Corrugated Transformer Tank

Custom Corrugated Transformer Tanks and Radiator Fin Enclosures

Our high-efficiency corrugated transformer tanks are designed for oil-immersed distribution and power transformers ranging from 50 kVA to 10,000 kVA. Built to withstand extreme thermal expansion, mechanical stress, and harsh environmental conditions, our tank enclosures ensure leak-free performance and long-term operating reliability.

Technical Specifications and Capability Standards

Parameter / Feature	Standard Specification	Optional / Customization
Applicable Transformer Rating	50 kVA to 10,000 kVA	Up to 20,000 kVA custom power tanks
Standard Compliance	IEC 60076, IEEE C57.12, EN 50464	GB/T 1094, DIN standards
Material Grade	Q235B, Q355B, S235JR, S355JR Carbon Steel	SS304 / SS316L Stainless Steel
Sheet Metal Thickness	Fin pitch: 1.0 mm to 1.5 mm; Tank wall: 4.0 mm to 8.0 mm	Custom thickness per mechanical analysis
Corrugated Fin Pitch	40 mm to 85 mm adjustable	Tailored to thermal dissipation requirements
Corrugated Fin Height	50 mm to 400 mm	Custom height for tight footprint constraints
Anti-Corrosion Protection	Shot blasting ISO 8501-1 Sa 2.5 + C3 to C5 Paint	Hot-dip galvanized coating (ISO 1461)
Operating Temperature Range	-40 deg C to +105 deg C	Extreme cold / tropical insulation packages

Core Manufacturing Features and Engineering Excellence

Advanced Automated Corrugated Fin Forming

Thermal Expansion Accommodation: Precision-engineered corrugated fins function as elastic expansion elements, absorbing oil volume changes caused by temperature fluctuations without conservative conservator tanks.

Optimized Cooling Efficiency: Computer-controlled fin pitch and height maximize heat dissipation surface area within a compact enclosure footprint.

Leak-Proof Welding and Structural Integrity

Robotic Gas Metal Arc Welding (GMAW/MIG): Automated continuous seam welding minimizes human error, ensuring full penetration welds on all fin joints and tank seams.

Reinforced Tank Base and Frame: Heavy-duty channel steel base plate and structural stiffeners prevent deformation during vacuum oil filling, transport, and lifting operations.

Surface Preparation and High-Durability Coating

Automated Surface Shot Blasting: All steel plates undergo Sa 2.5 surface cleaning to eliminate rust, mill scale, and impurities, achieving optimal primer adhesion.

Multi-Layer Anti-Corrosion Coating: Standard C3/C4 marine-grade epoxy primer with polyurethane topcoat, or optional C5-M coating for coastal, offshore, and high-humidity environments.

Quality Assurance and Testing Procedures

Dimensional Inspection: Laser measurement verification against approved shop drawings (+/- 1.0 mm tolerance).

Pressure and Leak Testing: 100% pneumatic pressure testing at 30 kPa to 50 kPa for a minimum of 24 hours, followed by dye penetrant or oil leakage verification.

Weld Integrity NDT: Radiographic testing (RT) or Ultrasonic testing (UT) performed on critical load-bearing structural welds.

Coating Thickness Verification: Dry film thickness (DFT) testing ensuring compliant primer and topcoat thickness (120 to 250+ microns).

OEM and ODM Customization Workflow

Engineering Drawing Approval：1 to 3 Business Days

Send your CAD / SolidWorks drawings or technical specifications. Our engineering team reviews heat dissipation metrics, structural frame requirements, and bushing placement.

Prototype or Sample Fabrication：7 to 10 Days

Precision laser cutting, automated fin forming, robotic welding, and pressure testing for prototype validation.

Batch Production and Coating：15 to 25 Days

Scalable mass production featuring inline automated welding, shot blasting, and environmental coating processes.

Final Inspection and Export Packaging：Prior to Loading

Comprehensive FAT inspection with detailed test reports, mounted protective shipping frames, and seaworthy wooden/steel pallet packing.

Packaging & Global Delivery

Structural Protection & Bracing: High-density foam blocks, wooden spacers, and protective corner guards are installed between individual corrugated fins to prevent bending or surface abrasion during loading and transit.

Anti-Corrosion Wrap: The entire tank body is wrapped in heavy-duty VCI (Vapor Corrosion Inhibitor) film and sealed with polyethylene sheeting. Unpainted machined faces, flange surfaces, and threaded holes receive a coat of rust-preventive oil and soft plastic protective caps.

Container Loading & Lashings: Tanks are loaded into standard 20GP/40HQ containers using soft slings to avoid paint scratching. Internal steel wire ropes, turnbuckles, and wooden chocks secure every skid to container floor D-rings to prevent shifting during sea freight. Open-top or Flat-Rack containers are used for oversized power transformer tanks.

Shipping Documentation: Every container includes a complete shipping dossier attached inside waterproof pouches, containing packing lists, bill of materials (BOM), EN 10204 3.1 material test certificates, and factory pressure leak test reports.

Honor Certificates

FAQ

Q: Can you manufacture corrugated tanks according to custom drawings and dimensions?

A: Yes. We specialize in OEM and ODM manufacturing. Our engineering department works directly with your CAD, STEP, or PDF drawings to match exact transformer dimensions, bushing hole patterns, and radiator mounting configurations.

Q: What anti-corrosion protection options do you offer for coastal or aggressive environments?

A: For C5-I or C5-M aggressive environmental applications, we provide hot-dip galvanizing per ISO 1461 or multi-layer zinc-rich epoxy paint systems with total dry film thickness exceeding 220 microns.

Q: How do you verify leak tightness prior to shipment?

A: Every single tank undergoes a 100% positive pressure air test or hot oil pressure retention test. Inspection certificates and pressure decay logs are provided with shipping documentation.

Q: How do you prevent structural sagging or permanent deformation during vacuum oil filling?

A: To withstand vacuum pressures (such as -0.08 MPa to -0.1 MPa) during factory oil filling, we engineer internal spot-welded support rods between corrugated fin roots and reinforce the top rim and bottom base frame. If specified in your technical drawings, we also install removable external vacuum clamping channels that support the fin walls during processing and are removed prior to final installation.

Q: What is the standard production lead time for custom transformer tank orders?

A: For custom engineering prototypes or initial sample approvals, lead time is typically 10 to 15 business days following drawing approval. Mass production batches (such as 20 to 100 units) generally require 20 to 30 days depending on raw material availability, custom tooling requirements, and surface finish complexity (such as hot-dip galvanizing vs. standard multi-layer epoxy paint systems).

Q: Can you pre-install or integrate accessories such as oil valves, cable boxes, and bushing plates?

A: Yes. We offer complete OEM assembly services. In addition to fabricating the main tank shell and corrugated fin walls, we precision-weld top cover mounting flanges, conservator connection pipes, thermometer pockets, oil drain valve blocks, cable enclosure boxes, and copper grounding lugs exactly according to your CAD center-distance specifications.

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