• For efficient combustion pre-heat the oil to have temp between 1050-1100C at burner tip and optimize air to fuel ratio.
• To stop abrasive particles FO filtration system should have filter mesh sizes as follows.
    a. Between Lorry & main storage tank-mesh size 10
    b. Between service tank & pre-heater- mesh size 40
    c. Between pre-heater and burner- mesh size 100
• Provide water draining facility and regularly drain water. This reduces sludge formation and other problems like erosion of burners and damage to the refractories.
• It is preferred to have parallel FO pumps of smaller capacity than one pump of larger capacity to avoid unnecessary re-circulation of huge quantity of FO.

Furnace:

• Control excess air with oxygen at 3.0 to 4% level in flue gas.
• Air flow to fuel feed rate should be controlled for oxygen level around 3.5% to 4% oxygen in flue gases.
• Normally flue gas temperature is beyond 5500C. To recover waste heat install recuperator of required capacity and pre-heat the air.
• Provide the doors and close the material charge and discharge doors partially during operation and fully during furnace idling time. (Reducing the heat loss through openings)
• Provide thermocouple to maintain and monitor furnace temperature.

• Clean the recuperator regularly. Close the gap between recuperator and furnace. Provide temperature gauge in pre-heating air line and ensure that the pre-heat air temperature is above 2000C.
• Reduce the stack losses by providing recuperator and pre-heat the combustion air to a temperature of 2500C-3000C in furnace (where not provided)

• Improve insulation and cladding of DG sets exhaust
• Insulate Flanges & valves to minimize heat loss. Insulation is to be of boxed type for maintenance ease.
• Steam line, boiler feed water lines to be checked periodically and damaged insulation to be repaired immediately.
• Improve insulation if the surface temperature exceeds 600C. Ensure that proper insulating material and thickness is provided for proper insulation.
• Arrange or ask for Industrial training programme in your cluster once a year.

• Switch off blower during idle time to avoid heat loss.
• Avoid no load operation of motors.
• Replace underloaded / overloaded motors with proper size motors & Replace the motors with energy efficiency motors.
• Production to be divided in two groups, lower size and higher size and accordingly tools should be manufactured in two groups of hammer and broach machines (lower size not to be manufactured on higher size machines)

• Replace 40W Tube light by slim 28W Tube light and electromagnetic choke with electronic choke.
• Replace 400 Watt Mercury Vapour lamps with 250 Watt sodium vapour lamps or 250 W metal hallide lamps.
• Replace 250 Watt Mercury Vapour lamps with 150 Watt sodium vapour lamps or 150 W metal hallide lamps.
• Provide more transparent sheet instead of asbestos sheets to use natural light.
• Install energy saver for reducing the lighting load.
• Rationalize lighting in identified areas i.e remove excess lighting in identified areas. Also relocate lighting, if necessary.
• Switch off unnecessary loads during period of lunch, tea etc.

• Cleaning of tubes should be carried out periodically.
• Oil temperature should be maintained at 1050C for better automation.
• Control excess air and fuel ratio. Repair the non functioning air damper to have better control of excess air.
• PRV to be maintained and kept in service so that steam header pressure is maintained properly at 3 kg/Cm2.

• Condensate net work should be insulated properly and steam traps should be rectified.
• Repair steam traps to recover 100% condensate, thus increase feed water temperature to 700-800C.

• Control excess air in dry off oven.
• Control excess air in baking oven.
• Add more load to both ovens to improve efficiency.

DG Set:

• The air inlet and fuel injector system calibration should be done in consultation with OEM
• DG room should be properly ventilated and a lagging over exhaust pipe line to be provided and air inlet temperature for DG set should not exceed ambient + 50C.