IXOM CHLORGUARD User manual

DOCUMENT No. CHL07-M
PART No. CHL01
REVISION 3.1.6
20/12/2015
CHLORGUARD USER'S MANUAL

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IMPORTANT INFORMATION
The equipment described in this manual is designed to be used in conjunction with liquefied chlorine
gas which is hazardous to personnel safety. It is important that persons employed in the vicinity of a
chlorine installation be given an appropriate level of training in chlorine safety practices and know the
location of safety equipment. Orica has wall charts and handbooks available which describe safe
practice in storing and handling chlorine.
This manual is provided for information purposes only.
All information included herein is subject to change without notice.
Orica should not be held responsible for any damages, direct or indirect, arising from or related to use
of this manual.

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TABLE OF CONTENTS Page
1General...................................................................................... 5
1.1 Typical Setup (70 kg cylinders).....................................................................5
1.2 Typical Setup 920Kg Drums..........................................................................6
2Key Components...................................................................... 7
2.1 Control Panel ................................................................................................8
2.1.1 DC (UPS) power supply........................................................................................11
2.1.2 PLC (Programmable Logic Controller) ..................................................................11
2.1.3 GMS wireless module...........................................................................................11
2.1.4 Warning LED’s: Visual Alarm ................................................................................11
2.2 Support Bracket ..........................................................................................12
2.3 Connecting Transmitting Key......................................................................12
2.4 Actuator Types............................................................................................13
2.5 Chlorine Transmitter & Sensor....................................................................13
3OPERATION............................................................................ 15
3.1 Overview.....................................................................................................15
3.1.1 Power Supply........................................................................................................15
3.1.2 Battery Back-Up....................................................................................................15
3.1.3 PLC Programmable Logic Controller.....................................................................15
3.1.4 DC (UPS) power supply........................................................................................15
3.1.5 Chlorine Sensor/Transmitter.................................................................................15
3.1.6 Closing Actuators..................................................................................................16
3.1.6.1 Electric Actuators ................................................................................................................. 16
3.1.6.2 Pneumatic Actuators............................................................................................................ 16
3.1.6.3 Air Regulator ........................................................................................................................ 16
3.1.6.4 Air Pressure Switch.............................................................................................................. 16
4Functional Description........................................................... 17
4.1 Control Panel ..............................................................................................17
4.1.1 PLC- Programmable Logic Controller....................................................................17
4.1.2 Back-Up Power Supply.........................................................................................17
4.1.3 Relay Interface......................................................................................................18
4.1.4 GSM Modem.........................................................................................................18
4.1.5 Solenoid Valve (Pneumatic Version Only).............................................................18
4.1.6 Pressure Switch (Pneumatic Version Only)...........................................................18
4.1.7 SCADA Digital Outputs.........................................................................................19
4.1.8 Mains Power Input................................................................................................22
4.1.9 Chlorine Sensor Pin Inputs ...................................................................................22
4.1.10 Electric Actuator Pin Inputs...................................................................................22
4.1.11 Pneumatic Actuator Inputs....................................................................................23
4.1.12 Chlorine Transmitter/Sensors ...............................................................................23

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4.1.13 Electric Actuator and Support Bracket Assembly ..................................................23
4.1.14 Electric Actuator Fitted to Standard Chlorine Valve...............................................24
4.1.15 Electric Actuator Fitted to Chlorine Institute Yoke & Siemens Vacuum Regulator.26
4.1.16 Electric Actuator Fitted to International Yoke & Acromet/Prominent Vacuum
Regulator............................................................................................................................27
4.1.17 Pneumatic Actuator and Support Bracket Assembly.............................................28
4.1.18 Pneumatic Actuator Fitted to Chlorine Institute Yoke and Siemens Vacuum
Regulator............................................................................................................................29
4.1.19 Pneumatic Actuator Fitted to International Yoke and Acromet/Prominent Vacuum
Regulator............................................................................................................................30
4.1.20 PLC Touch Screen Operation Menus....................................................................31
5Appendices............................................................................. 37

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1 GENERAL
Features of the ChlorGuard System
ChlorGuard provides an automatic emergency isolation system for chlorine cylinders and drums.
Operation of the system is initiated by an integral PLC and a Chlorine Sensor/Transmitter local to the
chlorine container. Further means of initiation can be by remote manual push buttons and trip inputs
from the user’s process.
1.1 Typical Setup (70 kg cylinders)

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1.2 Typical Setup 920Kg Drums

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2 KEY COMPONENTS
The chlorguard system includes the following key components
A. Control panel
B. Actuator (Electric or Pneumatic)
C. Cl2sensor
D. Frame (support of control panel)
E. Air Systems (only if the systems is pneumatic)
F. Support bracket
G. Connecting Transmitting Key
The following chlorguard assembly diagram to ilustrates the main components of the system:

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2.1 Control Panel
The Control Panel cabinet includes ports for:
Power
Sensors
Up to 8 Actuators (electrical or pneumatic)
Pneumatic solenoid valve input and output.
External devices (SCADA, Alarms etc.)
The Control Panel internal distribution design differs in the cabinet regarding if the actuator is electric
or pneumatic ; they’re illustrated in the following drawings:

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Control Panel Electric
Front View
Control Panel Pneumatic
Front View

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The following are the list of all components inside the cabinet :
Components
Control Panel
electronic
Pneumatic
a
Cabinet-plastic box


b
DC (UPS) power supply


c
PLC (Programable Logic Controller)


d
GMS wireless module


e
Battery


f
Relays (Auxiliary relay, base of the
relay and auxiliary relay)


g
Warning LED’s:
Visual Alarm (3 Flashing light)


h
Connectors (Hearvy load connector)


i
Pressure switch

j
Solenoid Valve

k
Sockets and plugs


The connection points the Control Panel are shown if the diagram below.

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2.1.1 DC (UPS) power supply
The DC Uninterrupted Power Supply (UPS) provides reliable 24 VDC Power Supply load to the
ChlorGuard system.
2.1.2 PLC (Programmable Logic Controller)
The ChlorGuard PLC includes a touch screen that provides system
information and access to menus within the program for those
authorised.
2.1.3 GMS wireless module
The GSM transfers information on the status and alarm conditions of the ChlorGuard system for
up to 4 operator phone contacts if required. Important information such as chlorine releases and
alarms are immediately transferred by wireless to operators letting them know when and how
much chlorine is in the work area. Operators can use their phones to log into the ChlorGuard
system to check the status of the system at any time.
2.1.4 Warning LED’s: Visual Alarm
Indicating lights on the front of the panel include the following.
The other indication light such as Low air pressure, etc., is show in the PLC screen.

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Allowance made to connect up a flashing “Warning Light” and “Audible” alarm connection so the
Customer can connect to.
2.2 Support Bracket
The patented support bracket has capability of attachment to both the pneumatic or electric type
actuators and is made from mild steel and powder coated.
Electric Support Bracket
Pneumatic Support Bracket
2.3 Connecting Transmitting Key
A small key which connects the actuator to the valve spindle.
Electric Actuator Key
Pneumatic Actuator Key

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2.4 Actuator Types
The ChlorGuard system provides a choice of using a 24V electric powered geared motor actuator or
alternatively using a pneumatically powered geared ratchet actuator.
Electric Actuator & Bracket Assembly Pneumatic Actuator & Bracket Assembly
2.5 Chlorine Transmitter & Sensor
The standard chlorine sensor for the ChlorGuard 7 system is the Drager Polytron 7000
Transmitter/Sensor system. The transmitter/sensor has a Safety Integrity Level 2 (SIL2) rating, which
assures reliable performance. The transmitter produces a 4-20 mA signal which is proportional to the
gas concentration and in combination with the controller system (PLC) can be used to activate safety
relevant functions in compliance with the requirements of the IEC 61508 / IEC 61511-1.
The Transmitter meets the following requirements:
Functional Safety acc. To IEC 61508 / IEC 61511-1
Explosion protection acc to EN 50014 and EN 50020
Electromagnetic Compatibility (EMC) acc. To EN 50270
The Sensor consists of a gel which creates a signal when it comes into contact with chlorine gas. The
sensor can be easily removed by just unplugging the sensor from the Transmitter.
The Polytron 7000 Transmitter/sensor should be Proof tested annually for accurate results and
corrects any small drift in span of the sensor.
The Transmitter transmits the signal from the chlorine Sensor and converts this to a reading of what
he chlorine level being detected to the ChlorGuard Control Panel PLC. The Transmitter also provides
a digital reading of the chlorine level.
The chlorine sensor Warning is set at 3ppm and alarm is set at 5ppm.
Warning of 3 ppm alerts personnel of presence of chlorine.
Alarm of 5pp will alert and activate the ChlorGuard system to shut the actuators on the
chlorine containers.

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DRAGER SENSOR
DRAGER TRANSMITTER

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3 OPERATION
3.1 Overview
ChlorGuard provides an automatic emergency isolation system for chlorine cylinders and drums.
Operation of the system is initiated by an integral PLC and a Chlorine Sensor/Transmitter local to the
chlorine container. Further means of initiation can be by remote manual push buttons and trip inputs
from the user’s process.
3.1.1 Power Supply
Power supply to the ChlorGuard7 is a standard 240V mains power plug and pin cable arrangement.
3.1.2 Battery Back-Up
Power backup consists of a pair of sealed lead acid batteries that provides 24V back-up power for a
minimum of 4 hours under load and 24 hours in Stand-By.
3.1.3 PLC Programmable Logic Controller
The touch screen PLC contains all the menus and control functions for the ChlorGuard7 system. The
program logic is fixed by Orica and cannot be tampered without Orica’s approval and access
password. Menus can be accessed by touching the screen and following the instructions on the
screen. A full description of the PLC menus is outlined in Appendix A.
3.1.4 DC (UPS) power supply
The DC Uninterrupted Power Supply (UPS) provides reliable 24 VDC Power Supply load to the
ChlorGuard system. If there is AC input, it will provide power supply for the load and at the same time
recharge the chargeable battery. If there is no AC input, the battery will provide power supply to the
load. There is a management circuit for the chargeable battery inside (including charging constant
current circuit, battery protection, battery discharge control and automatic battery swift transfer
circuit).
3.1.5 Chlorine Sensor/Transmitter
Orica have chosen the Drager Polytron 7000 Chlorine Sensor/Transmitter which has a SIL2
certification (Safety Integrity Level). This provides an assurance of 99.9% reliability on the sensor and
transmitter provided the system is calibrated as instructed. The transmitter transfers the signal from
the chlorine sensor to the ChlorGuard PLC which in turn activates the actuators on the chlorine
contains to close. The Polytron 7000 transmitter also displays the level of chlorine via a digital
display. Up to 2 chlorine sensors can be connected to the ChlorGuard system control panel if
required. Other brands of sensor/transmitters can be used and connected to the analogue inputs to
the Control Panel.

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3.1.6 Closing Actuators
3.1.6.1 Electric Actuators
Inputs activate the PLC and associated relays to activate an electric actuator(s)
attached to the container valve to close. The electric actuator is set to close the
container valve at a set torque of 30Nm and once this is achieved the electric
actuator is stopped via current feedback and timer. The torque for the electric
actuator is set in the factory by adjustment of a potentiometer inside the cover of the
motor and tested using a torque wrench. The timer will cut the power to the electric
actuator once the set time programmed in the PLC is reached.
The sequence of shutdown is set to activate the actuator, close the container valve,
stop the electric actuator once the desired torque is reached and electric current
feedback signal is reached. To prevent the electric actuator from running if there is no
feedback electric current signal a timer has been set to stop the electric actuator after
a set time that assures the valve is closed.
3.1.6.2 Pneumatic Actuators
These inputs activate the PLC and associated relays to activate an pneumatic
actuator(s) attached to the container valve to close. The pneumatic actuator is set to
close the container valve at a set torque of 20-30Nm and once this is achieved the
pneumatic actuator is stopped via a timer which shuts the air supply to the actuator
after 5 seconds.
The torque for the pneumatic actuator is set by the air pressure supply.
The sequence of shutdown is set to activate the actuator, close the container valve,
stop the pneumatic actuator once the desired torque is reached and timer feedback
signal is reached.
3.1.6.3 Air Regulator
The Air regulator provides a regulated (400 kPa Minimum-600 kPa Maximum) air
pressure supply to operate the pneumatic actuator.
3.1.6.4 Air Pressure Switch
Senses the pressure in the compressed air supply to the system and provides an
output to the Control Panel if the working air pressure is less than the set point
(normally 400 kPa).

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4 FUNCTIONAL DESCRIPTION
4.1 Control Panel
The Control Panel is IP65 rated cabinet that consists of the following elements and functions:
PLC- Programmable Logic Controller
Back-Up Power Supply
UPS Power Supply
Relay Interface
GPSM Modem Module
Solenoid Vale (Only for Pneumatic Version)
Pressure Switch (Only for Pneumatic Version)
External Contacts Analogue Plug Inputs
Mains Power Input
Chlorine Sensor Pin Inputs
Electric Actuator Pin Inputs
Pneumatic Actuator Inputs
4.1.1 PLC- Programmable Logic Controller
Function:
The touch screen PLC manages the operating function for the ChlorGuard 7 system.
Each ChlorGuard 7 system PLC is programmed prior using standard logic. Once the PLC is
programmed and set there is no further need to adjust the PLC and therefore maintains the integrity
of the ChlorGuard operating system
Touch Screen
The touch screen displays the following:
Chlorine Alarm
Actuators Closing
Health Status
Menus and Functions
Just press the screen to activate the menus.
Menus
Refer to screen menus page 28.
4.1.2 Back-Up Power Supply
The Back-Up power supply provides uninterrupted 24 volt power supply.
Consists of 2x12 Volt Seth batteries which provide sufficient charge to maintain power for at
least 4 hours power under load and up to 24 hours in backup mode.

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4.1.3 Relay Interface
Contact relays inside the Control Cabinet relay electronic signals to perform the following functions:
Supply power to devices such as lights, alarm, actuators, and solenoid valves.
4.1.4 GSM Modem
Only applies on Leased ChlorGuard7 systems.
The GSM transfers information on the status and alarm conditions of the ChlorGuard system for up to
3 operator phone contacts if required. Important information such as chlorine releases and alarms are
immediately transferred by wireless to operators letting them know when and how much chlorine is in
the work area. Operators can use their phones to log into the ChlorGuard system to check the status
of the system at any time.
HOW TO SET THE MODEM
- Place SIM card in modem.
- Add phone number via screen menu using F2 using format +614XXXXXX.
4.1.5 Solenoid Valve (Pneumatic Version Only)
The solenoid valve allows compressed air to flow to the pneumatic actuators when activated at the
chlorine alarm point and when the operator wishes to manually activate the pneumatic actuators.
4.1.6 Pressure Switch (Pneumatic Version Only)
This switch activates the solenoid valve to open and close.

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4.1.7 SCADA Digital Outputs
The control panel includes a set of voltage free contacts for SCADA connection.
Each contact has a predefined function as follow:
- System Healthy
- Chlorine alarm
- Low battery
EVENT
SCADA OUTPUT
PIN
NUMBER
CONTACT
RESPONSE
‐Total loss of power AC
- and low battery charge.
‐PLC failure
‐Sensor Failure
( Drager Polytron 7000)
‐Low air Pressure
(pneumatic model)
System Healthy
1
Open in the event
Chlorine leak is detected or
emergency shutdown is
perform
Chlorine Alarm
2
Close in the event
AC power loss and battery
Charge close to be finish
Low battery
3
Close in the event
Socket Pins Designation

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SCADA DIGITAL OUTPUT DIAGRAM.
Socket Circuit Diagram (at Chlorguard panel bottom)