SMP#: 436001 Rev. 8 Effective: September 28, 2010 Page 1 of 14 ...

SMP#: 436001 Rev. 8 Effective: September 28, 2010 of 14

NJ TRANSIT MECHANICAL DEPARTMENT

STANDARD MAINTENANCE PROCEDURE

Subject: Microphor Toilet Inspection and Servicing - Arrow, Comet, & Multi-Level Equipment Number: 436001 Revision: 8 Effective: September 28, 2010 Supersedes: Rev. 7 of January 27, 2009

The following approvals were obtained prior to the issuance of this procedure:

Director Quality Assurance

Director Technical Services

Superintendent Cars

Senior Director QA / Technical Services

General Superintendent Equipment MMC

General Superintendent Equipment Field

I. GENERAL SAFETY PRECAUTIONS

Applicable safety rules governing M of E Employees are to be followed: Rail Employee Safety and On-track Safety Procedure Manual (TRO-5), with special attention to TRO-5 Rule 9 - Blue Signal Safety Rules for Mechanical Department Personnel; Electrical Operating Instructions (TRO-3); and the Air Brake and Train Handling Rules and Instructions (TRO-4).

IMPORTANT: NJ Transit requires employees to wear appropriate Personal Protective Equipment (PPE) when performing these duties. The PPE listed below is the minimum required. When performing duties requiring the use of chemicals, employees must wear appropriate gloves and eye protection, and any additional PPE recommended on the Material Safety Data Sheet (MSDS). Always observe all safety precautions provided on product labels and/or MSDS. For further direction, see your supervisor. 1. Approved Hard Hat 2. Approved Safety Glasses, Goggles, or Full Face Shield 3. Approved Protective Gloves 4. Approved Work Boots 5. Disposable Particulate Respirator (if recommended in MSDS) 6. Disposable Ear Plugs (if noise exceeds 85-90dB) 7. Reflective Vest (when walking through yard facilities) 8. Chlorinator Inspection & Microculture Record, form Y2221-4/10

The user of any printed copy of this controlled document is responsible for verifying that it is the current version prior to use. The current version is available on

the NJ Transit network; on the “N” drive in the folder “QA Mech,” and may be accessed by any network computer.


WARNING: PUNCTURE RESISTANT GLOVES (NJT P/N 46-389666-0) SHOULD BE USED WHILE HANDLING TRASH OR PICKING UP TRASH AND/OR SHARP OBJECTS FROM SEATS, FLOORS, OR VESTIBULE AREAS.

DANGEROUS VOLTAGES ARE PRESENT THROUGHOUT EQUIPMENT. TO PREVENT INJURY OR DEATH FROM ELECTRICAL SHOCK, EXERCISE EXTREME CARE WHEN WORKING IN CLOSE PROXIMITY OF ELECTRICALLY CHARGED APPARATUS, OR WHEN MAKING CURRENT MEASUREMENTS. SHUT OFF ELECTRICAL POWER TO THE CAR WHENEVER CONTINUITY IS TO BE TESTED.

MAKE SURE THE AREA IS WELL VENTILATED WHEN WORKING WITH MATERIALS, WHICH PRODUCE HARMFUL FUMES.

ALL TOOLS AND PARTS MUST BE REMOVED FROM THE WORK AREA BEFORE POWER IS TURNED ON TO THE EQUIPMENT TO AVOID SHORT CIRCUITING OR DAMAGING THE EQUIPMENT. TOOLS MUST BE COUNTED BEFORE AND AFTER ANY MAINTENANCE PROCEDURES ARE PERFORMED.

Before working, employees must secure equipment against movement.

CLEAN-UP OF BLOOD CONTAMINATED MATERIALS OR SPECIFIED HUMAN BODILY FLUIDS Observe “Universal Precautions” (assume that all human blood and specified human body fluids are infectious for HIV, HBV, and other blood borne pathogens). For the clean up of blood contaminated materials, use Bio-hazard spill kits (item No. 46-561751-0). Refer to NJ TRANSIT Rail Blood borne Pathogens – Exposure Control Plan (BBP-ECP) for detailed procedures for the clean up and disposal of human blood and specified human body fluid contaminated materials. A copy of the BBP-ECP should be kept at every NJT Rail location. It can also be found on the “N” drive in the “Rail SAFETY/Blood borne Pathogens” folder.

II. PURPOSE

This document provides the standards for inspecting and servicing Microphor toilets on all equipment during each Calendar Day Inspection, 21 Day Inspection, and Periodic Inspection.

III. POLICY

It is NJ TRANSIT'S policy to properly inspect and service all Microphor toilets on all equipment during each Calendar Day Inspection, 21 Day Inspection and Periodic Inspection.


IV. EQUIPMENT/MATERIALS/TOOLS

1. Microphor Micro Clean, NJT P/N 47-137113 2. Microphor Microculture, NJT P/N 47-210009 3. Chlorine Removal Tongs, NJT P/N 45-724091 4. Microphor Chlorinator Cleaning Brush P/N 94496 5. Chlorine slugs, NJT P/N 47-130906 6. VITON ‘O’ ring, NJT P/N 24-525970 7. Silicone‘O’ ring lubricant, 1cc tube, NJT P/N 47-395524 8. Chlorinator Inspection & Microculture Record, form Y2221-4/10

(Can be obtained through Staples forms program) 9. Silicone based oil, NJT P/N 12-132658 10. 5/32” Allen key (for timing adjustment) 11. Spare Chlorinator Cap, NJT P/N 24-119000 12. Chlorine Tablet Holder NJT P/N 24-387201-0 13. Chlorinator Inspection & Microculture Record, form Y2221-4/10

V. TOILET INSPECTION AND SERVICING PROCEDURES

A. CHLORINATOR INSPECTION AND SERVICING PROCEDURES PERFORMED DURING THE CALENDAR DAY INSPECTION (FIELD LOCATIONS)

The following procedures must be followed when inspecting and servicing toilets on Arrow, Comet and Multi-Level equipment during the Calendar Day Inspection: 1. All toilets must be inspected and serviced during the Calendar Day Inspection.

2. Test the operation of all toilets and make sure that they are working properly.

3. Add water to the car’s water tank.

4. A) Visually inspect the ‘Chlorinator Inspection / Microculture Record’ (Form Y2221-

Figure 7) and determine if the chlorinator has been inspected within the last 21 days. Physically check the chlorine tablets by pulling the chlorinator rack out to verify number of tablets and if any is bridged (if bridged tap rack to get tablets to drop to bottom of rack, and then add tablets to bring to a maximum of 6 tablets as intended). If there is no rack and tablets are in the neck of the tank, all tablets must be removed, and the rack must be installed.

5. If no ‘Chlorinator Inspection / Microculture Record form’ is present, the chlorinator must

be inspected and a new form affixed to Access Panel. Microculture must also be added.


B. CHLORINATOR INSPECTION AND SERVICING PROCEDURES PERFORMED AT THREE WEEK INTERVALS (21 day service) (FIELD LOCATIONS)

The chlorinator must be inspected and serviced at least once every three weeks as indicated below:

1. While wearing rubber gloves, check the chlorinator for chlorine.

Note: Chlorine Slugs may be re-used provided they are at least 75% of their original size and are not broken (1” Thick minimum).

2. Physically check chlorinator rack for number of tablets by pulling the rack out of the

tank (A single tablet can be hung up (this is called a bridge) in the top of the chlorinator rack giving the appearance that the chlorinator is full).

3. Inspect the chlorinator’s ‘VITON’ (brown) ‘O’ ring for damage and replace as necessary.

Each time the chlorinator is inspected, this ‘O’ ring must be lubricated using only Silicone lubricant, NJT P/N 47-395524. Do not use a petroleum or lithium based lubricant, as they will react with the chlorine and cause premature failure of the ‘O’ ring.

4. Inspect the chlorinator cap and external fitting body for breaks or cracks and replace if

damaged (NJT P/N for the chlorinator cap is 24-119000). If the neck of the chlorinator is damaged, preventing the cap from sealing correctly, this must be reported so arrangements can be made for the car to be shopped and all repairs can be made.

5. Record the service results of the chlorinator on the ‘Chlorinator Inspection / Microculture

Record’ (Form Y2221-Figure 7) form. This form is affixed to the inside of the Air Water Sequence Valve Access Panel. When serviced, the date, location, and inspector’s name must be entered on the form.

6. Unless effluent is already observed dripping from the discharge pipe, flush the toilet

sufficiently but no more than 25 times until effluent discharge is visible. Re-inspect after 15 to 20 minutes, if necessary, to verify that the effluent is discharging through the discharge pipe. If no effluent discharge is present through discharge pipe, or if effluent discharges from the tank vent, the tank is likely clogged and the chlorinator needs to be checked as follows:

7. Physically check chlorinator rack for number of tablets by pulling the rack out of the

tank (A single tablet can be hung up (this is called a bridge) in the top of the chlorinator rack giving the appearance that the chlorinator is full).

a. Inspect the inlet of the primary chlorinator using a mirror and flashlight for clogs in the Chlorinator. If sludge or chlorine residue is present, a hook or wire (i.e. coat hanger) must be used to break it up and/or remove it.

b Once the chlorinator is clear, flush the toilet approximately 25 times to ensure the effluent

discharge begins dripping. If no discharge is present, or foreign material / sludge is found at the primary chlorinator (blocking the inlet), the toilet tank requires additional maintenance and must be reported so arrangements can be made to shop the car, and all repairs can be made.

c If discharge is dripping from the vent and no clog is visible at the chlorinator, the tank may

be full. If the facility is equipped with a pump truck, the tank should be pumped out and retested. (See Section C for pump out of tank)


8. Add Microculture to the system as follows:

a. Make sure the toilet bowl has water in it, then place one 8-ounce bag of Microculture (see photo below) (NJT# 47-210009) in the toilet bowl, (the plastic bag dissolves in water). Allow to dissolve for 30 seconds. If needed, add water to the bowl using a bucket, jug, etc.

b. Flush twice. Only one bag is necessary.

c. Record Microculture servicing on the ‘Chlorinator Inspection / Microculture Record’ (Form Y2221 - Figure 7). This form is affixed to the inside of the Air Water Sequence Valve Access Panel. When Microculture is added, the date, location and inspector’s name must be entered on the form.

8. If the restroom is equipped with floor Drain, open the valve under the car (in the area

below bathroom) (SEE FIGURES 8, 9, AND 10) to ensure that the accumulation of water on the bathroom floor drains is evacuated.

C. TANK PERIODIC INSPECTION PROCEDURE PERFORMED DURING A 92 DAY OR 180

DAY PERIODIC INSPECTION (PUMP-OUT/VACUUM TANKS)

*Attach a sewage pump-out/vacuum truck connection to the P/N 94370 3” slide valve to the open position on the tank and drain the tank completely.

FIGURE 1 - Vacuum Truck FIGURE 2 - Water Hose thru Cleanout

Port and 3” Slide Valve Drain


WARNING! Vacuum truck tank must be vented before positive displacement pumping is performed.

* Close the slide valve after the tank has been drained (See Figures 1 and 2).

1. While wearing rubber gloves and a fitted respirator, remove all chlorine slugs/solid pieces from the primary chlorinator with Chlorine Slug Removal Tongs P/N 94495.

Note: Previously used chlorine tabs must be disposed of properly as hazardous waste. Be sure to close the primary chlorinator cap when finished Important: Any damaged chlorinators must be replaced at this point! * MAXIMUM OF six SLUGS IN CHLORINATOR Note: While chlorine rack is out you should flush chlorinator neck until clear discharge comes out of discharge. Chlorine Slugs may be re-installed and re-used in the system after cleaning of the used slugs provided they are at least 75% of their original size and are not broken (1” Thick minimum).

2. Add 2-guarts (2 Bottles) of Micro Clean (NJT P/N 47-137113) to the waste tank by pouring it in through the toilet. Allow system to soak with the Micro Clean for a minimum of 15 minutes to aid in breaking up any sludge

FIGURE 3 Brushing Chlorinator FIGURE 4 Chlorinator Brush 3. Apply city water pressure to the tank only for 3 minutes (@15 gpm) to begin the initial tank flushing.

Remove the chlorinator cap and brush the inside of the chlorinator thoroughly using the P/N 94496 Chlorinator Cleaning Brush bent and formed as required (See Figures 3 and 4), and use the hose to rinse out the inside of the chlorinator. Replace the chlorinator cap when finished brushing.

Note: Effluent will begin dripping faster out the discharge pipe (See Figures 5).


FIGURE 5 – Discharge pipe FIGURE 6 - 1 ½” Slide Valve Assembly 4. Turn on water supply hose once again and flood the tank up to one inch below the vent pipe. Open the

3” slide valve and pump out the waste tank. After the water is pumped out of the tank, do not forget to close the 3” slide valve.

NOTE: Open the 3” slide valve and drain the upper primary treatment tank completely. If water does not leak out of discharge, then close the 3” slide valve when the tank is drained. Repeat twice, If discharging continues. If no discharge is present, the tank must be dropped.

5. Open the Slide Valve on the effluent discharge piping and drain the rest of the tank completely. Leave this slide valve open. (See Figure 6)

6. Once the upper primary treatment tank is fully drained, close the 3” slide valve then remove the vacuum truck attachments and replace the end cap on the valve elbow assembly. Note: You must verify that the 3” slide valve is operational and closes completely. If not, remove it from the tank and rebuild or replace it before putting the tank back into service.

7. Open the slide valve on the effluent discharge piping and allow the rest of the tank to fully drain.

Remove the slide valve assembly and vacuum truck/hose attachments from it when the flow has slowed/stopped and it is safe to do so.

8. Replace any guards/shrouds/piping/fasteners removed during the tank cleaning process. Replace all

previously removed plastic cleanout port plug(s) using plastic compatible thread sealant Note: effluent discharge pipe may be dripping, which is normal. (figure 5)

9. While wearing rubber gloves and a fitted respirator, refill primary chlorinator with Chlorine Slugs to top

of rack (see picture Below), being careful not to tumble them, they are to be lying flat atop one another -Maximum of 6 tablets. Inspect chlorinator cap and o-ring for condition, lubricate/replace cap and o-ring (silicone lubricant only) as necessary, and re-apply system power.


Notes:

1. The date on the toilet tank must be checked. If the tank is more than 2 year old, inform your supervisor.

2. During an ABPI, the tank must be dropped and cleaned.

Note: When dropping tank, wires are to be DISCONNECTED, NOT CUT!

10. Check the toilet for proper operation and look for any leaks.

11. Ensure that effluent drips from discharge pipe, and not the vent pipe. 12. Test the operation of the flapper. If the flapper seal is damaged or bubbles are present, replace the seal

using NJT# 24-678631. 13. Inspect the treatment tank assembly and connections for leaks, deterioration or other damage. If the

service date stenciled on the treatment tank is two years old or more, the tank must be dropped and sent to the treatment tank service shop


Note: When dropping the tank, the wires are to be DISCONNECTED WITHOUT CUTTING!

14. Check the toilet sequence valve for proper timing and operation.

If the flapper remains open for longer than 8 seconds’, adjust the sequence valve timing (see Fig. A, right), or replace the timing orifice. To adjust, use a 5/32” Allen key in the location shown, and turn clockwise for a longer flush cycle, and counter-clockwise for a shorter flush cycle. The total sequence time from flush to fill is about 30 seconds. If necessary, clean or replace the Bleed-Off Plug, using Microphor P/N 30382-3.

15. Check the lubricator oil level - it should be at the FULL mark. Add oil, if necessary, using NJT P/N 12-132658.

16. Check the oil regulator and ensure that it is set at 1 drop per flush.

WARNING! BEFORE OPENING THE OIL CONTAINER, CLOSE THE AIR VALVE AND BLEED THE AIR FROM THE SYSTEM.

17. Inspect the oil regulator filter for leaks, dirt or moisture in the filter.

18. Inspect toilet accessories.

19. Test lavatory sink for proper operation and inspect it for any leaks.

20. Test the operation of the faucet. Replace it if defective.

21. Test the sink and make sure it drains properly and does not leak.

22. If the restroom is equipped with a floor drain, use a small amount of water to test the drain.

(ensure that the accumulation of water on the bathroom floor drains is evacuated by opening valve) (See figure 8, 9, and 10).

23. Inspect the soap dispenser, toilet paper holder and mirror, replacing any damaged, or missing items.

24. Check heat trace electrical circuit. Inspect all heat traces to and from the treatment tank. Insulated

and wrapped heat traces to protect from debris. One must properly terminate and protect the heat trace ends. If not, repair as necessary.

25. Inspect the P trap behind the toilet and ensure that it is present and not damaged. Replace it if found

defective or missing.

26. Inspect the toilet piping insulation and make sure that it is not missing or damaged. If insulation is missing or damaged, replace it. Check the heat tape for proper electrical function.

27. Add Microculture to the system, as required in Part C. (1 Bag with 2 flushes to make sure Bio has

started)

Figure A


D. UNSCHEDULED SHOP REPAIRS

In the event that a car with a toilet is brought to the shop for unscheduled repairs and the date of the next Chlorinator service is within seven days, the 21-Day Chlorinator Inspection / Microculture Servicing Procedures (part B, above) must be performed.

E. TOILET TANK EFLUENT VENT SPILL CLEANUP

• Cleaning-up Small Spills that contain Fecal Matter Minimum Required PPE:

Hard hat Work shoes Approved Rubber gloves Safety Glasses

Cleanup the area and disinfect with Quaternary Ammonium Salt. Item# 47-256024-0 for concentrate solution Item# 47-256032-0 for spray bottles

• Cleaning-up Large Spills that contain Fecal Matter Minimum Required PPE:

Hard hat Work shoes Approved Rubber gloves Safety Glasses Disposable Coveralls Disposable boot covers

Cleanup the area and disinfect with Quaternary Ammonium Salt and wash down the area with water.

Item# 47-256024-0 for concentrate solution Item# 47-256032-0 for spray bottles

• Cleaning Equipment contaminated with fecal matter Minimum Required PPE:

Hard hat Work shoes Approved Rubber gloves Safety Glasses *As a precaution, prior to pressure washing, disinfect the equipment with Quaternary Ammonium salt.

Item# 47-256024-0 for concentrate solution Item# 47-256032-0 for spray bottles


FIGURE 7


Figure 8 (Comet IV) Figure 9 (Comet V)

Figure 10 (Comet ML)


SMP REVISION LOG

Revision# Date Description of Revisions Originator

5 6/23/06 Add toilet tank cleaning procedure. DKM

5a 8/31/06 Corrects typo (O-ring lubricant P/N) and add NJT P/N for Micro clean. Add new chlorinator / Microculture form.

VV

6 9/26/07 Remove toilet tank cleaning procedure for separate SMP (436002).

VV

6 “ Remove requirement for respirator, as directed by Safety Dept.

JPK

6 “ Added section D for unscheduled shops RML

6 “ Step C.4. Remove wording “or if date will exceed one year at next 92day PI.”

EJB

7

Addition of Cleanup of fecal matter FC

7 1/27/09 Addition of instructions for vent spill cleanup is added FC

8 8/16/2010 New form Y2221-04/10 CHM

8 8/16/2010 Addition of instructions for pump out on 92 day/180 day CHM

8 8/16/2010 Addition of instructions for bathroom floor drains CHM

SMP#: 436001 Rev. 8 Effective: September 28, 2010 Page 1 of 14 ...

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