Schedule XXII

MANUFACTURING PROCESS OR OPERATION 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 there under.

2. Construction, installation and operation-

(1) 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.

(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 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.

(3) The electric furnace supports shall be firmly grouted about 60 centimetres 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 in charge 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 1n 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.

(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 to stop the further supply of

water. The alarrtl 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 !eve\ 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 separatorto prevent entry of pieces of charcoal

into the condensers and piping.

6. Rupture discs 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) A safety water seal 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 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 pressure-

(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- or for replacing

electrodes.

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

(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 be

closely inspected; and

(c) Any plates forming shall 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.

(a) Manometer readings at the points specified 1n 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 light or spark in buildings in which carbon disulphide

1s 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 be kept clear of all

obstructions and so 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 -

(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 nearby locomotives, etc., and

precautions sha\l 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.

(2) 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.

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

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

shall be employed during handling and non-sparking tools 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

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 -

(1) 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.

(2) Workers in charge of operation and maintenance of electric furnaces andthe 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-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-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 equipment -

(1) Suitable goggles and protective clothing consisting of overalls without packets, gloves

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

(a) when operating valves or cocks controlling fluids etc.,

(b) drawing off a molten sulphur from sulphur pots;

(c) handling charcoal or sulphur.

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

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

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

equipment.

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

employed in the processes a suitable 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 shallbe

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.