Post on 08-Dec-2021
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 1 of 12
INDIAN RAILWAYS
TECHNICAL SPECIFICATION FOR
“TROLLEY MOUNTED MOBILE SEWAGE EVACUATION
MACHINE” FOR IR-DRDO BIO-TOILET WASTE
DISPOSAL FROM INDIAN RAILWAY COACHES”
Issued By:
Indian Railways Centre for Advanced Maintenance Technology (CAMTECH)
Maharajpura, Gwalior - 474005.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 2 of 12
Contents
Sr. No. Description Page No
1. Scope 3
1.1 Objectives 3
2. Operating and environmental Conditions 3
3. Design Requirements 4
3.1 Complete system 4
3.2 Other Accessories 5
3. 3 Reliability 5
3.4 Collection tank 5
3.5 Drive system 5
3.6 Tank Mounting 6
3.7 Pumping system 6
3.8 Suction and Discharge hose 7
3.9 Control Panels 7
3.10 Vacuum Gauge 8
3.11 Trolley 8
3.12 Power tool Bag 8
4. System Working Flow Chart 8
5. System Interface 8
5.1 Mechanical interface 8
5.2 Electrical Interface 9
5.3 Interface with piping arrangement 9
5.4 Interface with Bio-Toilet tank 9
6. Prototype Approval 9
7. Installation & Commissioning 11
8. Scope of Supply 11
9. Delivery 11
10. Inspection 11
11. Guarantee 12
12. Marking 12
13. Training 12
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 3 of 12
“TROLLEY MOUNTED MOBILE SEWAGE EVACUATION MACHINE
FOR IR-DRDO BIO-TOILET WASTE DISPOSAL FROM INDIAN
RAILWAY COACHES”
1.0 Scope
Indian Railways has adopted Bio-Toilets for use on Coaches. The Bio-Toilet get
choked sometimes due to various garbage like bottles, plastic, pouches, napkins
etc. dumped by passengers. These items are required to be removed without
removing tank from Coach through a top cover by means of suction machine.
This specification covers the Technical & General requirements including supply,
installation & commissioning of Trolley Mounted Mobile Sewage Evacuation
Machine. The tenderer should offer clause wise comments and shall also submit
deviation statement. Comments such as ‘noted’ are not acceptable where
compliance is warranted. Failure to adhere to this clause will render the offer
invalid.
1.1 Objectives
Evacuation Machine is intended to perform the following task-:
1.1.1. Transfer of medium from Bio-Toilet tank to GRP tank.
1.1.2. Transfer of screened inoculums from screened chamber in GRP tank to Bio-Tank.
1.1.3. Transfer of accumulate waste from the GRP contaminated chamber to outside dump.
1.1.4. Transfer of waste directly from bio-tank to dump, if required.
2.0 Operating & Environmental Condition:
Trolley Mounted Mobile Sewage Evacuation Machine should function with full
efficiency under the following operating conditions:
2.1 Ambient Conditions:
2.1.1 -40C to 55
0C with 100% humidity and dust. Temperature variations can be quite
high in the short period of time.
2.1.2 Machine may operate in areas, where may be continued exposure to salt laden air.
2.1.3 The machine should be portable for movement in Railway yards.
2.2 Vacuum Generation:
Vacuum generation shall be done for sucking the Sludge / slurry from Bio-Toilet
tank of IR coaches by a vacuum suction pumping System, capable of developing
vacuum pressure in the range of -0.90 bar to -0.95 bar and discharging the collected
sludge by reverse operation of pump and gravity discharge both.
2.3 Power Supply:
2.3.1 210-240 V, Single phase, 50 Hz AC supply is available in the Coaching
depot/Railway yards.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 4 of 12
2.4 Operating condition:
The machine should be portable for movement in Railway
yards/Sickline/Maintenance bay. Minimum ground clearance between the rail level
and any part of the Machine should be 180 mm.
2.5 Duty Cycle:
2.5.1 The Machine should be capable for frequently use on system for evacuation and
discharging.
2.5.2 The Machine shall be used upto approx 100 times in 24 hrs.
2.6 Maintenance conditions:
2.6.1 Coach cleaning is being done by high pressure jet in Coaching depots. In case any
electronic components are used, environment protection for the same may be
indicated with the offer.
2.7 Special Conditions:
2.7.1 It should be ensured that the sludge/human excreta should not come out of any
joint etc. and there should not be any need to operate a mechanism having human
excreta on it so that it is not touched by the operator.
2.7.2 Special features incorporated in to the machine, if any shall be clearly indicated
separately by the manufacturer, clearly indicating the advantages of these features.
2.7.3 Connection interfaces for different applications to be developed by supplier in
consultation with user.
2.7.4 Mutually agreed modifications if any may be done by supplier.
3.0 Design Requirements:
3.1 The complete equipment system shall be mounted on a sturdy 4 wheel based
Trolley, suitable for evacuation from Bio-toilet tank of IR coaches filled with
human excreta along with small crushable solids passing into the toilet tanks. The
Vacuum Suction Unit shall comprise of the following:-
3.1.1 Pump with solid/sludge waste like napkin, bottle cap, sachets, wrappers etc.
handling capacity.
3.1.2 Drive System (Electric operating prime mover, single phase)
3.1.3 GRP translucent material Tank suitable to handle 200 liters.
3.1.4 Conveniently located and easily visible Controls and reversing switch
3.1.5 Activated Carbon filter for absorbing foul smell at the exit port of bio-gas.
3.1.6 Over all weight of machine should not be exceed 250 Kg (empty condition) for
portable movement in Railway yards/Maintenance lines.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 5 of 12
3.2 Other accessories:- Other accessories of system are as following:-
3.3.1 Proper holding arrangement for the suction and the discharge pipe.
3.3.2 Proper cable rack for 20 meters, 3 core, suitable sheathed power cable as per IS 694:
1990, make of Finolex, BCH, Polycab, Havells etc.
3.3.3 All mounting shall be in such a way so as to remain within the overall trolley
dimensions.
3.3 Reliability:- It shall be robust, reliable and require low maintenance. This should
be quantified with mean time between failures (MTBF) and mean time to repair
(MTTR).
3.4 Collection Tank:-
3.4.1 The tank shall be of corrosion resistant Glass reinforced plastic (Translucent) GRP
(long life, low weight-high strength ratio and excellent corrosion resistance), box
shape with Isopthalic Polyester resin BS4994-87.
3.4.2 The size of the tank should not be more than: L x B : 875 x 580 with capacity of 200
Liters.
3.4.3 The maximum outside side dimensions shall be within the trolley platform.
3.4.4 The GRP tank shall be suitable to handle medium temperature up to 55°C and a pH
of 6.0-8.0.
3.4.5 The GRP tank shall have a wall thickness of at least 3mm.
3.4.6 The tank shall be mounted on a sub-frame of corrosion resistant steel grade to 409
which in turn bolted to the trolley base and shall be within the trolley dimension of
not exceeding 1500 x 900mm.
3.4.7 The GRP tank will have an inbuilt screening system so that the screened Inoculum
can pass from the contaminated chamber to screened chamber. The filtered
Inoculum will pump from GRP screened chamber back to Bio-Toilet tank for reuse.
3.4.8 There should be float switch arrangement of the GRP tank for auto cut-off in case of
“tank full” condition to ensure that there is no spill over during operation.
3.4.9 Manufacturing of GRP tank shall be done complying the requirements , properties
and procedure defined in RCF/Kapurthala’s specification no. MDTS-133 Rev.
latest (Technical specification for hand lay-up FRP component for all passenger
coaches).
3.5 Drive System:
3.5.1 The drive / prime mover will be an electric motor of suitable ratings not less than
2.2 kW. Controls should be utilized to drive the suction pump.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 6 of 12
3.5.2 The motors shall be of standard manufacturers such as Kirloskar, Crompton, Bharat
Bijlee, Seimens etc.
3.5.3 The motor shall be of the following specifications:
i. Single phase AC, 230V/50Hz
ii. Output Rev. – Min.760 rpm
iii. Closed coupled/face mounted gear.
iv. Environmental Protection type: IP-55
v. ISO Class of insulation- F
vi. Duty Class-S1
vii. Type Design: B-5.
3.5.4 The single phase motor should be suitable for reverse operation with adequate
starting torque to start on an on-load condition.
3.6 Tank Mounting
3.6.1 The tank will be mounted on Trolley frame of Warp & corrosion resistant Steel
grade to 409 of not less than 60mm X 30mm and 6mm thickness.
3.6.2 In addition, the holding brackets for the wires and hose pipe shall be on either side
of the tank.
3.6.3 The cable and the pipe holding bracket shall be of min. 40mm width and of 5mm
thickness Section of steel grade to 409.
3.6.4 The main frame section of trolley shall be of 55mm X 35 mm and shall be not less
than 3mm thick of steel grade to 409 (for mounting bracket).
3.7 Pumping System :
3.7.1 The collection tank of machine should able to be emptied by reversing pump
operation and gravity force discharge both. The arrangement has to be leak proof to
avoid any spillage in the non-designated areas. The system should facilitate the
following directions of flow:
i. Sludge including plastic garbage + Inoculum from Bio-Toilet Tank to GRP tank
ii. Liquid effluent + sludge form Bio-Toilet tank to the drainage directly.
iii. Filtered liquid/inoculum from GRP tank to Bio toilet tank for recharging.
iv. Solid waste from GRP Tank to drainage.
3.7.2 The system should be compatible with above drive system of para 3.5.
3.7.3 The suction pump shall be positive displacement rotary lobe type of an ISO 9001 or
any other international standard certified company make suitable of 20-30 start stops
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 7 of 12
per hour or 30 reversing operation per hour.
3.7.4 It shall be suitable to handle solid sludge/waste like napkin, bottle cap, sachets,
wrappers etc., handle fluctuating viscosity from 01 to 20 cP and develop a vacuum
in the range of -0.90 bar to -0.95 bar.
3.7.5 The pump shall be with automatic lubricating oil system.
3.7.6 The application being critical, a proper, reliable and a long life sealing arrangement
is required. The seal should be a cartridge block ring mechanical seal, compact with
all components in a single cartridge to ensure easy and fast replacement.
3.7.7 The pump shall be of low and easy maintenance with one single cartridge for easy,
quick and facilitating proper alignment.
3.7.8 The pump shall have adjustable housing segments for wear compensation, gap
adjustments and long life without any Liners or inserts.
3.7.9 The pump shaft should be step less and of low L/D ratio and with reversible
operation the shaft diameter shall not be less than 45mm for minimal shaft
deflection for intermittent solid pumping and vibrations. The L / D ratio shall not be
more than 2.50
3.7.10 Connector box should be so provided that it is easy to maintain and shall have a
Vacuum gauge mounted on it suitable for the specified medium.
3.8 Suction & Discharge Hose :
3.8.1 Suction hose shall be of approx. 30 Meters length size 62mm (2.5”) with suitable
interface attachment.
3.8.2 The interface attachment shall be designed, in consultation with the User to allow
easy access and insertion into the Bio toilet tank for the waste evacuation within the
allowable space.
3.8.3 The discharge hose shall be of approx. 15 meters length size 62mm (2.5”).
3.8.4 Make of the heavy duty flexible suction & discharge hose- Bevo, Parker, Polyhose,
Tornado, Dunlop etc.
3.8.5 All connectors shall be of Camlock quick coupling type and leak proof.
3.9 Control Panels
3.9.1 The control panel shall be with an On / Off and a Forward and Reverse switch. It
will also have a light indicator for the incoming power.
3.9.2 The On-Off switch and the control box shall be mounted on a MS galvanized plate
of not less than 2mm thickness and shall cover the On-Off switch and the control
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 8 of 12
box on the top as a protection.
3.9.3 All electrical switches/wires will of reputed makes i.e. Crompton, polycab, L&T or
equivalent.
3.10 Vacuum Gauge : Vacuum gauge of 150 mm. dia capable of indicating vacuum
from 0 to 760 Hg shall be mounted on the connector box and placed for easy
visibility.
3.11 Trolley:-
3.11.1 The complete system should be mounted on Pedestrian-controlled, fixed- platform
trolley, Single-axled bolster steering.
3.11.2 For the trolley, the frame will be manufactured to the size and of an all electrically
welded construction of steel grade 409. Complete fabricated trolley shall be power
coated with RAL 5007 shade or equivalent shade for corrosion resistant.
3.11.3 The four wheel trolley shall be of turning arrangement. The trolley shall be mounted
on Solid rubber tyre wheels with 360 degree free movement of size of 16”X4” with
min. 180 mm ground clearance and capable of a load of 1000 Kgs.
3.11.4 Trolley platform : Overall length –1450- 1500 mm
Overall width – 850-900 mm
3.12 Power tool Bag:
3.12.1 One tool box consisting following spanners, keys & electrically/pneumatic power
tool for opening of nut/bolts shall be provided by the contractor with machine &
suitable training to be provided.
i. Screw Driver cum tester - 02 Nos.
ii. Adjustable spanners (6”) - 02 Nos.
iii. Special tool kit - 01 set
4.0 System Working Flow Chart:
4.1 Manufacturer shall provide their system flow chart of the basic logic of the main
system components & system working.
4.2 All necessary control wiring & connections that ensure the system performances
shall be designed by the manufacturer. The manufacturer may use the available
inputs of electric supply. Design requirements of above inputs and requirement of
any special / additional inputs shall be worked out in consultation with consignee
prior to submission of prototype for approval.
5.0 System Interface:
5.1 Mechanical interface:
5.1.1 The system shall be mounted on trolley. The normal structural tolerances of the
components shall be sufficiently accommodated in the design of mountings.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 9 of 12
5.1.2 For all systems, the control panel shall be encased in a small locked box and box
size mounting arrangement and electrical and water inlets/outlets should be clearly
indicated.
5.2 Electrical Interface:-
5.2.1 System components including the cable layout for electricity shall be pre-
assembled and supplied in knocked down condition. All the wiring work within
the system shall be completely concealed from view and properly clamped.
Sketches and description of the proposed piping arrangement shall be provided by
the tenderer.
5.2.2 Colour coded cables should be used. Cables/wires should be numbered.
5.2.3 All Electric wiring shall be covered with conduits to protect from damage.
5.3 Interface with piping arrangement:
5.3.1 System components including the three way valve, intermediate pipe between
pump & three way valve, three way valve & tank, screened chamber & three way
valve etc. shall be pre-assembled and supplied in knocked down condition. All
the pipe work within the system shall be completely concealed from view and
properly clamped. Sketches and description of the proposed piping arrangement
shall be provided by the tenderer.
5.3.2 All pipes and pipe connections shall be completely leak proof & should be fire
retardant material. Valves & isolating cocks shall be located for easy accessibility
for maintenance. It shall be possible to isolate different circuits for repairs without
dismantling.
5.3.3 Different Colour coded pipes & isolating cocks should be used for different works.
5.4 Interface with Bio-Toilet tank.
5.4.1 The interface of the suction hose should suit to interface dimensions of Bio-Toilet
tank opening for evacuation.
5.4.2 The size of the waste collection tank including suction & discharge hose shall
confine to the space available. Supplier shall give details of brackets required.
6.0 Prototype Approval:
6.1 For the first time supplier the prototype approval will be required from the
consignee. In case of any design change prior approval shall be obtained from the
consignee.
6.2 The supplier must also submit the following documents along with prototype for
approval:
6.2.1 System description and installation drawings in sufficient detail to evaluate the
system design.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 10 of 12
6.2.2 Certificates of the material used in the various components of the system.
6.2.3 Complete maintenance manual including troubleshooting and dismantling
instructions in paper and electronic form.
6.2.4 List and likely sources for procurement of spare parts/consumables required for
maintenance.
6.2.5 In case the prototype of the firm has been commissioned and satisfactory trials and
commissioning has been done in the earlier rating supply, the above prototype
approval shall not be applicable unless any change in specification.
6.3 Testing of Prototype:
6.3.1 The testing of prototype should be shown to consignee representative using a test
stand, where the complete assembly can be tested. The supplier must design and
commission a test facility in India for this purpose. The supplier shall prepare a
detailed proforma for all the checks in consultation with consignee. Once this
proforma is finalized, the check shall be carried out as per the prescribed format
for the tests mentioned below. The following parameters are to be tested and
demonstrated:
Dimensional check as per specification.
Proper and leak free connections of water pipelines
Proper working of system control and indications
Collection tank capacity and functioning of screening system
Capacity of the evacuation pump & certification of manufacturer.
Rating of drive system & details of manufacturer as per specification.
Emergency cut-off in case of “Full tank condition”.
Endurance & functioning of testing of system as per clause No. 6.3.2
6.3.2 System should provide uninterrupted service for suction/evacuation/blowback of
200 systems. No malfunctioning/abnormality/failure of any component should be
reported during this period.
6.3.3 After qualifying of the testing of the prototypes in a suitable test facility, the
system shall be installed and commissioned in consignee’s premises and subjected
to field-trials for a minimum period of three months and after its satisfactory
service performance has been proven, the vendor can be considered for approval
for further orders. The supplier shall supply consumables for 3 months use along
with the supplies for field trials.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 11 of 12
7.0 Installation & Commissioning:
7.1 Installation & commissioning of the prototypes shall be carried out by the supplier
at consignee’s premises after prototype testing is completed.
7.2 The installed and commissioned systems shall be checked for functionality after
which prototype shall be finally approved.
8.0 Scope of Supply:
The complete machine covering following units will be in the scope of supply:
Suction pump
Drive system.
Suction and discharge pipe
Three way valve and Isolating cocks.
Storage tank with inlet & discharge arrangement.
Control panel & associated ancillaries for the system operation.
Trolley with frame
9.0 Delivery:
9.1 The supplier shall indicate the delivery period. Deliveries made earlier may be
accepted as per consignee’s convenience.
9.2 Before commencing supplies, specifications indicating functional and technical
details of the system shall be submitted by the firm for approval. The fitment
drawings shall clearly indicate dimensions critical for proper functioning of the
system. Specifications of critical components shall also be pre-approved by
consignee. Notwithstanding any such approval, the supplier shall stand fully
responsible in respect of design, manufacture and serviceability of the complete
system.
9.3 The supplier shall assist consignee in developing the interface of the Evacuation
machine with the Bio-Toilet tank.
9.4 Consignee may ask the supplier at this stage to undertake modifications to the
balance supplies, if considered necessary by them. These changes shall be
incorporated in the drawings and specification and advised to consignee within the
time period given by consignee.
9.5 After successful installation, the remaining supplies shall be delivered.
10.0 Inspection: 10.1 The inspection of the supply will be done by the consignee’s representative at the
firm’s premises in India where prototype testing facilities have been set up.
Signature
Name & Prepared By: Checked By: Approved By:
Designation SSE/Mech./CAMTECH Dir/Mech./CAMTECH ED/CAMTECH
Spec.:-CAMTECH/M/SUCTION SYSTEM/Bio/1.0 Date of Issue: March-2017 Page 12 of 12
10.2 Inspector may also conduct some or all of the tests specified for prototype testing
on samples taken from the lot under inspection. This sample size shall not be more
than 10% of the lot under inspection.
11.0 Guarantee:
11.1 The equipment shall be under warranty for any manufacturing defect for a period
of 30 months from the date of manufacturing or 24 months from the date of
commissioning, whichever is earlier.
11.2 In the event of 'non-satisfactory performance' of any of the items as indicated
above, supplier will have to replace the same at his own expense without levying
any cost involved in transportation, handling and replacement of such items on the
Purchaser.
11.3 The supplier must express his willingness to enter into an Annual Maintenance
Contract for a 3 years period after expiry of guarantee period. Indian Railways and
tenderer will separately or mutually decide terms of this AMC.
12.0 Marking:
Manufacturer’s name with the serial/batch number and month, year of manufacture
shall be marked at a visible location for identification on major components.
Notices for users and maintenance personnel shall also be supplied for fixing in the
system, as decided between the supplier and consignee.
13.0 Training:
The Supplier shall provide training to personnel of Indian Railways in installation,
operation trouble-shooting, repairs and preventive maintenance of the system at his
cost. This training should be for 100 man-hours minimum.
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