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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
Important T&P required for smooth Important T&P required for smooth maintenancemaintenance
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
Important T&P required for smooth Important T&P required for smooth maintenancemaintenance
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..
Delegation of Powers Pertaining to T&PDelegation of Powers Pertaining to T&P
S.No Nature of Power Authority Extent of powers
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..
Delegation of Powers Pertaining to T&PDelegation of Powers Pertaining to T&P
S.No Nature of Power Authority Extent of powers
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
Checklist for Body conditionChecklist for Body conditionCode Item Description Remarks
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
Checklist for Body conditionChecklist for Body conditionCode Item Description Remarks
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