Rule 95
SCHEDULE XXIII
CARBON DISULPHIDE PLANTS
1. Application:--- This Schedule shall apply to all electrical furnaces in where carbon disulphide is generated and all other plants where carbon disulphide after generation, is condensed, refined and stored.
These rules are 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 electrical furnaces are installed and carbon disulphide after generation is condensed and refined shall be segregated from other parts of the factory and shall be open type to ensure optimum ventilation and the plant layout shall be such that only minimum number of workers are exposed to the risk of any fire or explosion at any one time.
(b) Every electrical 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 signed that carbon disulphide liquid and gas are in closed system during their normal working.
(c) The electric furnace support shall be firmly grouted about 2 feet in concrete or by other effective means.
(d) Every electric furnace shall be installed and operated according to manufacturer’s instructions and these instructions shall be clearly imparted to the personnel in-charge of construction and operation.
(e) The instruction regarding observance of correct furnace temperature, sulphure 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 seamless tube construction and shall have arrangements 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 everyday.
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. Charcoal Separator:--- A cylone type of charcoal separator shall be fitted on the offtake pipe between the electric furnace and sulphur separator to prevent entry of pieces of charcoal into the condensers piping.
6. Rupture Discs and Safety Seal:---
(a) At least two rupture discs of adequate size which shall below 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. Pyrometers and Monometers:---
(a) Each electric furnace shall be fitted with adequate number of pyrometers to give an indication of the temperature as correctly as practicable at various point in the furnace. The dials for reading the remparatus;res shall be located in the control room.
(b) Monometers or any other suitable devices shall be provided for indicating pressure---
(i) in the offtake pipe before and after the sulphur separator; and
(ii) in primary andsecondary 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 an 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 of repairs; and
(iii) Periodically every time the furnace is opened for cleaning or deashing or for replacing electrodes.
(b) when an electric furnace is shut down for cleaning or deashing.
(i) the brick lining shall be checked for continuity and any part found defective moved.
(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 7 (b) (i) and (ii).
(ii) Gas temperature indicated by pyrometers and all other vital points near the sulphur separator and primary and secondary condensers.
(iii) Water temperature and flow or water through the siphon in the electrodes.
(iv) Primary and secondary voltages and current and energy consumed.
11. Electrifcal apparatus, wiring and fittings:--- All buildings in which carbo 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 light or spark in buildings in which carbon disulphide is refined or stored, and notice in the language understood by a majority of the workers shall be posted in the plant prohibiting smoking and carrying to matches, fire or naked light or other means or 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 stair cases 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. Fire-fighting Equipment:---
(a) 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.
(b) 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:---
(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 locomotive etc., and precautions shall be taken to see that flames, smoking and matches and other sources of ignition do not come in contact with he clouds of dust arising during handling of bulk sulphur.
(b) All enclosures for bulk sulphur shall be of non-cumbustible 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.
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:---
(a) All electric furnaces and all plants 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 standpipes 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.
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 using 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 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 or 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 operations and those accompanied by authorised persons shall be admitted into the plant.