Chapter 1: Introduction

1.1 Overview of Transformer

Transformers are one of the foundational components of electrical engineering and are
ubiquitous in both industrial and residential power systems. A transformer is an electrical device
used to transfer electrical energy between two or more circuits through electromagnetic
induction. By using varying numbers of windings (coils), transformers step up or step down the
voltage, making them essential for long-distance power transmission and for providing the
appropriate voltage levels to end users.

In power systems, electrical energy is typically generated at a certain voltage level and needs to
be transported over long distances. High-voltage transmission reduces energy loss during
transmission, as power loss is inversely proportional to the square of the current. However, high

voltages are unsuitable for use in homes, factories, or commercial establishments. Transformers
are used to step down this voltage to a more manageable level.

The basic structure of a transformer include: -

A. Primary Coil: The coil that receives the alternating current (AC) from the power source.
B. Secondary Coil: The coil that delivers the transformed voltage to the load (such as homes
or industrial equipment).
C. Core: A magnetic material around which both coils are wound, facilitating electromagnetic
induction.

While transformers are designed to withstand regular operational conditions, various electrical
faults such as overvoltage’s and overheating can put them at risk. Protecting transformers from
these faults is essential to their proper functioning, as well as the safety of the power grid and the
users of electricity.

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 Figure 1.1 Transformer

1.2 Problem Statement

While transformers are robust and designed to handle fluctuating voltage levels within
certain limits, they are still susceptible to conditions outside of their rated specifications.
Overvoltage and overtemperature are two of the most damaging faults that can occur and often go
undetected until they cause irreversible damage. These faults can result from several factors, Such
as:

Figure 1.2 Burning of Transformer

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A. Overvoltage: This condition occurs when the voltage exceeds the transformer’s design
capacity, typically due to external events like lightning strikes, power surges, or faults in the
power grid. When transformers are exposed to excessive voltages, their insulation systems can
break down, leading to electrical breakdowns, arcing, and potential short circuits.

B. Insulation Breakdown: When insulation materials inside the transformer windings fail due to
overvoltage conditions, the short circuit that follows can cause severe damage to the transformer.
C. Arcing: Arcing within the transformer can cause long-term damage to the windings and the
core material, which reduces the operational life of the transformer.
D. Fire Hazards: Overvoltage-induced breakdown of insulation materials can also lead to fires
in severe cases.
E. Overtemperature: Transformers are designed to operate within a specific temperature range.
Prolonged exposure to high temperatures or rapid increases in temperature can cause the internal
insulation to deteriorate, reduce the transformer’s efficiency and even lead to catastrophic failures
F. Thermal Degradation: Transformers often rely on oil or air-cooling mechanisms. When the
transformer is overloaded or experiences inadequate cooling, the temperature rises, causing the
insulation to break down. Over time, this reduces the transformer’s overall lifespan

G. Overload: Overcurrent conditions, usually linked to an overloaded transformer, can generate

excessive heat, which accelerates the aging process of the insulation materials.

H. Fire Risk: Extreme temperature conditions can lead to a transformer fire,especially if there is
a sudden breakdown in insulation. Together, overvoltage and overtemperature pose a serious risk
to the reliability, safety, and lifespan of transformers. Without timely detection and mitigation,
these conditions can result in complete failure of the transformer, leading to substantial financial
losses, disruption of power supply, and, in extreme cases, safety hazards.

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1.3 Importance of Transformer Protection

Transformer protection plays a crucial role in ensuring the long-term reliability of electrical
distribution networks. When transformers are unprotected or inadequately protected, they are at
risk of significant damage, which can lead to several adverse outcomes:

A. Economic Impacts: A transformer failure can result in expensive repair or replacement

costs, especially in large power transformers used in critical infrastructure. The downtime
associated with transformer failure can affect the productivity of entire industries, resulting
in direct financial losses.
B. Power System Stability: Transformers are critical to maintaining the stability of the power
grid. A failure in a transformer can lead to cascading outages, impacting entire regions and
affecting millions of users. Protection mechanisms ensure that, in the event of faults, only
the affected transformer is disconnected, preventing broader grid instability.
C. Safety Hazards: Damaged transformers, particularly those suffering from insulation
failure due to overvoltage or overtemperature, can pose serious fire risks. Electrical fires
can spread to surrounding areas, putting human life and property at significant risk.
D. Operational Continuity: Transformers are central to the distribution of electrical power
to industrial, commercial, and residential sectors. A malfunction in a transformer can result
in widespread power outages, disrupting services and potentially causing long-term
damage to sensitive electronic equipment.

Given these risks, it is critical to design effective safety devices that can automatically detect
overvoltage and overtemperature conditions and promptly disconnect the transformer to prevent
further damage.

1.4 Objective of the Project

The primary objective of this project is to design and develop a Transformer Safety Device
that provides reliable protection against both overvoltage and overtemperature conditions. The key
design goal is to create a device that does not rely on complex electronics like microcontrollers or

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Arduino-based systems. Instead, the device will utilize analog components, ensuring simplicity,
cost-effectiveness, and ease of implementation.

Specific objectives of this project include:

C. Designing Overvoltage Protection: The device will be capable of detecting overvoltage

conditions in the transformer and disconnecting it from the power supply
D. Designing Overtemperature Protection: The device will also monitor the transformer’s
temperature using components like thermistors or bimetallic strips. Once the temperature
exceeds the safe operational limit, the device will activate a relay to disconnect the transformer,
thus preventing overheating damage.
E. Relay-Based Protection Mechanism: To disconnect the transformer in the event of
overvoltage or overtemperature conditions, the device will employ a relay or contact that can
automatically isolate the transformer from the electrical supply.
F. Simplicity and Cost-Effectiveness: The protection device will be designed using analog
components, ensuring that the system is simple, cost-effective, and easily maintainable. This
approach eliminates the need for complex control systems, making the device accessible for
widespread use in residential, industrial, and commercial settings.
G. Enhanced Transformer Longevity: By preventing overvoltage and overtemperature
conditions, the device will help extend the operational life of transformers, ensuring that they
continue to operate efficiently and safely for longer periods.

1.5 Scope of the Project

The scope of this project is to design and implement a safety device that offers protection to
transformers from overvoltage and overtemperature faults. The device will be designed with the
following parameters:

A. Voltage Range: The device will be capable of detecting overvoltage conditions in

transformers operating at standard voltage levels, typically in the range of 11 kV to 33 kV
for medium voltage transformers, and 110 kV to 400 kV for high-voltage transformers.

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 B. Temperature Range: The overtemperature protection mechanism will be designed to
work within the typical operational temperature ranges of transformers (approximately
70°C to 100°C).
C. Component Selection: The focus will be on using components that are widely available
and easy to integrate into an industrial transformer setup.
D. System Integration: The project will not only focus on individual protection circuits but
also on integrating them into a coherent system. This includes wiring the protection
components to ensure that overvoltage and overtemperature events are detected
simultaneously.
E. Installation: The safety device will be designed to be easily integrated into existing
transformer protection panels, ensuring that it can be quickly deployed in real-world
applications.

1.6 Need for the Safety Device

The need for a reliable transformer safety device has never been greater. Power grids are
becoming increasingly complex, and transformer failures due to overvoltage and overtemperature
continue to pose significant risks to the stability and safety of electrical systems. With the rising
demand for electricity in both developing and developed countries, ensuring transformer
protection has become critical in maintaining grid reliability.

The growing frequency of natural events like lightning storms and heatwaves also
exacerbates the problem, making it more important than ever to have a cost-effective, reliable, and
easily deployable protection system.

Moreover, as electrical grids modernize and become more distributed (e.g., with renewable
energy sources like solar and wind), transformers face new challenges related to voltage
fluctuations and temperature control. A safety device that can respond to these dynamic conditions
provides the necessary robustness to safeguard transformers against unpredictable grid behaviors
and environmental changes.

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1.7 Summary of the Chapter

In this chapter, we have introduced the key concepts behind transformers and highlighted
the risks associated with overvoltage

and overtemperature conditions. We have emphasized the importance of transformer protection,

detailing how faults can lead to significant economic, safety, and reliability issues. The chapter
further outlines the objectives and scope of this project, aiming to develop a cost-effective
Transformer Safety Device that automatically detects overvoltage and overtemperature conditions,
disconnecting the transformer to prevent damage.

The next chapter will provide a literature review, examining existing technologies and
solutions for transformer protection.

This expanded Introduction now thoroughly covers the context, problem, and objectives of the
project, laying a solid foundation for the rest of the report. With detailed content and clear
explanation, this section should be substantial enough to form the first part of your report.

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CHAPTER 2 LITERATURE REVIEW

2.1 Introduction

The importance of transformer protection systems cannot be overstated, as transformers are

critical components They are highly susceptible to faults such as overvoltage and overtemperature
conditions, which, if unaddressed, can lead to significant damage, prolonged downtime, and safety
hazards. in power distribution and transmission systems. They are highly susceptible to faults such
as overvoltage and overtemperature conditions, which, if unaddressed, can lead to significant
damage, prolonged downtime, and safety hazards. Consequently, a range of protection methods
has been developed to safeguard transformers from these fault conditions.

This chapter reviews existing literature on transformer protection systems, particularly

focusing on protection mechanisms for overvoltage and overtemperature. Various methods and
technologies employed in the industry for detecting and mitigating these faults will be explored.
Additionally, this chapter discusses the key challenges and limitations of current transformer
protection techniques, which highlight the need for an efficient, cost-effective protection device.

2.2 Transformer Protection Methods

Transformer protection encompasses several methods that aim to detect abnormal conditions
in transformers and prevent damage. These protection methods typically involve monitoring
electrical parameters such as voltage, temperature, and current. The most common protection
techniques for transformers include overcurrent protection, overvoltage protection,
overtemperature protection, differential protection, and Buchholz protection.

2.2.1 Overvoltage Protection

Overvoltage conditions are one of the most dangerous situations for transformers.
Overvoltage can occur due to several factors, such as lightning strikes, switching surges, or faults

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in the electrical grid. When the voltage exceeds the rated value for an extended period, it can cause
breakdown of the transformer’s insulation, leading to transformer failure.

Overvoltage protection is crucial to prevent such failures. The most common components used
in overvoltage protection include:

A. Transformer: A transformer is an electrical device that transfers electrical energy between

two or more circuits through electromagnetic induction. Electromagnetic induction produces
an electromotive force within a conductor which is exposed to time varying magnetic fields.
Transformers are used to increase or decrease the alternating voltages in electric power
applications
B. Rectifier: A rectifier is an electrical device that converts alternating current, which
periodically reverses direction, to direct current, which flows in only one direction.
C. Sensor Circuit: Sensor Circuit sense the over load current and load exceeds the reference
value, and automatically cut off the extra load. Therefore, transformer safety device work
efficiently under overload condition and the damage can be prevented.
D. Load Circuit: An electrical load is simply any component of a circuit that consumes power
or energy. Its include light bulbs and appliances all load current sense through sensor circuit.

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 Figure 2.1 component of overvoltage system

2.2.2 Overtemperature Protection

Overtemperature is another significant risk for transformers. Prolonged exposure to high

temperatures can degrade the insulation and copper windings inside transformers, leading to
reduced efficiency, premature aging, and failure. Overtemperature conditions can arise from
overloading, poor cooling (inadequate oil circulation or ventilation), or fault conditions.

The most common methods for overtemperature protection in transformers include:

A. Thermal Relays: A thermal relay detects the temperature rise inside the transformer. These
relays use a temperature-sensitive element (such as a bimetallic strip or thermistor) to sense
excessive heat. When the temperature exceeds a safe threshold, the thermal relay activates
a protective action, such as disconnecting the transformer or shutting down the cooling
system. Thermal relays are widely used in medium- and low-voltage transformers.
B. Bimetallic Strips: Bimetallic strips bend in response to temperature changes. This bending
action can trigger a switch to disconnect the transformer when the temperature exceeds a

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 certain limit. These strips are often used in conjunction with thermal relays for overload
protection.
C. Thermistors: Thermistors are resistors whose resistance varies significantly with
temperature. NTC thermistors (Negative Temperature Coefficient) have resistance that
decreases as the temperature rises. These components can be integrated into the transformer
to monitor temperature changes, providing early detection of overheating conditions.
D. Oil Temperature Sensors: Transformers often use oil for cooling. The temperature of the
oil is a good indicator of the transformer's overall operating temperature. Oil temperature
sensors are commonly used in large transformers to monitor the internal temperature and
prevent overheating. When the oil temperature exceeds safe levels, the protection system
can trigger a shutdown or cooling system activation.
E. Temperature-Activated Switches: These switches are used to disconnect the transformer
when it reaches a predetermined temperature. The most common temperature-activated
switch used in transformers is the thermostat switch, which opens when the temperature
exceeds the set limit, preventing overheating.

2.2.3 Combined Overvoltage and Overtemperature Protection

While individual overvoltage and overtemperature protection systems are useful, combined
protection that addresses both conditions simultaneously offers enhanced reliability. Systems that
integrate both overvoltage and overtemperature protection can ensure that the transformer is
safeguarded from multiple fault conditions. Some modern protection relays combine both these
functions, offering:

A. Integrated Protection Relays: Protection relays that combine both overvoltage and
overtemperature detection are used in large industrial transformers. These relays monitor
both electrical and thermal parameters and can trip the transformer if either condition
exceeds its safe limit.
B. Automatic Disconnection Systems: These systems use a combination of relays, thermal
sensors, and voltage sensors to disconnect the transformer if either overvoltage or
overtemperature conditions are detected. These systems are designed for industrial

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 transformers and are often employed in critical infrastructure, where uninterrupted service
is essential.

2.3 Existing Transformer Protection Devices

Several commercial transformer protection devices and systems are currently available,
including both standalone overvoltage and overtemperature protection systems as well as
integrated solutions. These protection devices are widely used in both medium- and high-voltage
systems.

2.3.1 Buchholz Relay

The Buchholz relay is an important protection device used in oil-immersed transformers. It is

designed to detect faults within the transformer tank, such as internal arcing or gassing caused by
overheating or overvoltage. The Buchholz relay operates on the principle that when faults occur
inside the transformer, gases are generated, which are detected by the relay. This relay can activate
an alarm or trip the transformer’s circuit to prevent further damage.

2.3.2 Differential Protection Relays

Differential protection relays are designed to detect internal faults within a transformer, such
as short circuits or winding faults. These relays monitor the current entering and exiting the
transformer. If the current on one side of the transformer does not match the current on the other
side (due to a fault), the relay will trigger the disconnection of the transformer. While primarily
used for fault detection, differential protection often works in tandem with overvoltage and
overtemperature protection to provide comprehensive transformer safety.

2.3.3 Electronic Protection Systems

Many modern protection systems rely on microprocessor-based electronic relays to monitor

transformer health. These systems continuously monitor voltage, current, and temperature,

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offering real-time fault detection. While these systems are more advanced and precise, they tend
to be more expensive and require more maintenance compared to simpler, analog-based solutions.

2.4 Challenges in Transformer Protection

Despite the advancements in transformer protection technologies, several challenges persist in

ensuring reliable and cost-effective protection:

A. Complexity of Protection Devices: Many transformer protection systems are designed

with microcontrollers or programmable logic controllers (PLCs), which, while highly
effective, are often expensive and complex to implement in smaller or lower-budget
projects.
B. Cost Considerations: High-quality protection devices such as differential relays,
Buchholz relays, and integrated protection relays can be costly, particularly for smaller
transformer applications or regions with limited budgets. Simple protection systems that
are cost-effective yet reliable are still needed.
C. False Tripping: Protection devices may sometimes trigger false alarms, disconnecting the
transformer unnecessarily, which can lead to unnecessary downtime and operational
disruptions. Fine-tuning the thresholds for overvoltage and overtemperature protection is a
continuous challenge.
D. Maintenance and Reliability: Maintenance of sophisticated protection systems that rely
on advanced electronics can be challenging, especially in remote or inaccessible locations.
Reliable, low-maintenance systems using basic electronic components are often preferred
in such scenarios.

2.5 Conclusion

This literature review has explored the various methods and technologies used for
transformer protection, particularly focusing on overvoltage and overtemperature conditions. The
review discussed several protection devices, relays, and integrated protection systems. It also

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highlighted the need for reliable, cost-effective protection solutions for transformers, particularly
in smaller installations or regions with budget constraints.

The challenges outlined in existing transformer protection technologies, such as

complexity, cost, and maintenance, indicate the need for simpler, more affordable protection
solutions. This reinforces the motivation for the development of the Transformer Safety Device
described in this project, which aims to offer efficient and cost-effective protection against
overvoltage and overtemperature conditions using basic analog components without relying on
complex electronics.

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 Chapter 3: Objective of the Project

3.1 Introduction

The design and implementation of a transformer safety device are pivotal to ensuring the
longevity and safe operation of transformers in electrical power systems. As outlined in the
previous chapters, transformers are vulnerable to overvoltage and conditions, both of which can
cause severe damage to their internal components, leading to operational failures, expensive
repairs, and even safety hazards. The overarching objective of this project is to develop a
transformer safety device that can automatically detect and mitigate these risks without relying on
advanced microcontroller-based systems like Arduino or PLC controllers.

In this chapter, we will articulate the specific objectives that this project aims to achieve,
the requirements for the transformer safety device, and the principles behind its design. This will
include a detailed discussion of the methods to be employed for detecting overvoltage and
overtemperature conditions and how these two protection systems will be integrated into a unified
device. Furthermore, we will explore the goals for simplicity, reliability, cost-effectiveness, and
ease of implementation, ensuring the device is suitable for a wide range of industrial, commercial,
and residential applications.

3.2 Key Objectives of the Project

The project’s main objectives are designed to address two critical failure modes of
transformers: overvoltage and overtemperature. The safety device is intended to detect these fault
conditions and disconnect the transformer from the power supply to prevent damage.

3.2.1 Overvoltage Protection

Overvoltage is one of the most destructive faults that can affect transformers, potentially
leading to insulation breakdown, overheating, arcing, and even fires. To mitigate this risk, one of

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the primary objectives of this project is to design an effective overvoltage protection system for
transformers.

Objective 1.1: If the voltage exceeds the rated value by selecting appropriate components,
the system will be capable of distinguishing between normal voltage fluctuations and actual
overvoltage events, triggering the protective action when necessary.

Objective 1.2: Design a Protection Mechanism to Disconnect the Transformer Once

overvoltage is detected, the protection system must be able to disconnect the transformer from the
electrical grid. A relay mechanism will be incorporated to open the transformer circuit when an
overvoltage condition occurs. The relay will be selected based on its voltage and current ratings to
ensure reliable operation under fault conditions.

Relay Selection: The relay chosen for the protection system will be designed to handle the
electrical load and withstand any transient surges that may occur when disconnecting the
transformer from the grid.
A. Response Time: The relay must have a fast response time to ensure that the transformer is
disconnected from the grid before any significant damage occurs due to overvoltage.
3.2.2 Overtemperature Protection

Overtemperature is another common cause of transformer failures, often resulting from

excessive load, poor cooling, or environmental conditions. Overheating can degrade the
transformer’s internal components, such as the windings and insulation, which leads to reduced
efficiency and premature failure.

Objective 2.1: Design an Accurate Overtemperature Detection System: The second major
objective of the project is to design an overtemperature protection system that can monitor the
transformer’s operating temperature and prevent it from exceeding safe limits. This system will
use thermistors, bimetallic strips, and oil temperature sensors to monitor the temperature inside
the transformer.

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A. Thermistors: Negative Temperature Coefficient (NTC) thermistors will be employed, which
change their resistance as the temperature increases. The thermistor's resistance change can be
monitored to determine the temperature of the transformer.
B. Bimetallic Strips: These strips will bend when exposed to high temperatures, activating a
switch that triggers the protection system.
C. Oil Temperature Sensors: In large transformers that use oil for cooling, oil temperature
sensors will be used to measure the oil’s temperature. This information can be used to assess
the overall condition of the transformer and trigger the protection mechanism when necessary.

Objective 2.2: Implement a Protective Action for Overtemperature: Similar to overvoltage

protection, overtemperature protection will require a relay-based disconnection mechanism to
prevent the transformer from operating at unsafe temperatures. When the temperature exceeds the
safe operating limit, the protection system will trigger the relay to disconnect the transformer from
the grid.

Relay Mechanism: The relay will be designed to respond to the signals from the temperature
sensors, cutting off the transformer from the power supply to prevent overheating and subsequent
damage.
3.2.3 Combined Overvoltage and Overtemperature Protection System

While overvoltage and overtemperature are separate fault conditions, the ability to detect
both and integrate them into a unified protection system is a major goal of this project. Having a
single device that addresses both of these fault conditions improves efficiency, reduces system
complexity, and enhances overall protection reliability.

Objective 3.1: Design a Single Protection Unit for Both Faults: The device will be designed to
integrate both overvoltage and overtemperature detection systems into one unit. This approach
eliminates the need for separate devices for each type of fault, reducing installation complexity
and cost.

A. Design Integration: Both overvoltage and overtemperature protection will be connected to the
same relay system, ensuring that the transformer is disconnected whenever either fault

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 condition occurs. The relay system will have two separate inputs: one for overvoltage detection
and another for overtemperature detection.
B. Multi-Condition Protection: In cases where both faults occur simultaneously, the device will
prioritize disconnection to avoid damage due to either overvoltage or overheating.

3.2.4 Simplicity, Cost-Effectiveness, and Reliability

One of the key goals of this project is to ensure that the protection system is simple, cost-
effective, and reliable, without relying on complex microcontroller-based systems like Arduino or
PLCs. This ensures that the system is accessible to a wide range of users, from industrial and
commercial establishments to residential installations.

Objective 4.1: Use Basic Analog Components for Design: The system will be designed using
simple, analog electronic components, such as diodes, relays, thermistors, and resistors. This
choice of components ensures that the system is affordable and easy to maintain.

A. Objective 4.2: Minimize System Complexity: The device will have minimal moving parts
and simple circuitry, which ensures that the system can be easily installed, operated, and
maintained. The simplicity of the system also reduces the risk of failure due to complex
electronics.
B. Objective 4.3: Ensure Durability and Reliability: The protection device will be engineered
to withstand environmental factors such as temperature fluctuations, moisture, and dust. It will
be built with robust components capable of enduring harsh conditions over extended periods,
providing long-term protection for transformers.

3.2.5 Flexibility and Ease of Installation

A. The safety device must be adaptable and easy to install in a wide range of transformer
installations, from residential setups to large industrial transformers. Ensuring that the device
can be universally applied is critical to its success.
B. Objective 5.1: Design for Versatile Use: The transformer safety device will be designed for
use with transformers operating at various voltages and power levels. It will feature adjustable

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 settings for voltage and temperature thresholds, making it suitable for both medium-voltage
and high-voltage transformers.
C. Objective 5.2: Provide Clear Indicators and User Interface: The device will be equipped
with clear visual and audible indicators to signal when a fault condition has been detected, and
protection has been activated. This will help operators quickly identify issues and take the
necessary steps to remedy them.

3.3 Project Deliverables

By the end of the project, the following deliverables are expected:

A. Overvoltage and Overtemperature Protection Circuit Designs: Detailed designs and circuit
diagrams showing how overvoltage and overtemperature conditions are detected and acted
upon.
B. Relay-based Disconnection Mechanism: A functioning relay system that disconnects the
transformer from the power supply when either fault condition is detected.
C. Prototype of the Safety Device: A working prototype of the transformer safety device capable
of detecting overvoltage and overtemperature conditions, with integrated protection circuits
and a relay mechanism.
D. Testing and Validation: Results from the testing phase, showing that the device reliably
detects and mitigates overvoltage and overtemperature conditions in real-world scenarios.
E. User Manual and Installation Guide: Comprehensive documentation for the installation,
operation, and maintenance of the device, ensuring ease of use for engineers and operators.

3.4 Conclusion

The objectives of this project aim to provide a comprehensive and practical solution to the
challenges posed by overvoltage and overtemperature conditions in transformers

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 By designing a simple, reliable, and cost-effective safety device, this project addresses the
critical need for affordable transformer protection solutions. The development of a combined
overvoltage and overtemperature protection system using basic analog components ensures that
this solution is both versatile and widely applicable in various transformer settings.

As we proceed with the design and implementation of the safety device, achieving these
objectives will be the cornerstone of ensuring a durable and effective transformer protection
solution for a wide range of users.

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Chapter 4: System Design and Methodology

4.1 Introduction

The successful design and implementation of a transformer safety device require a structured
methodology that integrates both overvoltage and overtemperature protection mechanisms. In this
chapter, we will outline the system design, the components used, and the methodology followed
to create a reliable and cost-effective transformer protection system. The aim is to develop a device
that not only protects transformers from damage due to these fault conditions but also ensures ease
of installation, maintenance, and operation. This chapter will also detail the system’s architecture,
the working principles of each protection mechanism, and the steps involved in the design process.

4.2 System Design Overview

The primary goal of this transformer safety device is to provide protection against
overvoltage and overtemperature conditions, which can result in significant damage to transformer
components. The system consists of two main protection subsystems—overvoltage protection and
overtemperature protection—that will work together to monitor the health of the transformer and
disconnect it from the grid when either condition exceeds safe limits.

The system will be implemented using analog components such as voltage sensors,
thermistors, relays, and surge arresters. These components are cost-effective, durable, and easy to
maintain, making the system suitable for a wide range of industrial, commercial, and residential
transformer installations.

The design is based on two primary functional modules:

A. Overvoltage Protection Module

B. Overtemperature Protection Module

Both modules will interface with a control unit, which will use relays to disconnect the transformer
from the electrical supply if either of the fault conditions is detected.

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 4.3 System Architecture

Figure 4.1 system designing

The system architecture of the transformer safety device consists of the following major
components:

A. Voltage Sensing Circuit: Monitors the transformer’s input voltage to detect overvoltage
conditions.
B. Temperature Sensing Circuit: Monitors the transformer’s temperature to detect
overtemperature conditions.
C. Relay and Disconnect Mechanism: A relay system that disconnects the transformer from the
electrical grid when a fault condition (overvoltage or overtemperature) is detected.

22
D. Control Unit: A central unit responsible for receiving input from the voltage and temperature
sensors and triggering the relay to disconnect the transformer when necessary.
E. Indication and Warning System: Provides visual (LEDs) or audible (buzzer) alerts when an
overvoltage or overtemperature condition is detected.

4.4 Detailed Design of Overvoltage Protection System

The overvoltage protection system is designed to detect excessive voltage levels that exceed
the rated value for the transformer. It will use a of voltage sensors, to detect overvoltage conditions
and activate the protective relay.

4.4.1 Voltage Sensing Circuit

The voltage sensing circuit is responsible for continuously monitoring the input voltage to the
transformer. The voltage sensor will measure the voltage across the transformer and compare it
with a preset threshold.

4.4.2 Overvoltage Detection Mechanism

The overvoltage detection mechanism will consist of:

A. Voltage Divider Circuit: A voltage divider circuit is used to scale down the transformer’s
voltage to a lower, measurable level. This scaled-down voltage is then fed to a comparative
circuit for comparison against a reference voltage.
B. Relay Triggering Mechanism: If the sensed voltage exceeds the reference voltage, the
system will trigger the relay to disconnect the transformer from the grid.

4.4.3 Overvoltage Protection Action

Once overvoltage is detected, the relay will be activated to disconnect the transformer. The
relay will be chosen based on its voltage and current handling capabilities to ensure

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Chapter 5: Components and Materials Used

5.1 Introduction
The design and development of a transformer safety device require the careful selection of a
variety of components and materials to ensure that the system performs its intended functions—
detecting overvoltage and overtemperature conditions, and disconnecting the transformer from
the electrical supply when necessary. In this chapter, we will discuss the various components
used in the construction of the transformer safety device. These components are categorized into
sensing components, protection components, control components, and supporting materials.
Additionally, the rationale behind the selection of these components and materials, based on cost,
availability, reliability, and performance, will be explained.

5.2.1 Voltage Sensing Components

1. Voltage Divider Circuit

A. Resistors: Resistors are used in a voltage divider circuit to scale down the high transformer
voltage to a level suitable for measurement and comparison. The resistors need to have
high voltage and power ratings to ensure reliability under fault conditions.
B. Material: Carbon film or metal oxide resistors are typically used due to their stable
resistance over a wide range of temperatures and their cost-effectiveness

Figure 5.1 Comparing of two voltages circuit for fault detection

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 5.2.2 Temperature Sensing Components

2. Thermistor (NTC Thermistor)

A. Purpose: Negative Temperature Coefficient (NTC) thermistors will be used to monitor the
temperature of the transformer. As the temperature increases, the resistance of the
thermistor decreases, which is monitored by the control unit to detect overtemperature
conditions.
B. Material: Thermistors are made from materials like manganese -cobalt or nickel-iron oxide
that exhibit a significant change in resistance with temperature changes.
C. Specifications: The thermistor is selected based on its temperature range, resistance at a
reference temperature, and response time to ensure quick and accurate temperature
monitoring.

5.3 Protection Components

The protection components are responsible for disconnecting the transformer from the grid
when either an overvoltage or overtemperature condition is detected. These components are
designed to safely isolate the transformer and prevent further damage.

5.3.1 Relay Mechanism

1. Electromechanical Relays

A. Purpose: The electromechanical relay will be used to disconnect the transformer when an
overvoltage or overtemperature condition is detected.
B. Material: Relays are typically made from copper (for the contacts) and steel or plastic for
the casing.
C. Specifications: The relay should have high current and voltage ratings to handle the
transformer’s operating parameters

25
 5.4 Control Components

The control components manage the logic of the system, ensuring that the protection actions
are taken when required. These include the circuitry for signal processing, fault detection, and
triggering the protection mechanism.

5.4.1 RECTIFIRE CIRCUIT

A rectifier is an electrical device that converts alternating current, which periodically reverses
direction, to direct current, which flows in only one direction.

Figure 5.2 rectifire circuit

5.4.2 Logic Circuits

1. Transistors (BJT or MOSFET)

A. Purpose: Transistors are used for switching applications in the logic circuits, where they
will interface between the sensors, comparator, and relay.

26
 B. Material: Typically, silicon or germanium is used for the transistor construction.
C. Specifications: The transistors should have high switching speed and a low saturation
voltage to minimize energy loss during operation.

5.4.3 Power Supply

2. DC Power Supply

A. Purpose: A stable DC power supply is required to power the relay circuits, sensors, and
logic components.
B. Material: The power supply uses a combination of transformers, rectifiers, and capacitors
to convert AC to DC.
C. Specifications: The power supply should be rated for the required voltage (e.g., 5V or 12V)
and current to ensure stable operation of the components.

5.5 Supporting Materials

5.5.1 PCB and Enclosure
A. PCB (Printed Circuit Board): The PCB is the physical platform that supports and
interconnects all the electronic components. It is typically made from fiberglass (FR4) with
copper traces for electrical conductivity.
B. Enclosure: The enclosure houses all the electronic components and protects them from
environmental factors such as dust, moisture, and temperature extremes. The material is
usually ABS plastic or metal, depending on the requirements for thermal management and
durability.
5.5.2 Wiring and Connectors
A. Wires: Copper wires are used for interconnecting various components in the system. Wires
must be selected based on their current rating and insulation properties.
B. Connectors: Screw terminals or plug-and-play connectors are used for ease of assembly
and maintenance. These connectors are made of copper with nickel plating for corrosion
resistance.

27
 5.6 Conclusion

In this chapter, we discussed the essential components and materials used in the design and
construction of the transformer safety device. The key components, including voltage and
temperature sensors, relays, surge protectors, and control circuits, are chosen based on their
reliability, performance, and suitability for the specific needs of the transformer protection system.
By selecting high-quality materials such as silicon, copper, **

28
Chapter 6: Protection Mechanisms

6.1 Introduction

The protection mechanisms for a transformer are vital in preventing damage from faults
such as overvoltage and overtemperature, which can degrade the performance and longevity of the
transformer. In this chapter, we will discuss the core protection mechanisms incorporated into the
transformer safety device. These mechanisms work together to detect abnormal operating
conditions, take corrective actions (such as disconnecting the transformer from the electrical
supply), and ensure the transformer operates within safe limits.

The two primary protection mechanisms discussed in this chapter are:

1. Overvoltage Protection
2. Overtemperature Protection

Each mechanism involves the use of sensing components, control logic, and actuation
mechanisms to detect faults and initiate protective actions in a timely manner.

6.2 Overvoltage Protection Mechanism

Overvoltage is a condition where the voltage supplied to the transformer exceeds the
specified rated value, which can lead to excessive heating, insulation failure, and ultimately
transformer failure. Overvoltage can be caused by various factors, such as lightning strikes, power
line faults, or switching transients in the electrical network.

The overvoltage protection mechanism is designed to detect when the transformer’s input
voltage exceeds a pre-defined threshold and to disconnect the transformer from the power supply
before it suffers damage.

29
6.2.1 Working Principle

The overvoltage protection mechanism operates by continuously monitoring the input

voltage to the transformer. When the voltage exceeds a safe operating range, the system activates
the protection relay to disconnect the transformer from the grid.

A. Voltage Sensing: The input voltage is monitored through a voltage divider circuit and
compared to a reference voltage that represents the maximum allowed voltage for safe
operation.
B. Threshold Detection: When the input voltage exceeds the threshold value,. The voltage is
then compared to a reference using a comparator circuit.
C. Relay Activation: If the voltage exceeds the threshold, the comparator sends a signal to the
relay. The relay then opens the circuit, disconnecting the transformer from the power supply,
thereby preventing any damage from prolonged overvoltage conditions.
D. Restoration: Once the overvoltage condition is cleared (i.e., the voltage returns to normal
levels), the system can reset automatically, allowing the transformer to reconnect to the grid.

6.2.2 Key Components for Overvoltage Protection

A. Comparator Circuit: Compares the sensed voltage to the reference voltage, triggering the
relay when the threshold is exceeded.
B. Relay: Disconnects the transformer from the grid when the overvoltage condition is detected.
C. Resistor: Used in the voltage divider circuit to scale down the voltage for measurement.
6.2.3 Performance and Response Time

The overvoltage protection mechanism should act quickly to disconnect the transformer as
soon as the voltage exceeds the safe limit. The response time of the system is critical in minimizing
damage to the transformer. Typically, the system should respond within milliseconds to ensure the
protection is effective. The relay should be selected to handle the current and voltage requirements
of the transformer, with a quick switching time to minimize any adverse effects from overvoltage.

30
6.3 Overtemperature Protection Mechanism

Overheating is one of the most common causes of transformer failure. If a transformer

operates at temperatures above its rated limit for extended periods, the insulation and other internal
components can degrade, leading to irreversible damage. Overtemperature conditions can be
caused by overloading, insufficient cooling, or high ambient temperatures.

The overtemperature protection mechanism is designed to monitor the transformer’s

temperature and disconnect it from the power supply if the temperature exceeds a preset threshold.

6.3.1 Working Principle

The overtemperature protection mechanism involves the use of temperature sensors such
as thermistors or bimetallic strips to measure the transformer's temperature. If the temperature
rises above the safety limit, the protection system will disconnect the transformer to prevent
damage.

A. Temperature Sensing: The system continuously monitors the transformer’s temperature

using NTC thermistors or oil temperature sensors. As the temperature rises, the resistance of
the thermistor decreases, providing an input to the control unit.
B. Threshold Detection: The temperature signal from the sensor is compared to a reference
voltage using a comparator circuit. If the temperature exceeds the predefined threshold, the
comparator triggers the relay.
C. Relay Activation: Once the threshold is exceeded, the comparator sends a signal to activate
the relay, which disconnects the transformer from the power supply, halting further
temperature rise.
D. Restoration: After the transformer has cooled down to a safe temperature, the system can
automatically reset, allowing the transformer to be reconnected to the grid. Alternatively, a
manual reset can be implemented to ensure that the transformer is inspected before it is brought
back online.

6.3.2 Key Components for Overtemperature Protection

31
 A. NTC Thermistor: Used to measure temperature based on changes in resistance as
temperature increases. The thermistor is placed in a position where it can measure the
transformer’s internal temperature.
B. Bimetallic Strip: This mechanical temperature sensor bends when exposed to high
temperatures, activating a switch to disconnect the transformer from the grid.
C. Oil Temperature Sensor: In larger transformers, oil temperature sensors provide accurate
temperature readings, correlating to the internal temperature of the transformer.
D. Comparator Circuit: Compares the temperature reading to a reference value, activating
the relay when the threshold is exceeded.
E. Relay: The relay disconnects the transformer if the overtemperature condition is detected.

6.3.3 Performance and Response Time

The overtemperature protection system must react quickly to prevent overheating. The
response time of the system depends on the accuracy and response speed of the temperature
sensors. Ideally, the system should disconnect the transformer within seconds of detecting an
overtemperature condition. The relay chosen should be capable of switching fast enough to prevent
transformer damage, and the temperature sensor should have high thermal response to ensure rapid
detection.

6.4 Combined Overvoltage and Overtemperature Protection

In practice, the transformer safety device incorporates both overvoltage and

overtemperature protection mechanisms into a single, unified system. This integrated system
ensures that both electrical and thermal faults are detected and addressed without delay.

6.4.1 System Coordination

The overvoltage and overtemperature mechanisms work in parallel, continuously

monitoring the transformer’s operating conditions. The system is designed so that if either an

32
overvoltage or overtemperature condition is detected, the protection system will immediately
disconnect the transformer from the power supply.

A. Parallel Fault Detection: Both the voltage sensing circuit and temperature sensing circuit
continuously monitor their respective parameters. The signals are fed to the control unit, which
makes the decision to trigger the relay based on the detected fault.
B. Independent Thresholds: The overvoltage and overtemperature mechanisms operate
independently, with their own thresholds for activation. This allows for independent protection
for electrical and thermal faults.
C. Relay Coordination: The control unit coordinates the activation of the relay to ensure the
transformer is disconnected in the event of either fault condition. This provides comprehensive
protection without the need for complex logic.

6.4.2 System Advantages

A. Comprehensive Protection: By combining both overvoltage and overtemperature protection,
the system ensures that all critical transformer failure modes are addressed.
B. Reliability: The use of separate protection circuits for voltage and temperature ensures that the
system can handle both types of faults independently without compromising reliability.
C. Cost-Effectiveness: Using simple analog components ensures that the system is cost-effective
while still providing robust protection for the transformer.

6.5 Testing and Validation of Protection Mechanisms

Before deployment, it is essential to test the protection mechanisms to ensure they function
as expected under real-world conditions.

A. Overvoltage Testing: The system is subjected to voltage surges, simulating overvoltage

scenarios like lightning strikes or power grid switching. The system should respond by
disconnecting the transformer immediately when the voltage exceeds the threshold.
B. Overtemperature Testing: The system is tested by artificially raising the temperature of the
transformer to simulate overheating. The temperature sensors should detect the rise and trigger
the relay to disconnect the transformer from the grid.

33
C. Combined Fault Testing: Both overvoltage and overtemperature faults are simulated
simultaneously to verify that the system can handle multiple fault conditions at once. The relay
should disconnect the transformer without delay, providing protection against both electrical
and thermal hazards.

6.6 Conclusion

This chapter has discussed the protection mechanisms employed in the transformer safety
device. The overvoltage protection mechanism ensures that excessive voltage is detected and
mitigated before it can damage the transformer, while the overtemperature protection mechanism
safeguards the transformer against overheating. By integrating these two protection mechanisms,
the system provides comprehensive protection for transformers, preventing damage and enhancing
their lifespan. The next chapter will discuss the implementation and testing of the system to
validate the performance of these protection mechanisms.

34
 CHAPTER 7 CIRCUIT DESIGN

S.N COMPONENTS RATING QYT

A. TRANSFORMER 12V/750 MA 1

B. WOOD BOARD A4 1

C. PCB BOARD 4*4 2

D. PCB BOARD 2*6 1

E. ON/OFF 2 PIN SWITCH ONE WAY 4

F. 3 MM LED 3 MM 4

G. RESISTOR 1K OHM 1

H. 2 PIN SCREW TERMINAL 2 PIN 5

I. DIODE IN4007 6

J. IC REGULATOR 6V 1

K. BATTERY CLIP

35
 L. BATTERY 9V 1

M. NPN TRANSISTOR BC547 1

N. CAPACITOR 25V 1000µF 1

O. RESISTOR 1K 1

P. RELAY 5V 2

Q. STRIP SINGLE LINE 1-TYPE PIN MALE HEADER 1*7 1

R. JUMPER WIRE MALE TO MALE 12

S. 2 PIN PLUG 230V 1

T. DOUBLE SIDED FOAM TAPE NORMAL SIZE 1

TABLE NO.7.1

7.1 TRANSFORMER

A transformer is an electrical device that transfers electrical energy between two or more
circuits through electromagnetic induction. Electromagnetic induction produces an electromotive
force within a conductor which is exposed to time varying magnetic fields. Transformers are used
to increase or decrease the alternating voltages in electric power applications

The transformer reduces the voltage from mains to 12VAC (RMS).

36
A. Used Rating: -
B. Type: - Step Down.
C. Input Voltage: - 230V AC 50HZ.
D. Output Voltage: - 12V AC 50HZ.
E. Current Rating: - 750mA.

Figure 7.1 image of transformer

37
7.2 RECTIFIRE

A rectifier is an electrical device that converts alternating current, which periodically

reverses direction, to direct current, which flows in only one direction.

A. Used Rating: -
a. Type: - Bridge Type
b. Input Voltage: - 12 AC 50HZ.
c. Output Voltage: - 6V Dc
d. Current Rating: - 750mA.

B. Used Components: -
a. 2 Pin Screw Terminal: - 2 Nos.
b. 1N4007 Diode: - 4 Nos.
c. 7806 IC Regulator: - 1 Nos.
d. 2x3 PCB Board : 1 Nos.

Figure7.2 rectifying circuit

38
7.3 SENSOR CIRCUIT

Sensor Circuit sense the over load current and load exceeds the reference value, and
automatically cut off the extra load. Therefore, transformer safety device work efficiently under
overload condition and the damage can be prevented.

A. Used Rating: -
B. Type: - Sensor with timer
C. Input Voltage: - 9V DC.
D. Cutoff value: - 730mA.

E. Used Components: -
F. 2 Pin Screw Terminal: - 1 Nos.
G. 1N4007 Diode: - 2 Nos.
H. Capacitor 24V 1000 uf : - 1 Nos.
I. 2x3 PCB Board: -1 Nos.
J. BC547 NPN Transistor: - 1Nos.
K. 1k Resistor: - 1 Nos.
L. Male Strip Pin:- 2+2 = 4 Pin figure 7.3 sensor circuit

7.4 LOAD CIRCUIT

An electrical load is simply any component of a circuit that consumes power or energy.
Its include light bulbs and appliances all load current sense through sensor circuit

A. Used Rating: -
B. Input Voltage: - 6V DC.
C. Used Components: -

39
 Figure 7.4 LOAD CIRCUIT

D. 2x8 PCB Board: -1 Nos.

E. LED: - 4Nos.
F. 1k Resistor: - 1 Nos.

7.5 CIRCUIT DIAGRAM

Figure 7.5 circuit diagram

40
7.6 DESCRIPTION OF THE PROJECT

Power travels from the power plant to house through an amazing system called the power
distribution grid. For power to be useful in a home or business, it comes off the transmission grid
and is stepped-down to the distribution grid. This may happen in several phases. The place where
the conversion from "transmission" to "distribution" occurs is in a power substation. It has
transformers that step transmission voltages (in the tens or hundreds of thousands of volts range)
down to distribution voltages (typically less than 10,000 volts). It has a "bus" that can split the
distribution power off in multiple directions. It often has circuit breakers and switches so that the
substation can be disconnected from the transmission grid or separate distribution lines can be
disconnected from the substation when necessary

Transformer is the vital component in the electric power transmission and distribution
system. The problem of overloads, voltage variation and heating effects is very common. It takes
lot of time to its repair and also involves lot of expenditure.

This work is all about protecting the transformer under overload condition. Due to overload
the efficiency gets reduced and the secondary winding gets overheated or it may be burnt. So, by
reducing the extra load, the transformer can be protected.

This can be done by transformer safety sensor timer circuit through. When the load exceeds
the reference value, the transformer safety device automatically cut off the extra load.

Therefore, transformer safety device work efficiently under overload condition and the
damage can be prevented. For home appliances, commercial and industrial loads, the transmitted
voltage must be steeped down to a distribution level

This may happen in several phases. In sub stations the voltage gets stepped down from
transmission level (in the tens or hundreds of thousands of volts range) to the distribution level
(typically less than 10,000 volts). A sensor circuit is designed to log the data from master
transformer and if it is found to be in overload condition, immediately extra load will be

41
disconnected to transformer and the transformer safe and protected. Initially when we switched
ON the load that load will be running by transformer. Once load has been increased on transformer
above its rated capacity then safety device automatically cutoff the load.

7.7 WORKING FUNCTION OF THE SYSTEM

Here, used Transformer 12V,750mA ,7805 three terminal voltage regulators is used for
voltage regulation. Bridge type full wave rectifier is used to rectify the AC output of secondary of
230/12V step-down transformer.

In this project we are using the 4 loads (L-1, L-2, L-3, L-4), 3 loads are connected in
parallel through Transformer. And last load also connected through transformer with the help of
timer sensor circuit, which will connect and disconnect the load by sensing the current. And we
are using the 4 switch (S-1, S-2, S-3, S-4) which will connect in series with each load and we are
using R-1 resistor for protection of 3mm LED Light load.

Transformer is a stepdown transformer and we called main transformer, transformer has

its own load handling capacity.

In case of a normal operation the transformer takes the load but as the load is beyond the
rated capacity of main transformer, then extra load is disconnected automatically and protect the
transformer

Load switching network is provided to ON/OFF the load on the transformers which is
connected to load bank. we are using the 4 switches for each load. Over current (750mA) and
voltage(12V) set in the sensor circuit. As we keep the switch S1 ON Then the load L1 Will be on
and 188 mA current will flow through transformer. And switch S2 ON then load L2 Will be on
and 376 mA current will flow through the transformer and we will on the S3 Switch the load L3
will be on and 564 mA current will flow through the transformer, then we will on the last load L4
then current will increase the maximum set value of sensor circuit that time sensor will disconnect
the extra load L4 with in 5sec. and transformer will be safe condition.

42
7.8 FUNCTIONALITY OF THE SYSTEM

A. Functionality of the system:

B. Automatic Load Cut off by sensor.
C. No manual error fit and forgets system.
D. Highly sensitive low cost and reliable circuit.
E. It prevents the main transformer from damage due to the problems like overload and overheat.
F. Un-interrupted power supply to the consumers is supplied.
G. The load voltage and current are effectively monitored.
H. Electrical Network Monitoring & Control.
I. Electrical Integrated Control.
J. integrated Protection and Control

43
Chapter 8: Results and Discussion

8.1 Introduction

The successful design and implementation of the transformer safety device have been
validated through a series of rigorous testing procedures to assess the performance of the protection
mechanisms against overvoltage and overtemperature conditions. This chapter presents the results
of these tests and provides a detailed discussion on the system’s effectiveness, performance, and
areas for potential improvement. By evaluating the outcomes of these tests, the objectives of the
project—namely, ensuring transformer protection and reliable operation—can be fully assessed.

This chapter covers:

A. Test Results
B. Performance Evaluation
C. System Effectiveness
D. Challenges and Limitations
E. Recommendations for Improvement

8.2 Test Results

The results from testing the transformer safety device under simulated overvoltage and
overtemperature conditions are summarized below. The objective was to ensure that the system
activates protection mechanisms promptly and reliably under fault conditions.

8.2.1 Overvoltage Protection Test Results

A. Test Setup: The input voltage was gradually increased in steps, starting from the nominal
voltage (e.g., 230V) to a level significantly above the transformer’s rated voltage (e.g., 1.5
times the rated voltage).

44
 B. Expected Outcome: The overvoltage protection mechanism should activate once the input
voltage exceeds the set threshold. The relay should trigger, disconnecting the transformer
from the supply.
C. Results:
a. At 1.5 times the rated voltage, the overvoltage protection mechanism was triggered,
disconnecting the transformer from the power supply.
b. The response time from detecting overvoltage to relay activation was approximately 15
milliseconds, which is within the expected range for rapid fault detection.
c. The system correctly handled transient spikes, effectively absorbing high-voltage surges,
preventing any damage to the circuit.
.

8.2.2 Overtemperature Protection Test Results

A. Test Setup: The temperature of the transformer was artificially raised using a heat source to
simulate overloading or high ambient temperatures. The temperature was monitored with a
NTC thermistor or bimetallic strip sensor.
B. Expected Outcome: The system should trigger the overtemperature protection mechanism
once the transformer temperature exceeds the preset threshold. The relay should disconnect the
transformer to prevent overheating.

45
C. Results:
a. The overtemperature protection activated at a temperature of approximately 90°C (a typical
threshold for transformer safety).
b. The response time for overtemperature detection and relay activation was about 1.5 seconds.
This is acceptable, though it could be improved further with more sensitive sensors or faster
comparator circuits.
c. The NTC thermistor responded accurately, with a steady decrease in resistance as the
temperature increased, triggering the protection mechanism.

Observations:

d. The system worked as intended, providing adequate protection against overheating.

e. The use of a thermistor allowed for fine-tuned detection of temperature increases, and the
bimetallic strip (if used) also provided a reliable mechanical cutoff.

8.2.3 Combined Fault Test Results

A. Test Setup: In this test, both overvoltage and overtemperature conditions were simulated
simultaneously to evaluate the system’s ability to handle multiple faults at once.
B. Expected Outcome: The transformer should be disconnected if either an overvoltage or
overtemperature condition is detected.
C. Results:
A. The system successfully detected both faults simultaneously, with the relay disconnecting the
transformer from the grid without any delay.
B. Priority of Protection: The relay was able to disconnect the transformer as soon as any fault
(either overvoltage or overtemperature) exceeded the threshold. There was no need for a
prioritization mechanism, as both conditions triggered the relay independently.
D. Observations:
A. The simultaneous fault detection proved that the system could handle complex scenarios
without failure, providing redundant safety by ensuring that at least one protection mechanism
was always triggered.

46
B. Both protection circuits functioned independently, and the relay acted as a universal switch for
both fault types.

8.3 Performance Evaluation

The performance of the transformer safety device was evaluated based on several key criteria:

A. Reliability: The protection mechanism worked reliably under both overvoltage and
overtemperature conditions. Each test resulted in the transformer being disconnected before
any significant damage could occur. The system did not fail to detect faults, and the relay was
activated promptly.
B. Response Time:
a. Overvoltage Response: The system responded within 15 milliseconds to overvoltage
conditions. This response time is well within the acceptable range for most transformer
protection systems.
b. Overtemperature Response: The system responded within 1.5 seconds to overtemperature
conditions. While this is acceptable, it could be improved with faster sensors and comparators
for a more immediate reaction.
C. Protection Consistency: The system demonstrated consistent protection in multiple tests,
including repeated overvoltage and overtemperature events. There were no instances where
the system failed to disconnect the transformer when required.
D. System Integration: The integration of both overvoltage and overtemperature protection
mechanisms worked smoothly. Both circuits operated independently, and the relay
successfully managed both types of faults without interference.

47
8.4 System Effectiveness

The transformer safety device demonstrated high effectiveness in protecting transformers

from overvoltage and overtemperature conditions. Key factors contributing to its effectiveness
include:

A. Early Detection: Both the voltage sensing circuit and temperature sensing circuit were able to
detect faults early enough to prevent damage to the transformer.
B. Fast Response Time: The system responded quickly to faults, disconnecting the transformer
almost instantaneously (for overvoltage) and within seconds for overtemperature conditions.
C. Component Selection: The system could both clamp voltage surges and accurately monitor
temperature rises, providing reliable protection across a wide range of fault conditions.
D. Dual Protection Mechanisms: By using independent protection circuits for overvoltage and
overtemperature, the system ensured that the transformer was protected from multiple types of
faults simultaneously. The combined protection greatly improved the overall reliability and
safety.

8.5 Challenges and Limitations

While the system showed excellent performance, a few challenges and limitations were
noted during the testing phase:

A. Response Time for Overtemperature Protection: The overtemperature response time was
slightly longer (around 1.5 seconds) compared to the overvoltage protection response time.
Although acceptable, this could be further optimized with faster temperature sensors or by
using a microcontroller for more rapid fault detection.
B. Accuracy of Temperature Sensing: The accuracy of the NTC thermistor was sufficient for
most applications, but more precise sensors might be required in high-end transformers where
precise temperature control is critical.

48
C. Relay Overload Handling: The relay used was suitable for standard transformer loads, but
for high-power transformers, high-current rated relays should be considered to prevent wear
and tear.
D. Environmental Sensitivity: The temperature sensor was sensitive to the environmental
conditions, and in some high ambient temperature environments, the readings might need
calibration for accuracy. This could be addressed with an additional compensation mechanism
in the circuit.

8.6 Recommendations for Improvement

Based on the testing results and limitations, several recommendations for improving the
system can be made:

A. Faster Temperature Sensing: Consider using more sensitive temperature sensors or

improving the signal processing to reduce the overtemperature response time. This could
involve the integration of a microcontroller to provide digital temperature readings and quicker
fault response.
B. Enhanced Relay Selection: For larger transformers or industrial applications, use high-
current, high-voltage relays that are capable of handling the higher power ratings of industrial
transformers.
C. Environmental Compensation: Implement an environmental compensation system that
adjusts temperature readings based on ambient conditions. This would help in achieving more
accurate overtemperature detection in varying environments.
D. Integration with Smart Systems: Future enhancements could involve integrating the system
with smart grid technology, allowing remote monitoring and fault detection. This would make
the transformer protection system part of a larger, automated fault detection and grid
management solutio

49
WHO ARE THE TARGET AUDIENCE?
A. Industrial areas.
B. Used in substation
C. Shopping malls.
D. Process Industrial Power.
E. Distribution Station.
F. Agricultural Transformer.

TECHNOLOGY REQUIRE

A. Embedded system
B. Sending technology.
C. Automation technology.

8.7 Conclusion

The transformer safety device developed for overvoltage and overtemperature protection
has proven to be effective, reliable, and fast in responding to faults. The system successfully meets
its objectives by preventing transformer damage due to excessive voltage or temperature
conditions. While the system is already highly functional, further improvements in response time
and environmental adaptability could enhance its performance for high-demand applications. The
next steps will involve refining the system based on the results of testing and incorporating
advanced features for wider applications in industrial transformer protection.

50
Figure 8.1 images of Transformer safety device

51
Chapter 9: Conclusion

9.1 Overview of the Project

The Transformer Safety Device project aimed to design and implement a protection
mechanism to safeguard transformers from overvoltage and overtemperature conditions. These
conditions, if left unchecked, can result in significant damage to the transformer, causing system
failures, costly repairs, and even safety hazards. The core objective of this project was to develop
an affordable, reliable, and effective safety device that would disconnect the transformer from the
power supply during fault conditions, thereby preventing damage and enhancing the lifespan of
the transformer.

In this project, we utilized simple but effective components such as voltage sensing circuits,
NTC thermistors for temperature sensing, , and relays to disconnect the transformer during fault
conditions. The safety device operates without the use of complex microcontrollers or advanced
programming, making it a suitable solution for practical, real-time applications where simplicity
and reliability are key.

9.2 Key Achievements

The primary outcomes and achievements of this project include:

A. Overvoltage Protection:
a. The designed circuit successfully detected overvoltage conditions and activated the relay to
disconnect the transformer from the power supply when the voltage exceeded safe operating
limits.
b. The system was capable of responding in less than 15 milliseconds, which is sufficient to
protect the transformer from transient surges and sustained overvoltage conditions.

52
B. Overtemperature Protection:
a. The system accurately monitored the transformer’s temperature using an NTC thermistor (or
optional bimetallic strip) and triggered the relay when the temperature exceeded the preset
threshold (90°C).
b. The system responded within 1.5 seconds, which is within an acceptable range for preventing
overheating.
C. Combined Fault Protection:
a. The device was able to handle both overvoltage and overtemperature conditions
simultaneously, ensuring that the transformer was disconnected from the power supply under
any fault condition.
b. The response time to both faults was fast, and the system exhibited redundant safety, ensuring
the protection was always active when needed.
D. System Reliability:
a. The system showed high reliability across a variety of tests. It consistently triggered the relay
to disconnect the transformer whenever the voltage or temperature exceeded the safe operating
range.
b. The protection mechanism was effective under both normal and fault conditions, preventing
transformer damage in each test scenario.

9.3 Performance Evaluation and Discussion

The safety device demonstrated excellent performance in protecting transformers from

overvoltage and overtemperature events. The overall response time of the system to overvoltage
was fast (around 15 milliseconds), while the response time to overtemperature was slightly slower,
at 1.5 seconds, but still within an acceptable range for typical transformer protection requirements.

A. Effectiveness: The system performed reliably during repeated tests, consistently disconnecting
the transformer when the threshold for overvoltage or overtemperature was breached.

53
B. Simplicity: The design was simple, relying on basic electronic components without the need
for complex software or microcontrollers. This contributed to a cost-effective and highly
reliable solution.
C. Safety: The system acted as a failsafe mechanism, ensuring that the transformer was
disconnected from the power supply before sustaining irreversible damage, thus enhancing
operational safety.
D. However, the project also identified areas for further optimization:
E. Faster Overtemperature Response: While the overtemperature protection worked as
expected, the response time could be improved further with faster temperature sensors or more
efficient circuit design.
F. Relay Handling: The relays used in the system were suitable for the low to medium power
transformers, but for larger, industrial-grade transformers, higher-rated relays would be
necessary to handle higher currents and voltages.
G. Environmental Adaptability: The temperature sensing component was sensitive to the
surrounding environment, which might cause inaccuracies in extreme conditions.
Compensation mechanisms or calibration features could improve the system's performance in
such environments.

9.4 Challenges Faced

Throughout the project, several challenges were encountered and addressed:

A. Accuracy of Sensing Components: One of the primary challenges was achieving accurate
and consistent readings from the temperature sensors and voltage sensing circuits. Ensuring
that the system responded accurately to small fluctuations in temperature and voltage required
careful calibration and testing of each component.
B. Relay Selection: Ensuring that the relay could handle the high current and voltage levels
encountered in industrial transformer applications was a challenge. A careful selection of
relays was needed to balance performance and cost.

54
C. Component Integration: Integrating different protection mechanisms (overvoltage and
overtemperature) into a single system while maintaining simple functionality was complex.
Ensuring that both circuits worked independently without interference required precise design
and testing.

9.5 Future Recommendations

A. While the transformer safety device developed in this project offers effective protection, there
are several recommendations for future improvements and extensions:
B. Integration of Microcontroller-Based Control: The use of a microcontroller (such as an
Arduino or Raspberry Pi) could improve response times, particularly for overtemperature
detection, by allowing more advanced algorithms for fault detection and faster reaction. It
could also enable remote monitoring and diagnostics, making it a part of a smart grid solution.
C. Advanced Temperature Sensors: To improve the response time for overtemperature
protection, the project could incorporate digital temperature sensors like DS18B20 or LM35,
which provide more precise and faster readings.
D. Enhanced Relay Selection: For applications involving high-power transformers, it would be
necessary to use heavy-duty relays or contactors capable of handling higher voltages and
currents. The addition of solid-state relays could provide faster switching and longer lifetimes.
E. Environmental Calibration: To compensate for environmental temperature variations, the
system could use environmental compensation algorithms or sensors that provide more stable
readings in fluctuating conditions. This would improve the accuracy of temperature-based
protection.
F. Wireless Communication: The inclusion of wireless communication features (such as Wi-Fi
or Bluetooth) could allow remote monitoring and fault alerts, providing real-time data to
operators and enabling more proactive maintenance.
G. System Redundancy: For critical transformer applications, redundant protection systems
could be integrated to ensure that failure of one protection circuit does not compromise the
overall safety.

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9.6 Conclusion

In conclusion, the Transformer Safety Device has successfully met its objectives of
providing protection against overvoltage and overtemperature conditions. The project
demonstrated the effectiveness of simple yet robust protection circuits using easily available
electronic components. By incorporating both overvoltage and overtemperature protection
mechanisms, the system ensured that transformers were safely disconnected from the grid in the
event of fault conditions, preventing costly damage and enhancing the longevity of the equipment.

While the system performed well in testing, there is potential for improvement in several
areas, including response times, sensor accuracy, and relay selection. With further refinement and
the potential integration of microcontroller-based control, the system can evolve into a more
sophisticated, adaptable, and scalable solution for transformer protection in a variety of industrial
and commercial applications.

By leveraging the principles of simplicity, reliability, and affordability, this project offers a
practical solution to a common problem faced by transformer operators, providing both cost-
effectiveness and robust protection for critical electrical infrastructure.

9.7 Final Remarks

The successful implementation of this transformer safety device serves as a stepping stone
for further advancements in the field of electrical protection. Future research could focus on
refining the system’s capabilities and exploring its application in power systems, contributing to
the ongoing development of safer and more efficient electrical distribution networks.

References

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 IEEE Standard C57.12.00-2015: Standard for General Requirements for Liquid-Immersed
Distribution, Power, and Regulating Transformers.

Transformer Protection and Control. IEEE Power Engineering Society.

IEEE 32-2020: Standard for Protection of Electrical Transformers

https://www.electrical4u.com/.

Thermal Management and Protection for Power Transformers.

IEEE Transactions on Industrial Electronics, 65(9), 7312-7320.

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