Project Report

on
Iot Based Distribution
Transformer Health Monitoring
System

Submitted to the department in partial fulfillment of the

requirements for the award of the degree of Bachelors of
Technology in Electrical Engineering of Assam Engineering
College

Session- 2023

By:
KULDIP DAS (ROLL NO- 190610003046)
GITARTHA SONOWAL (ROLL N0- 190610003036)
GUNJAN SONOWAL (ROLL NO- 190610003037)
DADU PATHARI (ROLL NO- 190610003027)

Under the guidance of

DR. DAMODAR AGARWAL
Professor
Department of Electrical Engineering
Assam Engineering College

Department of Electrical Engineering, Assam

Engineering College, Jalukbari, Guwahati-781011

1
 Declaration

We hereby declare that the work presented in this project report entitled, IoT based
Distribution Transformer Health Monitoring System submitted in the department of
Electrical Engineering, Assam Engineering College, in partial fulfillment for the degree
of Bachelors of Technology (B.Tech.), is an authentic record of our own work carried
out during the period September 2022 to January 2023, under the guidance of Dr.
Damodar Agarwal, Professor, Electrical Engineering, Assam Engineering College.

KULDIP DAS
190610003046

DADU PATHARI
190610003027

GITARTHA SONOWAL
190610003036

GUNJAN SONOWAL
190610003037

Department of Electrical Engineering,

Assam Engineering College,
Guwahati-781013, Assam, India

2
 Certificate

This is to be certified that Kuldip Das (190610003046), Gitartha Sonowal

(190610003036), Dadu Pathari (190610003027) and Gunjan Sonowal
(190610003037), students of Final Year of B.Tech., Department of Electrical
Engineering, Assam Engineering College, Guwahati, Assam have completed their Major
Project entitled IoT based Distribution Transformer Health Monitoring System.

They have submitted their project report for the partial fulfillment of the curriculum
of the Degree of Bachelor of Technology in Electrical Engineering, Assam Engineering
College, Guwahati.

..........................................
Dr. Damodar Agarwal
Professor, Department of Electrical Engineering
Assam Engineering College,
Guwahati- 781013, Assam, India 10th January, 2023

3
 Acknowledgement

It is a genuine pleasure to express our deep sense of thanks and gratitude to our mentor and
guide Dr. Damodar Agarwal, Professor, Electrical Engineering, Assam Engineering College
for his timely advice and unique scientific approach that have helped us to a very great
extent to accomplish this task.

We thank profusely all the Staff and faculties of EE Department, Assam Engineering College
for their kind help and co-operation during the whole time of our project work.

Date:

Kuldip Das 190610003046

Dadu Pathari 190610003027
Gitartha Sonowal 190610003036
Gunjan Sonowal 190610003037

4
 Contents

Abstract 7
Abbreviation 8
1. Introduction 9
1.1 Problem statement 10
1.2 Literature Review 11
1.3 Objectives 12
2. Theoretical Considerations 14
2.1 Internet of Things (IoT) 14
2.1.1 Applications 14
2.2 Hardwares and Softwares 15
2.2.1 Hardwares used 15
2.2.2 Softwares used 23
2.3 Transformers 24
2.3.1 Distribution Transformer main parts 24
2.3.2 Transformer Fault Conditions 26
3. Methodology 29
3.1 Proposed model 29
3.2 Flow chart 31
4. Simulation 32
4.1 Introduction 32
4.1.1 Proteus Simulator 32
4.2 Design Procedure 32
4.3 Circuit Parameters 34
4.4 Circuit Diagram 35
4.5 Program Execution and testing 36
4.5.1 Analysis and Results 37
5. Conclusion, Limitation and Future Direction 38
5.1 Conclusion 38
5.2 Limitation 38

5
 5.3 Future Direction 38
Appendix 39
Bibliography
42

6
 Abstract

Transformers are the main building block in a power system. Any damage in transformers
adversely affects the balance of a power system. The damages mainly occur due to
overloading and inefficient cooling. The main objective of the project is real time monitoring
of the health conditions of the distribution transformer using IOT technology. The
parameters, such as temperature, voltage, humidity and current of a transformer are
monitored, processed and recorded in servers. For this purpose, we have used sensors
interfaced with Arduino. The recorded data can be sent using Wi-Fi module and accessed
from anywhere around the world using IOT technology. This helps in identifying and solving
a problem before the occurrence of failure without human dependency.

7
 Abbreviations

IDE - Integrated Development Environment

IoT - Internet of Things
LCD - Liquid Crystal Display
I/O - Input/output
ADC - Analog to Digital Converter
GND - Ground

8
Chapter 1

Introduction

Distribution transformers have a long service life if they are operated under good and
rated conditions. However, their life is significantly reduced if they are overloaded,
resulting in unexpected failures and loss of supply to a large number of customers thus
affecting system reliability. Overloading and ineffective cooling of transformers are the
major causes of failure in distribution transformers.

Distribution transformers are generally monitored manually where a person

periodically visits a transformer site for maintenance and recording the parameters. This
type of monitoring cannot provide information about occasional overloads and
overheating of transformer oil and windings. All these factors can significantly
reduce transformer life. This project aims to design a system based upon online
monitoring of different operational parameters of distribution transformers, which can
provide useful information about the health of transformers and to assess their operation.

Many operational problems will be identified before any catastrophic failure, thus
resulting in a long life service for transformers. It also has the advantages of significant
cost savings and greater reliability.

The proposed monitoring system integrates Internet of Things (IoT), with Arduino Mega
microcontroller and sensor packages. Data f o r operational condition of transformer
received in the webpage of thingspeak using the suggested online monitoring system
will help engineers to keep transformers in service for longer of times.

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1.1 Problem Statement

In power systems, distribution transformer is electrical equipment which distributes power to

the low voltage users directly, and its operational condition is an important component of the
entire distribution network operation. Operation of distribution transformers under rated
condition guarantees their long life. However, their life is significantly reduced if they are
subjected to overloading, resulting in unexpected failures and loss of supply to a large
number of customers, thus affecting system reliability. Overloading and ineffective cooling
of transformers are the major causes of failure in distribution transformers. The monitoring
devices or systems which are presently used for monitoring distribution transformer suffer
from the following problems:

1. Detection system itself is not reliable. Detection data is not sent to monitoring centers
in time.
2. Many monitoring systems use power line carrier communication to send data, but the
power line carrier communication has some disadvantages, such as frequency
interference, signal attenuation with the increase in distance, and large electrical
noises caused by load changes.

Thus, there is a need of real-time monitoring system to detect all operating parameters’
operation, and send these data to the monitoring center in time. Widespread use of mobile
networks and GSM devices, such as GSM modems and their decreasing costs have made
them an attractive option for wide area network applications.

Abnormality in distribution transformer is accompanied with variation in various parameters,

such as oil temperature, load current, overvoltage, and rises in oil level. Online monitoring
system consists of embedded system, Wi-Fi module, mobile-users and Wi-Fi networks and
sensors installed at transformer site. Sensors are installed on transformer side which reads and
measures the physical quantity from distribution transformer, and then converts it into analog
signal. These analog signals are then processed in ADC, and fed to a microcontroller. The
preprogrammed microcontroller sends signal to Wi-Fi module. The user receives data from
the Wi-Fi module. The comfort of being able to control a transformer from one particular

10
location has become imperative as it saves a lot of time and effort.
1.2 Literature Review:

The transformer plays a significant role in the electricity domain. Observing the condition of
the transformer is a very critical task. Any small problems in the transformer also lead to
major issues. Regular monitoring of transformer health condition is important. Preventive
devices are used to identify the fault, and they are helpful at the time of fault.
Amutha elakkiya et al.( 2019) collected real-time data from the transformer with the help of
the IoT(Internet of Things).This system can be used to monitor the important transformer
features like temperature and the current level. The collected data are sent through the
TCP/IP internet protocol using this system; the user receives an alert signal when a power
failure occurs. The LED display is used to display the phase defect message. The important
parameter of the transformer is regularly sent to the android system. With the help of these
parameters, the concerned people take necessary action and maintain the transformer in a
better manner. This proposed embedded system is used to measure the current level, oil level,
and temperature level of the transformer. The main goal of this system is to predict and
prevent the fault of the transformer.

P.G.Navamanikumar et al., (2018) propose a new system to collect the information from the
transformer and send the conditions to the users' mobile by using IoT and GSM concept.
Mainly this system is used to monitor the temperature, current, and voltage level of the
transformer. MQTT protocol is used to transfer the message to the concerned people. By
using this system, the authorized persons receive an alert message before the transformer
going to the fatal condition.

K. Santhiya et al., 2020 implemented a new system to assess the current load, voltage level,
oil level, and temperature of the transformer using an Arduino microcontroller and various
sensors. This system is mounted at the transformer. System generated output values are
stored and processed using system memory. The designed system was developed with an
inbuilt function to verify the abnormal state of the transformer. The main goal of this system
is to identify the abnormal condition of the transformer before any severe Breakdown.

D.Sarath kumar et al., 2018 propose a system to obtain transformer data in real-time with the
help of the IoT technique.Data collected from the temperature sensor, current transformer,

11
and potential transformer are transferred to the remote place in real-time These collected
analog values are transferred to the 8051 microcontrollers using ADC 0808. These data are
then directly sent to wifi part with TCP IP to committed IP that visualizes the information
through the chart. The major benefit of this system is to observe the condition of the
transformer automatically, and real-time data is updated on the webpage when the condition
is abnormal.

Mali Pushpak et al., 2019 propose a new system for monitoring transformer in a better
manner and compute oil level, oil quality, the temperature of the transformer, and oil tank
outflow. It is also used to measure the voltage level, copper robbery, current flow level, and
find the affected place of the transformer automatically. The proposed system monitors the
transformer continuously without human interaction. In case of any serious problem that
occurs, the message will be sent to the concerned people using the IoT technique, and the
fault are displayed on the system LCD.

Dnyaneshwar J. Mali et al., 2018 established a system for protecting the transformer using a
relay coupled microcontroller. The model circuit is implemented using proteus and
MATLAB software. Compared with other systems, this system is more economical and small
in size.

Ankush Rameshrao Kadam et al., 2019 proposed a project to record and monitor the
important metrics of a transformer, such as oil level, load current level, temperature, and
voltage level. This system is developed with the help of an Arduino controller and different
kinds of sensors. By using the system memory the collected data will be processed and
stored. If any emergency conditions occur, the measured values will be exhibited in the
monitoring based inbuilt functions.

1.3 Objectives

The objectives of this project are summarized as follows -

 To study various faults occurring in a distribution transformer and their causes

 To design a system which uses sensors or indicators to measure and monitor the
defined parameters of the transformer and display them

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 To design a system to constantly transmit the sensed data or parameters recorded to
remote monitoring station using IoT
 To design a control system to control the parameters remotely

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Chapter 2

Theoretical Considerations

2.1 Internet of Things (IoT)

The term Internet of Things (IoT) represents a general concept for the ability of network
devices to sense and collect data from the desired platform, and then share that data across
the Internet where it can be processed and utilized for various purposes.

IOT is a sort of "universal global neural network in the cloud”. It is a platform of

intelligently connected devices and systems which comprise of smart machines interacting
and communicating with other machines, environments, objects and infrastructures and the
Radio Frequency Identification (RFID) and sensor network technologies. An enormous
amount of data is being generated, stored, and that data is being processed into useful
actions that can command and control the things to make our lives much easier and safer.

The connectivity, networking and communication protocols used with these web enabled
devices largely depend on the specific IoT applications deployed. The proposed system fits
into the category of IoT applied to external and public environments, and it fulfills the
following necessary requirements of IoT services:

1. Reliability:
Trustworthy and reliable communication is needed in order of carrying out
communication between devices as this type of IoT has a large service domain. Hence
the proposed system interacts with each other, based on wireless network which
provides great reliability.
2. Mobility:
IOT devices may be required to shift in the outer atmosphere. The proposed system
works with a battery instead of the permanent power source, resulting in a great level
of mobility. The mobility of the system is protected with a power supply of its
needs.
3. Service Continuity:

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 Data interactions and services should be conducted faultlessly at any time and in
any location in IoT with a large service domain. Bins are positioned at regular
space of distance to ensure service continuity.
4. User Convenience:
The introduction of IoT has improved the user convenience. For user ease, the
proposed system reduces the procedure delay time of the existing garbage gathering
systems, which enables users to set free their garbage without a long wait and
timely elimination of filled bins.

The figure below shows an example of an IoT system where we get a basic idea about its
working.

2.2. HARDWARES and SOFTWARES

Several hardware components and software’s have been used to make this project. The
details are discussed briefly in this section.

2.2.1. Hardwares used:

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2.2.1.1. NODEMCU (ESP 8266):

The Expressive Systems ESP8266 is a low-cost Wi-Fi microchip that includes a full
TCP/IP stack as well as microcontroller capability. The NodeMCU is an open-
source software and development kit that can be used to create IoT products with
a few lines of arduino code. It also has Wi-Fi capabilities, allowing us to wirelessly
control it and easily make it work on a remote installation. We can instruct our board
by sending a set of instructions to the microcontroller on the board. We can do this by
using the Arduino software (IDE).

The ESP8266 Wi-Fi Module is a self-contained system on chip (SOC) with in

integrated TCP/IP protocol stack that allows any microcontroller to connect to your
Wi-Fi network. The ESP8266 can run applications or operate to all Wi-Fi
networking functions to another processor. Each ESP8266 module comes pre-
programmed with AT command software, allowing us to connect it to our Arduino
device and get roughly the same Wi-Fi functionality as a Wi-Fi Shield. The
ESP8266 module is a low-cost board with a sizable and rapidly expanding user base.

Figure 2: NodeMCU ESP8266

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2.2.1.2 Construction of NodeMCU:

a) Power Pins: There are four power pins. VIN pin and three 3.3V pins.
b) VIN- It can be used to directly supply the NodeMCU/ESP8266 and its peripherals.
Power delivered on VIN is regulated through the onboard regulator on the
NodeMCU module. We can also supply 5V regulated to the VIN pin.
c) 3.3V-pins are the output of the onboard voltage regulator, and can be used to supply
power to external components.
d) GND-are the ground pins of NodeMCU/ESP8266.
e) I2C Pins are used to connect I2C sensors and peripherals. Both I2C Master and I2C
Slave are supported. I2C interface functionality can be realized programmatically,
and the clock frequency is 100 kHz at a maximum. It should be noted that I2C clock
frequency should be higher than the slowest clock frequency of the slave device.
f) GPIO Pins- NodeMCU/ESP8266 has 17 GPIO pins which can be assigned to
functions, such as I2C, I2S, UART, PWM, IR Remote Control, LED Light and
Button programmatically. Each digital enabled GPIO can be configured to internal
pull-up or pull-down, or set to high impedance. When configured as an input, it can
also be set to edge- trigger or level-trigger to generate CPU interrupts.
g) ADC Channel- the NodeMCU is embedded with a 10-bit precision SAR ADC. The
two functions can be implemented using ADC. Testing power supply voltage of
VDD3P3 pin and testing input voltage of TOUT pin. However, they cannot be
implemented at the same time.
h) UART Pins- NodeMCU/ESP8266 has 2 UART interfaces (UART0 and UART1)
which provide asynchronous communication (RS232 and RS485), and can
communicate at up to 4.5 Mbps.
i) SPI Pins- NodeMCU/ESP8266 features two SPIs (SPI and HSPI) in slave and master
modes.
j) SDIO Pins- NodeMCU/ESP8266 features Secure Digital Input/Output Interface
(SDIO) which is used to directly interface SD cards. 4-bit 25 MHz SDIO v1.1 and 4-
bit 50 MHz SDIO v2.0 are supported.
k) PWM Pins- The board has 4 channels of Pulse Width Modulation (PWM). The PWM
output can be implemented programmatically and used for driving digital motors and
LED

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 l) Control Pins are used to control the NodeMCU/ESP8266. These pins include Chip
Enable pin (EN), Reset pin (RST) and WAKE pin.

i. EN: The ESP8266 chip is enabled when EN pin is pulled HIGH. When
pulled LOW the chip works at minimum power.
ii. RST: RST pin is used to reset the ESP8266 chip.
iii. WAKE: Wake pin is used to wake the chip from deep-sleep.

2.2.1.4 DHT22:

This is a calibrated digital temperature and humidity module with onboard sensor DHT22
(AM2302), which features higher accuracy and a wider measuring range than DHT11. It can
be used for detecting ambient temperature and humidity, through the standard single-wire
interface.

Specification:

 Temperature
 Resolution : 0.1°C
 Accuracy : ±0.5℃
 Measuring range : -40°C ~ 80°
 Humidity
 Resolution : 0.1%RH
 Accuracy : ±2%RH (25°C)
 Measuring range : 0%RH ~ 99.9%RH
 Operating voltage : 3.3V ~ 5.5 V
 Recommended storage condition
 Temperature : 10°C ~40°C
 Humidity: 60%RH or below.

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2.2.1.5 LCD
The display used in this project is 16x2 LCD which means 16 characters per line by
2 lines; each character is displayed in 5x8 pixel matrix.

This LCD has two registers, namely, Command and Data:

The command register stores the command instructions given to the LCD. A command
is an instruction given to LCD to do a predefined task like initializing it, clearing its screen,
setting the cursor position, controlling display etc
The data register stores the data to be displayed on the LCD. The data is the ASCII
value of the character to be displayed on the LCD.

LCD 16x2 pins description

Pin No Name Function
1 Vss Ground (0V)
2 Vcc Supply voltage; 5V (4.7V – 5.3V)
3 VEE Contrast adjustment; through a variable resistor
4 Register 0=Instruction Input
Select 1=Data Input
5 Read/write 0=Write to LCD
1=Read From LCD
6 Enable Sends data to data pins when a high to low pulse is
given
7 DB0
8 DB1
9 DB2

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 10 DB3
11 DB4
12 DB5 8-bit data pins
13 DB6
14 DB7
15 Led+ Backlight VCC (5V)
16 Led- Backlight Ground (0V)
Table 2: LCD 16x2 pins description

There are three control lines in LCD 16x2: EN, RS, and RW.

The EN line is called "Enable" This control line is used for telling the LCD that the
data is b e i n g sent. For sending data to the LCD, the program should make sure
that the line is low (0) and then set the other two control lines or put data on the
data bus. When the other lines are ready completely, bring EN high (1) and should
wait for specific required time, then end by bringing it low (0) again.

The RS line is "Register Select" line. When RS is low (0), the data is treated as a
command or special instruction (such as clear screen, position cursor, etc.). When the
RS is high (1), the data sent is text data which is displayed on the screen. For
example, to display the letter "B" on the screen you would set RS high.

The RW line is "Read/Write" control line. When RW is low (0), the information on the data
bus is written to the LCD. When RW is high (1), the program is effectively
questioning (or reading) the LCD. Only one instruction ("Get LCD status") is read
command. All the others are write commands, so RW will always be low. Table
(2.3) shows pin description of LCD [20].

2.2.1.6 Current Sensor ACS712:

Current transformer of CT ratio 50 A/10mA is used at the secondary of transformer to

measure variation in load current. It is expected that transformer overloads with a load

20
exceeding 90% of its capacity. Secondary current of transformer is needed to calculate
harmonic load current which builds excessive heat as well as winding losses during
overloading. An arduino based current sensor ACS712 produces an analog output voltage
proportional to the current sensed by the terminals. The current sensor can operate from a
voltage of 5 V DC. Even high AC mains current can be measured. The sensors are based on
the Allegro ACS712ELC chip. These sensors are available in full-scale reading of 5 A, 20 A
and 30 A. For a 30 A sensor, the output sensitivity is 66mV/A, and it can measure a current
from 30 A to – 30 A range.

ACS712 consists of a low offset, precise linear Hall Effect sensor circuit having a copper
conduction path around the die surface. The Hall Effect circuit converts the electromagnetic
field produced during current flow through the copper part to output voltage.

Current produced in secondary of CT is converted to voltage with a parallel resistor across its
secondary terminals.

2.2.1.7 Ultrasonic Sensor:

ITEMS COMPONENTS PARAMETERS

1. Power supply ±5 VDC
2. QUIESCENT ≥2mA
3. Working current -15mA
4. Effective angle 15°
5. Ranging distance 2cm-400cm/1-13ft
6. Resolutions 0.3cm
7. Measuring angle 30°

2.2.1.8 Bridge Rectifier:

A bridge rectifier makes use of four diodes in a bridge arrangement to achieve full wave
rectification. This is widely used configuration, both with individual diodes wired as
shown in fig. and with single component bridges where the diode bridge is wired

internally.

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 Fig. Bridge Rectifier
2.2.1.8.1 Operation:
During positive half cycle of secondary, the diodes D2 and D3 are in forward biased while D1
and D4 are in reverse biased as shown in the fig(b). The current flow direction is shown in the
fig (b) with dotted arrows.

During negative half cycle of secondary voltage, the diodes D1 and D4 are in forward biased
while D2 and D3 are in reverse biased as shown in the fig(c). The current flow direction is
shown in the fig (c) with dotted arrows.

2.2.1.9 Optocoupler Relay:

An optocoupler relay, also known as an opto-isolator relay, is a device that combines the
functionality of an optocoupler and a relay into a single integrated package. It is
commonly used in electronic circuits to provide electrical isolation and signal
amplification between different sections of a circuit.

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The optocoupler relay consists of two main components: an optocoupler and a relay. The
optocoupler is composed of an infrared light-emitting diode (LED) and a phototransistor
or a photothyristor. The LED is optically coupled to the phototransistor/photothyristor,
which means that when the LED is activated, it emits light that is detected by the
photosensitive component.

Fig. Optocoupler Relay

2.2.1.9 Voltage Divider:

A voltage divider is a simple electronic circuit that is used to divide a voltage into
smaller values. It consists of two or more resistors connected in series across a voltage
source, and the output voltage is taken from the junction between the resistors. The
purpose of a voltage divider is to obtain a desired voltage level from a higher voltage
source.

The basic principle behind the operation of a voltage divider is the division of voltage
across the resistors in proportion to their resistance values. According to Ohm's law, the
voltage across a resistor is directly proportional to the current flowing through it and
inversely proportional to its resistance.

Fig. Voltage Divider Circuit

2.2.1.10. Bulk Converter:

Buck Converter is a type of chopper circuit that is designed to perform step-down conversion
of the applied dc input signal. In the case of buck converters, the fixed dc input signal is

23
changed into another dc signal at the output which is of lower value. This means it is
designed to produce a dc signal as its output that possesses a lower magnitude than the
applied input.

2.2.1.11. Power supply:

The power supplies are designed to convert high voltage AC mains electricity to a suitable low
voltage supply for electronic circuits and other devices. A power supply can by broken down
into a series of blocks, each of which performs a particular function. A d.c power supply which
maintains the output voltage constant irrespective of a.c mains fluctuations or load variations is
known as “Regulated D.C Power Supply”

For example a 5V regulated power supply system as shown below:

2.2.2 Software’s used

2.2.2.1 Arduino IDE:

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The Arduino integrated development environment (IDE) is a Java-based cross-platform
(Windows, macOS, and Linux) application. It evolved from the IDE for the programming
languages processing and wiring. It comes with a code editor that allows for text cutting and
pasting, text searching and replacing, automatic indenting, brace matching, and syntax
highlighting, as well as simple one-click mechanisms for compiling and uploading programs
to an Arduino board. It also includes a message area, a text console, a tool- bar with buttons
for common functions, and a hierarchy of operation menus. By utilizing special code
structuring rules, the Arduino IDE supports the programming languages C and C++. The
wiring projects software library, which provides many common input and output procedures,
is included with the Arduino IDE. User-written code only requires two basic functions, which
are compiled and linked with a program stub main() into an executable cyclic executive
program with the GNU tool chain, which is also included with the IDE distribution. The
Arduino IDE makes use of the programme to convert executable code into a text in
hexadecimal encoding, which is then loaded into the Arduino board by a loader programme
in the boards firmware.

2.2.2.2 Thingspeak:

ThingSpeak is an IoT analytics platform service that allows you to aggregate, visualize, and
analyze live data streams in the cloud. One can send data to ThingSpeak from your devices,
create instant visualization of live data, and send alerts. ThingSpeak is an open-source
software written in Ruby which allows users to communicate with internet enabled devices. It
facilitates data access, retrieval and logging of data by providing an API to both the devices
and social network websites. ThingSpeak was originally launched by ioBridge in 2010 as a
service in support of IoT applications. It has integrated support from the numerical computing
software MATLAB from MathWorks, allowing ThingSpeak users to analyze and visualize
uploaded data using MATLAB without requiring the purchase of a MATLAB license from
MathWorks.

2.3 Transformers:
A transformer is an electrical device which is used to convert electrical power from one
electrical circuit to another without change in frequency.

25
 Transformers convert AC electricity from one voltage to another with little loss of power.
Transformers work only with AC and this is one of the reasons why mains electricity is AC.
Step-up transformers increase in output voltage, step-down transformers decrease in output
voltage. Most power supplies use a step-down transformer to reduce the dangerously high mains
voltage to a safer low voltage. The input coil is called the primary and the output coil is called
the secondary. There is no electrical connection between the two coils; instead they are linked by
an alternating magnetic field created in the soft-iron core of the transformer. The two lines in the
middle of the circuit symbol represent the core. Transformers waste very little power so the
power out is (almost) equal to the power in. Note that as voltage is stepped down current is
stepped up. The ratio of the number of turns on each coil, called the turn’s ratio, determines the
ratio of the voltages. A step-down transformer has a large number of turns on its primary (input)
coil which is connected to the high voltage mains supply, and a small number of turns on its
secondary (output) coil to give a low output voltage.

Turns ratio = Vp/ VS = Np/NS

Power Out= Power In
VS X IS=VP X IP
Vp = primary (input) voltage
Np = number of turns on primary coil
Ip = primary (input) current

2.3.1 Distribution transformer main parts:

1. Expansion oil tank (Conservator)

Installed above the main oil tank on the outer transformer frame and is connected to the
main tank through a metallic tube. Oil can freely contract and expand during loading
and thus the temperature of the oil increases and decreases. Loading can increase

26
expansion up to 8%. Tank compensates any loss in oil that may occur in the main tank.

2. Radiator

Radiator is added to increase cooling efficiency of the transformer. In this case,

cooling is assumed to be “natural air” as it depends on natural circulation and air
cooling the oil.

3. Temperature detector

This detector is used to monitor oil temperature. Typically, there are mainly two types
of temperature indicators used in transformer. Principally both of the instruments are
the same but, one is used for oil temperature and the other is used for winding
temperature.

4. Buchholz Relay:

It is placed when a conservator tank is used, as it indicates faults and errors, such as oil
loss when oil level goes low, improper oil flow between the oil tank and the
transformer. Moreover, it shows gas emission inside transformer due to any unusual
operation (excessive loading or short circuit), and can issue a control signal which
can be used to disconnect the transformer. It is equipped with a release valve in
case oil exceeded its level.

5. Breather unit:

As mentioned earlier, any decrease in oil is being compensated by the conservator tank
which leads to decrease in oil in the conservator tank itself, and thus the air gap
widens in the tank and air is pulled from outside through what is known as
“dehydrated breathing unit’ which contains “Silica gel” that absorbs any moisture
present in the oil. Silica change its color from blue to pink if it unable to absorb
moisture.
5. Main tank.

Windings are placed and soaked in oil.

1. Pressure relief device.

27
It reduces pressure inside the transformer through external pressure release to avoid
explosion of transformer.

Figure 2.2: Distribution transformer main parts

2. Oil level indicator.

This device is used to indicate the position of transformer oil level in conservator of t h e
transformer, which is a mechanical device. Decrease in oil can cause flash-over if it is
not refilled.

3. HV/LV bushings.

These bushings are responsible for connecting the internal windings of the
transformer with the external electrical network. It isolates the internal windings from
the transformer body. Bushings are fixed using flanges to avoid any humidity, dirt
and dust from reaching the points of contact.
1. Oil level indicator.

This device is used to indicate the position of transformer oil level in conservator of t h e
transformer, which is a mechanical device. Decrease in oil can cause flash-over if it is

28
not refilled.

2. HV/LV bushings.

These bushings are responsible for connecting the internal windings of the
transformer with the external electrical network. It isolates the internal windings from
the transformer body. Bushings are fixed using flanges to avoid any humidity, dirt
and dust from reaching the points of contact.

2.3.2 Transformers Fault Condition

1. Internal faults →
a. Phase faults
b. Ground faults
c. Inter-turn faults.
d. Tap changer failure
e. Leakage of oil from tank

2. External faults →
a. System phase faults.
b. System ground faults.
c. Over loads.
d. Over-fluxing.

Phase faults → Associated between two phases. Two adjacent phases are short circuited.
Chances of occurring this type of fault is very less because different limbs phase windings
placed on of the core.
Ground faults →Any conductor or windings is grounded due to insulation failure.
Generally, core is grounded when insulation fails between conductor and core, leakage
current will leak to the ground. These faults are ground faults
Inter-Turn faults →
Oil in Transformer serves two purposes
I. Cooling
II. Insulation

As time goes, Oil absorbs moisture. As a result, dielectric strength decreases. Thus, the

29
amount of insulation provided decreases. Insulation between two turns decreases because of
moisture. As a consequence, leakage current will start flowing. This is called inter-turn fault.
It cannot be measured from differential protection scheme because current in the external
circuit remains same.
Over heating →Can be due to internal or external faults, overloading, leakage of oil,
increase in iron losses etc.
Open circuit fault →Any one or two phases are open circuited. This creates unbalanced
system. It also leads to overheating.
Over-fluxing →The flux density in the transformer is proportional to the ratio of voltage to
frequency, ie, V/f

 The power transformers are designed to work with a certain value of flux density in
the core.
 In generator-transformer unit, if full excitation is applied before generator reaches its
synchronous speed, then due to high v/f ratio the over flexing at core may result.
 Higher core flux means more core loss and overheating of the core.
 The saturation of magnetic circuit is also the probable cause for the over-fluxing
operation.

Short circuit faults → can be internal or external.

I. Internal → Due to insulation failure, due to temperature rise, deterioration of oil.
II. External faults→ occurs outside the transformer, Such as line phase fault, line to
ground fault etc. Differential protection cannot be employed.

During Switching→ Magnetic Inrush current passes. This is also called charging of the
transformer. At the time of closing of switch of the transformers, even when the transformer
is operating under no load condition, no load current which is equal to 5 to 6 times of the full
load current flows for a few cycles. This current will be unsymmetrical current. It will have
dominating 2nd harmonics.

Chapter 3

Methodology for Designing of a System to sense and display

30
various parameters of a transformer

3.1 Proposed Model

Continuous Monitoring of transformers for parameters, such as oil level, oil temperature and
voltage output is very important to prevent faults that are costly to repair and result in a loss
of service life time.

In this project, a low cost system is proposed for determining the health condition of
transformer by using the parameters of oil level, oil temperature, and output voltage
range and power availability. An SMS alert is sent through GSM modem to the
authorized person whenever these parameters exceed the predefined limits.

Figure 3: Block Diagram of Proposed System

The block diagram shown in Figure (3) is proposed to be implemented in a real

circuit. It consists of Arduino board, Node MCU, Humidity and Temperature sensors. The
sensors sense the parameters and send these to Arduino mega. It processes the data and send
to Wi-Fi module. The sensed signals from and to microcontroller board are represented with
thin arrows, while power for sensors and other devices are represented by thick arrows. To

31
receive stable power of 5 V DC, the AC power should be converted to DC, and regulated.
There is a battery for continuous supply of power in case the transformer trips. All the
sensors need DC power source to give the sensed signals to the microcontroller.

3.1.1 Flow Chart of Transformer Health Monitoring using IoT

32
 Start

Chapter 4

Power Supply
Simulation

Check Humidity, Current, Temperature

4.1 Introduction

4.1.1 Proteus Simulator

Send Signal to microcontroller

The proposed design of a distribution transformer monitoring system consists from a

microcontroller connected to a group of sensors, LCD, Wi-Fi module and a Buzzer. This
circuit can be easily simulated with specialist software called Proteus. Proteus was the
first product toIs bridge
it above reference value??
the gap between schematic and Printed circuit board (PCB) for
embedded design, offering system level simulation of microcontroller based designs inside
the schematic package itself. It is easy to change hardware design by rewiring the
schematic, changing component values for resistors, capacitors etc., and deleting or
Send signal to Wi-Fi module
adding new components to the design. This gives a total freedom to experiment with
different ideas and to find the optimal design solution for a project. The schematic serves as
a virtual prototype forsensed
Display the firmware.
data on server

4.2 Design Procedure

Stop
The design procedures for the proposed monitoring system based on Arduino UNO R3
board and IoT is described as follows:

Fig 3.1. Flow Chart of Transformer Health Monitoring using IoT

1. Initializing input/output ports:

In this system, Arduino UNO R3 is used because of its features. It is low power
high performance device, has RISC architecture. It is faster than 8051 and
PIC. Here Temperature & Humidity sensor (DHT11), LCD, oil level sensors, Wifi
module, and Current sensor (to simulate variation in main transformer current) are
interfaced with this microcontroller unit.

33
 Arduino UNO R3 has 14 digital I/O ports AND 6 analog inputs. These pins are
configured as follows:

 Arduino analog pin A0 is connected with the V OUT pin of current sensor
 Arduino digital pin 2 is connected with the data pin of DHT11 sensor
 Arduino digital pin 8 is connected with the Echo pin of ultrasonic sensor
 Arduino digital pin 9 is connected with the trigger pin of ultrasonic sensor
 Arduino digital pin 7 is connected with the positive of the buzzer

2. LCD Interfacing:

Figure 4: LCD interfacing with Arduino UNO R3

I2C LCD Adapter:

At the heart of the adapter is an 8-bit I/O expander chip – PCF8574. This chip converts the
I2C data from an Arduino into the parallel data required for an LCD display.
An I2C LCD has only 4 pins that connect it to the outside world. The connections are as
follows:
GND is a ground pin. Connect it to the ground of the Arduino.

34
VCC supplies power to the module and LCD. Connect it to the Arduino’s 5V output or an
external 5V power supply.
SDA is the I2C data pin. Connect it to the Arduino’s I2C data pin.
SCL is the I2C clock pin. Connect it to the Arduino’s I2C clock pin

4.3 Circuit parameters:

Here are a summary of sensors’ parameters as discussed in chapter 2:

 Humidity and Temperature (DHT11) sensor:
 45 °C for high temperature alarm.
 76 % RH (Relative Humidity) for high humidity alarm
 Current sensor:

The primary winding full load current Ip is calculated as:

Ip =S/ root3*Vp

Where,

S is the transformer rating.

Vp is the primary winding voltage

The secondary winding full load current Is is calculated as:

Is =S/ root3*Vs

Where,

S is the transformer rating.

Vs is the secondary winding voltage.

 Accordingly a range is calculated for current and a value out of this range will
be treated as alarm.

 Oil level sensors:

35
  A push button with high activated is used to increase the distance of
Ultrasonic sensor from the oil level.
 Similarly, a push button with low activated is used to decrease the oil
level.

 BUZZER:
 Used as output device for local alarm, and it will activate at different cases
of input sensors which will be discussed in details later in circuit
description.

4.4 Circuit Diagram:

Figure 4.1: The proposed transformer monitoring system when

simulated by Proteus software.

From Figure (4.3), the microcontroller reads the transformer oil temperature, current

36
sensor value, and oil level sensor, and then compare them with safe values, and show
these readings on LCD. If these values are within the specified limits, no action will be
taken.

An example of displaying data i.e Temperature and Humidity is shown in Figure (4.2).

Figure 4.2: Transformer monitoring system when Temperature and Humidity are displayed
on LCD

4.5 Program execution and testing:

The system is based on microcontroller programming. The program for Arduino is

written in Arduino IDE. It is written and burned into microcontroller, and then saved
as Hex file. Program hex file is compiled in microcontroller flash compiler. This compiler
converts program into machine language code as well as check program for error; if
any error is found, it notifies and these errors are corrected manually. Then it is successfully
executed in the compiler. After successful program burning, Arduino UNO R3 becomes
ready for use.

37
In testing, after successful program burning, microcontroller (Arduino UNO R3)
should be provided with following four parameter of transformer:
1. Current
2. Temperature
3. Oil level
4. Humidity
Therefore any change occurred in above rating during running of system model will be
shown in LCD, and Buzzer will be activated depending on the rated range of the parameters.

4.6 Analysis and results:

In the circuit diagram, the microcontroller will receive the input analog
signals and will convert into digital signals in the microcontroller, and the result of
transformer condition will be displayed on the LCD display screen.

38
Chapter 5
Results and Photograph:
For our project we got certain results after its completion. Following are the
picture of the results that we got. It consist of PCM implementation along with
complete hardware and website for real time monitoring of the project.
5.1. Complete Hardware(with no power connection)

Fig. PCB hardware

5.2. Transformer with no power load:

39
5.3 Transformer with load:

5.4. Overview of Web Page for real time monitoring:

40
Chapter 6

Conclusion, Limitation and Future Direction

5.1 Conclusion

The IoT based monitoring of distribution transformer is quite useful as compared to

manual monitoring, and also it is reliable as it is not possible to monitor always the oil
level, oil temperature rise, load voltage variation and transformer trip manually. In
the past, maintenance of transformers was done based on a pre-determined schedule.
With the advancement of communication technology, now it is possible to receive
fault information of transformer through IoT technology remotely so one can able to take
possible solution before the fault leads to fatal situation.

5.2 Limitations

1. The range of NodeMCU is limited for transmitting and receiving signal for a local
area network.
2. Connection between Wifi module and thingspeak server is quite difficult because of
proper network connection.
3. Due to unavailability of colour sensor and voltage sensor we were not able to read
the silica gel colour and voltage.

5.3 Future Direction

For further extension to this design, a voltage sensor could be added to measure
transformer’s voltage and monitor its overvoltage value. This design could be improved
by adding control actions in case of any abnormal normal conditions which need
fast response. Linking all the transformers to SCADA system could be a suitable option
to view them in Human Machine Interface (HMI) with their parameters.

41
 Appendix

Program code

#include <Wire.h>
#include <LiquidCrystal_I2C.h>
#include "DHT.h"
#include <SoftwareSerial.h>
#define DHTPIN 2 // Digital pin connected to the DHT sensor
#define DHTTYPE DHT22
DHT dht(DHTPIN, DHTTYPE);
LiquidCrystal_I2C lcd(0x27, 16, 2);
const int trigPin = 9;
const int echoPin = 10;
long duration;
int distance;
SoftwareSerial espSerial(5,6);
String str;

void setup()
{
pinMode(trigPin, OUTPUT); // Sets the trigPin as an Output
pinMode(echoPin, INPUT) ; // Sets the echoPin as an Input
Serial.begin(9600);
espSerial.begin(9600);
dht.begin();
lcd.begin(); // initialize the LCD
// Turn on the blacklight and print a message.
lcd.backlight();
lcd.print("TRANSFORMER HEALTH MONITORING");
delay(1000);
lcd.clear();

42
}
void loop()
{
delay(2000);
// Reading temperature or humidity takes about 250 milliseconds!
// Sensor readings may also be up to 2 seconds 'old' (its a very slow sensor)
float h = dht.readHumidity();
// Read temperature as Celsius (the default)
float t = dht.readTemperature();
// Read temperature as Fahrenheit (isFahrenheit = true)
float f = dht.readTemperature(true);
// Check if any reads failed and exit early (to try again).
if (isnan(h) || isnan(t) || isnan(f)) {
Serial.println(F("Failed to read from DHT sensor!"));
return;
}
// Compute heat index in Fahrenheit (the default)
float hif = dht.computeHeatIndex(f, h);
// Compute heat index in Celsius (isFahreheit = false)
float hic = dht.computeHeatIndex(t, h, false);
Serial.print(F("Humidity: "));
Serial.print(h);
Serial.print(F("% Temperature: "));
Serial.print(t);
Serial.print(F("°C "));
Serial.print(f);
Serial.print(F("°F Heat index: "));
Serial.print(hic);
Serial.print(F("°C "));
Serial.print(hif);
Serial.println(F("°F"));
lcd.setCursor(0,0);
lcd.print("TEMPERATURE= ");
lcd.setCursor(13,0);

43
lcd.print(t);
lcd.setCursor(19,0);
lcd.print("C");
lcd.setCursor(0,1);
lcd.print("HUMIDITY=");
lcd.setCursor(11,1);
lcd.print(h);
lcd.setCursor(17,1);
lcd.print("%");
digitalWrite(trigPin, LOW);
delayMicroseconds(2);
// Sets the trigPin on HIGH state for 10 micro seconds
digitalWrite(trigPin, HIGH);
delayMicroseconds(10);
digitalWrite(trigPin, LOW);
// Reads the echoPin, returns the sound wave travel time in microseconds
duration = pulseIn(echoPin, HIGH);
// Calculating the distance
distance = duration * 0.034 / 2;
// Prints the distance on the Serial Monitor
Serial.print("Distance: ");
Serial.println(distance);
lcd.setCursor(0,2);
lcd.print("OIL LEVEL=");
lcd.setCursor(11,2);
lcd.print(distance);
lcd.setCursor(17,2);
lcd.print("cm");
delay(1000);
str = String("coming from arduino:")+ String("H= ")+String(h)+String("T= ")+String(t)
+String("OilLevel= ")+String(distance);
espSerial.println(str);
delay(1000);
}

44
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