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Trouble shooting/Bio-Toilet

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

Trouble Shooting of

IR-DRDO Bio-Toilet System for

Coaching Depot Staff

IRCAMTECH/MECH/GWL/Trouble shooting/Bio-Toilet/1.0

April 2016

For official use only

Maharajpur, Gwalior – 474005 (MP)

Ph: 0751 -2470803 & Fax: 0751 -

2470841

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Trouble shooting/Bio-Toilet

Preface

On the basis of MoU between Indian Railways and

DRDO, the bio toilet trial on IR is going on. At

present, day to day maintenance is being carried out

by Coaching depot staff. Trouble shooting of IR-

DRDO Bio-Toilet Sytem for coaching depot staff has

been prepared by CAMTECH with the objective to

improve knowledge of Coaching Depot staff about

corrective and preventive maintenance of Bio-Toilet

fitted Coaches to overcome difficulties in

maintenance of Bio-Toilet system and reduce enroute

failure.

It is clarified that this Pocket book does not supersede

any existing procedures and practices laid down in the

maintenance instructions issued by manufacturers or by

Railway Board/RDSO.

(K.P.Yadav)

Director/Mechanical

CAMTECH, Gwalior

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Trouble shooting/Bio-Toilet

INDEX

SN Description Page

No.

Preface 1

Correction slip 3

1 Choking of Bio-toilets 5

2 Accumulation of garbage in Toilet pan

7

3 P-Trap Choking 7

4 Pedals not operating for operation of Ball valve

8

5 Leakage from Rubber connector 9

6 Non functioning of Ball valve opening Mechanism

9

7 Leakage of effluent from colonized rubber gasket of Bio-toilet tank

11

8 Tilting of chlorinator chamber (in case

of vertical chlorinator) 12

9 Tilting of chlorinator chamber (in case

of vertical chlorinator) 12

10 Falling of water on Bio-Toilet tank 12

11 Foul smell coming in Rolling-in & Rolling-out Examinations

14

12 Failure of lab sample in testing in Coaching depots-

15

13 Cutting of Strands of SS Safety Wire Ropes of Bio-Toilet tanks

15

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Trouble shooting/Bio-Toilet

CORRECTION SLIPS

The correction slips to be issued in future for

these Guidelines will be numbered as follows:

CAMTECH/2016/MECH/GWL/Trouble

shooting/Bio-Toilet/1.0/C.S. # XX date ….

Where “XX” is the serial number of the concerned

correction slip (Starting from 01 onwards)

CORRECTION SLIPS ISSUED

Sr.No. of

C.Slip

Date of

issue

Page No. and Item

no. modified

Remarks

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Trouble shooting/Bio-Toilet

Trouble Shooting of

IR-DRDO Bio-Toilet System

for Coaching Depots staff

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Trouble shooting/Bio-Toilet

SN Problem in Mantenance

Steps to be taken

1 Choking of Bio-toilets-

Due to accumulation of Garbage in toilet pan thrown by passengers i.e. plastic bottles, news papers, sanitary pads and tea cup etc.

a) Display Laminated Stickers in the toilets for sensitizing the Passengers “Not to throw foreign materials” in toilet.Provide Dust Bins in all Bio-Toilet coaches including Non-AC coaches.

b) Provide Dust Bins in all Bio-Toilet coaches including Non-AC coaches

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Trouble shooting/Bio-Toilet

c) Audio playing in Bio toilets fitted trains for the awareness of passengers.- CAMTECH has prepared an audio clip for awareness of passengers.

d) Broadcasting of Short Video films on Bio-Toilet at Railway stations for awareness of passengers.- CAMTECH has prepared video films of about 57 sec, 02 min. and 05 min.

e) Provision of SS Jali to

avoid bottles/Garbage etc. in to commode pan.

.

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Trouble shooting/Bio-Toilet

2 Accumulation of garbage in Toilet pan –

Thrown by passengers in Bio-Toilets.

Garbage Picking Tongs should be used to avoid manual scavenging and also for easy removal of garbage from toilet pans.

Garbage Picking Tongs

3 P-Trap Choking – Due to stucking of tea cups and garbage in P-

Choke Remover Devices should be kept in Coaching depots & enroute stations to clear P-Trap jam. Procedure is given in Compendium of Bio-Toilet.

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Trouble shooting/Bio-Toilet

Trap

100 mm/150 mm dia Conventional Choke remover

4 Pedals not operating for operation of Ball valve -

Due to different types of foot pedals.

A Universal pedal should be used by Coaching depots like NRly and SCRLy.

Universal pedal used in NRLy & SCRLy

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Trouble shooting/Bio-Toilet

5 Leakage from Rubber connector- Due to uncoupling or rupturing of rubber connector.

120/160 mm dia SS clamp should be used for proper clamping of rubber hose connector with toilet pan. If found ruptured, replace with new rubber connector.

160 mm dia SS clamp

6 Non functioning of Ball valve opening Mechanism -

Due to failure of components in operating

a) 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

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Trouble shooting/Bio-Toilet

mechanism i.e. lever, foot pedal etc. or lack of maintenance.

mechanism and then

mechanism to pedal).

b) Attend the necessary

repairs by replacing the

failed parts.

c) Ensure free movement of Ball valve operating mechanism by clearing the obstructions if any in each round trip.

d) If Clutch wire opening closing mechanism provided, check tightness of wire if found loose, tight properly holding screw by Alen key.

Holding Screw

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Trouble shooting/Bio-Toilet

7 Leakage of effluent from colonized rubber gasket of Bio-toilet tank-

Due to rupturing of rubber gasket or choking in chlorinator unit

a) Check rupturing of colonized rubber gasket & replace if required.

Colonized rubber

b) Remove chlorinator and clear the input hole of chamber provided in bio-toilet tank.

c) Clean the chlorinator and chlorine jacket/Container.

d) Ensure free flow of water from toilet pan to overflow pipe of chlorine chamber in each trip.

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8 Tilting of chlorinator chamber (in case of vertical chlorinator)-

Due to hitting of Ballast or loose threads caused by vibrations in running train.

Anti-Rotation Clamp to be provided on the body of tank

Anti rotation clamp

9 Scale formation on

porous of chlorine jacket.

Periodical checking of chlorine jacket and clean the porous or replace if required.

10 Falling of water on Bio-

Water outlet of lavatory push cock may be removed and

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Toilet tank –Due to leakage from water outlet of lavatory. (if provided in BEML coaches).

proper slope should be provided for clearing water in to lavatory pan as modified in RCF/ICF Coaches. For western style toilets lavatory outlet pipe to be extended away from Bio-Tank.

In BEML Coaches

In ICF/RCF Coaches

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Trouble shooting/Bio-Toilet

Extended pipe for western

style toilets

11 Foul smell coming in Rolling-in & Rolling-out Examinations-

Due to leakage of effluent from Rubber Hose Connector or Colonized Rubber gasket.

a) Check the leakage from Rubber Hose Connector due to uncoupling from toilet pan due to loose SS-Clamp of connector in bottom or rupturing on the body. Replace if required.

b) Check the leakage from colonized rubber gasket due to breakage/rupturing. Attend or replace gasket if required.

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12 Failure of lab sample in testing in Coaching depots-

Due to non matching of test parameters to defined level.

If parameters of any Bio-Toilet tank are not matching to the defined levels, testing of the diseased tank should be made two more times at a interval of 15 days. If the test parameters are beyond the permissible limits, even after 3 consecutive testings of the effluent then recharging of 60 liters Inoculum should be ensured as recommended

by JWG committee.

13 Cutting of Strands of SS Safety Wire Ropes of Bio-Toilet tanks-

Due to rubbing action with Bio-tank body edges during running of train due to non

a) Use of min.08 mm dia SS safety wire rope with prescribed spec. for securing Bio-toilet tanks.

b) Atleast 5 mm gap should be maintained between safety wire rope and tank body edges so that rubbing

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Trouble shooting/Bio-Toilet

availability of 5 mm gap in-between.

of wire rope with tank can be avoided.

Min. 05 mm gap between

edge of tank and wire

rope should be

maintained.