Schedule XXII

Carbon Disulphide Plants

1. Application.-

(a) 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.

(b) These rules are in addition to and not in derogation of any of the provisions of the Code

and rules made thereunder.

2. Construction, Installation & 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 explosion 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 about 0.75 meters 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 personnel in-charge of

construction and operation.

(e) The instructions regarding observance of correct furnace temperature sulphur doze,

admissible current/power consumption and periodical checking of charcoal level shall be

strictly complied with.

3. Electrodes.-

(a) Where upper ring electrode (s), 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.

(b) The arrangement for cooling water referred to in clause (a) 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 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 for vibrating the charcoal. This

means shall be employed as often as necessary to maintain correct charge and level of the

charcoal.

‍557

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.-

(a) 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.

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

separator and the sulphur separator.

7. Pyrometer and Manometers.-

(a) Each electric shall be fitted with adequate number of pyrometers to make a correct

assessment of the temperature at various points in the furnace. The dials for reading the

temperatures shall be located in the control room.

(b) Manometer shall be provided for indicating pressure,-

(i) in the 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 flowing back into any electric furnace in the event

of its shut down.

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:-

(i) Manometer readings at the points specified in item (i) and (ii) of sub-clause (b) of

clause7;

(ii) Gas temperature indicated by pyrometer's and all other vital points near the sulphur

separator and primary and secondary condensers;

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

(iv) Primary and secondary voltages and current and energy consumed.

11. Electrical apparatus, wiring and fittings.- All buildings in which carbon disulphide is

refined or store shall be provided with electrical apparatus, wiring and fittings which shall

afford adequate protection from fire and explosion.

12. Prohibitions 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 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 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 for dealing with risks involved and depending on the amount and nature of

materials stored.

(b) Clear instruction 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.-

(a) 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's and matches and other sources of

ignition do not come in contact with the clouds of dust rising 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 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.

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

enclosure where bulk sulphur is stored.

‍559

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 & 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.- 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. All the workers employed in the sulphur storage,

handling and melting operations shall be provided with a nail brush.

20. Personal protective equipment.-

(a) Suitable goggles and protective clothing consisting of overalls without pockets, gloves

and footwear shall be provided for the use of operatives,-

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

(ii) drawing off of molten sulphur from sulphur pots; 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. 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.