This presentation was made at the International Summit on Energy Technologies in Railways, at Taj Palace Hotel, New Delhi India on Nov 6th, 2015

1. HIGH VOLT ELECTRICALs PVT. LTD
RDSO approved source of
transformers for to Indian
Railways for last 30 years
Reduction of
losses in
Transformers
thru
Better
Material and
Superior
Design
Nov 6th, 2015
Taj Palace Hotel, New Delhi India

2. TOT partners of Indian Railways www.highvolt.in
Business
Essentials
Ravinder Bhan
BE Elect + 30 Years across
functions in several MNCs at
Senior Management Position
Director Strategy and Corporate
Planning , High Volt Electricals,
Mumbai India
The Presenters
Rajesh V Shah
BE Elect + 30 Years of
Transformer Design,
Engineering and
Re-Engineering
CMD, High Volt Electricals,
Mumbai India

3. TOT partners of Indian Railways www.highvolt.in
HIGH VOLT ELECTRICALs PVT. LTD.
(AN ISO-9001 : 2008 CERTIFIED COMPANY)
TOT partners of Indian Railways www.highvolt.in
30
years of service to IR
An RDSO
approved source
for manufacture
& Re-Engineering
of transformers

4. Energy Scenario IR
20%
10% 10%
70%
30%
• About 1.8% of the total country’s power generation
• Traction and non-traction applications
10,000 Cr
17.5 Billion
2013-14
https://www.railsaver.gov.in/en_scenario.html

5. TOT partners of Indian Railways www.highvolt.in
ENERGY INITIATIVES
Energy Saved is
Energy Gained

6. Transformer
Everybit of those 17.5Billion units pass through one or the other

7. Every Transformer
wastes some
energy internally
in the shapes of
losses.
Savings Through Losses
A 10% reduction in
these losses could
amount to 1% of the
energy delivered
175 Millions
Units / Year
Without any reduction
in passenger comfort
or safety

8. TOT partners of Indian Railways www.highvolt.in
Choose
Better
Materials
Improve Design
& Redesign
Identify Existing Efficiency
levels, limitations and
objectives
Re Engineered
Unit with
Lower Losses
And fresh
lease of life
How Really Do We Reduce Waste
Losses in a Transformer

9. TOT partners of Indian Railways www.highvolt.in
Design Approach
Track the pain points in
Thermal System
Identify causes
of thermal
failures
Decide
elements that
need to be
robust
In order to Reduce Losses
Winding insulation
breakdowns
29% 16.4% 5.4% 2.7%
Transient
over-voltage
disturbances
Other insulation
component
breakdowns Overheating
Improving the integrity of the insulation system thus became the Design Objective

10. TOT partners of Indian Railways www.highvolt.in
Material & Design
Aramid materials
like NOMEX®
provide the highest
withstand to
thermal and
electrical stress in
the windings.
Superior withstand
compared to
traditional
cellulosic
insulation results
in lower losses and
longer reliable life.
1. HVEPL was the first Manufacturer in India to Design and Reengineer transformers
along with DuPont and RDSO
2. These Re-Engineered Transformers are since then working satisfactorily
Improving the integrity of the insulation system

11. TOT partners of Indian Railways www.highvolt.in
Proven Advantages
Thermal
Benefits
• Least insulation aging at higher temperatures enables range of normal /emergency
loading
• During emergency peak loads – no embrittlement of the dielectric insulation.
• Preserves the integrity of the solid insulation and liquid dielectric system.
• Does not break down to form water thus extending the life of the insulation system.
Mechanical
Benefits
• Greater compression resistance enables tighter windings in assembly, and life of the
unit.
• Resists compression set during mechanical cycling (during short circuits) prolongs
the short circuit strength capability of the insulation structure.
• Exposure to elevated temperatures (during emergency load conditions) results in
negligible shrinkage of the insulation.
Electrical
Benefits
• Superior dielectric impulse properties enable higher margins of safety, improving
reliability.
• Lower dielectric constant enables better stress distribution between the solid and
the liquid in the insulation system.
• Lower dissipation factor at elevated temperatures minimizes the risk of failure due
to dielectric heating of the solid insulation.

12. TOT partners of Indian Railways www.highvolt.in
Impact of Advantages
Thermal
Benefits
• Reduction in losses , resulting in lesser thermal
stress results in decelerating the aging of
insulating materials and hence longer life of
transformer!
Abuse Ability
• Due to better withstand of sudden increase or
decrease in the load - ability to withstand over
loads increases, resulting in higher withstand to
abuse,
• This reduces the in service failure

13. TOT partners of Indian Railways www.highvolt.in
Lower Losses : Increased Capacity
Up to 50%
Increase in
capacity
• Typically obtained using the
thermal capabilities of
Aramid material to allow
more space for copper in the
core window and an
increased average winding
rise
Applicable for
new or
Re Reengineered
units,
• Designers approach may vary
if he is staring without the
limitations imposed by an
existing core and tank.

14. TOT partners of Indian Railways www.highvolt.in
Traction Transformers
• On-board traction transformer is a PART of the locomotive,
– Must handle full operating power of the motor unit under severe
conditions.
• Recent trend of high speed trains designs
– Needs to reduce size and weight.
• These transformers must operate at a higher temperature than
conventional units.
• The Material and Design advantage provides mechanical and safety
benefits to a traction transformer.
• High ambient, repeated accelerations and decelerations, and
hauling heavy loads, can cause temperatures to go beyond
designed conditions.
• This improved design unique to High Volt allow a safely factor to
withstand these conditions.In case of one design, for the same weight and kV, the output
was actually enhanced using unique design and Armid Materials

15. TOT partners of Indian Railways www.highvolt.in
Re- Place or Re-Engineer
All these for Re-Engineering cost of around
25% cost of a new unit
A reduction in losses at the original capacity in the order of 20%
Plus a more reliable transformer
Re-Engineered with Armide materials and ReDesign process
Received upto 20% increase in capacity over the original design.
High Volt Design as a Re-Engineering solution.
Often Repair and Re-Engineer is the rational answer because
Additional Capacity or Reliability, is possible with Armide Material
A vital decision
for Old Age or
failed
Transformers

16. TOT partners of Indian Railways www.highvolt.in
Up Rating Areas of Focus
1. Winding Hot Spot
2. Top Oil Temperature/Oil
Preservation System
3. Oil Expansion Space
4. Auxiliary Components
5. Tap Changers (LTC, PETC)
6. Bushings
7. Current Transformers
8. Preventative Auto-Transformers etc.
9. Impedance Limits
10. Short Circuit Stress in the windings
Parameters’ in addition to the average winding rise of
the transformer

17. TOT partners of Indian Railways www.highvolt.in
How do you foresee the growth
of your business?
Result was a 6%
reduction in losses
2014 2015
Modern design
techniques made it
possible to improve
heat dissipation
thereby reducing
temp rise
2012 2013
Design techniques
used modern
Materials like Nomex®
instead of
conventional
insulation system
based on cellulose
solid insulation
At High Volt we
pioneered this working
closely with RDSO and
Du Pont
What Was Done and Achieved?

18. TOT partners of Indian Railways www.highvolt.in
Reliability & Capacity
Enhancement of
conventional Locomotive
Transformer
5400 KVA to 6670 KVA for
IR

19. TOT partners of Indian Railways www.highvolt.in
Type Before After % age
KVA 5400 6670 + 27%
Iron 7.5 KV 7.5 KV NIL
Copper at 6670 75 KW 70 KW - 6.67%
Copper at 5400 75 KW 54 KW - 20%
Project Objectives & Results
Objectives
1. Increase hotel load Power by 1080 KVA.
2. Strictly Maintain Existing transformer Dimensional envelops
Improve Transformer reliability.
Process & Resources
1. A design and engineering team comprising RDSO, High Volt & DuPont
developed and implemented an enhanced insulation scheme with
Aramid paper
2. The challenge of keeping the overall mechanical envelope exactly
same was successfully met
Results

20. TOT partners of Indian Railways www.highvolt.in
Conversion of 3-Ph
Locomotive Transformer
7475 KVA to 7775 KVA
Project Objectives
1. To separate the hotel load winding.
2. Cater additional capacity of 300 KVA.
3. Increase voltage of hotel load winding from 750 to 960 Volts.

21. TOT partners of Indian Railways www.highvolt.in
WINDING KVA V A
Before After Before After Before After
HV 7475 7775 25000 25000 299 311
HOTEL LOAD 945 1245 750 960 1260 1296
Design Process & Results
Using Valuable data available with RDSO, High Volt Engineering team
reengineered the Transformer with two separate windings with 15%
coupling impedance to eliminate circulating current
Results
Learning Points
1. All 7475 KVA transformer lying with IR can be converted to 7775 KVA at an cost
of Rs 20 lacs as against an estimated cost of Rs 1.2 Cr for new transformer
2. With same specification and still to live life of 10+ years. Conversely these
transformer can be reengineered to reduce losses by 16-20% at Original
Capacitys

22. TOT partners of Indian Railways www.highvolt.in
22 I
Best Way Forward
Public Private Partnership

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Qualifying Standards
1. RDSO Approved
2. Proven Experience of
Re Engineering NOT Repair
3. Five Years Warranty

24. TOT partners of Indian Railways www.highvolt.in
Conclusion Transformer is the common equipment through which ALL Traction
or Non Traction Energy passes.
A reduction of 20% in the copper losses within the Transformer can
bring about 1% over all reduction in the Energy Consumed
This is possible with modern Materials and Proven designs
Bringing legislation for new units will reduce future loss but the
bigger chunk is the Existing and Aged Transformers
Proven cases exist where transformers aged more than 15 years were
Re Engineered to 20% enhanced capacity or 20% reduction in Copper
Losses besides a fresh lease of extended life.
The investment involved is just about 25% of what will be come
inevitable when they fail
Vendors should be RDSO approved with having proven past
experience of this Reengineering not Repair

25. TOT partners of Indian Railways www.highvolt.in
Rajesh V Shah: +91 9869037184 Ravinder Bhan : +91 954 5578626
HIGH VOLT ELECTRICALS PVT. LTD.
203 Saurabh, Above Andhra bank , 116 Andheri-Kurla Road,
Mumbai- 400093.INDIA
Tel : + 91-22-2836 1716, Fax : + 91-22-2837 5682.
website : www.highvolt.in