Powering India’s urban rail expansion: Traction transformers supporting Titagarh’s next‑generation fleets
Customer Story | 5 min read
India’s railways are the nation’s daily lifeline, moving millions of passengers and supporting economic mobility at national scale. Within this vast system, Urban Rail Transit has become increasingly central, as metros, regional rapid transit, and suburban networks expand rapidly to meet the needs of growing cities.
By May 2025, India’s operational metro and rapid rail transit had expanded to 1,010 kilometers across 23 cities, four times its size just a decade earlier. This rapid growth positions the country as the world’s second-most electrified rail network[1], with ridership exceeding 10 million passengers each day and more than 60 kilometers of new lines added annually[2].
Yet modernization is no longer defined solely by long inter‑state corridors. Increasingly, its pace and pressure are felt in the heart of India’s cities, where millions depend on train punctuality. Here, constant acceleration and braking, fast platform turnover, and peak‑hour density leave virtually no margin for error. For Titagarh Rail Systems Ltd., one of India’s leading manufacturers of passenger and freight rail mobility solutions, supporting this next phase of growth required more than supplying new rolling stock: it called for advanced traction power capable of delivering higher speeds, heavier loads, and rising frequency without placing additional strain on India’s electrification network.
Challenge
Modernize at the speed of India
Growth
More capacity for a rapidly expanding nation.
Modernization
A shift to advanced, reliable rolling stock technology.
Sustainability
Solutions that cut losses, emissions, and long-term operating costs.
Performance improvements could not compromise safety or network stability. Any increase in power capacity had to remain fully compatible with India’s 25 kV single-phase electrification system, ensuring smooth integration into existing infrastructure. Fire safety standards were also critical, particularly for passenger trains operating in tunnels or densely populated areas, where material behavior in extreme conditions becomes a key regulatory requirement.
In parallel, sustainability and cost efficiency were essential considerations. Reducing energy losses, lowering emissions through improved efficiency, and minimizing maintenance requirements were necessary to support long-term operational and environmental goals.
The challenge, therefore, was not simply to increase power, but to do so in a way that strengthened reliability, ensured safety compliance, and supported the broader modernization of India’s rail network.
Hitachi Energy's Solution
Traction Transformers "Made in India, for India"
Titagarh partnered with Hitachi Energy to supply 54 traction transformers rated at 1250 kVA, specifically engineered for India’s ICF (Integral Coach Factory) and RCF (Rail Coach Factory) coach factories, where passenger coaches used across the country are designed and produced.
Although not visible to passengers, these transformers are a critical part of a train’s electrical system, safely converting the high-voltage electricity collected from overhead lines into the appropriate power needed to operate the train. They form part of a broader ecosystem of carefully designed coach components that ensure the safety, comfort, and long-term durability of India’s railway coaches, which transport millions of passengers every day. Together, Titagarh and Hitachi made this possible through the indigenous manufacturing of these transformers and their successful integration into the propulsion systems.
Designed for seamless compatibility:
The transformer's engineering was focused on reliable performance under high-duty cycles common in Indian railways, reducing costs and enabling seamless integration with existing Electric Multiple Unit (EMU) and Mainline Electric Multiple Unit (MEMU) systems for faster installation and testing.
EMU and MEMU trains are modern electric passenger trains that power themselves without the need for a separate locomotive at the front. Instead of relying on one engine to pull the entire train, they use traction motors installed across multiple carriages, allowing power to be distributed throughout the train. This design improves acceleration, enhances energy efficiency, and increases overall reliability. The main difference lies in how they are used, EMUs are typically deployed on suburban and high-frequency commuter routes with closely spaced stations, while MEMUs are designed for longer regional and mainline services where stops are farther apart. Both types operate on the 25 kV AC overhead electrification system.
Proven traction transformer platform:
For this project, Titagarh leveraged a proven traction transformer platform in collaboration with Hitachi Energy, based on an established onboard design already in operation across large train fleets and adapted to meet the specific requirements of Indian Railways. Because the core technology had already been validated through multiple deployments, Titagarh was able to move efficiently from defining technical requirements to implementation, helping reduce development time and project risk.
HL2 compliant design:
The transformers were built to meet strict HL2 fire safety standards and additionally used synthetic ester insulation for enhanced fire safety and better environmental performance. HL2 compliance establishes strict requirements for fire behavior, smoke emission, and toxicity of materials used in railway vehicles, particularly important for trains operating in tunnels or underground sections, where fire safety is critical.
Empowering India from within:
All units have been manufactured locally at Hitachi Energy’s facility in Savli, Gujarat, reinforcing India’s Aatmanirbhar Bharat vision, a broader push to strengthen domestic manufacturing and supply‑chain resilience. Local production not only supports this strategic objective but also improves supply chain resilience and enables closer collaboration on quality control and delivery timelines, ensuring smoother project execution. Titagarh has further supported this initiative by integrating these transformers into the propulsion system and indigenously manufacturing all other key components. This also marks a significant step for Titagarh towards making the entire propulsion system fully indigenous, a true testament to the spirit of Make in India and Atmanirbhar Bharat, aligned with the vision of a Viksit Bharat.
Impact
Connectivity that lifts a nation
For Titagarh, the outcome was more than the delivery of equipment; it represents faster deployment, access to local expertise, reduced lifecycle costs, and tangible progress toward Indian Railways’ ambition of building a greener and more sustainable rail.
The impact of this project is both immediate and long-term. By improving traction efficiency, the transformers reduce energy losses and can cut CO₂ emissions by up to 30 percent compared with traditional technologies, directly contributing to sustainability objectives. Greater efficiency and reliability also translate into tangible economic benefits: over the lifetime of the fleet, we can achieve up to a 50 percent reduction in total cost of ownership, driven by lower energy use, fewer maintenance interventions, and improved operational stability.
This progress is grounded in experience. The solution builds on a globally proven platform with more than 30,000 traction transformers installed worldwide, providing strong assurance of long-term performance and maintainability. Enhanced traction capability supports a more resilient and productive rail network, while smoother and more consistent train performance improves the daily travel experience for millions of passengers.
At the same time, this collaboration between Hitachi and Titagarh strengthens manufacturing in India by enhancing domestic industrial capabilities and generating employment. It ensures that railway modernisation goes beyond expanding fleet capacity to building local expertise, reinforcing long-term economic resilience, and advancing India’s ambition to emerge as a global hub for rail manufacturing.
Notes:
Transformer for Railways
Railway transformers deliver safe, reliable and efficient power for traction and auxiliary systems, built to withstand demanding conditions while ensuring high availability, low maintenance and enhanced safety for modern, sustainable rail networks.