Essay: Develop low cost solution for monitoring transformer health condition and controlling its parameter

ABSTRACT
Transformer is an electrical static device which transfers electrical energy from one circuit to another circuit without changing the frequency through electromagnetic induction. It is very important device in transmission and distribution of electricity. It is necessary to monitor it, before occurrence of any problem. There are some critical parameters for e.g. Voltage, current, Temperature which are need to be monitored continuously. If any of them is out of safe limit, it can create big problem & due to this the life of transformer gets reduced. We will design a system which will continuous monitor the critical parameters of transformer & It will control. This system consists voltage sensor, current sensor, temperature sensor, microcontroller, LCD display, control part involves cooling fan, pump for water circulation.
1. INTRODUCTION
1.1 Problem Summary
We will design such a system which will monitor critical parameters continuously and It will display to the operator. As transformer is a combination of many parts, this all parts must be checked regularly to maintain the transformer in perfect operating condition. If the temperature of transformer increases beyond the rating then it will deteriorate the insulation of transformer. There are many reasons for increase in temperature like vibration caused by flux in the core changing direction, Localized heating by eddy currents, Thermal heating caused by overloading, Expansion and contraction caused by thermal cycling. Moreover, it will also decrease the life of transformer and it’s efficiency. So a comprehensive transformer technique has to be used to control the temperature.
1.2 Aim & Objective
The objective of our project is to develop low cost solution for monitoring transformer health condition and controlling its parameter as well. To learn hardware interfacing and controlling. To have basic idea about electrical as well as instrumentation branch.
1.3 Problem Specifications
Overloading, winding temperature, load current and ineffective cooling of transformer are the major causes of failure in distribution transformer. So we have selected three parameters like temperature of winding, secondary and primary voltages, current which are critical parameters to measure and continuous monitor it.
2.Brief literature review and Prior Art Search
Basically, to understand whole project knowledge as well as some technical understanding we refer so many research paper, Practical video, Google search and international journals. We found some methods for sensing the parameters & transmitting data from one point to another for e.g. Optical methods for sensing winding temp, PLC & SCADA, ZigBee protocol, GSM Modem etc. Some industries are using PLC & SCADA system for visualization and control purpose. Prior to this, cables are used for transmitting data to remote. After successfully completion of PSAR in our project we briefly gain knowledge about various patents which are approved by International Journal. Some glace of literature serves that given below:
1) Distribution transformer monitoring using GPRS modem
Used component: CT (Current transformer)
PT (potential transformer)
RTD (Resistance temperature detector)
PIC16F87A (microcontroller)
GPRS modem (wireless technology)
Limitation: Hardware kit is necessary
2) Design and implementation of Real Time Transformer Health Monitoring
Used component: ACS712
LM35
GSM modem
Ultrasonic module
Limitation: GSM module is compulsory.
It is slower.
3) Monitoring of Distribution Transformer Parameters using PLC
Used component: Voltage sensor (PT)
Current sensor (CT)
Temperature sensor (RTD)
Relay
PLC system
Limitation: Fixed circuit operation.
Limited design
High cost
4) Wireless Transformer Parameter Monitoring System Using RF Module
Used component: Temperature sensor (LM35)
Microcontroller (AT89s51/52)
RF transmitter and receiver
Limitation: Complex and bulky circuit
RF module network is compulsory.
5) Zigbee Wireless Transformer Monitoring, Protection and control System
Used components: Level sensor (using op-amp) capacitance type
Microcontroller (ATMEGA 16)
Zigbee module (transmitter and receiver)
Temperature sensor (RTD)
Limitation: USART protocol is compulsory
3.0 Design: Analysis, Design Methodology and Implementation Strategy
3.1 Materials / Tools required
To measure critical parameters which are decided by us to continuous monitor, we have selected some components and/or sensors like
1) current sensor – (ACS 712) hall effect sensor
2) In design of voltage sensor- step down transformer, diodes, filter circuits,
3) Temperature sensor- RTD PT100
4) Microcontroller 8051
5) Relay driver IC uln2003
6) Relay
7) Multisim
8) Keil uvision
9) Flash Magic
10) Proteus8
11) Signal Conditioning Circuit(OP-Amp, Resistors)
12) LCD Display
13) A to D Converter
3.2Description
Our aim is to measure the critical parameter of distribution transformer like winding temperature, oil temperature, current of secondary winding. This system will sense the critical parameter of transformer through sensor, Microcontroller will collect the data from the sensors and it will display the parameter value through LCD display and it will control the temperature of oil when it exceeds above critical value.
3.3 Block Diagram
Fig.1
As shown in block diagram Microcontroller takes input from voltage sensor, current sensor & temperature sensor through adc and signal conditioning circuit. It controls the transformer parameters according to input values from the sensors. Here we are controlling temperature of transformer by measuring oil temperature and controlling fan and pump through relay..
3.4 PCB Layout
Fig.2
This is the PCB layout of 8051 development board. It is built in Proteus8 professional v8.6.
4. Selection of Sensors
4.1 Design of voltage sensor
Voltage sensor are available in market but we have designed our own voltage sensor. This voltage measurement circuit includes
• Step down transformer 230-12
• Rectifier circuit
• Capacitor for filtering
• Zener diode
• Resistors for voltage divider circuit
4.1.1 Simulation circuit
Fig.3
4.1.2 Simulation results
Primary Voltage Secondary Voltage Output voltage
87 5.07 1.585
108 5.637 2.056
175 9.136 3.564
199 10.38 4.106
211 11.015 4.377
230 12.008 4.807
4.1.3Hardware Results
Primary Voltage Secondary Voltage Output Voltage
87 4.7 1.70
108 6.0 2.22
175 9.9 3.86
199 11.2 4.43
211 11.9 4.72
230 12.9 5.7
4.2 Current sensor
ACS 712 sensor is based on hall effect principle and it is non-contact type instead of current transformer.
Supply voltage:5v
Input current :5A
Non-linearity:1.5%
Sensitivity: 180 mv/A
Fig.4
4.2.1Simulation circuit of ACS712-05B
Fig.5
This is the signal conditioning circuit for ACS712 current sensor.
Since output of acs sensor includes offset and sinusoidal waveform, to get output in the range of 0-5v to interface with microcontroller. We designed circuit which includes
• Opamp as differential amplifier
• Diode for rectification
• Capacitor for filtering
• ACS712 hall effect current sensor
4.2.2 Simulation Result
IRMS Output Voltage
0.50 1.08
1.0 1.98
1.5 2.83
2.0 3.62
2.5 4.36
2.99 4.94
4.3 Temperature sensor
PT100 RTD are an excellent choice for temperature sensing and control element Which is highly accurate and reliable sensor. It is used to measure temperature winding. Range of measurement: 00C to 1650C
Below Fig.6 consists of Wheatstone bridge for converting resistance to voltage and instrumentation amplifier for amplification purpose.
From Wheatstone bridge(Fig.6)
RT= Resistance of RTD(PT-100)
Temp. coefficient of Resistance for platinum α = 0.0039 0C-1
Rt= R0(1+ α(T2-T1))
For temp. range 0 to 1700C RT varies from 100 to 165Ω
Output of Wheatstone bridge = 5*((RT/(RT+100))-0.5) volt
= from 0 to 0.61 volt
From instrumentation amplifier
Output voltage= (R2/R1) *(output voltage of Wheatstone bridge)
Gain= Output voltage/ output voltage of Wheatstone bridge =5/0.61 =8.2
4.3.1 Simulation circuit for instrumentation Amplifier
Fig.6
This is the signal condition circuit which conditions output of RTD PT100 temperature sensor. This circuit includes
• Wheatstone bridge for converting resistance to voltage
• Instrumentation amplifier
4.3.2 Simulation result
Resistance
Wheatstone bridge output Output voltage
110 0.12 0.99
120 0.23 1.87
130 0.32 2.67
140 0.41 3.40
150 0.50 4.09
160 0.57 4.70
170 0.64 5.28
4.3.3 Hardware result
Resistance Wheatstone bridge output Output voltage
110 0.1 0.8
120 0.21 1.71
130 0.30 2.52
140 0.40 3.30
150 0.48 3.99
160 0.56 4.63
170 0.63 5.25
5.Cooling Control System
If temperature exceeds its rated rating then it has to be controlled. If temperature exceeds 700c then we are starting fan through 5V DC relay to keep the temperature at nominal value. Nevertheless if still it exceeds 900c the we are starting submersible pump(165-250V,9W,Max.Height= 0.75M) again through 5V DC relay
6. Hardware of Monitoring Circuit
Fig.7
This is the hardware set up of transformer monitoring circuit. In which we have used POT as input to microcontroller through ADC0808 and output is displayed on LCD.
By varying the POT value, we are getting variation in parameters like voltage, Current & Temperature.
If temperature goes above certain limit then the microcontroller gives signal to relay through uln2003 relay driver ic to operate cooling fan and pump.
Pump will circulate Oil through the transformer to maintain the temperature in safe limit
7. The Business Model Canvas
Fig.8
KEY PARTNERS
•Torrent Power
•Adani Power
•GNFC
•Essar Power
•Reliance Power
•NPCIL
KEY ACTIVITIES
•Monitoring
•Controlling
•Maintenance
•Distribution
KEY RESOURCES
•Technician
•Engineers
•IC
•Sensor
VALUE PROPOSITION
•Low Cost
•Higher Quality
•Safety
•Small Size
•Industrilisable
CUSTOMER RELATIONSHIP
•Service
•Maintenance
•Low Cost
CHANNELS
•License
•Contract
•Direct Sales
CUSTOMER SEGMENTS
•Technical Management
•Solution
•Torrent Power
•Adani Power
•GNFC
•Reliance Power
•Essar Power
•NPCIL
COST STRUCTURE
•Sensor
•IC
•PCB
•Components
REVENUE STREAM
•Portable
•Model Installation
•Low Size
•Services
8.CONCLUSION
We are measuring critical parameters which requires continuous monitoring and controlling same if it exceeds its limits. To achieve above motto, we select some sensors which are highly accurate, low cost and optimal. Hence, We have made project which will monitor the critical parameters of transformer and when it reaches to unsafe limit then control action is taken place through cooling system.
ACKNOWLEDGEMENT
It would be Impossible to name each and Every Individual who had offered the Support Encouragement and Ideas Which Made This Project a Possible Thing. We Are Greatly Thankful to Our Internal Guide Prof. KAMAKSHI KAUL of VISWAKARMA GOVERNMENT ENGINEERING COLLEGE for Shaping Our Ideas and Knowledge According to the Industrial Requirements. They have helped us On Reaching Each and Every Milestone of the Project, they have Encouraged us in Every Failure during the Project, and They Has Increased Our Confidence with Every Success in the Project. On The Other Hand, We Are Greatly Thankful to our Head of Department Dr. Manish Thakker sir Who Made Us Aware with the Requirement of this Project What We should try to Learn That Ideas Was Planted by him and We Had Grown It up during This Period with his Helps We are Deeply Grateful to our Parents for Their Support and Encouragement to Attain Our Destination without Any Trouble.
ABSTRACT
Transformer is an electrical static device which transfers electrical energy from one circuit to another circuit without changing the frequency through electromagnetic induction. It is very important device in transmission and distribution of electricity. It is necessary to monitor it, before occurrence of any problem. There are some critical parameters for e.g. Voltage, current, Temperature which are need to be monitored continuously. If any of them is out of safe limit, it can create big problem & due to this the life of transformer gets reduced. We will design a system which will continuous monitor the critical parameters of transformer & It will control. This system consists voltage sensor, current sensor, temperature sensor, microcontroller, LCD display, control part involves cooling fan, pump for water circulation.
Table of Contents
1. INTRODUCTION 5
1.1Problem Summary 5
1.2 Aim & Objective 5
1.3 Problem Specifications 5
2.Brief literature review and Prior Art Search 6
3.0 Design: Analysis, Design Methodology and Implementation Strategy 8
3.1 Materials / Tools required 8
3.2Description 8
3.3 Block Diagram 9
3.4 PCB Layout 10
4. Selection of Sensors 11
4.1 Design of voltage sensor 11
4.1.1 Simulation circuit 11
4.1.2 Simulation results 11
4.1.3Hardware Results 12
4.2 Current sensor 13
4.2.1Simulation circuit of ACS712-05B 14
4.2.2 Simulation Result 14
4.3 Temperature sensor 15
4.3.1 Simulation circuit for instrumentation Amplifier 16
4.3.2 Simulation result 17
4.3.3 Hardware result 17
5.Cooling Control System 18
6. Hardware of Monitoring Circuit 19
7. The Business Model Canvas 20
8.CONCLUSION 22
9.REFERENCES 23
1. INTRODUCTION
1.1Problem Summary
We will design such a system which will monitor critical parameters continuously and It will display to the operator. As transformer is a combination of many parts, this all parts must be checked regularly to maintain the transformer in perfect operating condition. If the temperature of transformer increases beyond the rating then it will deteriorate the insulation of transformer. There are many reasons for increase in temperature like vibration caused by flux in the core changing direction, Localized heating by eddy currents, Thermal heating caused by overloading, Expansion and contraction caused by thermal cycling. Moreover, it will also decrease the life of transformer and it’s efficiency. So a comprehensive transformer technique has to be used to control the temperature.
1.2 Aim & Objective
The objective of our project is to develop low cost solution for monitoring transformer health condition and controlling its parameter as well. To learn hardware interfacing and controlling. To have basic idea about electrical as well as instrumentation branch.
1.3 Problem Specifications
Overloading, winding temperature, load current and ineffective cooling of transformer are the major causes of failure in distribution transformer. So we have selected three parameters like temperature of winding, secondary and primary voltages, current which are critical parameters to measure and continuous monitor it.
2.Brief literature review and Prior Art Search
Basically, to understand whole project knowledge as well as some technical understanding we refer so many research paper, Practical video, Google search and international journals. We found some methods for sensing the parameters & transmitting data from one point to another for e.g. Optical methods for sensing winding temp, PLC & SCADA, ZigBee protocol, GSM Modem etc. Some industries are using PLC & SCADA system for visualization and control purpose. Prior to this, cables are used for transmitting data to remote. After successfully completion of PSAR in our project we briefly gain knowledge about various patents which are approved by International Journal. Some glace of literature serves that given below:
1) Distribution transformer monitoring using GPRS modem
Used component: CT (Current transformer)
PT (potential transformer)
RTD (Resistance temperature detector)
PIC16F87A (microcontroller)
GPRS modem (wireless technology)
Limitation: Hardware kit is necessary
2) Design and implementation of Real Time Transformer Health Monitoring
Used component: ACS712
LM35
GSM modem
Ultrasonic module
Limitation: GSM module is compulsory.
It is slower.
3) Monitoring of Distribution Transformer Parameters using PLC
Used component: Voltage sensor (PT)
Current sensor (CT)
Temperature sensor (RTD)
Relay
PLC system
Limitation: Fixed circuit operation.
Limited design
High cost
4) Wireless Transformer Parameter Monitoring System Using RF Module
Used component: Temperature sensor (LM35)
Microcontroller (AT89s51/52)
RF transmitter and receiver
Limitation: Complex and bulky circuit
RF module network is compulsory.
5) Zigbee Wireless Transformer Monitoring, Protection and control System
Used components: Level sensor (using op-amp) capacitance type
Microcontroller (ATMEGA 16)
Zigbee module (transmitter and receiver)
Temperature sensor (RTD)
Limitation: USART protocol is compulsory
3.0 Design: Analysis, Design Methodology and Implementation Strategy
3.1 Materials / Tools required
To measure critical parameters which are decided by us to continuous monitor, we have selected some components and/or sensors like
1) current sensor – (ACS 712) hall effect sensor
2) In design of voltage sensor- step down transformer, diodes, filter circuits,
3) Temperature sensor- RTD PT100
4) Microcontroller 8051
5) Relay driver IC uln2003
6) Relay
7) Multisim
8) Keil uvision
9) Flash Magic
10) Proteus8
11) Signal Conditioning Circuit(OP-Amp, Resistors)
12) LCD Display
13) A to D Converter
3.2Description
Our aim is to measure the critical parameter of distribution transformer like winding temperature, oil temperature, current of secondary winding. This system will sense the critical parameter of transformer through sensor, Microcontroller will collect the data from the sensors and it will display the parameter value through LCD display and it will control the temperature of oil when it exceeds above critical value.
3.3 Block Diagram
Fig.1
As shown in block diagram Microcontroller takes input from voltage sensor, current sensor & temperature sensor through adc and signal conditioning circuit. It controls the transformer parameters according to input values from the sensors. Here we are controlling temperature of transformer by measuring oil temperature and controlling fan and pump through relay..
3.4 PCB Layout
Fig.2
This is the PCB layout of 8051 development board. It is built in Proteus8 professional v8.6.
4. Selection of Sensors
4.1 Design of voltage sensor
Voltage sensor are available in market but we have designed our own voltage sensor. This voltage measurement circuit includes
• Step down transformer 230-12
• Rectifier circuit
• Capacitor for filtering
• Zener diode
• Resistors for voltage divider circuit
4.1.1 Simulation circuit
Fig.3
4.1.2 Simulation results
Primary Voltage Secondary Voltage Output voltage
87 5.07 1.585
108 5.637 2.056
175 9.136 3.564
199 10.38 4.106
211 11.015 4.377
230 12.008 4.807
4.1.3Hardware Results
Primary Voltage Secondary Voltage Output Voltage
87 4.7 1.70
108 6.0 2.22
175 9.9 3.86
199 11.2 4.43
211 11.9 4.72
230 12.9 5.7
4.2 Current sensor
ACS 712 sensor is based on hall effect principle and it is non-contact type instead of current transformer.
Supply voltage:5v
Input current :5A
Non-linearity:1.5%
Sensitivity: 180 mv/A
Fig.4
4.2.1Simulation circuit of ACS712-05B
Fig.5
This is the signal conditioning circuit for ACS712 current sensor.
Since output of acs sensor includes offset and sinusoidal waveform, to get output in the range of 0-5v to interface with microcontroller. We designed circuit which includes
• Opamp as differential amplifier
• Diode for rectification
• Capacitor for filtering
• ACS712 hall effect current sensor
4.2.2 Simulation Result
IRMS Output Voltage
0.50 1.08
1.0 1.98
1.5 2.83
2.0 3.62
2.5 4.36
2.99 4.94
4.3 Temperature sensor
PT100 RTD are an excellent choice for temperature sensing and control element Which is highly accurate and reliable sensor. It is used to measure temperature winding. Range of measurement: 00C to 1650C
Below Fig.6 consists of Wheatstone bridge for converting resistance to voltage and instrumentation amplifier for amplification purpose.
From Wheatstone bridge(Fig.6)
RT= Resistance of RTD(PT-100)
Temp. coefficient of Resistance for platinum α = 0.0039 0C-1
Rt= R0(1+ α(T2-T1))
For temp. range 0 to 1700C RT varies from 100 to 165Ω
Output of Wheatstone bridge = 5*((RT/(RT+100))-0.5) volt
= from 0 to 0.61 volt
From instrumentation amplifier
Output voltage= (R2/R1) *(output voltage of Wheatstone bridge)
Gain= Output voltage/ output voltage of Wheatstone bridge =5/0.61 =8.2
4.3.1 Simulation circuit for instrumentation Amplifier
Fig.6
This is the signal condition circuit which conditions output of RTD PT100 temperature sensor. This circuit includes
• Wheatstone bridge for converting resistance to voltage
• Instrumentation amplifier
4.3.2 Simulation result
Resistance
Wheatstone bridge output Output voltage
110 0.12 0.99
120 0.23 1.87
130 0.32 2.67
140 0.41 3.40
150 0.50 4.09
160 0.57 4.70
170 0.64 5.28
4.3.3 Hardware result
Resistance Wheatstone bridge output Output voltage
110 0.1 0.8
120 0.21 1.71
130 0.30 2.52
140 0.40 3.30
150 0.48 3.99
160 0.56 4.63
170 0.63 5.25
5.Cooling Control System
If temperature exceeds its rated rating then it has to be controlled. If temperature exceeds 700c then we are starting fan through 5V DC relay to keep the temperature at nominal value. Nevertheless if still it exceeds 900c the we are starting submersible pump(165-250V,9W,Max.Height= 0.75M) again through 5V DC relay
6. Hardware of Monitoring Circuit
Fig.7
This is the hardware set up of transformer monitoring circuit. In which we have used POT as input to microcontroller through ADC0808 and output is displayed on LCD.
By varying the POT value, we are getting variation in parameters like voltage, Current & Temperature.
If temperature goes above certain limit then the microcontroller gives signal to relay through uln2003 relay driver ic to operate cooling fan and pump.
Pump will circulate Oil through the transformer to maintain the temperature in safe limit
7. The Business Model Canvas
Fig.8
KEY PARTNERS
•Torrent Power
•Adani Power
•GNFC
•Essar Power
•Reliance Power
•NPCIL
KEY ACTIVITIES
•Monitoring
•Controlling
•Maintenance
•Distribution
KEY RESOURCES
•Technician
•Engineers
•IC
•Sensor
VALUE PROPOSITION
•Low Cost
•Higher Quality
•Safety
•Small Size
•Industrilisable
CUSTOMER RELATIONSHIP
•Service
•Maintenance
•Low Cost
CHANNELS
•License
•Contract
•Direct Sales
CUSTOMER SEGMENTS
•Technical Management
•Solution
•Torrent Power
•Adani Power
•GNFC
•Reliance Power
•Essar Power
•NPCIL
COST STRUCTURE
•Sensor
•IC
•PCB
•Components
REVENUE STREAM
•Portable
•Model Installation
•Low Size
•Services
8.CONCLUSION
We are measuring critical parameters which requires continuous monitoring and controlling same if it exceeds its limits. To achieve above motto, we select some sensors which are highly accurate, low cost and optimal. Hence, We have made project which will monitor the critical parameters of transformer and when it reaches to unsafe limit then control action is taken place through cooling system.
ACKNOWLEDGEMENT
It would be Impossible to name each and Every Individual who had offered the Support Encouragement and Ideas Which Made This Project a Possible Thing. We Are Greatly Thankful to Our Internal Guide Prof. KAMAKSHI KAUL of VISWAKARMA GOVERNMENT ENGINEERING COLLEGE for Shaping Our Ideas and Knowledge According to the Industrial Requirements. They have helped us On Reaching Each and Every Milestone of the Project, they have Encouraged us in Every Failure during the Project, and They Has Increased Our Confidence with Every Success in the Project. On The Other Hand, We Are Greatly Thankful to our Head of Department Dr. Manish Thakker sir Who Made Us Aware with the Requirement of this Project What We should try to Learn That Ideas Was Planted by him and We Had Grown It up during This Period with his Helps We are Deeply Grateful to our Parents for Their Support and Encouragement to Attain Our Destination without Any Trouble.
ABSTRACT
Transformer is an electrical static device which transfers electrical energy from one circuit to another circuit without changing the frequency through electromagnetic induction. It is very important device in transmission and distribution of electricity. It is necessary to monitor it, before occurrence of any problem. There are some critical parameters for e.g. Voltage, current, Temperature which are need to be monitored continuously. If any of them is out of safe limit, it can create big problem & due to this the life of transformer gets reduced. We will design a system which will continuous monitor the critical parameters of transformer & It will control. This system consists voltage sensor, current sensor, temperature sensor, microcontroller, LCD display, control part involves cooling fan, pump for water circulation.
Table of Contents
1. INTRODUCTION 5
1.1Problem Summary 5
1.2 Aim & Objective 5
1.3 Problem Specifications 5
2.Brief literature review and Prior Art Search 6
3.0 Design: Analysis, Design Methodology and Implementation Strategy 8
3.1 Materials / Tools required 8
3.2Description 8
3.3 Block Diagram 9
3.4 PCB Layout 10
4. Selection of Sensors 11
4.1 Design of voltage sensor 11
4.1.1 Simulation circuit 11
4.1.2 Simulation results 11
4.1.3Hardware Results 12
4.2 Current sensor 13
4.2.1Simulation circuit of ACS712-05B 14
4.2.2 Simulation Result 14
4.3 Temperature sensor 15
4.3.1 Simulation circuit for instrumentation Amplifier 16
4.3.2 Simulation result 17
4.3.3 Hardware result 17
5.Cooling Control System 18
6. Hardware of Monitoring Circuit 19
7. The Business Model Canvas 20
8.CONCLUSION 22
9.REFERENCES 23
1. INTRODUCTION
1.1Problem Summary
We will design such a system which will monitor critical parameters continuously and It will display to the operator. As transformer is a combination of many parts, this all parts must be checked regularly to maintain the transformer in perfect operating condition. If the temperature of transformer increases beyond the rating then it will deteriorate the insulation of transformer. There are many reasons for increase in temperature like vibration caused by flux in the core changing direction, Localized heating by eddy currents, Thermal heating caused by overloading, Expansion and contraction caused by thermal cycling. Moreover, it will also decrease the life of transformer and it’s efficiency. So a comprehensive transformer technique has to be used to control the temperature.
1.2 Aim & Objective
The objective of our project is to develop low cost solution for monitoring transformer health condition and controlling its parameter as well. To learn hardware interfacing and controlling. To have basic idea about electrical as well as instrumentation branch.
1.3 Problem Specifications
Overloading, winding temperature, load current and ineffective cooling of transformer are the major causes of failure in distribution transformer. So we have selected three parameters like temperature of winding, secondary and primary voltages, current which are critical parameters to measure and continuous monitor it.
2.Brief literature review and Prior Art Search
Basically, to understand whole project knowledge as well as some technical understanding we refer so many research paper, Practical video, Google search and international journals. We found some methods for sensing the parameters & transmitting data from one point to another for e.g. Optical methods for sensing winding temp, PLC & SCADA, ZigBee protocol, GSM Modem etc. Some industries are using PLC & SCADA system for visualization and control purpose. Prior to this, cables are used for transmitting data to remote. After successfully completion of PSAR in our project we briefly gain knowledge about various patents which are approved by International Journal. Some glace of literature serves that given below:
1) Distribution transformer monitoring using GPRS modem
Used component: CT (Current transformer)
PT (potential transformer)
RTD (Resistance temperature detector)
PIC16F87A (microcontroller)
GPRS modem (wireless technology)
Limitation: Hardware kit is necessary
2) Design and implementation of Real Time Transformer Health Monitoring
Used component: ACS712
LM35
GSM modem
Ultrasonic module
Limitation: GSM module is compulsory.
It is slower.
3) Monitoring of Distribution Transformer Parameters using PLC
Used component: Voltage sensor (PT)
Current sensor (CT)
Temperature sensor (RTD)
Relay
PLC system
Limitation: Fixed circuit operation.
Limited design
High cost
4) Wireless Transformer Parameter Monitoring System Using RF Module
Used component: Temperature sensor (LM35)
Microcontroller (AT89s51/52)
RF transmitter and receiver
Limitation: Complex and bulky circuit
RF module network is compulsory.
5) Zigbee Wireless Transformer Monitoring, Protection and control System
Used components: Level sensor (using op-amp) capacitance type
Microcontroller (ATMEGA 16)
Zigbee module (transmitter and receiver)
Temperature sensor (RTD)
Limitation: USART protocol is compulsory
3.0 Design: Analysis, Design Methodology and Implementation Strategy
3.1 Materials / Tools required
To measure critical parameters which are decided by us to continuous monitor, we have selected some components and/or sensors like
1) current sensor – (ACS 712) hall effect sensor
2) In design of voltage sensor- step down transformer, diodes, filter circuits,
3) Temperature sensor- RTD PT100
4) Microcontroller 8051
5) Relay driver IC uln2003
6) Relay
7) Multisim
8) Keil uvision
9) Flash Magic
10) Proteus8
11) Signal Conditioning Circuit(OP-Amp, Resistors)
12) LCD Display
13) A to D Converter
3.2Description
Our aim is to measure the critical parameter of distribution transformer like winding temperature, oil temperature, current of secondary winding. This system will sense the critical parameter of transformer through sensor, Microcontroller will collect the data from the sensors and it will display the parameter value through LCD display and it will control the temperature of oil when it exceeds above critical value.
3.3 Block Diagram
Fig.1
As shown in block diagram Microcontroller takes input from voltage sensor, current sensor & temperature sensor through adc and signal conditioning circuit. It controls the transformer parameters according to input values from the sensors. Here we are controlling temperature of transformer by measuring oil temperature and controlling fan and pump through relay..
3.4 PCB Layout
Fig.2
This is the PCB layout of 8051 development board. It is built in Proteus8 professional v8.6.
4. Selection of Sensors
4.1 Design of voltage sensor
Voltage sensor are available in market but we have designed our own voltage sensor. This voltage measurement circuit includes
• Step down transformer 230-12
• Rectifier circuit
• Capacitor for filtering
• Zener diode
• Resistors for voltage divider circuit
4.1.1 Simulation circuit
Fig.3
4.1.2 Simulation results
Primary Voltage Secondary Voltage Output voltage
87 5.07 1.585
108 5.637 2.056
175 9.136 3.564
199 10.38 4.106
211 11.015 4.377
230 12.008 4.807
4.1.3Hardware Results
Primary Voltage Secondary Voltage Output Voltage
87 4.7 1.70
108 6.0 2.22
175 9.9 3.86
199 11.2 4.43
211 11.9 4.72
230 12.9 5.7
4.2 Current sensor
ACS 712 sensor is based on hall effect principle and it is non-contact type instead of current transformer.
Supply voltage:5v
Input current :5A
Non-linearity:1.5%
Sensitivity: 180 mv/A
Fig.4
4.2.1Simulation circuit of ACS712-05B
Fig.5
This is the signal conditioning circuit for ACS712 current sensor.
Since output of acs sensor includes offset and sinusoidal waveform, to get output in the range of 0-5v to interface with microcontroller. We designed circuit which includes
• Opamp as differential amplifier
• Diode for rectification
• Capacitor for filtering
• ACS712 hall effect current sensor
4.2.2 Simulation Result
IRMS Output Voltage
0.50 1.08
1.0 1.98
1.5 2.83
2.0 3.62
2.5 4.36
2.99 4.94
4.3 Temperature sensor
PT100 RTD are an excellent choice for temperature sensing and control element Which is highly accurate and reliable sensor. It is used to measure temperature winding. Range of measurement: 00C to 1650C
Below Fig.6 consists of Wheatstone bridge for converting resistance to voltage and instrumentation amplifier for amplification purpose.
From Wheatstone bridge(Fig.6)
RT= Resistance of RTD(PT-100)
Temp. coefficient of Resistance for platinum α = 0.0039 0C-1
Rt= R0(1+ α(T2-T1))
For temp. range 0 to 1700C RT varies from 100 to 165Ω
Output of Wheatstone bridge = 5*((RT/(RT+100))-0.5) volt
= from 0 to 0.61 volt
From instrumentation amplifier
Output voltage= (R2/R1) *(output voltage of Wheatstone bridge)
Gain= Output voltage/ output voltage of Wheatstone bridge =5/0.61 =8.2
4.3.1 Simulation circuit for instrumentation Amplifier
Fig.6
This is the signal condition circuit which conditions output of RTD PT100 temperature sensor. This circuit includes
• Wheatstone bridge for converting resistance to voltage
• Instrumentation amplifier
4.3.2 Simulation result
Resistance
Wheatstone bridge output Output voltage
110 0.12 0.99
120 0.23 1.87
130 0.32 2.67
140 0.41 3.40
150 0.50 4.09
160 0.57 4.70
170 0.64 5.28
4.3.3 Hardware result
Resistance Wheatstone bridge output Output voltage
110 0.1 0.8
120 0.21 1.71
130 0.30 2.52
140 0.40 3.30
150 0.48 3.99
160 0.56 4.63
170 0.63 5.25
5.Cooling Control System
If temperature exceeds its rated rating then it has to be controlled. If temperature exceeds 700c then we are starting fan through 5V DC relay to keep the temperature at nominal value. Nevertheless if still it exceeds 900c the we are starting submersible pump(165-250V,9W,Max.Height= 0.75M) again through 5V DC relay
6. Hardware of Monitoring Circuit
Fig.7
This is the hardware set up of transformer monitoring circuit. In which we have used POT as input to microcontroller through ADC0808 and output is displayed on LCD.
By varying the POT value, we are getting variation in parameters like voltage, Current & Temperature.
If temperature goes above certain limit then the microcontroller gives signal to relay through uln2003 relay driver ic to operate cooling fan and pump.
Pump will circulate Oil through the transformer to maintain the temperature in safe limit
7. The Business Model Canvas
Fig.8
KEY PARTNERS
•Torrent Power
•Adani Power
•GNFC
•Essar Power
•Reliance Power
•NPCIL
KEY ACTIVITIES
•Monitoring
•Controlling
•Maintenance
•Distribution
KEY RESOURCES
•Technician
•Engineers
•IC
•Sensor
VALUE PROPOSITION
•Low Cost
•Higher Quality
•Safety
•Small Size
•Industrilisable
CUSTOMER RELATIONSHIP
•Service
•Maintenance
•Low Cost
CHANNELS
•License
•Contract
•Direct Sales
CUSTOMER SEGMENTS
•Technical Management
•Solution
•Torrent Power
•Adani Power
•GNFC
•Reliance Power
•Essar Power
•NPCIL
COST STRUCTURE
•Sensor
•IC
•PCB
•Components
REVENUE STREAM
•Portable
•Model Installation
•Low Size
•Services
8.CONCLUSION
We are measuring critical parameters which requires continuous monitoring and controlling same if it exceeds its limits. To achieve above motto, we select some sensors which are highly accurate, low cost and optimal. Hence, We have made project which will monitor the critical parameters of transformer and when it reaches to unsafe limit then control action is taken place through cooling system.
9.REFERENCES
[1]Vishakha Shinge1, Omika Shukla2, Prateek Panday3, Prof. Megha chaple4 “Wireless Transformer Parameter Monitoring System Using RF Module” IJIREEICE,Vol.4,Issued:4,April2016 Available: https://www.ijireeice.com/upload/2016/april-16/IJIREEICE%2086.pdf [Accessed: Aug,2017]
[2] D S Suresh1 , Prathibha T2 , Kouser ,Taj3 “ Oil Based Transformer Monitoring System” International Journal of Science and Research (IJSR) [Accessed: Oct,2017].
[3] Rahul, “Internet of Things Based Real Time Transformer Health Monitoring System” IJARIIT, vol.3,issue 4, 2017 Available: https://www.ijariit.com/manuscripts/v3i4/V3I4-1167.pdf
[4]Ismail Sarwar,”AC Voltage Measurement using ATMega8,” Available:http://engineerexperiences.com/ac-voltage-measurement.html.[Accessed: sep,2017]
[5]Shubhangi Landge , Snehal Waydane ,Sanjay Sangale,Somesh Gaikwad, “Monitoring of Distribution transformer using PLC,”. International Journal of Emerging Research in Management &Technology, vol. 5, issue. 5, May,2016.
Available: https://www.irjet.net/archives/V4/i3/IRJET-V4I3314.pdf
[6] Dr.J. Jaykumar, J.Hephzibah Jose Queen ,Thanu James ,G. Hemalatha,
Neethu Lonappan , “ Distribution Transformer Monitoring using GPRS,”. International Journal of Scientific & Engineering Research, Vol. 4, Issue6,June-2013 Avilable: https://www.ijser.org/researchpaper/distribution-transformer-monitoring-using-gprs.pdf
[7]Arijit benrjee , sunil shri nivas murthy , shrinivas satya sai mallampalli,ravindra shyam bhide ,”Method and system for monitoring transformer health”,Available: https://patents.google.com/patent/US8635034