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