Chemical Handling & Auto-Doser Safety

The Plunge All-In Commercial Max uses an automated dosing system to maintain water quality. While this system improves precision, it requires strict adherence to safety protocols during chemical handling and tank refills. A single mistake in chemical identification can result in the immediate release of toxic chlorine gas.

This SOP covers two chemicals:

• Muriatic Acid — 14.5% Hydrochloric Acid (HCl)
• Liquid Pool Chlorine — 10% Sodium Hypochlorite (NaOCl)

All operators must read and understand this SOP before handling either chemical. Plunge strongly recommends that every facility operating the All-In Commercial Max have at least one Certified Pool Operator (CPO) on staff. A CPO-certified team member provides a baseline of chemical safety knowledge that directly reduces risk during routine maintenance and emergency situations.

Chemical Quick Reference

Here are the safety data and chemical safe handling sheets for the chemicals used for the Plunge All-In Commercial Max: Muriatic Acid (14.5% Hydrochloric Acid) and Liquid Pool Chlorine (10% Sodium Hypochlorite).

• HDX Muriatic Acid MSDS
• Acid Blue Muriatic Acid MSDS
• HDX Liquid Pool Chlorine MSDS

⚠️ Critical Hazard: Never Mix These Chemicals

Combining Muriatic Acid and Liquid Pool Chlorine in any concentration — including inside a dosing tank — triggers an immediate violent chemical reaction. The result is the rapid release of chlorine gas, a toxic, potentially lethal substance.

Chlorine gas is yellow-green in color, has a sharp suffocating odor, and is immediately dangerous to life and health (IDLH: 10 ppm per NIOSH).

1. Cross-Contamination Prevention

Dedicated Equipment Rule

• Use a separate, clearly labeled funnel and measuring cup for each chemical. Never share tools between chemicals, even after rinsing.
• Color-code or permanently label all equipment to prevent confusion.
• Note: the All-In Commercial Max uses integrated pumps built into the Hanna dosing system. Do not introduce external pumps or transfer equipment not designed for this system.

Safe Handling Best Practices

• One refill at a time: Do not handle acid and chlorine refills at the same time. Complete one chemical's refill process in full, including resealing and stowing the container, before beginning the other. This is the single most effective way to prevent cross-contamination.
• Buddy system: Never handle chemicals alone. Always have a second person present during any chemical refill. In the event of a spill, splash, or gas release, a second person can call for help or assist with first aid response immediately.

Tank Identity Rules

• NEVER top off a tank unless you have 100% verified both the chemical inside the tank and the chemical you are adding.
• NEVER repurpose a tank (e.g., do not convert an acid tank into a chlorine tank under any circumstances).
• Tanks must be permanently labeled. If a label is missing or unclear, treat the tank as unidentified and do not refill until it is verified.

2. Refill Protocol: Verify Twice, Pour Once

Follow these steps in order before refilling any dosing tank.

1. Ensure the area is well-ventilated before beginning.
2. Put on all required PPE (see Section 3) before opening any container.
3. One-at-a-time rule: Only ONE chemical container may be open at a time. If refilling chlorine, the acid container must remain sealed and vice versa.
4. Read the manufacturer label on the supply bottle.
5. Read the label on the dosing tank you are about to fill.
6. Confirm both labels match. Do NOT rely on liquid color or jug shape.
7. Pour using the dedicated equipment for that chemical only.
8. Immediately re-seal both the supply bottle and the dosing tank cap.
9. Return all equipment to its designated storage location.

3. Required PPE

Eyewash Station: An eyewash station must be accessible within 10 seconds of the chemical handling area. Verify it is functional before beginning any refill.

4. Storage Requirements

• Store Muriatic Acid and Liquid Chlorine as far apart as physically possible.
• Store both chemicals in a cool, dry, well-ventilated location away from direct sunlight and heat sources.
• Keep all containers tightly sealed when not actively in use.
• Ensure all auto-doser tank caps are tight-fitting to prevent reactive vapors from mixing in the air.
• Do not store near incompatible materials: acids must not be near oxidizers or bases; chlorine must not be near acids, ammonia, aluminum, or steel.
• Store in original, manufacturer-labeled containers only. Never transfer to unlabeled or repurposed containers.
• Keep containers locked up and out of reach of unauthorized personnel.

5. First Aid

These procedures apply to both chemicals. Call Poison Control at (866) 366-5048 for all exposures, or dial 911 for severe incidents.

6. Accidental Spill Response

For spills of either chemical individually (no mixing):

• Keep people and ignition sources away from the spill area.
• Ensure adequate ventilation, especially in confined areas.
• Wear full PPE before approaching the spill.
• Contain the spill using inert absorbent material (sand, silica gel, acid binder, or universal binder).
• Transfer absorbed material to properly labeled containers for disposal.
• Dispose of all waste in accordance with federal, state, and local regulations.
• Do not allow spilled material to enter waterways or drains. Sodium Hypochlorite (Liquid Chlorine) is classified as very toxic to aquatic life with long-lasting effects.

Neutralizing an acid spill (Muriatic Acid only): Sodium bicarbonate (baking soda) can be used to neutralize a Muriatic Acid spill on surfaces. Apply it carefully to the affected area. This reaction produces hydrogen gas as a byproduct, so it must only be done in a well-ventilated area. Do not use sodium bicarbonate in a confined or enclosed space.

7. Emergency Response: Wrong Tank Addition / Gas Release

If Muriatic Acid is added to a Chlorine tank, or vice versa, a chemical reaction may begin immediately. Chlorine gas may be produced. Act without hesitation.

1. STOP IMMEDIATELY. Do not attempt to neutralize the reaction by adding more of the correct chemical. This will make it worse.
2. EVACUATE THE AREA. Do not wait to assess the situation. A yellow-green gas or sharp suffocating odor confirms the reaction has started.
3. DO NOT MOVE THE TANK. Moving a reacting container accelerates gas dispersion and risks splashing corrosive liquid onto personnel.
4. CALL 911 IMMEDIATELY. Inform emergency services: "A Chlorine Gas release has occurred due to mixing Sodium Hypochlorite and Hydrochloric Acid."

Gas release warning signs:

• Yellow-green visible gas or cloud near the dosing system
• Sharp, suffocating, bleach-like odor that burns the nose and throat
• Eye, nose, or throat irritation experienced by nearby personnel
• Hissing or bubbling from within a dosing tank

If any of these signs are present: evacuate immediately. Do not re-enter until emergency services declare the area safe.

8. Regulatory & Disposal Information

CERCLA Reportable Quantities

• Hydrochloric Acid: 5,000 lb reportable quantity. Spills reaching waterways or the environment must be reported.
• Sodium Hypochlorite: 100 lb reportable quantity. This lower threshold requires extra care to prevent environmental release.

SARA Section 313

• Hydrochloric Acid (HCl) is a SARA 313 reportable chemical. Reporting threshold: 1.0%.

Disposal

• Dispose of all chemical waste in accordance with applicable federal, state, and local regulations.
• Do not reuse empty chemical containers.
• Contact your local waste disposal authority for guidance on corrosive liquid disposal.

Emergency Contact Reference