• Ensure transformers loading is more than 50%. Stand by transformers should be de-energized to conserve energy wherever possible except for monsoon period to avoid the possibility of moisture contamination
• Install additional KVAR for power factor improvement.
• Install VFD for DG cooling water pump, Boiler feed pump or where load varies heavily.
• Install screw chiller according to the capacities only. Run chillers according to the capacity depending upon weather conditions. Ensure chillers are loaded more than 70%.
• Install online tap changer (OLTC) to avoid Voltage Fluctuations on one of the lighting transformer.
• Replace faulty capacitors to avoid excess power consumption.
• Use high efficiency fans in humidification plants.
• Replace under rated Air Circuit Breaker with correct rated Air circuit breaker.
• Switch off the blowers during the idle time of the plant.

Fuel Handling and Operation:

• 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.
• Prepare a hard ground for stacking coal

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.

• Maintain carbon dioxide at 13% or higher level in flue gas so as to improve efficiency
• Control excess air with oxygen at 3.0 to 4% level in flue gas.
• Maintain stack temperature in the range of 1800-2000 C by oil pressure adjustment, burner cleaning, filtering fuel, soot & scale removal and excess air to 2-3%.
• Install a properly designed condensate recovery tank thus save energy to the tune of 5-7%.
• Improve the condensate recovery so as to raise the feed water temperature up to 750-800 C.

• Maintenance of steam traps to be carried out regularly.

Coal

• Prepare a hard ground for stacking coal and avoid carpet loss.

DG Sets Operation and Maintenance

• Improve SFC of the DG sets
• DG sets flue gas temperature is more than 4500C install waste heat recovery boilers on DG sets to generate additional power & pre heat fuel oil
• Improve specific electricity generation by loading in excess of 60% and upto 80%

Insulation

• Improve insulation and cladding of DG sets exhaust
• Insulate Flanges & valves to minimize heat loss. Insulation is to be boxed type for maintenance ease.
• Bare steam line, Steam traps and leaky valves etc to be checked periodically and insulated.
• Improve insulation if the surface temperature exceeds 600C. Ensure that proper insulating material and thickness is provided for proper insulation.
• Insulate the boiler feed water tank after implementing condensate recovery.(if not existing)
• Arrange or ask for Industrial training programme in your cluster once a year.

• Reduce compressed air pressure from 8 Kg/Cm2 to 7.0 Kg/Cm2 where ever possible to conserve energy, when required pressure at usage point is 6.0 Kg/Cm2
• Stop use of compressed air for floor/ machine cleaning.
• Check for compressed air leakage.

Humidification:

• Replace conventional nozzles by humidification nozzles in all units.

• Ensure installed cooling water pumps are of rated capacity and not of higher capacity.