DOCUMENT NO. # REV.

DATED
QUALITY MANUAL
233-234,SECTOR -58,
FARIDABAD, HARYANA CIL/OCS/QMPI/01 02 15/10/2012

Quality Management Procedure &

Implementation

General Requirement
The Organization has an established, documented, implemented & maintained quality management
system. The organization carries out continuous improvement in quality management system as
identified by users through their feedback or by the management reviews.

To implement the quality management system, the organization has identified the major processes as
Marketing, Processing, Design/Development, Purchasing, Incoming Inspection, Fabrication, Assembly,
Testing Painting, Packing, Dispatch Technical Documentation & Costumer Complaint that affect the
quality of its Products.
Major Identified Processes are: -
 Marketing.
 Processing.
 Design & Development.
 Purchasing.
 Incoming Inspection.
 Fabrication.
 Assembly.
 Testing.
 Painting.
 Packing.
 Dispatch.
 Technical Documentation.
 Customer Complaint

Marketing
Since Lubrication Oil Systems are tailor made for individual request, hence marketing of these systems
are done individually based on identified application industry wise. The identified application industry
wise are as under:-

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 DOCUMENT NO. # REV. DATED
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FARIDABAD, HARYANA CIL/OCS/QMPI/01 02 15/10/2012

 POWER SECTOR
 Lube oil & control oil system (steam turbine).
 Hydrostatic lubrication (Thrust bearing of hydro generator).
 Gear box lubrication & propeller shaft lubrication (Wind turbine).
 ID, FD, PA, SA FAN Lubrication (Boker).
 HSD fuil & forwarding, distribution and control system (Gas Turbine).
 High pressure grease system for guide vane bearings/spherical valve/servo motor.
 Lube, Control & hydraulic system for Boiler Motor
 Planetary Gear Box Lubrication (bowl Mill).
 Seal oil unit & Stator cooling system (Turbo Generater).
 STEEL PLANTS
 Hot rolling / Cold Rolling mill.
 Bloom caster/slab caster/continuous caster
 Conveyors/roller table
 Roll coolant system
 Morgoil lubrication system
 Annealing/preheating furnace
 Gear boxes
 Converter
 PAPER PLANTS
 Drying cylinder
 Suction couch roll bearings
 Size Press roll
 Felt carrying roll
 MG cylinder
 CEMENT PLANTS
 Oil (low + high) lubrication system for journal and slide shoe bearing
 Kiln roller bearing
 SUGAR PLANTS
 Mill bearings lubrication
 Gear box lubrication

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233-234,SECTOR -58,
FARIDABAD, HARYANA CIL/OCS/QMPI/01 02 15/10/2012

 Boiler bearing lubrication

 Transmission gear lubrication

The marketing of tailor made Lubrication Oil System are made as per following activities
(Reference flow chart No. CIL/OCS/MAFC/36)

Enquiry Generation

As Cenlub makes tailor made Lubrication Oil Systems, enquiries are generated by direct
marketing through visits/e-mails/telecom for the identified application industries wise.
Or Directly from Contractors & end user based on our registration / earlier supplies with
them

 Technical/Commercial proposal submission

In response to the enquiries received from the customer proposals are made which
include:
 Technical Proposals
o BOM
 BOM i.e. Bill of Material, it includes the list of all the items being
used in the manufacturing of the system. It specifies the following:-
 Name of the item
 Make of the item
 Brief Specification of the items
 Quantity of items used in per system
o Drawings BOM:
 It consists of Piping and Instruments Drawings of the system which
includes the sizes of the pipelines, equipments and instruments
used along with the brief specifications of important items like
pump, motor, filter, fluid used and the cooler.
o Technical Data Sheets
 This includes information and specifications related to the various
items are being quoted to the customer, (if required)
 Commercial Proposals
o Scope of supply

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QUALITY MANUAL
233-234,SECTOR -58,
FARIDABAD, HARYANA CIL/OCS/QMPI/01 02 15/10/2012

 Detailed scope of Supply is Clearly maintained .

o Commercial Details
 Commercial Quotation gives the Total price of the system which in
General includes the following Details:-
 Price Basis
 Discounts (if any)
 Packing & Forwarding charges (Included / Extra
 Excise Duty
 Sales Tax
 Insurance (Included / Extra)
 Freight (Included / Extra)
 Octroi/Local Taxes (Included / Extra)
o Delivery date
o Inspection Clause
o Payment Terms
o Warranty Clause
o Validity of the quote
o Installation & Commissioning (if required)
 Evaluation of Techno/Commercial Proposals
 Evaluation of Technical offer
o Technical specifications are thoroughly evaluated by the customer on the
basis of their enquiry/specification.
o In case of any query, customer reverts back to the marketing department to
get the clarification.
o The same is done by the means of visits/e-mails/telecom and only after
getting all technical clarifications, our technical proposal is cleared.

 Commercial evaluation
o After the offer technically evaluated and cleared. Then price proposal is
scrutinized.
o Negotiations on the prices are done by visits mail / Phone Call & the most
competitive prices is given to customer or negotiation are done from
reverse auctioning .
o All the other commercial proposals are settled keeping all the regulatory and
the statutory conditions in mind.

 Release of Techno/Commercial order

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o After Techno / Commercial Evaluation is Completed to entire satisfaction of

purchaser & in case our offer is completive, customer releases
Techno/Commercial Order which includes:-
 Technical Specifications
 Commercial Specifications

 Preparation of Contract Check List

After release of detailed Techno/Commercial order, Technical as well as Commercial
check lists are made accordingly to which various technical and commercial aspects
related to the project are checked.

Order processing
 After releases of detail techno / commercial order, technical as well as commercial check lists
are made accordingly to which various technical & commercial aspects related to the project &
any non conformity is intimated to customer P.O. Amendment obtained (Commercial check list
Doc. No. CIL/OCS/CCL/01) (and technical check list dos. No. CIL/OCS/TCL/01).
 One receipt of correct techno / commercial order .order distribution is done as under
 Technical order with tech. Check. List
 Engg. Department for drg. Preparation
 Purchase for Procurements action.
 PPC FOR Planning of Material
 Production for Planning Manufacturing
 Commercial order with commercial check list
 A/C Department

Design & Development

 On receiving the order, Drg. is made by the Design Department conforming the customer’s
drawings & requirements while preparing the drawing, adequate care is taken to Comply to
Drg. Submitted during offer storage .

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FARIDABAD, HARYANA CIL/OCS/QMPI/01 02 15/10/2012

 Depending upon the customer’s order for the LOS and with reference to the previous drawings
sent to the customer, at offer stage following detailed drawings are made for approval:-
o General Arrangement (GA)
o Piping & Instrumentation (P&I)
o Power Terminal Box Drawing
o Instrument Terminal Box Drawing
o Control Panel Drawing

 All these drawings are been given a unique number and are recorded in the drawing register.
 Drawing are sent for the approval to the customer/ Consultant upon which they make
comments (if necessary).
 A review on these comments is made and desired changes are done and revised Drg. are sent
back for the final approval after incorporating comments (If required).
 A detailed data of the above drawings are being maintained in On Going Projects Drg./Work
Orders List which is updated weekly (CIL/OCS/OGPD/01).

Purchasing
 On receiving of any order, purchase department initiates procurement action of bought out
items of approved sources.
 All approved suppler are annually rated for their product performance, finally suppliers and
each of then is rated accordingly any supplier with over all rating <85% is put on hold for future
supply ()doc.no.CIL/OCS/SR/22).
 In case of supplier commences us for improving their performance, the supplier hold is
removed.
 The raw Material / BOI are procured strictly as per the approved specification / makes from
selected suppliers on the basis of their ability to meet specific quality assurance requirements.
 With reference to the previous orders and rate list available with us enquiries for the desired
products are been sent to the various suppliers.
 After receipt of most suitable quotes & tech. scrutiny is done by engg. Department,
 In Event OF quoted technically cleared by our Engg. Department, competitive rates, delivery
confirmation withal the above factors in mined, orders is released their commercial terms are
frozen.

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233-234,SECTOR -58,
FARIDABAD, HARYANA CIL/OCS/QMPI/01 02 15/10/2012

Incoming Inspection
Based on approved documents, all incoming Materials are checked for its quality, technical suitability
workmanship etc. strictly as per order specification / approved technical documents. The incoming
inspection details for bought out items are

1. Tech. Specification of Item (Order Copy)

2. Incoming QAP.

The items cleared by inspection department are tagged & identified with colour code & handed over to
stores for documented / rejected based on reference document The rejected items are sent back to
manufacturer for replacement giving reason for rejection. Material traceability is maintained in line
with material traceability guideline documents Ref: - CIL/OCS/MTC/04.

Fabrication
Based on approved GA drawings & P & I drawings, the unit is fabricated. Material for same is selected
as per specification, type, make etc. given in approved drawings / vendor list.

The Tank fabrication is done as per desired dimension. The piping is done as per approved P & I
Drawing. Final welding is done as per the welding specification controlled copy of WPS & PQR. Root
layer with GTAW & successive layer by SMAW. Initial & interpass cleaning is done by brushing,
chipping, grinding etc.

All the welded joints are checked by dye penetration test for weld Quality. Incase of any defect, re
welding is done. In case desired by customer weld quality can also be checked by radiography.

Fabricated tank is blast cleaned & Piping is cleaned by Acid Pickling. All fabrication works is done as per
set fabrication process guideline document Ref: - CIL/OCS/FP/05.

Assembly
Based on approved drawings, oil circulatory system is assembled.

During assembly care is taken to ensure only quality items as per approved vendor list / make are used.
Complete assembly of LOS, junction box wiring is carried out as per approved drawings.

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All the manufacturing / Assembly activities are followed in conformance with manufacturing flow chart
document Ref: - CIL/OCS/MANUF/06.

Internal Inspection
When the Oil Lubrication system is fabricated / Assembled as per approved drawings. Each of the
system is internally tested for following as per LOS Testing flow chart Ref: - CIL/OCS/TEST/07.

 Ensure make of each components fitted as per approved makes / approved drawings.
 Check up Overall dimensions as per approved GA drawings.
 Check for workmanship, finish & aesthetic appearance.
 Check & verify the bought out items (BOI) Fitted are in line with the ones give in approved
vendor list / approved drgs.
 Check & verify test certificate of (BOI) as in line with details give in ref. quality plan & Meeting
the desired specification.
 Run test the system with specified grade of oil for 4 hours each pump for smooth & leak free
operation using duly calibrated testing instruments (ref. list of instruments Doc. No.
CIL/OCS/IC/15 & Calibrated Schedule Doc.No. CIL/OCS/ICS/16 & record the following:-

 Flow at rated pressure.

 Current drawn at rated flow and pressure.

 Noise Level.

 Vibration.

 RPM of Motor.

 Check operation of Relief Valve.

 Check the Pressure drop across the filter All the test observation is recorded in

inspection report format ref No. CIL/OCS/IR/08.

 Verification of loose supply (if any) in line with approved doc.

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 Check & verify that all stickers, audize plate etc. are affixed in desired location.

Hydro test of LOS

Hydro test of LOS is done at 1.5 times the working pressure & the unit is checked for leakage of
welding joints, valves etc.

 Record the internal inspection finding in our inspection format Ref: - CIL/OCS/IR/8.

Customer / Third Party Inspection

Each of the Lube Oil Unit is thoroughly check for P.D.I. (Pre Dispatch Inspection) & the same is
documented in a format Ref: - CIL/OCS/PII/9.

Each of the unit is offered the customer /third party inspection witnessing(if required),The Inspection is
carried out in line with customers approved QAP (Quality Assurance Plan) &Testing Procedure).

On successfully Inspection witnessing, Inspection clearance is obtained from Customer / Inspecting

agency.

Painting

Lube Oil Unit

 Complete oil in Tank, Piping, Cooler, Filter etc is flushed out.
 Tank internal are thoroughly cleaned & dried with no. Traces of Oil.
 All Painting surface of Lube Oil System is thoroughly cleaned prior to painting.
 Each of the Lube Oil Unit is subject to primer coat & subsequently final paint as
per the Customer specified painting scheme / procedure (if specified) / CIL Paint Procedure.

Pre Dispatch Inspection

Each of LOS after successful Inspection & painting is again thoroughly checked before dispatch as per
set procedure given in our ref document: - CIL/OCS/PDI/10.

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FARIDABAD, HARYANA CIL/OCS/QMPI/01 02 15/10/2012

Packing
 Lube Oil unit is bolted to the base.
 Lube Oil unit is thoroughly cleaned again internally & externally.
 All identification stickers are affixed at respective places.
 All Connecting flanges are closed by counter flanges, rubber gasket & nut, bolts.
 Filter element cleaned & refitted.
 All threaded openings are closed by plastic caps.
 Instrumentation panel is adequately secured by thermocol & sealed by transparent stretch
sheet.
 Complete lube oil system is sealed by Transparent Stretch sheet & tapes.
 The Lube oil unit is next packed by adequate wooden boxes.
 The wooden Box / Crate is Properly marked for secure lifting.

Loose Supply
Loose supply for pipeline at site (if in our scope) is properly tagged.

Each of the items is sealed in plastic pouches & packed in wooden boxes.

A comprehensive packing slip for each of LOS / Loose items prepared & verified.

Dispatch

After successful pre dispatch Inspection. Clearance report is given by 3 rd party inspecting agrees /
Customer

Dispatch Instruction is given by customer (if required).

Stores is advised to arrange for dispatch & following document is handed over to them.

Inspection Clearance Report

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Dispatch Instruction

Packing Slip

Road Permit

Order Copy

After Dispatch Customer is inform of dispatch list etc.

Customer Complaints

 All the complaints received from customer are attached on SOS Basis and detailed analysis done
for fault finding.
 All the complaints received are recorded in complaint report format as Ref. ClL/OCS/CR/18.
 After attaching the complaint at site, input for concerned service Engg. Is documented in
Complaint report.
 Quarterly all the complaints are reviewed, the nature of faulty item analyzed & if received the
supplier informed.
 Modification /review of design of item by supplier is ensured & Prototype checked before
approving. In Event the items does not perform the Supplier rating is revaluated put under
hold. Until the item does not perform sans factory.
 All approved supplier item wise are annually rated for their performance for delivery & quality.
Any supplier with overall rating < 85% is put under hold

Technical Documentation
After dispatch of units following technical documents are submitted along with our commercial
documents.

 Operation & maintenance manual with as built drawings.

 Test Certificate of major items.
 Inspection Report.
 Inspection Clearance Report.

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