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Company LOGO

ENERGY MANAGEMENT SYSTEM MANUAL

(AS PER ISO 50001:2018)

Company Name,

Address,

Contact Details,

E-mail: ___________________

Website: _________________

COPY NO:-……………

Approved By : CEO/Director

Signature:

Approved by - CEO/Director Reviewed by - Energy Leader Prepared by - Energy Coordinator

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0.1 TABLE OF CONTENTS

Section Section Title Rev. Page

No. No. No.

0.0 Cover Page 00

0.1 Table of Contents 00

3.0 Terms and definitions 00

4.0 Context of the Organization 00

4.3 Scope of Energy Management System 00

5.1 Leadership and Commitment 00

5.2 Energy Policy 00

5.3 Roles, Responsibility and Authority 00

6.0 Planning 00

6.1 Actions to address risk and opportunities 00

6.2 Objectives, energy targets and planning 00

6.3 Energy Review ( Criteria & Methodology) 00

7.2 Competence 00

7.3 Awareness 00

7.4 Communication 00

7.5 Documented Information 00

7.5.3 Control of Documented information, Revision History, Distribution

00

8.1 Operational Planning & Control 00

8.3 Procurement 00

9.1 Monitoring and Measurement 00

9.1.2 Evaluation of Compliance 00

9.2 Internal Audit 00

9.3 Management Review 00

10.1 Nonconformity and Corrective Action 00

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3.0 Terms and definition

Abbreviations

EnMS Energy Management Services

EnPI Energy Performance Indicator
EnB Energy Baseline
SEU Significant Energy Use
ERC Energy Review Committee

3.1.1
organization
Person or group of people that has its own functions with responsibilities, authorities and
relationships to achieve its objectives

3.1.2

Top management

Person or group of people who directs and controls an organization at the highest level.

3.1.3
Boundary
Physical or organizational limits

3.1.4
Energy management system scope
EnMS scope
Set of activities, which an organization addresses through an energy management system

3.1.5
Interested party (preferred term)
Stakeholder (admitted term)
Person or organization that can affect, be affected by, or perceive itself to be
affected by a decision or activity

3.2.1
Management system
Set of interrelated or interacting elements of an organization to establish policies and
objectives and processes to achieve those objectives

3.2.2
Energy management system
EnMS
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Management system to establish an energy policy, objectives, energy targets, action plans
and process(es) to achieve the objectives and energy targets.

3.2.3
Policy
Intentions and direction of an organization, as formally expressed by its top
management

3.2.4
Energy policy
Statement by the organization of its overall intention(s), direction(s), and commitment(s)
related to its energy performance, as formally expressed by top management

3.2.5
Energy management team
Person(s) with responsibility and authority for effective implementation of an energy
management system and for delivering energy performance improvement.

3.3.1
Requirement
Need or expectation that is stated, generally implied or obligatory.

3.3.2
Conformity
Fulfilment of a requirement

3.3.3
Nonconformity
Non-fulfilment of a requirement

3.3.4
Corrective action
Action to eliminate the cause of a nonconformity and to prevent recurrence

3.3.5
Documented information
Information required to be controlled and maintained by an organization and the medium
on which it is contained.

3.3.6
Process
Set of interrelated or interacting activities which transform inputs into outputs

3.3.7
Monitoring
Determining the status of a system, a process or an activity.

3.3.8
Audit
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Systematic, independent and documented process for obtaining audit evidence and
evaluating it objectively to determine the extent to which the audit criteria are fulfilled

3.3.9
Outsource (verb)
Make an arrangement where an external organization performs part of an organization’s
function or process

3.4.1
Measurement
Process to determine a value

3.4.2
Performance
Measurable result

*Performance can relate either to quantitative or qualitative findings.

**Performance can relate to the management of activities, processes, products (including

services), systems or organizations.

3.4.3
Energy performance
Measurable result(s) related to energy efficiency, energy use and energy consumption

3.4.4
Energy performance indicator
EnPI
Measure or unit of energy performance, as defined by the organization

3.4.5
Energy performance indicator value
EnPI value
Quantification of the EnPI at a point in or over a specified period of time

3.4.6
Energy performance improvement
Improvement in measurable results of energy efficiency, or energy consumption related to
energy use, compared to the energy baseline
3.4.7
Energy baseline
EnB
Quantitative reference(s) providing a basis for comparison of energy performance
3.4.8
Static factor
Identified factor that significantly impacts energy performance and does not routinely
change.
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EXAMPLE Facility size; design of installed equipment; number of weekly shifts; range of
products.

3.4.9
Relevant variable
Quantifiable factor that significantly impacts energy performance and routinely changes

EXAMPLE Weather conditions, operating conditions (indoor temperature, light level),

working hours, production output.

3.4.10
Normalization
Modification of data to account for changes to enable comparison of energy performance
under equivalent conditions

3.4.11
Risk
Effect of uncertainty

3.4.12
Competence
Ability to apply knowledge and skills to achieve intended results

3.4.13
Objective
Results to be achieved

3.4.14
Effectiveness
Extent to which planned activities are realized and planned results achieved

3.4.15
Energy target
Quantifiable objective of energy performance improvement

3.4.16
Continual improvement
Recurring activity to enhance performance

3.5.1
Energy
Electricity, fuels, steam, heat, compressed air and other similar media

3.5.2
Energy consumption
Quantity of energy applied
3.5.3
Energy efficiency
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Ratio or other quantitative relationship between an output of performance , service, goods,

commodities, or energy , and an input of energy

EXAMPLE Conversion efficiency; energy required/energy consumed.

3.5.4
Energy use
Application of energy

EXAMPLE Ventilation; lighting; heating; cooling; transportation; data storage; production

process.

3.5.5
Energy review
Analysis of energy efficiency , energy use and energy consumption based on data and other
information, leading to identification of SEUs and opportunities for energy performance
improvement

3.5.6
Significant energy use
SEU
Energy use accounting for substantial energy consumption and/or offering considerable
potential for energy performance improvement

4.0 CONTEXT OF THE ORGANIZATION

4.1 Understanding the Organization

XYZ Limited has grown to become one of the major manufacturer and supplier of automotive
components to Original Equipment Manufacturer and their Tier 1 suppliers in India and
abroad. We are also supplying parts for home appliances and white goods.

Our obsession with the driving force which is why our esteemed customers keep on coming
back to us with repeat orders. We are proud to share that none of our customers have ever
left us. Quality improvement and Quality Assurance is an ongoing process at the company.
There is a continual process of improvement of product, process and quality system. The
focus is on defect prevention rather than defect detection and correction.

One of our strength is the wide range of machine. Our production facilities include a wide
variety of machines which are a combination of CNC, Conventional and special purpose
machines. This helps the company in developing different range of products. It is continuous
endeavour to upgrade the technology involved in production and development of
components.

Our commitment towards achieving customer delight is shown by the fact that today we
are associated with top companies in our wheelers and home appliance industry. Besides
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OEM Customers in India, we also export to leading automotive parts manufacturer and OEM
vendors in Europe.

Human Resources are also among our strength. The company has enjoyed excellent
industrial relation with it’s associates and has never faced any instances like strikes or lock
out.

We continually invest in development of manpower and increase skills. It is ensured that all
people get related training all through the year.

We have been regularly invested in getting new technology which has helped us to stay
competitive in the market and first choice for our customers. Besides this, we practice lot
of cost saving and productivity exercise like Gemba Kaizen, 5S, Poke Yoke, SMED etc. to
remain competitive and give best value to our esteemed customers. We have good
experience in efficient methods of manufacturing like single piece flow and TQM

The organization has determined external and internal issues as per Annex A-01 which
affect the intended outcome and energy performance.

4.2 Understanding the needs and expectations of interested parties

The organization has also understood the needs and expectations of the interested parties
which are relevant to energy performance and the EnMS.
The needs and expectations are reviewed in the Energy Review committee meetings for
changes, if any.
The interested parties are organization, Employees, customers and suppliers and their
basic need is energy cost.

The legal bodies are also the interested party and the need is legal compliance.
The organization has also identified the applicable legal requirements.
There is no other requirement at present and as and when is applicable the same shall be
identified and complied with.

4.3 SCOPE OF ENERGY MANAGEMENT SYSTEM

Scope of EnMS:
Manufacturing of XYZ using Power from State Electricity Board, DG Sets as Power Backup,
and Compressed Air from Air Compressors.

The scope shall be confined to the physical boundaries of site <Plant Name and Address.>
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The top management has the authority to control its energy efficiency, energy use and
energy consumption within the scope and boundaries. The organization has included all
energy type within the scope and boundaries.

4.4 Energy management system

This has been established, implemented, maintained for having continual

improvement in Energy Performance, including the organizational processes and
their interactions.
The processes and their interactions with Energy has been established as per Annex A-02.

5.1 LEADERSHIP AND COMMITMENT

The organization has defined the Scope, boundaries, objectives and targets, has
approved the action plans to achieve the identified objectives. The objectives has
been aligned with the business processes.

To achieve the intended results, the Top Management has assured the resources to
be provided, which are needed for the EnMS. The communication of the EnMS, its
requirements, effectiveness and performance is done through the displays, Digital
media and meetings.

The Top Management has formed the cross functional energy management team as per
Annex A-03

The management

- directs and support the team to work for effectiveness of the EnMS and to review
energy performance improvement.

- ensures that processes are established and implemented to identify and address
changes affecting the EnMS and energy performance.

Sign

Executive Director
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5.2 ENERGY POLICY

The Energy Policy has been defined by top management (Executive Director – MAPL)
considering the energy aspects associated with the location’s activities, products and
services, and the requirements of ISO 50001:2018. The Energy Policy is a framework for
the location’s “energy efficiency” initiatives, objectives & targets along with the
compliance to legal and for continually improving its energy performance.

This policy supports the procurement of energy efficient product and services impacting
energy performance, support design activities that considers energy performance
improvement.

Energy team ensures that the Energy Policy is communicated and understood by all
personnel at the location. The Policy is also made available to the stakeholders and public
on request.

The Energy Policy is reviewed by the Executive Director in conjunction with Energy Team in
the Energy Review Committee Meetings and revised, if necessary.

The Energy Policy is presented on the following page:

Energy Policy

(XYZ Limited)

We at XYZ Limited, are committed to improve our energy performance in all our activities,
products Purchase and services, having Energy sustainable for future generations. We also
committed to reduce our specific energy consumption on a continual basis.
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To achieve this we shall, in particular,

• An Energy Management System.

• Impart awareness to all employees, contractors and vendors on energy efficiency
aspects and their contribution to Energy Management System.
• Comply with applicable legal and organizational requirements pertinent to the
energy management objective and targets.
• Encourage and promote waste minimization, energy efficiency and resource
conservation.
• Evaluate effectiveness of the Energy Management System through periodic audits
and Energy Reviews.

04.02.20
Mr……….
Executive Director

5.3 ROLES, RESPONSIBILITY AND AUTHORITY

Top management has assigned the responsibility and authority to the energy team for
establishing, implementing , maintaining and continually improve EnMS as per the
requirements of the standard.

Executive Director`

1. Ensure that there is in place an EnMS in line with the requirements of

ISO50001:2018, is regularly and periodically reviewed and relevant records
maintained.
2. Provide adequate resources for the implementation of EnMS at XYZ Private Limited.
3. Implementing the Energy Policy at XYZ Private Limited.
4. Will chair the Energy Review committee meeting
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5. Communicate with the external agencies on energy matters.

Energy Coordinator

Executive Director has appointed one competent person as the Energy Coordinator from
Engineering for EnMS and is a member of energy team. The responsibilities of EC, in addition
to his other responsibilities, are:

1. Coordination between top management, energy team and functional team.

2. Organizing resources for the implementation and maintenance of EnMS.
3. Gap identification in establishing, implementing and maintaining ISO 50001:2018
requirements
4. Implementing the Energy Policy at XYZ Private Limited.
5. Control of EnMS documentation.
6. Organizing Energy Review committee meetings, making of MOMs and distribution
to relevant responsibility centers.
7. In consultation with Executive Director , respond to external communication
related to EnMS.
8. Reporting Energy Performance of the location

Energy Team

The responsibilities of energy team are:

1. Ensuring that the EnMS requirements are established, implemented and

maintained as per the ISO 50001:2018 requirements.
2. To prepare the Energy Policy at the Location
3. To establish base line, performance indicator and to identify risk and opportunities
with respect to energy efficiency.
4. Ensuring that Energy Objectives and Targets are identified and are established for
relevant functions
5. Conduct EnMS Audits at specified intervals.
6. To document applicable legal requirements of the XYZ Private Limited.
7. Evaluation of compliance against applicable legal requirements.
8. Ensure appropriate actions on non-conformances, corrective action reports and
close-out.
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9. Collating performance data against Objectives and targets and reporting to the
location management.
10. Ensure that EnMS training is imparted to all employees.

Functional HOD

Department HOD’s are responsible for overall operational control in various areas of EnMS
as follows:

1. Ensure that relevant EnMS requirements with respect to the function are
established, implemented and maintained.
2. Implementation of EnMS for achievement of Objectives and targets and
periodically review the implementation status and effectiveness of energy
management
3. Identification of resources essential to implement and control the EnMS.
4. Reporting the performance of EnMS to Energy Team/EC for review.
5. Ensure communication of Energy Policy and Significant Energy aspects relevant to
the employees.
6. In conjunction with EC/ Energy Team, identify training needs of personnel whose
works have a significant impact on energy, and imparting EnMS training to all their
personnel.

6.0 PLANNING

6.1 Actions to address risks and opportunities

The organization has identified risks & opportunities with respect to internal and external
issues on bases of Significant or Nonsignificant and has taken appropriate actions to achieve
continual improvement.
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6.2 OBJECTIVES AND ENERGY TARGETS

Setting of Energy Objectives and Targets

The Organization has established Energy Objectives and targets at the location / functional
level considering the Energy Policy, internal/external energy audit, legal requirements, risk
analysis and views of interested parties. Availability of technological options for increasing
energy efficiency, financial, operational and business requirements has also be considered
while defining the objectives and corresponding targets.

System for Defining Energy Objectives

Energy saving objective, action items and targets has been identified as per Annex A-04
while defining the Energy Objectives, the following has been considered:

1. Identified the significant SEU’s (Significant Energy Users) such as compressors,

Fuels for thermal energy like LPG for burners and Diesel for DG sets, Gases (Co2),
Motors & Electrical distribution system
2. Energy Objectives are improvement based, wherever possible or otherwise
maintenance based.
3. Action items has been identified by the energy team to achieve the set objectives
and targets
4. The targets are measurable/ quantifiable to the extent feasible for facilitating
tracking of energy performance against these action items of the objectives.
5. The time frames has been clearly defined.

System of Reviewing /Revising Objectives and Targets

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The performance status against set Objectives and Targets are monitored and reported by
the Energy Coordinator once in a month as per Annex A-05 Or minimum in the Energy
Review Committee (ERC) Meeting. Energy Review Committee (ERC) meetings is decided to
held at least once in six months. The Energy Review committee has members of energy
team and workers to review and to give/take suggestion for energy performance
improvement. Once a target has achieved, the same is reviewed for possibility of further
performance improvement. In case, it is be not feasible for the location to revise the target
for improvement, the same is maintained as a performance standard on an on-going basis.

In case of any deviation in terms of implementation and / or non-achievement of

objective/target, reasons for the same is analyzed, corrective actions are planned and
implemented. Information on deviations is provided to the ERC members also.

Objective and targets are revised/amended in Energy Review committee meetings where
relevant to ensure that Energy management also applies to projects related to new
developments and new or modified activities, technology, products, equipment or services
as per Annex A-06

6.3 Energy Review (Criteria & Methodology)

The organization is using following methodology and criteria for energy review

The organization is analyzing current/past energy use and consumption based on

measurement and other data to:

a) Identify SEUs (Significant Energy Users)

b) Set targets of action items

c) Determine relevant variables and current energy performance

d) Prioritize opportunities for improving energy performance;

e) Estimate future energy use(s) and energy consumption.

The energy review is presented in Energy Review Committee in response to major changes
in facilities, equipment, systems or energy-using processes.
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6.4 Energy performance indicators

The organization has determined EnPIs for each action items which are:

a) Appropriate for measuring and monitoring its energy performance;

b) Enable the organization to demonstrate energy performance improvement.

6.5 Energy baseline

The organization has establish EnB for each action items using the information from the
energy review(s) taking into account a suitable period of time.

Energy base line is revised in ERC meeting if:

a) EnPI(s) no longer reflect the organization’s energy performance.

b) there have been major changes with respect to equipment/facility/technology/system.

6.6 Planning for collection of energy data

The organization has ensured that key parameters affecting energy performance are
identified, measured, monitored and analyzed at planned intervals. Measurement and
monitoring plan as per Annex A-07 .

7.0 Support

Recourses

The resources required for implementation and control of the EnMS is included in Annual
Operating budget. Additional requirement, if identified during the plan period shall be
provided by the location head.

COMPETENCE, AWARENESS AND TRAINING

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Awareness training is provided to all employees on Energy Policy, Energy Objectives &
targets, energy review associated with their work and their roles and responsibilities within
EnMS.

EnMS Training plan has been prepared by the Energy team in consultation with EC/ Area
In-charges every year as per Annex A-08. Training is conducted on the job and / or formally
in the classroom. Training attendance records has been maintained as per Annex A-09. The
effectiveness of training is evaluated by asking questions to the trainees during the training.

Competence of Energy Team

Energy team is a cross functional team having members from Top management,
Engineering, Purchase and Production. All the members must be competitive enough to
drive, to take decision, have skills with respect to energy management and have ability to
present report to higher management.
The team members and their competency is approved by top management as per Annex A-
10

COMMUNICATION

Internal Communication

The location has institute Energy Review Committee Meetings (frequency – half
Yearly) under the EnMS to.

- Review of energy performance against set Objectives and Targets,

.
- Report of significant energy performance indicators, contribution of employees ,
applicable legal requirements

- Review Energy performance deviations

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These are communicated in the form of Minutes of meetings by Energy coordinator to all
those within the location who are responsible for Energy performance actions decisions.

The Energy Policy is communicated to all employees through displays / handouts by Energy
Team etc.

Communication with External Interested Parties

Location’s external communication involves communication with regulatory authorities,

Vendors, and suppliers.

The energy policy shall be communicated to the external parties like the contractors working
on the location, suppliers, legal authorities if applicable through verbal communication or
distribution of policy pamphlets, as far as practicable.

DOCUMENTED REQUIREMENT

To ensure that the activities, products and services conform to the specified EnMS
requirements, the EnMS has been documented in the following 3 levels.

Level 1:

EnMS MANUAL as an apex manual describes the commitment of the Management towards
energy performance. The sections of this Manual has been aligned to the structure of ISO
50001:2018 Standard. It addresses how the requirements of various clauses of ISO
50001:2018 has been fulfilled by the location.

Level 2:
OCPs provide guidance for carrying out specific activities that are associated with the
identified significant energy saving action items for the objectives and targets.

Level 3:
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RECORDS for providing evidence that the EnMS is working effectively and are generated
concurrently as the procedures are performed. Forms and Formats used to maintain records
are also be a part of Level 3.

Cross References to the relevant documents is provided at the end of the Manual and
procedures.

CONTROL OF DOCUMENTED INFORMATION

Energy performance records and the persons responsible for maintaining them is identified
in the EnMS Manual.

Records are identified by their title and/or their number. All files / registers containing
records are labeled. All records are legible and maintained in an orderly manner.

For easy retrieval and protection against deterioration and loss, records are stored at
specified location. Locations shall be allocated keeping in mind the convenience of access
to the relevant users. Retention period, is the minimum period for which each record is to
be maintained.

List of records is maintained containing title of the record, retention period, storage location
and custodian as per Annex: A-11 Records are disposed off after retention period, but for
each disposal an approval of disposition is taken from the Location Head

Identification of Documents

The documents generated by the location as part of EnMS are identified by their unique
title/ the Unique Numbering System as per Annex: A-12

Document Approval and Issue

The documents are reviewed & approved for adequacy prior to issue. The personnel
authorized for document approval and issue of documents is as per Annex: A-13
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Document Changes

To carry out amendment in any document, the change initiator shall make the necessary
changes in the document, reviews the adequacy as well as changes in revision number,
date etc. and forwards the amendment to the approving authority, highlighting the changes
made. The reasons for change shall be explained to the approving authority by the change
initiator. The approving authority shall review the amendments for its adequacy and
effectiveness. On confirming the amendment is complete and adequate, the approving
authority shall approve the amended document. In case of amendment in the EnMS Manual,
the revision number shall be changed page wise wherever changes have been made, and
the amendments shall be recorded in the Revision History of the EnMS Manual. However,
in case of amendment of any other EnMS document, the revision number of the entire
document shall be changed. The amendments shall be recorded in the Revision History
maintained for the document.

Master Copy of the obsolete documents related to EnMS shall be retained by Location Energy
Coordinator at least for the last change for reference purpose and shall be suitably identified
as “SUPERSEDED”. All the Controlled Copies of the documents shall be collected back by
the issuer and destroyed.

REVISION HISTORY

Section Page Current Revision Details Sign. of

No. No. Revisio Approving
n No. Authority
with Date
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Status of Document

The original copy of the document is a Master Copy. The Master Copy is signed by approving
authority in original. The Controlled copy of the document is obtained by taking the
photocopy of the Master Copy.

In every level of document, the status of the document is indicated. The following is the
identification for indicating status:

1. Master Copy

Green colour seal bearing "MASTER COPY" on the back side of every page.

2. Controlled Copy

Red Color Seal bearing "CONTROLLED COPY" on the front side of every page.

3. Obsolete Copy

blue Colour seal bearing "OBSOLETE COPY" on the front side of every page.

Control of Documents of External Origin

1. The documents of external origin received by the location includes acts / rules issued
by statutory bodies etc.

2. Externally Originated documents is maintained by the Location Energy Coordinator.

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DISTRIBUTION LIST OF EnMS MANUAL

The EnMS Manual is a confidential document and is to be issued to individuals /

organizations except those listed below without the prior approval of the Executive Director
of the company

The EnMS Manual is circulated to the personnel shown hereunder. The holders of the Manual
is responsible for maintenance and sharing amongst personnel in their respective area of
work.

COPY NO. DESIGNATION OF THE HOLDER

MASTER COPY
Executive Director

CONTROLLED COPY NO. 1

Energy Coordinator

CONTROLLED COPY NO. 2

Functional Head

This Manual can be made available to all Line Managers in soft form as a ‘pdf’ file. In
addition the manual can also be made available in digital form with in the company
if feasible.

8 OPERATION
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OPERATIONAL PLANNING & CONTROL

Location has instituted operational controls for its processes and operations in line with its
Energy Policy, significant energy objective, action items and targets, legal requirements,
and views of interested parties including customers. These include:

1. Documented OCPs detailing the manner of conducting activities associated with

significant energy action items for the identified objective and targets.

2. Appropriate Energy performance criteria to monitor capabilities of processes, plant

and equipment vis-à-vis the objectives and targets.

3. Monitoring and control of relevant energy parameters to meet the energy

performance requirements.

List of relevant OCP are as per Annex: A-14

Preventive Maintenance Schedule of SEU’s

Preventive maintenance schedule is prepared and executed as per Annex: A-15.

Monitoring, measurement, analysis and evaluation of energy performance and

the EnMS

The organization monitors, measures, evaluates the Energy Performance and the
EnMS: through monitoring and measurement covering

1. key parameters.

1. the effectiveness of the action plans in achieving objectives and energy

targets;

2. EnPI(s);

3. Energy performance of action items for SEUs; actual versus expected energy
consumption

4. the methods for monitoring, measurement, analysis and evaluation, as

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applicable, to ensure valid results;

5. when the monitoring and measurement is performed;
6. when the results from monitoring and measurement is analyzed and
evaluated
7. The organization evaluates its energy performance and the
effectiveness of the EnMS
8. Improvement in energy performance shall be evaluated by comparing
EnPI value(s) against the corresponding EnB(s)
9. Investigate and respond to significant deviations in energy
performance.

8.3 Procurement
The organization has establish guidelines for evaluating energy performance over the
planned or expected operating lifetime, when procuring energy using products, equipment
and services which are expected to have a significant impact on the organization's energy
performance.

When procuring energy using products, equipment and services that have, or can have, an
impact on energy performance, the organization shall inform suppliers that energy
performance is one of the evaluation criteria for procurement.

Where applicable, the organization has define and communicate specifications as per
guidelines for:

a) Ensuring the energy performance of procured equipment and services;

b) the purchase of energy.

Design

The organization has consider energy performance improvement opportunities and

operational control as per defined guidelines in the design of new, modified and renovated
facilities, equipment, systems and energy-using processes that can have a significant
impact on its energy performance over the planned or expected operating lifetime.

9.0 PERFORMANCE EVALUATION

MONITORING AND MEASUREMENT

Monitoring of Key Prarameters

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Measurement and monitoring requirement of key performance indicators has been identified
and included in the Measurement and Monitoring Plan. The Plan has define the Energy
parameters to be measured / monitored, frequency of monitoring, allowable limits and
calibration/verification of instruments used for measurement and monitoring.

The measured Key Performance Indicators has been used to track effectiveness of
operational controls and also conformance with the location’s energy performance
objectives and targets. The performance against objectives/ action items is tracked and
reviewed as per defined frequency.

Calibration of Energy Monitoring Instruments

The significant energy monitoring instruments has been calibrated either internally or
through external agency. Required energy monitoring instruments has been mentioned in
monitoring and measurement plan. The calibration records is maintained by Engineering.

Where energy monitoring is outsourced, the concerned function has ensured that the
instruments used are having valid calibration status and maintains record of the same.

EVALUATION OF COMPLIANCE WITH LEGAL REQUIREMENT

The organization has identified & documented for legal requirement related to energy in
Annex A-16 compliance is documented and reviewed during energy review committee
meetings for any noncompliance and required action to mitigate the risk.

9.2 INTERNAL AUDIT

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Company Name / Logo
MANUAL ISSUE: 0
REVISION No.: 0
DATE:

EnMS audits is be carried out in order to:

1. Determine whether or not the EnMS conforms to planned arrangements for energy
management including the requirements of ISO 50001: 2018 and also to determine
whether the EnMS has been properly implemented and maintained.

2. Provide information on the results of audits to management.

Internal Audits is conducted at least once in 6 months. Annual Internal Audit Plan is
prepared by ER taking into consideration the Energy Performance importance of the activity
concerned and the results of previous audits as per Annex: A-17

The internal audit schedule is prepared by the EC which defines the activities / functions to
be audited, scope of audit, date and time of audit and also the name of the auditor(s) as
per Annex: A-18 The audit schedule is circulated to the auditees and the auditors concerned
in advance. The auditors used for the purpose are trained in internal auditing. The audit
schedule takes care that the auditors are not auditing their own function(s).

Auditing

The audit is carried out with respect to:

1. Compliance to the requirements of ISO 50001:2018.

2. Compliance to Energy Policy.
3. Effectiveness of objective, targets, action items,
4. Communication, Staff awareness and training.
5. Monitoring and measurement.
6. Status of the non-conformity report and the implementation of preventive action.
7. Legislative and regulatory compliance

The auditors follow the following basic steps:

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1. Investigate and understand the management systems.

2. Assess the internal controls including awareness of personnel.
3. Review of records, sampling and verification.

Reporting of Non-Conformities and Their Closure

The audit observations are recorded by the auditor in the “Audit Checklist & Observation
Sheet”. Both the areas of conformance and non-conformance observed by the auditor are
recorded in the Audit Checklist & Observation Sheet. The observations clearly identifies as
“Conforming” and “Non-conforming” by the auditor in the Audit Checklist & Observation
Sheet as per Annex: A-19 Potential non-conformities is identified and recorded in the Audit
Observation Sheet. The non-conformities identified during audit is recorded in NCR forms
as per Annex: A-20 Auditors submit the Audit Checklist & Observation Sheet and Non
Conformance Reports to the Executive Director.

The NCRs are closed by internal auditors after reviewing the corrective actions taken. The
concerned person is committed to take immediate corrective actions without undue delay
and report the status of corrective actions against the NCRs in Energy Review meetings.

10.0 Improvement

NON-CONFORMITY AND CORRECTIVE ACTION

Non-conformance may be identified with the help of

1. Monitoring and measurement activities

2. Deviations not identified and no corrective action
3. No action on Audits observation (internal or external)
4. Evaluation of compliance against Legal and Other requirements
5. Non compliance to identified action items
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Corrective Actions

In case of major or repetitive non-conformance as identified and /or by any other source as
mentioned above, the cause of the non-conformance is determined and the corrective
actions is planned. Corrective Actions is taken in a planned manner considering the
technological options and severity of the non-conformance. Record of corrective actions is
maintained in Corrective Action Report.

Reporting and Review of Non-conformances/Corrective Actions

The non-conformances and corrective actions are reviewed in the Energy Review meetings.

Document Change due to corrective Actions

The corrective / preventive actions may necessitate changes in the documented procedures.
The same is carried out as per the procedure for control of documents.

Continual Improvement

The organization continually improves the suitability, adequacy and effectiveness of the
EnMS. The organization demonstrates continual energy performance improvement
through the case studies or suggestions or energy saving results. If the results are not
achieved, the causes are identified and subsequent actions are taken. Documented
information is kept.
List of Annexure
Annexure
Sr. No Title
Number

01 External and Internal issues A-01

02 Process-Energy interactions matrix A-02

03 Energy Management Team A-03

Identification of Energy saving objective and targets

04 A-04
along with Action Items

Performance Review Report against set Objectives and

05 A-05
Targets

Revision/Amendment of Objective and Targets along

06 A-06
with action items

07 Measurement and Monitoring Plan A-07

08 EnMS Training Schedule A-08

09 Training Attendance Records A-09

10 Team members and their competency Matrix A-10

11 List of EnMS Records A-11

12 Document Numbering System A-12

13 Document Approval & Issue Authority Matrix A-13

14 List of OCP’s & OCP’s A-14

15 Preventive Maintenance Schedule of SEU’s A-15

16 Legal Requirement Related to Energy A-16

17 Internal Audit Plan A-17

18 Internal Audit Schedule A-18

19 Audit Checklist & Observations A-19

20 Non-Conformities Report A-20

 A01 - List of External & Internal Issues

Significant /Non
Control Measure/
S.No External & Internal Issues Significant ( If Legal Remarks
Action Plan
always Significant)

Restriction or ban on usage of

existing fuel
Frequent Interruption in supply
of power from state electricity
board impacting production
/quality/safety
Regulations impacting the
1 External existing setup of utilities such as
electricity/boiler/Storage of
Gases

Increasing Cost of fuel & Power

Adverse impact of
weather/climate change on
availability of power/Fuel/Gases
 Emissions of exhausts/flue gases
during power
generation/Steam/Gases
generation impacting adversely
on Environment

Non availability of Utilities such

as power/steam/Air/Gases for
target production and Quality
Non availability of required
resources such as
spares/skill/manpower to
maintain the design efficiency of
equipments/Machines
Lack of awareness/Skill/Trainings
to develop energy sustainable
2 Internal culture

No or Inadequate contingency
Plans to counter interruptions in
energy supply

Usage of Outdated/Inefficient
technology

Operational risk such as usage of

hazardous chemical/gases/tools
& tackles

A02 - Process Energy Interaction Matrix

 Interaction with Processes ( Department/Equipment Name)
Type of Energy
Melting Core Preparation Core Setting Moulding Shot Blasting Utilities

Furnace

Electricity

Compressed Air

Steam

Fuel

Gases

Significant Use
Normal Use
Minor Use

A03 - Scope
Manufacturing of Sheet Metal. Machined, Fabricated Components and Sub-Assemblies for Automotive Application & General Engineering
using Power from State Electricity Board, DG Sets as Power Backup , LPG in the coating process,CO2 in the welding process and Compressed
Air from Air Compressors.
 Energy Policy
(XYZ Ltd.)
We at XYZ Ltd. are committed to improve our energy performance in all our activities, products, Purchase and services, having Energy
sustainable for future generations. We are also committed to reduce our specific energy consumption on a continual basis.
To achieve this we shall ensure, in particular,

• An Energy Management System.

• Impart awareness to all employees, contractors and vendors on energy efficiency aspects and their contribution to the Energy
Management System.

• Comply with applicable legal and organizational requirements pertinent to the energy management aspects.

• Encourage and promote waste minimization, energy efficiency and resource conservation.

• Evaluate effectiveness of the Energy Management System through periodic audits and management reviews.

This policy shall be reviewed & updated periodically.

Name of Person Date

CEO/Director
 EnergyTeam Structure
Plant Head
(……………………….)

EnergyCo-coordinator
( …………………………. )

…………………. …………….. ………………………. ………………….

Production Purchase Electrical Production

A04 - Identification of Objective & Targets

 For Year _______________

Control
Baseline
S.N Objective to be Achieved by taking Identified Energy Performance Targe Measur
SEU with
o Actions Indicators (EnPI) t e (
Justification
EnMP)

Free air delivery test,

Capacity test
kW/CFM
1. Pressure setting of
generation pressure
compressor to be optimized
(kg/cm2), bar
2. Installation of VFD's
To improve
performance of 1. Record it/ Energy Meters
energy Consumption / day or
compressed air 2. Control on running hrs (Lunch
/week or/ Month
generation. time/ shift change etc)

Compressor 1. Record & optimize unload hrs

1 2. Scheduling Running hours, Load hours &
s
Cleanliness of air Filter/ Any unload hours
other activities
Pressure loss from Receiver
To improve 1.Minimize losses.
to Farthest end,0.3 bar in
performance of 2.Reciver size and location
mains header at the farthest
compressed air analysis
point & 0.5 bar in distribution
distribution 3.Drain valve of receiver check
system.
1.Scheduled compressed air
To improve
leakage test & maintain record Leakage (%)
performance of
of arrested points
 compressed air 1. Check the dew point after the Moisture Free air,dew point
use dryer for moisture free air of the air should be less - 40
*c
1. Check the capacity and Minimum fluctuation of
location of air receiver to avoid compressed air at receiving
fluctuation in air pressure end, Air receiver capacity (
Generation capacity X 4.6
liters)
Compressed air consumption
Reduce use of compressed air (cfm/ kWh/day or /week
or/month)
1.Segregating compressed air
Air pressure at application
pressure user based
point- pressure setting at user
on pressure requirement, Use
end (kg/cm2)
of blower, Trivector gun
1. Compare with designed
pump efficiency &
replace with available high
efficient pumps Pump efficiency test (%),
2. Installation of VFD's and Designed pump efficiency (%)
To improve optimize pressure & flow
performance of 3.Right size pump selection
2 Pumps
performance of based on your requirement
pumps 1. Record it & control on
running hrs
2. ground water charging for energy Consumption kWh/
borewell pumps day or /week or/ Month
3.Spillage/ leakages to be
monitored and controlled
 1.Monitor & reduce its running
hrs. Performance check of Chilling
2. Temp setting of air/water system (kW/TR)
3. Installation of VFD's

To improve 1. Check to what temp. of

performance of chilled water/ Air could be
Chilled water temperature
chiller system increased without affecting
(deg C)
process requirement and
maintain it
Chiller
3 1. maintain record of it/ Energy energy Consumption kWh/
System
meters day or /week or/ Month

To improve Performance of air handling

1.Installation of VFD on AHU
performance of unit kW/CFM
chilled
Monitoring of Insulation over
water/Air
chilled water line/ Ducting
distribution
To improve
performance of Increasing temperature of
User temp setting (deg C)
chilled water/air to save power
water/Air use
Recording of rewinded motors
Rewinded motors, no load
To Reduce and no load current after
current should be < 30 %
Electricity rewinding
Major
Consumption Batch time reduction / idle time
4 Motors
with optimal control kWh/no of components or
utilization / maximum capacity utilization/ kWh/Ton of production etc
production planning
To reduce Batch time reduction / idle time kWh/ton, kwh/day or /week
5
electrical /Fuel control or/month,Fuel
 consumption/T / maximum capacity utilization/ consumption/per tonne
on of production planning molten metal
production Perform flue gas analysis in case Flue gas analysis for O2 (gas -
of fuel fired furnaces 1-2%Liquid3-4%- soild-5-6%),
For CO,(gas -<50PPm
Liquid<100PPm- solid
Electrical/ <200PPM)
Fuel fired
To maintain the draft in side the Maintain the draft ,slightly
Furnaces
furnace positive thn atm
Radiation loss,Power loss in
Insulate heated surfaces to
crucible=18-25%,Radiation
Reduce heat losses.
loss =7-9%)
Monitor the cycle time Cycle time (minutes/hours)

Electricity bill analysis Electricity Bill

To reduce
Electrical Check Monthly and maintain Power Factor, Max demand
6 distribution
System record of PF, MDI Indicator (KVA)
losses.
Check Monthly and maintain Capacitor performance
record of Capacitor test & (kVAR)
voltage drop Voltage drop (Volts)
Fuel consumption / day or
Monitor & maintain record
/week or /Month
Boiler / To improve
Evaporation ratio,kg of
Thermic performance
steam/per unit of fuel
fluid generation of
7 Monitor & maintain record consumption for Coal fired ( 4
heater/ steam / hot
- 5.5), oil fired (13.5-14.5) ,
Hot water water/ thermic
gas fired (11 to 13)
generator fluid.
Fuel Quality ( Like Calorific
Monitor & maintain record
Value, Moisture, Ash% etc)
 Generation pressure(kg/cm2)
Monitor & control
& temp (deg C)
Periodic monitoring & Percentage of (O2, CO2, SOx,
optimization NOx etc)
Optimize blow down frequency Blow down frequency as per
based on TDS TDS,TDS Level <5000ppm
Identification the opportunities Waste heat recovery in
to utilize waste heat identified processes

Feed water temp (deg C) and

Increase condensate recovery Condensate recovery (%)
(%) & feed water temp. / make up water
consumption (lit/day)

Automation and control of FD/

FD/ID fan power consumption
ID fans

Steam trap / insulation Pressure & temp drop from

maintenance generation to user end

Measure fuel loss because of

Avoid steam leakages
To improve steam leakages
performance of Insulation losses,skin tem of
steam insulated line should not
distribution & more ambient + 20*c
use
Batch time reduction / idle time
control
Cycle time (minutes/hours)
/ maximum capacity utilization/
production planning
 Steam traps
Maintain record of Steam selection/operation/mainten
Leakages identification & ance, inlet and outlet tem diff
arresting it along the steam trap should
be >50*c
Improve Lux level ( Maintain
To reduce Monitor and measure lux level
lux level as per IS)
power
8 Lighting
consumption in Energy efficient lighting system,
lighting Control on running hrs & idle kWh/day or month
running
Any Other
Monitor and reduce specific
thermal To reduce
power
9 Equipment energy kWh/production
consumption of energy
/ process consumption
intensive machines.
system

Note:- For establishing baseline, Records of daily/weekly/monthly consumption

to be monitored for each EnPI
 A05 - Review Report of Objective & Targets

For Month
______________________
___

Targ
Energy et % Reaso
Baseline Actio
S.N Objective to be Achieved by Performance Targ Achi Var n of Rema
SEU with n
o taking Identified Actions Indicators et eved iati Deviat rks
Justification Plan
(EnPI) Till on ion
Date
Free air delivery
Capacity test
test, kW/CFM
1.Pressure
setting of
generation
compressor to
pressure
be optimized
To (kg/cm2), bar
2. Installation of
improve
VFD's
performa
1. Record it/
Compres nce of
1 Energy Meters energy
sors compress
2. Control on Consumption /
ed air
running hrs day or /week
generatio
(Lunch time/ or/ Month
n.
shift change etc)
1.Record &
optimize unload Running hours,
hrs Load hours &
2. Scheduling unload hours
Cleanliness of
 air Filter/ Any
other activities

Pressure loss
To
1.Minimize from Receiver
improve
losses. to Farthest
performa
2.Reciver size end,0.3 bar in
nce of
and location mains header at
compress
analysis the farthest
ed air
3.Drain valve of point & 0.5 bar
distributi
receiver check in distribution
on
system.
1.Scheduled
compressed air
leakage test &
Leakage (%)
maintain record
of arrested
points
1. Check the Moisture Free
To
dew point after air,dew point of
improve
the dryer for the air should
performa
moisture free air be less - 40 *c
nce of
1. Check the Minimum
compress
capacity and fluctuation of
ed air
location of air compressed air
use
receiver to avoid at receiving
fluctuation in air end, Air
pressure receiver
capacity (
Generation
capacity X 4.6
liters)
 Compressed air
consumption
Reduce use of
(cfm/ kWh/day
compressed air
or /week
or/month)
1.Segregating
compressed air
Air pressure at
pressure user
application
based
point- pressure
on pressure
setting at user
requirement,
end (kg/cm2)
Use of blower,
Trivector gun
1. Compare with
designed pump
efficiency &
replace with
available high
efficient pumps Pump efficiency
2. Installation of test (%),
To VFD's and Designed pump
improve optimize efficiency (%)
performa pressure & flow
2 Pumps nce of 3.Right size
performa pump selection
nce of based on your
pumps requirement
1. Record it &
control on energy
running hrs Consumption
2. ground water kWh/ day or
charging for /week or/
borewell pumps Month
3.Spillage/
 leakages to be
monitored and
controlled

1.Monitor &
reduce its
running hrs. Performance
2. Temp setting check of Chilling
of air/water system (kW/TR)
3. Installation of
VFD's
1. Check to what
To temp. of chilled
improve water/ Air could
performa be
Chilled water
nce of increased
temperature
chiller without
(deg C)
system affecting
Chiller
3 process
System
requirement
and maintain it
energy
1. maintain Consumption
record of it/ kWh/ day or
Energy meters /week or/
Month
Performance of
To 1.Installation of
air handling
improve VFD on AHU
unit kW/CFM
performa
Monitoring of
nce of
Insulation over
chilled
chilled water
water/Air
line/ Ducting
 distributi
on
To
improve
Increasing
performa
temperature of User temp
nce of
water/air to setting (deg C)
chilled
save power
water/Air
use
Recording of
Rewinded
rewinded
motors, no load
motors and no
To current should
load current
Reduce be < 30 %
after rewinding
Electricit
Batch time
Major y
reduction / idle
Motors Consump
time control kWh/no of
tion with
/ maximum components or
4 optimal
capcity kWh/Ton of
utiliztion
utilization/ production etc
production
planning
Batch time
kWh/ton,
reduction / idle
To kwh/day or
time control
reduce /week
/ maximum
5 Electrical electrical or/month,Fuel
capacity
/ Fuel /Fuel consumption/p
utilization/
fired consump er tonne molten
production
tion/Ton metal
planning
Furnaces of
Perform flue gas Flue gas
producti
analysis in case analysis for O2
on
of fuel fired (gas -1-
furnaces 2%Liquid3-4%-
 soild-5-6%), For
CO,(gas -
<50PPm
Liquid<100PPm-
solid <200PPM)
Maintain the
To maintain the
draft ,slightly
draft in side the
positive than
furnace
atm
Radiation loss,
Insulate heated
Power loss in
surfaces to
crucible=18-
Reduce heat
25%,Radiation
losses.
loss =7-9%)
Monitor the Cycle time
6
cycle time (minutes/hours)
Electricity bill
7 Electricity Bill
analysis
Check Monthly
To Power Factor,
and maintain
8 reduce Max demand
Electrical record of PF,
distributi Indicator (KVA)
System MDI
on
Check Monthly Capacitor
losses.
and maintain performance
9 record of (kVAR)
Capacitor test & Voltage drop
voltage drop (Volts)
Boiler / To Fuel
Thermic improve Monitor & consumption /
8
fluid performa maintain record day or /week or
heater/ nce /Month
 Hot generatio Evaporation
water n of ratio,kg of
generato steam / steam/per unit
r hot of fuel
Monitor &
water/ consumption
maintain record
thermic for Coal fired ( 4
fluid. - 5.5), oil fired
(13.5-14.5) , gas
fired (11 to 13)
Fuel Quality (
Like Calorific
Monitor &
Value,
maintain record
Moisture, Ash%
etc)
Generation
Monitor & pressure(kg/cm
control 2) & temp (deg
C)
Periodic Percentage of
monitoring & (O2, CO2, SOx,
optimization NOx etc)
Blow down
Optimize blow frequency as
down frequency per TDS,TDS
based on TDS Level
<5000ppm
Identification
Waste heat
the
recovery in
opportunities to
identified
utilize waste
processes
heat
Increase Feed water
condensate temp (deg C)
recovery (%) & and Condensate
 feed water recovery (%)
temp. / make up
water
consumption
(lit/day)
Automation and FD/ID fan
control of FD/ ID power
fans consumption
Pressure &
Steam trap /
temp drop from
insulation
generation to
maintenance
user end
Measure fuel
Avoid steam
loss because of
leakages
steam leakages
Insulation
losses,skin tem
of insulated line
To
should not
improve
more ambient +
performa
20*c
nce of
Batch time
steam
reduction / idle
distributi
time control
on & use
/ maximum Cycle time
capacity (minutes/hours)
utilization/
production
planning
Maintain record Steam traps
of Steam selection/opera
Leakages tion/maintenan
identification & ce, inlet and
arresting it outlet tem diff
 along the steam
trap should be
>50*c
Improve Lux
Monitor and
level ( Maintain
To measure lux
lux level as per
reduce level
IS)
power
9 Lighting Energy efficient
consump
lighting system,
tion in kWh/day or
Control on
lighting month
running hrs &
idle running
Any
Monitor and
Other To
reduce specific
thermal reduce
power kWh/productio
10 Equipme energy
consumption of n
nt / consump
energy intensive
process tion
machines.
system

A06 - Revision of Objective & Targets

Revision Date &

Month__________________

SEU
 Exis
ting Re
Ne Ne
Targ New as
Exis w/R New/R w/R
S. Existing Objectives & Existing Energy Existing et /Revised on Justi
ting evis evised evis
N already Identified Performance Indicators Baselin Acie Objectiv of ficat
Tar ed Baselin ed
o Actions (EnPI) e ved e& Ch ion
get EnP e Tar
Till Action an
I get
Dat ge
e
Free air delivery test,
Capacity test
kW/CFM
1.Pressure
setting of
compressor to generation pressure
be optimized (kg/cm2), bar
2. Installation
To of VFD's
improve 1. Record it/
perform Energy Meters
ance of 2. Control on
energy Consumption /
compre running hrs
Compr day or /week or/ Month
1 ssed air (Lunch time/
essors
generati shift change
on. etc)
1.Record &
optimize
unload hrs
Running hours, Load
2. Scheduling
hours & unload hours
Cleanliness of
air Filter/ Any
other activities
To 1.Minimize Pressure loss from
improve losses. Receiver to Farthest
perform 2.Reciver size end,0.3 bar in mains
ance of and location header at the farthest
compre analysis point & 0.5 bar in
ssed air 3.Drain valve distribution system.
distribu of receiver
tion check
1.Scheduled
compressed air
leakage test &
Leakage (%)
maintain
record of
arrested points
1. Check the
dew point after Moisture Free air,dew
the dryer for point of the air should be
moisture free less - 40 *c
air
To
1. Check the
improve Minimum fluctuation of
capacity and
perform compressed air at
location of air
ance of receiving end, Air
receiver to
compre receiver capacity (
avoid
ssed air Generation capacity X 4.6
fluctuation in
use liters)
air pressure
Compressed air
Reduce use of consumption
compressed air (cfm/ kWh/day or /week
or/month)
1.Segregating
compressed air Air pressure at
pressure user application point-
based pressure setting at user
on pressure end (kg/cm2)
requirement,
 Use of blower,
Trivector gun

1. Compare
with designed
pump
efficiency &
replace with
available high
efficient pumps
Pump efficiency test (%),
2. Installation
Designed pump
of VFD's and
efficiency (%)
optimize
To pressure &
improve flow
perform 3.Right size
2 Pumps ance of pump selection
perform based on your
ance of requirement
pumps 1. Record it &
control on
running hrs
2. ground
water charging energy Consumption
for borewell kWh/ day or /week or/
pumps Month
3.Spillage/
leakages to be
monitored and
controlled
To 1.Monitor &
Chiller
improve reduce its Performance check of
3 Syste
perform running hrs. Chilling system (kW/TR)
m
ance of 2. Temp setting
chiller of air/water
system 3. Installation
of VFD's
1. Check to
what temp. of
chilled water/
Air could be
increased Chilled water
without temperature (deg C)
affecting
process
requirement
and maintain it
1. maintain energy Consumption
record of it/ kWh/ day or /week or/
Energy meters Month
To 1.Installation Performance of air
improve of VFD on AHU handling unit kW/CFM
perform
ance of
Monitoring of
chilled
Insulation over
water/A
chilled water
ir
line/ Ducting
distribu
tion
To
improve
Increasing
perform
temperature of
ance of User temp setting (deg C)
water/air to
chilled
save power
water/A
ir use
 Recording of
rewinded Rewinded motors, no
To
motors and no load current should be <
Reduce
load current 30 %
Electrici
after rewinding
ty
Major Batch time
Consum
Motor reduction / idle
ption
s time control
with kWh/no of components
/ maximum
4 optimal or kWh/Ton of
capcity
utilizati production etc
utilization/
on
production
planning

Batch time
reduction / idle
time control kWh/ton, kwh/day or
/ maximum /week or/month,Fuel
5
capacity consumption/per tonne
To utilization/ molten metal
Electri reduce production
cal/ electric planning
Fuel al /Fuel Perform flue Flue gas analysis for O2
fired consum gas analysis in (gas -1-2%Liquid3-4%-
ption/T case of fuel soild-5-6%), For CO,(gas -
Furnac on of fired furnaces <50PPm Liquid<100PPm-
es product solid <200PPM)
ion To maintain
the draft in Maintain the draft
side the ,slighty positive thn atm
furnace
Insulate heated Radiation loss,Power loss
surfaces to in crucible=18-
 Reduce heat 25%,Radiation loss =7-
losses. 9%)
Monitor the Cycle time
6
cycle time (minutes/hours)
Electricity bill
7 Electricity Bill
analysis
Check Monthly
Electri To
and maintain Power Factor, Max
8 cal reduce
record of PF, demand Indicator (KVA)
distribu
MDI
Syste tion
Check Monthly
m losses.
and maintain Capacitor performance
9 record of (kVAR)
Capacitor test Voltage drop (Volts)
& voltage drop
Monitor &
Fuel consumption / day
maintain
or /week or /Month
To record
Boiler
improve Evaporation ratio,kg of
/
perform steam/per unit of fuel
Therm Monitor &
ance consumption for Coal
ic fluid maintain
generati fired ( 4 - 5.5), oil fired
heater record
8 on of (13.5-14.5) , gas fired (11
/
steam / to 13)
Hot
hot Monitor & Fuel Quality ( Like
water
water/ maintain Calorific Value, Moisture,
gener
thermic record Ash% etc)
ator
fluid. Generation
Monitor &
pressure(kg/cm2) &
control
temp (deg C)
 Periodic
Percentage of (O2, CO2,
monitoring &
SOx, NOx etc)
optimization
Optimize blow
Blow down frequency as
down
per TDS,TDS Level
frequency
<5000ppm
based on TDS
Identification
the
Waste heat recovery in
opertunities to
identified processes
utilize waste
heat
Increase Feed water temp (deg C)
condensate and Condensate recovery
recovery (%) & (%)
feed water / make up water
temp. consumption (lit/day)
Automation
FD/ID fan power
and control of
consumption
FD/ ID fans
Steam trap / Pressure & temp drop
insulation from generation to user
maintenance end
To Measure fuel loss
Avoid steam
improve because of steam
leakages
perform leakages
ance of Insulation losses,skin tem
steam of insulated line should
distribu not more ambient + 20*c
tion & Batch time
use reduction / idle
Cycle time
time control
(minutes/hours)
/ maximum
capcity
 utilization/
production
planning
Maintain
Steam traps
record of
selection/operation/mai
Steam
ntenance, inlet and oulte
Leakages
tem diff along the steam
identification &
trap should be >50*c
arresting it
Monitor and Improve Lux level (
measure lux Maintain lux level as per
To level IS)
reduce Energy
Lightin power efficient
9
g consum lighting
ption in system, kWh/day or month
lighting Control on
running hrs &
idle running
Any
Other
Monitor and
therm
To reduce specific
al
reduce power
1 Equip
energy consumption kWh/production
0 ment /
consum of energy
proces
ption intensive
s
machines.
syste
m

Note:- For establishing baseline, Records of

daily/weekly/monthly consumption to be
monitored for each EnPI
 A07 - ENERGY MEASUREMENT & MONITORING PLAN
This plan shall include all monitoring carried out to achieve identified objective and targets, also monitoring is carried out for internal control
purpose.

S. Description of Parameters to Allowable Limits Measurement Frequency of Instrument to Instrument

No. objective be monitored Location(s) Monitoring be used for calibration status
measurement

Date: _____________ Prepared By: ____________________ Approved By: _________________________

 A08 - EnMS TRAINING SCHEDULE

PERIOD: From _____________ to _______________

Training Title Participant Group Trainer Duration Tentative Time Frame Actual Training
(Month) Date(s)
(Hrs.)

Date: ___________________ Prepared By: ________________________

 A09 - EnMS TRAINING RECORD

Section Name: Location :

Date: Time:

Venue: Trainer :
TOPIC :
Training Contents
(In brief)

S.No. Name of Participant E.Code Department Signature

A10 - Energy Team Competency Matrix

 Name of Members for Dept. Name Job responsibility in Qualification Competency of the person in respective

Energy Team Energy Team field

Prepared By:_______________ Approved By:____________

Name & Sign:________________ Name & Sign: ____________

A11 - LIST OF EnMS RECORDS

S.No. Retention Storage

Record Title Custodian
Period (Yrs) Location
Date: ______________ ___________________
(Energy Coordinator)

DOCUMENT NUMBERING SYSTEM

A12 - EnMS documents is numbered as per the following numbering system:

ZZZ/ABC/DEF/XXX Rnn where the alphabets denote:

ZZZ Location name

ABC Document Code

DEF Department Code

XXX Running serial number (001 onwards)

 Rnn Revision status (R - Revision, nn-Running serial number)

The details are as under:

Document Code

EOT Energy Objectives and Targets

EnMP Energy Management Program

OCP Operating Control Procedures

ENM EnMS Manual

ET Energy Team

IEA Internal Energy Management Audit

Formats (Basic templates for record keeping as arising out of OCPs

FMT
etc)

Department Code

MPN Production Module

Engineering (Utilities, Mechanical, Electrical, Mechanical,

ENG
Instrumentation, Horticulture, Civil, Contractors)

ETP ETP includes

STO Stores (All warehouses)

ADM Administration (Admn. Building, IT, Canteens, OHC, Security)

 EnMS Energy Management System (For formats etc.)

Prepared By:_______________ Approved By:____________

Name & Sign:________________ Name & Sign: ____________

A13 - DOCUMENT APPROVAL & ISSUE AUTHORITY

Activities EnMS Manual Energy Management Objective & Targets / OCPs Formats

Review and Approval Executive Director Energy Team Energy Coordinator

Issue Energy Coordinator Energy Coordinator Energy Coordinator

Change Review & Approval Executive Director Departmental Head Departmental Head / ER

Change Issue Energy Coordinator Energy Coordinator Energy Coordinator

Disposal of Obsolete document Energy Coordinator Energy Coordinator Energy Coordinator

Prepared By:_______________ Approved By:____________

Name & Sign:________________ Name & Sign: ____________

 A14 - List of Operation Control Procedure

Sr. No Title OCP Number

Prepared By: ___________ Approved By: ____________

Name & Sign:__________ Name & Sign: _____________

 A15 - Frequency of Maintenance ( Periodic )
Sr. No Description of the equipment Frequency
01 Transformers Annually
02 DG sets As per OEM
03 HT panels Annually
04 LT panels Annually
04 LT Motors Quarterly/Half Yearly
05 Boiler &Thermopack As per OEM
06 Chillers As per OEM
07 Cooling Tower As per OEM
08 Air Compressor As per OEM
09 Pumps Quarterly
10 HVAC Quarterly
Inspection & Maintenance of Distribution Network
Sr. No Description of the equipment Frequency
01 Insulation ( Lines/Furnace) Annually
02 Air Leakages Monthly
03 Steam Traps Half Yearly

A16 - List of Legal Requirements

Reviewed on Dated____________
 *Compliance Status (
Reasons of Non
S.No Legal Requirement Compliance/Non Control Measure Remarks
Compliance
Compliance)

Compiance to Energy
1 Conservation act 2001, if
applicable

Approval of Electrical
2 Installation from approval
authority

Approval of boiler and

3 installation from approval
authority.

No pending Govt Energy

4
fee/ bill
 No pending Govt dispute
5
case

Monitoring of stack
6
Emmissions

7 Lux level as per standard

* Enter Not Applicable, if mentioned legal requirement is not applicable on the Industry

Prepaired By Approved BY

Name & Sign____________ Name & Sign_____________

A17 - ANNUAL EnMS AUDIT PLAN

 EnMS Audit Plan

Plan Period: ___________ to ____________

Function/ Department/ Area Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec

Date: ______________
Energy Coordinator

A18 - INTERNAL EnMS AUDIT SCHEDULE

Audit No.: ______________

Standard Ref.: ISO 50001:2018
 Auditee Function/ Department/
Date Time AUDITORS
Area

Date: ______________ Energy Coordinator

 A19 - Internal Audit

Area/Process Covered:…………………………… Ref: Audit no……………………

Process Owner Name:………………………………. Auditee Name:…………………..

Name of the Internal Auditor:……………………. Guidelines: Please mark the clause audited by internal auditor.
Date:

Claus Remarks
S.N e Objective
Requirements Findings (NC/No
o Cove Evidence, if any
NC)
red (Observation / NC)

Status of awareness level in the organization about ISO

01 3.0
50001: 2018 Energy management System.

a) Are internal, external issues and Interested parties &

their needs expectations have been determined?
4.1, b) Is access to the applicable legal requirements and other
02 requirements related to its energy efficiency, use &
4.2
consumption available?
c) Whether review frequency for its legal and other
requirement has been defined?
03 4.3 Has the Scope of certification been defined and
acceptable?
04 4.4 Interaction of different energies for all Processes.
Is the Energy Policy as per requirements of standard,
05 5.2 displayed and understood by the people, sampling
required.
06 5.3 Does the energy team performs as per defined
responsibilities
 How the energy team is communicating the performance
of EnMS and at what interval?
07 6.1 Whether risk and opportunities determined considering
internal and external issues & requirement of interested
parties and actions thereof.
08 6.2 Have the EnMS Objectives defined at the functional levels
along with action plan and responsibilities, how the
objectives are tracked, reviewed and subsequent actions
a) Whether the process/area has framed energy
objectives which are measurable, communicated &
monitored?
b) Whether the action plan has been made for each above
objective?
09 a) How the company has carried out the energy review
w.r.t. past and present data, variables affecting energy
6.3,6. consumption, criteria, what is the present status &
4,6.5, prioritize the opportunities.
6.6 b) Whether the appropriate energy performance
indicators defined?
c) Whether Energy base line has been established and
record has been maintained?
d) Whether the Monitoring plan have been prepared & its
status w.r.t actions and new projects.
11 7.1 Are the required resources been determined and
available?
12 7.2 a) Is the energy team competent to identify the
deviations, energy wastages and continual improvement
areas?
b) Is the competence level identified, training need, and
evaluation of effectiveness of training
13 7.3 Whether the persons working in the area/process are
aware of energy policy, objectives, their role and
contribution, impact of their activities and behavior and
the implication of not conforming with the EnMS ?
14 7.4 How the energy performance is communicated Internally
& Externally by the organization?
15 7.5 Has the organization prepared Master List of documents,
and numbering, availability, protection, distribution,
control of changes, retention, and disposition as per
standard?
8.1 a) How the Operation Controls have been defined w.r.t
16 energy & applied.
b) How operational control criteria are communicated to
concerned persons.
8.2,8. How the effect of energy use and consumption has been
17 considered effecting the baseline in Design &
3
Procurement process?
18 9.1 What are the Monitoring & Measurement parameters
and how the company is checking the same?
19 9.1.1 Which are the data company monitoring, Analyzing &
evaluating energy performance.
20 9.1.2 Has the organization evaluated legal issues and its
compliances and at what interval?

21 9.2.1 Has the internal audit been conducted as per defined

interval?

22 9.2.2 Has the Internal Audit Plan, Audit Schedule has been
developed, Audit Checklist & Audit result sheet prepared.

23 9.3.1 Whether the Management review been conducted at

defined interval?
24 9.3.2 Whether the required consideration as per standard been
included in Review?
Whether the input such as performance of objectives,
25 9.3.3 energy performance monitoring and measurement
results, status of action plan etc. included in Review?
 Whether the output as required by the standard in terms
26 9.3.4 of decisions and continual improvement opportunities
been available as record in MOM.
Has the company identified Non Conformances, and
10.1 initiated corrections, root cause arrived, and appropriate
27 corrective action implemented with review of
effectiveness of actions taken
28 10.2 Has the company identified the opportunities for
Continual Improvement in energy performance?

Name of the Auditor:__________ Sign & Date:___________

A20 - NON-CONFORMANCE REPORT

Audit No.: NCR No.:

Department: Date:

Auditee Name: Auditor Name:

Audit Observations:
 Attribute: Clause No. ___________ of ISO 50001:2018
Auditor’s Signatures:

Corrective Actions (to be filled by Auditee):

Correction (s) :

Root Cause(s):

Corrective Actions Taken:

Follow up Audit Observations (to be filled up by Auditor):

Auditor Sign: Date:

NCR Closed: Yes / No Sign of EC: Date: