Requirements of chlorination equipment, Part 5: Bleaching powder solution feeder displacement type chlorinator
1987 Edition

Summary for Scope of Chlorinator (IS 10553 Part 5)

• Scope: Defines sizes, materials, and construction standards for displacement chlorinators that feed bleaching powder solution.
• Materials: Detailed in Table 1 (Clause 3.1), specifying component materials.
• Rounding Guidelines: Test and calculation outcomes must conform to IS 2:1960 rounding rules, preserving significant digits.

Highlights:

Rounding Procedure (IS 2:1960):

• Digits less than 5 after last significant digit are rounded down.
• Digits 5 or greater are rounded up.
• Number of significant figures must match the original standard value.

Refer to Table 1 in IS 10553 Part 5 for detailed material and size information.

Key Features of Displacement Chlorinator (Clause 2.1)

• Pressure Vessel:

  • Constructed from fabricated mild steel with a removable flanged lid.
  • Equipped with drain and outlet valves.
  • Houses a flexible plastic or rubber bag containing bleaching powder solution.
  • Rated for working pressure of 0.175 N/mm² and test pressure of 0.35 N/mm².

• Differential Pressure Device:

  • Includes an orifice plate or venturi tube.
  • Generates an adjustable differential pressure of about 2 meters water column at maximum flow.

• Injection Fitting:

  • Incorporates a withdrawal fitting with isolating valve.
  • Connects the pressure vessel to the pipeline via tubing.
  • Designed to withstand the chlorinator’s pressure.

• Dose Indicator and Control Valve:

  • Mounted on the pressure vessel to regulate and indicate dosing flow.

• Solution Preparation Tank:

  • Equipped with valves and piping to allow gravity feed into the pressure vessel.

Differential Pressure Calculation Formula:

[ \Delta P = \rho g h ]

Where:

• ( \rho ) = water density (~1000 kg/m³)
• ( g ) = acceleration due to gravity (9.81 m/s²)
• ( h ) = differential height (~2 m)

Conceptual Assembly Diagram:

flowchart LR
    A[Solution Preparation Tank] -->|Gravity Feed| B[Pressure Vessel]
    B -->|Bleaching Solution| C[Injection Fitting with Isolating Valve]
    C --> D[Water Pipeline with Orifice/Venturi]
    D -->|Differential Pressure| B
    B -->|Dose Indicator & Regulating Valve| E[Flow Control]

This configuration ensures precise chlorination by controlling the dosing through pressure differential and regulating valves in compliance with IS 10553 Part 5.

Material Requirements for Chlorinator Components (Clause 3.1, Table 1)

Notes:

• Mild steel is commonly used for structural parts.
• Plastic and PVC materials are chosen for corrosion resistance and chemical compatibility.

Sizing Guidelines for Chlorinators (Clause 4.1)

• Chlorinator size depends on the volume capacity of the plastic or rubber bag used inside the pressure vessel.
• Standard sizes offered (liters): 40, 80, 100, 150, and 250.

Selection Criteria:

• Based on daily water consumption.
• Required chlorine dosage.
• Bag capacity sufficient to minimize frequent refills.

Capacity Calculation Formula:

[ \text{Chlorinator Capacity (l)} = \frac{\text{Daily Water Volume (m}^3\text{)} \times \text{Chlorine Dose (mg/l)}}{\text{Chlorine Solution Concentration (mg/l)}} ]

Where:

• Chlorine Dose is the target chlorine concentration (typically 1-3 mg/l).
• Chlorine Solution Concentration refers to the bleaching powder solution strength.

Size Application Table:

flowchart LR
    A[Determine Water Demand & Chlorine Dose] --> B[Compute Required Chlorine Volume]
    B --> C[Choose Appropriate Chlorinator Size]
    C --> D{Available Options}
    D -->|40 l| E[Small Units]
    D -->|80 l| F[Medium Units]
    D -->|100 l| G[Moderate Units]
    D -->|150 l| H[Large Units]
    D -->|250 l| I[Very Large Units]

Refer to IS 10553 Part 5 and associated standards for detailed design guidance.

Method to Select Doser Size (Clause 5.1)

Volume of Bleaching Powder Solution Required:

[ v = \frac{Q \times x}{y \times z} ]

Where:

• ( v ) = bleaching powder solution volume (liters/day)
• ( Q ) = volume of water to be disinfected (m³/day)
• ( x ) = chlorine dose (mg/l)
• ( y ) = bleaching powder solution strength (percentage, typically 3-5%)
• ( z ) = available chlorine fraction in bleaching powder (usually 0.25 to 0.3)

Available Chlorinator Capacities:

• 40 l, 80 l, 100 l, 150 l, and 250 l

Select a chlorinator with a capacity equal to or exceeding ( v ).

Component Materials Overview (from Table 1):

Additional Notes:

• Pressure vessel working pressure: 0.175 N/mm²
• Test pressure: 0.35 N/mm²
• Differential pressure at orifice: ~2 m water head
• Bolt sizes: 12 mm for diameters under 150 mm, 16 mm above 150 mm

flowchart TD
    A[Compute solution volume v] --> B{Choose Doser Size}
    B -->|v ≤ 40 l| C[40 l chlorinator]
    B -->|40 l < v ≤ 80 l| D[80 l chlorinator]

Design Criteria According to IS 10553 Part 5

1. Material Selection (Clause 3.1, Table 1)

• Specifies appropriate materials for different chlorinator components.
• Common materials include:
  • Cast iron for main structural parts.
  • Brass or bronze for valves and fittings.
  • Stainless steel for components exposed to severe corrosion.
• Refer to Table 1 for detailed material assignments.

2. Rounding Off (Clause 0.4)

• Results of tests or calculations should be rounded following IS 2:1960.
• The rounded value must maintain the same number of significant figures as the original specification.

Additional Design Considerations:

• Pressure vessel thickness can be calculated using:

[ t = \frac{P \times d}{2 \times \sigma \times E + P} ]

Where:

• ( t ) = wall thickness

• ( P ) = design pressure

• ( d ) = vessel diameter

• ( \sigma ) = allowable stress for material

• ( E ) = joint efficiency

• Corrosion allowance is generally 1-2 mm, depending on environment.

Example Material Summary:

flowchart TD
    A[Material Selection] --> B[Cast Iron for Body]
    A --> C[Brass/Bronze for Valves]
    A --> D[Stainless Steel for Internals]
    E[Thickness Design] --> F[Pressure, Diameter, Stress Considerations]
    E --> G[Include Corrosion Allowance]

Refer to Table 1 of IS 10553 Part 5 and IS 2-1960 for detailed specifications.

IS 10553 Part 5 (1987) emphasizes the testing and inspection requirements for chlorination equipment.

Key Testing and Inspection Points:

• Rounding of Results: Final measurements must be rounded according to IS 2-1960, maintaining consistent significant figures.
• Material Verification: Confirm materials per Table 1 (Clause 3.1) before testing.

Common Testing Methods:

• Visual inspection for surface defects and dimensional accuracy.
• Mechanical testing including tensile, compression, and bend tests following relevant IS codes.
• Non-destructive testing such as ultrasonic or radiographic examination for weld integrity and internal flaws.
• Sampling frequency and procedures per IS 10553 or IS 2500 series.

Summary of Rounding Rules (IS 2-1960):

flowchart TD
    A[Material Selection] --> B[Visual Inspection]
    B --> C[Mechanical Testing]
    C --> D[Non-Destructive Testing]
    D --> E{Test Outcome}
    E -->|Pass| F[Accept Component]
    E -->|Fail| G[Reject or Repair]

Refer to Table 1 of IS 10553 Part 5 and IS 2-1960 for detailed guidance.

While IS 10553 Part 5 primarily specifies equipment requirements, it does not explicitly detail installation or operation procedures.

Key Points to Consider:

• Materials: Components must meet corrosion resistance requirements as specified in Clause 3.1 and Table 1.
• Installation Practices:
  • Secure foundations and anchoring to minimize vibrations.
  • Ensure proper ventilation and drainage.
  • Allow easy access for maintenance and emergency shutdown.
• Operation:
  • Maintain controlled dosing rates.
  • Conduct regular leak inspections and routine maintenance.
  • Incorporate safety devices such as alarms and interlocks.

Chlorine Dosing Calculation (Typical Formula):

[ Q_c = \frac{C \times Q_w}{1000} ]

Where:

• ( Q_c ) = chlorine flow rate (kg/hr)
• ( C ) = target chlorine concentration (mg/L)
• ( Q_w ) = water flow rate (m³/hr)

Material Selection Summary:

flowchart LR
    A[Chlorine Cylinder] --> B[Valve]
    B --> C[Flow Meter]
    C --> D[Dosing Point]
    D --> E[Water Supply Pipeline]

For comprehensive installation and operational details, consult manufacturer manuals and relevant safety standards such as IS 2825 and IS 13428.

Although IS 10553 Part 5 (1987) emphasizes structural and material aspects, direct clauses on maintenance and safety are limited. The following best practices are derived from standard engineering principles and IS guidelines:

Maintenance and Safety Recommendations:

• Routine Inspection: Conduct visual and detailed checks for corrosion, cracks, and wear.
• Material Consistency: Use replacement materials conforming to Table 1 (Clause 3.1) to ensure compatibility.
• Load Monitoring: Verify operational loads remain within design limits.
• Safety Factors: Apply prescribed safety margins to accommodate unexpected stresses.
• Preventive Care: Schedule regular cleaning, painting, and lubrication to extend equipment life.
• Safety Measures: Install signage and barriers to protect personnel during maintenance work.

Safety Factor Calculation:

[ \text{Safety Factor} = \frac{\text{Ultimate Strength}}{\text{Working Stress}} ]

Example Material Specifications:

flowchart TD
    A[Inspection] --> B[Detect Defects]
    B --> C[Material Testing]
    C --> D{Defects Present?}
    D -- Yes --> E[Repair or Replace Using Table 1 Materials]
    D -- No --> F[Continue Operation]
    E --> F

For detailed maintenance protocols and safety procedures, consult the full IS 10553 Part 5 and related operational standards.

Key Features of Bleaching Powder Solution Feeder (IS 10553 Part 5)

• Pressure Vessel:

  • Fabricated from mild steel.
  • Designed for a working pressure of 0.175 N/mm² and tested at 0.35 N/mm².
  • Includes removable flanged cover, drain and outlet valves.
  • Contains a flexible plastic or rubber bag for holding bleaching powder solution.

• Differential Pressure Device:

  • Orifice plate or venturi tube creating about 2 m water head differential pressure at maximum flow.

• Injection Fitting:

  • Withdrawal fitting with isolating valve.
  • Connects pressure vessel to pipeline via tubing.
  • Designed to withstand operating pressure.

• Dose Indicator and Regulating Valve: Mounted on vessel for precise flow control.

• Solution Preparation Tank: Gravity feeds solution into pressure vessel.

Assembly Concept Diagram:

flowchart LR
    A[Solution Preparation Tank] -->|Gravity Feed| B[Pressure Vessel with Bag]
    B -->|Bleaching Solution| C[Injection Fitting with Valve]
    C --> D[Water Pipeline]
    D --> E[Orifice Plate / Venturi Tube]
    B --> F[Dose Indicator & Regulating Valve]

This layout provides controlled and safe delivery of bleaching powder solution to water systems as per IS 10553 Part 5.

Material Specifications Overview (Clause 3.1 & Table 1)

• Various components such as pipes, fittings, and joints must comply with specified materials listed in Table 1.
• Common materials include:
  • Cast iron for pipes and fittings.
  • Rubber for gaskets and sealing elements.
  • Cement mortar for joint sealing.
• All materials must conform to relevant IS standards, e.g., IS 1538 for cast iron, IS 5382 for rubber.

Rounding Off Requirements (Clause 0.4)

• Test or analysis results are to be rounded according to IS 2:1960.
• The precision of rounded values must match the standard’s required significant figures.

Sample Materials Table:

For detailed properties and comprehensive tables, consult Table 1 in IS 10553 Part 5.