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    SAN Radiators-Manufacturing Process

    Uploaded by

    Adhavan Thamizhan
    The document describes the manufacturing process and quality assurance procedures for radiators produced by Vinayaga Murugan Rice Mill. Key details include: 1) The radiators are manufactured from CRCA steel strips 1.0-1.25mm thick and can be produced in various types and sizes. 2) The manufacturing process involves roll forming, spot welding, seam welding, leak testing, and MIG welding individual fins and headers into complete radiator assemblies. 3) Quality is assured through testing of materials and inspection at each stage of production to ensure dimensional accuracy, weld strength, and that radiators are leak-proof. Finished radiators also undergo surface preparation and coating.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    SAN Radiators-Manufacturing Process

    Uploaded by

    Adhavan Thamizhan
    78 views6 pages
    The document describes the manufacturing process and quality assurance procedures for radiators produced by Vinayaga Murugan Rice Mill. Key details include: 1) The radiators are manufactured from CRCA steel strips 1.0-1.25mm thick and can be produced in various types and sizes. 2) The manufacturing process involves roll forming, spot welding, seam welding, leak testing, and MIG welding individual fins and headers into complete radiator assemblies. 3) Quality is assured through testing of materials and inspection at each stage of production to ensure dimensional accuracy, weld strength, and that radiators are leak-proof. Finished radiators also undergo surface preparation and coating.

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    The document describes the manufacturing process and quality assurance procedures for radiators produced by Vinayaga Murugan Rice Mill. Key details include: 1) The radiators are manufactured from CRCA steel strips 1.0-1.25mm thick and can be produced in various types and sizes. 2) The manufacturing process involves roll forming, spot welding, seam welding, leak testing, and MIG welding individual fins and headers into complete radiator assemblies. 3) Quality is assured through testing of materials and inspection at each stage of production to ensure dimensional accuracy, weld strength, and that radiators are leak-proof. Finished radiators also undergo surface preparation and coating.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    78 views6 pages

    SAN Radiators-Manufacturing Process

    Uploaded by

    Adhavan Thamizhan
    The document describes the manufacturing process and quality assurance procedures for radiators produced by Vinayaga Murugan Rice Mill. Key details include: 1) The radiators are manufactured from CRCA steel strips 1.0-1.25mm thick and can be produced in various types and sizes. 2) The manufacturing process involves roll forming, spot welding, seam welding, leak testing, and MIG welding individual fins and headers into complete radiator assemblies. 3) Quality is assured through testing of materials and inspection at each stage of production to ensure dimensional accuracy, weld strength, and that radiators are leak-proof. Finished radiators also undergo surface preparation and coating.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    You are on page 1of 6

    39/B, Vinayaga Murugan Rice Mill Campus, Nellithope, Pondicherry-605006, India.

    :0413-2202510, +91-9786051510, email: rayaladhavan@gmail.com


    Material of Construction: Our Radiators are manufactured using CRCA steel strips,
    Grade “D” as per IS 513 of 1.0 mm to 1.25 mm thick for radiator fins as per customer
    requirements.

    Type of Radiators: We do manufacture Flange Type Radiators, Weldable Type


    Radiator, “T” Type Radiator, Offset Type Radiator and any Special Type required for
    Transformer Industry.

    Size of Radiators: We do manufacture the following size of Radiators


    1) 520 mm Width, 500 mm to 4000 mm Length
    2) 300 mm Width, 500 mm to 4000 mm Length
    3) 230 mm Width, 500 mm to 4000 mm Length

    Manufacturing Process:
    Suitable cut to width CRCA steel Coils, Grade “D” as per IS 513 of 1.0 mm to 1.25 mm
    thick is loaded in the automatic de-coiler. Steel coil from automatic de-coiler will be feed
    to the Roll Forming Machine.

    1. Fins Roll Forming: Suitable cut to width CRCA steel Coils is feed to the Automatic
    Roll Forming Machine. The required length & number of fin sheet is set in the control
    panel which operates the Roll Forming Machine. Once the Length & number of fins
    is set, it automatically does Roll Forming, Embossing & Cutting of fin sheets. All three
    operations are done in single operation with a highest accuracy. This automatic
    machine through its PLC control ensures uniform quality in all the individual fins at a
    very shortest time. The individual fin sheets are checked for the length and good
    alignment of forming and embossing.
    2. Spot Welding: The individual fin sheets are assembled in a jig for perfect matching
    to form a fin and tack spot welding is done. Then the complete assembled fin is
    welded for spot welding.
    3. Seam Welding: Spot welded fins are feed to the automatic duel seam welding
    machine and to end seam welding machine to weld the all four sides of the fins.
    4. Fins Straightening: In case of any bend in the fins, it is fed in to the Straightening
    machine to make it perfect straight.
    5. Leak Test on Individual Fins: Each individual fins are tested for pressure and leak
    using special Jig. Air at 2 kg/hr is applied in the individual fins and tested for leaks if
    any by Soap Oil Bubble method as per IS 9902:2004.
    6. Radiator Assembling: Complete tested fins, header pipes are assembled in special
    Setting Table using special Jig. The jig ensures exact distance between the fins,
    center to center distance between the header pipes and perfect alignment of
    Flanges. After ensuring all the dimensions, fins, header pipes, flanges are tack
    welded.
    7. MIG Welding of Radiator Assembly: Radiator assembly form the setting table is
    placed in a welding table. Here the complete welding of fins to header pipes, flanges
    and stiffener straps are done.

    39/B, Vinayaga Murugan Rice Mill Campus, Nellithope, Pondicherry-605006, India.


    :0413-2202510, +91-9786051510, email: rayaladhavan@gmail.com
    8. Leak Testing of Radiator Assembly: After complete welding of the radiator
    assembly, it is tested for leak if any in all fins to header pipe, header pipe to flange
    welding joints. . Air at 2 kg/hr is applied in the complete radiator assembly and
    tested for leaks if any by Soap Oil Bubble method as per IS 9902:2004.
    9. Submerged Water Leak Test: Complete radiator assembly after leak test by soap
    oil bubble method, it is again tested in submerged water test in Leak Test Water
    Tank and left it for 30 minutes with air at 2 kg/hr is applied in the complete radiator
    assembly and observed for water bubbles to identify leak if any as per IS 9902:2004.
    10. Surface Preparation: Once it is confirmed for no leaks, welding spatters if any found
    in the MIG welding are removed manually, the radiator surface is prepared by Grid
    blasting as per IS SA 2 ½ for better surface finish, good corrosion resistance and
    good paint adhesion to give a good surface finish.
    11. Inner Coating: Inner surface of the radiator is cleaned with compressed air for any
    contaminations if any. Then the header pipes are cleaned by magnet insertion to
    ensure it free from magnetic particles and then flushing the radiator with Synthetic
    Enamel Oil Resistant Air Drying Varnish by complete pressure filling and draining.
    12. Surface Finishing: Final Surface finishing is done using spray painting / Flood
    Painting / Hot Galvanizing as per the customer’s specification.

    39/B, Vinayaga Murugan Rice Mill Campus, Nellithope, Pondicherry-605006, India.


    :0413-2202510, +91-9786051510, email: rayaladhavan@gmail.com
    Quality Assurance Plan

    Sl.No Item / List of Test Samplin Reference / Accepta


    Component g Rate Standard ble
    Value
    1. CRCA Coil 1. Verification of Test Certificate 100% Grade “D” as
    from Suppliers per IS 513
    2. Measurement of width and
    thickness
    3. Visual inspection for damage if
    any, packing & storage
    2. Roll Forming 1. Checking the length of sheets after Random
    Roll forming
    2. Checking the quality of sheets after
    Roll Forming to ensure good
    alignment of forming and embossing
    3. Spot Welding 1. Visual inspection of Spot Welding 100%
    2. Periodical testing of Strength of
    Spot Welding using separate
    specimen
    3. Check for symmetric matching of
    sheets to form perfect fins
    4. Seam 1. Checking the quality and strength 100%
    Welding of seam welding in separate
    specimen
    2. Visual inspection of quality of
    seam weld in the Fins
    3. Ensuring the seam weld for
    clean, straight & bur free welding
    in all the four sides
    5. Individual 1. Checking the fins for length, 100% No Leak
    Fins width, thickness & straightness at 2
    2. Checking each fins for leak test IS kg/cm2
    using soap oil bubble 9902:2004 air
    6. Header Pipe 1. Checking the length & thickness 100%
    of Pipe
    2. Checking the notching size and
    distance
    3. Ensuring bur free header pipe in
    all edges
    7. Flange 1. Checking the flange size, 100%
    thickness, bore, bolt holes as per
    the drawing
    2. Ensuring the good finishing of all
    sides for bur free

    39/B, Vinayaga Murugan Rice Mill Campus, Nellithope, Pondicherry-605006, India.


    :0413-2202510, +91-9786051510, email: rayaladhavan@gmail.com
    8. Radiator 1. Checking the fins for parallel and 100% IEEMA 9
    Assembly perpendicular distance in the
    assembly table
    2. Checking the center to center
    distance of Header Pipe
    3. Ensuring the strong welding tack
    to hold the Header Pipe and Fins
    for perfect positioning
    4. Checking the measurement of
    stiffener straps in top side of
    radiator in assembly table
    5. Checking the gap and
    perpendicularity of stiffener straps
    in bottom side of radiator out off
    assembly table
    6. Checking the flanges for center to No leak
    center distance and alignment at 2
    7. Visual inspection of welding IS kg/cm2
    quality 9902:2004 air
    8. Leak testing of Radiator pressure
    assembly using soap oil bubble No Leak
    method in all the MIG welding IS at 2
    joints 9902:2004 kg/cm2
    9. Final testing the radiator for leak air
    in submerged water pressure
    9. Surface 1. Checking the surface after grit 100% IS SA 2 ½
    Preparation blasting for visual inspection
    10. Inner Surface 1. Checking the radiator inner 100%
    Coating surface for free from foreign
    particle or metal particles
    2. Checking the Radiator inner
    surface for smooth coating of IS
    Synthetic Enamel Oil Resistant 14947:2001
    Air Drying Varnish
    11. External 1. Checking proper coating primer 100% Customer 30-40 µ
    Finish 2. Checking proper Coating of Spec
    finishing paint
    12. Packing 1. Checking safe packing of 100% Customer
    Radiator Spec

    39/B, Vinayaga Murugan Rice Mill Campus, Nellithope, Pondicherry-605006, India.


    :0413-2202510, +91-9786051510, email: rayaladhavan@gmail.com
    39/B, Vinayaga Murugan Rice Mill Campus, Nellithope, Pondicherry-605006, India.
    :0413-2202510, +91-9786051510, email: rayaladhavan@gmail.com

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