compendium on ir-drdo biotoilets for indian railways

8/13/2019 Compendium on IR-DRDO Biotoilets for Indian Railways

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(Govt. of India)(Ministry of Railways)

COMPENDIUM

on

IR-DRDO BIO-TOILETS

For

INDIAN RAILWAYS

(For official use only)

IRCAMTECH/2012/M/GWL/io!Toile"sApril- 2013

Centre

for

Advanced

Maintenance

MAHARA#$%R& GWALI'R!!00*


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INDEX

SN Description Page

1. Environment Friendly Toilet Systems. 3-11

2. Performance perameters of Bio-toilets 12

3. Instructions for Pressurised Cleaning of Bio toilets. 12

4. Guidelines for Coaching Depots for Handling of Bacteria. 12

5. List of Cleaning Agents being used in Mechanized Coach Cleaning in

Bio Toilet system.

13

6. Mixing of Cleaning agents before application 14

7. Testing Scheme for Bacteria Culture (Inoculum) & Bio Toilet Effluent. 16-70

8. Minutes of The Meeting held at DRDE on 22.12.2011. 71-73

9. Testing Instruments Specifications and Approximate Cost. 75-82

10. Guidelines for Annual Maintenance and Operation Contract (AMOC).

(No. RDSO/ 2010/CG/ CMI-03 Revision 01) issued in December -2011

83-99

11. Trail/Test Scheme for Field Trail of Bio Toilets (IR-DRDO

Technology) on Indian Railway Passenger Coaches issued by

RDSO/LKO

100-122

12. MOU between DRDO & Railways for joint technology development for

IR-DRDO bio-toilet for IR - Formation of joint Working Group (JWG)

dated 29.03.2010

123

13. Minutes of the meeting with DRDO on 29.05.2012 at Railway Board 124

14. Standards for disposal of waste water from mobile bio-toilets 125

15. Testing Scheme for bio-toilet effluent and Bacteria culture (Inoculum)

for IR

126

16. List of the TOT holders for Bio-digesters & supply of Inoculum for

Railways

127-130

17. Instruction for POH of coaches fitted with IR-DRDE type Bio-Toilets 131-133

18. Procedure for Retro-fitment of DRDE Bio-toilet Tank on ICF/ RCF

Design BG Coaches

134

19. Collection of Effluent Samples 137-140

20. Abstract for Quantities Estimated Approximately for Inoculum

(Bacteria) Generation Facility for 100 M3Plant Capacity.

141-157

21. Bio-Toilet Maintenance Proforma 1& 2. 158-160

22. Source of Supply of Testing Equipment of Effluent of Bio-toilets 161-164

23. Maintenance Instructions on Bio-Toilet System for Coaching DepotStaff

167

24. Provision of Stickers in Bio-Toilets 168

25. P-Trap chokedksfudkyusdh fof/kA 169

26. Welding Failure on Bio-Digester Tank 170


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SN Description Page

27. Drawing of Inoculum Generation Facility (Cap.100 M3) 173

28. Layout Drawing Showing Bacteria Generation Facility

29. Structural Drawing of Inoculum Generation Facility (Cap.100 M3)

30. Instructions of RLy Board for IR-DRDO Bio-Toilets in Passengercoaches

31. Simplified Procedure- pH test and Total Disolved Solids for Effluent ofBio-Digesters

32. Joint check Report of Bio-Digester Tank in Gorakhpur Workshop

33 Training in Bio-Toilet System


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Environment Friendly Toilet Systems

Green toilet aims at - Zero-Defecation on the ground

Discharge on track, besides creating environmental issues creates problem inworking to workmen. A multi directional strategy has been implemented for adoption

of Environment friendly toilets on IR passenger coaches. A MOU has been signed

with DRDO for joint technology development. The first prototype rake with bio-toilets

based on the designs developed jointly with DRDO is running successfully in

Bundelkhand express since 18th January 2011. Indian Railways have decided 05

more rakes to be fitted with DRDE technology Bio-toilets from the production of

2011-12 and 2500 more coaches from the production of 2012-13.

Benefits of green toilet Environment friendly

Preventing damages to tracks due to corrosion

Improved aesthetics at Railway Stations

Types of Environment friendly toilets are:

Bio toilets- The Bio toilet system, discharge processed waste on track

Vacuum toilets:Based on the principle of direct transport from the toilet bowl to the tankaided by vacuum creation in the tank and pipeline.

Zero discharge toilet systems:In Zero Discharge toilet system, waste is collected at terminus andthen processed. Solid and liquid separation is done in the tank itselfand liquid is recycled as flush water.

A+,an"a-e of Anaero.ic .io!"oile" i" Mo% i" RE an+ IR

Require less maintenance

Simple in design

Easier Retro fitment on existing coaches in service

Can be in operation upto years together


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Working of Biological toilet System ( Anaerobic )

Note : System does not require oxygen and also does not require regular cleaning

Brief about bacteria aerobic/anaerobicAerobic Bacteria

Growth rate of aerobic bacteria is higher

Requires forced aeration and large surface area Large amount of bio-mass is generated Disposal of bio-mass is again an environmental problem

Anaerobic bacteria

Can process doubling its population within 6 to 8 hrs

Dominates and de-compose matter into liquid and gases. Can be kept for 3-4 months at ambient temperature in biodigester tank Can withstand sub zero temperature as well as upto 60 degree

centigrade

Cold temperature would not affect the inside processing becauseAnaerobic process is exothermic in nature & thus in cold regions, heatwill be available inside the chamber because of chemical process.

Advantage of IR-DRDO Bio-Digester

1. No bad smell in toilets from the tanks2. No infestation of Cockroaches & flies

3. Fecal matter in the tank not visible

4. No clogging of digester

5. Effluent is free from off odour and solid waste6. No maintenance required

7. Reduction in organic matter by 90%8. No requirement of adding bacteria/ enzyme

9. No need of removal of solid waste

Human Waste

Anaerobic bacteria(Li uid bacteria)

Liquid waste

Chlorination

Disinfected liquid

discharged to track

Co2! "ethane gases

released to atmosphere


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IR!R' io!+i-es"er Tan3 for Coaces

Tese "an3s are 4a+e of s"ainless s"eel an+ a,in- folloin- cons"ruc"ional

fea"ures

$he si%e of the tan& is 4' ( 11' ( )2' "" *ith the provision of '4 nos mounting brac&ets

at both the sides along the length of the tan&+ Each brac&et is *ith the provosion of '2 nos+

"1# Si%e bolts *hich are tigten in the under slung on mounting bra&ets+

Main 5ar"s of "e io+i-es"er "an3

1+ Stainless steel tan& *ith '# partition *alls in side the tan&

2+ ,oly grass mats for protection of bacteria in side the *alls+

3+ -all valve *ith handle for operation during emrgency for ma&ing toilet direct

discharge in case of choc&ing+

4+ SS fasteners in place of "S on tan& covers+

+ Stronger bonding of Coloni%ed rubber mat *ith vertical *alls+

I45or"an" i4ensions 6 7olu4e of io+i-es"er Tan3

1+ .ength / 11' mm 2/0idth / )2' mm 3+ eight 4' mm

4+ $otal olume of $an& 4'' lt+ + Effective olume of $an& 3'' it+

#+ Empty $an& *eight 11' 5g+ )+ 6ull $an& 0eight 41' 5g+7+ eight from Rail level /22 mm

11' mm

4' mm

)2' mm


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Other components of Bio-Digester Tank

1. Mounting Bracket - 04 Nos

2. Safety Rope - 04 Nos

3. Locking Plate - 08 Nos

4. Hex. Head Bolt (M16 X70) - 16 Nos

5. Hex. Nut (M16) - 16 Nos

6. Spring Washer (B16) - 16 Nos

7. Hex. Head Bolt (M8 X35) - 16 Nos

8. U Bracket(8 X20 X38) - 08 Nos

Sketch of Bio-Digester Tank

P-Trap

Manual Slider

Handle

Sampling Port

Mounting

Bracket

Overflow Pipe

Chlorinator


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7

ifferen" ,arian"s of io "oile"s

Fea"uresrief +escri5"ion

Pneumatics Electrics PLC Flush

System with flapper valve Yes Yes Yes Pressurized

System with manual slider

valve

no no no gravity

System with reducedopening at inlet

For western style Hindware

commode is proposed

no no no gravity

System with solid liquid

separator

no no no gravity

Variant-IFail safe mode exist- chute system can be operated without dismantling of tank

Variant-2Fail safe mode exist- chute system can be operated without dismantling of tank

PLC= Programmable Logic Controller


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Variant-3

Fail safe mode does not exist

Variant-4

Fail safe mode exist- chute system can be operated without dismantling of tank

Waste Flow Path


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Brief about variant 4 with PLC fitted at ICF

Fea"uresrief +escri5"ion

Pneumatics Electrics PLC FlushSystem with Solid liquid

separator with the provision

of Ball valve.

Yes Yes Yes Pressurized


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Bio toilets with Ball Valve


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Bio-Digestar Tank Mounting

Performance Parameters of Bio Toilets:

SN Parameter (as per APHA

Test Method).

Recommended Values for next

six months

Targeted value

(Max.)

1 pH 6 to 9 6 to 9

2 Total Solids Max 750 mg/100 ml 750 mg/100 ml

3 Total Volatile solids Max 500 mg/100 ml 500 mg/100 ml

4 Total Dissolved solids Max 350 mg/100 ml 350 mg/100 ml

5 COD levels Max 2000 MgO2/Lts Max 2000

MgO2/Lts

6 Fecal Coli Forms count 99% Red(Less than 108/100ml)

Performance Parameters Inoculum:

SN. Parameter (as per APHA Test Method). Recommended Values

1. pH 6-9

2. Percentage methane 40-70%

3. MPN for methanogens 103


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INSTRUCTIONS FOR PRESSURISED CLEANING OF BIOTOILETS:

The preventive maintenance schedule for maintenance of coaches being followed in

IR and time schedule to be followed for maintenance of the IR-DRDO Bio-toilet

system are issued by RDSO under guidelines for AMOC for Bio-toilets (DRDE type).

Maintenance of the Bio-toilet systems and Guidelines for handling of Bacteria

Visual inspection of complete toilets system including under slung

equipments.

Toilet chute to be cleared in bio-toilets if there is chocking.

Checking the toilets system for any deficiency.

Collection and transportation of sample from retention tanks to DRDE,

Gwalior or any other nominated Govt. accredited lab as per the test scheme. Charging of chlorine tables and examination of chlorinator.

Checking of following equipments/repair/replacement for proper functioning:

i. Flapper/slider/ball valve

ii. Leakage in piping, flush system, pneumatics, tank etc. valves,

pressurise, PLC, pneumatic valves, ball valves etc.

iii. Charging of Bio-culture if required (based on test reports).Culture will be

supplied by DRDE/IR

(Issued by the RDSO document no. RDSO/2010/CG/CMI-03(Rev.1)

Guidelines for coaching depots for handling of Bacteria

1. 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 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.


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List of cleaning agents being used in mechanized coach

cleaning in Bio toilet system

Following cleaning agents are being used for cleaning of bio-toilets in

NCR. These agents are considered to be suitable for IR-DRDO bio

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

Harpic/Retoil/Domex

4 Glass Cleaning Taski R3 (Johnson Diversey) or OC Glass cleaner of

Eco Lab or Collin

5 Laminated Plastic

Sheet & Berth Rexene

cleaner:

Taski R7 (Johnson Diversey) or OC Neutral cleaner

of Eco Lab or Collin

6 Painted Surface Spiral (Johnson Diversey) or Absorbit of Eco Lab or

Collin

7 Stainless Steel Polisher Suma Inox (Johnson Diversey) or Chromol of Eco

Lab or Collin

8 Disinfectant Brands Stride (Johnson Diversey) or Antiback of

EcoLab or Collin or Lizol

Note : Revised specification/alteration brands can be issued by Railways for

achieving better performance.

(Ref: DRM (M)S/JHS Letter No. JHS/ M/ CW/ 130/OBHS dated 26.08.2010 to ED/

CAMTECH)


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Evaluation of Cleaning Agents provided by Railway

pH % COD

Reduction

Total VFA (mM)S No Treatments Cumulative Biogas

(ml)

42 days 42 days 42 days

1 control 16790 7.61 94.72 1.26

2 Harpic 100 ppm 15820 (94%) 7.54 84.08 1.08

3 Harpic 250 ppm 14750 6.50 76.28 4.70

4 Domex 100ppm 14660 7.23 93.55 0.923

5 Domex 250 ppm 13620 6.33 74.78 2.19

6 Lizol 100 ppm 14340 7.28 85.58 1.83

7 Lizol 250ppm 14250 6.27 58.38 5.00

8 R7 cleaner 100ppm 16030 7.20 77.77 1.22

9 R7 cleaner 250ppm 14210 6.26 45.29 9.16

10 PVC floor cleaner

100ppm

14320 7.31 82.32 1.31

11 PVC floor cleaner

250ppm

14070 (83%) 6.46 62.32 4.94

12 Toilet cleaner 100ppm 15450 7.50 77.92 1.28

13 Toilet cleaner 250ppm 14550 6.51 69.71 3.57

Conclusion: All the six chemicals do not show any deleterious effect on

biodegradation up to 100 ppm during 42 day study period (30 ml/Toilet)


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1)

(Govt. of India)

(Ministry of Defence)

DRDE/GWL L.No.: BT/BKB/002/Biodig/2011-12 dated 26.03.2012

RDSO/LKO L.No.: MC/CB/LF/Anaerobic dated 15.05.2012

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TESTING SCHEME FOR

BACTERIAL CULTURE (INOCULUM)

& BIO TOILET EFFLUENT

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.wj-kk/kPhone: 91-751-2347545, 3902,2390100

01D!

Fax : 91-751-2341148b'& esye-mail : [email protected]


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4

Testing Scheme for Bio-Toilet Effluent and Bacteria culture(Inoculum)

on Indian Railways

On the basis of MOU between Indian Railways and DRDO, the bio toilet trial on IR

is going on. For intensive monitoring of the system, a test scheme has been

deveopled for implementation after formal approval of RDSO/LKO. As per Railway

Boards guidelines, the bio-toilet tanks i.e. Bio digesters are being fitted in the new

coaches being turned out from RCF. At present, the initial charging of bacteria

culture in the coaches is being done by DRDE/ Gwalior by providing Inoculum in

the barrels. The quality check of the product and bio toilet effluent is also done

according to ALPHA testing methods in DRDE by collecting samples from coachingdepot / Gwalior,

As per Railway Boards guidelines, a 100 M3 capacity Inoculum generation plant is

being developed in the Motibagh workshop in S.E.C. Railway, Nagpur and in

future, similar plants are proposed to be developed in ICF and RCF also. Hence, it

was felt necessary to develop lab sample testing facilities in Railways for doing

minor testings in Railway premises/Railway Labs/ production units & major testings

in Govt. approved labs. To cater the requirement of doing these tests efficiently, it

has also been proposed to provide suitable trainining to Railway staff in liaison with

DRDE sothat proper monitoring can be ensured at approprate level in the zonal

Railways. Some of the minor tests of effluent of bio-toilets have been proposed to

be carried out by coaching depot staff for which procedure has been explained in

detail in this booklet.

The testing scheme for effluent & Bacteria culture(Inoculum) has been tantatively

finalized by DRDE based on the past experience of 12 months trial, which should

be carried out in the existing Railway Labs/ diesel sheds/ coaching depots. The

necessary record of monitoring and testing should also be maintained & kept in the

concerned depots. The critical biological tests which can not be carried out in the

railway labs, such samples may be got tested in govt. labs/ DRDE. The critical

tests which should be carried out in Govt. labs only, has been marked clearly

against the test procedure in the booklet for ready reference.


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4#


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4)

(A) Testing Scheme for Bio-Toilet Effluent in Coaching Depots.

Folowing tests and parameters have been recommended for effluent dischargedafter bio degradation from the bio toilets of coaches in Indian Railways.

1. pH Value Test:

To measure pH value of the effluent of bio toilets to ensure environmentalsafety.

S.No.

Description Details

1. Purpose of test To measure pH value of the effluent of biotoilets to ensure environmental safety.

2. Target value 6 9 pH

3. Equipments required Table top pH meter / Portable pH meter / pHindicator strips & magnetic stirrer

4. Consumables pH calibration buffers (4.0, 7.0, 10.0), andmagnetic stirrer bars

5. Quantity of sample 50-100 ml

6. Electricity requirement Yes

7. Frequency of sampling 90 days

8. Testing spot Railway laboratory9. Staff required 1

Procedure:

First of all, take 02 ltrs. Effluent sample in the bottle from bio-toilet tank.

Take 50 100 ml of mixed effluent sample in a beaker.

Put a magnetic bar and keep the beaker on a magnetic stirrer and switch on themagnetic stirrer to mix it continuously.

Wash the electrode and Temperature compensation rod with distilled water andwipe it with tissue paper.

Put the electrode and automatic temperature compensation rod into the sampleand keep it until stable reading appears in the displays; note the reading.

Discard the sample and wash the electrode and automatic temperaturecompensation rod with distilled water and wipe it with tissue paper.

Keep the electrode back in the container.

Precaution: Do calibration with appropriate buffers before taking readings.


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47

pH Value Test (Simlified Procedure):

To measure pH value of the effluent of bio toilets to ensure environmentalsafety.

S.No.

Description Details

01 Purpose of test To measure pH value of the effluent of biotoilets to ensure environmental safety.

02 Target value 6 9 pH

03 Equipments required Portable pH meter

04 Other equipments pH indicator paper of all ranges

05 Consumables pH calibration buffers (4.0, 7.0, 10.0)06 Quantity of sample 50-100 ml

07 Electricity requirement Yes

08 Frequency of sampling 90 days

09 Testing spot Railway laboratory

10 Staff required 01

Procedure:

First of all, take 02 ltrs. Effluent sample in the bottle from bio-toilet tank.

Take 50 100 ml of mixed effluent sample in a beaker.

Put pH meter on the stand .

Mix the liquid properly.

Put the electrode of portable pH meter in the beaker until stable reading appearsin the displays;

Note the reading from display of Ph meter. Discard the sample and wash the electrode of pH meter with distilled water and

wipe it with tissue paper.

Keep the electrode back in the container.



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48

2. Total Solids (TS) Test:

This test should be carried out to estimate amount of total solids available in theeffluent.

S. N Description Details

1. Purpose of test To estimate amount of total solids in the effluent.2. Set Target


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3. Total Dissolved Solids (TDS):

This test should be carried out to estimate amount of total dissolved solids availablein the effluent.


1. Purpose of test To estimate amount of total dissolved solids in

the effluent.

2. Target value < 350 mg /100 ml

3. Equipments required Electronic weighing balance, pipettes, Silica

crucibles, Hot air oven, desiccators, filter

assembly, vacuum pump

4. Consumable Self indicating silica gel. Whatman Glass wool

filters

5. Quantity of sample 25 ml



8. Testing spot Railway laboratory

9. Staff required 1

Procedure:

1. Heat an empty and clean silica crucible at 180 2C for 1 to /2 hour in a hot air

oven, cool it in desiccator to room temperature and weight.

2. Insert disc and filter assembly, apply vacuum and wash disc with three

successive 20-mL volumes of reagent grade water.

3. Dry it in a hot air oven at 180 2C for 1 hour in an oven. Store in desiccators

until needed. Weigh immediately before use.4. Stir sample with a magnetic stirrer and pipette a measured volume (25 ml) into a

glass fiber filter with applied vacuum.

5. Wash with three successive 10-mL volume of distilled water, allowing complete

drainage between washings.


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1

6. Transfer total filtrate (with washings) to a pre-weighed clean silica crucible.

7. Dry it in a hot air oven at 180 2C for 1 hour in an oven. Cool it in desiccators

to room temperature. Note the final weight

Calculations:

mg total dissolved solids/ 100 mL = (A B) X 100 X1000 / Volume of sample (mL)

Where,A Weight of the dried residue + dish (g)

B - Weight of dish (g)


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2

Total Dissolved Solids (TDS) (Simplified Procedure):

This test should be carried out to estimate amount of total dissolved solids availablein the effluent.

S.

No.

Description Details

01 Purpose of test To estimate amount of total dissolved solids in

the effluent.

02 Target value < 350 mg /100 ml

03 Equipments required Portable TDS meter

04 Other equipments Beaker 100-150 ml

05 Quantity of sample 100 ml

06 Frequency of sampling 90 days

07 Testing spot Railway laboratory

08 Staff required 01

Procedure:

1. Ensure availability of all the equipments and effluent in the lab

2. Fill the sample effluent in the beaker and mix it properly.

3. Keep the TDS meter ON and put electride in the beaker up to marking

line.

4. TDS value will appear on the display of TDS meter. It should be noted.

5. Repeat the test again and record the TDS value in the register.


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3

4. Total Volatile Solids (TVS):

This test should be carried out to estimate amount of total volatile solids available

in the effluent.

S.

No.

Description Details

1. Purpose of test To estimate amount of total volatile solids available in

the effluent.

2. Target value < 500 mg /100 ml

3. Equipments required Electronic weighing balance, pipettes, Silica

crucibles, Hot air oven, muffle furnace, desiccators,

filter assembly.

4. Consumable Self indicating silica gel. Whatman Glass wool filters





9. Staff required 1

Procedure:

1. Heat an empty and clean silica crucible at 550C for 1/2 hour in muffle furnace.

2. Cool it in dissicator to room temperature and take the initial weight.

3. Pipette a measured volume of well mixed sample (25 ml) to a pre-weighed silica

crucible.

4. Keep the silica crucible in a hot air oven at 103 105C; keep till the water gets

dried.

5. Remove the silica crucible and keep it in muffle furnace at 550C for 1 hour.

6. Keep the silica crucibles in desiccators.

7. Note the final weight

Calculations:mg total volatile solids/ 100 mL = (A B) X 100 / Volume of sample

(mL)

Where,

A Total solids (mg)

B - Weight of the dried residue + dish (g) - Weight of dish (g) then

convert the value to milli gram

Note: The total solids amount is calculated as described above.


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4

5. Chemical Oxygen Demand (COD) Test:

This test should be carried out to estimate COD of the effluent to ensureenvironmental parameters.

S.No.

Description Details

1. Purpose of test To estimate COD of the effluent to ensure

environmental parameters.

2. Target value < 2000 mg O2/ Litre

3. Equipments COD digester along with digestion tubes and

condensers, Burettes, magnetic stirrer, magnetic

bars.

4. Consumable required Sulphuric Acid, Silver sulphate, mercuric chloride,

potassium dichromate, ferroin indicator, ferrous

ammonium sulphate.

5. Quantity of sample 5-10 ml of sample

6. Electricity

requirement

Yes

7. Frequency of

sampling

90 days

8. Testing spot Govt. approved Labs./DRDE

9. Staff required 01

Regents:

A. Standard potassium dichromate solutions (0.04167M) Dissolve 12.259 g

K2Cr2O7, previously dried at 150C for 2 hours, in distilled water and dilute to

1000 mL.

B. Sulfuric acid reagent: Add Ag2SO4 crystals or power to concentrate H2SO4 at

the rate of 5.5 g Ag2SO4/ Kg of H2SO4. Let it stand 1 or 2 days to dissolve.

C. Ferroin indicator solution : Dissolve 1.485 g of 1, 10 phenanthroline

monohydrate and 695 mg FeSO4 .7 H2O in distilled water dilute to 1000 mL.


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D. Standard Ferrous ammonium Sulphate titrant ( 0.25) Dissolve 98 g of

Fe(NH4)2 .6 H2O in distilled water. Add 20 mL con. H2SO4 , cool and dilute to 1

litre standardize this solution on the day of estimation against Standard

potassium dichromate solution.

E. Mercuric sulphate - HgSO4 crystals or powder.

F. Sulfamic acid interference of nitrates is to be eliminated.

G. Potassium Hydrogen Phthalate:lightly crush and then dry KHP to constant

weight at 110C. Dissolve 425 mg in distilled water dilute to 1000 mL. KHP

has a theoretical COD of 1.176 mg O2/ mg and this solution has a theoretical

COD of 500g O2 / mL.

Procedure:

Take 5 ml of sample and dilute it to 50 ml. (Note: In case higher COD samples

dilute 100 times).

Add 100 mg HgSO4, several glassbeads/ Chemstones, and very slowly add

5.0 ml of sulfuric acid, with mixing to dissolve HgSO4.

Cool while mixing to avoid possible loss of volatile materials.

Add 25.0 mL 0.04167 M K2Cr2O7solution and mix. Attach condenser to digestion tubes and cool the contents by swirling and

mixing in running tap water.

Add sulfuric acid reagent (20 mL) through open end of condenser.

Continue swirling and mixing while adding sulfuric acid reagent.

Cover open end of condenser with a small beaker / aluminum foil to prevent

foreign material from entering refluxing mixture and to avoid possible loss of

volatile materials. Do reflux / digestion for 2 hours @ 150C.

Cool and wash down condenser with distilled water.

Disconnect reflux condenser and dilute mixture to about twice its volume with

distilled water. Cool to room temperature.

Titrate excess K2Cr2O7with FAS, using 0.10 0.15 mL (2 3 drops) ferroin

indicator.


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#

Observe sharp colour change from blue green to reddish brown that persists

for 1 min or longer.

Duplicate determinations should agree within 5% of their average.

In the same manner reflux and titrate a blank containing the regents and a

volume of distilled water equal to that of sample.

Determination of a STD solution:

Evaluate the technique and quality of the reagents by conducting the test on a

standard KHP solution.

Calculations:

COD (mg/ ml) = (A-B) X N X 8000 X Dilution Factor / mL of sample

Where,

A mL of FAS used for blank

B mL of FAS used for sample

N Molarity of FAS (0.25)

8000 Mill equivalent weight of Oxygen.

Precautions:

1. Mix reflex mixture thoroughly before applying heat to prevent local heating offlask bottom and a possible blowout of flask contents.

2. Make dilution according to the COD range of the samples.

3. Ensure complete dissolution of silver sulphate in sulphuric acid reagent.

4. Store sulphuric acid reagent in a amber colored bottle in dark or wrap it with

aluminum foil.

5. Wear lab coat and hand gloves during handling of acids.

6. Always add acid along the wall of the container to the water.

7. Do titration once the content reaches room temperature.


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)

6. Fecal Coli Forms count:

This test should be carried out to estimate the fecal coli form bacteria count onbio toilet effluent.


1. Purpose of test To estimate the fecal coli form bacteria count on

effluent.

2. Target value > 99% reduction ( Lessthan 108/100 ML )

3. Equipments Laminar Air Flow Chamber, Incubator

4. Consumables Test tubes, FC media plates, spreaders,

pipettes, conical flasks, Glass marker, magnetic

stirrer.




8. Testing spot Only in Govt. Labs.


Procedure:

Media & Plate Preparation:

A. Media Composition:

S. No. Constituents Amount (g/ L)

1. Lactose 12.5

2. Tryptone 1

3. Protease Peptone 5

4. Sodium chloride 5

5. Yeast extract 3

6. Bile salts 1.5

7. Aniline blue 0.1

8. Distilled water 1000 ml

1. Boil the media for 30 minutes, do not sterilize the media.

2. Add approximately 25 ml of cooled FC medium to each Petri dish. Upon

solidification of the media close the aids and keep it for further use.


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7

B. Dilution preparation:

1. Label 90 ml water blank conical flask as No.1(10-1) and subsequent 9 ml water

blank test tubes as No. 2(10-2), No. 3(10-3), No. 4(10-4), No. 5(10-5), No. 6(10-

6), No. 7(10-7), No. 8(10-8), with a glass marker.

2. Take 10 ml of well mixed effluent sample and add to 90 ml water blank to make

(10-1) dilution. (Note: Use sterile pipettes for transfer and carry out dilution in

laminar air flow chamber)

3. Vigorously shake the dilution in a magnetic stirrer for 2 minutes to obtain uniform

suspension.

4. Transfer 1 ml of suspension from No.1 into No.2 tube to make (10-2

) dilution andshake it vigorously for 1 min.

5. Make further dilutions as prepared above.

Note: Do estimation of fecal coli form count in human excreta for comparison and

calculation.

C. Inoculation:

1. Place the spreader into a beaker containing 95% ethyl alcohol. Remove thespreader and pass it through burner flame. Burn off the alcohol completely and

cool the rod for 30 to 45 seconds.

2. Transfer 0.1 ml (100l) of suspension each from different dilution into 3 plates.

Place it in the center of the plate.

3. Remove the Petri dish cover, with one hand touch the spreader gently on the

surface of the agar and move it back and forth while rotating the plate with the

other hand.

4. When the suspension gets dried or absorbed on the agar medium, replace the

cover.

5. Incubate the plates in an uprght position in an incubator at 44.5C for 48 hours.


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8

Observations:

1. Observe the plates for number and distribution of Blue/ Bluish tinged colonies.

Do not consider white or creamy or dull white colonies.

2. Select the plate from the appropriate dilution which contains colonies in therange of 30 to 300 and make the plate counts.

3. Determine the average of the triplicate colony count.

4. Record your results.

Calculation:

Calculate fecal form count in terms of number of CFU / 100 ml by applying the

following formulas.

Fecal coli form count (CFU / 100 ml)= Mean plate count X Dilution factor X 100Volume of sample

% reduction = (count in human excreta count in sample) X 100count in human excreta

Example

If 160 colonies were counted (average of 3 replicate) in 10-3dilution the fecal coli

form count would be:

FC count (CFU / 100 ml) = 160 X 1000 X 1000.1

= 1.6 X 108

Precautions:

1. The sample should be mixed homogenously.

2. Each dilution must be thoroughly shaken before removing an aliquot for

subsequent dilution.

3. Use separate sterile pipettes or tips for each dilution.

4. All dilution making and inoculation should be done in laminar air flow chamber.

5. The plates should be incubated in a upright position.

6. 25-30 ml media should be added to avoid cracking of medium during incubation.


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#'

(B) Testing Scheme for Bacteria Culture(Microbial Inoculum).

Following parameters have been recommended for testing of Microbial Inoculumproduced in Inoculum generation Plant .

1. pH Value Test:

This test should be carried out to measure pH value of the inoculum.

S.

No.

Description Details

1. Purpose of test To measure pH value of the inoculum.

2. Target value 6.5 7.5. pH

3. Equipments required Table top pH meter / pH indicator strips,

magnetic stirrer.

4. Consumables pH calibration buffer (4.0, 7.0, 10.0), magnetic

stirrer bars.

5. Quantity of sample 50 100 ml.

6. Electricity requirement yes

7. Frequency of sampling Once in a week.



Procedure:

Take 50 100 ml of well mixed inoculum in a beaker.

Put a magnetic bar and keep the beaker on a magnetic stirrer and mix it

continuously.

Wash the electrode and Temperature compensation rod with distilled water

and wipe it with tissue paper.

Put the electrode and automatic temperature compensation rod into the

sample and keep it until stable reading appears in the display; note the

reading.

Discard the sample and wash the electrode and automatic temperature

compensation rod with distilled water and wipe it with tissue paper.

Keep the electrode back in the container and put them in stand.



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#1

2. Bio-gas Test:

This test should be carried out to measure amount of Biogas produced duringfermentation in the Inoculum generation plant.

S.

No.

Description Details

1. Purpose of test To measure amount of biogas produced during

fermentation.

2. Target value -

3. Equipments Gas flow meter / water displacement assembly.

4. Consumables Glass wares, cork, Glass L bends

5. Quantity of sample Not applicable

6. Electricity requirement No.

7. Frequency of sampling Daily

8. Testing spot At Plant/Site


Procedure:

Take 2000 ml of well mixed inoculum in a 3 L beaker.

Set the water displacement assembly.

Incubate the set-up in BOD incubator @ 30 0C for 24 hours.

Measure the volume of water displaced.

The amount of water displaced is equal to amount of gas produced.

Precaution:Make sure water column in the exit tube of the water beaker.


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#2

3. Percentage Methane Test:

This test should be carried out to measure the methane content of biogas producedduring fermentation in the Inoculum generation plant.


1. Purpose of test To measure the methane content of biogasproduced during fermentation.

2. Target value 40 70 %

3. Equipments required Gas chromatograph / online gas analyzer.

4. Consumables Serum bottles, Aluminum crimp, Butyl rubber

septum, Gas tight syringe (50 250 l), Nitrogen

cylinder, Zero air/O2cylinder, Hydrogen cylinder,

standard methane gas.

5. Quantity of sample Not applicable

6. Electricity requirement Yes.

7. Frequency of sampling weekly



Procedure:

Take 2000 ml of well mixed inoculum in a 3 L beaker. Set the water displacement assembly.

Incubate the set-up in BOD incubator @ 30 0C for 24 hours.

Fill a 30 ml serum vial with water, put a butyl rubber septum, aluminum crimp

and crimp it all the side.

Inject the biogas formed in the water displacement assembly into the serum vial

through a silicone tube fitted with needle.

Allow the exit of water through another needle inserted in the butyl rubber

septum.

Collect at least 15 ml of biogas.

Store it in a inverted position untill analysis.

Note: Make sure, gas bubble should not be there in the serum bottle before

biogas collection.

Inject 100 l standard methane gas and record the elution time of the gas.

(Note: Elution time is the time elapsed between injection of sample and response of the peak at top).

Inject 100 l of the biogas sample. Record the % methane in biogas.


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4. MPN Count for Methanogens:

This test should be carried out to estimate the methane producing bacteria count ininoculum.

S.No.

Description Details

1. Purpose of test To estimate the methane producing bacteria count ininoculum.

2. Target value >1000 / ml

3. Equipments required Gas chromatograph, Gassing manifold, hotplatestirrer, laminar air flow chamber, incubator,micropipettes, hand operated crimper, hand operatedDecapper.

4. Consumables Serum bottles, Aluminum crimp, Butyl rubber septum,Gas tight syringe (50 250 l), Nitrogen cylinder, CO2

cylinder, Hydrogen cylinder, sterile Disposablesyringes, Resazurin and chemicals listed below in thetable.

5. Quantity of sample ~ 50 ml

6. Electricity requirement Yes.

7. Frequency of sampling Monthly

8. Testing spot In Govt. approved Laboratory Only


Procedure:

Growth medium preparation:

SlNo

Constituents Amount (g / L)

1 KH2PO4 0.32 K2HPO4 0.33 (NH4)2SO4 0.34 NaCl 0.65 MgSO4.7H2O 0.136 CaCl2.2H2O 0.008

7 FeSO4 0.0028 Yeast extract 2.09 Trypticase 2.010 Trace element solution 1.0 ml

11 Trace vitamin solution 1.0 ml12 Sodium acetate 2.513 Sodium formate 2.514 Resazurin 1.0 ml

15 Reducing agent 12.5 ml

16 pH 6.817 Gas phase (N2:H2) 80:20

Trace Element Solution:


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SN Constituents Amount (g / 100 ml)

1 Nitrilo triacetic acid 1.52 MgSO4.7H2O 3.03 MnSO4.2H2O 0.54 NaCl 1.05 CoCl2 0.1

6 FeSO4.7H2O 0.17 CaCl2.2H2O 0.18 ZnSO4 0.19 CuSO4.5H2O 0.0110 AlK(SO4)2 0.0111 H3BO3 0.0112 Na2MoO4.2H2O 0.1Note:Dissolve nitrilotriacetic acid with KOH to pH 6.5 and thenadd other salts.

Trace Vitamin Solution:

Reducing Agent:

SlNo

Constituents Amount (g / 100 ml)

1 Cysteine hydrochloride 2.02 Sodium sulphide 2.0Adjust pH of Cysteine hydrochloride to 9.0

Indicator Solution:

Sl No Constituents Amount (g / 100 ml)1 Resazurin 0.10

1. All the ingredients of the medium were added in the required amount except theheat labile components and half the volume (6.25 ml) of reducing agent.

2. Heat the medium on a hot plate or heating mantle at 70 0C and sparge themedium continuously with O2free N2till the medium becomes colorless.

3. Take 60 ml serum vials and replace the air with nitrogen for 2 min.

4. Dispense media (22.5 ml) in individual vials and seal it with butyl rubber andaluminum crimps and seal it tightly.

5. Do autoclaving for 15 min at 121 0C for 20 min.

SlNo

Constituents Amount (mg / 100 ml)

1 Biotin 2.02 Folic acid 2.03 Vitamin B12 0.14 Pyridoxine HCl 10.05 Thiamine 5.06 Riboflavin 5.07 Nicotinic acid 5.08 D,L- Calcium pantothenate 5.0

9 p- aminobenzoic acid 5.010 Lipoic acid 5.0


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6. Let the medium to cool to room temperature and add rest of the amount ofreducing agent (6.25 ml) with syringe and heat the butyl rubber seal for 10 secwith a sprit lamp.

Note: The medium should be colourless.

Dilution Preparation:1. Label 22.5 ml anaerobic diluent medium containing serum vials as No.1(10-1)

No. 2(10-2), No. 3(10-3), No. 4(10-4), No. 5(10-5), No. 6(10-6), No. 7(10-7), No.8(10-8)with a glass marker.

2. Take 2.5 ml of well mixed effluent sample and add to 22.5 ml water blank tomake 10-1 dilution. Vigorously shake the dilution for 15 seconds to obtainuniform suspension.

3. Transfer 2.5 ml of suspension from No. 1 into No. 2 tube to make 10-2dilutionwith a sterile syringe and shake it vigorously for 15 seconds.

4. Make further dilutions as prepared above.Inoculation:

For each dilution prepare 5 replicate serum bottles for inoculation. Total 45medium bottles are needed.

Transfer 2.5 ml of suspension each from different dilutions into set of 5 serumvials with medium by sterile syringe and heat the butyl rubber septumimmediately.

Incubate the serum vials in an upright position along with uninoculated controlin an incubator at 30 0C for 20 days.

Observations:

Analyze the gas from the head phase for presence of methane as describedabove with gas chromatograph.

Note the number of positive and negative vials for each dilution.

Methanogenic MPN is computed on the basis of bottles showing positive test.Dilution factor is taken into consideration while calculating the MPN.

Record your results

Calculation:

1. To calculate MPN of methanogens in the original sample

Select as P1: the number of positive tubes in the least concentrated dilution inwhich the greatest number of tubes is positive; and p2 and p3 represent thenumbers of positive tubes in the next two higher dilutions.

Use table of MPN for use with 5 tubes per dilution, then find the row ofnumbers in MPN table in which p1 and p2 correspond to the values observedexperimentally. Follow that row of numbers across the table to the columnheaded by the observed value of p3. The figure at the point of intersection isthe most probable number of organisms in the quantity of the original sample

represented in the inoculum addedin the second dilution (p2). Multiply this figure by the appropriate dilution factorto obtain the MPN for the original sample.


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Example

Suppose the following observations were made:

Dilution No. of positiveNeat 5

10-1 510-2 510-3 510-4 310-5 110-6 0

In this series, p1 = 5, p2 = 3, p3 = 1. For this combination of p1, p2 and p3, the MPN

table gives 1.1 as the most probable number of organisms in the quantity of the

inoculum applied in the10-4

(p2) dilution. Multiplying this number with dilution factor104gives 1.1 X 104 as the MPN for the original sample (2.5 ml). Convert the value to

1 ml by dividing with 2.5 i.e. 1.1 X 104/2.5 = 4.4 X 103

Precautions:

1. The sample should be mixed homogenously

2. Each dilution must be thoroughly shaken before removing an aliquot for

subsequent dilution

3. Use separate sterile pipettes or tips for each dilution

4. Use sterile pipettes for transfer,

5. Carry out dilution as quick as possible and immediately seal the butyl rubber

septum and aluminum crimps. Alternatively the dilution can be done in

anaerobic glove box.

6. The Heat labile compounds should be added after autoclaving.

7. Trace element solution and reducing agent solution should be prepared

separately and should be autoclaved.

8. Trace vitamin solution should be sterilized by filtration.

9. At least three consecutive dilutions should be inoculated.


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Minutes of the Meeting held at DRDE on 22.12.2011

A meeting was held at DRDE on 22.12.2011 in connection with finalization of detailedschedule of work for floating tender by MIB workshop NGP & following observationshave been recorded.

Meeting attended:

1. CME/PL/SECR2. Director (Mech)/CAMTECH3. JE/RCF4. SSE/ICF

Civil Work:

Inoculum Generation Facility -

S.No. Work Proposed1. Excavation:Total Excavation in earth for foundation of Sump well i.e. dressing of sides

in all types of soil, rectangular storage tank, gas collection chamber, including disposalof earth-

= 264.66 Cum

2. Foundation: Providing and laying plain cement Concrete mechanically mixed, vibrated,M-15 grade with 20 mm, graded metal (Hard Metal B.T.) for foundation course up tocomplete work.= 12.50 Cum

3.

i.

ii.

iii.

iv.

v.

Proving and laying M-20 reinforced Cement Concrete Mechanically mixed vibrated with20 mm, hard graded metal (B.T. Metal) excluding cost of reinforcement but i/c form workpropping bracing etc. completeBottom Slab = 3.43 Cum

Cylindrical Wall = 13.85 Cum

Haunching = 0.18 Cum

Top ring Beam = 0.75 Cum

Top Dome = 2.45Cum

Total= 20.66 Cum.

4. Reinforcement for concrete work @ 2% of volume i.e. 37.15Cum => 0.75M3 x 7850kg/Cum.= 5,832.55 kg. i/c cutting bending, centering, overlaps, wastage etc. complete.

5. Provision of providing & fixing 4 pipes approx.120 feet for inlet, outlet, scour, overflowincluding labour and material nut, bolts, valves, bends, transportation, testing etc. asshown in the drawing

6. Provision for 20 feet long Aluminum ladder, ventilation shaft, manhole covers, watergauge, water proofing treatment, back filling, site grading, plinth protection andmiscellaneous work.

7. FRP Lining inside the walls of tank for area approx.50 m2 and approx. 70 m2 P/Uinsulation from outside the walls.


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S.No. Work Proposed

8. Water Chiller: Water cooled chiller of 20 ton capacity consisting of 10 ton capacityDanfoss scroll hybrid compressors each with FRP cooling tower of 30 TR capacityand 5 HP electrical motor with mono block pump with all f itting arrangements.

9. Rectangular Storage Tank: Overflow chamber (Rectangular Storage Tank) of 32M3 Capacity of Brick wall construction covered with 5 mm thick M.S. Sheetfabricated cover with handle along with the provision of one end hinges.

10. Gas collection chamber: 1480 mm inner dia S.S./FRP floating dome (sheetthickness size 1.5mm) volume approx. 500 ltrs capacity, round chamber for methanegas collection with the provision of holding cantilever height approx.12 feet alongwith steel wire rope of suitable capacity & iron counter weight with container.

11. Mud Pump:Provision of one Mud pump of 5HP capacity for agitation of slurry with 5HP elect. motor with starter & other accessory.

12. Standby Mud Pump:Provision of one Mud pump of 5HP capacity for agitation ofslurry with 5 HP elect. motor with starter & other accessory.

13. Gas cooling coil: (19 mm ) Tin coated copper cooling coil fitted approx. 1000feet inside the inoculums plant as per chiller capacity.

14. Covered shed: 12000 mm long X 9000 mm width X 3600 mm height M.S. Shedwith RCC foundation with 6 MS channels and jally & provision of Antilock tileflooring at plant area .

15. Operators Cabin:Construction of RCC roof operators cabin size 3000 x 3000 mm(

U/R pile foundation) with the provision of 02 nos. windows & one door & flooring

16. Store & Bio Toilet: Construction of RCC roof store size 3000 x 3000 mm withattached toilet ( U/R pile foundation) size 2000 x 1800 mm with the provision of 02nos. windows & one door & flooring

17 Surrounding wall and chain link fencing: Construction of 2 feet high brick walland fitting of chain link fencing supported on iron angles height approx. 1.82 metersabove the wall size 55 X 45 feet & fabrication of 12X6 feet size MS gate or brickwall as shown in estimate.

******

Copy to/: CME/PL/SECR, JE/RCF , SSE/ICF for information.


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Electrical Work:

SN Work proposed Load/quantity

Estimatedcost

( in lacks)

1. Installation and electrical connections to water cooledchiller plant of 20 Ton capacity (with 02 compressors of10Ton capacity each)

15 kW --

2. Installation and electrical connections to cooling towerwith 3 HP Motor & lifting Pump

2 kW --

3. Installation and electrical connections to agitation mudpump with 3 HP low rpm Motor

2 kW --

4. Installation and electrical connections to 02 nos. MudPump with 1.5 HP Motor

2 kW --

5. Installation and electrical connections to 02 nos. MudPumps with 5 HP Motor

3.5 kW --

6. 100 Amp Main distribution Board with TPIC switch andControl Panel consists of 3-phase supply bus bar for mudpumps, water pump, chiller and circulating pump etc.,single phasing preventer, earth fault preventer,distribution MCBs, phase indicators etc..

1.50

7. 05 No. Industrial out door type 2 x 36 Watt T5 FTL polemounted fittings.

0.5 kW 0.50

8. 03 Core 4 Wire 35 mm2 Armoured main service cable Railway supply to plant MDB with standby cable.

50 meters 0.75

9. 03 Core 4 Wire 10 mm2 cable from MDB to chiller and 5/3HP pump motors.

50 Meters 0.30

10. 03 Core 4 Wire 06 mm2

cable from MDB to 1.5 HP pumpmotors, room lights and area lights.

50 Meters 0.20

11. Maintenance free earthing arrangement 02 earthingSet

0.25

12. Light & Fan wiring with accessories in operator room,store room and toilet02 Fan, 04 F/T, 04 Sockets -05Amp, 02 Power Sockets -15 Amp

--- 0.10

13. Fire Extinguishers (DCP Type) 04 Nos. 0.10Total Load 28.5 kW 03.70

Total Estimated Cost of work (Approximately) 3.70 Lacks

***


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Effluent parameter Analysis, instruments

Specifications and approximate cost

S.No Instrument Specifications ApproximateCost (Rs)

1. Table top pHmeter

Ph accuracy 0.01 units,Calibration up to 3 points with auto bufferrecognition,Display large dual line,Temperature compensationAutomatic/manual 0 - 100C,Memory 50 data sets,Power requirements 220 VWarranty 1 Year for instrument and 6 months forelectrode.

25,000

2. Portable pHmeter

Ph accuracy 0.01 units,Calibration up to 2 points with auto bufferrecognition,Temperature compensationAutomatic/manual 0 - 100C,Power requirementsBattery operated, Auto poweroff for 10 minutes.Warranty 1 Year for instrument and 6 months forelectrode.

5000

Table to H meter Portable H meter


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3. Hot air oven Temperature Up to 250C,Temp control Thermostatic 2C,Oven Double walled Aluminum/SS, outside MSwith epoxy coating.ShelvesWire mesh shelves.

Door With synthetic rubber gasket.Air circulation Fan present.Size 455 mm x 455 mm x 455 mm (W x D x H)

40,000

HOT AIR OVEN Filter flask

assembly

4. Filtering flaskassembly

Assembly SS/ Glass.Filter Dia- 47 mm.Filtration area :5 -10 cm2.Size 15-20 cm X 5-10 cmOut let No. 8 perforated silicone

Volume -500 mlStopper mounted on 1 L Glass vessel

10,000

Silica crucibleWeigi!g bala!ce


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5. Muffle Furnace Size 125 mm x 125 mm x 300 mm (W x D x H)

Power 3.0 KW

Temperature Up to 900C,

Outer Casting MS with epoxy coating.Temp Control Digital Temperature controller cum

indicator.

Heating element- Kanthal wire/ special high

temperature alloy

25,000

"#FF$E F#RNA%E


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6 COD Digester Controller Microprocessor Based Digital TemperatureIndicator cum ControllerDisplay LED with set value (SV) and process value(PV)Block Dimensions (WxDxH) in mm-

270 mm(L) x 150 mm(W) x 70 mm(D)Heater Load 1.0 KWTube cavity 40 mm()x 65 mm (D)No. of cavities 15 holes to accommodate 15 samplesGlass Tube Size Supplied with 15 Nos of glass tubesof size 38 mm ()x 200 mm (Length)Glass Air Condenser Size 15 nos. of air condensersof 600 mm length each.Temperature RangeAmbient+5C to150 CTemperature Accuracy +1 CSensor RTD (Pt- 100)Material External Power Coated CRC SteelBlock Polished AluminumTube Rack -1 No.Power Supply 230 V AC, 50/60 Hz.Optional spare digestion tubes (15 No.)Tube rack (1 No.)

42,000

6a. Lab Coat and Hand Gloves

%O& &I'ESTION APPARAT#S


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7. Magnetic Mixingplatform

Maximum Stirring Capacity 1 liter (0.26 gallons)

Speed Range Min. 100 rpm, Max. 1000 rpm

Cover Material ABS plastic

Dimensions 137 mm (dia) x 51 mm (h)Weight 640 g (1.4lb)

Accessories:Micro Stir Bars for Magnetic Stirrers.

25,000

5H Eui54en"s

8. Autoclave Material of vessel inside Stainless steel, outside epoxy coated MSEffective volume 22 L (250 mm x 450 mm; Dia xdepth)Weight -15 - 25 Kg.Power consumption 2 - 3 KW.Operating temperature Range 120 10CKeep warm temperature 45 C 60 C.Safety device Safety valve, over temperature &over pressure limiter, Error indicators.Accessories 2/3 stainless steel baskets, indfoss

piezostat to adjust pressure between 15 to 22 PSI

20,000

pH i!(icator strips"ag!etic bars"ag!etic stirrer


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9. Laminar air flowchamber

Size 1200 mm x 600 mm x 600 mm (L x W x D)

Door Acrylic

Light Both UV and Flourescent

Outer casting Duro board / SS 304.Filter HEPA with 0.3 m pore size.

Accessories:Cock for Gas/vacuum line, Bunsen

burner

1,50,000

$ami!ar air flo) camber


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10. Incubator Temperature Ambient to 60 C.

Temp Control Thermostatic 1C

Size 450 mm x 450 mm x 600 mm (LxWxD)

Heating elements:Bottom.Casing inside Double walled

Aluminium/SS, outside MS with epoxy coating

Door Glass window and with synthetic rubber

gasket.

Shelves Wire mesh shelves,

Power 240 V AC

Air circulation Fan Present.

40,000

I!cubator


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11 Burette Class A class.Make PTFE pathway.Capacity 50 ml.Graduation interval 0.1 ml.Height 720 mm.

Tolerance 0.1 ml.Accessories:leak proof stopcocks.

2500

12 Fume HoodSystem

Internal size:L 1200 x D 600 x H 600 mmMake:woodWorking Space: Stainless steel 316, Acid resistant.Wash basin size:250 x 200 x 150 mm depth ofStainless Steel 316.Sliding slash:Glass make moves vertically up anddown with concealed counter balanced weight.Exhaust system:Exhaust fan with stainless steeldeck & Duct to take out fumes.Electrical:1 fluorescent lamp, power socket (5/15A).Accessories:Cock for Gas supply

50,000

13 Micropipettes Digital micropipetteChemical resistantAutoclavableVolume Range

20l - 200 l100l - 1000 l1 ml - 5 ml

50,000

Graduated glassware 10,000Sampling containers of plastic / Glass make 5,000Refrigerator 15,000Thermometer 1,000Volumetric glassware 10,000Magnetic bars all range 5,000Tissue paper -Blotting paper -Para film -Cotton -

14 GeneralFacilitiesRequired

Test tube bucket -

"icro i ette


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INDIAN RAILWAYS

TRIAL/TEST SCHEMEFOR

FIELD TRIAL OF BIO TOILETS

(DRDE TECHNOLOGY)ONINDIAN RAILWAY PASSENGER COACHES

S.No.

Amend./Rev. No.

Date/Monthof Issue

Page No. Reason for Amend./ Rev.

1 Rev.Nil Dec., 2010 NA Ist Issue

2 Rev. 1 Jan., 2011 3 Frequency of testing of effluentdischarge changed & agency specified.

3. Rev.2 May, 2011 All pages i) Reasons of chocking/

malfunctioning of toilet with coach&lav. variant added in visualobservations.

ii) Annexure-I Generalised.4. Rev.3 June, 2012 All Pages i) Review of testing parameters &

inclusion of parameters VolatileSolids & Faecal Coliforms.

ii) Inclusion of:- Sampling Criteria- Testing procedure

5 Rev-4 October,

2012

All pages - Complete trial scheme revised.

- Sampling procedure and list of testlabs added as annexure III and IV.

ISSUED BY:

CARRIAGE DIRECTORATERESEARCH, DESIGNS AND STANDARDS ORGANISATION

(MINISTRY OF RAILWAYS)MANAK NAGAR LUCKNOW-226 011


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1. TRIAL/TEST SCHEME FOR IR-DRDO BIO TOILETS IN INDIAN RAILWAY

Indian Railway has developed IR-DRDO bio-toilets jointly with the DRDO. Toestablish it in IR conditions trials on IR is going on. For proper monitoring ofthese bio-toilets, a test/trial scheme has been prepared. This Test /Trialscheme may be divided mainly in two parts.

A) Visual inspection.B) Quality check of the effluent discharged from bio toilet.

Period for monitoring of above Test /Trial scheme shall be 2 POH Period i.e.36 months. Consolidated test / trial report shall be submitted to RDSO on 6monthly basis.

To cater the requirement of doing these tests efficiently, it has also beenproposed to provide suitable training to Railway staff by CAMTECH in liaisonwith DRDE so that proper monitoring can be ensured at appropriate level inthe Zonal Railways. Some of the minor tests of effluent of bio-toilets havebeen proposed to be carried out by coaching depot staff at In-House Labsbeing setup at diesel sheds/ coaching depots for this purpose.

The sampling procedure and testing procedure of effluent discharge of IR-DRDO bio toilets has been tentatively finalized by DRDE based on the pastexperience of 12 months trial is attached as Annexure - IIIand Annexure - V.

2. VISUAL INSPECTION DURING FIELD TRIAL

The following parameters will be monitored during field trial by concern Railwayin each trip.

Date of Inspection Coach No. Type of coach .. Toilet Variant...

S.No.

Parameters to be checked Observations/Remarks

1. Thorough inspection of mounting/securingarrangement for the bio-digester tank.

2. Any leakage in joints/connections in thecomplete system including retention tank, air& water pipelines

3. Adequacy of the provisions made forsegregation of non-bio-degradable items.

4. Functionality of all controls & indications i.e.Flush button/leverWater tapsPneumatics operation efficiency (if any)

5. Adequacy of flushing of the pana) By using pressurized flushingb) By Normal manual flushing

6. Any mal odour/stench Yes/No

(Specify if yes, Light, Medium or Heavy)


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7. Overall Cleanliness level of the toilet room

8.Notices for users and maintenance personnelin Hindi, English & Regional Language of theoriginating & destination station.

9.Emergency operation of flush arrangement

without power/air supply.10. Performance of non-bio-degradable wasteejection system. Its effectiveness andreliability.a) Check operation of flapper/ ball valve,

whether working Satisfactorily (Yes/No).If No, Give reason & remarks formalfunctioning.

b) Chocking of toilet pan/ P-Trap (Yes/No)If yes, Give reason & remarks forChocking.

11. Tank evacuation date (if any) with coachnumber and date.

12 Details of attention/maintenance requiredwith coach number, date and time taken.

13 Adequacy of strength & capacity of Wastetreatment tank.

Consolidated trial report shall be sent by monitoring Railway to RDSO at theinterval of 6 months inthe prescribed format at Annexure II.

3. QUALITY CHECK OF THE EFFLUENT DISCHARGED FROM BIO TOILET

3.1 Sampling:.

i) Sample shall be collected from the toilet retention tanks sampling port inthe nominated coaching depot/washing line on quarterly basis.

ii) Samples will be collected randomly from lot of 5% coaches of the totalcoach holding but minimum one coach of each type.

iii) Sampling will start after coach is put into passenger service for 10 days ormore.

iv) The samples should be collected as per specified detailed samplingprocedure given in Annexure-III and sealed in the presence of railwayrepresentative.

3.2 Test Parameters:

For the quality check of effluent discharged from Bio-toilets, followingparameters shall be tested.

SN Parameter (as perAPHA Test Method).

RecommendedValues

In-house/Govt. Lab

1 pH 6 to 9 In-house /Govt. Lab2 Total Solids Max 750mg/100ml In-house /Govt. Lab3 TDS 350mg/100 ml max. In-house /Govt. Lab4 COD levels Max 2000 ppm Govt. Lab

5. Volatile Solids Max 500mg/100ml In-house /Govt. Lab6. Faecal Coliform


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3.3 Testing Procedure:

i) Samples collected may be divided in two category one for In-house testingand second for Govt. Accredited Lab.

ii) The samples marked for Govt. Lab testing shall be transported to thenearest Govt. Accredited testing Labs listed in Annexure IVat the earliest.However prior consent for testing of the samples shall be required by therespective railway from such Govt. Approved Lab.

iii) Samples marked for in-house testing shall be tested as per test procedureattached at Annexure V

iv) The test results shall be furnished in prescribed format attached as

Annexure-I.

v) The necessary record of monitoring and testing should also be maintained

& kept in the concerned depots in the format of Annexure I.vi) In case of samples not meeting the requirements, tests will be repeated

after taking necessary corrective actions within a fortnight.

Consolidated all the test reports (In-House/Govt. Approved Labs ) of effluentdischarge shall be submitted to RDSO on Six monthly basis.


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Annexure-I

Date of Sampling: ..................... Date of Lab Testing: .......................

Observations/Results

CoachNo.

Variant of

Bio-digester

pHValue

Total Solids(mg/100ml)

TDS

(mg/ 100ml)

CODLevel

(ppm)

VolatileSolids

(mg/100ml)

FaecalColiformCount

(MPN/100ml)

Signature of Evaluating Authority :

Name & Designation :

Seal :


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Field Trial of Bio-Toilet (IR-DRDO Technology) on Indian Railway Passeng

Train No Rake No. Coach No. ....DateName of SE/ JE R/ Ma

Parameters to be checkedSl.

No. Coach no.

1. Thorough inspection of mounting / securing arrangement for the bio-digester tank.

2. Any leakage in joints/ connections in the complete system includingretention tank, water pipe line.

3. Adequacy of the provisions made for segregation of non bio-degradableitems.

4. Functionality of flush buttons/ lever & water tabs

Adequacy of the flushing of the pan5.

(a) By using pressurized flushing(b) By normal manual flushing

6. Any mal odour/ stench: (yes/No),if yes, please specify Light, medium or Heavy

7. Overall cleanliness level of the toilet room.

8. Notices for users and maintenance personal in Hindi/English & regionallanguage of the originating & destination station.

9. Emergency operation of flush arrangement without power / air supply.

10. Performance of non-bio-degradable waste ejection system itseffectiveness and reliability.a. Check operation of flapper / Ball valve whether working satisfactorily

(Yes/ No),If no, give reasons and remarks for malfunctioning.

b. Choking of toilet pan/ P-Trap (Yes/ No),If yes give reasons and remarks for choking.

11. Tank evacuation date (if any) with coach No. and date.

12. Details of attentions / maintenance required with coach no. , date andtime taken for maintenance.

13. Adequacy of strength & capacity of waste treatment tank


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Annexure-III

EFFLUENT SAMPLING PROCEDURE

Objective: Procedures to be followed for collection of valid and representative effluentsamples from bio-digester.

Scope: This document contains the procedure that should be followed to collect eff luentsamples from bio-digester for analysis of physiochemical and biologicalparameters. The sample size is small enough in volume to be transportedconvenientlyand yet large enough for analytical purposes.

Requirements:

Sample container -Autoclavable plastic (polyethylene or equivalent) /Glass

container marked in red/black for eff luent samples.

Refrigerator -For storage of samples.

Description:

General Requirements:

Ensure all sample equipment and containers are clean and quality assured before use.

Use sample containers that are clean and free of contaminants.

Fill sample containers without pre-rinsing with sample; pre-rinsing results in loss of anypre-added preservative and sometimes can bias results high when certain components

adhere to the sides of the container.). Leave an air space approximately 10% of the container volume to allow for thermal

expansion during shipment.

Collect samples 2-3 times from the same source with 2 minutes interval between eachof them and make composite sample, take necessary amount and use it for analysis.

Make record of every sample collected and identify every bottle with a unique samplenumber, preferably by attaching an appropriately inscribed tag or label.

In unique identification number write/mention name of the sampler, date of samplecollection, train No/Name of sample, coach no, toilet no.

Use water proof ink to record all information (preferably with black, non solvent basedink).

Maintain the sampling information in bound sample log book at the sampling site at thetime of sample collection.

Always prohibit eating, drinking, or smoking near samples, sampling locations, and inthe laboratory.


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Collection of samples:

1. Sample collection guidelines: Collect sample from the bio-digester 30 minutes after the train becomes stationery/still.

Sample should be collected from sampling port only, in case sampling port is not there,

can be collected from effluent discharge port. If water is not draining from sample port remove the debris which may plugged the

sample port by iron wire and let i t drain for 2 minutes and collect composite sample.

Even after cleaning of sampling port, if water is not draining from sample port, flush mildsteam of water with intermittent pause for 5 minutes into the bio-digester. Collectcomposite sample.

Too much of water also should not be flushed.

2. Type of sample Composite sampling may be done by combining small portions of multiple grab samples

taken from the same Bio-digester.

Collect individual portions in a wide mouth bottle every 2 min and mix it at the end of thesampling period or combine in a single bottle as collected.

3. Sampling methods Manual sampling may be used for routine sampling programmes.

Trained field technician is often necessary for sample collection.

4. Sample containers: Containers are typically made of plastic (PTFE Poly Tetra Fluoro Ethylene) or glass

may be used. The containers cap should made of foil or PTFE liners.

In rare situations it may be necessary to use containers not specifically prepared foruse, or otherwise unsuitable for particular situation.

Please thoroughly document these situations.

For QA purposes the inclusion of a bottle blank may be necessary.

5. Number of samples: Because of variability from analytical and sampling procedures (i.e. population

variability) small number of samples is insufficient to reach any reasonable desired level

of confidence.

Minimum three consecutive sampling has to be done from same Bio-toilet to drawconclusion.

6. Sample volume: Collect 1 L of sample for most physical and chemical analyses.

Always collect enough sample volume in appropriate container in order to comply withsample handling, storage and preservation requirements.


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7. Check the sample for the following:Quantity -Does the sample have sufficient quantity (500 -1000ml)Label -Label on the container should bear the following details:

Name of sample/train no, Date of collection, Sample no.Integrity of the seal across the sample should be checked.

8. Person handling the sample:

If leakage is observed, wipe the container with cotton soaked in spirit and transfer thespecimen into a new

compendium on ir-drdo biotoilets for indian railways

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