Schedule B XII

Chemical Works

PART I

1. Application.—This schedule shall apply to all manufacture and processes

incidental thereto carried on in chemical works.

2. Definitions.-For the purpose of this schedule -

a. "chemical works" means any factory or such parts of any factory as are

listed in appendix 'A' to this schedule;

b. "efficient exhaust draught"means localised 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" means chlorate or perchlorate;

e. "caustic" means hydroxide of potassium or sodium;

f. "Chrome process" means the manufacture of chromate or bichromate

of potassium or sodium, OT 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 para 20 of Part II ;

"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 64, 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 neighbourhood in a serious manner, demanding immediate

action;

k. "dangerous chemical reactions" means high speed reactions, runaway

reactions, delayed reactions, etc. and are characterised by evolution of large

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

sudden pressure build-up etc.;

I.

"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 ISI 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 all the works in Appendix 'A'

1. Housekeeping.-

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

II. Floors, platforms, stairways,passages and gangways shall be free of any

obstructions.

III. There shall be provided easymeans of access to all parts of the parts of the

plant to facilitate cleaning.

2. Improper use of chemicals.Chemicals or solvents or empty containers

containing chemicals or solvents shall be permitted to be used by workers for

any purpose 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.-

I. 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.

II.

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 unauthorised 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 1 month of their employment and for old

DUEE

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 stuck

5. Evaluation and provision of safeguards before the commencement of

process.—

I. Before commencing any process or any experimental work, or any new

manufacture covered under Appendix 'A, 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.

II.

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-para (I) above should be sent to the Chief

Inspector at the earliest but in no case less than 15 days before commencing

manufacture, handling, or storage of any of items covered under Appendix 'A,

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

large scale manufacture.

III.

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.

IV. The requirements under the sub-Para (I) to (III) shall not act in lieu of or in

derogation to, any other provisions contained in any Act governing the work.

• Authorized entry.-Authorized 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.-

I. 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 competent person. Records of such tests and examinations

shall be maintained in a register.

II

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.

• Electrical installations.—All electrical installations used in the process

covered in Appendix 'A' 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 explosivity etc. and shall confirm to

the relevant ISI specifications governing their construction and use for that

9. Handling and storage of chemicals.-

I. The containers for handling and storage of chemicals shall be of adequate

strength taking into consideration then hazardous nature of the contents.

They shall also be provided with adequate labelling 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.

IL.

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 66.

III.

Without prejudice to the generality of the requirements in sub- Para (II)

above, the arrangements shall have suitable ventilation facilities and shall

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

other chemicals stored nearby.

IV. (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;

Weceeded, the permissesnof the cee onperereota l

be obtained ;

Notwithstanding anything contained in clauses (a) and (b) above, the

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

processes covered in Appendix 'A' to further limit the storage of

hazardous substances to quantities less than two months on

considerations of safety:

d. 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 container resulting

in the release of toxic substances.

V. Any storage facility constructed using non-metallic material such as Fibreglass

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, access ladders, pipelines 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.-

I. 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 in a clean,

sterile and hygienic condition before issue.

II.

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

workers in the use of personal protective equipment while carrying out

the job.

IIl.

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 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 alarmsystems shall be checked daily and tested every month at

least once to ensure its performance efficiency at all times.

The Chief Inspector-cum-Facilitator may direct such system to be installed in

case of plants or processes where toxicmaterials are being used and spillage

or leakage of which may cause wide spread poisoning in or around the plant.

13.

1.

Control of escape of substances into the work atmosphere .-

Effective arrangements such as, enclosure, or by pass, or efficient exhaust

draught, maintenance ofnegativepressure etc., shall be provided in all

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

pipes and equipment, to control the escape and spread or 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.

II. 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.

the substances that would have escaped into the work atmosphere before

taking immediate steps as required in sub- Para (II), shall be rendered

innocuousbydiluting with air or water or any other suitable agent or by

suitably treating the substances.

• Control of dangerous chemical reactions.—Suitable provision, such as

automatic and or remote control arrangements, shall be made for controlling

the effects of 'dangerous chemical reactions'. In the event of failure of control

arrangements automatic flooding or blanketing or other effective

arrangements shall come into operation.

15.

I.

Testing, examination and repair of plant and equipment.-

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 procedures. In carrying out

the test 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, internallyalso for

surface defects, corrosion and foreign matters. 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 pyropheric nature or

contains spontaneously combustible chemicals ;

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.

II. All parts of plant, equipment, machinery which is the likely event of failure

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

the competent person.

III.

Records of testing and examination referred to in paragraphs (I) and (II) shall

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

in use.

IV. 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, butt welding of joints shall be

preferred. Wherever necessary, the responsible person shall regulate the

aforesaid work through a 'Permit to work system.

• Staging.-

I. 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.

II.

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.

III. All the staging constructed for the purpose of this Para shall have appropriate

access which are safe and shall be fitted with proper hand rails to a height of

one metre 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 inthe 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 spaces.-

I. The occupier of every factory to which the provisions 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 neutralising agents; or

purging with steam or inert 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.

II. The manager 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 log

book so maintained shall be retained as long as the concerned workers are in

service and produces to the Inspector when demanded.

19.

Maintenance work etc.—

I. 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.

IL.

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 predetermined 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 fir 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 procedures 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

23.

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 used 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.

Procedures for meeting emergencies. -

I. The occupier of every factory carrying out the works covered in

Appendix 'A', 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.

II.

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

emergencies including arrangements for summoning outside help for

rescue and firefighting arrangements for making available urgent

medical facilities.

The occupier shall send the list of emergencies and the details of

procedures and plans formulated to meet the emergencies, to the

Chief Inspector of Factories.

IV. The occupier shall arrange to install distinctive and recognisable

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

the neighbouring 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 arrangements and their meaning. The

arrangements must be checked for its effectiveness every month.

Alternate power supply arrangements shall be made and interlocked

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.

VL. The occupier shall arrange to suspend the further process work in a

place where emergency is established and shall forthwith evacuate all

persons in that area except workers who have been assigned

emergency duties.

VII. All the employees of the factory shall be trained about the action to be

taken by them including evacuation procedures during emergencies.

VIII.

All emergency procedures must be rehearsed every three months and

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

be corrected.

IX. The occupier shall arrange to have ten per cent of the workers trained

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

specific hazards of the particular process.

X. The occupier shall furnish immediately on request the specific chemical

identity of the hazardous substance to the treating physician where the

information is needed to administer proper emergency or first-aid

treatment to exposed persons.

24.

Danger due to effluents. —

I. Adequate precautions shall be taken to prevent the mixing of effluents from

different processes and operations which may cause dangerous or poisonous

gases to be evolved.

11.

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 Explosion Risks

1. Sources of ignition including lighting installation. -

I. 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 in the process area where there could be fire

and explosion hazards.

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.

IIl.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.

IV. Where a 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 conveyors shall be

conductive type.

V. All tools and appliances used for work in this area shall be of

non-sparking type.

VI. 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 into specified areas.

2. Static Electricity. -

I. 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.

Mobile tanker wagons shall be earthed during filling and

discharge, and precautions shall be taken to ensure that

earthing is effective before such filling or discharge take place.

2. Lightening protection. -Lightening protection arrangement shall be

fitted where necessary, and shall be maintained.

3. 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. -

I.

Proviso s umha bee als site iekages mean s or age esac,

containing flammable liquids.

Waste material in contact with flammable substances shallbe

disposed off

uitably under the supervision of knowledgeable

and responsible person.

III. Adequate and suitable fire-fighting appliances shall be installed

in the vicinity of such vessels.

2. Safety valves. —Every still and every closed vessel 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.

3. Installation of pipe line etc.-All pipelines carrying flammable or

explosive substances shall be protected from mechanical damage and

shall be examined by a responsible person once 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 systems. -

I. Every factory employing 500 or more persons and carrying out

processes listed in Appendix 'A' shall provide

a. Trained and responsible firefighting squad so as to effectively

handle the fire fighting and lifesaving 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 8 such trained persons to be available at any

time, The squad shall consist of watch and ward personnel; fire

pumpman and departmental supervisors and operators trained

in the operation of fire and emergency services;

b. Squad leaders shall preferably be trained in a recognized

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.

II. 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.

III.

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 be brought to the notice of squad leader.

IV.

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

factory be connected to allmanufacturing or storing areas through

telephone interlined and placed in a convenient location near such

PART IV

Risks of Toxic Substances

1. Leakage.-

I 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 buildings shall be so designed as to

localize any escape of toxic substances.

II.

Catch pits, bund 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 neutralised, treated or otherwise rendered

safe before it is discharged into public drains or sewers.

3. Covering of vessels.-

I. 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.

II. Such vessel shall, unless its edge is at least 90 centimetres

above the adjoining ground or platform, be securely fenced to a

height of at least 90 centimetres above such adjoining ground or

platform.

III. Where such vessels adjoin and the space between them, clear

of any surrounding brick or other work is either less than 45

centimetres in width or is 45 or more centimetres in width, but

is not securely fenced on both sides to a height of at least 90

centimetres, secure barriers shall be so placed as to prevent

passage between them :

Provided that sub-paragraph (II) 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.-

I. 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.

II. In the event of failure of continuous exhaust arrangement

means shall be provided to automatically stop the process.

2. Work Bench.—All the work benches used in the processes involving

the manipulation of toxic substances shall be graded properly and shall

be made of smooth impervious surface which shall be washed daily

after the completion of work.

6. Waste disposal.-

I. 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 receptacle shall be

destroyed by burning or using other suitable methods under the

supervision of a responsible person.

II.

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.

The empty containers of toxic substances shall be cleaned thoroughly

before disposal under the supervision of a responsible person.

Il.

PART V

Special Provisions

1. Special precautions for Nitro or Amino Processes.-

I.

Unless the crystallized intro or amino substances or any of its

liquor is broken or agitated in a completely enclosed processso

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.

II.

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.

IIl.

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.

IV. Processes involving the steaming into or around any vessel

containing 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.

V.

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'.-

Grinding and sieving of raw materials in chrome 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.

II. There shall be washing facilities located very near to places

where wet chrome processes such as leaching, acidification,

sulphate settling, evaporation, crystallisation, centrifugation or

packing are carried out, to enable quick washing of affected

parts of body with running water.

Weekly inspection of hand and feet of all persons employed in

chrome process shall be done by a qualified nurse and record of

such inspections shall be maintained in a form approved by the

Chief Inspector of Factories.

IV. Thereshallbealways available at designated places of work

suitable ointment such as glycerine, 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.-

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.

II. Any spillage or emission of vapour from the 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 risks of fire or explosion or

health hazards.

4. Special precautions for processes involving chlorate manufacture.-

L.

Crystallisation, 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.

II. The personal protective equipment likes overall, etc. provided

for the chlorate workers shall not be taken from the place of

work and they shall be thoroughly cleaned daily.

III. Adequate quantity of water shall be available near the place of

chlorate process for use during fire emergency.

IV. Wooden vessels shall not be used for the crystallisation of

chlorate or to contain crystallised ground chlorate.

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

reinforced plastics.-

I All plant and equipment shall conform to appropriate Indian or any

other National Standard.

II. Care shall be taken during storage, transport, handling and installation

of plant and equipment to avoid accidental damage.

III. All plant and equipment 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 manufacture.

IV.

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.

V. After erection all plant and equipment 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 a competent person shall be obtained and

kept available at site.

VI. All plant and equipment shall be subjected to periodical test and

examination and record maintained as per Paragraph 15 in Part II of

this Schedule.

VII.

Plant and equipment during their use shall not be subjected to over

filling or over loading beyond rated capacity.

PART VI

Medical Requirements

1. Decontamination facilities.-In all places where toxic substances

are used in processes listed in Appendix 'A' 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, parts

of body of persons, and clothing of persons who have been

No. of persons

contaminated with such toxic and corrosive substances,and

such means shall be as shown in the Table below :

No. of drenching showers employed at any time

Upto 50 persons 2

Between 51 to 100 3

101 to 200

3+ 1 for every 50 persons thereafter

201 to 400

5 + 1 for every 100 persons thereafter

401 and above

7 + 1 for 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 centre.-In all the factories carrying out processes

covered in Appendix 'A' there shall be provided and maintained in good order

an occupational health centre with facilities as per scale laid down

hereunder-

i.

For factories employing upto workers-

a.

the services of a qualified medical practitioner hereinafter known as

Factory Medical Officer, available on a retainership 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.

il. For factories employing 51 to 200 workers -

a.

The occupational health centre shall have a room having a minimum

floor area of 15 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 Factory Medical Officer will be in over all 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.

ili. For factories employing above 200 workers-

a. There shall be one full-time Factory Medical Officer for factories

employing upto500workers and one moremedical officer for every

1000 workers or part thereof.

b. The occupational health centre in this case shall have a minimum of 2

rooms each having a minimum floor area of 15 sq.m. with floors and

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

adequately illuminated, ventilated and equipped.

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.-

In every factory carrying out processes covered in Appendix "A, there shall be

provided and maintained in good condition, a suitably constructed and fully

equipped ambulance van as per Appendix 'C' manned by a full-time 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 Centre.

II. The relaxation to procure Ambulance Van from nearby places provided for in

sub-para (I) above will not be applicable to factories employing more than

500 workers.

4. Medical examination.-

I. Workers employed in processes covered in Appendix "A' shall be medically

examined by a Factory Medical 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

worker ; and

c. Threied out aat presaid shal e record pec inc the presciae eorminaions

II. Any finding of the Factory Medical 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

workers and communicate his findings within 30 days. If the Medical Officer is

of the opinion that the person so examined is required to be suspended 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 person so

suspended from the process shall be provided with alternate placement

facilities unless he is fully incapacitated in the opinion of the Medical Officer, in

which case the person affected shall be suitably rehabilitated :

Provided that the Medical Officer on his own may examine any other worker whom

he feelsnecessary to be examined for ascertaining the suitability of his employment

in the process covered in Appendix 'A' or for ascertaining the health status of any

other worker and his opinion shall be final.

III.

No person shall be newly appointed without the Certificate of Fitness granted

by the Factory Medical Officer. If the Factory Medical Officer declares a person

unfit for being appointed to work in the process covered in Appendix 'A, such

person shall have a right of appeal to the Medical Officer, whose opinion shall

be final in this regard.

IV. The worker suspended from the process owing to the circumstances covered

in sub-para (2) shall 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. Washing facilities.-

I.

There shall be provided and maintained in every factory for the use of

all the workers taps for washing,at the rate of one 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.

Il.

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.—

I.

The occupier of all the factories carryingout processes covered

in Appendix 'A' 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.

II. Such facilities shall include suitable arrangements for cleaning

and washing and shall be maintained in a clean and hygienic

condition.

3. Cloakroom facilities.-

I.

The occupier of every factory carrying out any process covered in

Appendix "A' 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.

II. The cloak room facilities provided in pursuance of sub-para

(1) shall be located as far as possible near to the facilities provided for washing in

pursuance of para 1(I). If it is not possible to locate the washing facilities the

cloakroom facilities shall have adequate and suitable arrangements for cleaning and

washing.

4. Special bathing facilities.—

I.

The occupier of any factory carrying out the process covered under

Appendix 'B' shall provide special bathing facilites 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.

The occupier shall insist all the workers employed in the processes

covered in Appendix 'B' 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.

Notwithstanding anything contained in sub-para (I) above, the Chief

Inspector may require in writing the occupier of any factory carrying

out any other process for which his opinion bathing facilities are

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

facilities.

PART VIII

1. Duties of workers.-

I. Every worker employed in the processes covered in Appendix 'A

and Appendix'B' 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.

II. Before commencing any work, all workers employed in

processes covered in Appendix 'A' shall check their workplace as

well as the machinery, equipment or appliance used in the

processes and report any mal-function or defect immediately to

the supervisor or any responsible person of the management.

III.

All workers shall co-operate in all respects with the management

while carrying out any work or any emergency duty assigned to

them in pursuance of this schedule and shall always use all the

personal protective equipment issued to them in a careful

manner.

IV. All workers employed in the processes covered in Appendix 'A' or

Appendix "B shall not smoke in the process area or storage

area. If special facilities are provided by the management only

such facilities should be used.

V.

All workers employed in the processes covered in Appendix 'A'

shall not remain in unauthorised place or carry out unauthorised

work or improvise any arrangement or adopt short out method

or misuse any of the facilities provided in pursuance of the

Schedule, in such a manner as to cause risk to themselves as

well as or to others employed.

VI.

The workers shall not refuse undergoing medical examination as

required under these rules.

PART IX

and women

Restrictions on the employment of young persons under 18 years of age

The Chief Inspector of Factories mayby an order in writing,

restrict or prohibit the employment of women and young

persons under the age of 18, in any of the processes covered in

Appendix 'A' of this schedule on considerations of health and

safety of women and young persons.

2. Such persons who are restricted or prohibited from working in

the process due to the order issued in pursuance of sub-para (1)

above shall be provided with alternate work which is not

detrimental to their health or safety.

PART X

Exemptions

1. Power of exemption.—The State Government or subject to the

control of the State Government the Chief Inspector may exempt from

the compliance with any of the requirements of this Schedule partly or

fully, any factory carrying out processes covered in Appendix 'A, 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.

Appendix 'A'

Any works or that part of works in which-

a. the manufacture,manipulation or recovery of any of the

following is carried on :-

sodium, potassium, iron, aluminium, cobalt, nickel,

copper, arsenic, antimony, chromium, zinc, selenium,

magnesium, cadmium, mercury, beryllium and their

organic and inorganic salts, alloys, oxides and hydroxides

ammonia, ammonium hydroxide and salts of ammonium;

il.

the organic or inorganic compounds of sulphurous,

sulphuric, nitric, nitrous, hydrochloric, hydrofluoric,

hydriodic, hydro sulphuric, hydrobromic, boric;

iv. cyanogen compounds, cyanide compounds, cyanate

compounds;

v. phosphorous and its compounds other than oregano

phosphorus insecticides ;

vi. chlorine.

b. hydrogen sulphide is evolved by the decomposition of metallic

sulphides, or hydrogen sulphide is used in the production of

such sulphides ;

c. bleaching powder is manufactured or chlorine gas is produced in

chlor-alkali plants;

d. i. gas tar or coal tar or bitumen or shale oil asphalt or any

residue of such tar is distilled or is used in any process of

chemicals manufacture ;

ii. tar based synthetic colouring matters or their intermediates are produced ;

e. nitric acid is used in the manufacture of nitro compounds;

f. explosives are produced with the use of nitro compounds;

g. aliphatic or aromatic compounds or their metallic and non-metallic

derivatives or substituted derivatives, such as chloroform, ethylene

glycol, formaldehyde, benzyle chloride, phenol, methyl ethyl keytone

peroxide, cobalt carbonyl, tungsten carbide etc. are manufactured or

recovered.

AppendixB'

Concerning Special Bathing Accommodation in pursuance of Para 4 of Part

1. Nitro or amido processes.

2. All chrome processes.

3. Processes of distilling gas or coal tar or processes of chemical manufacture in

which tar is used.

4. Processes

involving manufacture, manipulation, handling or recovery of

cyanogen's compound, cyanide compound, cyanate compounds.

5. Processes involving

manufacture of bleaching powder or production of

chlorine gas in chloralkaline plants.

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

7. All processes involving the manufacture, manipulation or recovery of aliphatic

or aromatic compounds or their derivatives or substituted derivatives.

Appendix 'C'

Ambulance should have the following equipment

General :

• An wheeled stretcher with folding and adjusting devices; Head of the stretcher

must be capable of being tilted upward ;

• Fixed suction unit with

equipment;

• Fixed oxygen supply with equipment ;

• Pillow with case ;

• Sheets ;

• Blankets ;

• Towels ;

• Emesis bag ;

• Bed pan ;

• Urinal ;

• Glass

Safety equipment:

• Flares with life of 30 minutes

• Flood lights;

• Flash lights;

• Fire extinguisher dry powder type;

• Insulated gauntlets. Emergency care equipment :- Resuscitation :

• Portable suction unit ;

• Portable oxygen unit ;

• Bag-valve-mask, hand operated artificial ventilation unit ;

• Airways ;

• Mouth gags ;

• Tracheostomy adapters ;

• Short spine board;

• I. V. Fluids with administration unit ;

• B.P. manometer;

• Cugg;

• Stethoscope

Immobilisation :

• Long and short padded boards;

• Wire ladder splints ;

• Triangular bandage ;

• Long and short spine boards.

Dressings :

• Gauze pads - 4" x 4" ;

• Universal dressing 10" x 36";

• Roll of aluminium foils;

• Soft roller bandages 6" x 5 yards ;

• Adhesive tape in 3" roll ;

• Safety pins ;

• Bandage sheets ;

• Burn sheet.

Poisoning :

• Syrup of Ipecac; (Pre-packeted in doses) ;

• Activated charcoal;

• Snake bite kit ;

• Drinking water.

Emergency Medicines :

• As per requirement (under the advice of Medical Officer only)