actuator stem shall be recorded and compared with the
calculated nominal stroke.

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2nd edition
14.10.2.4.2 Operating test with pressure

The test described in 14.10.2.4.1 shall be repeated but using the design pressure under the
disc/ball of the internal valve.
Note: During the tests conducted under 14.10.2.4.1 and 14.10.2.4.2, any accessories shall
be controlled and adjusted.
14.10.2.4.3 Manual override
The manual override shall be fitted and the test described in 14.10.2.4.2 shall be repeated
by using only the manual override to operate the external and internal valve.
There shall be no motive fluid pressure applied to the pneumatic actuator.
14.10.2.4.4 Dimensions "A" and "B" requirements
Dimension “A” is the distance between the end of the external valve stem and the top of the
internal valve disc/ball.
Dimension "B" is the distance between the top of the internal valve ball/disk and the internal
valve face. B shall be at least 2 mm.
Dimensions "A" and "B" are critical for a good performance in operation (see sketch) and
therefore each valve shall be subjected to a specific, individual, measurement of these
dimensions.
a) A pneumatic pressure of 5 barg shall be applied under the disc/ball of the internal
valve;
b) The bubble tightness of the internal valve shall be checked by slightly opening the
valve using the manual override;
c) Using the manual override the valve shall be closed;
d) Using the manual override the valve shall be opened slowly and carefully;
e) When the valve starts leaking, the stroke shall be noted.

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2nd edition
This stroke corresponds to the dimension "A" and shall be compared with the calculated
nominal dimensions (based on drawings) and with the calculated value based on actual
measurements during manufacturing.
14.10.2.5 Cv measurement
At the request of the user, a flow test shall be carried out and the actual Cv of the valve
determined
15 Enquiry and ordering information

The following information should be specified (if appropriate) on enquiries or orders for valves
meeting the requirements of this specification:
1) State that valves are to comply with this GEST 17/492
2) State detailed valve requirements:
(a) Quantity,
(b) Nominal size,
(c) Full or reduced bore (ball valves),
(d) Pressure designation,
(e) End flange standard,
(f) The gasket contact surface finish of the body end flanges if other than raised face
(g) Method of operation (hand wheel, lever, actuator),
(h) Face-to-face dimensional standard,
(i) Body and bonnet material specification,
(j) Bellow material (globe valves),
(k) Back seat (if relevant),
(l) Characteristics (for process/shut off valves),
(m) Paint finish and colour required.
3) State additional requirements:

(a) Locking arrangements,
(b) Anti-static,
(c) Leak detection/purge tappings,
(d) Buyer inspection during manufacture,
(e) Additional non-destructive testing/examination,
(f) Bellow leakage detection tapping (globe valves, if required/relevant),
(g) Special packaging/labelling,
(h) Special drying requirements,
(i) Soft seal ring (if required/relevant),
(j) State what maintenance instructions are to be provided,
(k) Special design requirements, e. g. ambient conditions, vibration.
16 Maintenance instructions
Please take also the manufacturing maintenance instruction into account.
16.1 Definition
Practical experience has shown that the installation of dry gaseous and liquid chlorine valves
necessitates specific precautions to avoid their deterioration and consequent loss of gas

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tightness. This recommendation has been written to provide a number of simple rules that
will help avoid deterioration of such valves; the guidance is applicable:
➢ During initial installation or following replacement on an operating installation;
➢ In the course of maintenance to or inspection of the installation;
➢ During repairs to or overhaul of such types of valve.
16.2 General principals

1. A chlorine valve must not come into contact with water after it has been installed,
because subsequent complete drying out with dry air is virtually impossible.
2. A valve removed from an installation which has contained chlorine should be
immediately neutralised (see Section 3 below), because of the very rapid corrosion
which will take place on all the surfaces which have been in contact with chlorine.
3. A valve should not be put back into service without having been checked, repaired,
tested, degreased, dried and confirmed as a chlorine valve suitable for the required
service.
4. The bling flanges on the valve should only be removed shortly before the valve will be
installed on its final position.
16.3 Removal of valves

If the installation is to be vented down (see GEST 80/84 – Code of Good Practice for the
Commissioning of Installations for Dry Chlorine Gas and Liquid), the valve should be
removed and immediately neutralised by soaking in an alkaline solution (e.g. sodium
carbonate), followed by rinsing with water and drying. The flanges should be protected to
avoid any deterioration during subsequent handling. All valves should be fitted with a label
indicating that they have been used for chlorine. The valve should then be dispatched to the
workshop for inspection or repair.
16.4 Repairs
The following rules should be followed when overhauling chlorine valves.
16.4.1 Disassembly
The valves should be dismantled into all its components parts. All consumable parts such as
joint rings and gland packing should be discarded.
16.4.2 Work to be carried out
After suitable de-rusting, such as sand or shot blasting, passivation and washing all the
components, each component shall be rigorously examined and dried. Any defective
component may be repaired by machining so long as their dimensions after machining are
within specified tolerances and compatible with proper operation of the valve. To this effect,
thicknesses shall be compatible with the standards EN 12516 -1 to -3 or ASME B16.3. If not,
the component should be rejected.
The valve seat should be made good by welding and then re-machined if necessary.
The disc should be ground or lapped and if necessary, made good by welding and then re-
machined.
The sealing faces (flanges, valve head) shall be machined if necessary.

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The state of the spindle surface shall be checked. If inadequate, it shall be replaced or super
finished.
Any new component used should be either in the same material of construction as the original
component, or of a quality recommended in this recommendation.
16.4.2.1 Valves with a packed gland
The back-seating arrangement used to obtain a gas seal when the valve is fully opened should
be checked, and if necessary, made good by welding and then re-machining.
16.4.2.2 Bellow valves
It is preferable to change the bellows and especially when it is in stainless steel. Bellows
made from nickel base alloy 2.4619, e.g. Hastelloy C276 ® or nickel-copper alloy 2.4360, e.g.
Monel®, may be reused. If the bellows are welded to the spindle, this operation of welding
shall only be carried out in an approved workshop specially equipped for this work and tested
to verify a good bellow welding.
16.4.3 Reassembly
Responsible plant staff shall ensure that all components used are the correct materials and
dimensions for the duties envisaged. The reinstallation of the valve shall be carried out with
new joint rings and gland packing. Lubrication of components which may come into contact
with chlorine shall be carried out with a special grease, compatible with chlorine (chloro-
fluorinated greases). All components and the fully reassembled valve shall be dried.
Components which should be greased, notably the thread and the operating spindle, shall
exclusively be treated with a grease which is compatible with chlorine (chloro-fluorinated
greases).
16.5 Inspection
The following inspection and tests should be carried out. As a preliminary, the satisfactory
operation of the fully reassembled valve shall be confirmed.
16.5.1 Pneumatic leak testing
Pressure test: 6 bars

Test fluid: dry air or nitrogen
Method: the test shall be carried out with the valve partially opened. The gland
follower on the packed gland shall be tightened such that it has not taken
up more than half its travel.
Standards: with a test duration of two minutes and no leakage being tolerated.
16.5.2 Leak testing of the sealing arrangements (disc/seat)
Test pressure: 6 bars

Method: with the valve closed with normal hand pressure and with the gland
packing partially slackened off.
Standard: duration two minutes, no leakage being tolerated.

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16.5.3 Valves with a packed gland - leak testing of the back-seating arrangement
Leak testing of the back-seating arrangement

Method: the valve should be completely opened and the packed gland shall be
slackened off.
Standard: duration two minutes with no leakage being tolerated. In practice, this
operation can be carried out first before installation of the gland follower.
16.5.3.1 Leak testing of the packed gland
Method: the valve shall be half-open, and the gland follower should be tightened to
the extent that it is not compressed more than half-way.
Standard: duration two minutes with no leakage being tolerated. In practical terms,
this operation can be combined with that of Paragraph 17.5.1.
16.5.4 Bellow valves - leak testing of the bellows

Method: with the valve partially opened and with gland packing partially slackened
off.
Standard: duration two minutes, no leakage should be tolerated.
16.6 Preparation for service

For refurbished valves the similar procedures should be used as for new valves.
Valves delivered new or being returned from maintenance shall be completely dry (for
example by drying in a vacuum oven). All traces of grease, oil and solvent used during their
manufacture, testing or inspection, and likely to cause reaction with chlorine, shall be
removed. External non-machined surfaces should be treated with a layer of antirust paint.
Machined surfaces, such as flange faces and particularly joint bearing areas and threaded
surfaces, shall avoid any trace of paint. These surfaces should be coated with a protective
layer which is easily removed or with a layer of grease compatible with chlorine. The valve
orifices shall be blanked off and protected with plastic plugs. The diameter of the plugs shall
be such that the joint surfaces are completely protected.
A plate shall be attached which indicates the name of the valve repairer, the month and year
the repair was carried out, or some identification number (fixed to the flanges of the bonnet
or the valve flanges).
16.7 Storage
To avoid any subsequent confusion, all chlorine valves once assembled shall be identified
specifically for this duty. All precautions must be taken to maintain valves in an area where
they will be protected from moisture. To this effect, they should be stored in a location which
is maintained if possible at a reasonable temperature. It is a good precaution to keep them
in a gas-tight plastic bag containing a drying aid such as silica gel. For valves which are waiting
installation, another possibility consists of putting them in a cupboard which is purged by dry

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2nd edition
gas. The same precautions shall be taken for removable components, which if they need to
be greased, shall be treated with a chloro-fluorinated grease.
16.8 Certification
If the maintenance of the valves is sub-contracted to an external organisation, the workshop
carrying out valve maintenance shall provide for each batch, a certificate confirming that the
tests and preparation of the valve have been carried out in conformity with the requirements
laid down in Paragraphs 17.5 and 17.6.
16.9 Installation
The installation of valves in their subsequent location after selection of the correct valve,
should only be done when all of the activities associated with maintenance, inspection,
cleaning and drying of the installation, have been completed. The valve should be withdrawn
from the store just before its installation. If the storage conditions do not provide a guarantee
that the valve will be kept away from moisture, there needs to be prior drying of the valve.
The valve shall be taken to its point of installation, either maintained within its protective
seal, or fitted with plastic or magnetic plugs which shall not be removed until just before
installation. Except for special circumstances, the valve should be installed in such a way that
the direction of fluid flow will be in the direction indicated on the arrow (liquid entering from
below the disc).
16.10 Commissioning
After installation, the valve shall be subjected to a final operation of drying out and leak
testing as laid down in GEST 80/84 – Code of Good Practice for the Commissioning of
Installations for Dry Chlorine Gas and Liquid.
17 Approval of the valves specified under this document

This chapter covers the following points.
➢ The procedure for Euro Chlor approval of the design, manufacture and performance
of process valves for use on liquid & dry gas chlorine duties and which are covered by
this specification (GEST 17/492);
➢ The procedure for the approval/verification of modification(s) to existing
approved/verified valves design;
➢ The periodic re-approval (re-verification) procedure for previously approved (verified)
equipment is also included.
A logic diagram depicting the procedure is given in Appendix 3.
17.1 General
The procedure for Euro Chlor approval/verification requires that the design, manufacture and
performance of valves are assessed by an external competent body before they are
approved/verified by our association for use on liquid chlorine duties.
This procedure involves:
a) Confirmation that the valve design complies with the requirements this Euro Chlor
guideline;
b) Confirmation that manufacture of the valve satisfies the Quality Assurance
requirements of ISO 9001 or ISO 9002 (or equivalent);

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c) Assessment of the valve performance by checking, inspecting and testing, if necessary,

a valve (see Paragraph 17.6) and reviewing the operating experience of the valve on
chlorine duties (see Paragraph 17.7).
17.2 Application by valve manufacturer

Manufacturers wishing to apply for Euro Chlor approval of their chlorine valves shall write to:
Euro Chlor Secretariat
Rue Belliard 40, Box 15
B – 1040 BRUSSELS
Email : eurochlor@cefic.be
Internet: http://www.eurochlor.org
The valve manufacturer’s application shall request Euro Chlor approval for specifically
nominated valves and shall propose an independent inspection body to carry out the
assessments referred to in Paragraphs 17.4, 17.5 and 17.6. In case of valve verification, only
Paragraphs 17.4 and 17.6 will need to be assessed and this can be done directly by the
manufacturer.
The application shall include a copy of a file containing a legible detailed, large scale
sectional drawing of the valves with nomenclature for the complete assembly with the full
description of the different options.
In addition, the manufacturer must provide a detailed report justifying the compliance of
their valves to the requirements of the relevant part of the corresponding Euro Chlor
guideline.
If practical experience already exists, the supplier should add a list of plants from Euro Chlor
members’ companies where the nominated valves are installed. This gives Euro Chlor the
opportunity to gather reports of experience from those users (see Appendix 4).
The file shall be specific to the application, kept confidential and retained by Euro Chlor.
Final submission to Euro Chlor shall be in English.
17.3 Receipt of application by Euro Chlor

On receipt of the application, Euro Chlor shall:
a) Acknowledge receipt of the application;
b) Confirm acceptability of the independent inspection body (if applicable);
c) Check the operating experience coming from users;
d) Register a master file which shall contain all information related to the application
for Euro Chlor approval.
No further action shall be taken by Euro Chlor until the manufacturer sends to Euro Chlor the
complete inspection report from the independent inspection body that contains the
information from an assessment in accordance with Chapter 18.
17.4 Production quality assurance

For valves to be approved, the independent inspection body shall confirm that the design of
the valves is compliant with the requirements in this specification and that the manufacture
of valves, for which approval has been applied, has been assessed to ISO 9001 or ISO 9002 (or
equivalent) at the manufacturer’s premises.

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The manufacturer will accept visits of its production, testing and packaging facility by a
delegation of the Euro Chlor Equipment Working Group and the independent inspection body.
In case of change of supplier or in machining, assembling, testing plant, the manufacturer
must notify it to Euro Chlor. Euro Chlor can decide to ask the manufacturer to make an audit
by an independent inspection body at the cost of the manufacturer.
17.5 Technical specification approval

The independent inspection body (in case of valve approval and/or valve verification) shall
confirm that:
a) The manufacturer has designed and manufactured the valve to appropriate
professional standards by means of a general assessment of documents such as design
calculations, manufacturing drawings, weld procedures, etc.;
b) The valve is in accordance with the manufacturer’s drawings;
c) The valve meets all the requirements of the relevant part of the applicable Euro Chlor
guideline.
Variations from the relevant part of this GEST specification shall not be permitted without
prior written agreement of the Equipment Working Group.
17.6 Valve testing

In case of valve approval or valve verification, the independent inspection body shall confirm
that the valve has been successfully checked, inspected, tested and satisfies the
requirements of this Euro Chlor guideline (all diameters of the approval range).
This requirement may be waived by the Euro Chlor Equipment Working Group for
improvements to already approved valves, provided the technical analysis made by an
independent inspection body of the proposed “light” modifications shows they cannot be the
possible cause of problems.
“Light” modifications are those considered by the Equipment working group as not affecting
the valves integrity (not increasing the potential risk of chlorine leak).
17.7 Operating experience

The Equipment Working Group shall assess the operating experience of the nominated valves
by a detailed review of the valve performance questionnaire (see Paragraph 17.3 c) and
discussions with users.
For “light” modifications of already approved valves, no additional field test will be required.
The requirements for Euro Chlor approval/verification are:
➢ Satisfactory operating experience of a minimum of 6 valves on liquid chlorine duties
by at least two World Chlorine Council member companies (at least 3 valves per
company);
➢ For process valves, different diameters of valves shall be tested (testing a specific DN
will qualify the valves having one DN lower and one DN higher; the test of DN 50 will
also qualify the DN 25);
➢ The duration of the field test shall be at least two years for valves subject to testing
according to Paragraph 17.6

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17.8 Review by Euro Chlor

When the manufacturer has sent to Euro Chlor written confirmation from the independent
inspection body that an assessment in accordance with the applicable Euro Chlor guidelines
has been completed, the Equipment Working Group shall meet to confirm that all appropriate
stages of this procedure have been satisfactorily completed and that all relevant
documentation is satisfactory and is filed in the Secretariat of Euro Chlor.
When necessary, the Equipment Working Group shall arrange a meeting with the valve
manufacturer and independent inspection body to discuss and resolve any problem.
On completion of this review, the Equipment Working Group shall, either recommend or not
recommend the issue of a Euro Chlor approval/verification Certificate for the valve.
17.9 Issuing of certificate

Following confirmation by the Equipment Working Group that all appropriate stages of this
procedure have been satisfactorily completed, the Euro Chlor Secretariat shall file copies of
all relevant documentation and the GEST shall issue a certificate for all approved/verified
valves.
This certificate shall also be signed by the manufacturer.
When signing the Euro Chlor Certificate, the manufacturer undertakes, for all valves
subsequently manufactured that are covered by this Certificate:
➢ To make no alteration to the specifications and documents which make up the master
file;
➢ To manufacture valves to an identical standard to those submitted for approval, in
terms of quality, size and materials of the valve components;
➢ When making any repairs, to comply with the criteria and methods specified in the
master file;
➢ To carry out all the tests and inspections laid down in the master file;
➢ To make no modification to anything given on the approved drawings or in the master
file (production process/location …) without prior agreement of Euro Chlor who may,
after reviewing the manufacturer’s proposals, either uphold the approval or withdraw
it and require a new assessment;
➢ To inform Euro Chlor prior to any change in material, part suppliers or production
process/location.
17.10 Modification of approved/verified valve

In case of a proposed modification to an approved/verified valve (see here above), an
application shall be made to the Euro Chlor secretariat as per Chapter 17.2.
The manufacturer will ask an independent inspection body (which has to have the approval
of Euro Chlor) to fully assess the implication of the proposed modification and define a
relevant inspection and test procedure, if needed.
Modifications that affect the pressure containing envelope (e.g. new casting design) will
typically require testing and operating experience as defined in Chapters 17.6 and 17.7.
In the case of a change in casting supplier, the quality and dimensional accuracy of the new
casting shall be verified; an operating field test will normally not be necessary.

GEST 17/492
2nd edition
17.11 Periodic review

The valve manufacturer shall proceed with a re-assessment of the files (independent
inspection body for approved valves) not more than 5 years after the date of issue of the
Certificate and communicate the results to Euro Chlor.
Particular circumstances, for example the bad operating experience of a user, may
necessitate an earlier review by the Euro Chlor working group.
This review will check for any changes in the design, material supply, production and quality
processes, and that the products comply with the last revision of the applicable Euro Chlor
guideline. Also the management of change procedure of the valve manufacture will be
checked.
A detailed report (by the independent inspection body) will be submitted to the Euro Chlor
Equipment working group for review which shall determine which of the following actions
shall be taken:
a) Confirmation of the approval/verification for a further period of up to 5 years,
b) Withdrawal of the Certificate.
18 Procedure to be used by the inspection body

This chapter describes the procedure to be used by an independent inspection body when
carrying out an assessment to establish the adequacy of the quality assurance system, design,
manufacture, inspection and testing of valves for use on liquid chlorine. The assessment is
carried out prior to consideration for Euro Chlor approval.
18.1 Quality assurance

18.1.1 General
The independent inspection body shall establish that the valve manufacturer has a quality
system that satisfies the requirements of ISO 9001 or ISO 9002 (or equivalent). Checks shall
be made to ensure that the quality system is properly established, documented, implemented
and maintained and that both internal and external audits are properly carried out.
In particular, the checks shall include that documentation relating to the requirements of
Paragraphs 18.1.2 to 18.1.11 here below is available and meets the requirements of this
procedure.
18.1.2 Manufacturer’s quality policy
The valve manufacturer’s quality policy shall be understood, implemented and maintained
throughout the valve manufacturer’s organisation.
18.1.3 Quality assurance system
The documents relating to the quality assurance system organisation, responsibilities,

authority etc. shall be up-to-date.
The quality manager shall have the authority to initiate actions to correct any quality
problem, even if this requires stopping the production process.

GEST 17/492
2nd edition
18.1.4 Inspection and testing personnel
Personnel used for carrying out inspection and testing shall have technical competence and
experience commensurate with the needs of the specified methods of inspection and testing.
In particular, the level and category of personnel carrying out non-destructive
examination/testing shall be in accordance with an appropriate national certification
scheme.
The availability of personnel competency certificates shall be confirmed.
18.1.5 Design control
The control of design shall ensure that the design of the valve(s) satisfies the requirements
of the relevant part of the Euro Chlor GEST specification and that the basis of the design is
properly documented and references made to calculations and associated standards. Design
changes and modifications shall be properly controlled and documented.
18.1.6 Document control
The control of documents shall ensure that both external and internal documents relevant to
the quality system are authorised and the current revision status identified. Withdrawn and
obsolete documents shall be secured against unintentional use. Changes to documents shall
be authorised and appropriate records of the changes shall be kept.
18.1.7 Control of purchase materials/services
The suppliers of materials/services shall have a quality system consistent with that of the
valve manufacturer. The valve manufacturer’s quality system shall cover verification of
purchased products against the relevant specifications, supplier’s provision of documentation
(material/test certificates) and the valve manufacturer’s control of supplier’s non-
conformances.
18.1.8 Manufacture
Any process that affects quality of the valve shall be identified and the valve manufacturer
shall ensure that all such processes are fully documented and carried out under controlled
conditions which may include the work, for example welding, being carried out by qualified
personnel using qualified procedures.
Records shall be kept and maintained of qualified personnel and qualified procedures.
18.1.9 Material identification and traceability
The valve manufacturer shall maintain a positive system of identification and traceability for
the materials used during manufacture.
18.1.10 Inspection and testing
Inspection and testing shall be carried out in order to verify that materials, components,
assemblies and completed valves conform to the specified requirements. Test methods and
acceptance criteria shall be specified and shall relate where appropriate to incoming
materials, in-process materials and the final product. The valve manufacturer shall maintain
records as evidence that the relevant inspection and testing has been carried out.

GEST 17/492
2nd edition
18.1.11 Inspection and test equipment
The inspection and test equipment used shall be suitable for the inspection method or test
to be applied and of the appropriate range and accuracy. Inspection and test equipment shall
be uniquely identified, properly maintained and calibrated at prescribed intervals.
18.2 Technical specification evaluation

18.2.1 General
The independent inspection body shall verify that the valve manufacturer’s quality assurance
activities, implemented within the quality system, ensure that the valves produced conform
to the requirements of the relevant part of this Euro Chlor specification. The activities shall
be fully documented (quality procedures/work instructions) and the documents readily
available to those carrying out quality control.
18.2.2 Euro Chlor GEST specification for valves
The independent inspection body shall ensure that the assessment is carried out relative to
the current edition of the relevant part of this Euro Chlor GEST 17/492.
18.2.3 Assessment of design
The valve manufacturer shall make available documentation relevant to the design of the
valves. The documentation shall include the calculations, general arrangement drawings,
detailed drawings and parts lists giving the material/material specification and grade of each
part (including seats, gaskets, packing and fasteners).
18.2.4 Materials
The valve manufacturer shall make available the current sources from which materials
(specific to the nominated valves) including raw, semi-finished or finished components are
obtained. In those cases, where a supplier has more than one source, each shall be given.
The valve manufacturer shall, when requested by the independent inspection body, provide
access to supplier’s premises for inspection or audit of the facilities, quality control, records
etc. Checks at the valve manufacturer’s premises and where necessary at a supplier’s
premises shall include those relating to:
a) Material specifications,
b) Purchase documents,
c) Method of manufacture and treatment,
d) Material identification and traceability,
e) Identification of batches, heat numbers etc.,
f) Quality control,
g) Documents (materials certificates, test certificates etc.),
h) Records of inspections/tests,
i) Provision of temporary corrosion protection,
j) Restrictions on chemical analysis and physical properties of carbon and carbon
manganese steel forgings and castings,
k) Repairs to forgings and castings.

GEST 17/492
2nd edition
18.2.5 Inspection procedures/methods and acceptance criteria
The valve manufacturer shall inform the independent inspection body of all relevant
inspection procedures/methods and acceptance criteria. Additionally, information shall be
provided of all relevant inspection equipment and the competence of inspection personnel.
The inspection shall cover incoming materials, in-process inspection, final inspection and
control of non-conforming materials. The independent inspection body shall verify that all
the ‘Examination’ requirements given in the relevant part of this Euro Chlor GEST
specification are covered by the valve manufacturer’s quality assurance documentation.
18.2.6 Production testing
The independent inspection body shall verify that the “Production Testing” requirements
given in the relevant part of this Euro Chlor GEST specification are covered by the valve
manufacturer’s quality assurance documentation. The hydrostatic and pneumatic pressure
testing facilities shall be verified and test personnel confirmed as having the appropriate
training and expertise to carry out the work. Hydrostatic pressure testing of valve bodies,
bonnet/cover and bellows and the pneumatic pressure testing of assembled valves shall be
witnessed on a random basis.
Calibration and test records shall be examined by meaningful random check.
18.2.7 Marking
The independent inspection body shall verify that the “marking” requirements given in the
relevant part of the Euro Chlor GEST specification are covered by the valve manufacturer’s
quality assurance documentation. The valve manufacturer’s system of valve serial numbers
(the unique number that identifies the valve in all aspects) shall be examined.
18.2.8 Preparation for dispatch
18.2.8.1 General
The independent inspection body shall verify that the “Preparation for Dispatch”
requirements given in the relevant part of this Euro Chlor GEST 17/492 are covered by the
manufacturer’s quality assurance documentation.
18.2.8.2 Painting
The equipment and procedures for degreasing, mechanical or chemical cleaning and
priming/painting shall be examined.
18.2.8.3 Lubrication
The system for ensuring that only chlorine-compatible chloro-fluorinated grease is used, for
those parts requiring lubrication, shall be examined.
18.2.8.4 Drying and blanking
The equipment and procedures for drying, use of desiccants and blanking shall be examined
and the operation witnessed on a random basis.
18.2.9 Certificates
The manufacturer’s system for ensuring the accuracy of information on the certificate
provided with each order for valves shall be examined. It shall be confirmed that material
certificates of materials used in the manufacture of a valve are retained for at least ten years
from the date of despatch of that valve.

GEST 17/492
2nd edition
18.2.10 Records
A review shall be carried out of the system for indexing, filing and retrieving records.
18.3 Production examination

18.3.1 Drawings
The valve manufacturer shall supply documentation relating to the valve(s) to be assessed.
The documents shall include a general arrangement drawing, detailed component drawings
and parts lists identifying the material/material specification(s) and grade(s). The documents
shall provide full manufacturing details including dimensions, tolerances, surface finishes,
thread type, welding procedure reference, weld preparations, heat treatment, hardness
limits, material identification and traceability.
18.3.2 Inspection and tests by the independent inspection body
The independent inspection body shall carry out or witness the inspections and tests required
by Paragraphs 18.3.3 and 18.3.4. Physical tests, chemical analysis and some non-destructive
examinations may have to be performed by an external organisation which shall be acceptable
to the independent inspection body.
Number of valves to be examined (first production batch):
The valve manufacturer shall make available the following valves:
• three forged valves (if asked for approval),
• three cast valves (at least one DN 50 and one DN 100 (if asked for approval),
and this for each specification type, pressure designation and material.
Testing a specific DN will qualify the valves having one DN lower and one DN higher; the test
of DN 50 will also qualify the DN 25.
In the case of an already existing valve type, the independent inspection body shall verify
that the valves offered are representative of normal production valves and have not been
produced specifically for the assessment.
The independent inspection body shall select one valve from each set of three and apply an
appropriate and unique identification mark to the body and bonnet/cover prior to testing.
When, during the inspection and tests by the independent inspection body, a material or
component does not comply with the specified requirements this shall be brought
immediately to the attention of the valve manufacturer and a further valve selected from
the original set of three. When a material or component of the second valve does not comply,
the assessment shall be discontinued.
18.3.3 Pressure testing
The valve manufacturer’s records, for the specific valve, of the production testing, i.e.
hydrostatic pressure testing of individual components, pneumatic shell test, pneumatic seat
test and leak test (according Paragraph 9) shall be examined to verify conformance to the
requirements of the relevant part of this Euro Chlor GEST 17/492.

GEST 17/492
2nd edition
18.3.4 Compliance with manufacturer’s drawings
18.3.4.1 General
Following satisfactory pressure testing, the valve shall be examined and the appropriate data
recorded and compared with the specified requirements. Checks shall include, where
appropriate, those listed in Paragraphs 18.3.4.2 to 18.3.4.5. Hardness and chemical
composition shall preferably be determined non-destructively. However, where considered
necessary by the independent inspection body, test samples may be cut from the valve
components. See Paragraphs 18.3.4.5 c) and e).
18.3.4.2 Dimensions, etc.
a) Assembled valve:
1. Face to face dimension,
2. Flange dimensions and position of flange bolt holes,
3. Centre to top dimension,
4. Hand wheel diameter/lever length,
5. Projection of studs/stud bolts etc. through their nuts,
6. Mass,
7. Operability: fully closed to fully open and check indicator positions,
8. General appearance,
9. Cleanliness.
b) Individual components of dismantled valve:

1. Body and bonnet/cover thicknesses,
2. Stuffing box and gland follower dimensions,
3. Stem diameter, length, circularity and straightness,
4. Packing: type, dimensions, number of rings,
5. Gaskets: type and dimensions,
6. Bellows: dimensions and number of convolutions,
7. Method of attaching and locking the stem to disc,
8. Clearance between obturator (disc) and body,
9. Presence of lubricator and lubricant,
10. Attachment of seat(s) to body,
11. Hardness of metal seat and disc seating.
18.3.4.3 Surface finish

a) Stem,
b) End flange gasket contact facing,
c) Body to bonnet/cover joint gasket contact facing,
d) Cast surfaces of body, bonnet/cover, after removal of any paint. Compare with
the specified surface requirements.
18.3.4.4 Bolting and threads

a) Type of thread,
b) Type, number, diameter, length of body to bonnet/cover fasteners,
c) Type and diameter of gland fasteners,
d) Dimensions and straightness of pillars.

GEST 17/492
2nd edition
18.3.4.5 Materials
a) Material identification,
b) Material certificate giving chemical, mechanical and impact properties,
c) Chemical composition of body, bonnet/cover, stem, seating, bellows, yoke nut
d) Material of packing and gaskets,
e) Welding consumables used for welding, including repairs by welding and weld
deposition.
18.3.5 Welding
The welding procedure specifications and welder qualification for all welding, including
repairs by welding, shall be examined. Radiographs shall be checked. The extent of any
repairs shall be recorded. Records including photographs relating to magnetic particle or
liquid penetrant inspection shall be examined. The possible weld repairs will be done
according to Chapter 5.7.
Any post-weld heat treatment procedures and furnace records shall be examined.
18.3.6 Marking
The body and bonnet/cover marking and identification plate marking shall be checked for
clarity and conformance with the requirements as specified in this Euro Chlor GEST 17/492.
18.3.7 Preparation for dispatch
Records shall be checked to confirm that the valve had been properly dried, the body and
bonnet/cover mechanically or chemically cleaned, primed, painted and blank flanges fitted.
18.4 Mechanical strength test

18.4.1 General
First production valves shall be tested unless the requirement for testing is waived by the
GEST Equipment Group on evidence that:
Similar valves have been satisfactorily subjected to a strength test equivalent to Appendix
5 prior to the assessment and the results are fully documented.
18.4.2 Valve to be tested
The valve used for the production valve examination and the record of the dimensions,
straightness, freedom from damage etc. may be used for the mechanical strength test.
Alternatively, a valve shall be selected from those remaining from the original set of three.
18.4.3 Test requirements
Valves shall undergo a mechanical strength test unless the test is waived by the GEST
Equipment Group (see 19.4.1).
The mechanical strength tests for globe valves shall comply with the procedures given in
Appendix 5. The preparation and testing shall be witnessed by the independent inspection
body. The test results shall be recorded and certified as correct by the valve manufacturer
and examined and signed by the independent inspection body.

GEST 17/492
2nd edition
18.5 Inspection report

The independent inspection body shall provide a fully detailed report of the assessment
carried out in accordance with the requirements of this procedure. The report shall include:
a) Quality assurance:
Detailed comments relating to each of the individual sub-clauses 18.1.1 to 18.1.11
inclusive. A statement as to whether or not the valve manufacturer’s and supplier’s
quality assurance systems fulfil the Euro Chlor quality requirements.
b) Technical specification evaluation:
Detailed comments relating to each of the individual sub-clauses 18.2.1 and 18.2.3 to
19.2.10 inclusive.
A statement as to whether or not the valve manufacturer has the ability to comply fully
with the Euro Chlor technical requirements.
c) Production valve examination:
Detailed comments relating to each of the individual sub-clauses 18.3.1 to 18.3.8
inclusive. A statement as to whether or not the valve manufacture can consistently
provide valves that conform to the requirements of the relevant part of the Euro Chlor
GEST specification.
d) Testing:
A statement as to whether or not the valve can withstand the mechanical strength test
procedure given in Appendix 5. In the case of a satisfactory test, the certification and
test data have to be documented.
The report shall be in English, French or German and sent to the Euro Chlor Secretariat within
90 days of the completion of the assessment.
18.6 Documents for the Euro Chlor master file

The manufacturer shall provide to the independent inspection body all documents required
for the production valve examination to be carried out.
The independent inspection body shall review the file and confirm that the documentation is
consistent with the examination and send it to the Euro Chlor Secretariat within 90 days of
the completion of the assessment.
19 References
GEST 79/82 - Materials of Construction for Use in Contact with Chlorine
GEST 80/84 – Code of Good Practices for the Commissioning of Installations for Dry
Chlorine Gas and Liquid
GEST 88/134 - Stud Bolts, Hexagon Head Bolts and Nuts for Liquid Chlorine
GEST 94/216 - Experience of Gaskets on Liquid and Dry Chlorine Gas Service
UIC 573 - Technical Conditions for the Construction of Tank Wagons

GEST 17/492
2nd edition
Appendix 1: Standards
This chapter mentions the main standards of interest for the valves used on liquid and also
dry gaseous chlorine.
ASME B16.5 American Society of Mechanical Engineers: Pipe flanges and flanged fittings
ASME B16.34 American Society of Mechanical Engineers: Valves-Flanged, Threaded, and
Welding End
ASTM E446 ASTM International: Standard reference radiographs for steel castings up to
2 in. (50.8 mm) in thickness, 2015
EN 19 European standard: Marking of general purpose industrial valves, 2016-03
EN 288 European standard: Specification and approval of welding procedures for
metallic materials.
- Part 1: General rules for fusion welding, 1992-02
- Part 3: Welding procedure tests for the arc welding of steels, 1992-02
EN 473 European standard: Non-destructive testing - Qualification and
certification of NDT personnel - General principles, 2008-06
EN 558 European standard: Industrial valves- Face-to-face and centre-to-face
dimensions of metal valves for use in flanged piping systems – PN and Class
designated valves
EN 764 European standard: Pressure equipment - Terminology and symbols -
Pressure, temperature, volume, 1994-07
EN 1759 European standard: Flanges and their joint – Circular flanges for pipes,
valves, fittings and accessories, Class designated
- Part 1 Steel flanges, NPS ½ to 24, 2004-11
EN 1983 European standard: Industrial valves – Steel ball valves, 2013-08

EN 1092 European standard: Flanges and their Joint – Circular flanges for pipes,
valves, fittings and accessories, PN designated.
- Part 1: Steel flanges, 2018-04
EN 10204 European standard: Metallic products – Types of inspection documents,
2004-10
EN 10228 European standard: Non-Destructive testing of steel forgings
- Part 1 Magnetic particle inspection, 2016-06
- Part 3 Ultrasonic inspection of ferritic or martensitic steel forgings,
2016-06
EN 10308 European standard: Ultrasonic testing of steel bars, 2001-11
EN 12266 European standard: Industrial valves – Testing of metallic valves
- Part 1: Pressure tests, test procedures and acceptance criteria –
Mandatory requirements, 2012-04

GEST 17/492
2nd edition
- Part 2: Pressure tests, test procedures and acceptance criteria –

Supplementary requirements, 2012-02
EN 12516 European standard: Industrial Valves – Shell design strength
- Part 1: Tabulation method for steel valves, 2014-10
- Part 2: Calculation method for steel valves, 2014-10
- Part 3: Experimental method, 2002-10
EN 12569 European standard: Industrial Valves - Valves for chemical and
petrochemical process industry - Requirements and tests, 1999-09
EN 12570 European standard: Industrial valves - Method for sizing the operating
element, 2000-05
EN 12681 European standard: Founding – Radiographic testing
- Part 1: Film techniques, 2017-11
- Part 2: Techniques with digital detectors, 2017-11
EN 13480 European standard: Metallic industrial piping
- Part 4: Fabrication and installation, 2017-06
- Part 5: Inspection and testing, 2017-06
EN 60529 European standard: Degrees of protection provided by enclosures (IP code),
1991-10
IEC 60534 International Electro-Technical Commission: Industrial-process control
valves
- Part 2-1: Flow capacity – Sizing equations for fluid flow under installed
conditions, 2011-03
ISO 4063 International Organization for Standardization: Welding and allied
processes - Nomenclature of processes and reference numbers, 2009-08
ISO 4287 International Organization for Standardization: Geometrical Product
Specifications (GPS) -- Surface texture: Profile method -- Terms, definitions
and surface texture parameters, 1997-04
ISO 4986 Steel castings – magnetic particle inspection, 2010-03-15
ISO 4987 International Organization for Standardization: Steel castings - Liquid
penetrant inspection, 2010-03
ISO 5210 International Organization for Standardization: Industrial valves - Multi-turn
valve actuator attachments, 2017-03
ISO 5211 International Organization for Standardization: Industrial valves – Part-turn
actuator attachments, 2017-03
ISO 9606 International Organization for Standardization: Qualification testing of
welders – Fusion welding
- Part 1: Steels, 2012-07

GEST 17/492
2nd edition
ISO 15607 International Organization for Standardization: Specification and

qualification of welding procedure for metallic materials – General rules,
2003-12
ISO 7121 International Organization for Standardization: Steel ball valves for
general-purpose industrial applications, 2016-04
ISO 9001 International Organization for Standardization: Quality management
systems – Requirements, 2015-09
ISO 9002 International Organization for Standardization: Quality systems - Model for
quality assurance in production and installation, 1987-03
ISO 15848 Industrial valves - Measurement, test and qualification procedures for fugitive
emissions
- Part 1: Classification system and qualification procedures for type testing
of valves, 2015-06

GEST 17/492
2nd edition
Appendix 2: Examples of statistical casting inspection of production batches

A casting batch can be composed of pieces of different patterns (a pattern refers to a
particular part -bonnet or body- of a particular size)
The method of statistical casting inspection shall be agreed with the valve manufacturer at
the time of homologation but shall as a minimum include the 100% radiographic and surface
testing of one casting from each pattern in the batch and amounting to a total of at least 10%
or 3 pieces per batch (whichever is greater), applying the acceptance criteria of Table 3 in
7.4.2.
To illustrate the principle of the statistical inspection defined in 7.4.5, some examples are
given here below.
Total number of pieces Number of different Pieces to be tested

per batch patterns
20 1 3
50 1 5
5 5 5
20 5 5
Table 19 - Number of pieces to inspect per casting batch

GEST 17/492
2nd edition
Appendix 3: Approval diagram & requirements for independent inspection body
Approval diagram:
Appendix 3
Requirements for independent inspection body:
Appendix 3a
Appendix 4: Field test report
Appendix 4

GEST 17/492
2nd edition
Appendix 5: Mechanical strength test procedure for globe valves

Procedure
Step 1 Check dimensions of all valve components and record;
Step 2 Assemble valve, including the gland packing;
Step 3 Measure and record the torque necessary to achieve a bubble tight shut-off at a
pressure appropriate to the pressure rating and the materials of the body and
bonnet/cover;
Step 4 Release test pressure;
Step 5 Fully close the valve and apply the “Seating Torque”. Then fully open the valve and
apply the “Seating Torque”. Do this ten times;
Step 6 Repeat Steps 7 and 8;
Step 7 Fully close the valve and apply a torque of (900 x d) Nm. Then fully open the valve
and apply a torque of (900 x d) Nm. Do this ten times;
Step 8 Repeat Steps 7 and 8;
Step 9 Dismantle valve;
Step 10 Dimensionally check and visually e;xamine all valve components. Record dimensions
and compare with those recorded in Step 1. Note any pertinent changes and any
damage;
Step 11 Repeat Step 2. New stem packing and a new body to bonnet/cover gasket may be
used;
Step 12 Fully close the valve and apply a torque sufficient to cause a component failure.
Record the torque at which failure occurs;
Step 13 Apply a hydrostatic pressure test until evidence of leakage or the required test
pressure is achieved;
Step 14 Dismantle valve and inspect the valve components;
Step 15 Prepare test report.

GEST 17/492
2nd edition
Appendix 6: Globe valve and part list
Figure 1: Globe valve bellow sealed

GEST 17/492
2nd edition

Ref German English Spanish French Italian Finnish Norwegian Dutch Polish Czech Swedish
1 Gehäuse Body Cuerpo Corps Corpo Runko Hus Huis Korpus Teleso Hus
2 Sitz Seat Asiento Siège Sede Istukka Sete Zitting Gniazdo Sedlo Säte
3 Kegel Disc Clapote Clapet Otturatore Lautanen Kjegle Klep Grybek Kuzelka Kägla
4 Mutter Nut Tuerca Ecrou Dado Mutteri Mutter Moer Nakretka Matice Mutter
Sruba
5 Stiftschraube Studbolt Espárrago Tige filetée Prigioniero Vaarnaruuvi Pinneskrue Draadeind Svornik Pinnbult
dwustronna
Pokrywa Ventilöverd
6 Aufsatz Bonnet Tapa Chapeau Calotta Kansi Ventiloverdel Bovenstuk Viko telesa
el
7 Dichtung Gasket Empaquetadura Joint Guarnizione Tiiviste Pakning Pakking Uszczelka Ploche tesneni Packning
8 Distanzbolzen Pillar Columna Colonnette Colonnette Sankaruuvi Distansebolt Afstandbus Ogranicznik Vodici sroub Distansbult
Stopfbuchs- Cuerpo de Flangia Kolnierz Ucpavkova Packboxflän

9 Gland flange Bride de fouloir Pakkboksflens Aandrukflens
flansch prensa premistoppa dlawika priruba s
Stopfbuchs- Gland Tiivistyslaipp Dlawik

10 Prensa-estopas Presse-étoupe Premistoppa Pakkboks-gland Aandrukstuk Viko ucpavky Gland
brille follower a
Stopbuspakki Uszczelnienie Stlacovana

11 Packung Gland packing Empaquetadura Garniture Guarnizione Tiiviste Pakning Packbox
ng ucpavka
Traverse Wspornik
12 Traverse Bridge/Yoke Puente Traverse Sanka Travers Brugstuk Trmen Brygga
d'arcade
Spindel mit Spindel med Wrzeciono Gängad

13 Stem Husillo roscado Tige Stelo Kara Spindel Vreteno
Gewinde gjenger gwintowane spindel
Volantino a Pokretto
14 Handrad Hand wheel Volante Volant Käsipyörä Ratt Handwiel Rucni kolo Ratt
mano
15 Faltenbalg Bellow Fuelle Soufflet Soffletto Palje Belg Balg Mieszek Vlnovec Bälg
Traversen- Cabeza del Standaanwijz Tuleja Matice

16 Yoke bush Ecrou de tige Boccola Gjengeak
buchse puente er gwintowana vretena
Table 10: Globe Valve part list

GEST 17/492
2nd edition
Figure 2 - Process control Valve and Shut Off Valve bellow sealed
Control valve Shut-off valve

GEST 17/492
2nd edition
Ref German English Spanish French Italian Finnish Norwegian Dutch Polish Czech Swedish
1 Gehäuse Body Cuerpo Corps Corpo Runko Hus Huis Korpus Teleso Hus
2 Sitz Seat Asiento Siège Sede Istukka Sete Zitting Gniazdo Sedlo Säte
3 Kegel Disc Clapote Clapet Otturatore Lautanen Kjegle Klep Grzybek Kuzelka Kägla
4 Mutter Nut Tuerca Ecrou Dado Mutteri Mutter Moer Nakretka Matice Mutter
5 Stift- Studbolt Espárrago Tige filetée Prigioniero Vaarnaruuvi Pinneskrue Draadeind Sruba Svorník Pinnbult
schraube dwustronna
6 Aufsatz Bonnet Tapa Chapeau Calotta Kansi Ventiloverde Bovenstuk Pokrywa Víko telesa Ventilöverde
l l
7 Dichtung Gasket Empaquetad Joint Guarnizione Tiiviste Pakning Pakking Uszczelka Ploché Packning
ura tesneni
8 Distanz- Pillar Columna Colonnette Colonnette Sankaruuvi Distansebolt Afstandsbus Ogranicznik Vodici sroub Distansbult
bolzen
9 Stopfbuchs- Gland flange Cuerpo de Bride de Flangia Aandrukflens Kolnierz Ucpávková Packboxfläns
flansch prensa fouloir premistoppa dlawika priruba
10 Stopfbuchs- Gland Prensa- Presse- Premistoppa Tiivistysholki Pakkboks- Aandrukstuk Dlawik Víko ucpávky Gland
brille follower estopas étoupe nlaippa gland
11 Packung Gland Empaquetad Garniture Guarnizione Tiiviste Pakning Stopbuspakki Uszczelnieni Stlacovaná Packbox
packing ura ng e ucpávka
12 Antrieb Actuator Puente Actionneur Traverse Sanka Aktuator Brugstuk Wspornik Trmen Brygga
13 Spindel mit Stem Husillo Tige Stelo Kara Spindel med Spindel Wrzeciono Vreteno Gängad
Gewinde roscado gjenger gwintowane spindel
14 Faltenbalg Bellow Fuelle Soufflet Soffietto Palje Belg Balg Mieszek Vlnovec Bälg
Table 11- Process and shut-off valve part list

GEST 17/492
2nd edition
Appendix 7: Ball valve and part List
Figure 6 - Typical bolted gland ball Valve

GEST 17/492
2nd edition
Ref English French German Dutch Spanish Italian Finnish Czech Swedish
1 Body Corps du robinet Ventilgehäuse Huis Cuerpo Corpo Runko Teleso Hus
2 Ball Tournant sphérique Kugel Kogel Bola Sfera Pallo Koule Kula
3 Body seat Siège Gehäusesitz Zittingsring Asiento Sede Tiivistysrengas Sedlo Säte
4 Stem Tige Spindel Spindel Husillo roscado Stelo Kara Drik Spindel
5 Friction bearing Rondelle de friction Anlaufscheibe Glijring Arandela de fricción Anello di tenuta Kitkarengas Treci lozisko O-ring
6 Primary stem seal Etanchéité primaire Primäre Packung Eerste Empaquetadura Tenuta primaria Ensisijainen tiiviste Primarni ucpavka Primär tätning
spindelafdichting primaria
7 Secondary stem seal Etanchéité Sekundäre Packung Tweede Empaquetadura Tenuta secondaria Toissijainen tiiviste Sekundarni ucpavka Sekundär tätning
secondaire spindelafdichting secundaria
8 Leak detection Detection de fuite Leckage Lekdetectie Detector de fugas Rilevatore perdite Vuodon ilmaisin Detekce netesnoti Läck indikator
überwachung
9 Bonnet Chapeau Deckel Deksel Tapa Cappello Venttiilin vläosa Viko telesa Ventil överdel
10 Lever Levier de manoeuvre Hebel Hendel Palanca Volantino Kahva Paka Handtag
11 Flange Bride de Flansch Flens Brida de Flangia Laippa Priruba Fläns
raccordement acoplamiento
12 Gland flange Fouloir de presse- Stopfbuchsbrille Pakkingdrukker Prensa-estopas Premistoppa Poksin painaja Ucpavkova priruba Gland
ètoupe
13 Lantern ring Lanterne Laternenring Lantaarnring Linterna Lanterna Holkki Zahlcovaci krouzek Distans hylsa
Table 12 - Ball valve parts list

GEST 17/492
2nd edition
Appendix 8: Assembly of a pneumatically operated storage tank valve

GEST 17/492
2nd edition
Appendix 9: Assembly of a pneumatic operated transport container valve

GEST 17/492
2nd edition
Appendix 10: Removal and Decontamination Procedure
1. General principles
When chlorine leak testing, replacing or decontaminating valves, the operators must be equipped
with chlorine protection masks, follow the documented procedures and respect the safety
requirements.
Any defect observed during the operations performed by the process workers should be
communicated to the maintenance unit (internal department or external workshop) and, if necessary,
to the valve manufacturer.
2. Introduction
There are two reasons to remove a pneumatically operated valve:
1. The valve is leaking (normally only the externally mounted valve should be removed);
2. The valve must be inspected (preventative action).
Normally, this inspection is done at the same time as the legal inspection of the vessel and the
complete valve is removed.
Disassembling and decontamination of the valve should be completed as quickly as possible in order
to avoid corrosion resulting from the mixture of chlorine with moisture in the air.
3. Removal of valve
• In the case of a leaking valve, if possible, the location of the leak (seat, bellow and/or
diaphragm) should be identified prior to venting down the tank. This information is important
for the maintenance workshop at the time of the inspection and the repair of the valve’s
internal parts;
• Vent down and purge the tank with dry air or nitrogen until chlorine free;
• Remove:
▪ the side-mounted plug of the chamber formed between the diaphragm and the bonnet
(opening in the upper chamber for connexion of the motor air),
▪ the side-mounted test plug of the chamber formed by the body valve, the diaphragm and
the bellow (opening in the middle chamber allowing the control, during normal operation,
of the integrity of the bellow).
• Always vent the bellow and diaphragm chambers (in case there has been any internal leakage
e.g. diaphragm or bellow failure);
• If necessary, move the mobile tanker to the maintenance workshop, or to a ventilated area;
• Remove the valve, seal immediately the tank opening(s) and examine the state of the gasket
and the contact surfaces (valve and tank plate if possible) in order to detect presence of dirt,
defects or inadequate tightening (always replace the gaskets).
4. Decontamination of valve
• Remove the blind flange (for mobile tankers);
• If necessary, open the valve about 50% with the manual override system to facilitate the
washing operation;
• Immediately wash the valve with:
▪ a weak alkaline solution (3-5% NaOH or 5-10% Na2CO3),
▪ or high flow of warm water (about 50°C),

GEST 17/492
2nd edition
▪ or steam.
until all ferric chloride has been removed.
Particular care is required around the bellow.
Preferably the valve should be disassembled immediately and:
• Each part washed with:

▪ a weak alkaline solution and then rinsed with water,
▪ or warm water (about 50°C),
▪ or steam.
• All the parts dried, for example in an oven at 60°C or above.
If disassembly must be delayed significantly, then proceed with decontamination as follows:
• Plunge the valve in a weak alkaline solution (3-5% NaOH or 5-10% Na2CO3), taking care that
all the parts are completely immersed (the treatment period must last at least 2 hours, but
not exceed 24 hours),
• Wash the valve thoroughly with water to remove all possible mud from the previous treatment
and drain all chambers,
• Blow dry air through the valve’s openings to facilitate the following drying operation,
• Dry for 24 hours in a drying oven at 60°C or above,
• Seal the valve to prevent moisture ingress.

GEST 17/492
2nd edition
Industrial consumers of chlorine, engineering and equipment supply companies worldwide and
chlorine producers outside Europe may establish a permanent relationship with Euro Chlor by
becoming Partners.
Details of Membership categories and fees are available from:
Euro Chlor
Rue Belliard 40 box 15
1040 Brussels
Belgium
Tel: +32 2 436 9511
Email: eurochlor@cefic.be
Internet: http://www.eurochlor.org

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Specifications and Approval Procedure

for Valves to be Used in Liquid Chlorine

EURO CHLOR PUBLICATION

• Improve awareness and understanding of the contribution that chlorine

• Maintain open and timely dialogue with regulators, politicians, scientists,

• Ensure our industry contributes actively to any public, regulatory or

• Promote the best safety, health and environmental practices in the

January 2021 Page 2 of 84

RESPONSIBLE CARE IN ACTION

January 2021 Page 3 of 84

January 2021 Page 4 of 84

12.4 Bonnet ....................................................................................... 25

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17.8 Review by Euro Chlor ...................................................................... 58

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Valve Temperature Nominal sizes

Flanged globe remotely operated shut-

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3.2 Ball valves

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3.3 Valves for transport containers and storage tanks

4.1 Pressure and temperature design

Graph 1 - Maximum allowable/operating pressure for valves

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The pressure-temperature ratings of valves to this specification shall be in accordance with

4.2 Corrosion and erosion allowance

• For di ≤ 50 mm → C = 1,5 mm;

DN-size Corrosion &

4.3 Stem sealing

4.4 Drain tapping

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4.5 End flanges and the body to bonnet flange

Valve nominal size Minimum nominal size of stud bolt/stud

Remark: bolts of a smaller diameter may be accepted if sufficient dimensioning is proved.

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4.8 Anti-static design

5 Materials and manufacturing

5.2 Restrictions on chemical analysis and physical properties of steel

5.3 Impact requirements

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5.4.1 Pilot batch testing

5.4.2 Radiographic examination

Discontinuity type Category Acceptable comparative plate

Prototype, pilot batch and production

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5.4.3 Surface testing

5.4.4 Batch Size

DN50 NPS 2 Number of castings <50

5.4.5 Production batch testing

Two approaches may be taken to testing of casting production batches:

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5.5.1 Pilot batch testing of forgings

Pilot batches shall be completed for the following cases:

5.5.2 Production forgings

Following successful documented completion of pilot batches of forgings, production forging

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5.5.2.2 Surface examination of production forgings

5.6 Packing and gaskets

5.7 Finishing welding

5.7.1 Allowable areas for welding

5.7.2 Allowable defects for welding repairs

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5.7.3 Repair specifications