Schedule B XXII

Manufacturing process or operation in carbon disulphide plants

1. Application.—This schedule shall apply to all electric furnaces in which carbon

sulphide 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 Codes and Rules made

thereunder.

2. Construction, installation and operation.-

I. 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.

II.

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 the 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.

III. The electric furnace supports shall be firmly grouted about 60 centimetres in

concrete or by other effective means.

IV. Every electric furnace shall be installed and operated according to

manufacturers" instructions and these instructions shall be clearly imparted to

the personnel in charge of construction and operation.

V. The instructions regardingobservance of correct furnace temperature, sulphur

dose, admissible current or power consumption and periodical checking of

charcoal level shall be strictly complied with.

3. Electrodes.-

I. 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 cooling water system through a siphon built in the

electrodes or through a positive pressure water-pump.

I1.

The arrangement for cooling water referred to in sub- paragraph (I) 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 stoppower 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.

Charcoal level indicator and vibrator.-Means shall be provided on each

electric furnace for indicating the correct level of charcoal in the furnace and

vibrating the charcoal. This mean shall employed often as necessary to

maintain correct charge and level of charcoal.

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 charcoal into the condensers and piping.

6. Rupture discs and safety seal.-

I. 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.

II. A safety water seal shall be provided and tapped from a point between the

charcoal separator and the sulphur separator.

7. Pyrometer and manometers.-

I. Each electric furnace shall be fitted with 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.

II.

Manometers or any other suitable devices shall be provided for

indicating pressure-

a. In the off-take pipe before and after the sulphur separator ; and

b. In primary and secondary condensers.

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.-

I.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

Periodically every time the furnace is opened for cleaning or for

replacing electrodes.

II.

When an electric furnace is shut down for cleaning

a.

The brick lining shall be checked for continuity and any part

found defective removed ;

b. After removal of any part of the lining referred to in (a) the

condition of the shell shall be closely inspected ; and

c. Any plates 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 7 (2) :

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 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 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 lighter

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 posted in

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

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 bekeptclear of all obstructions andso

designed to afford easy passage.

14.

Warnings in case of fire.There shall be adequate arrangements for giving

warnings in case of fire or explosion which shall operate on electrically and in

case of failure of electricity by some mechanical means.

15.

Fire-fighting equipment.-

I. 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.

II. 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.-

I. 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 nearby

locomotives, etc., and precautions shall be taken to see that flames, smoking

and matches and other sources of ignition do not come in contact with the

clouds of dust arising during handling of bulk sulphur.

II. 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.

III. The bulk sulphur in the enclosures shall be handled in such a manner as to

minimise the formation of dust clouds andnoflame, smoking and matches or

other sources of ignition shallbe employed during handling and non-sparking

tools shallbe used wheneversulphur is shovelled or otherwise removed by

hand.

IV. No repairs involving flames,heat 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 smoking and matches, shall be excluded from the vicinity of molten

sulphur.

18.

Training and supervision.-

I. 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 plants are in operation.

H1.

Workers in charge of operation and maintenance of electric furnaces and the

plants shall be properly qualified and adequately trained.

19.

Washing facilities.-

I. 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-pipes being spaced not less than 120 centimetres

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.

Il. All the workers employed in the sulphur storage, handling and melting

operations shall be provided with a nail brush.

20.

Personal protective equipment.-

I. Suitable goggles and protective clothing consisting of overalls without

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

21.

22.

a. When operating valves or cocks controlling fluids etc. ;

b. Drawing off a molten sulphur from sulphur pots ;

c. Handling charcoal or sulphur.

II. Suitable respiratory protective equipment shall be provided and stored in the

appropriate place for use during abnormal conditions or in an emergency.

III. Arrangements shall be made for proper and efficient deaning of all such

protective equipment.

Cloakrooms.There shall be provided and maintained for the use of all

persons employed in the processes asuitable cloakroom for clothing put off

during work hours and a suitable place separate from the cloakroom for the

storage or overalls or working clothes. The accommodation so provided shall

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

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.