TECHNICAL SPECIFICATION FOR

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 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.

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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

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“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.

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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.

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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.

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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

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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

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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.

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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.

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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.

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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.

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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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TECHNICAL SPECIFICATION FOR

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