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EDM 05-13 Design and Quality Standards For Radiators

This document outlines design, manufacturing, and quality standards for bolt-on cooling radiators. It specifies applicable standards for materials, corrosion protection, testing, and packaging. Radiator design is restricted to standard types and dimensions unless absolutely necessary. Materials must be mild steel with a minimum yield strength of 250MPa and hot-dip galvanized on the outside. Internal corrosion protection with 10 micron paint is also required. Radiators must undergo pressure and leak testing prior to shipment.

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101 views4 pages

EDM 05-13 Design and Quality Standards For Radiators

This document outlines design, manufacturing, and quality standards for bolt-on cooling radiators. It specifies applicable standards for materials, corrosion protection, testing, and packaging. Radiator design is restricted to standard types and dimensions unless absolutely necessary. Materials must be mild steel with a minimum yield strength of 250MPa and hot-dip galvanized on the outside. Internal corrosion protection with 10 micron paint is also required. Radiators must undergo pressure and leak testing prior to shipment.

Uploaded by

bhandaresagar83
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
You are on page 1/ 4

ENGINEERING DRAWING MANUAL

EDM 05/13 – Design and Quality Standards for Radiators

Prepared By: Ethan Hassell Version: 1.0

Position: Mechanical Team Lead Version Date: 8/03/2024

Issue Date: 8/03/2024 Next Review Date: 8/03/2025

1.0 Introduction
This document is related specifically to bolt on cooling radiators. This internal standard outlines the design,
manufacturing and quality details. Any specifications required that are not outlined or differ from this
document, should be clearly specified on the manufacturing drawing and in writing to the supplier.

2.0 Applicable Design Standards


IEC 60076-22-2 Power Transformer and reactor fittings – Removable radiators.
AS/NZS 4680 Hot-dip galvanised (zinc) coatings on fabricated ferrous articles.
AS/NZS 2312.1 Guide to the protection of structural steel against atmospheric corrosion by the use of
protective coatings
AS/NZS 1627.4 Metal Finishing – preparation and pretreatment of surfaces

3.0 Radiator Design (Not applicable to Suppliers)


Where possible “standard” radiators as pictured below should ONLY be used. Unless absolutely necessary,
can “offset” or “Swanneck” radiators be specified.

Swanneck (FR Type) Offset (FG type) Standard (FG Type)

Page 1 of 4 Version 1.0


ENGINEERING DRAWING MANUAL
EDM 05/13 – Design and Quality Standards for Radiators

Standard Radiator widths are 310mm and 520mm. Radiator fin bracing can be specified by supplier unless
clearance is limited on the transformer. Fixing to the transformer can be via 160PCD 4 bolt flanges or
threaded nipple mounted onto tank via gold passivated nut.
Gaskets must be TD 1049 cork material unless customer specified.

Please see EMM 04-02 for considerations when designing radiators and radiator-supports for transportation
and seismic loads (Internal).

Radiator fin material should be 1 ±0.05mm for ideal cooling and Maximum thickness 1.2mm. This should be
clearly stated on the drawing.

Radiator pipe diameter should be 80mm.

Note that external galvanising slightly reduces cooling, for improved cooling performance paint system A is
recommended. However, this is taken into consideration during engineering of transformer.

4.0 External Corrosion Protection


Radiator material should be Mild Steel with a minimum yield strength of 250MPa. A minimum average coating
of 45 micron hot dip galvanise (Zinc) should be applied on the OUTSIDE ONLY

Refer to QAS 02-00 Document for Visual Inspection Guide

Finish and quality details:


- The radiators shall have a bright smooth finish. No dags or excess build-up of Zinc is allowed.
- No touching up of bare spots is allowed. Zinc must have minimum 99% coverage of the radiator surface.
- Spray painting is only permitted on weld area post galvanising. Zinc rich 2 pack epoxy primer or
equivalent must be used (No aerosol paint allowed). Maximum 50 micron build-up.
- The thread on header pipes or holes on flanges, MUST NOT be galvanised.
- Any sharp galvanising points must be removed. It is CRITICAL that care be taken not to destroy the
integrity of the galvanised surface when cleaning any sharp points from the radiators. Any grinding of
radiators must be kept at a minimum.
- Quenching must not be done on radiators (As this affects paint adhesion)

5.0 Internal Corrosion Protection


Internal painting is critical, average build up is 10 micron. Take care when painting internally not to introduce
blockages with excess build-up. Zinc rich epoxy primer recommended. Good paint practice is expected.
Correct surface preparation and treatment to ensure paint adherence is good. As per AS 1627.4.

Endoscopic pictures looking inside the fins should be taken for samples per batch. This is to check
for blockages and manufacturing defects prior to dispatch. Pictures below for example of what a good
radiator should look like (Looking into the top of the fin).

Page 2 of 4 Version 1.0


ENGINEERING DRAWING MANUAL
EDM 05/13 – Design and Quality Standards for Radiators

Internal Galvanising IS NOT ALLOWED as this will result in blockages.

6.0 Air Purging and Oil Flushing


Internal air purging should be done after welding radiator to remove weld residue and slag. 40 PSI for 2
minutes minimum. A second air purge is recommended pre internal painting process to help remove any dust
or particles from inside the radiator.

Oil flushing is to be specified on a case-by-case basis for radiators. Oil flushing to be completed after internal
painting to ensure paint adhesion is not affected. Oil flushing helps further remove any contamination as the
radiator can be sealed immediately after flushing. Recommend minimum flushing time is 30 minutes.

7.0 Pressure and Leak Testing


All radiators must be pressure leak tested prior to dispatch. Recommended minimum test pressure is 30PSI
for minimum 30 minutes. This test should be completed under water to aid in leak detection and safety. This
test should be done post galvanising process.

8.0 Packaging, Transport and Traceability


Moisture Prevention
- Radiators to be supplied with inlet/outlet blanking plates and sufficient gasket to prevent air and moisture
ingress during transport.
- Radiators must NOT be shrink wrapped.
- To further prevent moisture ingress and for certain applications, radiators may be supplied pressurised to
1.5-2.5PSIG with pure nitrogen.

Reducing Transport Damage


- Units to be stacked on pallets suitable to be moved by a forklift.
- Pallets to be stacked in containers to allow sufficient space between. In order to minimise damage during
transport.
- Ensure radiators do not overhang pallets.

Traceability
- Radiators are to be stamped with clearly visible batch numbers and manufacturer ID.
- Any process changes later down the line require approval from ETEL Ltd.
- Changes to sub-contractors must be communicated clearly to ETEL Ltd prior to change.

9.0 Requirements for New Suppliers


- Radiator Dissipation type test documentation required as per IEC 60076-22-2.
- Radiator manufacturing process including all sub processes (painting, galvansing ect.) should be
reviewed for approval.

Page 3 of 4 Version 1.0


ENGINEERING DRAWING MANUAL
EDM 05/13 – Design and Quality Standards for Radiators

- Radiator leak test process.


- FAT is recommended.
- Confirmation supplier can meet all design standards as listed in this document.
- ETEL should supply Visual Inspection Guide QAS 02-00 to suppliers to help with quality control.

Page 4 of 4 Version 1.0

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