save energy thru reengineered transformers : indian railways
TRANSCRIPT
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
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 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
TOT partners of Indian Railways www.highvolt.in
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
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 LossesAnd fresh lease of life
How Really Do We Reduce WasteLosses 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
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
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
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 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
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 % 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
TOT partners of Indian Railways www.highvolt.in
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.
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 & 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
TOT partners of Indian Railways www.highvolt.in
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
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.INDIATel : + 91-22-2836 1716, Fax : + 91-22-2837 5682.
website : www.highvolt.in