Schedule ‘H’(xxiii)

MANUFACTURING PROCESS OR OPERATIONS IN 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.. This Schedule is in addition to and not in derogation of any of the provisions of the

Code and Rules made thereunder.

2. Construction, Installation and Operation- (1) The buildings in which electric furnaces area

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.

(2) Every electric furnace and every plant in which carbon disulphide is condensed, refined

and stored with all their fittings and attachments shall be of good construction, sound

material and of adequate strength to sustain the internal pressure to which, furnace or

the plant may be subjected to, and shall be so designed that carbon disulphide liquid and

gas are in closed system during their normal working.

(3) The electric furnace supports shall be firmly grouted about 60 centimeters in concrete or

by other effective means.

(4) Every electric furnace shall be installed and operated according to manufacturers'

instructions and these instructions shall be clearly imparted to the personnel incharge of

construction and operation.

(5) The instructions regarding observance of correct furnace temperature, sulphur dose,

admissible current, or power consumption, and periodical checking of charcoal level

shall be strictly complied with.

3. Electrodes : (1) Where upper ring electrodes made of steel are used in the electric furnace,

they shall be of seamless tube construction and shall have arrangement for being connected to

the cooling water system through a siphon built in the electrodes or through a positive pressure

water pump.

(2) The arrangement for cooling water referred to in sub-paragraph (1) 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 stop the future 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 covered with a charcoal bed.

5. Rupture disc and safety seal- At least: two rupture discs be fitted on the off take pipe between

the electric furnace and sulphur separator to prevent entry of pieces of charcoal into the

condensers and piping.

6. Rupture disc and safety seal-(1) 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.

(2) The safety water shall be provided and tapped from a point between the charcoal

separator and the sulphur separator.

7. Pyrometer and manometers-(1) Each electric furnace shall be fitted with an adequate number

of pyrometers to give an indication of the temperature as correctly as reasonably practicable at

various points in the furnace. The dials for reading the temperatures shall be located in the

control room.

(2) Manometers or any other suitable devices shall be provided for indicating pressúre-

(a) in the off take pipe before and after the sulphur separator; and

(b) in primary and secondary condensers.

8. Check valves-All piping carrying carbon disulphide shall be fitted with check valves 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-

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

(a) before being placed in service after installation;

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

(c) periodically every time the furnace is opened for cleaning or de-ashing or for

replacing electrodes.

(2) When an electric furnace is shut down for cleaning or de-ashing-

(a) the brick lining shall be checked for continuity and any part found defective be

removed;

(b) after removal of any part of the lining referred to in (a), the condition of the shell be

closely inspected; and

(c) any of the plate forming shells 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 log book.

(a) manometer readings at the points specified in sub-paragraph (2) of Paragraph 7;

(b) gas temperature indicated by pyrometers and all other vital points near the sulphur

separator and primary and secondary condensers;

(c) water temperature and flow of water through the siphon in the electrodes; and

(d) primary and secondary voltage 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 afford

adequate 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 understood by a majority of the workers shall be

pasted in the plant prohibiting smoking and carrying of matches, fire or naked light or other

means of producing naked 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 of reasonable intervals at opposite ends. These shall always be kept clean of all

obstructions and so designed as to afford easy passage.

14. Warnings in case of fire-There shall be adequate arrangements for giving warning 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-(1) 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.

(2) Clear instructions as to how the extinguishers or other equipment should be used printed

in the language which the majority of the workers employed understand, shall be affixed

to each extinguisher or other equipment and the personnel trained in their use.

16. Bulk sulphur : (1) Open or semi-enclosed spaces for storage of bulk sulphur shall be sited with

due regard to the dangers which may arise from sparks given off by near locomotives etc. and

precautions shall be taken to see that flame , smoking and matches and other sources of

ignition do not come in contact with the clouds of dust arising during handling of bulk sulphur.

(2) All enclosures for bulk sulphur shall be of non-combustible construction, adequately

ventilated and so designed as to provide a minimum of lodges on which dust may lodge.

(3) The bulk sulphur in the enclosures shall be handled in such a manner a minimise the

formation of dust clouds and no flame smoking and matches or other sources of ignition

shall be employed during handling, and non-speaking toll shall be used whenever

sulphur is shovelled or otherwise removed by hand.

(4) No repairs involving flames, heat or use of hand or power tools shall be made in the

enclosures where bulk sulphur is stored.

17. Liquid sulphur-Open fiames, electric sparks and other sources of ignition. including smoking

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

18. Training and supervision-(1) All electric furnaces and all plants in which ca rbon disulphide is

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

furnaces and plants are in operation. (2) Workers in charge of operation and maintenance of

electric furnaces and the plants shall be properly qualified and adequately trained.

19. Washing facilities (1) The occupier shall provide and maintain in a clean state and in good

repair, for the use of all persons employed wash place under cover with at least one tap or

stand-pipe, having a constant supply of clean water for every five such persons, the taps or

stand- pipe 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.

(2) All the workers employed in the sulphur storage, handling and melting operations shall

be provided with a nail brush.

20. Personal protective equipments : (1) Suitable goggles and protective cloth consisting of

overalls without pockets, gloves and footwear shall be provided for the use of operator :

(a) when operating valves or cocks controlling fluids etc;

(b) drawing-off of molten sulphur from sulphur pots; and

(c) handling charcoal or sulphur.

(2) Suitable respiratory protective equipment shall be provided and stored in the appropriate

place for use during abnormal conditions in an emergency.

(3) Arrangements shall be made for proper and efficient cleaning of all such protective

equipment.

21. Cloak-rooms : There shall be provided and maintained for the use of all workers 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 of working clothes. The

accommodation so provided shall be placed in the charge of a responsible person and shall be

kept clean.

22. Unauthorised persons : Only maintenance and repair personnel, persons directly, connected

with the plant operation and those accompanied by authorised persons shall be admitted into

the plant.