This paper proposes a modification in distribution transformer design to reduce losses occurring inside transformer during light loading conditions. Month wise Loading analysis of a particular financial year of all distribution transformers installed in network of TATA Power DDL was done to identify the light loading periods and under loaded transformers in the system. Further All day efficiency of transformers was calculated to establish their inefficiency during under loaded conditions. Further modifications in design of winding, their termination methodology inside tank and inside terminal box is discussed to operate transformers efficiently throughout the year. In the end analysis of efficiency with new design is done.


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