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Rdso Bio

BI TANK

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5K views99 pages

Rdso Bio

BI TANK

Uploaded by

obhsmonitoringcellghykyq
Copyright
© © All Rights Reserved
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(Govt. of India) (Ministry of Railways) COMPENDIUM ON IR-DRDO BIO-TOILETS FOR INDIAN RAILWAYS IRCAMTECH /MECH/GWL/Compendium on IR-DRDO Bio-Toilet/1.0/Rev-1 September - 2018 ae — qT nw ww ST STATE Transforming Railways aerarence In uunrewnce Indian Railways Centre for Advanced Maintenance Technology MAHARAJPUR, GWALIOR--474005 Preface ‘On the basis of MoU between Indian Railways and DRDO, the bio- system has been introduced in IR. Bio toilet is one of the major flag bearers of “Swach Bharat” mission, Indian railway is putting all effort to make bio toilet successful, Bio-toilet has now become an essential part of coaching stock. So it has become necessary to have fully fledged knowledge of bio-toilet system for the staff working at bottom li ‘guidelines for routine maintenance & operation of the system in open line maintenance of coaching stock in coaching depots as well as in workshop maintenance let So as to streamline the system of maintenance, To counter the problems, issues, queries’ regarding the bio-toilet system and. its maintenance, CAMTECI has brought out this revised compendium. 1 hope ‘that this compendium will short out the problems of the staffs deputed for bio toilet maintenance and fitment. Maintenance related instructions issued by Railway Board and RDSO have ‘been included in the Hand Book. ‘The purpose of this handbook is to improve and consolidate the knowledge ‘and expertise in a nutshell for easy understanding of staff working at bottom-line. There was a lot of up gradation in design and performance parameters of bio- toilet as per guidelines of RDSO and railway board and there was a need to revise this compendium in a simple and understandable for everyone. Itis clarified that this handbook does not supersede any existing procedures ‘and practices laid down in the maintenance instructions on Bio-Toilet system issued by manufacturers or by Railway Board/RDSO. {Lam thankful for the efforts of Shei D.Govind Kumar/ Ex. PED/CAMTECH, Shri Sanjeev Garg Director (SS) Carriage, Dr. Dev rat Kamboj Scientist ‘F", Dr. ‘Mukesh Kumar Meghvansi scientist “E’ of DRDE Gwalior who have given their ‘continuous support for this updated compendium. Lam also thankful forthe sincere efforts of Mr. Prashant Saraswat SSE/Mech CAMTECI, for bringing out this compendium. INDEX Description Protas lndex “Coneston sips Introduction of IR-DRDO Bio Toilets ‘Environment Friendly Bo-Tollet System. ‘Benefits of green tolets Types of Environment trendy iets of toilet AnaOoe Degradation process ofbactena 20 RS ‘Adopion of Bio-bietn Indian Ray ‘General Information of Bio-tank TIR-DROO Blo-digester tank for ICFIRGF coaches. ‘Other components of bo-cigestr tank ‘Sketch of fio digester tank TR-DROO Bio-dgester Tank for LNB Coaches: [important Dimensions & Volume of Bo-cigester Tank sisisialelelelels| ‘Variants of Bio-Toilets "Varian number one-Biotoiet system with PLC: ‘Variant number two:- Bio-olet system without any proumalic, loc¥onics ‘and electrical ‘Variant number 66 “Variant number four sls} als ining arrangement of Bio-aigester Wale ase Direct mounting arrangement (Positive Mounting) (C-Mounting Bracket ‘Direct mounting boted design Bio-cigester interface and S-Tap Prodsion ot STrap in BsToIets Main features of S-Trap Design ‘Drawing of Strap Rettosftment of Sap i ering Bio agastor ‘Reto-fment procedure of S-Trap to ROSO Drawing No. CG-T6008. 1m the ‘ole aiready fited with IR-DROO Bio-Tolets to the Design CG-14053 Reito-fiment procedure of Trap for he tolets already fited with -ORDO Bio-Tolets in LHB Type coaches: ‘Appicable Design of Bio- Tole take for Coaching Stock ‘Standardisation of dust-bin for Bio toiets Retro-fiment ‘cera Torro iment of Bio-Toiets in Exsing Coaches Procedure for revo fiment of Bio-Tolt tank on ICFIRCF design 8G ‘Coaches. BZ] Procedure metractons for rave Fimamt of IRDROO Bis Torat for aera] Ie ‘existing Crashworthy and retrofited CBC type Coaches ‘5S | Procedure for Retro-fiment of IR-DROO Bio-Toiet in ICF design SLR cy ‘coaches, ‘a | Procedure Tor Revo-fiment of R-DROO bi tolet on old BEML Coaches as | > ‘per ROSO design CG-18090 ‘BS | Procedure instructions for rev iment of IR-DRDO Bis Tolst for service | 7 ‘existing LHB type Passenger Coaches. ‘BE | Procedure | instructions for reto-itment of RDRDO Bis Toit for n-service | 33 ‘existing LHB power car ‘37 | Procedure | instructions for rae fiment of IR-DRDO Bie Toit for in-service] 34 ‘existing Hybrid LHB type Passenger Coaches, ‘5B | Procedure for Reto-ftment of IR-OROO bo toilet in MEMUITC as par 3 drawing no. MIO05854 & MIO0SS67 ‘58 | List of avalabie design/drawings of R-DRDO bo-digester tanks for ICEILHB coaches ‘Chaplers Quality control of Anaeroble Microbial Inoculum & efuent discharge Parameters of IR-DROO bio toilets 60 Significance of Quality Testing '6.1___[ Performance Parameters of 61 Toilet eluent & Inoculum ‘62 | Guidelines for Coaching Depots for handing of Bacteria ‘6.3 | Quality check and remedial action of the effuent discharged fom Botolet (6.4 | Performa for efuent discharged parameter testing from Biotolets 165 __| Abbreviations ‘6.6 | Testing Scheme for Bie Toll Efiuentin Coaching Depots ‘6.7 | Technical spectication for Chlorine tablets for use in IR- DRDO Bio. Toles ‘6.8 | Technical specication for KMNOS tablets for use in I-DROO Bio- Tole ‘6.9 | Testing Scheme for Bacteria Cuture (Microbal Inoculum) 6.10 | Tnoculum_Generaton Facies On IR 16.11 | Approved Drawing fr Inoculum Generation Faciy [siz] in plant 101 6.13 | Instruments for analysis of Effluent parameters 102 16.14 | Annexure IV ( The Environmental Laboratories] 1 ‘Chapler7 Maintenance Instructions on Bio- Toil System for Coaching Depot ‘Stath Ti instroctons for pressurized cleaning of Bibrolets i 72] List of cleaning agents being used in mechanized coach Gearing mB 119 Toilet system 73_—_[ Evaluation of Cieaning Agents provided by Railways To 7.4 [Mixing of Cleaning Agents. BL 75 | Maintenance of the Bio-toiet systems and Guidelines for handling oF 12 Bacteria T5___| Check Us for Bo-Toiets for Maintenance Stat 1 7.7 | Standareization of sticker for noculum storage 7.8 [Daily Maintenance proforma for bo-tiets 78 —[ Weting Fate a Sree mouring «Saleh choos bys 7.10 (DO's and DON'Ts for Bi-Todet Maintenance in Open Line Facities required mn Coaching Depots for mantenance of Coaches fied with Bio-olets. 7.72__| Mentoring of IR-DROO Bio-Tolets in Passenger Coaches. Chopter-B Trouble-shooting ‘5.0 Troubie-shooting 0 Bio: Totet Systom for Coaching Depots sia 3.1 Method of S-Trap choke Removing. ‘82 | Other general Process for choke removing 83 Evacuation Machine 3.3.1 | Components of Evacuation Suction Machine 8.32 | Features of Troley Mounted Suction Machine. "B33 | Technical spectication for"Trlley mounted mobile sewage evacuation machine" for IR-DRDO bio-tolet waste disposal rom Indian railway coaches ‘Chapter Annual Maintenance and operation contract (AMOC) for I-OROO Bio-Toilets. TO__[ Generat 20_—[ invosueton 3.0 —[Detntions 3.0 —| Technical 5.0 | Scope of Work 18.0 | AMOC Charges: 7.0 | Authority for Signing and Operation ofthe Contract '8.0__| Responsibities of Parbes 3.0 —[ Warranty 70.0 —| Valeity of contact 11.0 | Ownership ofthe rejecied or defecive componentsier paris 120 | Payments [130 Te 14.0 | Records to be maintained by Maintenance Depots 15.0 EMD and Secunty Depost 76.0 | Performance Guarantee 17.0 [Force Majeure Clause 78.0 [Arbitration 79.0 | Laws Governing the Contact 200 | Determination 21.0 | Subleting and "220 | Other terms and conditions os por Standard General Conditons of Contact 230 [Penalty 20 [lnsiruetions Yor POH ofthe coaches fited wih beolats ‘Chapier-10_ Terminology and Question Bank CORRECTION SLIPS The correction slips to be issued in future for these Guidelines will be numbered as follows: CAMTECIV2018/ MECI/GWLland Book on Bio-Toilet for open line staf 1.0/C.S. # XX date Where “XX” is the serial number of the concemed correction slip (Starting from 01 onwards) CORRECTION SLIPS ISSUED TeNo-of | Oatwollasae | Page No. and Wem no. modified Remarks stip Chapter -1 Introduction 1. Environment Friendly Bio-Toilet System ‘To overcome the environmental degradation and maintain the hygiene in railway premises, Indian Railway in association with DRDO (ORDE/Gwalior) has developed IR-DRDO Bio-tollets. Bio-digester filed with ‘anaerobic bacteria’ Converts human waste into liquid and gases. The gases escape to atmosphere and treated waste water is discharged after chlorination, 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 irigation purposes. IR-DRDO Bio-toilet system has following advantages: *Elimination of tollet discharge on stations, ralway tracks and coaching depots. ‘improvement in cleanliness level of station area improvement in working environment of coaching depots & improved working condition for maintenance staf Reduced corrosion of rails and rails tings, Green toilet aims at - Zero-Defecation on the ground Discharge on track, besides creating environmental issues along with ‘manual scavenging is problematic to workmen. A mult-drectional strategy has been implemented for adoption of Environment friendly toilets on IR passenger ‘coaches. A MOU was signed with DRDO for joint technology development. The first prototype rake with biollets based on the designs developed jointly with ROO is running successfully in Bundelkhand express since 18" January 2011. Indian Railways have decided that all coaches should be converted to ‘work with bio-tolet by December 2018. 14 Benefits of green toilet + Completely Environment & user Friendly. Odor tree and does not produce any foul smel ‘Uses Natures’ products to clean human waste. Water positive solution & preserves ground water quality ‘Eliminates load on existing Sewerage System. Virtually maintenance free. ‘Prevent damages to tracks due to corrosion. Improves aesthetics at Ralway Stations 1.2 Types of Environment friendly toilets are: + Bio tollets- Converts human waste into bio-gas and water and after sanitizing the water it discharges the water onto the track. ‘Vacuum toilets: - Based on the principle of direct transport from the toilet bow! to the tank aided by vacuum creation in the tank and pipeline, + Zero discharge toilet systems: - In Zero Discharge tole system, waste 's collected at terminus and then processed. Solid and liquid separation is done in the tank itself and liquid is recycled as flush water. Advantage of Anaerobic bio-toilet: Require less maintenance Simple in design Easier Retro fitment on existing coaches in service an be in operation up to years together No oxygen and sunlight required for processing 1.3. Working of Biological Toilet System (Anaerobic) “Anaerobic bacteria (Liquid bacteria) (CO; Methane gases released to atmosphere Liquid waste Disinfected liquid discharged to tack Note: System does not require oxygen and also does not require regular cleaning 14 Degradation process of Bacteria: [Complex organ mata (tora poyeccrrton te) | reacts |Mono and oligomers —— mtermecary products ional, ey ac, ace \s.6) HCO, see cH.+co, Brief about bacteria ~aerobiclanaerobic 1.4.1 Aerobic Bacteria Growth rate of aerobic bacteria is relatively higher Requires forced aeration and large surface area ‘© Large amount of bio-mass is generated ‘Disposal of bio-mass is again an environmental problem 1.4.2 Anaerobic bacteria * Can process doubling its population within 6 to 8 hrs, ‘© Dominates and de-composes mater into liquid and gases, ‘© Canbe kept for 3-4 months at ambient temperature in bio-digester tank ‘+ Can withstand subzero temperature as well as up to 60 °C, 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. 1.5 Advantage of IR-DRDO Bio-Digester over Conventional Toilet system: - No bad smelt in toilets from the tanks No infestation of Cockroaches & fies Faecal matter inthe tank not visible No clogging of digester Effient is free from odour and solid waste No maintenance required Reduction in organic matter by 90% No requirement of repeated adding bacteria/ enzyme No need of removal of solid waste 2. Adoption of Bi First bio-digester was putin operation on coach No. NCR-05207/A ofthe train 1123/1124 from date of 23.08, 2006, -toilet in In Railway. ‘An MOU was signed between DRDO and Indian Railway on 29.03.10 regarding joint technology development using ‘DRDE Bio-digester’ for IR toilet system and formation of joint working group. The purpose of working group was the implementation of the technology development in terms of provisions of the MOU. 3. General Information of Bio-tank 3.1 IR-DRDO Bio-digester Tank for ICFIRCF Coaches ‘These tanks are made of stainless steel and having following constructional features ‘The size of the tank is 540 X 1150 X 720 MM with the provision of 04 nos ‘mounting brackets at both the sides along the length ofthe tank. Each bracket is with the provision of 02 nos. M16 Size bolls which are tightened in the under slung on ‘mounting brackets. Main parts of the Bio digester tank: 1. ‘Stainless stee! tank with 06 partition walls inside the tank 2. Poly grass mats for protection of bacteria inside the walls 3. Ball valve with handle for operation during emergency for making toilet direct ‘discharge in case of choking. (P trap type) 4. SS fasteners in place of MS on tank covers. 5. Stronger bonding of Colonized rubber mats with vertical walls Important Dimensions & Volume of Bio-digester Tank: 4. Length - 1150 mm 3. Height - 540 mm 5. Effective Volume of Tank ~ 300 it 7. Full Tank Weight ~ 410 Kg. 32 Other components of Bio-Digester Tank 1 2 3 4 5 6 7. 8 Mounting Bracket Safety Rope Locking Plate Hex. Head Bolt (M16 X70) Hex. Nut (M16) ‘Spring Washer (816) Hex. Head Bolt (MB X35) "U Bracket(@ X20 x36) 2. Width = 720 mm, 4, Total Volume of Tank — 400 itr. 6. Empty Tank weight ~ 110 kg 8. Height from Rail level - 220 mm. 04 Nos 04 Nos 08 Nos 16 Nos 16 Nos, 16 Nos 16 Nos 08 Nos 3.3 Sketch of Bio-Digester Tank Banvatve Trap Oy Se TolletPan pipe 3.4 IR-DRDO Bio-digester Tank for LHB Coaches ‘These tanks are made of stainless steel and having following constructional features ‘The size ofthe tank is 547 X $80 X 1680 MM (HXWXL) with the provision of 02 10's inbuilt C-Type mounting system along the length of the tank. Each mounting is. with the provision of 02 nos. M16 Size bolts which are tightened with the inner and ‘outer head stocks. Main parts of the Bio digester tank 1. Stainless steel tank with 06 partion wall inside the tank 2. Poly grass mats for protection of bacteria inside the walls 3. Ball valve with handle for operation during emergency for making tllet direct discharge in case of choking, SS fasteners in place of MS on tank covers Stronger bonding of Colonized rubber mats with vertical walls 3.5 Important Dimensions & Volume of Bio-digester Tank: Length - 1680 mm 2.Width - 580 mm, 3. Height - 547 mm 4, Total Volume of Tank - 600 tt 5. Effective Volume of Tank ~ 450 it 6. Empty Tank weight ~ 120 kg. 7. Full Tank Weight ~ 425 Kg 8. Height from Rail level -220 mm Chapter-2 Variants of Bio-Toilets Intaty Raiway tested several variants of biotollets designed jinty by ORDO and Indian Railway. The tials of these variants were carried out in train Bundelkhand Express and Reva Expcess. nally four variants were tested and after Wal, second variant with manual sider and P-trap was selected fr rero-tment in coaches as per JING meeting held at Coaching Depot Gwalior on 01.04. 2011.However with due ‘course of ime, allthese variants have been changed and no variantis in use presently ‘Variants are for information only. Brief details of inital four variants are as folowing 1. Variant number One-Bio-toilet system with PLC: ‘&. The retention tank of this system has been designed keeping in view the: DRDE bacteria, The Faecal matter will pass through a U-trap tothe tank. U- trap bend towards inlet side of the tank shall be slanted to achieve double ‘seal and will also eliminate gas emission to the toilet room. Vent hole is [provided on the top of the retention tank for venting out gases 9Preferable in first and last chamber). One flapper valve is provided for water seal to arrest foul smell and will also act as @ passage to clear foreign materials ‘such as bottles, polythenes etc. This also acts as a fail-safe mode in case ‘of emergency. Since this system has PLC, ths flapper valve can be opened {at pre-determined cycles: say 40 cycles or so, to clear the foreign materials ‘ulomatically through a chute which is open to ground. There is no speed ‘sensor which is the major cause of non-operation of toilet systems. In this ‘system the flushing is pressurized. As suggested by DROE team, a chamber hhaving 1 litre capacity shall be provided after the chlorinator chamber. This ‘chamber has two outlets; one with tap for sample collection for testing the performance of the bio-degradation (effluent discharge parameters) and other for normal discharge i.e. chlorinated discharge. The tank exterior should be painted with heat shielding paint ». This PLC can also be simplified by providing a counter and a solenoid valve ‘and the flushing system with gravity only. Thus eliminating all the complexes of the system. 2. Variant number two: - Bio-toilet system without any pneumatics, electronics and electrical ‘The retention tank of this system is same as in variant-t above. In this ‘system also the faecal matter will pass through a Ustrap to the tank. But in place of flapper valve, one slider valve has been provided which will be ‘operated manually from outside ofthe coach. Later on the system has been re-designed with operating handle inside the lavatory. This also acts as a water seal to arrest foul smell and also acts as a passage to clear foreign material such as bottles, polythenes etc. manually. Ths also acts a fal-safe mode in case of emergency. If anything goes wrong this valve can be kept in open condition and the complete system act as the conventional chute ‘system type which is open to ground. There is no speed sensor, no pneumatics and no electronics to alleviate electrical and mechanical failures. In this system, the flushing is through the gravity head only 3. Variant number three- (@)Biotollet system with 50 mm outlet of pan without any pneumatics, ‘electronics and electrical: Wester style commode with 50 mm dia opening to be developed. The retention tank ofthis system is same as in option -1 ‘above but without any chute arrangement. The commode chute is integrated with flapper valve which operates manually through an integrated lever ‘arrangement. Water seal its inherent features and requires no additional Uztrap. In this case no Rapper or sider is required to provide fail-safe mode. ‘This system is deemed as fail-safe because there is no possibilty ofingress ‘of any foreign material due to its less operating a the entry point itself. Once this system is proved in westem style toilet it can be tailored to Indian style toilet. Til such time for Indian style can be opted (b) Indian style: For indian style, a pan having 100 mm opening can be used with 2 10mm divider with across the width of the opening. Trap is achieved through tapering off the inlet pipe inside the retention tank. This is also acts 28 water seal because itis always being dipped in the water in first chamber of the tank. This system is deemed as fail-safe because there is no possibilty of ingress of any foreign material due to its less opening at the entry point itself. 4. Variant number four: - (2) Biotolet system without any pneumatics, electronics and electrical in liquid ‘Solid separator system design. The retention tank of this system is same as in option-1 above but at the end of U-trap there will be a liquid solid ‘Separator. This arrangement will prevent excess watering in the main ‘chamber. This will provide additional time for bacteria to digest more waste ‘and also prevents flushing out of bacteria (©) Biotoilet system with liquid-solid separation system with pneumatics, ‘electronics and electrical: - The retention tank ofthis system is same as in ‘option-1 above but atthe end of U-trap there will be liquid-solid separator. This arrangement will prevent excess watering in the main chamber. This will provide additional time for bacteria to digest more waste and also Prevents flushing out of bacteria. Features on | Bret description Fe me [pn | Remarns or | Biotietoyatem Yes—[ Yes | ves | Pressutzed| Ths yom wn Pus oe ot ee] samosas counter| gravity | outintwo ‘oon 2 | Biowiet stem ve vo | vo | ervty | Tank ceson about ary ‘canes perma, veranto1 Sectoncs and rcent seccal wana oie wave 08 | System win 1 vo | wo | orevty | Tasaystem is reduced bow ourod as coening, 20 an ‘alate elt of an for vecause here srstem sje. Vi isn Dewinout any possi ot pours, lowectony Secon and ‘crn seal vata For Indian style: For No No No ‘Through tole toes, Indian style, a pan gravity | opening at the raving 100 an enty pont ‘opening can be teea naa 16mm der c+ | Syatumwansoia | veo | veo | ves [Pressuizea| tne vd separator with arrangement reuse, wa prevent Sectonics and ‘rcoss seca waerngin Se ' : ‘he main wot ony Nef Me | Mey yong | chamber Tis pneumatics, wit provide electronics and ne ae electrical with liquid- for bacteria to sotd separate digest more system. waste and ais prevents fishing oto bacteria, 10 Variant-1 Fail sale mode exist- chute system can be operated without dismantling of tank Variant-2 Fail sale mode exist- chute system can be operated without dismantling of tank = & PLC = Programmable Logic Controller Variant-3 Fail safe mode does not exist Bw ariant-4 Fail sale mode exist- chute system can be operated without dismantling of tank Waste Flow Path in the tank nr Chapter-3 Mounting arrangement of Bio-digester ‘There are various designs of mounting arrangement for securing of bio

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