Maintenance Management Fleet Health is secret of our Strength Best Practices in

Maintenance Management

Fleet Health is secret of Fleet Health is secret of our Strengthour Strength

Best Practices in

1st TIER1st TIER At depots, preventive maintenance

schedules, attention of running repairs, unit changes & fitness work and Coach work & Upkeep

2nd TIER2nd TIER At workshops - major overhaul of

units & buses At Tyre Retreading shops -

retreading and repair of tyres

Fleet Maintenance in Fleet Maintenance in APSRTCAPSRTC

Preventive maintenance to vehicles for roadworthy fleet with good appearance, upkeep & comfort

Punctuality

Zero Accident

Zero Breakdown & Zero Cancellation

Minimum operational cost to earn profits

Sustainability & growth of organization

Lowest emission levels

Objectives of Fleet Objectives of Fleet MaintenanceMaintenance

PARAMETER 2010-11

2011-12

Target

UptoJan’12

1 HSD KMPL (Total) 5.17 5.30 5.13

HSD KMPL(Excl.Spl type) 5.26 5.40 5.26

2 Breakdown Rate 0.10 0.07 0.08

3 % Mech. Cancelation 0.23 0.11

0.19

4 Total Tyre Life 1.68 1.84 1.70

5 % New Tyre Scrap 2.37 1.30 3.17

6 New Tyre Mileage 62897 -- 67282

7 RT Factor 2.70 -- 2.58

8 Lub KMPL 1117 1189 1174

9 Spring Consumption 78 50

55

10

Fleet Utilization99.45 99.60

95.40

APSRTC has established very precise Preventive Maintenance Policies which are flexible in design and rigid in implementation.

The Maintenance Policies are primarily designed based on the manufacturers’ recommendations, product duty cycles and application environment.

The vehicles undergo preventive maintenance schedules at Depots with the material support from Zonal Stores, aggregates support from Zonal Workshops and Tyres from Tyre Retreading shops

Manpower

Tools, Plants & Machinery

Spare PartsFuel & Lub

Unit aggregates

Infrastructure – Yard, Sheds,

Maintenance Pits, Illumination

Computers & Software

to Provide a Safe, to Provide a Safe, Clean, Comfortable,Clean, Comfortable,

Environment friendly, Environment friendly, Reliable and Reliable and

Cost effective Bus Cost effective Bus for Operationfor Operation

Basic Requirements for Basic Requirements for Effective Fleet MaintenanceEffective Fleet Maintenance

7

1.1. SecuritySecurity2.2. Vehicle dispatchVehicle dispatch3.3. GentsetGentset4.4. Cycle standCycle stand5.5. Oil BunkOil Bunk6.6. DC(oils)DC(oils)7.7. Washing PlantWashing Plant8.8. ToiletsToilets9.9. SmithySmithy10.10.ElectricalElectrical11.11.Painter & Painter &

TrimmerTrimmer12.12.TyresTyres13.13.DC(T&P)DC(T&P)14.14.Dining hallDining hall15.15.StoresStores16.16.MF/AMF roomMF/AMF room17.17.Maintenance Maintenance

PitsPits18.18.Sch-III/IV floorSch-III/IV floor

STANDARD DEPOT LAY OUTSTANDARD DEPOT LAY OUT

Function Custodian/ Incharge

Security of Premises, Property & assets

Security SI/Head Guard & Security Guards in three shifts

Indenting, Receipts, Issues & Accountal of HSD Oil & Lubricants

Depot Clerk & Asst.Depot Clerk (Oils)

Tools, Plants & EquipmentDepot Clerk/ Asst.Depot Clerk (T&P)

Tyres indenting, Receipt, issues & Accountal

Asst. Depot Clerk (Tyres)

Stores & InventoryStores Supervisor & Asst.Depot Clerk (Stores)

Shift MaintenanceSuperintendent(Mech)/Dy.Supdt (M)/Leading Hand

General ShiftSuperintendent (M)/ Dy.Supdt(M)

Maintenance of records, documentation & correspondence

Asst.Depot Clerk (Gen)

Delegation of various responsibilities in a Delegation of various responsibilities in a Depot GarageDepot Garage

9

HSD OIL DISPENSING STATION & WASHING PLANT

13

SCHEDULE-I/II MAINTENANCE GARAGE

14

PITS FOR VEHICLE INSPECTION & MAINTENANCE

17

TYPICAL SCHEDULE-III/IV MAINTENANCE GARAGE

21

There are 7 workshops situated at Uppal, Karimnagar, Vijayawada, Uppal, Karimnagar, Vijayawada, Vizianagaram, Kadapa, Nellore Vizianagaram, Kadapa, Nellore and TirupathiTirupathi

The main functions of Workshops are : i) Complete Overhauling of Buses. ii) Sundry repairs of Buses. iii) Reconditioning of aggregates like Engine, Gear box, Front Axle, Rear Axle, FIP etc, and supply to depots on counter exchange basis.

OVERHAULING ACTIVITIES AT OVERHAULING ACTIVITIES AT WORKSHOPSWORKSHOPS

22

Zonal workshops - UppalZonal workshops - Uppal

23

Zonal workshops – Engine SectionZonal workshops – Engine Section

Zonal workshops – Body SectionZonal workshops – Body Section

24

Tyre Retreading ShopTyre Retreading Shop

25

Tyre Retreading ProcessTyre Retreading Process

Preventive Maintenance Schedules Preventive Maintenance Schedules adopted at Depotsadopted at Depots

S.No

Maintenance Schedule

Periodicity of Maintenance

District Operation

City Operations

1 Sch-I Daily Daily

2 Sch-II Weekly Weekly

3 Sch-III 12,000 Kms for Ord 15,000 kms for New& special type

9,000 Kms for all 12,000 kms for New

4 Sch-IV 36,000 Kms for Ord 45,000 kms for New& special type

27,000 Kms for all 36,000 kms for New

5 F.C.Attention

Initially after 2 yrs of commissioning & annually thereafter

Initially after 2 yrs of commissioning & annually thereafter

Oil, Filter & Coolant changesOil, Filter & Coolant changesDescription of LubricantDescription of Lubricant LEYLANDLEYLAND TATATATA

Engine Oil Long Life CH436,000 for Dist

24,000 for City

36,000(18,000

for Cummin

s)

Engine oil other than CH415,000/

16,00018,000

Gear Box oil Ordinary 32,000 18,000

Gear Box oil Extra Long life

40,000 72,000

Differential oil Ordinary 32,000 18,000

Differential oil Extra long life

48,000 72,000

P.Steering oil & Filter 80,000 80,000

Clutch Kits & Clutch Fluid 40,000 72,000

Coolant 75,0003.00 lakhs(or) 2Yrs

Contd..

Filter ChangesFilter Changes

Description of FilterDescription of Filter LEYALNDLEYALND TATATATA

Fuel Filter Felt 20,000 27,000

Fuel Filter Paper30,000 & 20,000 for

BS-II

36,000 & 18,000 for

BS-II

Spinon Fuel filters 25,000 BS-II 18,000 TC

Fuel Strainers (Baby filters)

50,000clean at

9,000

Dry Air Filter element Primary

72,000 72,000

Dry Air Filter element Secondary

2,16,000 2,16,000

• In addition to the above certain periodical works like Refurbishing of Special type vehicles, Chemical washing of Seats are also incorporated in the Preventive maintenance programmes

29

• The advance planning of vehicles for various preventive maintenance activities is obtained through computer software called “Vehicle Maintenance System” (VEMAS).

• The due dates, done dates and coverage of Kms etc for all types of maintenance activities are generated by VEMAS

30

Programming of Preventive Programming of Preventive Maintenance Schedules at DepotsMaintenance Schedules at Depots

A typical VEMAS based report ( FOR DISTRICT DEPOTS )SCHEDULE II/III/IV DUE STATEMENTF Date: 25 -10-2009 PAGE : 1Circular No. 23/94-MED Dt. 23-07-1994 DEPOT : ONGOLE=================================================================================================================== VEHICLE LAST LAST KMS KMS KMS FC HSD LUB SL . NO ENG. VEH. CH-3 SCH III SCH IV SINCE SINCE SINCE ENG. FIP INJ. DUE KMPL KMPL NO . TYPE TYPE GRP. DATE DATE III IV HGC KMS KMS KMS DATE====================================================================================================================

ESCHEDULE - IV VEHICLES :F

1. 28Z4606 K HT A 02/10/09 04/08/09 14905 56259 168640 168270 168270 168270 27/01/11 4.73 0

2. 10Z6953 H OR D 18/09/09 17/06/09 11080 36157 140598 327929 30330 30330 30/03/10 5.39 0

3. 11Z1276 J OR B 30/09/09 04/08/09 9918 39030 166512 35016 314366 59630 01/01/10 5.95 0

4. 28Z5069 E HT C 08/10/09 12/08/09 8816 46468 110828 110828 110828 110828 11/05/11 4.93 0

5. 10Z7444 H OR C 24/09/09 26/06/09 8038 37118 149085 322597 306526 52133 12/10/10 5.39 0

6. 28Z2139 K HT B 14/10/09 18/08/09 6786 44172 340465 517491 517491 517491 14/09/10 5.13 15660

ESCHEDULE - III VEHICLES :F

1. 28Z3999 K HT D 22/09/09 22/09/09 17979 17979 215460 215460 215460 215460 03/10/10 4.90 12985

2. 28Z5406 V GD C 22/08/09 22/08/09 16849 16849 37623 37623 37623 37623 27/06/11 2.97 0

3. 28Z2811 K SL D 02/10/09 06/09/09 16470 34438 285570 378820 100886 175626 30/01/10 5.47 0

4. 28Z1447 V GD 0 30/09/09 30/09/09 15460 15460 594300 594300 594300 594300 21/04/10 2.94 16888

5. 28Z2717 K SL B 03/10/09 05/09/09 15020 32152 274849 344637 344637 344637 16/01/10 5.65 16520

6. 28Z1439 V GD 0 30/09/09 30/09/09 14956 14956 596276 596276 596276 596276 21/04/10 3.05 4985

( FOR DISTRICT DEPOTS )SCHEDULE II/III/IV DUE STATEMENT Date: 25-10-2009 PAGE : 2Circular No. 23/94-MED Dt. 23-07-1994 DEPOT : ONGOLE================================================================================================================== VEHICLE LAST LAST KMS DAYS KMS FC HSD LUB SL . NO ENG. VEH. CH-3 SCH III SCH II SINCE SINCE SINCE ENG. FIP INJ. DUE KMPL KMPL NO . TYPE TYPE GRP. DATE DATE III II HGC KMS KMS KMS DATE==================================================================================================================

ESCHEDULE - II VEHICLES :F

* 1. 28Z5406 V GD 22/08/09 22/08/09 16849 64 37623 37623 37623 37623 27/06/11 2.97 0

* 2. 28Z1447 V GD 30/09/09 30/09/09 15460 25 594300 594300 594300 594300 21/04/10 2.94 16888

* 3. 28Z1439 V GD 30/09/09 30/09/09 14956 25 596276 596276 596276 596276 21/04/10 3.05 4985

* 4. 28Z4606 K HT 02/10/09 20/10/09 14905 5 168640 168270 168270 168270 27/01/11 4.73 0

* 5. 10Z6693 H OR 01/09/09 16/10/09 14630 9 162163 261372 262904 718572 20/11/09 5.89 0

* 6. 11Z844 J OR 15/09/09 18/10/09 13630 7 994428 10266 386861 30414 19/08/10 5.61 0

7. 28Z0112 V GD 06/10/09 06/10/09 12410 19 860550 860550 860550 860550 27/01/10 2.93 7918

8. 28Z5123 E HT 08/10/09 18/10/09 11334 7 107356 361190 407452 407452 11/05/11 5.10 0

9. 11Z1165 J OR 24/09/09 20/10/09 10717 5 160760 265527 267851 267851 09/12/09 5.65 0

10. 11Z5717 J OR 30/09/09 19/10/09 10492 6 4293 102562 102563 102563 19/04/10 5.69 0

* 11. 11Z1276 J OR 30/09/09 20/10/09 9918 5 166512 35016 314366 59630 01/01/10 5.95 0

12. 10Z5535 J OR 23/09/09 20/10/09 9424 5 162218 62309 123967 352468 16/07/10 6.19 0

EOILS & FILTER CHANGES DUE STATEMENT DEPOT: ONGOLE DATE : 25-10-2009 PAGE : 4===================================================================================================================================================================

EOC PROGRAM |DOC PROGRAM |GOC PROGRAM |FEC PROGRAM |PEC PROGRAM |GCC PROGRAM |POC PROGRAM |APF PROGRAM |ASF PROGRAM VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS |VEH-NO MK KMS

===================================================================================================================================================================

1 10Z409 H 14084 10Z7851 J 31509 10Z7851 J 31509 10Z6693 H 20186 10Z3004 H 29805 10Z7851 J 74180 28Z0112 R 8980 11Z4092 V 111176 28Z3999 K 215460

2 10Z6718 H 14028 11Z0808 J 31928 11Z0808 J 31928 11Z1351 J 19196 10Z9423 J 29514 28Z2447 K 79749 11Z4093 V 109326

3 10Z6953 H 14670 11Z0843 J 31016 11Z0843 J 31016 11Z3590 J 19084 11Z0749 J 30410

4 11Z1337 J 16094 11Z1165 J 31763 11Z1165 J 31763 11Z4349 J 19221 11Z2161 J 29458

5 11Z2411 J 16238 11Z3589 J 31955 11Z3589 J 31955 11Z4968 J 19794 28Z2137 K 49524

6 28Z0112 V 25792 11Z5583 V 101322 11Z5583 V 101322 28Z0112 V 25792

7 28Z3505 K 35346 11Z844 J 31238 11Z844 J 31238 28Z3999 K 24717

8 28Z5069 E 36652 9Z9697 H 20078

Sch-I MaintenanceSch-I MaintenanceSchedule-I or Daily Maintenance is carried out in two shifts.All the vehicles after completion of the scheduled operation undergo Sch-I Maintenance.Sweeping, Cleaning & Washing of buses, Arresting leakages of water, fuel, oils, replenishing the levels, tightening of all bolts and nuts, Checking of road springs & their mountings, Rectification of defects pointed out by Drivers, Inspection of Tyres and minor coach works are taken up in Sch-I.The works allotted & works attended in Sch-I are recorded by the Shift Incharge Supervisor duly obtaining the Signatures of the concerned.

Vehicle Back History RegisterVehicle Back History RegisterDate Complaints on the

condition of vehicle

Failures Remarks

of the

Supervisor

who supervised

the repairs/

maintenance

Signature

of AE/ DM

As per

logsheet

As per

Tyre Mech.

Observation

VBH register is a very important register in maintenance management. It gives complete picture of the health of the

vehicles. The repetitive nature of complaints depicts the quality of scheduled maintenance at the depot. The vehicle defects shall be thoroughly reviewed by the Sch-III/IV maintenance

incharge before docking the vehicle and ensure that root cause for the defect is totally eliminated during Sch-III/IV maintenance.

Sch-II MaintenanceSch-II MaintenanceEvery vehicle undergoes Sch-II Maintenance once in a week (Excluding those undergone Sch-III/IV) for about 2-3 hoursIn addition to all the activities of Sch-I, the following works are taken up in Sch-II

Complete washing through MWPLubricating all grease pointsCleaning of BreathersAir Cleaner maintenanceBattery MaintenanceTyres rotationSteering & Brake test

Sch-III & IV MaintenanceSch-III & IV MaintenanceSch-III/IV Maintenance is carried out based on the prescribed mileage. The vehicle is docked for 8 hrs in General shift.One senior most Supervisor is deployed at each depot to look after Sch-III/IV maintenance.Two Mechanics & Two assistants for Sch-III and Three Mechanics & 3 Assistants for Sch-IV are deployed per vehicle in addition to the Artisans.All major repair & maintenance works are carried out in Sch-III/IV maintenance.The vehicles are inspected before docking & after completion to ensure qualityThe workdone along with signature of the concerned are recorded in a register

Important aspects while docking the Important aspects while docking the vehicles for Sch-III/IVvehicles for Sch-III/IV

Take up the vehicle for maintenance at the right time. Avoid delay/backlog.

Inform the fixed Drivers about docking of vehicles for Sch-III/IV.

Ensure thorough washing/MWP before docking.

Synchronize other maintenance activities like FC, Unit changes, Filter/Oil/Coolant changes, Body attention, Painting etc with Sch-III/IV to save manpower & vehicle days

Important Coach works covered Important Coach works covered during Sch-III/IVduring Sch-III/IV

Tightening of all Body U’bolts, cabin foundation bolts.

Repairs to damaged body panels, exterior & interior roof panels, parcel racks, Luggage carrier, ladder & unloader

Repairs to Stepwell, stanchions, Passenger Assist rails, Driver partition, flooring, Dashboard, Engine hood, Entrance door & Driver’s door

Dicky doors, locks and gas springs in Special type vehicles

Contd..

Important Coach works covered Important Coach works covered during Sch-III/IVduring Sch-III/IV

Repairs to broken pillars & cross bearersAttention to Destination frames & boardsReplacement/ repairs to broken seat

frames, torn seat cushions & upholsteryAttention to Seats inclining mechanism,

Hand rests, foot rests, pouches, bottle holders etc in special type vehicles

Attention to Driver Seat and adjusting mechanism

Contd..

Attention to Antisag bar & out riggersReplacement of damaged window

frames, broken shutter glasses, windscreen glasses.

Replacement of terene felt, fitment of shutter knobs

Attention to battery boxArresting water leakagesExterior/ Interior paint touch up

Manpower Planning for Preventive Maintenance

at Depots

Manpower planning is an essential prerequisite in Depot MaintenanceHead Office communicates sanctions for each category of manpower by working out the requirement based on the average schedules operated by an unit during the period from July to December.The requirement of Supervisors and Artisans is worked out based on the slabs in schedules.The arrived norm based on the slabs is generally adopted for staff requirement at depotsFilling of vacancies either through direct recruitment or through promotion is strictly based on sanctions only

The success of Depot Maintenance management primarily depends on proper deployment of manpower and effective utilization of their servicesHighly skilled and experienced men shall be deployed in major maintenance programmes like Sch-III/IV, H.R.G and KMPL works.Senior most supervisor of the Depot next to Maintenance Incharge shall be assinged to look after of General Shift maintenance.

Depot Slabs for Supervisors & Depot Slabs for Supervisors & ArtisansArtisans

Category

up

to 4

4

45 to

49

50 to

54

55 to

59

60 to

64

65 to

69

70 to

74

75 to

79

80 to

84

85 to

89

90 to

94

95 to

99

100 to

109

120 to

149

150 &

A

bv

AE(M) 0 0 0 0 0 1 1 1 1 1 1 1 1 1 1SUPDT(M)

1 1 1 1 1 1 1 1 1 1 1 1 2 2 2

DY.SUP(M)

0 0 0 1 1 2 2 2 2 2 2 2 2 2 2

LH 2 2 2 2 2 2 2 2 2 2 3 3 4 4 4CB/PB 2 2 2 2 2 3 3 3 3 3 3 4 4 4 4TYRE MECH

1 2 2 2 2 2 2 2 3 3 3 3 3 4 5

ELEC AC/DC

2 2 2 3 3 3 3 4 4 4 4 4 5 5 5

PAINTER 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2WELD/T.S 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1TRIMMER 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2B.SMITH 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2H.MAN 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2

Typical Man Power Deployment for Typical Man Power Deployment for maintenance in a Depot with 100 maintenance in a Depot with 100

fleetfleetCategory Norm Men

Mechanical Foreman

0.049

1

Asst. Mechanical Foreman 2

Chargeman 2

Leading Hands 0.037 4

Total Supervisors 0.086 9

Mechanics 0.35 35

Helpers/ Shramiks 0.50 50

Artisans 0.21 21

Total 1.15 115

Deployment of Mechanics & Helpers Deployment of Mechanics & Helpers for maintenance in a Depot with for maintenance in a Depot with

100 fleet100 fleetActivity Mechanics

@ Norm 0.35

Helper/ Shramik

@ Norm 0.50Sch.I Maintenance 16 18

Sch.II Maintenance 4 4

Sch.III/IV Maintenance 9 10

Heavy Repairs 1 1

KMPL Attention 2 2

Oil changes 2 2

Vehicle Dispatch 1 3

Tyres preparation 2

DGT & Stores 2

Battery maintenance 2

HSD oil top-up 4

Total 35 50

Deployment Artisans for Deployment Artisans for maintenance in a Depot with 100 maintenance in a Depot with 100

fleetfleetCategoryCategory NormNorm Men Men

Coach Bulider 0.039 4

DC/AC Electrician 0.047 5

Tyre Mechanic 0.034 3

Welder/ Tinsmith 0.010 1

Trimmer 0.024 2

Painter 0.024 2

Blacksmith 0.022 2

Hammerman 0.022 2

Total 0.21 21

Manpower deployment for shift Manpower deployment for shift maintenancemaintenance

Deployment of manpower for Sch-I/II maintenance shall be done carefully keeping the number of vehicles to be maintained in each shift into considerationThe allocation of man power should match the buses to be maintained in that shift based on bus schedules. Allocation of manpower dis-proportionate to the number of buses will lead to underutilization of men and ineffective maintenance Care shall be taken to ensure adequate manpower during night shifts as majority of the vehicles undergo Sch-I/II maintenance during this shift.

Outsourcing activities at DepotsOutsourcing activities at Depots

In order to overcome shortage of manpower, and difficulties in filling of vacancies, APSRTC is outsourcing certain maintenance activities like Cleaning, sweeping & washing of Buses, HSD oil Top-up, Semi-skilled men as Assistant to Mechanics etc at Depots for smooth maintenance of vehicles.

Outsourcing activities at DepotsOutsourcing activities at Depots

It is equally important for Supervisors to monitor the deployment of men by the outsourcing agencies and their quality of work.It is the responsibility of the Supervisors to ensure proper work allocation to the outsourced men.Supervisors shall also ensure the safety of the workers engaged through outsourcingThe records of attendance, details of work done etc, pertaining to outsourcing shall be maintained properly by the Supervisor concerned.

Provision of required tools, plants and equipment for smooth maintenance of vehicles is of highest importance in Depot Maintenance management.Depot Clerk is the custodian of all Mechanic tools, special tools, plants and machinery available in the Depot. The ‘T&P Return’ shall be maintained properly indicating the locality of each & every item of the Garage.

S.No

Description Expected life in Years

1 D.G.Set 20

2 Air Compressors 15

3 Car washers 7

4 Automatic Washing Plant 15

5 Arc Welding M/c 20

6 Gas Welding equipment 8

7 HP Greasing equipment 10

8 Bucket type Grease Gun 7

9 Jib Crane 10

10 Trolley Jack 10

11 Bench Vice 5

12 Bench Grinder 7

Important T&P required for smooth Important T&P required for smooth maintenancemaintenance

Contd..

S.No

Description Expected life in Years

13 Drilling M/c 10

14 Sewing M/c 10

15 Pop rivet guns 5

16 Paint Spray gun 10

17 Battery Charger 5

18 Cell Tester 3

19 Hydrometer 5

20 Injector Tester 10

21 Wall gauges 3

22 Electronic gauges 5

23 Hand grinding M/c 7

24 Mechanic’s work bench 10


Contd..

S.NoDescription Expected life in

Years

25 Hand Platform Trolley 10

26 Bench Arbor Press 10

27 Anvil 10

28 Torque Wrench 5

29 Swage Block 10

30 Vehicle Stands 10

31 Compressor Tester 10

31 Well Pump 7

33 Automatic Tyre inflators

34 Ralli-wolf end mill kit

35 Dial gauge with magnetic base

36 Spring Cambering M/c

37 Diamond Glass cutter

38 Smoke Meter


A separate Log book is maintained for each plant & machinery and the entries are made in the Log book as and when repairs and maintenance are carried out.

It is the responsibility of Mechanical Supervisors to ensure preventive maintenance to the Plants & Equipment at the prescribed intervals

The Mechanical Supervisors ensure periodical calibration of certain T&P items like Dial gauges, Injector testers, Wall gauges, Torque wrenches etc, as per the stipulated periodicity.

The worn out and defective T&P are replaced in time so that the work is not hampered.

Additional requirement of T&P owing to increased number schedules or introduction of new models are submitted to the Dy.CME concerned for obtaining the same.

Mechanic Tools for TATA DepotsMechanic Tools for TATA Depots

D.E.Flat Ring TubularSocke

t6x7 mm 6 x 7 mm 8 x 9mm 10mm

8x9 mm 10 x 11 mm 10x11 mm 13mm

8x10 mm 12x 13mm 12x13 mm 14mm 9x10 mm 17x19 mm 12x14 mm 17mm

10x11 mm 21 x 23 mm17x19 mm

19mm

10x13 mm 22 x 24 mm

22 x 24 mm 22mm

12x 14 mm

27 x 32 mm

27 x 32 mm 24mm

14x17 mm 41 x 46 mm 27mm

17x19 mm 3/8’’22 x 24

mm 27 x 32

mm

Other Tools55mm single end FlatTommy bar 125mm

long Tommy bar 250mm

long Extension 6 Extension 12"

Cutting Plier 8"

Cutting plier 10”

Hammer Ball pane

1/2Kg. File round smooth 8" File flat smooth 6" Feeler Gauge SetTorque wrench (4 to 20 m-Kgs) Circlip Plier 6’’Screw Driver 6’’ & 12’’Nose Plier 6’’

Mechanic Tools for LEYLAND Mechanic Tools for LEYLAND DepotsDepots

D.E.Flat RingSocke

t3/16’’x1/4’’ 3/16’’x1/4’’ ½’’¼’’x5/16’’ ¼’’x5/16’’ 10mm

5/16’’x3/8’’ 5/16’’x3/8’’11mm

7/16’’x1/2’’ 7/16’’x1/2’’ 12mm 9/16’’ x 5/8’’ 9/16’’ x 5/8’’ 13mm 11/16’’x3/4’’ 11/16’’x3/4’’ 14mm 6 x 7mm 6 x 7mm 17mm 8 x 9mm 8 x 9mm 19mm 10 x 11mm 10 x 11mm 21mm 12 x 13mm 12 x 13mm 22mm14x 15mm 14x 15mm 24mm16 x 17mm 16 x 17mm 46mm18 x 19mm 18 x 19mm20 x 21mm 20 x 21mm22 x 23mm 22 x 23mm24 x 27mm 24 x 27mm

Other Tools55mm single end Flat

wrenchTommy bar 125mm long Tommy bar 250mm long Extension 6 Extension 12" Cutting Plier 8" Cutting plier 10”

Hammer Ball pane 1/2Kg. File round smooth 8" File flat smooth 6" Feeler Gauge SetTorque wrench (4 to 20 m-Kgs) Circlip Plier 8’’Screw Driver 8’’ & 12’’Nose Plier 6’’MalletAllen Key set

Fast moving Mechanic ToolsFast moving Mechanic Tools

DE Ring Socket10 x

1114 x

15 12,1314 x

1519 x

22 14, 1719 x

22 8 x 9 19BSF3/16” X ¼” 5/16 X 3/8” Feeler gauge

DE Ring Socket17 x

1917 x

19 9, 1013 x

1413 x

14 13, 1419 x

2219 x

22 17, 199 x 10 9 x 10Feeler Gauge

ASHOK LEYLANDASHOK LEYLAND TATATATA

Special tools for Tata vehiclesSpecial tools for Tata vehicles• Crow foot spanner for

cylinder Head Nut tightening with rocker assembly

• Check nut spanner on front hub

• Check nut spanner on rear hub

• Front Hub puller• Rear Hub Puller• Water pump flange puller • Drift for oil seal on Hub

(outer) • Steering ball joint puller• Drift for oil seal on hub

(inner)• Holders for coupling flange• Drift for removal of Rear

hub inner oil seal• Puller for clutch release

bearing

• Adopter for checking engine compression

• Puller for spigot bearing in crank shaft

• Puller for C.J. Bearing

• Puller for Rear hub Bearing outer race

• Puller for water pump inner bearing

• Drift for oil seal in timing case

• Spanner for wheel nut

• Socket wrench for removal of Injectors

• Piston ring compressor

• Strap wrench for Spin-on filters

Special tools for Leyland vehiclesSpecial tools for Leyland vehicles• Retainer for Liners (for

Hino) • Cylinder Head Bolt wrench (for Hino) • Cylinder liner puller• Injector Extractor• Piston Ring Compressor• Drift King Pin bush bottom• Drift King Pin Bush bottom• Centre bearing Nut

Spanner• Puller steering wheel• Spanner set rocket shaft• Spanner spring clamp nut• Clutch alignment tool• Clutch Height setting

gauge (Z-gauge)

• Dial gauge (for hub setting with Magnetic base)

• Strap wrench for Spin-on filters

• Drop arm puller ZF• Drop arm puller Rane• Drift for Rear hub oil seal• Drift for F.Hub inner bearing• Drift for Bearing outer race• Rear Hub nut spanner• Front Hub nut Spanner• Guide F.Hub inner bearing• Puller Stub axle inner brg

Delegation of Powers Pertaining to T&PDelegation of Powers Pertaining to T&PS.No Nature of Power Authority Extent of powers

32.i) Standardization of depot equipment, inclusion of new items, fixation of norms, classification of T&P value-wise fixation of guidelines, expectancy etc

MDMD Full powers with the concurrence of FA/CAO on the recommendations of ED(E)/CCOS/CME/ CFM

ii) Inclusion of new equipment on experimental basis

ED(E)ED(E) Powers upto Rs 1.00 lakh per occasion with the concurrence of FA/CAO

CMECME Powers upto Rs 50,000 per annum with the concurrence of Dy.CAO

WM/WM/

Dy.CMEDy.CME

Powers upto Rs 10,000 per annum with the concurrence of Dy.CAO

Contd..

Delegation of Powers Pertaining to T&PDelegation of Powers Pertaining to T&P

S.No Nature of Power Authority Extent of powers

33.i) Sanction for replacement of T&P equipments including premature replacements at Depots/ W.shops

CME/CME/

ED(Z)ED(Z)

Full powers on the recommendations of Dy.CME/ WM with the concurrence of DyCAO

ii) Sanction for replacement of T&P items after their normal utilization for Depots/ W.shops as per guidelines issued from time to time

DyCME/ DyCME/ WMWM

Full powers with concurrence of DyCAO

DMDM Powers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annum

Contd..



34.i) Sanction for replacement of T&P equipments for New Depots/ W.shops

ED(Z)/ED(Z)/

CMECME

Full powers as per guidelines

ii) Sanction of additional T&P for existing Depots/ W.shops on account of increase in Fleet stength/ acitivity as per guidelines

CME/CME/

DyCME/ DyCME/ WMWM

Full powers with concurrence of CFM/ DyCAO as per guidelines

DMDM Powers upto Rs 300/- at a time subject to a limit of Rs 2,000 per annum

Contd..



35 Sanction the expenditure incurred for overhaul repairs and maintenance of tools, plant & machinery and replacement of parts thereof in Depots & production units and entering into contract with authorized suppliers or manufacturers

ED(E)ED(E) Full powers with concurrence of FA/CAO

CME/ CME/ ED(Z)ED(Z)

Full powers with concurrence of CFM/ DyCAO upto Rs 20,000 at a time

SSOSSO Full powers upto Rs 5,000 at a time with concurrence of Dy.CAO

JSOJSO Upto Rs 1,500 at a time

Float aggregates are essential resource inputs for depot maintenance.

The purpose of providing float aggregates is to make available important units readily available at the depots at all times so that the defective units are replaced immediately and the vehicles are put onroad.

Inadequacy/ non-availability of float units affect the Fleet utilization, punctuality of operations and earning potentiality of a depot.

Over-provisioning of floats leads to excessive inventory lock-up

The requirement of Float aggregates depends on the volume of operations, lead time of supply and the average life of the aggregates.The Mechanical Engineering Department, from time to time; decide the list of float aggregate units to be provided to the depots.Floats are also provided for Workshops as an in-process inventory for uninterrupted supply to the depots and maintain optimum service levels.

The following formula is adopted in assessing the requirement of floats for a depot.

No.of Float aggregates = (N/n - C) x t x a

(Subject to a minimum of 1)

Where,N = Operated Kmsn = average life of aggregate in Kmst = Lead time replenishment in days which is the period

that elapses between the day of removal of defective unit to the day of replacement being received from workshops or the day of completion of repair in the depot if such repair is within the permissible repairs of depot.

C = Complete overhauls demand per daya = Number of units per vehicle

Provisioning of Float Units to Provisioning of Float Units to DepotsDepots

S.No UNIT NORM

1 Engine1 for 10,000

KMs.

2 Front Axle1 for 14,000

KMs.

3 Rear Axle1 for 14,000

KMs.

4 Gear Box 1 for 8,500 KMs.

5 Steering Box1 for 10,000

KMs.

6 FIP 1 for 5,000 KMs.

7 Self Starter 1 for 4,000 KMs

8 Alternator 1 for 4,000 KMs.

MAJOR UNITS

S.No UNIT NORM

1 Injectors (set) 1 for 2,000 KMs.

2 P. P. Shafts (set) 1 for 6,000 KMs.

3 Air compressor 1 for 5.000 KMs.

4 Clutch pressure plate 1 for 5,000 KMs.

5 (Leyland)/ Springer (Tata) 1 for 5,000 KMs.

6 Water pump assembly 1 for 5,000 KMs.

7 Cylinder head assembly 1 for 5,000 KMs.

8 Radiator 1 for 5,000 KMs.

SUB ASSEMBLIES

S.No UNIT NORM1 Front hub 1 for 15,000 KMs.

2 Rear hub 1 for 15,000 KMs.

3 Clutch housing 1 for 15,000 KMs.

4 Air cleaner complete 1 for 5,000 KMs.

5 Fuel twin filter assembly 1 for 5,000 KMs.

6 Feed pump 1 for 5,000 KMs.

7 Fly wheel ring gear 1 for 10,000 KMs.

8 Unloader valve 1 for 3,000 KMs.

9 Set (4) of slack adjusters 1 for 3,000 KMs.

10 Set (4) of spring brake chambers 1 for 5,000 KMs.

11 Hand brake valve 1 for 10,000 KMs.

12 A. C. Head 1 for 5,000 KMs.

MAJOR SPARES

S.No UNIT NORM13 Air tank 1 for 10,000 KMs.

14 Clutch disc 1 for 5.000 KMs.

15 U. J. Cross 1 for 6,000 KMs.

16 Set of brake drums front (2 off) 1 for 5,000 KMs.

17 Set of brake drums rear (2 off) 1 for 5,000 KMs.

18Set of spring brackets front (2

off) 1 for 5,000 KMs.

19 Set of spring brackets rear (2 off) 1 for 5,000 KMs.

20 Axle shafts 2 off 1 for 5,000 KMs.

21 H. S. D. Oil Tank 1 for 6,000 KMs.

22 Wiper Machine 1 for 5,000 KMs.

23 Batteries 10% of the batteries

24 Hydraulic jacks 1 for 2,000 KMs.

MAJOR SPARES

All depots send a periodical statement on availability of floats to the concerned Dy.CME once in a year.

The Dy.CME of the region reconciliates figures with those maintained by workshops.

The Dy.CME concerned processes cases for provision of floats for new models and also for increase of floats on account of increase in schedules, duly recommending the surrender of obsolete models.

76

Provision of Spare Vehicles to Depots

• Spare vehicles are provided to the Depots to meet the requirements for docking the vehicles for preventive maintenance (Sch.III/IV), FC attention, Complete overhauls, Sundry repairs, Units replacement etc,.

Fleet Held Norm

Upto 50 8%

51 to 80 7%

81 & above

6%

Norm for Provision of Spare Buses

Physical Inspection of Buses by Physical Inspection of Buses by Depot Manager & Maintenance Depot Manager & Maintenance InchargeIncharge

The Depot Manager shall inspect atleast 30 vehicles (1/3rd Fleet) every month covering 15 vehicles undergone Sch-II maintenance, 10 vehicles undergone Sch-III and 5 vehicles undergone Sch-IV maintenance.

This is highly essential to ensure effective execution of preventive maintenance schedules

Check-list for inspection of vehiclesCheck-list for inspection of vehiclesS.No System Item

1 EngineAir cleaner

maintenance2 ,, A/c Suction hose3 ,, Engine mounting4 ,, Engine oil leakages5 Fuel HSD tank cap seals6 ,, Fuel pipe clamping7 ,, Fuel leakages

8Coolin

gRadiator Cap

9 ,, Coolant concentration10 ,, Radiator mountings

Contd..

S.No System Item

1Steerin

gTie-rod/ drag link end play

2 ,, ATF oil leakages3 ,, King pin lubrication4 Susp. Broken spring leaves

5 ,,Spring side clamps/

ferrules6 ,, Welded side clamps7 ,, Spring brackets/ shackles

8 ,,Air suspension mounting

bolts Tightness

9 ,,Condition of rubber bushes in Air suspension

Contd..

S.No System Item

1Transmissi

onClutch free play

2 ,, Gear lever play

3 ,, Gear Box oil leakage

4 ,, Loose CJ check nuts

5 ,, CJ bearings condition

6 ,, UJ Crosses condition

7 ,, Sleeve yokes condition

8 ,, CJ rubber beds condition

9 ,, Slip joint Rubber boot

10 ,, PP shafts alignment

11 ,, Missing grease nipples

12 ,, Chassis greasing

13 ,, Differential oil leakage

14 ,, Cleanliness of breathers

S.No System Item1 Brakes Air tank condensate2 ,, Brake pipe clamps3 ,, Air leakage4 ,, Air Dryer working5 ,, Hand brake condition6 ,, Brake dust covers7 Tyres Wheel alignment8 ,, Matching of duals9 ,, Less than 2mm NSD tyres

Contd..

S.No System Item

1Electric

alBattery Maintenance

2 ,, Head Lights

3 ,, Signal Lights

4 ,, Self condition

5 ,, Saloon Illumination

6 Body Exterior/ Interior cleanliness

7 ,, Body damages

8 ,, Painting

9 ,, Seat Mounting

10 ,, Seat Upholstery

11 ,, Inclining mechanism

12 ,, Shutter glasses

13 ,, Doors

14 ,, Window Shutter Knobs

15 ,, Tightness of body U bolts

16 ,, Under chassis cleanliness

Checklist for Body conditionChecklist for Body conditionCode Item Description Remarks

EXT-1 Body Panels Dents, Scratches, Damages

EXT-2 Front/ Rear Bumpers Broken/missing

EXT-3 Front Grill Damages/ missing

EXT-4 Front Cowls Damages

EXT-5 Corner Domes Dents

EXT-6 Passenger Doors Damages/ missing

EXT-7 Driver’s Door Damages/ locks

EXT-8 Ladder Damages/ missing

EXT-9 Rear Luggage Booth (Dicky) Damages/ locks

EXT-10 Exterior Paint Faded

EXT-11 Roof Leakage Area of Leakage

DEST-1 Destination Board Frame Size and condition

DEST-2 Destination Lettering/Paint Faded

DEST-3 Destination Board lighting Visibility

DEST-4 LED Destination Condition


INT-1 Stepwell Damages

INT-2 Flooring Condition

INT-3 Stanchions Broken/missing/loose

INT-4 Parcel Rack Broken/loose

INT-5 Grab rails/ Assist rails Broken/loose

INT-6 Cabin Partition door Condition

INT-7 Interior Roof/ side panel Fabric Condition

INT-8 Interior painting Faded

INT-9 Saloon Cleanliness Dirt & cobwebs

GLS-1 Window Glasses Missing/ Broken

GLS-2 Terene felt/Flock channel Rubber Worn out/ missing

GLS-3 Window shutter knobs Missing/loose

GLS-4 Windscreen Glasses Broken

GLS-5 Top-fixed glasses Broken/missing

GLS-6 Windows leakage Condition of Rubber flap


SEAT-1 Seat Frames Loose/broken

SEAT-2 Seat Cushions Hard/missing/damaged

SEAT-3 Seat rexine/fabric Torn

SEAT-4 Back rests Missing/loose

SEAT-5 Reclining mechanism Condition

SEAT-6 Arm Rests Broken/missing/loose

SEAT-7 Head Rest Covers Missing/dirty

SEAT-8 Bottle Holders Damged/missing

SEAT-9 Magazine Pouches Damaged

SEAT-10 Foot Rests Damaged

CAB-1 Bonnet Damaged

CAB-2 Dash Board Damaged

CAB-3 Vision Mirrors Damaged

CAB-4 Cabin Cleanliness Dirty

Checklist for Body conditionChecklist for Body condition

Code Item Description Remarks

LHT-1 Interior Lightining Condition

LHT-2 Head Lights Condition

LHT-3 Tail lights/ signal indicators Condition

SPL-1 Speakers Condition

SPL-2 TV/Audio System Condition

SPL-3 Cell phone chargers Condition

STR-1 Body U Bolts Loose/missing

STR-2 Ballata Packing Loose/missing

STR-3 Cabin Foundation Loose

STR-4 Antisag Bar Loose

STR-5 Out Riggers Loose

STR-6 Battery Box Condtion

Indicators for Quality ofIndicators for Quality ofSch-III/IV maintenanceSch-III/IV maintenance

• Backlog in Sch-III/IV maintenance and failures within 15 days after maintenance are the key indicators for Standards of preventive maintenance at the depot.

TypeFleet Held

OptdKms

Sch-IIISch-IIIFailures within15 days

Due Done Backlog % Backlog Nos %

ORDEXPTotal

TypeFleet Held

OptdKms

Sch-IVSch-IVFailures within15 days

Due Done Backlog % Backlog Nos %

ORDEXPTotal

88

Important Registers maintained in Important Registers maintained in Preventive Maintenance ManagementPreventive Maintenance Management

Daily RG Register RTC-126Vehicle Back History RTC-109Sch-I Maintenance RTC-127Sch-II Maintenance RTC -128Sch-III work done MTD -194Preventive Maintenance Master

register RTC-110Unit changes registerRegister for Inspection of vehiclesFC RegisterBreakdowns RTC-129Cancellation of Kms RTC-130

Vehicle Replacement PolicyVehicle Replacement Policy

APSRTC replaces Mofussil buses at 11.00 lakh kms and City Buses at 11.50 lakh kms or 15 years (whichever is earlier) against scrap.

Ghat Buses & Super Luxury buses are replaced at 5.50 lakh kms and Volvo Buses at 10.00 lakh kms

The other special type buses like Express, Deluxe, Metro Exp etc are replaced at 6.50 lakh kms

Type2010-11 2011-12 (Jan’12)

Aug. Rep. Total Aug. Rep. Total

S.Luxury 137 109 246 57 778 835

Indra -- -- -- 8 61 69

Garuda/ Garuda+ 0 30 30 27 41 68

Deluxe 32 89 121 169 69 238

Express 274 330 604 174 904 1078

Pallevelugu -- -- -- 152 547 699

Sap.Express & Ord 27 123 150 22 57 79

City Ordinary -- -- -- 10 55 65

City Ord (CNG) -- -- -- 0 138 138

LF A/C Diesel 28 0 28 51 0 51

LF A/C CNG 0 0 0 8 0 8

LF N-A/C Diesel 16 80 96 3 1 4

LF N-A/C CNG 0 0 0 33 0 33

SLF Diesel 75 118 193 9 0 9

SLF CNG 12 58 70 5 0 5

Mini Buses 52 0 52 48 0 48

Total 653 937 1590 676676 27512751 3427

Green initiatives & Green initiatives & Use of Alternate Use of Alternate fuels in APSRTCfuels in APSRTC

92

APSRTC’s Environmental ConcernsAPSRTC’s Environmental Concerns

APSRTC always takes lead in sharing the public concern on automobile pollution and climate change.

APSRTC is a forerunner in introducing environment friendly vehicles through product upgradation and innovative measures especially in the area of alternate fuels and pollution control.

Continued…

93

APSRTC’s Environmental ConcernsAPSRTC’s Environmental Concerns

Sophisticated Electronic Smoke Meters are provided to Depots to check the smoke emission levels of buses at regular intervals.With a commitment towards mitigation of GHG emissions and reduction of smoke levels, APSRTC has started using Biofuels and Compressed Natural Gas on large scale.

APSRTC installed 40 Wind Turbines to generate green power to an extent of 10 Mw of Electrical energy

APSRTC launched 100 CNG buses in Vijayawada City during the year 2006, which is first of its kind in South India.

The number of CNG buses has been increased to 300 in Vijayawada.

Introduced 120 CNG buses recently in Hyderabad which include Ultra Low Floor Buses with BS-III/IV compliant CNG rear Engine model is under progress.

The Fuel efficiency of CNG buses in VJA is 4.40 km/kg and in Hyd it is 4.49 km/kg

101

Experiences with BiodieselExperiences with BiodieselAs a stake holder in promoting the use of biofuels, APSRTC had promptly responded to the call given by the Govt. of Andhra Pradesh and started trials using Biodiesel blended fuel on one City bus, in June’2005.The vehicle was operated with B20 fuel for 8 months to assess the operational feasibility and performance in respect to fuel efficiency and emission reduction. Intermittently the vehicle was also operated with 100% HSD fuel for 2 months for comparison

102

Emission levels of Biodiesel Vehicle Emission levels of Biodiesel Vehicle during trial periodduring trial period

Against the maximum permissible smoke density of 65 Hatridge units, the following emission levels were observed on the vehicle when operated with 20% Bio-diesel.

Jun-05 41.3

Aug-05 35.4

Sep-05 36.2

Oct-05 32.6

Nov-05 35.0

Dec-05 11.8

Feb-06 25.0

Mar-06 11.7

103

Emission Levels of trial vehicleEmission Levels of trial vehicleWhen operated with When operated with 100% HSD oil100% HSD oil

During Trial period

Jul-05 33.3

Jan-06 34.0

Jan-05 35.0

Feb-05 32.6

Mar-05 11.2

Apr-05 37.3

May-05 45.4

Before Trial

104

Comparative Fuel Performance* ofComparative Fuel Performance* ofVehicle during trialsVehicle during trials

With 100% HSD oil

Jul-05 4.627

Jan-06 5.193

With Biodiesel

Jun-05 4.355

Aug-05 4.538

Sep-05 4.662

Oct-05 4.778

Nov-05 4.430

Dec-05 4.516

Feb-06 4.797

Mar-06 5.008

* Fuel Performance in Kms/Lit

105

Extended trials with BiodieselExtended trials with Biodiesel

The trial was extended to three more vehicles at the same Depot with 5%, 10% and 20% blends respectively. It was observed during the trials that the vehicle with 20% blend shown improvement in fuel efficiency by 0.27 Km/Lt.

The trials were conducted with the Biodiesel supplied by M/S Southern Online Biotechnologies Limited.

106

VehicleNo

Bend %

Before Trials During Trials% Emissi

on Reduction

Mar

2006

Apr2006

May2006

Avg of three Month

s

Jun2006

Jul2006

Aug200

6

Avg of three month

sAP11Z3845

5% 44.3 55 30.4 43.23 35.4 41 30.6 35.67 17.49

AP11Z4045

10% 29.3 33.7 40.1 34.37 32.7 22.1 20.1 24.97 27.35

AP11Z4037

20% 27.7 31.9 20.9 26.63 11.7 21.6 16.67 16.67 59.75

Vehicle No Bend %Avg Km/Lit

Before Trial

Avg Km/Lit During Trial

% Improvem

entAP11Z 3845

5% 5.29 5.33 0.76%

AP11Z 4045 10% 5.20 5.38 3.46%AP11Z 4037 20% 4.91 5.21 5.47%

Comparative Emission LevelsComparative Emission Levels

Comparative Fuel EfficiencyComparative Fuel Efficiency

107

Several firms like M/s Cleancities Bio-diesel India limited, M/S Naturol Bioenergy Limited and M/S Universal Biofuels Pvt. Limited have come forward to offer Bio-diesel for conducting wider trials.

The trials were extended to other regions like Visakhapatnam and East Godavari, where all the vehicles of 4 depots were operated with Biodiesel blended in 1:9 ratio for about one month.

108

With the encouraging trial performance, Corporation has taken a decision to use Bio-diesel at 10% blend on regular basis for all vehicles in the 12 Depots of Hyderabad City Zone in the first phase by procuring the Bio-diesel from M/S Southern Online Biotechnologies Limited

The supplier had installed a separate overhead tank for biodiesel storage and made necessary arrangements to mix the Biodiesel with the HSD oil in the fixed proportion.

109

In the second phase, tenders were floated in September 2009 for bulk procurement of Bio-diesel at an estimated quantity of 30 Million liters for regular blending at 129 Depots in 14 Regions.

The supply contract was awarded to three firms viz, M/S Cleancities Bio-diesel India limited (108 Depots), M/S Southern Online Biotechnologies Limited (12 Depots) and M/S Universal Biofuels Pvt (9 Depots)

110

Dip Rod

Tank Level Gauge

Biodiesel Storage Tank

1 ½’’ MS Line

1’’ MS Line

1’’ Flexible Hose

Underground HSD Oil Tank

Truck with Biodesel Transfer Pump

Ground Level

Biodiesel Stocking & Blending Biodiesel Stocking & Blending Arrangement Arrangement

at Depotsat Depots

111

Procedure of Blending Biodiesel with Procedure of Blending Biodiesel with HSD OilHSD Oil

Blending Biodiese with HSD for first time1. Know the quantity of (Q1) of HSD in Ground Tank2. Calculate required qty (Q2) of Biodiesel @10% blend

with HSD (Q1x10/90)3. Transfer calculated qty (Q2) of Biodiesel from Storage

tank by gravity using Flowmeter F1

Procedure for subsequent replenishments1. Ignore the quantity of B10 blend existing in the

storage tank on fresh receipt of HSD oil2. Know the fresh quantity (Q3) of HSD that is being

decanted into the underground tank3. Calculate the required quantity (Q4) of Biodiesel to

mix by using the formula Q3 x 10/904. Transfer the quantity Q4 of Biodiesel from Storage

tank to the Underground tank with the help of Flow meter F1

112

Reduction of Pollutants with B20 FuelReduction of Pollutants with B20 Fuel

POLLUTANTThe values

withPure HSD Oil

Reduction with

20% Blended Bio-diesel

Total Unburned Hydrocarbons

1.1gms/kwh 20%

Carbon monoxide 4.5 gms/kwh 12%

Particulate Matter 0.36 gms/kwh 12%

Oxides in Nitrogen 8 gms/kwh + 2%

Sulphates -- 20%

Polycyclic Aromatic Hydrocarbons (PAH)

-- 13%

Nitrated PAHs -- 50%

Ozone Potential Speculated Hydrocarbons

-- 10%

113

Comparative Specifications of HSD & Comparative Specifications of HSD & BiodieselBiodiesel

ParameterASTM Method

UnitPure Bio-

Diesel

Normal HSD Oil

Flash Point D93 OC 130 min 66 min

Water & SedimentD2709

% Volume

0.05 max

0.05 max

Kinematic Viscosity 40oc

D445 mm/Sec1.9 – 6.0

2 - 5

Sulphated Ash D874 % mass0.02 max

0.01 max

SulphurD5453

% mass0.05 max

0.035 max

Copper Strip Corrosion

D130No.3 max

Not worsethan No.1

Cetane Number D613 47 min 46 min

Cloud PointD2500

OC Report

Continued…

114

Comparative Specifications of HSD & Comparative Specifications of HSD & BiodieselBiodiesel

ParameterASTM Method

UnitPure Bio-

DieselNormal HSD Oil

Carbon Residue 100% Sample

D4530 % mass 0.05 max0.03 max on 10%

Acid Number D664mg

KOH/gm 0.8 max --

Free Glycerin D6584 % mass 0.02 max --

Total Glycerin D6584 % mass 0.24 max --

Phosphorus D4951 % mass0.001 max

--

Distillation Temp. Atmospheric Equivalent Temp90% Recovered

D1160Degrees

C360 max --

115

Some of the barriers in Some of the barriers in large scale application of Biodiesellarge scale application of Biodiesel

Availability and uninterrupted supply of biodiesel is a major constraint for large scale application in APSRTC.Very few firms have come forward to supply the Biodiesel in bulk quantity at a viable priceIt is difficult to assess the quality of the product at the user level

Contd…

There is scope for non-adherence to the prescribed specifications by the suppliers in the absence of required testing facilities.

116

It is difficult to send the samples to the laboratories too frequently.

The blending becomes uneconomical if the suppliers quote exorbitant prices due to monopoly

Premature clogging of filters is more prevalent while using Biodiesel

Documents

Maintenance Management Fleet Health is secret of our Strength Best Practices in