Schedule XXII

(See rule 84)

Manufacturing Process or Operations in Carbon Disulphide plant

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

scheduled is in addition to and not in derogation of any of the provisions of the Act and 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 lay out shall be such that only a minimum number of

workers are exposed to the risk of any fire or exploration 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 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 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 in concrete or by other effective means;

d) Every electric furnace shall be installed and operated according to manufactures instructions

and these instructions shall be clearly imparted to the personal in charge of construction and

operations;

e) The instructions regarding observance of correct furnace temperature, sulphur dose, admissible

current of power consumption and periodical checking of charcoal level shall be strictly complied

with.

3. Electrodes

a) 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 build in the electrodes or through a positive pressure water-pump.

b) 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 alarm system

and the actuating device shall be checked everyday.

4. Maintenance of charcoal levels – When any electric furnace is in operation, it shall be ensured that the

electrodes are kept covered 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 charcoal into the condensers

and piping.

6. Repair discs and safety seal

a) At least two rupture disc of adequate size which shall blow of at a pressure twice the maximum

operating pressure shall be provided on each furnace and shall either be mounted directly on the

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

b) A safety water seal shall be provided and tapped from a point between the charcoal separator and

the sulphur separator.

7. Pyrometer and Manometer

a) 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 temperatures shall be located in the control room.

b) Manometer or any other suitable devices shall be provided for indicating pressure.

(i) in he/she off take pipe before and after the sulphur separator; and

(ii) 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 slowing back in to any electric furnace in the event of its shutdown.

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 de-ashing or for replacing

electrodes.

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

(i) the brick lining shall be checked for continuity and any part found defective removed;

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

closely inspected; and

(iii) 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 log book-

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

b) gas temperature indicated by pyrometer and all other vital points near the sulphur 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 the disulphide is refined or

stored, and a notice in the language understood by a majority of the workers shall be pasted on the

plant prohibiting smoking and carrying of matches, fire of naked light or other means of producing

naked light of spark in to 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 as 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 electricity and in case of failure of electricity by some mechanical

means.

15. Firefighting equipment

a) Adequate number of suitable fire extinguishers or other firefighting equipment shall be kept in

constant readiness for dealing with risks involved and depending on the amount and nature of

material stored;

b) Clear instructions as to how the extinguishes 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 personal trained in their use.

16. Bulk Sulphur

a) Open or semi enclosed spaces for storage of bulk sulphur shall be sited with the due regard to the

dangers which may arise from sparks given off by nearby locomotive etc., and precautions shall

be taken to see those 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.

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, 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;

d) No repair involving flames heat or use of hand of power tools shall be made in the enclosure where

bulk sulphur is stored.

17. Liquid sculpture– Open flames, electric sparks and other sources of ignition, including smoking and

matches; shall be excluded from the vicinity of molten sculpture.

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

a) 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 cm 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.

b) All the workers employed in the sulphur storage, handling and melting operations shall be

provided with a nailbrush.

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 operators-

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

(ii) drawing off of molten sulphur from sulphur posts; 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 cleaning of all such protective equipment.

21. Cloak rooms – There shall be provided and maintained for the use of all persons employed in the

process a suitable clock 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. Then 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.