FUNCTIONAL REQUIREMENTS FOR DEVELOPMENT OF SPECIFICATION ... C1... · FUNCTIONAL REQUIREMENTS FOR DEVELOPMENT OF SPECIFICATION OF ... functional, design requirements by the ... functional

Ref: CG-WI-4.2.4 Ver. 1.0

Page 1 of 9 Date of issue: 03.04.2017

EOI NO. CARR-SS-02 Annexure C1

INDIAN RAILWAYS

FUNCTIONAL REQUIREMENTS FOR DEVELOPMENT OF SPECIFICATION OF BIO-VACUUM TOILETS FOR NEW LHB

TYPE COACHES.

S.No. Month/Year of issue

Revision / Amendment Page No. Reason for Amendment

1. April 2017 Nil N A First Issue

Issued By: Carriage Directorate

Research Designs and Standards Organization Manak Nagar, Lucknow - 226011.




FUNCTIONAL REQUIREMENTS FOR DEVELOPMENT OF SPECIFICATION OF

BIO-VACUUM TOILETS FOR NEW LHB TYPE COACHES.

1. Preamble : Fitment of vacuum toilets along with bio digester in LHB type coaches is proposed in new coaches. Operational, functional requirement of the vacuum toilets along with bio digester are listed in respective sections of this document.

For fitment of vacuum toilet along with bio digester in LHB type coaches, proposals may be submitted covering all aspects as listed under operational, functional, design requirements by the manufacturers of vacuum toilets or their authorized representatives. List of drawings applicable for lavatory modules of LHB type coaches are listed as annexure-I can be taken from RCF / Kapurthala.

2. Scope : This specification covers operational, functional requirements for development of specification of bio-vacuum toilets for new LHB type coaches. Bio-vacuum toilets shall be customised with existing lavatory module being fitted along with bio digester.

3. Functional Requirements 3.1. Vacuum toilet system shall be installed within the space envelope earmarked.

The space envelope for control panel and tank location etc. of LHB type coaches is shown in RCF drawing No. MI005426 & MI005710 respectively.

3.2. LHB type coaches have different combination (Indian squat pan type and western commode type) of toilets having 2, 3 or 4 toilets. Proposed design of the vacuum toilet system should be suitable for application on all LHB type coaches. its fitment should be done without losing coach / lavatory module aesthetics and ensuring serviceability.

3.3. Irrespective of coach type, the toilet system must meet the following objectives: a) Clean, odour-less, hygienic and aesthetically pleasing toilet. b) No discharge of untreated waste. c) No spillage of waste on the bogie parts, under gear, track, waste

processing tank or in depot. d) Effluent discharge criteria as defined for IR-DRDO bio toilets.

3.4. The toilet system should be of robust design, reliable, safe, simple to operate and passenger friendly and require minimum maintenance. It has to be a proven design suitably modified to match Indian condition and passenger habits.

3.5. The design of the toilet system should have protection from pilferage and Components used in vacuum toilet system shall be made of corrosion resistant material having intended service life of 35 years except




consumables or moving parts having wear and tear even these should have minimum four POH life (6 years).

3.6. The equipment should neither impede free movement of the bogies, nor the routine inspection & maintenance of various bogie/coach sub-assemblies. To ensure this the system should be contained within the space envelop as mentioned earlier.

3.7. The maintenance requirement of the toilet system should be clearly spelt out by the supplier.

3.8. The system should be able to handle normal waste and even some foreign objects thrown in and which are smaller than the toilet bowl outlet hole (such as bottle caps, napkins, plastic bags & cups etc.) either by segregating or suction by the pump into the tank. The water consumption shall be minimum, with I00% cleaning of the commode or pan {with 0.5 liter (min.) to 0.8 liter (max.). water per flush}. The system should have the facility to adjust water consumption further to a lower or higher value, if required.

4. Scope of work: Fitment of vacuum toilet in existing lavatory module shall be interfaced with existing bio-digester already fitted by Indian Railways in LHB type coach. Scope of work shall be as specified below.

4.1. The main system components would be: a) Lavatory pan/ bowl (Indian squatting/ Western design). b) Vacuum toilet system and pressurised flushing arrangement including

interfacing for supplies like water & compressed air etc. c) Control panel and associated accessories for the system operation. d) Associated water hoses, pneumatic piping and electrical wiring etc. e) Any other material and interface required with coach systems to make

the vacuum toilet fully functional & operational. 5. Operating Conditions

The vacuum toilet system should function efficiently under following operating conditions.

5.1. Ambient Conditions: (i) Altitude : Sea level to 2500m (ii) Operating temperature : 1oC to 55o

Max. Temperature under Sun : 70° C C

(iii) Relative humidity : upto 95% (iv) The rainfall is fairly heavy. (v) During dry weather, the atmosphere is likely to be dusty. (vi) Temperature variations can be quite high with-in range specified in the

same journey or short period of time. (vii) Coaches operate in coastal areas with continued exposure to salt laden

air.




(viii) Coaches may be subjected to frequent external washing with

detergents and cleaning of toilets by cleaning agents.

5.2. Water Supply: There is one tank of 30 ltr capacity available over each toilet at a height of about 2030 mm from toilet floor in air conditioned coaches. Water is pumped to these from under-frame mounted main water tanks. Water-flow to the flushing valve is by gravity. These tanks are not pressurized and the water flow from these tanks is by gravity.

5.3. Pneumatic Supply: 5.3.1. A limited quantity of air supply of around 15 lit/min./Coach can be made

available at around 6 Kg/cm2

5.3.2. It is desirable that at least minimum number of 2 (two) usages are feasible in the absence of air supply i.e. when the air supply as specified in clause No. 5.3.1 is cut-off.

for the toilet system, Requirement of compressed air per toilet used and per coach should be specified. Presently only two toilets at one end of the coach shall be of vacuum type.

5.3.3. There is a provision of one 75 ltr. reservoir in the coach exclusively for toilet system, which can be used to comply with clause No. 5.3.2. This reservoir is connected to feed pipe at 6 kg/cm2

.

5.4. Power Supply: 5.4.1. 110 Volt DC power supply is available in coaches. If any power is required,

the equipments be so designed to withstand 30% voltage fluctuations. DC- DC converter fitted should be of a reputed and established brand or made in-house and be able to withstand +/- 30% voltage fluctuations, 2 KVA surge, +/- 10% ripple and complying with IEC 60571 or any equivalent international standards. Industrial Grade Components are to be used in all electrical /electronic items. Total peak power requirement per coach shall not exceed 600 watts.

5.4.2. Requirement of power shall be clearly specified by the supplier.

5.5. Car-body dynamics: 5.5.1. Equipment shall withstand satisfactorily the vibrations and shocks normally

encountered in service as indicated below: i) Maximum vertical acceleration 1.0g ii) Maximum longitudinal acceleration 3.0g iii) Maximum transverse acceleration 2.0g

The vibrations are of sine wave form and the frequency vibration is between 1 Hz to 50 Hz. The amplitude ‘a’ expressed in millimeters is given as a function of f, by equations

a = 25/f for values of f from 1 Hz to 10 Hz.

a = 250/f2 for values of f exceeding 10Hz and up to 50 Hz.




5.5.2. In the direction corresponding to the longitudinal movement of the vehicle,

the equipment is subjected for 2 min. to 50 Hz. Vibrations of such a value that the maximum acceleration is equal to 3g.

5.5.3. LHB type coach length over coupler is approximately 24 meters. 5.5.4. Coach-body displacement encountered under dynamic conditions.

i) Vertically- ±100 mm

ii) laterally - ±55 mm

iii) longitudinally- ±10 mm

iv) bogie rotation about center pivot- ±4

v) Maximum Speed of train - 160 KMPH

0

5.6. Duty Cycle:

The toilet should be ready within maximum of 2 minutes after each use. One toilet may be used upto 50 times for defecations and 200 times for urination in 24 hrs.

6. DESIGN REQUIREMENT 6.1. The system offered must be modular and must be supplied as a complete

system to handle human waste as specified. It should take minimum possible time for replacement of modules. The supplier should indicate replacement time module wise. Since these vacuum toilets are proposed for fitment on newly built coaches only with minimal changes in existing lavatory module or coach structures.

6.2. The technical implications / reasons for capacity rating of important components of the system must be explained in detail by the supplier. Similarly, critical dimensions in the fixing & location drawings shall be clearly indicated by the supplier together with details of all mechanical and electrical interfaces between toilet system and the coach.

6.3. The system should be so designed that day to day maintenance does not require contact with waste by maintenance personnel. Before extensive repairs, complete evacuation and flushing of the system should be possible.

6.4. The supplier must indicate the consumption of power, air, water & cleaning chemical if any, each usage and hourly basis by the toilet system offered.

6.5. Flushing System: 6.5.1. The vacuum suction system and the design of toilet bowl should be such that

the toilet can be cleaned / flushed properly with minimum possible water consumption. System should be designed such that it can work satisfactorily with reduced level of normal vacuum level and it should be possible to increase the level of vacuum in case of choking etc.

6.5.2. Toilet flushing system should be pressurized. Water supply for flushing may contain dirt and other suspended impurities. Water filter need to be provided to ensure trouble free operation of flushing system. Maintenance free and leak proof, Isolating valve is to be provided for filter cleaning.




6.6. Water pressurizing unit

Water at a pressure of 4 bar or more should be used for efficient flushing of entire toilet bowl through nozzles. For this purpose electro pneumatic water pressurizer should be used.

6.7. TOILET PAN/ BOWL /Trough Floor 6.7.1. Toilet Pan/Bowl

a) In Western style toilets, a good quality toilet bowl of stainless steel to AISI 316L or superior (surface finish no. 7 or better of IS:6911-92 Tab. No. 8) with strong mounting and proper fittings will be provided. Seat and seat covers will be non metallic and will be made of Nylon or a superior Non Metallic material suitable for intended use with ruggedness. Height of the seat may be 400 to 425 mm above the toilet floor

b) Requirement of Indian style toilet pan will be similar to RCF Drawing no. LE63202 alt. 2 or latest of stainless steel to AISI 316L or superior.

c) Toilet pan / Bowl of Indian style and western commode style toilets shall be interfaced to existing provisions.

d) Drawings referred in the specification are representative in nature. Purchaser may ensure the issue of applicable drawings.

6.7.2. The diameter of the toilet bowl outlet hole should be 35 to 45 mm and shall be so designed as to prevent any obstruction in outflow of waste. The waste should never be visible or flow backwards into the bowl even in cases of malfunctioning.

6.7.3. The toilet system must be provided with an effective sealing arrangement of a proven design to ensure the sealing of odour from the waste tank to the toilet room. This condition must be satisfied not only during normal operation but also when there is loss of air or power or both.

6.7.4. In case of malfunctioning of the toilet the indication shall be provided so that the passengers refrain from using it.

6.8. BIO DIGESTER TANK 6.8.1. Bio digester tank shall be provided by the railway authorities to the applicable

design for LH and RH side . Vendor / supplier shall be required to ensure that they have acquired sufficient know how of IR-DRDO bio digester for interfacing vacuum toilet to the existing bio digester.

a) Interface System with bio digester should be so designed and manufactured that no unprocessed waste should spill, leak or overflow from the waste retention tank either during run or during maintenance in Depot.

b) Details of mounting arrangement to be worked out by supplier in consultation of purchaser with clearly indicating the scope of work.

6.8.2. List of Drawings applicable for provision of IR-DRDO bio digester in LHB type coaches are attached as annexure 1. Drawings listed at annexure 1 are for




reference purpose only, Intellectual property rights of Designs /Drawings shall remain with Indian Railways.

6.9. CONTROL PANEL 6.9.1. The control unit will be of sealed, modular and plug in type for easy fitment

and maintenance and will be inside the coach. The supplier shall indicate its size, location and fixing arrangements suiting to existing provisions made in lavatory module and coaches. The control panel should be provided in the space mentioned in the RCF drawing no. MI005425 alt. Nil.

The unit must have the following characteristics:

i. Maintenance friendly modular design ii. Rugged construction to withstand vibration, heat & dust of IR coaches iii. PLC system or microprocessor based module to allow adjustment of

variables such as flush water volume and utilization counter for number of toilet flushes.

iv. All electrical and pneumatic devices and connections on control panel should be plug in type.

v. All the electronic module of Control Panel should confirm to IEC 60571 or any equivalent international standards. Industrial Grade Components shall be used in all electrical/electronic items.

vi. Control panel, should be enclosed inside an SS box with lockable opening doors/ panel (Preferably special tooling for locking and unlocking) and should conform to IP 54.

vii. Manual override switch in the control panel be provided to operate the valves in case of emergency.

viii. It should be able to monitor as well as provide alarm /indications in case of the following: i) Failure of Compressed air supply ii) Failure of Water supply / shortages iii) Indication of Electrical supply iv) Vacuum failure and blockage in the system

6.9.2. Using the control panel, it should be possible for an authorized person to adjust air supply / pressure, vacuum level etc.

6.10. VACUUM GENERATION 6.10.1. Reliable and easily maintainable ejector should be used for vacuum

generation to achieve optimal capacity with least possible air consumption. Vacuum control switch should be provided, which will automatically start the ejector if the vacuum level decreases below the preset level.

6.10.2. A filter should be provided to prevent foul smell when the ejector is activated. The filter should be suitably located for easy replacement.




7. VALIDATION OF DESIGN PROPOSAL.

The supplier shall submit the complete details of the proposed bio-vacuum toilet system including layout drawings, interfaces required, integration requirement, operation and maintenance manual including requirement of spares and consumables for evaluation by RDSO.




Annexure

S.No.

-1

Drawings listed for Lavatory module of LHB type coaches are for reference purpose only, Intellectual property rights of Designs /Drawings shall remain with Indian Railways.

Drawing No. Description 1. MI005710 Mounting of IR-DRDO bio-digester system on LHB

coaches. MI005711 Mounting of IR-DRDO bio-digester system

on LHB coaches(RH) 2. MI005426 The space envelope for control panel 3. LE63202 Requirement of Indian style toilet pan 4. 1 10113.0.30.000.002 Sanitary facilities complete chair car 5. 1 10112.0.30.000.002 Sanitary facilities complete exec chair car 6. 1 10112.0.30.000.004 lavatory module euro 1 mounting

7. 1 10113.0.30.000.003 lavatory module orient mounting

8. 1 10113.0.30.000.005 lavatory module euro 2 mounting

9. 1 10112.0.30.000.014 lavatory module euro 1 complete

10. 1 10113.0.30.000.013 lavatory module orient complete

11. 1 10113.0.30.000.015 lavatory module euro 2 complete

12. 1 10112.0.30.100.005 pipe laying for water in lav module euro 1 complete

13. 1 10113.0.30.100.006 pipe laying for water in lav module euro 2 complete

14. 1 10113.0.30.100.007 pipe laying for water in lav module orient complete

15. 1 10113.0.30.100.004 pipe laying for water under the coach

16. 1 10113.0.30.100.003 pipe laying for water in the body of the coach

17. 1 10113.0.30.110.006 roof water tank mounting 30 L NPP end mounting

18. 1 10113.0.30.110.007 roof water tank mounting 30 L PP end mounting

19. 1 10113.0.30.130.002 lavatory equipment euro 2 mounting

20. 1 10113.0.30.130.003 lavatory bowl orient mounting.

21. 1 10113.0.30.130.005 lavatory bowl European mounting

Note : All the drawings should be read with latest alteration applicable only.

FUNCTIONAL REQUIREMENTS FOR DEVELOPMENT OF SPECIFICATION ... C1... · FUNCTIONAL REQUIREMENTS FOR DEVELOPMENT OF SPECIFICATION OF ... functional, design requirements by the ... functional

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