DESIGN AND IMPLEMENTATION OF A LOW COST DISTRIBUTION
TRANSFORMER MONITORING SYSTEM FOR REMOTE ELECTRIC
POWER GRIDS
E Kolyanga, ES Kajuba and R Okou
Makerere University, College of Engineering Design Art and Technology, Kampala, Uganda
ABSTRACT
The main utility company in Uganda owns and operates
over 8,000 Distribution Transformers (DTs) and loses
over 700 DTs annually due to various reasons. At
present, the distribution company uses a peak load
analysis scheme to determine the transformer load
conditions and effect the load growth, which is a tedious
task and doesnt solve the problem of DT failure
resulting from; load unbalance, over load, vandalism
among others. In order to achieve better DT
performance, a low cost monitoring system was sought
as most commercially available systems with SCADA
integration potential are costly.
This paper presents a distribution transformer (DT)
monitoring system designed and implemented with
GSM functionality capable of monitoring load
variations and relaying information concerning
transformer load state. Furthermore, the system was
able to store and analyse information received from the
monitoring device concerning the transformer state.
The system was able to benchmark the DT
measurements to abnormal operation and take action
before failure and was built at less than $200. The cost
can be further lowered with large scale production. The
future system will be integrated with a condition
monitoring plug to ensure loss of life prediction.
1. INTRODUCTION
Distribution Transformers (DTs) are an essential part of the
power network and their operation determines with a great
deal the efficiency of the power system [1].
In Uganda approximately 9% of the general population
has access to electricity [2]. With annual demand growing
at 6%. Electricity access expected to grow as more effort
is put in place to increase the supply to the wider areas. It
is also noted that even the connected consumers
experience loss in supply frequently as a result of the
unreliable power supply. Causes of unreliability in power
supply include; (i) faults in DTs and feeders, (ii)
vandalism of power supply equipment, (iii) failure of
transformers, (iv) limited power available for dispatch.
Recent statistics show that transformer failure due over
load and deviation accounts for a considerable percentage
of the causes of power outage to general consumers [3].
With a SCADA system still being considered an
expensive venture to monitor and control DTs, there has
been a great desire to explore other options such as
designing a small scale system for DT monitoring that
utilizes the available prominent communication
technology; the Global System for Mobile communication
(GSM) that can later be integrated into the current
SCADA system that is used for monitoring power
transformers.
Countries notably Thailand and South Korea have
adopted to the design of customised systems for
monitoring of DTs with the aim to prevent transformer
failure through analysis of loading data obtained on a
daily basis from the transformer. The Thailand project
was created by Metropolitan Electricity Authority (MEA)
Thailand. The purpose was to build a monitoring system
for medium voltage DTs since Transformers' data is
significant to load management and research about
transformers [4]. The South Korean company KEPCO
KDNTM provides a similar solution with much more
advanced features such as over load alerts, vandalism and
out of operation alerts [5]. Other solutions such as the
EDMI Distribution Transformer monitoring solution offer
alert messages via email which could be quite a less
responsive technique with no specific software
application to analyse the information as its received [6].
Smarter systems have been built by companies that is
Siemens; with a product named transformer monitoring
and diagnostics system (TMDSTM) built based on
acceptable IEEE and ANSI standards. TMDS provides
alarming and trending using models that work with rule
based logic, derived from accepted IEEE/ANSI
guidelines, to perform correlations on both measured and
calculated data. Alarm messaging includes
recommendations on maintenance activity as well as
suggested loading should TMDS classify the observed
deviation as severe enough that it may result in the
damage or potential failure of the transformer [7]. A
Notable feature well researched but not widely integrated
in todays systems is to determine the expected
transformer service life based on the present per-unit
loading, oil and winding temperature.
The purpose of this project was to design and implement a
low cost DT monitoring system with a key interest in
monitoring transformer load as it varies over time.
Specific objectives included: (i) Design and prototyping
of a monitoring device with GSM functionality capable of
relaying information concerning transformer load state;
(ii) Design of software application with a database to
record, analyse information received from the monitoring
device concerning the transformer state. With additional
alarming functionality in-case unacceptable loading
conditions are detected.
2. METHODOLOGY
The design and implementation was mainly partitioned into
two core activities that include;
x Hard ware system design and implementation
x Software system design and implementation
2.1 HARDWARE SYSTEM DESIGN AND
IMPLIMENTATION
The hardware system was built based as microcontroller
based system interfaced with current transducers for
measuring current in the Low Voltage (LV) phases of the
transformer, an SD-card for data offline storage, a Liquid
Crystal Display (LCD) for indication of variables during
system configuration and a backup battery to allow for
condition monitoring during blackouts so as to determine
the cause and time of transformer outage.
The figure 1 below shows a system design impression for
the hardware setup.
CTS RTU
Figure 1- Distribution transformer condition monitoring
hardware set up CAD design
The hardware design preceded with a Computer aided
model using sketchupTM 3D modelling software as shown
in the figure 1. The design consists of a Remote Terminal
Unit (RTU) and three Current Transducers (CTs). This was
followed by a system block, schematic design of the system
and then component selection based on the system
requirements, flexibility and ease of use.
2.1.1 System Design
The lay system layout diagram in figure 2 was developed to
depict system functional design. After development of the
system layout, design preceded with a system circuit
design; selecting and interconnecting the various
components based on the system layout. The circuit was
designed using Eagle Schematic layout editor as shown in
figure 3. The circuit consists current transducers (CTs) with
a burden resistor connected across the CT outputs; the
RMS to DC converter converts the AC voltage created
across the burden resistor to its RMS equivalent DC
voltage which is measured by the microcontroller.
Figure 2- System Layout
The microcontroller was to be programmed to process data
measured from the CTs periodically and relay the
information back to the monitoring system via GSM
communication.
Figure 3 - hardware circuit Design
With the circuit designed, component selection was the
next phase.
2.1.2 Component Selection
a) Microcontroller; the ArduinoTM development and
prototyping board was selected as the hardware system
central processing unit. This was to be programmed using
the ArduinoTM Integrated Development Environment (IDE)
[9].
b) Current transducers; these were selected based on the
maximum current requirement of a typical distribution
transformer, ease of use in terms of handling and electronic
interfacing. The current transducer model used is the
MASTECHTM MS3300 current transducer with a dc
voltage output [8].
c) LCD display; the LCD display selected was a 16x2
monochromatic parallel LCD based on the HITACHI
driver for easy interfacing with the microcontroller.
d) GSM module; this was a SIM900 based GSM module.
e) Flash memory; the flash memory card interface was
designed using an SD card slot built using the SPI
communication protocol for direct communication with
microcontroller [9].
f) Battery; a 12V 4Ah sealed lead acid battery was selected
for use with the device after measurement of device power
consumption.
g) Enclosure; a safety enclosure was obtained for safe
storage and protection of the unit components during field
testing.
2.2 SOFTWARE DESIGN
The software was designed using Microsoft Visual studio
and the C# programing language with a MySQL data base.
CT

2.1.3 Component integration

The component were inter-connected with the aid of Antenna

additional material to form the system unit based on the
schematic design after careful analysis. The current
transducers were connected to the analogue inputs of the
Arduino. The GSM module Serial port was connected to
the microcontrollers serial port for communication. The
SD-card socket was interfaced with the microcontroller via
the Serial Peripheral Interface (SPI) for data storage [9]; the
12V battery was connected through a 5V regulator to Figure 5 - Field Testing of the Hardware System Unit
supply the GSM module, 9V regulator to supply the
Current Transducers and the microcontroller.
2.2.1 Database design
2.1.4 Hardware Configuration and testing
The database was developed using the MySQL community
The microcontroller was programmed to process data server and linked to the application. The database structure
readings from the current transducers and transmit them was based on an entity relations model with the different
periodically via GSM. The GSM configuration was set entities linked by relationship. The entities included: (i)
using AT Commands at a baud rate of 9600bits/second. records entity for storing daily records of the transformer;
The fully developed system is shown in the figure 4 with an (ii) transformer entity for storing the transformer general
enclosure to facilitate protection during field testing information, (iii) daily summary entities for recording daily
summary of transformer records. The data base was linked
to the main application using a MySQL connector to allow
GSM for data retrieval and update.
module
MCU
2.2.2 Application development

The application was designed along with the database in

LCD order to allow for easy access of transformer records. The
basic control window was developed to input the
Battery transformer details as shown in the figure 6

Figure 4- Developed System unit

The hardware unit was tested on a 500kVA distribution

transformer to check for proper function current
transducers and phase current values were displayed on the
LCD. Calibration was based on use of the manufacturers
specification on transducer output voltages [8]. With the
transducers safely clamped, the phase currents were
displayed on the LCD which is shown in figure 5. System
battery unit was also checked to ensure the output battery Figure 6 - Transformer Input Dialog
voltage was within limits of operation and fully charged for
initial testing. The SIM900 GSM/GPRS module was
After inputting the transformer data the records are stored
configured allowing it to register to the network before
in the data bases and could be displayed in the main control
leaving the unit to initiate transmissions.
panel area of the application window shown in figure 8.
The records shown in the table include: the transformer
name, the district in which the transformer is located, the
ratings in kVA, the substation name, the name of the feeder
to which the transformer is connected and its GPS co-
ordinates; latitude and longitude. The information was then
loaded into the main database and displayed in the control
panel area of the software application as shown in figure 7.
The interface features included viewing of all transformers
in the database, a dropdown menu for selecting a particular
item and a menu strip with options for editing the
transformer records and viewing the map location for all
the recorded transformers.
from the average current to the average current in the
phases of the transformer. For all imbalance greater than
10% is classified as critical and if it persists then loading on
the phases of the transformer has to be reviewed. Deviation
over time is measured and displayed graphically.
c) Utilities map Application interface for viewing multiple
transformers during the monitoring to allow for easy
identification and access of transformer data during
analysis.
d) SMS based alerting of respective area engineer and the
maintenance field team in-case of abnormal conditions that
could lead to failure such as persistent overload and short
circuit conditions. Information sent includes condition for
alarm and location of transformer which is affected.
e) Monthly data analysis and calculation of load growth on
a weekly basis.

2.4 SYSTEM PROCESS FLOW

This was developed to aid in system programming as

shown in the flow chart in figure 8.

Figure 7- Section of Transformer Details window

Upon selection of a transformer, the application was

designed to display the transformer data with a drop down
menu allowing for selection of a data to view the load
variations. Additionally graphs of deviation and loading
variations were added and a statistical bar graph showing
the relative average of deviation and percentage load on the
transformer. The software application was also embedded
with real time Google maps to view the transformers in the
field as sorted by the district. The transformer status
reported summarised the daily loading on the transformer
indicating the times of peak and base load; the times of
maximum deviation and minimum from which a
conclusion was drawn; weather to make changes to the
load on the transformer phases in case of persistent loading
deviation or to replace the transformer in the case of
persistent overload as the previous method did not provide
clear guidance for carrying out any of these activities and
transformers were persistently failing.

2.3 SYSTEM FEATURES Figure 8-Process flow during start and monitoring

The features of the designed prototype include the
following;
a) Transformer loading measurement; mainly storing
information concerning transformer loading as it varies
over time. The software application classifies transformer
load in terms of days on which the loading was measured
and percentage of load relative to the transformer ratings.
Loading variation also displayed graphically.
b) Transformer deviation/imbalance measurement; the
software application computes the imbalance on the
transformer as a percentage ratio of the maximum deviation
With the hardware initialized fully, the software would be
started up after which transmission of data would be
initialized. Process would then proceed with transmission
and retransmission of data until the end of the monitoring
period where data would be analysed.
2.5 TESTING AND CONDITION MONITORING
The software and the hardware were set based on the
system process flow while carrying out the first system test.
The application was configured through the computer serial
port to receive the loading data from the transformer via a
GSM modem connected to the computer. The data was
displayed in real time as it was received from the hardware
setup. The condition monitoring was carried out for seven
hours with accurate transmissions throughout the testing.
The system approximate peak and time was constantly
computed by the software application through comparing
the stored values with the incoming values.
Display curves included; loading current for each phase as
shown in figure 9, percentage load on the transformer,
percentage deviation on the phases. Tables were added to
show the loading history on the transformer and the
percentage load deviation. The application was embedded
with Google maps to indicate the location of the
transformers as in figure 10.
Figure 9 - real time monitoring interface
Figure 10 - Transformer locations map per district
By selecting a district from the dropdown menu, one is able
to view the transformers with in that location and their
additional tool tip information such as current load state
and operating conditions.
3. RESULTS AND CONLUTIONS
3.1 MONITORING RESULTS
The set up was used to monitor a 500kVA distribution
transformer and on the date of Tuesday, 06 May 2014, the
following results were obtained
3.1.1 Loading and Deviation
Figure 11- loading and deviation curve
a) Deviation Summary
The deviation summary was as follows:
Maximum deviation: 71%
Time of Max deviation: 5:12PM
Minimum deviation: 13%
Time of Min deviation: 4:22PM
b) Loading summary
All expressed as percentage of the transformer rated current
Peak load: 9%
Time of Peak: 4:23PM
Base Load: 3%
Time of base: 6:52PM
The Loading summary was as follows:
3.1.2 Loading Trend
The loading variations in terms of phase currents indicated
that the blue phase was relatively less loaded as compared
to the other phases of the transformer throughout the
condition monitoring, this led to an average deviation of
40% for the time of monitoring.
Figure 12-Loading Trend Curve
With the deviation and loading frequency graph shown in
figure 13. The transformer status report analysis
recommended a solution to redistribute the load on the
phases since the transformer as a whole was relatively
under loaded as indicated in figure 13 with a majority of
the load lying below 10%. The Status report summary was
also delivered to a cell phone depicting the respective are
engineer.
 5.0 REFERENCES

[1] Abdul,R.A., Abdul,K. GSM Based Transformer

Monitoring System IEEE MELCON 2014 ,May
12-15,2004, pp. 1-4
[2] Office of the Auditor General. Value for Money
Audit Report on Implementation of Rural
Electrification Programme by the Rural
Electrification Agency in the Ministry Of Energy
and Mineral Development, Jan 2011, pp. 1

[3] Mr. Asingwire Wilberforce UMEME (U) Ltd,

[4]
[5]
Figure 13- Deviation and Lading Frequency Summary
3.2 CONCLUSION [6]
With continuous analysis over a period of days, with the
help of the daily status reports, the loading condition of the
transformer can be accurately established, and depending [7]
on the results, necessary steps can be taken.
In comparison to the peak load analysis method that is
being used by the distribution company to analyse
transformers, this system offers a much improved solution
as transformer loading is analysed over time before a
solution is reached. In-case of any abnormal conditions or [8]
persistent overload, the authority can put the transformer
out of service before any catastrophic failure happens. [9]
The system also offers potential for further transformer
condition analysis such as loss of life determination
through insulation aging calculations. 6. BIBLIOGRAPHY
1.
4.0 AREAS OF FUTURE RESEARCH
According to the IEEE Loading Guide for oil mineral
immersed transformers, transformer monitoring requires 2.
assessment of the transformer remaining service life. As an
area of further study, analysis of transformer remaining
service life requires probabilistic computations using
present data gathered from the transformer condition
monitor and previous monitoring history. A conclusion can
be drawn with regard to time of transformer failure
estimate. With this kind of information, the distribution
companies can plan to a great level of certainty how long it
will take before their assets in the field need replacement
and would further guide proper planned maintenance.
Planning Department
Wornpuen, A. Advanced distribution Transformer
Load Monitoring ECTI-CON, 2012 9th
International Conference IEEE 16-May-2012, pp.1
KEPCO KDN Power IT Company. n.d. Copyright
policy.
https://www.kdn.com/home3/we/gs/WEGS_0404.js
p
EDMI. Distribution Transformer Monitoring
Solution, n.d. Copyright policy
http://www.edmi-
meters.com/SolProduct.aspx?SC=1&SID=2
Siemens, Transformer Monitoring &Diagnostic
System [Accessed 12 May 2014] Copyright policy.
http://www.energy.siemens.com/us/en/services/pow
er-transmission-distribution/transformer-lifecycle-
management/transformer-monitoring-diagnostic-
system.htm
MASTECH. Digital Clump Transducer
MS3300/MS3302. Digital Clump Meters. pp. 1
Arduino. Arduino Uno Features. n.d
http://arduino.cc/en/Main/arduinoBoardUno
IEEE Guide for Loading Mineral-
Oil-Immersed Transformers and
Step-Voltage Regulators. IEEE Power & Energy
Society. 7 March 2012
SIMComTM SIM900 GSM/GPRS Hardware
reference Design
7. AUTHOR(S)

Principal Author: Emmanuel Kolyanga is a student

pursing a bachelors degree in
Electrical Engineering at Makerere
University.

Principal Author: Eleanor Sanyu Kajuba is a student

pursing a bachelors degree in
Electrical Engineering at Makerere
University.

Co-author: Dr. Richard Okou holds a PhD degree in

Electrical Engineering from the
University of Cape Town. He is
presently an Associate Professor at the
department of electrical and computer
engineering, College of Engineering,
Design, Art and Technology, Makerere
University

Presenter: The paper is presented by Assoc Prof Richard

Okou