Vous êtes sur la page 1sur 119

Presentation On

IR-DRDO Bio-Toilet System


03rd May-2016
What is Bio-Toilet (Bio-Digester Toilet)?

 Biological decomposition of Human waste

 Bio-Toilet is an innovative technology for


disposal of solid human waste in an eco-
friendly, economical and hygienic manner.

 A Bio-Toilet is a complete waste management


solution which reduces solid human waste to
Biogas and pure water, with the help of a
bacterial Inoculum.
What is Bio-Toilet (Bio-Digester Toilet)?

The residual water from Bio-Toilet

 Is colorless, odorless and devoid of any solid


particles.

 Requires no further treatment / waste


management.

 Can be used for irrigation purposes.


Extract of Budget Speech of 2016-17 of Hon’ble
Minister of Railways on Cleanliness
37. In pursuance of our mission Swachh Rail – Swachh
Bharat, I am happy to inform the House that
 17,000 bio-toilets in trains and additional toilet at 475
stations will be provided before the close of this
financial year.

 World’s first Bio-Vacuum toilet was developed by IR


and is being used in Dibrugarh Rajdhani Express.
 74 more trains have been added under on-borad
Housekeeping Service and another 400 are to be
covered soon, leading to a total number of almost
1000 trains under the scheme.
Sr. Type of Coach Qty.
1 LHB AC Coaches (EOG) 1644
2 LHB AC Coaches (SG) 09
3 LHB Non-AC Coaches (EOG) 261
4 LHB Non-AC Coaches (SG) 66
5 Stainless Steel Hybrid Design Coaches 434
(SG)
Sub Total 2414
Sr. Type of Coach Qty.
7 ICF Design AC Coaches (EOG) 539
8 Garib Rath Coaches 515
9 ICF Design AC Coaches (SG) 6694
10 ICF Design Non-AC Coaches (SG) 39898
Sub Total 47646
Total PCV Coaches 50060
Sr. Type of Coach Qty.
1 All type OCV’s Coaches 5795
Total OCV Coaches 5795
Total PCV & OCV Coaches 55855
Working of Bio-Toilet
Low Cost Bio-Toilet for Rural Areas
 Brief introduction of IR-DRDO bio toilets.
 Cleaning instructions for pressurized cleaning
 Sampling of effluent of bio tanks and record keeping.
 Testing of samples of bio toilet tanks.
 Guidelines for coaching depots for handling of bacteria
culture.
 Testing scheme and testing kit for bacteria culture & bio
toilet effluent.
 Instructions for POH and Retrofitment of Bio-Toilets
IR-DRDO Bio-Toilet System
An environment Friendly Toilet System
Green toilet aims at Zero – defecation on the ground
1. Discharge on track creates environmental problems as well as
problem in working to work man.
2. MOU has been signed with DRDO for joint technology
development.
3. The First Rake with bio-toilets developed with DRDO is running
in Bundelkhand Express since 18th January -2011.
4. 20 more rakes fitted with DRDO technology toilets have been
allotted to Zonal Railways.
5. Cumulatively approx. 12000 coaches have been fitted with Bio
toilet and approx. 30000 Bio-toilet fitted in coaches. (as on
31.01.2016).
1. No bad smell in toilets from the tanks

2. No Cockroaches & flies


3. Fecal matter in the tank not visible
4. Effluent is free from off odour and solid waste
5. No maintenance required
6. Reduction in harmful organic matter by 90%
7. No requirement of adding bacteria
8. No need of removal of solid waste
 Environment friendly
 Preventing damages to track
from Corrosion
 Improved Hygienic
Types of Toilets in Indian Railways
Description Environmental
friendliness

Direct discharge type toilet system No


– since long

Vacuum Toilet system Extensive High


- From Sweden by RCF in 1995 end technology
and frequent post
- Fitted by RCF in one IRZ coach
treatment

Control Discharge toilet system (CDTS) No


Description Environmental
friendliness

Aerobic type biological Toilet Yes


–M/s Aikon in Rewa Express
- 80 toilets

Anaerobic bio-toilet Yes


-MoU between DRDO and IR
- 89 toilets in Bundelkhand Express
Bacteria under
Microscope

16 OF 20
Faecal Material

CO2 + Methane gases


Anaerobic Bacteria released to atmosphere
(Liquid bacteria)

Liquid waste

Chlorination

Disinfected Liquid
discharged on
System does not
Track require Oxygen and
also does not require
regular cleaning
Anaerobic bio-digester system
-Bio gases & parameters
Composition of Bio-gases

Compound Chemical Name %

Methane CH4 50–75

Carbon dioxide CO2 25–50

Nitrogen N2 0–10

Hydrogen H2 0–1
Parameters being monitored
Hydrogen sulfide H2S 0–3

Parameter Recommended Values

pH 6 to 9

Total Solids Max 750mg/100ml

Total Dissolved solids Max 350mg/100ml

COD levels Max 2000 ppm


Anaerobic bacteria:
 Can process doubling its population within 6 to 8 hrs
 Dominates and decompose matter in to liquid and gases

 Can be kept for 3-4 months at ambient temperature


 Can withstand sub zero temperature as well as upto 60
degree centigrade but charging of Inoculum should be
done not less than 5ºC Temperature.
 Cold temperature would not affect the inside processing
because:
Anaerobic process is exothermic in nature thus, in cold regions heat
will be available inside the chamber because of chemical process.
• Initially 46 nos Bio-Digester toilet system with DRDE
technology were procured

• These were fitted in train no 11107 /11108 Gwalior-


Varanasi Bundelkhand Express w.e.f. 18.01.2011

• NCR had finalized the AMOC with M/s Darshan


Enterprises/NDLS and M/s Mohan Rail Components
KXH for their bio--digester for one year
No. of Coaches on
No. of Bio
Year Toilets
which these are
fitted
2010-11 57 31
2011-12 169 67
2012-13 1337 561
2013-14 8024 2988
2014-15 10159 3374
2015-16 8641 2388

Cuml. (Feb-16) 30,000 12000


These tanks are made of stainless steel and
having following constructional features

 The size of ICF coach tank- 540 X 1150 X 720 mm

 The size of LHB coach tank-547 X 1680 X 580 mm

 With the provision of 04 Nos mounting brackets


at both the sides along the length of the tank.

 Each bracket is with the provision of 02 nos. M16


Size bolts which are tighten in the under slung on
mounting brackets.
 Stainless steel tank with 06 partition walls in side
the tank
 Poly grass mats for protection of bacteria in side
the partition walls.
 By pass system with handle for operation during
emergency for making toilet direct discharge in
case of chocking.
 SS fasteners in place of MS on tank covers.
 Stronger bonding of rubber mat with vertical
walls.
Information about IR-DRDO Bio-digester Tank

1. Length - 1150 mm
2. Width - 720 mm
3. Height – 540 mm
4. Total Volume of Tank – 400 lt.
5. Effective Volume of Tank – 300 it.
6. Empty Tank weight – 115 Kg.
7. Full Tank Weight – 415 Kg.
8. Height from Rail level – 220 mm
Versions of Bio- toilets
• There are four versions of Bio toilets.
• 23 coaches with 43 toilets (three variants) inducted in Jan’2011.
• 8 coaches with 14 Bio toilets of 4th variants inducted in Jul’2011.
S. No. Toilet Type Nos. Description

1. Variant 1 16 PLC system with flapper valve. Modified to Manual


Slider valve system.

2. Variant 2 16 System with manual slider valve with Gravity


flushing.
3. Variant 3 11 System with reduced opening at inlet with Gravity
flushing, Modification not possible..
4. Variant 4 14 System with Solid-liquid separator with Gravity
flushing. Modified to Manual Slider valve system.

25
Features
Brief description Pneumatics Electrics PLC Flush
System with flapper Yes Yes Yes Pressurized
valve

PLC - Programmable Logic Controller


PLC is a digital computer used for automation
of electromechanical processes, such as
control of Mechanism.
Features
Brief description Pneumatics Electrics PLC Flush
System with manual no no no gravity
slider valve

Fail safe mode exist- chute system can be


operated without dismantling of tank
P-Trap
Manual Slider
Handle

Mounting
Bracket

Over flow
Pipe
Chlorinator

Sampling Port
Main parts of the Bio digester tank
1. Stainless steel tank with 06 partition walls
Chlorine Chamber

6
3
4

2 1 5
Main parts of the Bio digester tank
Stronger bonding of Rubber mat with vertical walls
WASTE FLOW PATH

1
2

3 4
6
Features
Brief description Pneumatics Electrics PLC Flush
System with reduced no no no gravity
opening at inlet

Fail safe mode does not exist


Features
Brief description Pneumatics Electrics PLC Flush
System with solid no no no gravity
liquid separator

Fail safe mode exist- chute system can be


operated without dismantling of tank
Developments/Improvements
(Common Bio-digester tank for DSLR coaches)

 Common tank for


passengers and
disabled lavatories

 30 ltrs retention tanks


for Guard compartment
 Design completed , Provided
inJune’15, 14 coaches turned
out
Design variants of Bio-digesters

 Two designs in operation:


 With J-Bracket type mounting
- Fitted by RCF till December’13.
 With C-type mounting brackets
(mounting brackets integrated with tank)
- Cut-in by RCF since Jan’14
(400 tanks fitted)

 RDSO issued 3rd design (for retro-


fitment and on 200 coaches by
Pus/MLR)
 Direct mounting type
Alternate Design of bio-digester tank
For strengthening of the Bio digester tank, an
alternate design has been developed by RCF
and approved by RDSO in the month of May -
2013.
 Alternate design finalised by RCF & RDSO for
fitment- Positive mounting with bolted
fastening.

Existing Design

Alternate Design
Alternate Design of bio-digester tank
Problem/Issues of old design Bio digesters have
been eliminated.
Re- location of chlorinator.

Smaller chlorinator-
Bigger chlorinator-
discharge at the
discharge on side of track
center of track
With C-type mounting brackets

Mounting
Mounting at at outer
inner head head stock
stock
 C-mounting bio-tank
–GS, SCN, AC-3T

 DSLR-Integrated bio-tank
for passenger and
disabled passengers

 DSLR-Guard lavatory
Applicable Designs of Bio-tanks
- for LHB coaches (30 coaches turned out)

 Common for all types except


power car.
 Power car will be smaller in
size.

Power car- CDTS will be replaced


Improvements
(between P-trap and pan)

 TPE Connector
Spread of feacal
matter over tank

Connector between
pan and P-trap
Improvements
(Modification of P-trap and Anti rotation measure)

Casted single piece

Anti rotation measure


P-Trap to RDSO drawing no. 14055
• P-trap has been made of 100 mm interface diameter with improved flow at
bend area.
• Retaining capacity of liquid is almost one liter only.
• Material has been defined AISI -316 investment casting only.
Developments/Improvements
(Development of KMnO4 Tablet )

 KMnO4 tablet development as an alternative of chlorine .

 DRDE /Gwalior has given the following details for Chlorine Tab. -
◦ Size and weight : Dia 78 mm, Weight :200 gms.

KMnO4
tablets

Chlorine
tablets
 Item no. 3.3 of 14th JWG-Feb.
2015 directed to undertake
trial with S-trap on 10
coaches.
 Provision already made in 02
AC coaches & same is running
successfully in JP-MYS Exp.
for almost 05 months.
 Further 10 coaches have been
fitted (total 25 coaches) till
Sep.2015.
 After analysing performance
in 17th JWG SEP.2015, fitment
of S-Trap has been extended
upto 100 Coaches.
 Provision of SS Mesh to avoid Choking of
 S-Trap
Main features of S-Trap Design are followings-
 Complete elimination of by pass system.

 In place of existing 60 mm dia P-trap, a S-band of 100 mm dia(ID) is


directly coupled to commode pan, increasing flow area and streamline the
waste flow into Bio-Toilet tank.

 1st chamber is increased.

 The material of S-Trap is Stainless Steel.

 S-Trap wall thickness is 3.5 + 0.5 mm.

 The S-Trap is seamless pipe of above material.

 Garbage can be collected from 1st chamber with the help of Evacuation
Machine during IOH.
 The S-trap provided is basically maintenance
free.

 The 60 mm dia. is the optimal diameter that can fit


into headstock pocket above bio-tank provided in
the pan for discharge of fecal matter restricts
passage of any other materials like small water
bottle, Napkin etc..

 Italso reduces the water requirement of flushing to


1 ½ to 2 liters.

Two piece design will make it easy for retro fitment in


 S-trap is connected to bio-tank with rubber hose
and it can be detached and replaced any time by
unscrewing four nuts.

 If blocked, by any another materials can be easily


cleaned from top by any suitable tool. Further it
requires just half bucket of (6-7 liters) water, if
poured from 2 feet height in hole, will clean the
passage.
Buffer

Push type
Flush valve

SCN coach shell No. 4795


Suction chute provided in toilet side wall to
get continuous evacuation of foul smell
during train running.
 Suction air speed
measured using
anemometer is 1.6 to
3.3 m/sec at 100 kmph
train speed.
 Side panel electric
exhaust fan - 3.4m/sec.
 Suction from near the
source of foul smell.
Fitment of Bio-Digester in
LHB coaches

 One LHB AC-2T coach turned


out in Jan’14 to WRly.
 Feed back after two months-
satisfactory from functioning
and mounting point of views.
 Now, LHB coaches are planned
to be provided with Bio-toilets.
 200 ltrs capacity
 Clutch wire type mechanism
 Procurement initiated
 Fitment started
Clutch wire type mechanism
All Conventional and LHB coaches of 2015-16

 Simple, Retro-fitable
 Minimum parts (3nos)
 Pulley
 Bearing
 Clutch wires

Pulley to be mounted
on ball valve

Bearing to be mounted
inside lavatory
Clutch wire type mechanism
All Conventional and LHB coaches of 2015-16

 Pulley mounted on
ball valve
 Bearing inside the
lavatory
 Clutch wire
connects the
above
Proliferation Issues/Suggestions

 RDSO cleared 4 Bio-Toilets in ACCN & SCN and GS.

 Standardisation of Dust Bin has been done in toilets


 Visual inspection of complete Toilets System including under slung
equipments.

 Toilet Pan to be cleared if there is chocking.

 P-Trap /S-Trap choking should be removed by choke remover

 Checking the toilets system for any deficiency.

 Collection and transportation of sample from Bio-tanks for lab as per


the test scheme.
 Charging of Chlorine/KMNO4 tablets and examination of
Chlorinator.
Checking of Equipments/Components for proper functioning:

 Ball valve/ Flapper/Slider.


 Leakage in piping, flush system, tank body, Rubber connector
& ball valve seal etc.
 Charging of Bacteria if required (based on test reports).
Inoculum is collected from MIBW & DRDE/GWL.
( Issued by the RDSO document no. RDSO/2010/CG/CMI-03(Rev.1)
 Wear gloves while handling bacterial culture.

 Store bacterial culture in containers with lid which can be


closed.
 During transportation, lids should be tightly closed.
 During storage, lids should be kept loose so that the gas
generated inside the container can escape easily otherwise
container will get damaged.
 Do not mix chemicals with bacteria at any stage during
use.

 Bio-Toilets should preferably be cleaned by pressurized


water cleaning system so as to minimize the water usage.

 Clean/sanitize hands with detergents/soaps after handling


of the bacteria.
Lab Testing Report of Delhi Sarai Rohilla Depot

Total Volatile
Date of
pH Value Total Solids TDS Solids
Coach (mg/100ml) (mg/100ml) (mg/100ml) (mg/100ml)
Type Lab
No.
Testing Room Target Target Target Target
Results Results Results Results
Temp C˚ Value Value Value Value

133459 GS 05-06-14 25.3 7.77 6-9 430 < 750 135 < 350 298 < 500

133452 GS 05-06-14 25 7.42 6-9 700 < 750 320 < 350 388 < 500

13417 GS 05-10-14 30.8 6.78 6-9 180 < 750 57 < 350 123 < 500

12914 GS 05-10-14 31 7.47 6-9 212 < 750 122 < 350 90 < 500

13537 GS 05-10-14 30 7.67 6-9 276 < 750 66 < 350 210 < 500

13418 GS 05-10-14 30 7.6 6-9 232 < 750 147 < 350 85 < 500
Performance of Bio-Digesters
(Data provided by DRDE/GWL)
 Percent samples showing
compliance
Values to be achieved
 pH: 442/465=95% 1. pH : 6-9
2. TS : <750mg/100ml
 TS: 392/462=85% 3. TDS : <350mg/100ml
4. COD : <2000ppm
 TDS: 360/463=78% 5. VS : <500mg/ 100ml
6. FC : <108CFU/ 100ml
 COD: 334/433=77%
 VS: 388/425=91%  Chennai-Guwahati Express
 NZM-INDB Intercity Express
 FC: 13/16=81%
Testing Scheme for
Bio-Toilet Effluent in Coaching Depots.

SNo. Name of Lab Test Place of Test


1 pH Value Test In Coaching Depot
2. Total Solids (TS) Test: In Coaching Depot
3. Total Dissolved Solids (TDS): In Coaching Depot
4. Total Volatile Solids (TVS): In Coaching Depot
5. Chemical Oxygen Demand (COD) Govt. Appd.
Test Lab/DRDE
6. Fecal Coli Forms count: Govt. Appd.
Lab/DRDE
pH Value
Purpose To measure pH value of the effluent of bio toilets to ensure
environmental safety.
Target value 6–9
Equipments Table top pH meter / Portable pH meter / pH indicator strips &
magnetic stirrer
Consumables pH calibration buffers (4.0, 7.0, 10.0), and magnetic stirrer bars
Quantity of sample 50-100 ml
Electricity Requirement Yes
Frequency of 90 days
sampling
Testing spot In laboratory at site
Staff required 1
Total Solid (TS)
Purpose To estimate amount of total solids in the effluent.
Set Target <750 mg /100 ml
Equipments Electronic weighing balance, pipettes, Silica crucible, Hot air
oven, desiccators.
Consumables Self indicating silica gel.
Quantity of sample 25 ml
Electricity requirement Yes

Frequency of 90 days
sampling
Testing spot In laboratory
Staff required 1
Testing Kit required for effluent of Bio-toilet
Total Dissolved Solids (TDS)
Purpose To estimate amount of total dissolved solids in the
effluent.
Target value < 350 mg /100 ml
Equipments Electronic weighing balance, pipettes, Silica crucibles,
Hot air oven, desiccators, filter assembly, vacuum pump
Consumable Self indicating silica gel. Whatman Glass wool filters
Quantity of sample 25 ml
Electricity Yes
requirement
Frequency of 90 days
sampling
Testing spot Laboratory
Staff required 1
Testing Kit required for effluent of Bio-toilet
Total Volatile Solids (TVS)
Purpose To estimate amount of total volatile solids available in the
effluent.
Target value < 500 mg /100 ml
Equipments Electronic weighing balance, pipettes, Silica crucibles, Hot air
oven, muffle furnace, desiccators, filter assembly.

Consumable Self indicating silica gel. Whatman Glass wool filters


Quantity of sample 25 ml
Electricity Yes
requirement
Frequency of 90 days
sampling
Testing spot Laboratory
Staff required 1
Chemical Oxygen Demand (COD)
Purpose To estimate COD of the effluent to ensure
environmental parameters.
Target value < 2000 mg O2 / 100 litres
Equipments COD digester along with digestion tubes and condensers,
Burettes, magnetic stirrer, magnetic bars.
Consumable Sulphuric Acid, Silver sulphate, mercuric chloride, potassium
dichromate, ferroin indicator, ferrous ammonium sulphate.
Quantity of sample 5-10 ml of sample
Electricity requirement Yes

Frequency of 90 days
sampling
Testing spot Laboratory/ DRDE/ Govt. approved Labs.
Staff required 2
Testing Scheme for
Bacteria Culture (Microbial Inoculum)

SNo. Name of Lab Test Place of Test

1. pH Value Test At Bacteria Plant

2. Bio-gas Test At Bacteria Plant

3. Percentage Methane Test At Bacteria Plant


pH Value
Purpose To measure pH value of the effluent of bio toilets to ensure
environmental safety.
Target value 6.5 – 8 pH
Equipments Table top pH meter / Portable pH meter / pH indicator strips &
magnetic stirrer
Consumables pH calibration buffers (4.0, 7.0, 10.0), and magnetic paper for pH
testing
Quantity of sample 50-100 ml
Electricity Requirement Yes

Frequency of Daily/Real time


sampling
Testing spot In laboratory at site
Staff required 1
Bio-gas production
Purpose To see the activity of various groups of Microbes in the
inoculum
Set Target -

Equipments Gas Flowmeter

Other equipment Gas flowmeter flexible pipe & adopter

Frequency of Daily/Real time


sampling
Testing spot Inoculum Generation plant.

Staff required 1
Methane % Test
Purpose To see the methane content of the biogas in side the plant

Set Target 40 – 70 %

Equipments Gas Chromatograph

Quantity of sample 10 – 15 ml of gas

Frequency of Weekly Testing


sampling
Testing spot In laboratory

Staff required 1
1. The sample shall be collected in 2 litre plastic bottle
by simply opening the knob provided in the
sampling port
2. The date and time of sampling and coach no. must
be mentioned on the bottle
3. The sample collected in the bottle shall be
transported to lab at the earliest but not later than
24 hours after collection of sample
Following instructions for POH of coaches fitted with IR-DRDO type bio-toilet
have been circulated by CAMTECH as Annexure-I of Guidelines for AMOC for
IR-DRDO Bio-Toilets Aug.-2015)
 Place the coach at maintenance workshop’s pit line, where fork lifter can be
placed under the tank.
 Mark all the tanks with their respective coach number and lavatory number.
 Remove all the nut bolts used for fastening of safety ropes and safety
ropes provided for IR-DRDE bio toilet retention tank.
 Dismount hose clamp provided for securing of Rubber hose at Lavatory
Pan.
 Remove all the pneumatic pipes for flapper valve if any.
 Open all the nuts and washer with the help of suitable spanner/ wrench.
Atleast one bolts should remain in the holes of each mounting brackets
and tank to avoid accidental dropage of tank during placement and lifting
of the tank.
 Place the arms of fork lifter below tank and lift the tank slowly about half
inch. Remove remaining bolts carefully.
 Remove all the tank with the help of fork lifer for thorough cleaning, tank
and mounting brackets should be inspected for any damage, leakages
etc.
 Complete tank evacuation and cleaning of whole tank.
 Attention to Ball valve linkages or operating mechanism.
 Ball valve should be overhauled and PTFE seal of Ball valve should be
renewed 100% during POH.
 Rubber connector should be renewed during POH.
 Replacement of poly grass mat with proper securing arrangement.
 If there is any damage or leakage in the tanks or non-confirming results
of effluent discharges are being reported etc., these tanks should be
drained out at designated place having proper drainage, cleaned properly
and tank should be rectified for the deficiency noticed.
 If there is no deficiency found, It should be stored after cleaning in the
racks (3tier stacks as suggested by CAMTECH / Gwalior) earmarked for
bio toilets. Racks should be placed in cool, safe area and without
sunlight.
 Ingress of water, chemicals or any other foreign object to the tank
should be prevented during storage of the bio toilet tanks.
 Then the coach should be sent to all regular stages of POH attention.
 After completion of POH of the coaches, tanks marked with respective
coach number and lavatory number should be taken out from storage
rakes and restored in position.
 Check the rubber hose used for joining of P-trap and Lavatory pan for
any defects, remove all dirt, scaling and old sealant before fixing it
again.
 Reconnect pneumatic pipes for flapper valve if fitted with PLC version.
 Nut, bolts and spring washers used for mounting bracket and
securing of safety rope should be checked for wear, tear or
corrosion etc. and should be replaced with same size material
and grades if defective.
 Check the safety rope before re-mounting for any defects.
 Ensure all the nuts and bolts used for mounting and securing of
safety rope are be properly tightened before dispatch of the
coach.
 NDT of J Brackets/Positive mounting bracket.
 Tanks should be Re-filled with the required level of bacterial
Inoculum before dispatch of the coach.
 Nut, bolts and spring washers used for mounting bracket and
securing of safety rope should be checked for wear, tear or
corrosion etc. and should be replaced with same size material
and grades if defective.
 Check the safety rope before re-mounting for any defects.
 Ensure all the nuts and bolts used for mounting and securing
of safety rope are be properly tightened before dispatch of
the coach.
 NDT of J Brackets/Positive mounting bracket.
 Tanks should be Re-filled with the required level of bacterial
Inoculum before dispatch of the coach.
TECHNOLOGY HOLDERS OF RAILWAY BIODIGESTERS

1. M/s Aikon Technologies Pvt. Ltd., New Delhi


2. M/s Stone India Limited, Kolkata
3. M/s Mohan Rail components (P) Ltd., Kapurthala
4. M/s Kemrock Industries & Exports Ltd., Vadodara
5. M/s Escorts Limited, New Delhi
6. M/s CBS Technologies Pvt. Ltd., Delhi
7. M/s Omax Autos Limited, Gurgaon
8. M/s Flexo Foam Pvt. Ltd., New Delhi
9. M/s CTS Management Services Pvt. Ltd. Noida
10. M/s Darshan Enterprises, New Delhi
11. M/s Daulat Ram Industries, Bhopal
12. M/s Rail Coach Engineers, PO Sheikhupur, Distt.
Kapurthala
13. M/s Rail Tech Group, New Delhi
14. M/s Sidwal Refrigeration, New Delhi
15. M/s Vishal Gas Services, Hyderabad
Consequent upon introduction of Bio-
toilets in coaches, it is necessary to
develop facilities for Dismounting,
Placing and handling of Bio-Toilet tanks
during POH in workshops.
The following basic facilities are
required for the coaches fitted with
Bio-Toilets.
A. M&Ps required for transporting and loading/unloading of bio
tanks of coaches.

S.N Name of item Total Capacit Purpose Approx.


nos. y cost

1 Low lift hydraulic jack 02 1 Ton To facilitate 1.5 lacs


fitted platform trolley loading/unloading
2 Fork lifter with 6 feet 01 5T For transportation 12 lacs
height
3 Evacuation system 01 To evacuate bio tank 15 lacs
(Spec. No. CAMTECH/M/SUCTION
SYSTEM/02/11)
B. Loading /unloading facilities for bacteria inoculum in
POH shop.

S.N Name of items Total Capacity Purpose Total


Nos cost
1 Plastic/fiber drums As per 100 liters For storing Inoculum 0.25
req. lac
2 Truck 01 9t Transportation 15 lacs
facility for Inoculum
from generation plant
to POH shed
C. Infrastructure required for storing of bio toilet tanks:

a. – Racks
b. - Covered shed
c. - Other handling and maintenance equipments
a Racks for storing of bio toilet tanks of size 1150 mm x 720 mm x 761
mm, the size of one 3-tire rack for housing of 9 tanks is as under -

Length – 1250 X 3 =3.7 Meters


Width – 1000 mm = 1.0 Meter
Height = 2.7 Meters
Total no of racks required for 90 bio tanks =10 rakes
Appx. Cost – 2 Lacs
b Covered shed for storing bio-toilet tanks

Size of covered shed for 10 (3–tire) racks:


* Height of shed – 4 Meters
* Width of shed – 7.4 Meters (2 racks shall be in one row)
* Length of shed – 13 Meters (5 rows will be in shed, 2 m
space for moving of fork lifter)
* Area of shed – 13 X 7.4 = 96.2 m2 say 100 m2
Appx. Cost – 15 Lacs
 As per JWG meeting held at GWL on 03.07.2015, it was decided by members
vide item No.12 that Infrastructural facilities should be developed in
coaching depots for dismounting of Bio-Toilet tanks for repairs and
washing/cleaning of tanks. For above activities, following facilities are
proposed –
1. Bio-Toilet CC Apron for unit exchange size 8M X 50M
2. Construction of Cleaning/Washing apron size 3m X 3m X 0.3m (H)
3. Water Jet Machine
4. Inoculum storage for charging in tanks
5. Scissor Platform Trolley for dismounting & Mounting of tank.
6. Covered Drainage Sump size 3m X 3m X 4m (Deep) with sewage
connection from Cleaning apron.
 Break up of cost: As per estimate prepared by NWR Ref: MLB item No.25
Project ID No. 09.03.53.15.4.52.025 dated 08.06.2015.

◦ Engineering Deptt. – Rs. 554000.00


◦ Electrical Deptt. – Nil
◦ S&T Deptt. – Nil
◦ Mech.(M&P) – Rs. 100000.00 Approx.
 Total – Rs. 654000.00 Approx.
Monitoring, Operation and maintenance of
IR-DRDO Bio-Toilets.
(Railway Board’s L.No. 2009/Dev.Cell/ICCI/1 Vol.IV Dated 24.12.2012)

1. Ensure that no Bio-toilet coach is put in service without charging of


bacteria in bio-tanks.
2. Base all Bio-toilet coaches at single nominated depot as of now.
3. Put these coaches in service in rake form, to the extent possible.
4. Ensure use of proper cleaning agents as prescribed by RDSO to avoid any
adverse effect on bacteria in the Bio-tanks.
5. Have spares/consumable as per the holding of Bio-toilet coaches.
6. Keep performance record and take passenger/staff feedback regularly.
7. Carry out monitoring as per trial/test scheme issued by RDSO.
8. Enter AMOC with supplier(s) as per RDSO instructions/guidelines.
In past, there were incidents of failure of welding of mounting
brackets. Recently, NR has reported the breakage of safety wire
ropes provided to hold the bio-tanks in case of bracket weld
failure. For fail-safe operation of these bio-toilet coaches, all
Railways must ensure -

1. The regular/periodic inspection of welding of mounting


brackets.
2. The regular/periodic inspection of safety wire ropes and
3. That fasteners for bio-tanks/safety wire ropes are intact.

Corrective/preventive action must be taken immediately, if


anything abnormal is found.
(B) Bio toilet Lab
Hkkjrh; jsy dks ck;ksVkW;ysV gfjr dzkfUr esa lg;ksx iznku djSaA
jsy ;kf=;ksa ls vuqjks/k &
;g ck;ks VkW;ysV gS vr%
1- d`i;k 'kkSpky; esa cksry] v[kckj] uSifdu]
ikWyhcsx] diM+k bR;kfn u MkysaA
2- 'kkSp ds ckn d`i;k ¶y'k vo’; pyk,a] vU;Fkk
'kkSpky; pksd gks tk,xkA
3- vko’;drkuqlkj VkW;ysV esa j[ks NksVs dwMknku
(MLVfcu) dk mi;ksx Hkh djSa A
4- Vk;ysV dks xank u djSa A
d`i;k bl gfjr&vfHk;ku esa gesa lg;ksx iznku djsaA
Hkkjrh; jsy dks ck;ksVkW;ysV gfjr dzkfUr esa lg;ksx iznku djSaA
dksp vuqj{k.k LVkQ ds fy, funsZ’k&
;g ck;ks VkW;ysV gS vr% vuqj{k.k ds nkSjku&
1- d`i;k 'kkSpky; esa iMs cksry] v[kckj] uSifdu] ikWyhcsx]
diM+k bR;kfn dks fudkysaA
2- ¶y'k pyk,a ftlls fd ih&Vªsi pksd gksus dh tkudkjh
gks ldsA
3- 'kkSpky; pksd gksus ij LVs’ku ij [kMh xkM+h ds
VkW;ysV esa yxs “QqViSMy” dks nck,a A
4- QqV iSMy dk;Zjr u gksus ij pksd&fjewoj dh lgk;rk
ls ih&Vªsi dh pksfdax dks nwj djSaA
5- VkW;ysV esa j[ks NksVs dwMknku (MLV&fcu) dks [kkyh
djSaA
6- VkW;ysV dh Bhd rjg ls lQkbZ djSa A
d`i;k bl gfjr&vfHk;ku esa gesa lg;ksx iznku djsaA
Kindly help the Railways for IR-DRDO Green Bio-Toilet System
Instructions for Coach Maintenance Staff
This is Bio-Toilet – Hence during maintenance-
 Remove Bottles, newspapers, napkins, polybags,
sanitary cloths etc. from toilet chute.
 Do flushing in each bio-toilet to check choking of
P-trap.
 In case of choking of Bio-toilet at train
examination station, operate Foot Paddle in
toilet.
 In case of defect in foot paddle, remove choking
of P-trap with the help of “Choke Remover”.
 At train examination station, get the portable
dustbin cleaned which is available in toilet.
 At CTS station, clean the Bio-toilet properly.

Hkkjrh; jsy dks ck;ksVkW;ysV gfjr dzkfUr esa lg;ksx iznku djSaA
1. Operate ball Valve with the help of foot Paddle
to drain garbage from Pan & P-trap.
2. Release the paddle and close ball valve and do
flushing. If still P-trap is choked, the flushed
water level will increase in Pan.
3. Now apply “choke Remover” equipment in to
the Pan with pressure 2-3 times, due to this
action, P-trap will be cleared of obstruction.
4. In case, P-trap is still having obstruction in
side, the “choke Remover” equipment should
be applied again in the Pan by flushing Bio-
toilet.
CHOKE REMOVING GADGETS

Conventional Choke Remover

Garbage Picking Tongs Pneumatic Choke Removers


High pressure
jet gun can be
used for
washing away of
scattered Bio
tank waste at
accident site.
Existing water
mist
pressurized
foam type
equipment can
be used for
covering layer
over scattered
Bio waste

Adequate nos. of sand bags can be kept in ART for


covering the Bio toilet waste affected area.
ENVIRONMENTAL LABORATORIES
(WITH VALID RECOGNITION UNDER SECTION 12(1} B OF THE
ENVIRONMENT (PROTECTION) ACT, 1986)

The Environmental laboratories (Govt./Semi-


Govt./Public Sector Undertakings/Educational
Institutes) with valid recognition (updated
upto 15th April, 2012) under the Environment
(Protection) Act, 1986 are as below:
S. No. Name of laboratory
1. Goa State Pollution Control Board EDC Plaza Patto, Panaji, Goa-
403001
2. Centre Laboratory Madhya Pradesh Pollution Control Board
·”Paryavaran Parisar", E-5, Arera Colony BhopaI-462 018. M. P.

3. Eco-Auditing Laboratory National Botanical Research Institute Rana


Pratap Marg, Lucknow-228 001 U.P.

4. Zonal Office Laboratory, Central Pollution Control Board Synergy


House-II Gorwa Subhanpura Road Subhanpura Vadodara-390 023
,Gujarat .

5. Central Laboratory Pollution Control Board. Assam Bamunimaidan


Guwahati-781 021. Assam

6. Environmental Management Division Central Pulp & Paper Research


Institute, Post Box No. 174, Paper Mills Road, Himmat Nagar
Saharanpur 247001,U.P.
S. No. Name of laboratory
Central Laboratory
National Fertilizers Limited Vijaipur Unit,Vijaipur-743111 Tehsil-Raghogarh
7. Dist.Guna, M. P.
8. Central Laboratory Andhra Pradesh Pollution Control Board A-3. Industrial Estate
Sanathnagar Hyderabad-500 018 Andhra Pradesh

Gujarat Pollution Control Board, Regional Office -Surat 338, Typical First Floor
Belgium Square Sliver Plaza Complex, Opp. Linear Bus Stand, Ring Road Surat-
9. 395 003, Gujarat

Gujarat Pollution Control Board


Regional 0fI'ice Laboratory-Vadodara Geri Compound Race Course. Opp. S. T.
10. Depot Vadodara-390 007 Gujarat
11. Regional Office Laboratory-Rajkot Gujarat Pollution Control Board Race Course.
Ring Road Near Union Bank, Rajkot-360 001 Gujarat

12. Environmental Laboratory Central Mine Planning & Design Institute limited
Gondwana Place ,Kanke Road, Ranchi-834 008. Jharkhand

13. Pollution Control Research institute, Bharat Heavy Electricals Limited Ranipur.
Haridwar-249 403 Uttarakhand
S.No. Name of laboratory
14. Central Laboratory Central Pollution Control Board Parivesh
Bhawan East Arjun Nagar Delhi-110032
15. Central Laboratory Punjab Pollution Control Board Vatavaran
Bhawan. PatiaIa, Punjab-147001
16. Regional Laboratory Maharashtra Pollution Board Control Jog
Centre, 3td Floor, Puna-Mumbai Road, Shivaji Nagar. Pune-
411003
17. Zonal Laboratory Central Pollution Control Board, Zonal
office , Kolkata 502, South end Conclave, 1582 Rajdanga Main
Road KoIkata700107
18. Environment Protection Training and Research Institute
(EPTRI), 91/4, Gachi BowIi. Hyderabad. 500032 Andhra
Pradesh
19. P.G. Department of Environment Management Chhatrapati
Shahu Institute of Business Education and Research (SIBER).
University Road, KoIhapur. 416004 Maharashtra
S. No. Name of laboratory
20. Punjab Bio-Technology Incubator Agri. And Food. testing
Laboratory SCO: 7 & 8 (Top Floor). Phase.V, SAS Nagar.
Mohali-160059 Punjab.
21. Regional Laboratory Maharashtra State Pollution Control
Board 6thFloor, “Udyog Bhawan” Civil Lines Nagpur-440001
Maharashtra
22. Regional Laboratory Maharashtra State Pollution Control
Board 1stFloor Udyog Bhawan. Rathi Chowk, Trimbak Road,
Nashik-422007 Maharashtra
23. Regional Laboratory Maharashtra State Pollution Control
Board "Paryavaran Bhavan” A-4/1,Chikalthana MIDC, Behind
Dhoot Hospital, Aurangabad·431210 Maharashtra
24. Central Laboratery Uttar Pradesh Pollution Control Board
PICUP Bhawan, 3rd Floor, B-Block Vibhuti Khand, Gomati
Nagar Lucknow.226010 U.P.
25. Regional Laboratory M.P. Pollution Control Board Plot No,
455/456, Vijay Nagar. Jabalpur-482002 Madhya Pradesh
S. No. Name of laboratory
26. Regional Laboratory M.P. Pollution Control
Board Sc-17,Bharatpuri Ujjain-456010
Madhya Pradesh
27. Regional Laboratory M.P. Pollution Control
Board Scheme No.-78 Part-II. Aranya Nagar
Indore 452010 Madhya Pradesh

Environmental laboratories and the Government Analysis so mentioned


shall remain valid only up to 31" Aug 2012 as per provision of office
memorandum dated 12th AUG-2011 Issued by ministry of Environment &
forest to acquire the required accreditation / certification to achieve
eligibility under the essential pre-requisite or office memorandum.
( As per Annexure-III of
Guidelines for AMOC for IR-DRDO Bio-Toilets Aug.-2015 )
1. The Annual Maintenance & Operation Contract (AMOC) entered
between Contractor and Base Railway will be inclusive of spares and
consumables required for maintenance and operation of Bio-Toilet
system (Anaerobic Technology herein after termed as Bio-toilet only).

2. The AMOC scope of work shall include supply/repair and fitment of


defective components in both kinds of coaches (i.e. coaches under
warranty period and coaches beyond warranty period) except supply of
ball valve & its operating mechanism, bio-toilet tank for which no
trend of repair/replacement is available and cost of which is very high.
In case replacement is necessary, ball valve, its operating mechanism,
bio-toilet tank and safety wire rope will be provided by Railways for
which fitment would be done by AMOC contractor without any extra
payment.

3. Railways may suitably modify the contract as per local conditions with
the approval of concerned HOD/CME.
 Bio Digester Tank
 PLC Controls – as applicableChlorinator
 Ball Valve/ Flapper/Slider– as applicable
 Operating mechanism with paddle- GEAR (Rake &
pinion) type, Link type, clutch-wire type or any
other design as applicable
 Flushing Unit/Pressuriser.
 Piping system
 Pneumatic Valve – as applicable
Man Power (minimum man power to be
deployed) in Depots:
 The contractor shall provide trained man power
for the prompt and efficient maintenance
(preventive as well as break down) and day to day
operation of the bio toilets as under.
 The team of contract staff should consist of
 Supervisor: 1 per shift.
 Skilled technician: 1 for every 30 Bio toilets or part
thereof.
 Semi skilled technician: 1 for every 30 Bio toilets or
part thereof.
Place of work will be washing line/Sick line/Coaching depot/Terminal
station/any other maintenance point selected by the nodal office. Bio-toilet
maintenance timing will depend on No. of trains and their maintenance
schedule. Contractor has to maintain the bio-toilet in the given maintenance
schedule of the respective trains. The manpower requirement can be assessed
by Nodal Officer and accordingly manpower deployment may be increased or
decreased.

Railway shall provide to contractor the following Facilities for AMOC:

• Suitable room (10 ft x 10 ft) and workplace of 100 sq feet for accommodating
the tanks etc. located in the proximity of maintenance activity.
• Suitable open space at convenient location for the storage of residual waste
which shall be removed and disposed of by the contractor ensuring clean and
hygienic environment in the depot.
• Air pressure at 05 bar on “as is where is” basis for maintaining the system.
• Suitable power supply connection will be made available at site on payment
basis as per Railway extant rules.
• Water supply on “as is where is” basis.
a. Attending the daily routine complaints received from the
users.
b. Removal of choking from toilets of on arrival rakes by
nominated choke removing gadgets only.
c. Checking of all the components of Bio-toilet system for any
deficiency
d. Attention to operating mechanism of Ball valve and
attention to TPE connector.
e. Examination of chlorinator unit for any leakage, tilting and
thread missing and Charging by Chlorine/Kmno4 tablets, if
required
f. Attention to PLC if fault is noticed ( if applicable).
g. Exterior washing of bio- digester tank at washing line
during maintenance.
a. All works to be carried out as mentioned in daily
schedule above;
b. Collection and transportation of samples from
retention tanks to DRDE, Gwalior or any other
nominated Govt. accredited lab as per the test
scheme (RDSO/2010/CG/TS-10 or any applicable
test scheme) issued by RDSO.
c. Visual inspection of complete Toilet system
including under slung equipments and mounting
arrangements of Bio-Toilet system and attend if
found any deficiency.
d. Charging of Chlorine/Kmno4 tablets and
examination of Chlorinator unit every 10 days or as
required depending on life of the tablet.
a) All works to be carried out in Daily and Monthly
schedules above;
b) Checking of following
equipments/repair/replacement for proper
functioning:
I. Ball Valve/ Flapper/slider with operating mechanism
II. Leakage in piping, flush system, pneumatics, tank etc. Valves,
pressuriser, PLC, pneumatic valves (if applicable) and Ball valves
etc.
III. Charging of Bio-culture if required (based on test reports).
Inoculum will be supplied by DRDE/IR(MIBW/SECR, Nagpur).
a. All jobs as mentioned in the quarterly work
schedule above;
b. Servicing of all PLCs if applicable.
c. Testing of complete Toilet system
d. Application of evacuation machine for removing
garbage from first chamber of the bio-digester.
e. Drawing and delivering of samples as per
requirement to Govt. Accredited labs as advised by
Railways. The cost of test will be born by Railways.
f. Charging of Bio–culture if required (based on test
reports)
All the works to be carried out as
mentioned in POH instructions in
Annexure-I in AMOC guidelines.
 Long duration contracts at this juncture are not advisable
due to non availability of experienced contractors and as
the technology are still evolving and a lot of improvements
are expected in future. Hence one year contract is
practically feasible however in case of lesser population of
bio-toilets in certain depot, it can be for a longer duration.

Payments:
 The payment for AMOC shall be made in instalments on
quarterly basis on certificate of satisfactory
performance for the Nodal Officer.
 Target for 2015-16:

Fitment of 17,000 bio-toilets in coaches.

Target 2016-17:

Elimination of direct discharge toilet system from all


type of newly manufactured coaches.
PUs to turn out all coaches fitted with bio-toilets
Target for fitment Bio-toilet in 2016-17 is _____.
Elimination of direct discharge toilet
system from entire coaching fleet

Initial target of 2021-22 is


squeezed to March’2019 by Hon’ble
MR & PMO under the Hon’ble PM’s
“स्वच्छ भारत अभभयान” of making India
open defecation free by 2019

Vous aimerez peut-être aussi