Bio toilets presentation

A presentation on bio-toilets working principle and their maintenance in Indian Railways is shown

1. Presentation on IR-DRDE-Bio Toilets By G.Srinivasa Rao- CDO/KCG SOUTH CENTRAL RAILWAY This presentation can also be seen at www.slideshare.net/srguduru with latest updates

2. Onboard Treatment of Human Waste in Indian Railways

3. World’s largest mobile toile t Indian Railways World’s largest rail network 115000 km Runs 10000 trains daily. 20 million passengers travel by train every day 59713 passenger coaches. The Indian Railways

4. The letter that lead to introduction of toilets in Indian Railways Beloved Sir, I am arrive by passenger train Ahmedpur station and my belly is too much swelling with jackfruit. I am therefore went to privy. Just I doing the nuisance that guard making whistle blow for train to go off and I am running with lotah in one hand and dhoti in the next when I am fall over and expose all my shocking to man and female women on platform. I am got leaved at Ahmedpur station. This too much bad, if passenger go to make dung that dam guard not wait train five minutes for him. I am therefore pray your honor to make big fine on that guard for public sake. Otherwise I am making big report to papers.

5. Introduction of Bio-toilets

6. Environment Friendly Green Toilet System Objectives: Environment friendly. Preventing damages to tracks due to corrosion. Improved aesthetic at Railway stations. Require less maintenance. Simple in design. Easier Retro fitment on existing coaches in service. Can be in operation upto years together.

7. Environment Friendly Toilet System Strategy: A multi directional strategy has been formulated for fitment of environment friendly toilets on all IR passenger coaches by 2021 .

8. Introduction of Bio-toilets As per the commitment to Supreme court, Indian railway in association with IR-DRDE developed a anaerobic bio-toilet tailor made to Indian railway passenger coaches in March 2010 by forming a joint working group consisting of IR Engineers and DRDO biotechnologists . Till date f our design variants were jointly developed by IR & DRDO which are as follows.

9. Variant-I Brief description Features Pneumatics Electronics PLC Flush System with flapper valve Yes Yes Yes Pressurized

10. Variant-2 Brief description Features Pneumatics Electronics PLC Flush System with manual slider valve No No No gravity

11. Variant-3 Brief description Features Pneumatics Electronics PLC Flush System with reduced opening at inlet For western style Hind ware commode is proposed No No No gravity

12. Variant-4 Brief description Features Pneumatics Electronics PLC Flush System with solid liquid separator No No No gravity

13. Difference of " aerobic " and " an aerobic " process Strictly speaking, the terms " aerobic " and " anaerobic " refer to the presence and absence of oxygen, respectively. Aerobic biodegradation V/S Anaerobic biodegradation Forced aeration/ agitation is essential and is energy intensive No aeration is required Incomplete aeration (partial aerobic condition) leads to foul smell Complete anaerobic conditions Not effective in pathogen inactivation More than 99% Pathogens inactivation Can not tolerate detergents/ phenyl Anaerobes can even degrade detergents/ phenyl Generates large amount of sludge Sludge generation is very less Repeated addition of bacteria/ enzyme is required for the process One time bacterial inoculation is enough Maintenance & recurring cost is high Minimal maintenance & no recurring cost

14. Working of Biological toilet system ( Anaerobic ) Human Waste Anaerobic bacteria ( Liquid bacteria ) Liquid Waste Chlorination Disinfected liquid Discharged to track CO 2 + Methane gases released to atmosphere

15. Main parts of the Bio digester tank- Variant-4 Bio-digester tank: 2 Chlorine Chamber 1 5 3 4 6

16. IR-DRDO Bio-digester Tank for Coaches These tanks are made of stainless steel and having following constructional features: Tanks are made of stainless steel. Size of the tank is 540 x 1150 x 720 mm. Provision of 04 Nos. mounting brackets at both the sides. Each bracket is provided with 02nos of M16 bolts. The tank is secured with ‘J’ brackets. Current procurement cost of each toilet is Rs.63 thousands approx. J - Brackets

17. Bio digester tank 2. Mats for nesting of bacteria:

18. Bio digester tank 3. Ball valve for direct discharge in case of chocking.

19. Bio digester tank 4.Gear Box of Bio-toilets

20. Bio digester tank 5. Loading of inoculums in Bio-tank.

21. Bio digester tank 6. Drawing for hose connector is approved by RCF this is address the alignment upto maximum 30mm

22. Testing parameters of discharge of Bio-digesters Effluent Discharge The system should be designed for discharge of non-obnoxious and odorless liquid matter. The effluent discharge should at least comply with the following pollution control requirements:- The effluent should have pH value between . 6 to 9.0. The effluent should not contain any visible solid mass of human waste. The effluent should not contain total suspended solids (TSS) more than 800mg/ litre . The effluent shall be subjected to chemical treatment and process ( es ) e.g. chlorination etc. prior to discharge, which will result in a most probable number (MPN) of fecal coliform bacterial density of less than 5000 per 100 ml prior to discharge.

23. Brief about bacteria – Anaerobic Anaerobic Bacteria Can double its population with in 06-08 hrs De-composes matter into liquid and gases Can be kept for two-three months at ambient temperature in bio-digester tank Can withstand sub-zero temperature upto 60 degree centigrade Inside processing is not effected by cold atmosphere, as anaerobic process is exothermic in nature, heat will be available inside the chamber of chemical process.

24. Guide lines for handling bacteria Always 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 physically . Do not mix detergents/acids with bacteria at any stage during use. Toilets fitted with bio-digesters/ bio toilets should be 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.

25. Requirements for Cleaning Agents All the cleaning agents used shall be bio-degradable. Should be phosphate free. Should not be a combustible liquid. Should be preferably have near neutral PH value in used dilution. Should have soothing fragrance & smell. It must be ensured all toilet cleaning agents of neutral PH value with bio degradable as specified in COFMOW Compendium only shall be used for cleaning the toilets.

26. Sr.No Locations Name of chemicals used 1 PVC Floor Cleaning Spiral (Johnson Diversey) or Sigla Neutral of Eco Lab 2 Ceramic Toilet fittings cleaning Taski R1/ Taski R 6 (Johnson Diversey) or Sigla Neutral of Eco Lab 3 Cleaning agent for commode pan & wall protector Taski R3 (Johnson Diversey) or OC Glass cleaner of Eco Lab or Collin 4 Laminated Plastic Sheet & Berth Rexene cleaner: Taski R7 (Johnson Diversey) or OC Neutral cleaner of Eco Lab or Collin 5 Painted Surface Spiral (Johnson Diversey) or Absorbit of Eco Lab or Collin 6 Stainless Steel Polisher Suma Inox (Johnson Diversey) or Chromol of Eco Lab or Collin 7 Disinfectant Brands Stride (Johnson Diversey) or Antiback of EcoLab or Collin or Lizol List of cleaning agents Following cleaning agents are being used for cleaning of bio-toilets . These agents are considered to be suitable for IR-DRDO bio toilets.

27. Sampling for Testing of Effluent Discharge Sample shall be collected on quarterly basis & sent for testing Samples will be collected randomly – from lot of 5% coaches of the total coach holding but minimum one coach of each type – at an interval of every three months during the trial period. Sampling will start after coach has been in passenger service for 10 days or more. The samples should be collected and sealed in presence of Railway representative. At least one test every quarter shall be carried out in Govt. lab. In case the samples do not meet the requirements, test shall be repeated after taking necessary corrective actions within a fortnight .

28. Procedure of Sampling The sample shall be collected in 2 liter plastic bottle by simply opening the knob provided in the sampling port. The date and time of sampling and coach no. must be mentioned on the bottle. The sample collected in the bottle shall be transported to lab at the earliest but not later than 24 hours after collection of sample. The test results shall be furnished in prescribed format . Consolidated trial report shall be sent by monitoring railway to RDSO at the end of prescribed trial period.

29. Summary of Sampling Tests for Bio toilet of Effluent S. No Sample Test Target value 1 PH value 6-9 pH 2 Total Solids (TS) < 750 mg / 100 ml 3 Total Dissolved Solids (TDS) < 350 mg / 100 ml 4 Total Volatile Solids (TVS) < 500 mg / 100 ml 5 Chemical Oxygen Demand (COD) < 2000 mg O 2 /Liter 6 Fecal Coli Forms Count > 99% reduction (<10 8 /100 ml) Periodicity :90 days .

30. (B) Testing Scheme for Bacteria Culture (Microbial Inoculum ) The following four tests have been recommended Microbial Inoculum produced in Inoculum generation plant . S.No Description Periodicity Target 1 PH value test Once in a week 6.5 to 7.5 pH 2 Bio gas test Daily -- 3 Percentage Methane Test Once in a Week 40 to 70 % 4 MPN count for Methanogens Monthly > 1000/- per ml

31. Preventive Maintenance Schedules Maintenance Schedules in Depots: Type of Schedule Periodicity Trip Schedule At the end of each trip or as prescribed Schedule ‘A’ or Monthly examination 1 Month +/-3 days Schedule ‘B” or tri-monthly examination 3 Months +/-3 days Schedule ‘C’ or Half yearly examination 6 Months+/-7 days IV. Special Schedule As prescribed by each Railway

32. Preventive Maintenance Schedules Trip Schedule: Attending the routine complaints received from the users. Cleaning the toilet and choking to be removed ,if any. Checking the complete toilet system for any deficiency.

33. Preventive Maintenance Schedules Schedule- A /Monthly examination: All works carried out as mentioned in daily schedule. Visual examination of complete toilet system including under slung equipments. Charging of chlorine tablets and examination of chlorinator

34. Preventive Maintenance Schedules Schedule-B/Quarterly examination: All works carried out as mentioned in A- schedule. Collection and transportation of samples from retention tanks to DRDE, Gwalior or Nominated government accredited lab. Checking of following equipment for repair / replacement for proper functioning A flapper/Slider/Ball. B Leaking in piping system, flush system charging. Charging of Bio-culture, if required.

35. Preventive Maintenance Schedules Schedule-C/Half Yearly examination All works carried out as mentioned in B- schedule. Testing of all toilet system Tightening of all nuts and bolts for proper securing of tanks Drawing and delivering of samples for six monthly tests to Govt. labs Charging of Bio-culture if required based on Test reports

36. Spares like rubber connectors, clamps, foot pedals are not available in the Coaching depots. The above material is not available in the coaching depots for replacement hence bio toilets are made through by opening bal-valve permanently by putting stone below lever stem. Standard drawings of all above components to yet be issued by RDSO for procurement.

37. Existing flushers are not suitable for flushing of human waste from pan to tank.

38. Chlorinator Leakage of effluent to be checked from threads of chlorinator pipe

39. Rubber gasket Waste material leaking from Rubber gasket due to blocking of bent pipes.

40. Ball valve shaft Ball valve shaft nut found loose and lever was not working.

41. Bio-toilet SAFETY WIRE ROPE OPENING MECHANISM FOR BALL VALVE FINAL DISCHARGE POINT ( AWAY FROM RAIL) RE-DESIGNED DETACHABLE CHLORINATOR MOUNTING BRACKET BIO DIGESTER TANK

42. Welding Failure in J-Bracket design Bracket 1 Bracket 1

43. Welding Failure in J-Bracket design Weld location of bracket Bracket came out due to weld failure

44. Welding Failure in J-Bracket design Weld location of bracket Bracket came out due to weld failure

45. Welding Failure in J-Bracket design Bracket partially broken due to weld failure Weld location of bracket Bracket partially broken due to weld failure

46. Maintenance of Bio-toilets

47. Tools to be carried The operator should carry the following tools for maintenance of Bio-toilets: Bottle picker. Polythene bag. Spanner. Pedals of different companies both LH and RH . Hand gloves. Nose mask. Torch light .

48. Maintenance of Bio tanks On arrival of the train, jammed toilets to be identified and released on platforms, by operating ball valve. If jam still persists or ball valve does not operate, the block shall be cleared with the help of bottle picker.

49. Maintenance of Bio tanks All pedals shall be operated for ensuring proper functioning of opening and closing of ball valve on maintenance.

50. Maintenance of Bio tanks By operating push cock, focus the torch light on the commode and ensure the water withstanding above the ball valve.

51. Maintenance of Bio tanks Ensure availability of stickers and dustbins in Bio toilets. Dust bin shall be emptied as frequently as possible.

52. Maintenance of Bio tanks During the rake maintenance, inspect mounting brackets for any weld failures or cracks in the supporting members.

53. Maintenance of Bio tanks Check bellow in between P-trap and commode chute and if any leakage is found the same to be attended by silicon sealant. If the bellow is pierced, the same needs to be changed.

54. Maintenance of Bio tanks Check sampling port cocks for missing/theft of Bio-digester tank.

55. Effluent is dropping on the heads of fitters During under gear examination, the effluent of tank is dropping on the head/back of the fitter in old design chlorinator.

56. Maintenance of Bio tanks Ensure intactness of fasteners of Bio-digester tank.

57. Innovations & Improvements

58. Notice on usage instructions for passengers A notice is displayed for passengers awareness on usage of bio toilets in Mar’14 which is giving good results.

59. Notice on usage instructions for passengers Due to the notice display in toilets, the passengers using dust bins. As a result, toilet jam cases are reduced from 417(Mar’14 ) to 183(Apr’14 upto date ).

60. Drain pipe cleaner for ‘P’ trap jam

61. Picker in use for clearing choking of toilet pan Video clip showing picking of foreign bodies with picker

62. To operate link mechanism for opening Ball valve in Western toilet Various other tools developed to clear jams

63. By pass the system (Ball valve system) only P.F. (Through trains) To clear cloth, Napkins Various other tools developed to clear jams

64. To clear the poly bags, panparag, supari sachets, bottle caps, liquor bottles etc…. Various other tools developed to clear jams

65. Non-awareness of passengers in Bio-Toilet system Standard stickers are still not pasted over the toilet doors for awareness of passengers. Audio-Video should be shown at station platforms. CAMTECH video film to be collected by zonal Rlys. Embedded audio system has been developed by SCR Embedded Audio System

66. Trolley Mounted Sewage Suction Machine Supplier: M/s Vogelsang India, Noida UP Working at Coaching depot, Gwalior.

67. Suction Machine Trolley Mounted Sewage Suction Machine

68. Design Improvements

69. Alternate Design of bio-digester tank Issues of old design digester: Following issues were raised by field staff in old design tanks: • Shape of connector – difficult to manufacture and prone to damage while cleaning. • Material proposed as TPE instead of EPDM. • Differential dia connector 150/125 mm: In old design connector, the dia was same at both the ends, now the dia on top is 150 mm and 125 mm in bottom. Diameter of pan and P-trap pipe same Differential dia connector 150/125 Same on both side with bellow formation

70. Developments/Improvements (Common Bio-digester tank for DSLR coaches) Common tank for passengers and disabled lavatories. 50 ltrs retention tanks for Guard compartment.

71. Alternate Design of bio-digester tank Smaller chlorinator- discharge at the center of track Bigger chlorinator-discharge on side of track Problem/Issues of old design Bio digesters have been eliminated. Re- location of chlorinator.

72. Design variants of bio-digester 3 rd Design for Retro-fitment: Additional 8 holes of 18 mm dia required in stock channels. Head stock channel already have : 4 holes of 27mm diameter for buffer mounting; One hole of 127mm diameter for buffer plunger Two elliptical hole of 60mm x 40mm for brake pipe.

73. TPE Connector Improvements (between P-trap and pan) Spread of fecal matter over tank Connector between pan and P-trap

74. Improvements (Modification of P-trap and Anti rotation measure) Anti rotation measure Casted single piece

75. Developments/Improvements (Development of KMnO4 Tablet ) KMnO4 tablet development as an alternative of chlorine. Evaluation/Validation by DRDE under final stages KMnO 4 tablets Chlorine tablets

76. Constraints in maintenance of Bio toilets The following service problems are notice. Due to in-adequate water being flushed by the passengers, the human excreta is not fully travelling from pan to the digester tank. Ball values continue to be leaking and hence there is no water curtain, as a result, foul smell is coming from digester tank. Hose connector between pan & P-Trap is getting torn while clearing the jammed / choked bio-toilet. The ball value opening / closing mechanism is not easily workable even after applying full force by standing on the paddle to operate it . Vide: Lr.No.M.271/C&W/Green Toilets / Vol.II dt.11.08.14 South Central Railway has decided to replace connectors for all tanks during POH to overcome the problems in service.

77. 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 The constructional features of the new design are shown as under:- Existing Design Alternate Design

78. Alternate Design of bio-digester tank Alternate Design of bio-digester tank Problem/Issues of old design Bio digesters have been eliminated. In old design tank, too much welding in mounting brackets with tank. Possible infringement of hangers with bigger chlorinator, relocation of chlorinator. Smaller chlorinator discharge at the center of track Bigger chlorinator discharge on side of track

79. Efforts for public awareness P ublic awareness booths were setup at major stations on 2 nd ,3 rd and 4 th October 2014 as a part of ‘ Swacch Bharat Abhiyan’. Pamphlets and posters etc. Regarding bio toilet, were also published. An audio/video film was also played to create public awareness .

80. Public Awareness Stickers in bio toilet coaches- To create awareness among passengers about use of bio toilet, stickers have been pasted inside bio-toilets and outside the coaches.

81. Public awareness Audio clips being played at major stations Video clips for running on electronic media. Press conferences to be organized for print and electronic media. Seminars to be organized in which print and electronic media was also invited to spread publicity among passengers.

82. Short film Video clip showing Development of Environment friendly Bio-Toilets for passenger coaches.

83. Present status & Railway Board concerns

84. Present status of bio-toilets Year No. of Bio toilets No. of coaches on which these are fitted 2010-11 57 31 2011-12 169 67 2012-13 1337 561 2013-14 8024 2988 2014-15 5238 1794 As on 31.10.2014 Cumulative 14825 5441

85. Railway Board’s concerns Target 2014-15: Fitment of 10500 bio-toilets Fitment in 1656 DMA coaches Retro-fitment in all eligible coaches undergoing POH/MLR 4 bio-toilets per GS coach & 3 bio-toilets per DSLR coach Funds of Rs. 40 crores distributed as below: Target 2016-17: Elimination of direct discharge in all newly manufactured coaches Fitment in DSLR coaches, LHB coaches Design for LHB Double Decker, DEMUs, OCVs like RAs etc

86. Railway Board’s concerns Constitution of JWG: Presently 7 members from IR with Convener (CDE/RCF) More representation from user railways/workshops Role of “Expert officers” nominated by Railways and periodicity of regular meeting for exchange of information Green Train Station(s): MR’s desire Coaches to be configured to run in rake formation to the extent possible Coaches to be fitted with full complement of bio-toilets Nomination of Station(s) and Depot(s) Development of RMM/SR & OKHA/WR as Green Train Stations

87. Railway Board’s concerns Retro-fitment in MLR Adoption of alternate design for retro-fitment Proliferation of DMA coaches ??? If DMA coaches: with J-bracket or C-bracket ??? Bolted design: Turning-out of coaches with drilled holes in Head Stocks Procurement plan for bio-toilet material

88. Maintenance aspects and problems of Bio toilets

89. Population of Bio-toilets in SCR (Rake wise) Bio-toilet coaches inducted in train services of S.C.Rly as on 01.02.2015 Sl.no Train No No of rakes. Type of coaches Total no of Bio-toilet coaches FACCW ACCW ACCN CZAC CN GS SLRD GSCZ WCB 1 12702/31(HYB - CSTM) Hussain Sagar Exp. 2   2 6   20 4 4     36 2 17032/01 (HYB - CSTM) Mumbai Exp 2 1 2 4   4 4       15 3 17015/16( SC- BBS) Visakha Express 3   3 6   45 6 2     62 4 12764/63(SC-TPTY) Padmavathi Exp 2   2 4   24 6 4     40 5 17035/36(SC - SKZR) Telangana Exp 1               19   19 6 17026/25(SC- MUGR) Express 2 2 2   16 12       32 7 12771/72(SC-NGP) Express 1   1 1   8 6       16 8 12706/05(SC- GNT) Inter city express 2               24   24 9 17249/50(MTM-SC) Express 2   2 2   14 8 2     28 10 17211/12(MTM - YPR) Kondaveedu Exp 1   1     9 6 1     17 11 17213/14(NS - NSL) Exp 1   1 2   6 4 2     15 13 12737 / 12738 (COA-SC) Gouthami Exp. 2     3   9   2     14 14 17210/17209 (COA-SBC) Seshadri Exp. 4   2     5 2       9 15 17652/17651 (KCG - MS) Egmore Exp. 1   1     3 7       11 12 12747/48(GNT-VKB) Palnadu Exp 1               6   6 16 12785/12786 (KCG - SBC) BANGLORE EXP. 2           5       5 17 Scattered in different trains.     5 16 1 15 30 3 1 1 72   TOTAL 29 1 24 46 1 178 100 20 50 1 421

90. Performance of Bio toilets in SCR

91. Analysis on Toilets Jam due to bottles Failure case Failure Cases % Jul’14 Aug’14 Sep’14 Oct’14 Nov’14 Dec’14 Toilet Jam due to bottles 23.74 17.37 11.40 07.95 13.03 14.24

92. Analysis on Mounting & Securing arrangement Failure case Failure Cases % Jul’14 Aug’14 Sep’14 Oct’14 Nov’14 Dec’14 Mounting & Securing arrangement 0.01 0.00 0.01 0.01 0.00 0.00

93. Analysis on Leakage in joints Failure case Failure Cases % Jul’14 Aug’14 Sep’14 Oct’14 Nov’14 Dec’14 Leakage in joints 5.25 1.27 1.27 0.25 0.09 0.06

94. Analysis on Operation of Ball valve Failure case Failure Cases % Jul’14 Aug’14 Sep’14 Oct’14 Nov’14 Dec’14 Operation of Ball valve 5.82 5.69 2.45 0.37 0.78 0.67

95. Analysis on Choking of Toilet pan & ‘P’ trap Failure case Failure Cases % Jul’14 Aug’14 Sep’14 Oct’14 Nov’14 Dec’14 Choking of Toilet pan & ‘P’ trap 12.04 4.59 3.72 3.09 3.70 3.50

96. Analysis on Foul smell cases Failure case Failure Cases % Jul’14 Aug’14 Sep’14 Oct’14 Nov’14 Dec’14 Foul smell 11.02 7.09 6.94 4.31 4.00 3.85

97. Maintenance Problems & Solution Suggested

98. Maintenance Problem Steps taken to overcome Chocking of Bio-toilets due to passengers throwing bottle, sanitary napkins, Tissues, News Paper, Gutka Sachets etc., 1. Display ed Laminated Stickers in the toilets for educating the Passengers “Not to throw foreign materials” . 2. Provided Dust Bins in all Bio-Toilet coaches including Non-AC coaches. 3. Proto-Type Embedded Audio System was innovated indigenously at Coaching depot HYB and fitted on trial basis in 02 Toilets in coach No. 14110 ACCN SC of Train no. 12702 Exp. 4. Jingles playing on station s for passengers awareness. 5.Audio played through PAS in Bio toilets fitted trains for the awareness of passengers. 6. Pasting of Bio toilet stickers on exterior side body of the coach 7.Provision of Cage to trap bottles in commode pan.

99. Maintenance Problem Steps taken to overcome Removal of garbage from Toilet pan Garbage pickers are procured from local market to avoid manual scavenging and also for easy removal of garbage from toilet pans.

100. Maintenance Problem Steps taken to overcome P-Trap Jam Tailor made Tools have been developed in-house materials to clear P-Trap jam

101. Maintenance Problem Steps taken to overcome Carrying of different types of pedals during maintenance An Universal pedal has been developed at this depot to operate 06 types of pedals of 03 different makes during maintenance, and any number of pedals can be replaced by adding suitable adopters.

102. Maintenance Problem Steps taken to overcome Damages to Bio-Toilets d ue to foreign body hit Application of adhesive sealant or component adhesive ( JB Weld Industro 2/ Sikaflex make) to cover hole to SS Bio-Tank.

103. Maintenance Problem Steps taken to overcome Missing / Leakages from connecting Hose due to worked out Attending by application of Sikaflex adhesive sealant and worm drive clamp to connecting Hose.

104. Maintenance Problem Steps taken to overcome Jam /non functioning of ball valve opening mechanism. 1. Periodical check of individual parts ( Ball valve lever, Mechanism and pedal connecting levers ) of ball valve opening mechanism ( By disconnecting the link between ball valve and mechanism and then mechanism to pedal) 2.Attend the necessary repairs replace the parts if required. 3.Ensure free movement of Ball valve operating mechanism for PU & Retrofitement coaches and attend all the obstructions if required 4. Periodical lubrication of moving parts .

105. Maintenance Problem Steps taken to overcome Leaking from top plate of Bio-toilet tank . 1.Operate P-trap cleaner and send Pressurizer water in to bio tank to clear obstructions of bent pipes/ passages between the chambers. 2.Remove the chlorine chamber and clear the input hole of chamber provided in bio-toilet. 3.Clean the chlorine chamber and chlorine jacket. 4.Ensure free flow of water from toilet pan to overflow of chlorine chamber.

106. Maintenance Problem Steps taken to overcome 1. Tilting of chlorination chamber Anti-rotation clamp to be ensured 2.Jam of inlet of chlorine chamber. Periodical check of overflow and clear jam. 3. Scale formation on porous of chlorine jacket. Periodical check of chlorine jacket and clean the porous or replace if required.

107. Paddle Related Problems ( Rounding up of Spigot & Link)

108. Effluent is dropping on the heads of fitters During under gear examination, the effluent of tank is dropping on the head/back of the fitter in old design chlorinator.

109. Notice on usage instructions for passengers on Toilet door

110. TEN Commandments SCR has published a leaflet by name “ Ten Commandments “ for Bio toilet maintenance and issued to maintenance of staff for increasing there awareness on maintenance issues.

111. Drain pipe cleaner for ‘P’ trap jam

112. To operate link mechanism for opening Ball valve in Western toilet To clear the ‘P’ trap jam Various other tools developed to clear jams

113. By pass the system (Ball valve system) only P.F. (Through trains) To clear cloth, Napkins To clear the poly bags, pan parag, supari packets, bottle caps, liquor bottles Various other tools developed to clear jams

114. Tools Tool kit with common long handle developed in-house These are distributed to OEM and other stations as per head quarters instructions

115. Training A centralized training program is organized at HYB depot for imparting training staff and supervisors on maintenance of Bio toilets. From May’14 to till date, the following staff have been imparted on train bio-toilet maintenance: Supervisors – 53 Technicians – 93 Group D – 84

116. Constraints & Improvements required

117. Different designs of Pedals from different Makes Railfab MRC JSL Each supplier has maintained different Pedals and Gear boxes necessitating to carry all models of pedals during maintenance.

118. The ball valve mechanism to be made the simplest design. Pneumatic / Electrically operated valve should be adopted. All makes of ball valve mechanism shall be inter-changeable. Maintenance friendly design of Ball valve mechanism

119. Need of easy removal of ‘P’ trap There are frequent ‘P’ trap jams in trains. Design to be explored for removal of ‘P’ trap from top in situ. ‘P’ trap

120. Provision of cages to avoid jamming To avoid jamming of ‘p’ traps with foreign bodies, it is suggested to introduce a cage at the entrance of ‘P’ trap. ‘P’ trap

121. Periodicity for Ball valve seal There is no stipulated periodicity for changing the Ball valve seal. A durable and long lasting seal to be explored to provide. Also periodicity of renewal of seal needs to be specified. Ball valve seal

122. Need of inbuilt dust bin As there is no proper securing arrangement for dust bins, pilferages are more. To avoid this, inbuilt design of dust bin needs to be done. Dust bin

123. Different dia. of Commode pan holes There are 2 different diameters of commode pan holes i.e., 100mm and 150mm . Already finalized to standardize 100 mm commode pan outlet, needs to be modified on all coaches. Commode pan hole

124. C-type mounting brackets for retro-fitment on in service coaches Mounting at inner head stock Mounting at outer head stock

125. Mounting Bracket arrangement ‘ J’ type Welded bracket ‘C’ type Bolted bracket

126. …. contd Bolted Design Bogie head stock

127. Other issues 1. Poor response of suppliers to field depots against warranty claims. 2. To feed Innoculum to maintenance depots continuously, an exclusive road mobile tanker needs to be explored for door delivery. 3. Curvature of P-trap should be uniform in all makes with out any weld joints for smooth flow into bio-digester.

128. Other issues 4. Scope of work for AOMC to be standardized. 5. Rate contract to be entered with the concurrence of Finance directorate for quick & easy implementation of AOMC by field units. 6. Jingles, videos have to be broadcasted in CCTV and satellite television channels during commercial breaks for involving the passengers in IR’s green initiative. 7. Issuing of instructions on provision of embedded audio equipment in all coaches.

129. Other issues 8. All bio tanks to be in variably grounded and 1 st chamber of Tank to be evacuated in POH for effective working for next subsequent POH. 9. Metered quantity of flush cock to be provided in place of existing commode flush cock for effective flushing human excreta To play video click on image

130. ICF MODIFICATIONS ON BIO TOILETS

131. 131 Bio toilet system Problem Reported Safety wire rope breaking at retention tank bottom corners. Features adopted Bend SS tubes are provided at the bottom corners of retention tank to guide the safety wire rope and to avoid possible ballast hit on wire rope at the corners. Status Implemented

132. 132 Bio toilet system Problem Reported Flushing water splashes outside pan bowl and stagnate above floor. Features adopted Vide point- 4 of MoM of 13th JWG meeting, ICF & RCF has to use standard SS lavatory inlay with 100mm outlet deeper pan.

133. 133 Bio toilet system Problem Reported Water leaks between rubber hose connector and P-trap Features adopted TPE connector is under development. This connector can be inserted over pan outlet & P-trap mouth and clamped. Sources issued by RCF (MD22301 dated 10-02-2015) included in the special condition of tender. Status Prototype is under development by M/s Kesara syntex as per drg . CG-14070 of RDSO.

134. 134 Bio toilet system Problem Reported Ball valve open close mechanism with link & levers not functioning Features adopted Ball valve open close mechanism with clutch wire type introduced in the design. Sources issued by RCF (MD22301 dated 10-02-2015) included in the special condition of tender. Status Retention tanks with clutch wire type open close mechanism for ball valve is under tender stage

135. 135 Bio toilet system Problem Reported Ball valve not fully opened or fully closed Features adopted Due to quality issue, sources for ball valve issued by RCF (MD22301 dated 10-02-2015) included in the special condition of tender. Status To be implemented.

136. 136 Bio toilet system Problem Reported Discharge from chlorine chamber falls over head of maintenance staff. Due to in sufficient space between two adjacent retention tanks it is very difficult for maintenance staff moving to attend bogie. Features adopted In the new design, location of chlorine chamber changed to end wall side and increased volume of chlorine chamber is introduced. Length and height of retention tank reduced by 60mm from center line side and 40mm from bottom of retention tank. Status To be implemented.

137. 137 Bio toilet system Problem Reported In sufficient flush water to clean the pan bowl Features adopted Vide point- 3.1 & 3.2 of MoM of 13th JWG meeting ICF & RCF has to use controlled discharge flush valve that discharges measured quantity of water, in 500 coaches as trial. Status Trail already conducted and found useful.

138. 138 Bio toilet system Problem Reported Chocking inside P-trap Features adopted Dust bin inside toilet provided to put garbage. Notices for passenger awareness provided. New embedded audio system inside toilet which announces the do's and dont's , as soon as passenger latches the door. Status Dust bin and notices are implemented from the early stage. Embedded audio system is tried and found successful.

139. Thank You