Schedule XXIII

CARBON DISULPHIDE PLANTS

1. Application

This Schedule shall apply to all electric furnaces in which carbon Disulphide

is generated and all other plants where carbon Disulphide, after generation

is condensed, refined and stored.

These rules are in addition to and not in derogation of any of the provisions

of the Act and the rules made thereunder.

2. Construction, installation and operation

(a) The buildings in which electric furnaces are installed and carbon disulphide

after generation is condensed and refined shall be segregated from other

parts of the factory and shall be of open type to ensure optimum

ventilation and the plant layout shall be such that only a minimum number

of workers are exposed to the risk of any fire or explosion at any one time.

(b) Every electric furnace and every plant in which carbon Disulphide is

condensed, refined and stored with all their fittings and attachments shall

he of good construction, sound material and of adequate strength to

sustain the internal pressure to which the furnace or the plant may be

subjected and shall be so designed that carbon Disulphide liquid and gas

are in closed system during their normal working.

(c) The electric furnace supports shall be firmly grouted about 61 centimeters

in concrete or by other effective means.

(d) Every electric furnace shall be instilled and operated according to

manufacturers' instructions and these instructions shall be clearly imparted

to the personnel in charge of construction and operation.

(e) The instructions regarding observance of correct furnace temperature,

Sulphur dose, admissible current/power consumption and periodical

checking of charcoal level shall be strictly complied with.

3. Electrodes

(a) Where upper ring electrodes made of steel or used in the electric furnace,

they shall be of seamless tube construction and shall have arrangement for

being connected to cooling water system through a hip on built in the

electrodes or through a positive pressure water-pump.

(b) The arrangement for cooling referred to in clause (a) shall be connected

with automatic alarm system which will actuate in the event of interruption

of cooling water in the electrodes and give visible and audible alarm signals

in the control room and simultaneously stop power supply for the furnace

operation and to stop the further supply of water. The alarm system and

the actuating device shall be checked every day.

4. Maintenance of charcoal level

When any electric furnace is in operation, it shall be ensured that the

electrodes are kept coveted with charcoal bed.

5. Charcoal separator

(a) Cyclone type of charcoal separator shall be fitted on the off take pipe

between the electric furnace and Sulphur separator to prevent entry of

pieces of char-coal into the condensers and piping.

(b) Any other design for gas off takes pipe which dues tic• allow charcoal

pieces into the condensers and piping may be adopted.

6. Rupture Discs and Safety Seal

(a) At least two rupture discs of adequate size which shall blow off at a

pressure twice the maximum operating pressure shall be provided on

each furnace and shall either be mounted directly on the top of the

furnace or each through an independent pipe as close as possible to the

furnace.

(b) A safety water seal shall be provided at the best possible location to

ensure the maximum and effective operation of the rupture discs

mentioned in (a) above.

7. Pyrometer and Manometers

(a) Each electric furnace shall be fitted with adequate number of

pyrometers Ito give an indication of the temperature as correctly as

reasonably practicable at various points in the furnace. The dials for

reading the temperature shall be located in the control room.

(b) Manometers or any other suitable devices shall be provided for

indicating pressure

i. In the off take pipe before and after the Sulphur separator; and

ii. In Primary and secondary condensers.

8. Check Valves or Water Seals

All piping carrying carbon Disulphide shall be fitted with check valves or

water seals at suitable positions so as to prevent gas from flowing back

into any electric furnace in the event of its shut down.

9. Inspection and maintenance of Electric Furnaces

(a) Every electric furnace shall be inspected internally by a competent

person

(i) before being placed in service after installation:

(ii) before being placed in service after reconstruction or repairs; and

(iii) periodically every time the furnace is opened for cleaning or (or

replaced electrodes.

In respect of item (iii) if it is felt by operators that during dashing it is not

necessary to inspect internally so as to conserve the heat in the furnace,

internal inspection can be done away with.

(b) When an electric furnace is shut down for cleaning,

(i) If removal of any part of the lining is resorted to, the condition of

the shell shall be closely inspected, and

(ii) any plates forming shell found corroded to the extent that safety of

the furnace is endangered shall be replaced:

10. Maintenance of Records

The following hourly records shall be maintained in a logbook

(i) Manometer reading at the points specified in clause (b) of rule7.

(ii) Gas temperature indicated by pyrometers and all other vital points

near the Sulphur separator and primary and secondary condensers.

(iii) Water temperature and flow of water through the siphon in the

electrodes.

(iv) Primary and secondary voltages and current and energy consumed.

11. Electrical apparatus, wiring and fittings

All buildings in which carbon disulphide is refined or stored shall be

provided with electrical apparatus, wiring and fittings which shall afforded

equate protection from fire and explosion.

12. Prohibition relating to smoking

No person shall smoke or carry matches, fire or naked light or other means

of producing a naked light or spark in buildings in which carbon Disulphide

is refined or stored, and a notice in the language under-stood by a majority

of the workers shall be posted in the plant prohibiting smoking and

carrying of matches, fire or naked light of other means of producing naked

light or spark into such rooms.

13. Means of escape

Adequate means of escape shall be provided and maintained to enable

persons to move to a safe place as quickly as possible in case of an

emergency. At least two independent staircases of adequate width shall be

provided in every building housing the furnaces at reasonable intervals at

opposite ends. These shall always be kept clear Mall obstructions and so

designed as to afford easy passage.

14. Warnings Incase of fire

There shall be adequate arrangements for giving warnings in case of fire or

explosion which shall operate on electricity and, in case of failure of

electricity, by some mechanical means.

15. Fire fighting equipment

(a) Adequate number of suitable fire extinguishers or other fire-fighting

equipment shall be kept in constant readiness for dealing with risks

involved and depending on the amount and nature of materials stored:

(b) Clear instructions as to how the extinguishers or other equipment should

be used shall be printed in the language which the majority of the workers

employed understand. The instructions shall be affixed to each

extinguisher or other equipment and the personnel trained in their use

shall be supplied with the instructions.

16. Bulk Sulphur

(a) Open or semi-enclosed space for storage of bulk Sulphur shall be sited

with due regard to the dangers which may arise from sparks given off

by nearby locomotive, etc., and precautions shall be taken to see that

flames, smoke and matches and other sources of ignition do not come

in contact with the clouds of dust arising during handling of bulk

Sulphur.

(b) All enclosures for bulk Sulphur shall be of non-combustible

construction, adequately ventilated and so designed as to provide a

minimum of ledges on which dust may lodge.

(c) The bulk Sulphur in the enclosures shall be handled in such a manner

as to minimize the formation of dust clouds and no flame, smoke and

matches or other sources of ignition shall be employed during handling

and non- sparking tools shall be used when ever Sulphur is shoveled or

otherwise removed by band.

(d) No repairs involving flames, beat or use of hand or power tools shall be

made in the enclosure where bulk Sulphur is stored.

17. Liquid Sulphur

Open flames, electric sparks and other sources of ignition, including smoke

and matches, shall be excluded from the vicinity of molten Sulphur.

18. Training and supervision

(a) All electric furnaces and all plants in which carbon Disulphide is

condensed, refined or stored shall be under adequate supervision at all

times while the furnaces and plant are in operation.

(b) Workers in charge of operation and maintenance of electric furnaces and

the plants shall be properly qualified and adequately trained.

19. Washing facilities

The occupier shall provide and maintain in a clean state and in good repair,

for the use of all persons employed awash-place under cover with atleast

one tap or stand-pipe, having a constant supply of clean water for every

five such persons, the taps or stand-pipes being spaced not less than 120

centimeters apart with a sufficient supply of soap and clean towels,

provided that towels shall be supplied individually to each worker if so

ordered by the Inspector-cum-Facilitator. All the workers employed in

Sulphur storage handling and inching operations shall be provided with a

nail brush.

20. Personal Protective equipment

(a) Suitable goggles and protective clothing consisting of overalls without

pockets, gloves and foot-wear shall be provided for the use of

operatives:

(i) When operating valves or cocks controlling fluids, etc.

(ii) Drawing off of molten Sulphur from Sulphur pots, and

(iii) Handling charcoal or Sulphur.

(b) Suitable respiratory protective equipment shall be provided and stored

in the appropriate place for use during abnormal conditions or in an

emergency.

(c) Arrangements shall be made for the proper and efficient clearing of all

such protective equipment.

21. Cloak-rooms

There shall be provided and maintained for the use of all persons employed

in the processes a suitable cloak-room for clothing put off during work

hours and a suitable place separate from the cloak-room for the storage of

overalls or working clothes The accommodation so provided shall be placed

in the charge of a responsible person and shall be kept clean.

22. Unauthorized persons: Only maintenance and repair personnel, persons

directly connected with the plant operation and those accompanied by

authorized persons shall be admitted into the plant.