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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
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
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
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
TOT partners of Indian Railways www.highvolt.in
ENERGY INITIATIVES
Energy Saved is
Energy Gained
Transformer
Everybit of those 17.5Billion units pass through one or the other
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
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
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
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
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.
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
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.
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
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
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
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?
TOT partners of Indian Railways www.highvolt.in
Reliability & Capacity
Enhancement of
conventional Locomotive
Transformer
5400 KVA to 6670 KVA for
IR
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
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.
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
TOT partners of Indian Railways www.highvolt.in
22 I
Best Way Forward
Public Private Partnership
logo here
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23 IPRESENTER NAME COMPANY NAME
Qualifying Standards
1. RDSO Approved
2. Proven Experience of
Re Engineering NOT Repair
3. Five Years Warranty
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
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

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Save Energy thru ReEngineered Transformers : Indian Railways

  • 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
  • 23. logo here Certificate of Text Example This is an example text. Replace with your own, your text here This is an example text. This is an example text. This is an example text. This is an example text. Replace with your own This is an example text. Replace with your own, your text here This is an example text. This is an example text. This is an example text. your own, your text here example text. example name text example text here. 23 IPRESENTER NAME COMPANY NAME 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

Editor's Notes

  1. TOT partners of Indian Railways. Remarkable Development. Three phase Loco transformer. Micro Processor based FDCS for Railways. Solar power solutions.
  2. Indian Railways (IR) consumed over 17.5 billion units during 2013-14 corresponding to about 4000 MW, which constituted about 1.8% of the total country’s power generation for its traction and non-traction applications and paid about Rs.10,000 crore towards electricity charges.
  3. For the sake of this discussion we take into account thousands of those distributions transformers that feed the non traction loads such as station auxiliaries, colonies, yards, and railway manufacturing plants, IR run schools, sports complexes, warehouses and godowns. It is rather impossible to guess the number and age of these transformers but what is sure that, as of today: - There is no standard for the minimum energy efficiency required of these transformers The average age of these transformers would be more than 10 years The actual efficiency level of these transformers would be much lesser than what they were designed for. Yet they contribute to a sizeable amount of energy delivered and wasted Some safe conclusions from the above are: The impossibility of acquiring the data on these DTs does not reduce the tremendous scope of savings possible from these DTs through a simple policy intervention – which is in line with internationally proven initiatives – as we will see in the next section. The replacing these transformers with new “energy efficient” transformers may sound like a good idea but will actually not take off, since junking such a vast number of assets would be an impossible decision to make considering the upfront investment involved and a ridiculously long pay-back period. Proven cases and technologies are now available through which these transformers, if sent for a Retro Fitment, Reconditioning and Uprating, can improve the efficiency levels to global levels, at costs that could be a fraction of the cost of replacing these. In the following section we shall examine how a PSU like IR could decide on the levels of “efficiency” which are implementable and yet fair to all sides. This is because, with a great emphasis on Energy Efficiency, there will be a bee line of commercially interested initiatives each pitching for itself.
  4. The 50% increase in capacity is an average number, in that some transformers are more “updatable” than others. This increased capacity is typically obtained using the thermal capabilities of NOMEX® to allow more space for copper in the core window and an increased average winding rise. This space for added copper is usually found in one or more of the following ways: Decrease insulation builds and clearances to those used in present day practice (using conventional materials) Reduce the size of oil ducts in the winding (due to the higher thermal capability of the NOMEX®, less cooling is needed). Modify the winding configuration and/or the conductor dimensions to improve the space factor within the windings. Increase the core flux density (within the limits of the core steel) to reduce the required number of turns, thereby allowing for more copper per turn. Many of these concepts apply to new transformers as well as repaired units, however the designers approach may be different, in that he is staring without the limitations imposed by an existing core and tank.
  5.  An on-board traction transformer is a part of the locomotive, and must handle the full operating power of the motor unit under very severe conditions. With the recent trend in designing and building high speed rail networks, many of the more recent designs have also needed to reduce size and weight. In order to meet this need, these transformers must also operate at a higher temperature than conventional oil filled transformers. In the case of one design, for the same weight and kV, the output was doubled. Many of the new high speed lines, including the TGV, ICE and the Chunnel trains incorporate NOMEX® insulated designs, utilizing both mineral oil and other high temperature fluids (such as silicone) Although most manufacturers use NOMEX® in this application due to it’s thermal benefits, NOMEX® also provides mechanical and safety benefits to a traction transformer. Thermally, conditions such as high ambient temperatures, repeated accelerations and decelerations, and hauling heavy loads, can cause temperatures to go beyond designed conditions. The improved thermal characteristics of NOMEX® allow a safely factor to be able to withstand these conditions. The increased compression resistance, reduced shrinkage and other mechanical characteristics provide a mechanically improved winding structure. The non-flammability and compatibility with all fluids (such as silicone) enable design of safer transformers needed for this on-board application.
  6. Client Chittaranjan Locomotive Works. Equipment 7475 KVA Locomotive Transformer. Problem Statement The main transformer type LOT 7500 for WAP5 locomotive was originally supplied by M/s. ABB Secheron/Switzerland and now is to be manufactured to the same design in terms of ToT document available with CLW. In exiting design there is only one hotel load winding on which two hotel load converters are connected. If two different make converters are used compatibility issue is faced & hence it is decided to use two separate winding for both converter but with slightly increased hotel load winding capacity and voltage. To separate the winding, cater additional capacity & to increase its voltage it is intended to development LOT 7775 KVA transformer with revised hotel load rating as 1245 KVA, 960V. Project Design Objectives To separate the winding, cater additional capacity & to increase its voltage it is intended to development LOT 7775 KVA transformer with revised hotel load rating as 1245 KVA, 960V without changing existing general arrangement of transformer i.e. in existing tank size & mounting arrangement. Design Processes Used Previous design was a single winding supplying to converter of the Hotel Load & converters were tripping at 17.5kV catenary voltage. During design two separate windings were made with 15% coupling impedance to eliminate circulating current. Output voltage was increased from 750v to 960v, so that even at 17.5KV catenary voltage the hotel load will not trip off. Project Resources used. RDSO High Volt Engineering team. Design Results achieved The transformer was successfully designed with zero circulating current & Temp Rise of the transformer was also maintained. General arrangement was kept intact. Conclusions. The transformer was successfully developed for the desired parameters with enhances capacity in existing tank size. Learning Points. All the 7475 KVA transformer lying with IR can be coveted to 7775 KVA at an cost of Rs 20 lacs as against an estimated cost of Rs 1.2 Cr for new transformer with same specification and left over life of more than 10 years.