Best Practices in
Maintenance Management
Fleet Health is secret of our Strength
Fleet Maintenance in APSRTC
1st TIER
 At depots, preventive maintenance
schedules, attention of running repairs,
unit changes & fitness work and Coach
work & Upkeep
2nd TIER
 At workshops - major overhaul of units
& buses
 At Tyre Retreading shops - retreading
and repair of tyres
Objectives of Fleet Maintenance
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
PARAMETER
1
2010-11
2011-12
Target
Upto
Jan’12
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
99.45
99.60
95.40
10 Fleet Utilization
 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
Basic Requirements for
Effective Fleet Maintenance
Tools, Plants
& Machinery
Manpower
Unit
aggregates
to Provide a Safe,
Clean, Comfortable,
Environment friendly,
Reliable and
Cost effective Bus
for Operation
Infrastructure –
Yard, Sheds,
Maintenance Pits,
Illumination
Spare Parts
Fuel & Lub
Computers &
Software
STANDARD DEPOT LAY OUT
1. Security
2. Vehicle dispatch
3. Gentset
4. Cycle stand
5. Oil Bunk
6. DC(oils)
7. Washing Plant
8. Toilets
9. Smithy
10.Electrical
11.Painter & Trimmer
12.Tyres
13.DC(T&P)
14.Dining hall
15.Stores
16.MF/AMF room
17.Maintenance Pits
18.Sch-III/IV floor
7
Delegation of various responsibilities in a Depot Garage
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 & Equipment
Depot Clerk/
Asst.Depot Clerk (T&P)
Tyres indenting, Receipt, issues &
Accountal
Asst. Depot Clerk (Tyres)
Stores & Inventory
Stores Supervisor &
Asst.Depot Clerk (Stores)
Shift Maintenance
Superintendent(Mech)/
Dy.Supdt (M)/Leading Hand
General Shift
Superintendent (M)/ Dy.Supdt(M)
Maintenance of records,
documentation & correspondence
Asst.Depot Clerk (Gen)
HSD OIL DISPENSING STATION & WASHING PLANT
9
SCHEDULE-I/II MAINTENANCE GARAGE
13
PITS FOR VEHICLE INSPECTION & MAINTENANCE
14
TYPICAL SCHEDULE-III/IV MAINTENANCE GARAGE
17
OVERHAULING ACTIVITIES AT
WORKSHOPS
There are 7 workshops situated at Uppal,
Karimnagar, Vijayawada, Vizianagaram,
Kadapa, Nellore and Tirupathi
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.
21
Zonal workshops - Uppal
22
Zonal workshops – Engine Section
Zonal workshops – Body Section
23
Tyre Retreading Shop
24
Tyre Retreading Process
25
Preventive Maintenance Schedules
adopted at Depots
S. Maintenance
No 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
Initially after 2 yrs
of commissioning
of commissioning
& annually thereafter & annually thereafter
Oil, Filter & Coolant changes
Description of Lubricant
LEYLAND
TATA
Engine Oil Long Life CH4
36,000 for Dist
24,000 for City
36,000
(18,000 for
Cummins)
Engine oil other than CH4
Gear Box oil Ordinary
Gear Box oil Extra Long life
Differential oil Ordinary
15,000/ 16,000
32,000
40,000
32,000
18,000
18,000
72,000
18,000
Differential oil Extra long life
P.Steering oil & Filter
Clutch Kits & Clutch Fluid
48,000
80,000
72,000
80,000
40,000
Coolant
75,000
72,000
3.00 lakhs
(or) 2Yrs
Contd..
Filter Changes
Description of Filter
Fuel Filter Felt
Fuel Filter Paper
Spinon Fuel filters
Fuel Strainers (Baby filters)
Dry Air Filter element
Primary
Dry Air Filter element
Secondary
LEYALND
TATA
20,000
27,000
30,000 &
36,000 &
20,000 for BS-II 18,000 for BS-II
25,000 BS-II
18,000 TC
50,000
clean at 9,000
72,000
72,000
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
Programming of Preventive Maintenance
Schedules at Depots
• 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
A typical VEMAS based report
( FOR DISTRICT DEPOTS )
SCHEDULE II/III/IV DUE STATEMENT F
Date: 25-10-2009
PAGE : 1
Circular 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
3. 11Z1276
J
OR
B
30/09/09
04/08/09
9918
39030 166512
4. 28Z5069
E
HT
C
08/10/09
12/08/09
5. 10Z7444
H
OR
C
24/09/09
6. 28Z2139
K
HT
B
30330
30330 30/03/10
5.39
0
35016 314366
59630 01/01/10
5.95
0
8816
46468 110828 110828 110828 110828 11/05/11
4.93
0
26/06/09
8038
37118 149085 322597 306526
52133 12/10/10
5.39
0
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 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
37623
37623
37623
( FOR DISTRICT DEPOTS )
SCHEDULE II/III/IV DUE STATEMENT
Date: 25-10-2009
PAGE : 2
Circular 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
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
10266 386861
11Z1165
J STATEMENT
OR
24/09/09
20/10/09 10717
5 160760
267851
09/12/09
5.65
0
EOILS 9.
& FILTER
CHANGES DUE
DEPOT:
ONGOLE
DATE : 265527
25-10-2009
PAGE :267851
4
===================================================================================================================================================================
10. 11Z5717|DOC JPROGRAMOR
EOC PROGRAM
VEH-NO MK
KMS |VEH-NO
* 11. 11Z1276
J
MK
30/09/09
19/10/09
|FEC PROGRAM
|GOC PROGRAM
KMS |VEH-NO MK
OR
KMS |VEH-NO
30/09/09
MK
10492
|PEC PROGRAM
KMS |VEH-NO MK
20/10/09
9918
6
4293 102562
102563 102563
19/04/10
|POC PROGRAM
|APF PROGRAM
|GCC PROGRAM
KMS |VEH-NO MK
5 166512
KMS |VEH-NO
MK
35016 314366
KMS |VEH-NO
MK
5.69
|ASF PROGRAM
KMS |VEH-NO MK
59630 01/01/10
5.95
0
KMS
===================================================================================================================================================================
1 10Z409
12.
10Z7851
J J
31509
OR
10Z785123/09/09
J 31509 10Z6693
H 20186
20/10/09
10Z3004
9424 H
298055 10Z7851
162218J
74180
R
8980
11Z4092
V 111176
6230928Z0112
123967
352468
16/07/10
2 10Z6718 H
H 14084
10Z5535
14028
11Z0808 J
31928
11Z0808 J
31928
11Z1351 J
19196
10Z9423 J
29514
79749
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
11Z844
28Z3999 K
24717
8 28Z5069 E
36652
9Z9697
20078
J
31238
J
31238
H
28Z2447 K
11Z4093 V 109326
0
28Z3999
6.19 K 215460 0
Sch-I Maintenance
Schedule-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 Register
Date Complaints on the
Failures Remarks
of the
condition of vehicle
Supervisor
As per
As per
who
logsheet Tyre Mech.
supervised
Observation
the repairs/
Signature
of AE/ DM
maintenance
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 SchIII/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 Maintenance
Every vehicle undergoes Sch-II Maintenance
once in a week (Excluding those undergone
Sch-III/IV) for about 2-3 hours
In addition to all the activities of Sch-I, the
following works are taken up in Sch-II
Complete washing through MWP
Lubricating all grease points
Cleaning of Breathers
Air Cleaner maintenance
Battery Maintenance
Tyres rotation
Steering & Brake test
Sch-III & IV Maintenance
Sch-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 quality
The workdone along with signature of the
concerned are recorded in a register
Important aspects while docking the
vehicles 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 during
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 during
Sch-III/IV
Repairs to broken pillars & cross bearers
Attention to Destination frames & boards
Replacement/ repairs to broken seat
frames, torn seat cushions & upholstery
Attention 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 riggers
Replacement of damaged window frames,
broken shutter glasses, windscreen
glasses.
Replacement of terene felt, fitment of
shutter knobs
Attention to battery box
Arresting water leakages
Exterior/ Interior paint touch up
Manpower Planning for
Preventive Maintenance
at Depots
Manpower planning is an essential prerequisite in
Depot Maintenance
Head 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 depots
Filling 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 services
Highly 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 & Artisans
Category
up to 44
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 & Abv
AE(M)
SUPDT(M)
DY.SUP(M)
LH
0
1
0
2
0
1
0
2
0
1
0
2
0
1
1
2
0
1
1
2
1
1
2
2
1
1
2
2
1
1
2
2
1
1
2
2
1
1
2
2
1
1
2
3
1
1
2
3
1
2
2
4
1
2
2
4
1
2
2
4
CB/PB
TYRE MECH
ELEC AC/DC
PAINTER
WELD/T.S
TRIMMER
B.SMITH
H.MAN
2
1
2
1
1
1
1
1
2
2
2
1
1
1
1
1
2
2
2
1
1
1
1
1
2
2
3
1
1
1
1
1
2
2
3
1
1
1
1
1
3
2
3
2
1
2
1
1
3
2
3
2
1
2
1
1
3
2
4
2
1
2
2
2
3
3
4
2
1
2
2
2
3
3
4
2
1
2
2
2
3
3
4
2
1
2
2
2
4
3
4
2
1
2
2
2
4
3
5
2
1
2
2
2
4
4
5
2
1
2
2
2
4
5
5
2
1
2
2
2
Typical Man Power Deployment for
maintenance in a Depot with 100 fleet
Category
Norm
Mechanical Foreman
Asst. Mechanical Foreman
Men
1
0.049
Chargeman
2
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 for
maintenance in a Depot with 100 fleet
Activity
Mechanics
Helper/ Shramik
@ Norm 0.35 @ Norm 0.50
Sch.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 maintenance in a
Depot with 100 fleet
Category
Norm
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 maintenance
Deployment of manpower for Sch-I/II maintenance
shall be done carefully keeping the number of
vehicles to be maintained in each shift into
consideration
The allocation of man power should match the
buses to be maintained in that shift based on bus
schedules. Allocation of manpower disproportionate 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 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 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 outsourcing
The 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.
Important T&P required for smooth maintenance
S. Description
No
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
Contd..
Important T&P required for smooth maintenance
S. Description
No
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..
Important T&P required for smooth maintenance
S.No Description
25 Hand Platform Trolley
Expected life in Years
10
26 Bench Arbor Press
27 Anvil
10
28 Torque Wrench
29 Swage Block
5
10
10
30 Vehicle Stands
31 Compressor Tester
10
31 Well Pump
33 Automatic Tyre inflators
7
34 Ralli-wolf end mill kit
35 Dial gauge with magnetic base
36 Spring Cambering M/c
37 Diamond Glass cutter
38 Smoke Meter
10
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 Depots
D.E.Flat
Ring
Tubular
Socket
6x7 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 mm
17x19 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
17x19 mm
22 x 24 mm
27 x 32 mm
27mm
3/8’’
Other Tools
55mm single end Flat
Tommy 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 Set
Torque wrench
(4 to 20 m-Kgs)
Circlip Plier 6’’
Screw Driver 6’’ & 12’’
Nose Plier 6’’
Mechanic Tools for LEYLAND Depots
D.E.Flat
Ring
Socket
Other Tools
3/16’’x1/4’’
¼’’x5/16’’
5/16’’x3/8’’
7/16’’x1/2’’
9/16’’ x 5/8’’
11/16’’x3/4’’
6 x 7mm
8 x 9mm
10 x 11mm
12 x 13mm
14x 15mm
16 x 17mm
18 x 19mm
20 x 21mm
22 x 23mm
24 x 27mm
3/16’’x1/4’’
¼’’x5/16’’
5/16’’x3/8’’
7/16’’x1/2’’
9/16’’ x 5/8’’
11/16’’x3/4’’
6 x 7mm
8 x 9mm
10 x 11mm
12 x 13mm
14x 15mm
16 x 17mm
18 x 19mm
20 x 21mm
22 x 23mm
24 x 27mm
½’’
10mm
11mm
12mm
13mm
14mm
17mm
19mm
21mm
22mm
24mm
46mm
55mm single end Flat wrench
Tommy 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 Set
Torque wrench
(4 to 20 m-Kgs)
Circlip Plier 8’’
Screw Driver 8’’ & 12’’
Nose Plier 6’’
Mallet
Allen Key set
Fast moving Mechanic Tools
ASHOK LEYLAND
DE
Ring
10 x 11 14 x 15
14 x 15 19 x 22
19 x 22 8 x 9
BSF
3/16” X ¼”
5/16 X 3/8”
Feeler gauge
Socket
12,13
14, 17
19
TATA
DE
Ring
17 x 19 17 x 19
13 x 14 13 x 14
19 x 22 19 x 22
9 x 10 9 x 10
Feeler Gauge
Socket
9, 10
13, 14
17, 19
Special 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 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&P
S.No Nature of Power
32.i) Standardization of depot
equipment, inclusion of new
items, fixation of norms,
classification of T&P value-wise
fixation of guidelines,
expectancy etc
ii)
Inclusion of new equipment on
experimental basis
Authority Extent of powers
MD
Full powers with the
concurrence of FA/CAO
on the recommendations
of ED(E)/CCOS/CME/
CFM
ED(E)
Powers upto Rs 1.00
lakh per occasion with
the concurrence of
FA/CAO
CME
Powers upto Rs 50,000
per annum with the
concurrence of Dy.CAO
WM/
Powers upto Rs 10,000
Dy.CME per annum with the
concurrence of Dy.CAO
Contd..
Delegation of Powers Pertaining to T&P
S.No Nature of Power
33.i) Sanction for replacement of T&P
equipments including premature
replacements at Depots/
W.shops
ii)
Sanction for replacement of T&P
items after their normal
utilization for Depots/ W.shops
as per guidelines issued from
time to time
Authority Extent of powers
CME/
ED(Z)
Full powers on the
recommendations of
Dy.CME/ WM with the
concurrence of DyCAO
DyCME/ Full powers with
WM
concurrence of DyCAO
DM
Powers upto Rs 300/- at
a time subject to a limit
of Rs 2,000 per annum
Contd..
Delegation of Powers Pertaining to T&P
S.No Nature of Power
34.i) Sanction for replacement of T&P
equipments for New Depots/
W.shops
ii)
Sanction of additional T&P for
existing Depots/ W.shops on
account of increase in Fleet
stength/ acitivity as per
guidelines
Authority Extent of powers
ED(Z)/
CME
Full powers as per
guidelines
CME/ Full powers with
DyCME/ concurrence of CFM/
DyCAO as per
WM
guidelines
DM
Powers upto Rs 300/- at
a time subject to a limit
of Rs 2,000 per annum
Contd..
Delegation of Powers Pertaining to T&P
S.No Nature of Power
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
Authority Extent of powers
ED(E)
Full powers with
concurrence of FA/CAO
CME/
ED(Z)
Full powers with
concurrence of CFM/
DyCAO upto Rs 20,000
at a time
SSO
Full powers upto Rs
5,000 at a time with
concurrence of Dy.CAO
JSO
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 Kms
n = average life of aggregate in Kms
t = 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 day
a = Number of units per vehicle
Provisioning of Float Units to Depots
S.No
1
2
3
4
5
6
7
8
MAJOR UNITS
UNIT
NORM
Engine
1 for 10,000 KMs.
Front Axle
1 for 14,000 KMs.
Rear Axle
1 for 14,000 KMs.
Gear Box
1 for 8,500 KMs.
Steering Box
1 for 10,000 KMs.
FIP
1 for 5,000 KMs.
Self Starter
1 for 4,000 KMs
Alternator
1 for 4,000 KMs.
SUB ASSEMBLIES
S.No
1
2
3
4
5
6
7
8
UNIT
Injectors (set)
P. P. Shafts (set)
Air compressor
Clutch pressure plate
(Leyland)/ Springer (Tata)
Water pump assembly
Cylinder head assembly
Radiator
NORM
1 for 2,000 KMs.
1 for 6,000 KMs.
1 for 5.000 KMs.
1 for 5,000 KMs.
1 for 5,000 KMs.
1 for 5,000 KMs.
1 for 5,000 KMs.
1 for 5,000 KMs.
MAJOR SPARES
S.No UNIT
NORM
1
2
3
Front hub
Rear hub
Clutch housing
1 for 15,000 KMs.
1 for 15,000 KMs.
1 for 15,000 KMs.
4
5
Air cleaner complete
Fuel twin filter assembly
1 for 5,000 KMs.
1 for 5,000 KMs.
6
Feed pump
1 for 5,000 KMs.
7
8
9
Fly wheel ring gear
Unloader valve
Set (4) of slack adjusters
1 for 10,000 KMs.
1 for 3,000 KMs.
1 for 3,000 KMs.
10
11
12
Set (4) of spring brake chambers 1 for 5,000 KMs.
Hand brake valve
1 for 10,000 KMs.
A. C. Head
1 for 5,000 KMs.
MAJOR SPARES
S.No UNIT
NORM
13
14
15
Air tank
Clutch disc
U. J. Cross
1 for 10,000 KMs.
1 for 5.000 KMs.
1 for 6,000 KMs.
16
17
Set of brake drums front (2 off)
Set of brake drums rear (2 off)
1 for 5,000 KMs.
1 for 5,000 KMs.
18
Set of spring brackets front (2 off) 1 for 5,000 KMs.
19
20
21
Set of spring brackets rear (2 off) 1 for 5,000 KMs.
Axle shafts 2 off
1 for 5,000 KMs.
H. S. D. Oil Tank
1 for 6,000 KMs.
22
23
24
Wiper Machine
Batteries
Hydraulic jacks
1 for 5,000 KMs.
10% of the batteries
1 for 2,000 KMs.
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.
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,.
Norm for Provision of
Spare Buses
Fleet Held Norm
Upto 50
8%
51 to 80
7%
81 & above 6%
76
Physical Inspection of Buses by Depot
Manager & Maintenance Incharge
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 vehicles
S.No System
1
2
3
4
5
6
7
8
9
10
Item
Engine Air cleaner maintenance
,,
A/c Suction hose
,,
Engine mounting
,,
Engine oil leakages
Fuel
HSD tank cap seals
,,
Fuel pipe clamping
,,
Fuel leakages
Cooling Radiator Cap
,,
Coolant concentration
,,
Radiator mountings
Contd..
S.No System
1
2
3
4
5
6
7
8
9
Item
Steering Tie-rod/ drag link end play
,,
ATF oil leakages
,,
King pin lubrication
Susp. Broken spring leaves
,,
Spring side clamps/ ferrules
,,
Welded side clamps
,,
Spring brackets/ shackles
Air suspension mounting bolts
,,
Tightness
Condition of rubber bushes
,,
in Air suspension
Contd..
S.No System
1
2
Item
Transmission Clutch free play
,,
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
1
2
3
4
5
6
7
8
9
Brakes
,,
,,
,,
,,
,,
Tyres
,,
,,
Item
Air tank condensate
Brake pipe clamps
Air leakage
Air Dryer working
Hand brake condition
Brake dust covers
Wheel alignment
Matching of duals
Less than 2mm NSD tyres
Contd..
S.No System
1
Item
Electrical Battery Maintenance
2
,,
Head Lights
3
,,
Signal Lights
4
,,
Self condition
5
,,
Saloon Illumination
6
Body
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
Exterior/ Interior cleanliness
Checklist for Body condition
Code
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 condition
Code
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 condition
Code
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 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 of
Sch-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.
Fleet Optd
Type
Held Kms
Failures within
15 days
Due Done Backlog % Backlog Nos
%
Sch-III
ORD
EXP
Total
Failures within
Fleet Optd
Sch-IV
Type
15 days
Held Kms
Due Done Backlog % Backlog Nos
%
ORD
EXP
Total
Important Registers maintained in
Preventive Maintenance Management
 Daily RG Register RTC-126
 Vehicle Back History RTC-109
 Sch-I Maintenance RTC-127
 Sch-II Maintenance RTC -128
 Sch-III work done MTD -194
 Preventive Maintenance Master register RTC-110
 Unit changes register
 Register for Inspection of vehicles
 FC Register
 Breakdowns RTC-129
 Cancellation of Kms RTC-130
88
Vehicle 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
Type
2010-11
2011-12 (Jan’12)
Aug.
Rep.
Total
Aug.
Rep.
Total
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
676
2751
3427
S.Luxury
Green initiatives &
Use of Alternate fuels
in APSRTC
APSRTC’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…
92
APSRTC’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
93
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
Experiences with Biodiesel
As 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
101
Emission levels of Biodiesel Vehicle
during 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
Nov-05 35.0
Aug-05 35.4
Dec-05 11.8
Sep-05 36.2
Feb-06 25.0
Oct-05 32.6
Mar-06 11.7
102
Emission Levels of trial vehicle
When operated with 100% HSD oil
During Trial period
Before Trial
Jul-05 33.3
Jan-05 35.0
Jan-06 34.0
Feb-05 32.6
Mar-05 11.2
Apr-05 37.3
May-05 45.4
103
Comparative Fuel Performance* of
Vehicle during trials
With 100% HSD oil
With Biodiesel
Jul-05 4.627
Jun-05 4.355
Jan-06 5.193
Aug-05 4.538
Sep-05 4.662
Oct-05 4.778
Nov-05 4.430
* Fuel Performance in Kms/Lit
Dec-05 4.516
Feb-06 4.797
Mar-06 5.008
104
Extended 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.
105
Comparative Emission Levels
Before Trials
Vehicle Bend
No
%
AP11Z
3845
AP11Z
4045
AP11Z
4037
Mar Apr May
2006 2006 2006
During Trials
Avg of
Jun Jul
three
2006 2006
Months
Aug
2006
Avg of
three
months
% Emission
Reduction
30.6
35.67
17.49
20.1
24.97
27.35
21.6 16.67
16.67
59.75
5%
44.3
55
30.4
43.23
35.4
41
10%
29.3
33.7
40.1
34.37
32.7 22.1
20%
27.7
31.9
20.9
26.63
11.7
Comparative Fuel Efficiency
Vehicle No
Bend %
Avg Km/Lit
Before Trial
Avg Km/Lit
During Trial
% Improvement
AP11Z 3845
5%
5.29
5.33
0.76%
AP11Z 4045
AP11Z 4037
10%
20%
5.20
4.91
5.38
5.21
3.46%
5.47%
106
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 Biodiesel 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.
107
With the encouraging trial performance,
Corporation has taken a decision to use Biodiesel 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.
108
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)
109
Biodiesel Stocking & Blending Arrangement
at Depots
Biodiesel
Storage Tank
1 ½’’ MS Line
Dip Rod
Tank Level
Gauge
1’’ Flexible Hose
1’’ MS Line
Truck with Biodesel Transfer Pump
Ground Level
Underground
HSD Oil Tank
110
Procedure of Blending Biodiesel with HSD Oil
Blending Biodiese with HSD for first time
1. Know the quantity of (Q1) of HSD in Ground Tank
2. 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 replenishments
1. Ignore the quantity of B10 blend existing in the storage
tank on fresh receipt of HSD oil
2. Know the fresh quantity (Q3) of HSD that is being decanted
into the underground tank
3. Calculate the required quantity (Q4) of Biodiesel to mix by
using the formula Q3 x 10/90
4. Transfer the quantity Q4 of Biodiesel from Storage tank to
the Underground tank with the help of Flow meter F1
111
Reduction of Pollutants with B20 Fuel
POLLUTANT
Reduction with
The values with
20% Blended
Pure HSD Oil
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%
112
Comparative Specifications of HSD & Biodiesel
Parameter
ASTM
Method
Flash Point
D93
Water & Sediment
D2709
Kinematic Viscosity 40oc D445
Unit
Pure BioDiesel
Normal
HSD Oil
OC
130 min
66 min
% Volume 0.05 max
0.05 max
mm/Sec
1.9 – 6.0
2-5
0.01 max
Sulphated Ash
D874
% mass
0.02 max
Sulphur
D5453
% mass
0.05 max 0.035 max
Copper Strip Corrosion
D130
Cetane Number
D613
Cloud Point
D2500
Not worse
No.3 max
than No.1
47 min
OC
46 min
Report
Continued…
113
Comparative Specifications of HSD & Biodiesel
Parameter
ASTM
Method
Unit
Pure BioDiesel
Normal HSD
Oil
Carbon Residue
100% Sample
D4530
% mass
0.05 max
0.03 max
on 10%
Acid Number
D664
mg
KOH/gm
0.8 max
--
Free Glycerin
D6584
% mass
0.02 max
--
Total Glycerin
D6584
% mass
0.24 max
--
Phosphorus
D4951
% mass
0.001 max
--
Distillation Temp.
Atmospheric
Equivalent Temp
90% Recovered
D1160
Degrees C
360 max
-114
Some of the barriers in
large 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 price
It is difficult to assess the quality of the
product at the user level
There is scope for non-adherence to the
prescribed specifications by the suppliers in
the absence of required testing facilities.
Contd…
115
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
116