Schedule XV

CHEMICAL WORKS

PART I

1. Application

This schedule shall apply to all manufacture and processes incidental

thereto carried on in chemical works.

2. Definition

For the purpose of this Schedule

(a) "Chemical works” means any factory or such parts of any factory wherein

the hazardous chemicals are manufactured, recovered or the manipulation

of such chemicals is carried on.

(b) "efficient exhaust draught" means localized ventilation effected by

mechanical or other means for the removal of gas, vapour, fume or dust to

prevent it from escaping into the air of any place in which work is carried

on;

(c) "bleaching powder" means the bleaching powder commonly called chloride

of lime ;

(d) "chlorate"mean schlorate or perchlorate;

(e) "caustic"mean shydroxide of potassiumor sodium;

(f) "chrome process"means the manufacture of chromateorbi-chromate

of potassium or sodium, or the manipulation, movement or other

treatment of these substances;

(g) "nitro or amino process" means the manufacture of nitro or amino

derivatives of phenol and of benzene or its homologues and the making of

explosives with the use of any of these substances ;

(h) the term 'permit to work' system means the compliance with the

procedures laid down under paragraph 20 of Part II ;

(i) "toxic substances" means all those substances which when they enter into

the human body, through inhalation or ingestion or absorption through

skin in sufficient quantities cause fatality or exert serious affliction of

health or chronic harmful effects on the health of persons exposed to it due

to its inherent chemical or biological effects in respect of substances whose

TLV is specified in Rule 49, exceeding the concentration specified therein

would make the substance toxic ;

(j) "emergency" means a situation or condition leading to a circumstance or

set of circumstances in which there is danger to the life or health of

persons or which could result in big fire or explosion or pollution to the

work and outside environment, affecting the workers or neighborhood in a

serious manner, demanding immediate action;

(k) "dangerous chemical reactions “means high speed reactions, rim-away

reactions, delayed reactions, etc., and are characterized by evolution of

large quantities of heat, intense release of toxic or flammable gases or

vapors, sudden pressure build-up, etc.;

(l) "manipulation" means mixing, blending, filling, emptying, grinding, sieving,

drying, packing, sweeping, handling, using, etc. ;

(m) "approved personal protective equipment" means items of personal

protective equipment conforming to the relevant BIS specifications or in

the absence of it, personal protective equipment approved by the Chief

Inspector-cum-Facilitator;

(n) "appropriate personal protective equipment" means that when the

protective equipment is used by the worker, he shall have no risk to his life

or health or body ; and

(o) "confined space" means any space by reason of its construction as well as

in relation to the nature of the work carried therein and where hazards to

the persons entering into or working inside exist or are likely to develop

during working.

PART-II GENERAL REQUIREMENTS

Applying to chemical works

1. House keeping

(1) Any spillage of materials shall be cleaned up before further processing.

(2) Floors,platforms,stairways,passages and gangways shall be kept free of

any

Obstructions.

(3) There shall be provided as mean so access to all parts of the plant to

facilitate cleaning.

2. Improper use of chemicals

No chemicals or solvents or empty containers containing residual

chemicals, solvents or vapors shall be permitted to be used by workers for

any purposes other than in the processes for which they are supplied.

3. Prohibition on the use of food,etc.,

No food, drink, tobacco, pan or any edible item shall be stored or heated or

consumed on or near any part of the plant or equipment.

4. Cautionary notices and instructions

(1) Cautionary notices in a language understood by the majority of workers

shall be prominently displayed in all hazardous areas drawing the attention

of all workers about the hazards to health, hazards involving fire and

explosion and any other hazard such as consequences of testing of

material or substances used in the process or using any contaminated

container for drinking or eating, to which the workers' attention should be

drawn for ensuring their safety and health.

(2) In addition to the above cautionary notice, arrangement shall be made to

instruct and educate all the workers including illiterate workers about the

hazards in the process including the specific hazards to which they may be

exposed to, in the normal course of their work. Such instructions and

education should also deal with the hazards involved in unauthorized and

unsafe practices including the properties of substances used in the process

under normal conditions as well as abnormal conditions and the

precautions to be observed against each and every hazard. Further, an

undertaking from the workers shall be obtained within one month of their

employment and (or old workers employed, within one month of coming

into operation of the rules, to the effect that they have read the contents

of the cautionary notices and instructions, understood them and would

abide by them. The training and instructions to all workers and all

supervisory personnel shall include the significance of different types of

symbols and colors used on the labels struck or painted on the various

types of containers and pipelines.

5. Evaluation and provisions of safeguards before the commencement of

process

(1) Before commencing any process or any experimental work, or any new

manufacture, the occupier shall take all possible steps to ascertain

definitely all the hazards involved both from the actual operations and the

chemical reactions including the dangerous chemical reactions. The

properties of the raw materials used, the final products to be made, and

any by-products derived during manufacture, shall be carefully studied and

provisions shall be made for dealing with any hazards including effects on

workers, which may occur during manufacture.

(2) Information in writing giving details of the process, its hazards and the

steps taken or proposed to be taken from the design stage to disposal

stage for ensuring the safety as in sub-paragraph (1) above should be sent

to the Chief Inspector-cum-Facilitator at the earliest but in no case less

than 15 days before commencing manufacture, handling, or storage

whether on experimental basis, or as pilot plant or as trial production, or

as large-scale manufacture.

(3) The design, construction, installation, operation, maintenance and

disposal of the buildings, plant and facilities shall take into consideration

effective safeguards against all the safety and health hazards so evaluated.

(4) The requirements under the sub-paragraphs (1) to (3) shall not ad in lieu

of or in derogation to, any other provisions contained in any Act governing

the work.

6. Authorized entry

Authorised persons only shall be permitted to enter any section of the

factory or plant where any dangerous operations or processes are being

carried on or where dangerous chemical reactions are taking place or

where hazardous chemicals are stored.

7. Examination of instruments and safety devices

(1) All instruments and safety devices used in the process shall be tested

before taking into use and after carrying out any repair to them and

examined once in a month, by a qualified person and once in every six

months, by a competent person. Records of such tests and examinations

shall be maintained in a register.

(2) All instruments and safety devices used in the process shall be operated

daily or as often as it is necessary, to ensure its effective and efficient

working at all times.

8. Electrical Installations

All electrical installations used shall be of an appropriate type to ensure

safety against the hazard prevalent in that area such as suitability against

dust, dampness, corrosion, flammability and explosion, etc., and shall

conform to the relevant ISI specifications governing their construction and

use for that area.

9. Handling and storage of chemicals

(1) The containers for handling and storage of chemicals shall be of adequate

strength taking into consideration the hazardous nature of the contents.

They shall also be provided with adequate labeling and colour coding

arrangements to enable identification of the containers and their contents

indicating the hazards and safe handling methods and shall conform to the

respective ISI standards. The instructions given in the label shall be strictly

adhered to. Damaged containers shall be handled only under supervision of

a knowledgeable and responsible person and spillage shall be rendered

innocuous in a safe manner using appropriate means.

(2) The arrangements for the storage of chemicals including charging of

chemicals in reaction vessels and containers shall be such as to prevent

any risk of fire or explosion or formation of toxic concentration of

substances above the limits specified in Rule 49

(3) Without prejudice to the generality of the requirements in sub-paragraph

(2) above, the arrangements shall have suitable ventilation facilities and

shall enable the maintenance of safe levels in vessels and containers. Such

arrangements shall also

(4) Take into consideration, the type of flooring and the capacity of flooring

and the compatibility requirements of substances with other chemicals

stored nearby.

(5) (a) Storage of chemicals and intermediate products, which are highly

unstable or reactive or explosive shall be limited to the quantities required

for two months use.

(b) Whenever the quantities laid down in the above clause (a) are to be

exceeded, the permission of the Chief Inspector-cum-Facilitator shall be

obtained.

(c) Not with standing any thing contained in clauses (a) and (b) above,

the Chief Inspector-cum-Facilitator may direct any factory carrying out

processes covered in chemical works to further limit the storage of

hazardous substances to quantities less than two months on considerations

of safety.

(6) Standby arrangements equal to the biggest container shall always be

available to transfer the toxic substances quickly into the standby storage

facility if any defect develops in any of the containers resulting in the

release of toxic substances.

(7) Any storage facility constructed using non-metallic material such as Fiber

glass Reinforced Plastics (FRP), all glass vessels, etc., shall have adequate

strength to withstand the stress, if any, exerted by the contents and shall

be properly anchored. Working platforms, atom ladders, pipe lines, etc.,

used in such storage facility shall not have any support on the structure of

the storage facility and shall be independently supported.

10. Facility for Isolation

The plant and equipment shall be so constructed and maintained as to

enable quick isolation of plant or part of plant or equipment, with

appropriate indication. One copy of the layout plan indicating the isolation

facilities shall always be available with the security personnel, the

maintenance and the Health and Safety personnel and these isolation

facilities shall be checked for its effectiveness once in a month.

11. Personal protective equipment

(1) All workers exposed to the hazards in the processes covered by this

schedule shall be provided with appropriate and approved type of personal

protective equipment. Such equipment shall be clean, sterile and hygienic

condition before issue.

(2) The occupier shall arrange to inform, educate and supervise all the

workers in the use of personal protective equipment while carrying out the

job.

(3) As regards any doubt regarding the appropriateness of any personal

protective equipment, the decision of the Chief Inspector-cum-Facilitator

will be final.

12. Alarm systems

(1) Suitable alarm and effective alarm systems giving audible and visible

indications, shall be installed at the control room as well as in all strategic

locations where process control arrangements are available so as to enable

corrective action to be taken before the operational parameters exceed the

predetermined safe levels or lead to conditions conducive for an outbreak

of fire or explosion to occur. Such alarm systems shall be checked daily

and tested every month at least once to ensure its performance efficiency

at all times.

(2) The Chief Inspector-cum-Facilitator may direct such systems to be

installed in case of plants or processes where toxic materials are being

used and spillage or leakage of which may cause wide spread poisoning to

or around the plant.

13. Control of escape of substances into the work atmosphere

(1) Effective arrangements such as enclosure, or by-pass or efficient exhaust

draught, maintenance of negative pressure, etc., shall be provided in all

plants, containers, vessels, sewers, drains, flues, ducts, culverts and

buried pipes and equipments, to control the escape and spread of

substances which are likely to give rise to fire or explosion or toxic hazards

during normal working and in the event of accident or emergency.

(2) In the event of the failure of the arrangements for control resulting in the

escape of substances in the work atmosphere immediate steps shall be

taken to control the process in such a manner, that further escape is

brought down to the safe level.

(3) The substances that would have escaped into the work

atmosphere before taking immediate steps as required in sub-paragraph

(2),shall be rendered innocuous by diluting with air or water or any other

suitable agent or by suitably treating the substances.

(4) The level of concentration of toxic substances in the work atmosphere

shall be monitored by suitable devices and shall not exceed the permissible

levels specified in rule 49

14. Control of dangerous chemical reactions

Suitable provisions, such as automatic and or remote-control

arrangements, shall be made for controlling the effects of "dangerous

chemical reactions". In the even to failure of control arrangements

automatic flooding or blanketing or other effective arrangements shall

come into operation.

15. Testing, examination, repair and maintenance of plant and equipment

(1) All parts of plant, equipment and machinery used in the process which in

the likely event of their failure may give rise to an emergent situation shall

be tested by a competent person before commencing process and retested

at an interval of two years or after carrying out repairs to it. The

competent person shall identify the parts of the plant, equipment and

machinery required to be tested as aforesaid and evolve a suitable testing

procedure. In carrying out the test as mentioned above in respect of

pressure vessels or reaction vessels the following precautions shall be

observed, namely :

(a) before the test is carried out, each vessel shall be thoroughly cleaned and

examined externally, and as far as practicable, internally also for surface

defects, corrosion and foreign matter. During the process of cleaning and

removal of sludge, if any, all due precautions shall be taken against fire or

explosion, if such sludge is of pyrophoric nature or contains spontaneously

combustible chemicals;

(b) as soon as the test is completed, the vessel shall be thoroughly dried

internally and shall be clearly stamped with the marks and figures

indicating the person by whom testing has been done and the date of test ;

and

(c) any vessel which fails to pass the test or which for any other reason is

found to be unsafe for use shall be destroyed or rendered unusable under

intimation to the Chief Inspector-cum-Facilitator.

(2) All parts of plant, equipment, machinery which in the likely event of

failure may give rise to an emergent situation shall be examined once in a

month by a qualified person and tested by a competent person once in

every six months.

(3) Records of testing and examination referred to in paragraphs (1)and(2)

shall be maintained as long as that part of the plant, equipment and

machinery are in use.

(4) All repair work including alteration, modification and addition to be carried

out to the plant, equipment and machinery shall be done under the

supervision of a responsible person who shall evolve a procedure to ensure

safety and health of persons doing the work. When repairs or modification

is done on pipelines and joints are required to be welded, but welding of

joints shall be preferred. Wherever necessary, the responsible person shall

regulate the aforesaid work through a 'permit to work system'.

(5) No machinery, plant or equipment shall be operated or maintained in

such a manner as to cause risk of bodily Injury.

16. Staging

(1) All staging that is erected for the purpose of maintenance work or repair

work or for work connected with entry into confined spaces and used in the

processes included in Appendix 'A shall be stable, rigid and constructed out

of substantial material of adequate strength. Such staging shall conform to

the respective Indian Standard Specifications.

(2) Staging shall not be erected over any closed or open vessel unless the

vessel is so constructed and ventilated to prevent exposure of persons

working on the stages.

(3) All the staging constructed for the purpose of this paragraph shall have

appropriate access which are safe and shall be fitted with proper hand rails

to a height of one meter and toe board.

17. Seating arrangements

The seating arrangements provided for the operating personnel working in

processes covered in Appendix 'A' shall be located in a safe manner as to

prevent the risk of exposure to toxic, flammable and explosive substances

evolved in the work environment in the course of manufacture or repair or

maintenance, either due to failure of plant and equipment or due to the

substances which are under pressure, escaping into the atmosphere.

18. Entry into or work in confined space

(1) The occupier of every factory to which the provision of this schedule apply,

shall ensure the observance of the following precautions before permitting

any person to enter or work inside the confined spaces:

(a) identify all confined spaces and the nature of hazards that are encountered

in such spaces, normally or abnormally and arrange to develop the most

appropriate safeguards for ensuring the safety and health of persons

entering into or working inside, the confined spaces;

(b) regulate the entry or work inside the confined spaces through a 'permit to

work system' which should include the safeguards so developed as

required under sub-clause (a) above;

(c) before testing the confined space for entry into or work, the place shall be

rendered safe by washing or cleaning with neutralizing agents or purging

with steam or men gases and making adequate forced ventilation

arrangements or such measure which will render the confined space safe;

(d) shall arrange to carry out such tests as are necessary for the purpose by a

competent person and ensure that the confined space is safe for the

persons to enter or work. Such testing shall be carried out as often as is

necessary during the course of work to ensure its continued safety;

(e) shall arrange to educate and train the personnel who would be required to

work in confined spaces about the hazards involved in the work. He shall

also keep in readiness the appropriate and approved personal protective

equipment including arrangements for rescue, resurrection and first aid,

and shall arrange supervision of the work at all times by a responsible and

knowledgeable person.

(2) The Occupier shall maintain a log of all entry into or work in, confined

spaces and such record shall contain the details of persons assigned for the

work, the location of the work and such other details that would have a

bearing on the safety and health of the persons assigned for this work. The

log book so maintained shall be retained as long as the concerned workers

are in service and produced to the Inspector-cum-Facilitator when

demanded.

19. Maintenance work, etc.

(1) All the work connected with the maintenance of plants and equipment

including cleaning of empty containers which have held hazardous

substances used in the processes covered in this Schedule, shall be carried

out under 'permit to work system' employing trained personnel and under

the supervision of responsible person, having knowledge of the hazards

and precautions required to deal with them.

(2) Maintenance work shall be carried out in such a manner that there is no

risk to persons in the vicinity or to persons who pass by. If necessary, the

place of such work shall be cordoned off or the presence of unconnected

persons effectively controlled.

20. Permit to work system

The permit to work system shall inter alia include the observance of

the following precautions while carrying out any specified work to be

subjected to the permit to work system

(a) all work subject to the permit to work system shall be carried out under

the supervision of a knowledgeable and responsible person;

(b) all parts of plant or machinery or equipment on which permit to work

system is carried out, shall remain isolated from other parts throughout

the period of permit to work and the place of work including the parts of

plant, machinery shall be rendered safe by cleaning, purging, washing,

etc.;

(c) all work subject to the permit to work system shall have pre-determined

work procedures which integrate safety with the work. Such procedures

shall be reviewed whenever any change occurs in material or equipment so

that continued safety is ensured;

(d) persons who are assigned to carry out the permit to work system shall be

physically fit in all respects taking into consideration the demands and

nature of the work before entering into the confined space. Such person

shall be adequately informed about the correct work procedure as well as

the precautions to be observed while carrying out the permit to work

system;

(e) adequate rescue arrangements wherever considered necessary and

adequate first-aid, rescue and resurrection arrangements shall be available

in good working condition near the place of work while carrying out the

permit to work system, for use in emergency ;

(f) appropriate and approved personal protective equipment shall be use while

carrying out the 'permit to work system';

(g) after completion of work subject to the 'permit to work system', the person

responsible shall remove all the equipment and tools and restore to the

original condition so as to prevent any danger while carrying out regular

process.

21. Safety sampling personnel

The occupier shall ensure the safety of persons assigned for collecting

samples by instructing them on the safe procedures. Such personnel shall

be provided with proper and approved personal protective equipment, if

required.

22. Ventilation

Adequate ventilation arrangements shall be provided and maintained at all

times in the process area where dangerous or toxic or flammable or

explosive substances could be evolved. These arrangements shall ensure

that concentrations, which are either harmful or could result in explosion,

are not permitted to be built up in the work environment.

23. Procedures for meeting emergencies

(1) The occupier of every factory carrying out the chemical works, shall

arrange to identify all types of possible emergencies that could occur in the

processes during the course of work or while carrying out maintenance

work or repair work. The emergencies so identified shall be reviewed every

year.

(2) The occupier shall formulate a detailed plan to meet all such identified

emergencies including arrangements for summoning outside help for

rescue and fire-fighting and arrangements for making available urgent

medical facilities.

(3) The occupier shall send the list of emergencies and the details of

procedures and plans formulated to meet the emergencies to the Chief

Inspector-cum-Facilitator.

(4) The occupier shall arrange to install distinctive and recognizable warning

arrangements to caution all persons inside the plant as well as the

neighboring community, if necessary, to enable evacuation of persons and

to enable the observance of emergency procedures by the persons who are

assigned emergency duties. All concerned must be well informed about the

warning arrangement and their meaning. The arrangement must be

checked for its effectiveness every month.

(5) Alternate power supply arrangements shall be made and inter-locked with

the normal power supply, system so as to ensure constant supply of power

to the facilities and equipment meant for compliance with requirements of

paragraphs 10,11,12,13, 14,18,22 and this paragraph of Part II, Part III,

Part IV and Part V of this Schedule.

(6) The occupier shall arrange to suspend the further process work in a place

where emergency is established and shall forthwith evacuate all persons in

the area except workers who have been assigned emergency duties.

(7) All the employees of the factory shall be trained about the action to be

taken by them including evacuation procedures during emergencies.

(8) All emergency procedures must be rehearsed every three months and

deficiencies, if any, in the achievement of the objectives shall suitably be

corrected.

(9) The occupier shall arrange to have ten percent of the workers trained in

the use of First-Aid Fire Fighting appliances and in the rendering of specific

First-Aid measures taking into consideration the special hazards of the

particular process.

(10) The occupier shall furnish immediately on request the specific chemical

identity of the hazardous substances to the treating physician when the

information is needed to administer proper emergency or first-aid

treatment to exposed persons.

24. Danger due to effluents

(1) Adequate precautions shall be taken to prevent the mixing of effluents

from different processes and operations which may cause dangerous

poisonous gas to be evolved

(2) Effluents which contain or give rise in the presence of other effluents to

poisonous gases shall be provided with independent drainage systems to

ensure that they may be trapped and rendered safe.

PART III

FIRE AND EXPLOSIONS RISKS

1. Source of ignition including lighting installation

(1) No internal combustion engine and no electric motor or other electrical

equipment and fittings and fixtures capable of generating sparks or

otherwise causing combustion or any other source of ignition or any naked

light, shall be installed or permitted to be used in the process area where

there could be fire and explosion hazards.

(2) All hot exhaust pipes shall be installed outside a building and other hot

pipes or hot surface or surfaces likely to become hot shall be suitably

protected

(3) The classification of work areas in terms of its hazard potential and the

selection of electrical equipment or other equipment that could constitute a

source of ignition shall be in accordance with the respective Indian

Standard.

(4) Where flammable atmosphere may be prevalent or could occur, the soles

of footwear worn by workers shall have no metal on them, and the wheels

of trucks or conveyers shall be conductive type.

(5) All tools and appliances used for work in this area shall be of non-

sparking type.

(6) Smoking in process areas where there are risks of fire and explosion shall

be prohibited, and warning notices in the language understood by majority

of workers shall be posted in the factory prohibiting smoking in the

specified areas.

2. Static Electricity

(1) All machinery and plant, particularly pipe lines and belt drives, on which

static charge is likely to accumulate, shall be effectively earthed.

Receptacles for flammable liquids shall have metallic connections to the

earthed supply tanks to prevent static sparking. Where necessary,

humidity shall be regulated.

(2) Mobile Tanker-wagons shall be earthed during filling and discharge;

precautions shall be taken to ensure that earthing is effective before suck

filling or discharge takes place.

3. Lightning protection

Lightning protection arrangement shall be fitted where necessary,

and shall be maintained.

4. Process heating

The method of providing heat for a process likely to result in fire and

explosion shall be as safe as possible and where the use of naked flame is

necessary, the plant shall be so constructed as to prevent any escaping

flammable gas, vapour, or dust coming into contact with the flame, or

exhaust gases, or other sources likely to cause ignition. Wherever possible,

the heating arrangement shall be automatically controlled at a pre-

determined temperature below the danger temperature.

5. Leakage of flammable liquids

(1) Provision shall be made to confine by means of suitable bund walls,

dykes, sumps, etc., possible leakages from storage vessels containing

flammable liquids.

(2) Waste material in contact with flammable substances shall be disposed off

suitably under the supervision of knowledgeable and responsible person.

(3) Adequate and suitable fire fighting appliances shall be in-stalled in the

vicinity of such vessels.

6. Safety valves

Every still and every closed vessel in which gas is evolved or into which gas

is passed, and in which the pressure is liable to rise above the atmospheric

pressure, shall have attached to it a pressure gauge and a proper safety

valve or other equally efficient means to relieve the pressure. These

appliances shall be maintained in good condition.

7. Installation of pipelines, etc.

All pipe lines carrying flammable or explosive substances shall be protected

from mechanical damage and shall be examined by a responsible person

once in a week to detect any deterioration or defects, or accumulation of

flammable or explosive substances, and record kept of any defects found

and repairs made.

8. Fire fighting system

(1) Every factory employing 500 or more persons and carrying out processes

listed in Appendix 'A' shall provide

(a) Trained and responsible fire fighting squad so as to effectively handle the

fire-fighting and life saving equipment in the event of fire or another

emergency. Number of persons in this squad will necessarily depend upon

the size of risk involved, but in no case shall be less than eight such

trained persons to be available at any time. The squad shall consist of

watch and ward personnel; fire pump man and departmental supervisors

and operators trained in the operation of fire and emergency services.

(b) Squad leaders shall preferably be trained in a recognised Government

institution and their usefulness enhanced by providing residence on the

premises.

(c) Squad personnel shall be provided with clothing and equipment including

helmets, boots and belts.

(2) A muster roll showing the duties allocated to each member of the squad

shall be prepared and copies supplied to each leader as well as displayed in

prominent places so as to be easily available for reference in case of

emergency.

(3) The pump man shall be thoroughly conversant with the location of all

appliances. He shall be responsible for maintaining all firefighting

equipment in proper working order. Any defect coming to his notice shall

be immediately brought to the notice of squad leader.

(4) As far as is practicable, the fire pump room and the main gate(s) of the

factory be connected to all manufacturing or storing areas through

telephone interlinked and placed in a convenient location near such areas.

(5) Fire hydrant system shall be capable of supplying a minimum of 4,500

liters per minute at a pressure of not less than 7 kilograms per square cm.

(6) Adequate provision of water supply for firefighting shall be made with

static storage capacity of not less than 2 hours aggregate pumping.

PART-IV

RISKS OF TOXIC SUBSTANCES

1. Leakage:

(1) All plants shall be so designed and constructed as to prevent the escape

of toxic substance. Where necessary, separate buildings, rooms, or

protective structures shall be used for the dangerous stages of the process

and the buildings shall be so designed as to localize any escape of toxic

substances.

(2) Catch pits, band walls, dykes, or other suitable safeguards shall be

provided to restrict the serious effects of such leakages. Catch pits shall be

placed below joints in pipelines where there is danger involved to

maintenance and other workers from such leakage.

2. Drainage

Adequate drainage shall be provided and shall lead to collection tanks

specifically provided for this purpose wherein deleterious material shall be

neutralized, treated or otherwise rendered safe before it is discharged into

public drains or sewers.

3. Covering of vessels

(1) Every fixed vessel or structure containing any toxic substance and not so

covered as to eliminate all reasonable risk of accidental contact of any

portion of the body of a worker, shall be so constructed as to avoid

physical contact.

(2) Such vessel shall, unless its edge is atleast 90 centimeters above the

adjoining ground or platform, be securely fenced to a height of atleast 90

centimeters above such adjoining ground or platform.

(3) Where such vessels adjoin and the space between them, clear of any

surrounding brick or other work is either less than 45 centimeters in width

or is45or more centimeters in width, but is not securely fenced on both

sides to a height of atleast 90 centimeters, secure barriers shall be so

placed as to prevent passage between them:

Provided that sub-paragraph (2) of this paragraph shall not apply to--

(a) Saturators used in the manufacture of sulphate of ammonia; and

(b) That part of the sides of brine evaporating pans which require raking,

drawing or filling.

4. Continuous exhaust arrangement

(1) Any process evolving toxic vapour, gas, fume and substance shall have

efficient continuous exhaust draught. Such arrangement shall be

interlocked in the process control wherever possible.

(2) In the event of failure of continuous exhaust arrangement, means shall

be provided to automatically stop the process.

5. Work bench

All the work benches used in process involving the manipulation of toxic

substances, shall be waded properly and shall be made of smooth

impervious surface which shall be washed daily after the completion of

work.

6. Waste disposal

(1) There shall be provided a suitable receptacle made of non-absorbable

material with a tightly fitting cover for depositing waste material soiled

with toxic substances and the contents of such saturators shall be

destroyed by burning or using other suitable receptacle methods under the

supervision of a responsible person.

(2) During the course of manufacture, whenever any batch or intermediate

products having toxicity is rejected on considerations of quality, sufficient

precautions shall be taken to render them innocuous or otherwise treat

them or inactivate them, before disposal.

(3) The empty containers of toxic substances shall be cleaned thoroughly

before disposal under the supervision of a responsible person.

PART-V SPECIAL PROVISIONS

1. Special precautions for Nitro or Amino Processes

(1) Un less the crystallized nitro or amino substances or any of its liquor is

broken or agitated in a completely enclosed process so as not to give rise

to dust or fume, such process shall be carried on under an efficient exhaust

draught or by adopting any other suitable means in such a manner as to

prevent the escape of dust or fume in the working atmosphere.

(2) No part of the plant or equipment or implements which was in contact with

nitro or amino compounds shall be repaired, or handled unless they have

been emptied and thoroughly cleaned and decontaminated.

(3) Filling of containers with nitro or amino compounds shall be done only by

using a suitable scoop to avoid physical contact and the drying of the

containers in the stove shall be done in such a manner that the hot and

contaminated air from the stove is not drawn into the work room.

(4) Processes involving the steaming into or around any vessel contain g nitro

or amino compounds or its raw materials shall be carried out in such a

manner that the steam or vapour is effectively prevented to be blown back

into the working atmosphere.

(5) Suitable antidotes such as methylene blue injections shall always be

available at designated places of work for use during emergency involving

the poisoning with nitro or amino compounds.

2. Special precautions for chrome processes

(1) Grinding and sieving of raw materials in chorine processes shall be carried

on in such a manner and under such condition as to secure effective

separation from any other processes and under an efficient exhaust

draught.

(2) There shall be washing facilities located very near to places where wet

chrome processes such as leaching, acidification, sulphate settling,

evaporation crystallization, centrifugation or packing arc carried out, to

enable quick washing of affected parts of body with running water.

(3) Weekly inspection of hand and fat of all persons employed in chrome

pawns shall be done by a qualified nurse and record of such inspections

shall be maintained in a form approved by the Chief Inspector-cum-

Facilitator.

(4) There shall be always available at designated places of work, suitable

ointment such as glycerin, Vaseline, etc., and water proof plaster in a

separate box readily accessible to the workers so as to protect against

perforation of nasal septum.

3. Special precautions for processes carried out in all glass vessels

(1) Processes and chemical reactions such as manufacture of vinyl chloride,

benzyl chloride, etc., which are required to be carried out in all glass

vessels shall have suitable means like substantial wire mesh covering to

protect persons working nearby in the event of breakage of glass vessel.

(2) Any spillage or emission of vapour from all glass vessel due to breakage,

shall be immediately inactivated or rendered innocuous by suitable means

such as dilution with water or suitable solvents so as to avoid the risk of

fire or explosion or health hazards.

4. Special precautions for processes involving chlorate manufacture

(1) Crystallization, grinding or packing of chlorate shall not be done in a place

used for any other purpose and such places shall have hard, smooth and

impervious surface made of non-combustible material. The place shall be

thoroughly cleaned daily.

(2) The personal protective equipment like overall, etc., provided for the

chlorate workers shall not be taken from the place of work and they shall

be thoroughly cleaned daily.

(3) Adequate quantity of water shall be available near the place of chlorate

process for use during fire emergency.

(4) Wooden vessels shall not be used for the crystallization of chlorate or to

contain crystallized ground chlorate.

5. Special precautions in the use of plant and equipment made from

reinforced plastics

(1) All plant and equipment’s shall conform to appropriate Indian or any other

National Standard.

(2) Care shall be taken during storage, transport, handling and installation of

plant and equipment’s to avoid accidental damage.

(3) All plant and equipment’s shall be installed in such a way as to ensure that

loads are distributed as intended in design or as per the recommendations

of the manufacturers.

(4) All pipe work shall be supported so that total loads local to the branches on

the vessel or tank do not exceed their design values.

(5) After erection, all plant and equipment’s shall be subjected to a pressure

test followed by a thorough examination by a competent person. The test

and examination shall be as per relevant standard. A certificate of test and

examination by competent person shall be obtained and kept available at

site.

(6) All plant and equipment’s shall be subjected to periodical test and

examination and record maintained as per paragraph 15 in Part II of this

schedule.

(7) Plant and equipment’s during their use shall not be subjected to over filling

or overloading beyond rated capacity.

6. Special precautions for fumigation process:

The Occupier shall ensure the health and safety of the workers required to

enter into the confined space where Fumigation process is carried on,

which includes personal protective equipment’s, supervision, testing

procedures to ensure the suitability of the workspace for human health and

safety.

PART-VI MEDICAL REQUIREMENTS

1. Decontamination facilities

In all places where toxic substances are used, the following

provisions shall be made to meet an emergency:

(a) Fully equipped first-aid box.

(b) Readily accessible means of drenching with water persons, part of body of

persons, and clothing of persons who have been contaminated with such

toxic and corrosive substances, and such means shall be as shown in the

table below:

Number of persons employed

Number of drenching showers

Number at any time

Up to 50 persons 2

between51to100 3

101to200 3+1for every 50 persons

thereafter

201to400 5+1for every 100 persons

thereafter

401and above 7+1for every 200 persons

thereafter

(c) a sufficient number of eye wash bottles filled with distilled water or suitable

liquid, kept in boxes or cupboards conveniently situated and clearly

indicated by a distinctive sign which shall be visible at all times.

2. Occupational health center

In all the factories carrying out chemical works, there shall be

provided and maintained in good order an occupational health center with

facilities as per scale laid down hereunder

(1) For factories employing up to 50 workers

(a) the services of a Health Surveillance Officer, available on retainer ship

basis, in his notified clinic near to the factory for seeking medical help

during emergency. He will also carry out the pre-employment and

periodical medical examinations as stipulated in paragraph 4 of this part.

(b) A minimum of five persons trained in first-aid procedures, amongst

whom at least one shall always be available during the working period

(c) A fully equipped first-aid box.

(2) For factories employing 51to200 workers

(a) The occupational health center shall have a room having a minimum

floor area of 1.5 sq. m. with floors and walls made of smooth, hard and

impervious surface and shall be adequately illuminated, ventilated and

equipped.

(b) A part-time Health Surveillance Officer will be in overall charge of the

Centre who shall visit the factory minimum twice in a week and whose

services shall be readily available during emergencies.

(c) There shall be one qualified and trained dresser-Cum-compounder on

duty throughout the working period.

(d) A fully equipped first aid box.

(3) For factories employing above 200 workers

(a) There shall be one full-time Health Surveillance Officer for factories

employing up to 500 workers and one more Health Surveillance Officer

for every 1,000 workers or part thereof.

(b) The occupational health center in this case shall have a minimum of 2

rooms each having a minimum floor area of 15 square meter with floors

and walls made of smooth, hard and impervious surface and shall be

adequately illuminated, ventilated and equipped.

(c) There shall be one trained nurse, one dresser-Cum-compounder and one

sweeper-cum-ward boy throughout the working period.

(d) The occupational Health Centre in this case shall be suitably equipped to

manage medical emergencies.

3. Ambulance Van

(1) In every factory carrying out chemical work there shall be provided and

maintained in good condition, a suitably constructed and fully equipped

ambulance van manned by a fulltime driver-cum-mechanic and a helper,

trained in first-aid for the purposes of transportation of serious cases of

accidents or sickness unless arrangements for procuring such facility at

short notice during emergencies have been made with the nearby hospital

or other places. The ambulance van shall not be used for any purpose

other than the purpose stipulated herein and will always be available near

the occupational health center.

(2) The relaxation to procure Ambulance Van from nearby places provided for

in sub-paragraph (1) above will not be applicable to factories if the

chemical work is also covered by hazardous process and for factories

carrying chemical works by employing more than 500 workers.

4. Medical examination

(1) Workers employed in chemical works shall be medically examined by a

Health Surveillance Officer in the following manner:

(a) Once before employment, to ascertain physical suitability of the person to

do the particular job;

(b) Once in a period of 6 months, to ascertain the health status of the

workers; and

(2) The details of pre-employment and periodical medical examinations carried

out as aforesaid shall be recorded in the Health register in Form : HR

(3) No person shall be employed for the first time without a Certificate of

Fitness in Form: XVII granted by the Health Surveillance officer. If the

Health Surveillance officer declares a person unfit for being employed in

any process covered under sub-rule (1), such a person shall have the right

to appeal to the Inspector-cum-Facilitator who shall refer the matter to the

Medical Officer whose opinion shall be final in this regard. If the Inspector-

cum-Facilitator is also a Medical Officer, he may dispose of the application

himself.

(4) Any findings of the Health Surveillance officer revealing any abnormality or

unsuitability of any person employed in the process shall immediately be

reported to the Medical Officer who shall in turn, examine the concerned

worker and communicate his findings to the occupier within thirty days. If

the Medical Officer is of the opinion that the workers examined is required

to be taken away from the process for health protection, he will direct the

occupier accordingly, who shall not employ the said worker in the same

process. However, the worker so taken away shall be provided with

alternate placement unless he is in the opinion of the Medical Officer, fully

incapacitated in which case the worker affected shall he suitably

rehabilitated.

(5) A Medical Officer on his own motion or on a reference from an Inspector-

cum- Facilitator may conduct medical examination of a worker to ascertain

the suitability of his employment in the scheduled Process/operation or for

ascertaining his health status. The opinion of the Medical Officer in such a

case shall be final. The fee required for this medical examination shall be

paid by the occupier.

(6) The worker taken away from employment in any process under sub-rule

(2) may be employed again in the same process only after obtaining the

Fitness Certificate from the Medical Officer and after making entries to that

effect in the Health Register.

PART-VII

ADDITIONAL WELFARE AMENITIES

(1) There shall be provided and maintained in every factory for the use of all

the workers tap for washing, at the rate of one tap for every 15 persons

including liquid soap in a container with tilting arrangements and nail

brushes or other suitable means for effective cleaning. Such facilities shall

be conveniently accessible and shall be kept in a clean and hygienic

condition.

(2) If washing facilities as required above are provided for women, such

facilities shall be separate for them and adequate privacy at all times shall

be ensured in such facilities.

2. Mess-room facilities

(1) The occupier of all the factories carrying out chemical works and employing

50 workers or more shall provide for all the workers working in a shift,

mess room facilities which are well ventilated and provided with tables and

sitting facilities along with the provision of cold and hygienic drinking water

facilities.

(2) Such facilities shall include suitable arrangements for cleaning and washing

and shall be maintained in a clean and hygienic condition.

3. Cloak room facilities

(1) The occupier of every factory carrying out chemical works shall provide for

all the workers employed in the process, cloak room facilities with lockers.

Each worker shall be provided with two lockers, one for work clothing and

another separately for personal clothing and the lockers should be such as

to enable the keeping of the clothing in a hanging position.

(2) The cloak room facilities so provided in pursuance of sub-paragraph (1)

shall be located as far as possible near to the facilities provided for

washing in pursuance of paragraph 1 (1). If it is not possible to locate the

washing facilities, the cloak room facilities shall have adequate and suitable

arrangements for cleaning and washing.

4. Special bathing facilities

(1) The occupier of any factory carrying out the following processes shall

provide special bathing facilities for all the workers employed and such

facilities shall be provided at the rate of 1 for 25 workers and part thereof,

and shall be maintained in a clean and hygienic condition.

I. Nitro or amino processes.

II. All chrome processes.

III. Processes of distilling gas or coal tar or processes of chemical

manufacture in which tar is used.

IV. Processes involving manufacture, manipulation, handling or recovery of

cyanogen compound, cyanide compound, cyanate compounds.

V. Processes involving manufacture of bleaching powder or production of

chlorine gas in choro alkali plants.

VI. Manufacture, manipulation or recovery of nickel and its compounds.

VII. All processes involving the manufacture, manipulation or recovery of

aliphatic or aromatic compounds or their derivatives or substituted

derivatives.

(2) The occupier shall insist all the workers employed in the processes listed in

subrule (1) above to take bath after the completion of the day's or shift

work using the bathing facilities so provided and shall also effectively

prevent such of those workers taking bath in any place other than the

bathing facilities.

(3) Notwithstanding anything contained in sub-paragraph (1) above, the Chief

Inspector-cum-Facilitator may require in writing the occupier of any factory

carrying out any other process for which in his opinion bathing facilities are

essential from the health point of view, to provide special bathing facilities.

PART VIII

1. Duties of workers

Every worker employed in a factory carrying chemical work shall always

co- operate in all respects with the management while carrying out any

work or any emergency duty assigned to them in pursuance of provisions

of this code and building occupational Safety & Health culture. In

particular, the workers shall carry out the following duties.

I. Every worker who comes to know about existence of any of unsafe or

unhealthy conditions in the establishment shall report to the employer or

health and safety representative or safety officer or concerned Supervisor

as soon as practicable, electronically or in writing or telephonically.

II. Every worker shall not make safety device or appliance or any guarding or

fencing arrangement, inoperative or defective and shall report the

defective condition of the aforesaid arrangements as soon as he is aware of

any such defect.

III. Before commencing any work, all workers shall check their work place as

well as the machinery, equipment or appliance used and report any mal

function or defect immediately to the supervisor or any responsible person

of the management.

IV. All workers shall always use all the personal protective equipment issued to

them in a careful manner.

V. All workers shall not remain in unauthorized place or carryout unauthorized

work or improvise any arrangements or adopt short cut method or misuse

any of the arrangements in the manner against to the interest of

Occupational Safety & Health.

VI. The workers shall not refuse undergoing medical examination as required

under these rules.

PART IX

Exemptions

1. Power of Exemption:-The State Government or subject to the control of

the State Government, the Chief Inspector cum Facilitator may exempt

from the compliance with any of the requirements of this schedule partly or

fully, any factory carrying out Chemical Works, if it is clearly and

satisfactorily established by the occupier that the compliance with any of

the requirement is not necessary to ensure the safety and health of

persons employed suitable and effective alternate arrangements are

available to any of the requirements covered in this schedule.