Bio toilets presentation

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

Onboard Treatment of Human Waste in Indian Railways

World’s largest mobile toilet
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

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.

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.

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 .

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 four design variants were jointly
developed by IR & DRDO which are as follows.

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

Variant-2
Brief description
Features
System with manual slider
valve
No No No gravity

Variant-3
Brief description
Features
System with reduced
opening at inlet
For western style Hind ware
commode is proposed
No No No gravity

Variant-4
Brief description
Features
System with solid liquid
separator No No No gravity

Difference of "aerobic" and "anaerobic" 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

Working of Biological toilet system ( Anaerobic )
Human Waste
Anaerobic bacteria
( Liquid bacteria )
Liquid Waste
Chlorination
Disinfected liquid
Discharged to track
CO2 + Methane
gases released to
atmosphere

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

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

Bio digester tank
2. Mats for nesting of bacteria:

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

Bio digester tank
4.Gear Box of Bio-toilets

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

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

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.

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.

Guide lines for handling bacteria
1. Always wear gloves while handling bacterial culture.
2. Store bacterial culture in containers with lid which can be
closed.
3. During transportation lids should be tightly closed.
4. During storage, lids should be kept loose, so that the gas
generated inside the container can escape easily otherwise
container will get damaged physically.
5. Do not mix detergents/acids with bacteria at any stage during
use.
6. Toilets fitted with bio-digesters/ bio toilets should be
preferably be cleaned by pressurized water cleaning system
so as to minimize the water usage.
7. Clean/sanitize hands with detergents/ soaps after handling of
the bacteria.

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.

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.

Sampling for Testing of Effluent Discharge
1. Sample shall be collected on quarterly basis & sent for
testing
2. 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.
4. 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.
5. At least one test every quarter shall be carried out in Govt.
lab.
6. In case the samples do not meet the requirements, test shall
be repeated after taking necessary corrective actions within a
fortnight .

Procedure of Sampling
1. The sample shall be collected in 2 liter 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.
4. The test results shall be furnished in prescribed format .
5. Consolidated trial report shall be sent by monitoring railway to
RDSO at the end of prescribed trial period.

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 O2/Liter
6 Fecal Coli Forms Count
> 99% reduction
(<108 /100 ml)
Periodicity :90 days.

(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

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

Trip Schedule:
1. Attending the routine complaints received from the users.
2. Cleaning the toilet and choking to be removed ,if any.
3. Checking the complete toilet system for any deficiency.

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

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

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

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.

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

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

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

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

Bio-toilet
SAFETY WIRE
ROPE
OPENING
MECHANISM
FOR BALL
VALVE
FINAL DISCHARGE
POINT ( AWAY FROM
RAIL)
RE-
DESIGNED
DETACHABL
E
CHLORINAT
OR
MOUNTING
BRACKET
BIO DIGESTER
TANK

Welding Failure in J-Bracket design
Bracket 1
Bracket 1

Weld location
of bracket
Bracket came out
due to weld failure

Weld
location of
bracket
Bracket came out
due to weld failure

Bracket partially
broken due to weld
failure
Weld
location of
bracket
Bracket partially
broken due to
weld failure

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

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.

 All pedals shall be operated for ensuring proper functioning
of opening and closing of ball valve on maintenance.

By operating push cock, focus the torch light on the
commode and ensure the water withstanding above the ball
valve.

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

During the rake maintenance, inspect mounting brackets for
any weld failures or cracks in the supporting members.

 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.

 Check sampling port cocks for missing/theft of Bio-
digester tank.

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.

 Ensure intactness of fasteners of Bio-digester tank.

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.

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).

Drain pipe cleaner for ‘P’ trap jam

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

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

By pass the system (Ball valve
system) only P.F. (Through trains)
To clear cloth, Napkins

To clear the poly bags, panparag, supari sachets, bottle
caps, liquor bottles etc….

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

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

Suction Machine
Trolley Mounted Sewage Suction Machine

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

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

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.

Design variants of bio-digester
 3rd 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.

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

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

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

Constraints in maintenance of Bio toilets
The following service problems are notice.
1. Due to in-adequate water being flushed by the passengers, the
human excreta is not fully travelling from pan to the digester tank.
2. Ball values continue to be leaking and hence there is no water
curtain, as a result, foul smell is coming from digester tank.
3. Hose connector between pan & P-Trap is getting torn while clearing
the jammed / choked bio-toilet.
4. 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.

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

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

Efforts for public awareness
• Public awareness booths were setup at major
stations on 2nd ,3rd and 4th 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.

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.

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.

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

Present
status &
Railway Board
concerns

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

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

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

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

Maintenance
aspects and
problems of
Bio toilets

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

Performance
of
Bio toilets in SCR

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

Analysis on Mounting & Securing arrangement
Failure case Failure Cases %
Mounting & Securing
arrangement
0.01 0.00 0.01 0.01 0.00 0.00

Analysis on Leakage in joints
Leakage in joints 5.25 1.27 1.27 0.25 0.09 0.06

Analysis on Operation of Ball valve
Operation of Ball
valve
5.82 5.69 2.45 0.37 0.78 0.67

Analysis on Choking of Toilet pan & ‘P’ trap
Choking of Toilet
pan & ‘P’ trap
12.04 4.59 3.72 3.09 3.70 3.50

Analysis on Foul smell cases
Failure case
Failure Cases %
Foul smell 11.02 7.09 6.94 4.31 4.00 3.85

Maintenance
Problems & Solution
Suggested

Maintenance Problem Steps taken to overcome
Chocking of Bio-toilets due
to passengers throwing
bottle, sanitary napkins,
Tissues, News Paper, Gutka
Sachets etc.,
1. Displayed 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 stations 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.

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.

P-Trap Jam
Tailor made Tools have
been developed in-house
materials to clear P-Trap
jam

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.

Damages to Bio-
Toilets due to foreign
body hit
Application of adhesive
sealant or component
adhesive (JB Weld
Industro 2/Sikaflex make)
to cover hole to SS Bio-
Tank.

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.

Maintenance
Problem
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.

Maintenance
Problem
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.

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.

Paddle Related Problems
( Rounding up of Spigot & Link)

Notice on usage instructions for passengers on Toilet door

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.

To operate link mechanism for opening Ball
valve in Western toilet
To clear the ‘P’ trap jam

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

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

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

Constraints
&
Improvements
required

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.

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

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

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

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

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

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

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

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

…. contd
Bolted Design Bogie head stock

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.

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.

Other issues
8. All bio tanks to be in variably grounded and 1st
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

ICF MODIFICATIONS ON BIO
TOILETS

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
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
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
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
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
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
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
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.

Bio toilets presentation

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