The Government of Maharashtra on May 14 , 2025 has officially notified the Maharashtra Factories (1st Amendment) Rules, 2025, introducing comprehensive safety measures for reactors used in exothermic chemical reactions. Issued by the Industries, Energy, Labour, and Mining Department, the new rules amend the Maharashtra Factories Rules, 1963, and aim to mitigate risks associated with hazardous chemical processes.
These amendments were made under the Factories Act, 1948, and focus extensively on predictive, preventive, and protective safety protocols, qualifications of operators, emergency preparedness, and detailed technical documentation for reactors.
🔹 Key Highlights of the New Rule (Rule 73-ZC):
✅ Applicability
Applies to all Reactors used for exothermic chemical reactions in Maharashtra factories.
🔍 Predictive Measures Include:
- Compatibility testing of reactants and reactor materials.
- Evaluation of heat of reaction, decomposition, and adiabatic temperature rise.
- Assessment of reactor cooling systems and prediction of runaway reactions.
- Study of risks due to agitator or pump failures.
- Control over reactant addition sequences and rates.
🔧 Preventive Safety Protocols:
- Use of engineering and administrative controls, before resorting to PPE.
- Alternative reaction methods such as semi-batch or flow reactors.
- Mandatory certificates from reactor manufacturers for pressure limits.
- Strict management of changes (MoC) in process and equipment with written logs.
- HAZOP studies and implementation of all safety recommendations.
🛡 Protective Controls Mandated:
- Automatic shutdown systems interlocked with heating and feeding mechanisms.
- Safety valves, rupture discs, and vent systems to handle pressure surges.
- Audio-visual alarms for system failures or parameter breaches.
- Emergency quenching, depressurization, or dumping protocols.
🧪 Regular Testing and Inspections:
- External check every 6 months, internal check yearly.
- Hydraulic testing every 2 years (or NDT where applicable).
- Reactor not to be used until all safety conditions are fulfilled after inspection.
🚨 Emergency Preparedness Measures:
- Display emergency instructions prominently in local languages.
- Regular worker training and biannual mock drills on reactor emergencies.
👨🔧 Personnel Qualification Requirements:
Supervisor:
- Degree in Chemical Engineering with 3 years experience
or - Diploma with 5 years experience in handling exothermic reactors.
Operator:
- Degree/Diploma/Certificate in Chemistry or Chemical Engineering.
- Must complete certified training on reactor operation and hazardous handling, with refresher courses every 3 years.
📋 General Operational Requirements:
- Display names of assigned operators and supervisors near each reactor.
- Maintain shift-wise logbooks for 3 months.
- Clearly marked corrosion-resistant nameplate on each reactor with:
- Serial number, material, design code, pressure/temp ratings, process type, manufacturer, and testing dates.
These amendments mark a major step toward enhancing industrial safety and risk management in chemical manufacturing and processing units across Maharashtra. The full notification is available through the Department of Labour and Industries or can be accessed through official government channels.
Industries must comply with the new rules to ensure continued operation and safety certification.
