save energy thru reengineered transformers : indian railways

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, 2015Taj Palace Hotel, New Delhi India

TOT partners of Indian Railways www.highvolt.in

Business Essentials

Ravinder BhanBE 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 ShahBE Elect + 30 Years of Transformer Design, Engineering and

Re-Engineering

CMD, High Volt Electricals, Mumbai India


HIGH VOLT ELECTRICALs PVT. LTD.(AN ISO-9001 : 2008 CERTIFIED COMPANY)


30 years of service to IR

An RDSO approved source for manufacture & Re-Engineering of transformers

Energy Scenario IR20%

10% 10%

70%

30%

• About 1.8% of the total country’s power generation • Traction and non-traction applications

10,000 Cr17.5 Billion

2013-14

https://www.railsaver.gov.in/en_scenario.html


ENERGY INITIATIVES

Energy Saved is Energy Gained

TransformerEvery bit of those 17.5 Billion 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


Choose Better Materials

Improve Design & Redesign

Identify Existing Efficiency levels, limitations and objectives

Re Engineered Unit with Lower LossesAnd fresh lease of life

How Really Do We Reduce WasteLosses in a Transformer


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


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


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.


Online Failure of Transformers can stall the entire Train, this

extremely critical

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


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.


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


Re- Place or Re-Engineer

A vital decision for Old Age or

failed Transformers


Up Rating Areas of Focus

1. Winding Hot Spot 2. Top Oil Temperature/Oil

Preservation System3. 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


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?


Reliability & Capacity Enhancement of conventional Locomotive Transformer 5400 KVA to 6670 KVA for IR


Type Before After % ageKVA 5400 6670 + 27%Iron 7.5 KV 7.5 KV NILCopper 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 & Resources3. A design and engineering team comprising RDSO, High Volt & DuPont

developed and implemented an enhanced insulation scheme with Aramid paper

4. The challenge of keeping the overall mechanical envelope exactly same was successfully met

Results


Conversion of 3-Ph Locomotive Transformer 7475 KVA to 7775 KVA

Project Objectives1. 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.


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 & ResultsUsing 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 Points1. 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.in22 I

Best Way Forward

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Qualifying Standards

1. RDSO Approved2. Proven Experience of

Re Engineering NOT Repair3. Five Years Warranty


Conc

lusio

nTransformer 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

Strategic Investment in ReEngineering Old and Aged Transformers Can help IR Save 175 Million Units per year


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.INDIATel : + 91-22-2836 1716, Fax : + 91-22-2837 5682.

website : www.highvolt.in

http://www.highvolt.in/

save energy thru reengineered transformers : indian railways

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