Schedule XXV

MANUFACTURING PROCESS OR OPERATIONS 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

thereunder.

2. Construction, Installation and Operation- (1) The buildings in which electric furnaces area

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, 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 centimeters 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 incharge of construction and operation.

(5) The instructions regarding observance of correct furnace tempèrature, 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 in the electric furnace, they

shall be of seamless tube construction and shall have arrangement for being connected to the 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 stop the future supply of water. The alarm system and the actuating device shall be

checked every day.

4.Maintenance of charcoal level- When any electric furnace is in operation, it shall be ensured

that the electrodes are kept covered with a charcoal bed.

5. Rupture disc and safety seal- At least: two rupture discs 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 disc 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) The safety water 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 an 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 pressúre-

(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 reconstruçtion or repairs; and

(c) periodically every time the furnace is opened for cleaning or de-ashing or for

replacing electrodes.

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

(a) the brick lining shall be checked for continuity and any part found defective be

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 of the plate forming shells found corroded to the extent that safety of the furnáce

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 (2) of Paragraph 7;

(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 voltage 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 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 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 of reasonable intervals

at opposite ends. These shall always be kept clean of all obstructions and so designed as to afford easy

passage.

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

fire or explosion which shall operate on electricity 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 near locomotives etc. and

precautions shall be taken to see that flame , 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 lodges on which dust may lodge.

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

of dust clouds and no flame smoking and matches or other sources of ignition shall be employed during

handling, and non-speaking toll 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 enclosures

where bulk sulphur is stored.

17. Liquid sulphur-Open fiames, 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 plants

are in operation. (2) Workers in charge of operation and maintenance of electric furnaces and the 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-pipe being spaced not

less than 120 centimeters 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 equipments-(1) Suitable goggles and protective cloth consisting of

overalls without pockets, gloves and footwear shall be provided for the use of operator :

(a) when operating valves or cocks controlling fluids etc;

(b) drawing-off of molten sulphur from sulphur pots; and

(c) handling charcoal or sulphur.

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

place for use during abnormal conditions in an emergency.

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

equipment.

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

processes, a suitable cloak-room for clothing put-off during work hours and a suitable place separate from

the cloak-room for the storage of overalls of working clothes. The accommodation so provided shall be

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

22. 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.