Académique Documents
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Faecal Material
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
Nitrogen N2 0–10
Hydrogen H2 0–1
Parameters being monitored
Hydrogen sulfide H2S 0–3
pH 6 to 9
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
25
Features
Brief description Pneumatics Electrics PLC Flush
System with flapper Yes Yes Yes Pressurized
valve
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
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)
TPE Connector
Spread of feacal
matter over tank
Connector between
pan and P-trap
Improvements
(Modification of P-trap and Anti rotation measure)
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.
Garbage can be collected from 1st chamber with the help of Evacuation
Machine during IOH.
The S-trap provided is basically maintenance
free.
Push type
Flush valve
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
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.
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.
Frequency of 90 days
sampling
Testing spot Laboratory/ DRDE/ Govt. approved Labs.
Staff required 2
Testing Scheme for
Bacteria Culture (Microbial Inoculum)
Staff required 1
Methane % Test
Purpose To see the methane content of the biogas in side the plant
Set Target 40 – 70 %
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
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 -
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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
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
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
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.
• 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:
Target 2016-17: