Your transformer is the
heart of your plant. Watch it.
Overloads, power quality faults, energy waste, and missed AMCs silently cost manufacturers crores each year. Real-time IIoT monitoring puts every critical parameter on your dashboard — before it becomes a breakdown.
What to monitor — and why it matters.
Each use case represents a real failure mode seen in Indian manufacturing plants. Combined, they give you complete transformer intelligence.
Overload & Overheating Monitoring
What We Monitor
- · Load %
- · Current (A)
- · Oil temperature
- · Winding temperature
Alerts Generated
- ▸ High load warning (>85%)
- ▸ Critical temperature threshold
- ▸ Sustained overload >15 min
Why It Matters
Unchecked overloads cause insulation breakdown, fire risk, and sudden production shutdowns — often with no warning until it's too late.
Real-World Outcome
A textile plant running at 92% load during peak shift saw winding temperature creep to 105°C. Automated alert triggered load shedding on non-critical lines. Transformer life extended by 4 years.
Power Quality Monitoring
What We Monitor
- · Voltage fluctuation
- · Harmonics (THD %)
- · Phase imbalance
- · Power factor
- · Frequency variation
Alerts Generated
- ▸ THD > 5%
- ▸ Phase imbalance > 3%
- ▸ Voltage sag/swell events
Why It Matters
Poor power quality silently damages CNC machines, VFDs, PLCs, and sensitive equipment — causing premature failures and mystery breakdowns.
Real-World Outcome
A pharma plant traced 3 VFD failures per year to THD at 8.4%. Harmonic filter installed. VFD failures dropped to zero. Maintenance savings: ₹6.2L per year.
Energy Consumption & Demand Tracking
What We Monitor
- · kWh usage
- · Peak demand (kVA)
- · Shift-wise consumption
- · Department-wise energy
Alerts Generated
- ▸ Peak demand approaching contract limit
- ▸ Shift consumption anomaly
- ▸ Idle load detection
Why It Matters
Demand charges on electricity bills can be 30–40% of the total cost — entirely avoidable with visibility into when and where energy peaks.
Real-World Outcome
A packaging unit discovered 18% of their transformer load was running during Sunday idle time — HVAC, compressors, and lighting left on. Auto-schedule shutdown reduced monthly bill by ₹1.1L.
Alarm & Fault Monitoring
What We Monitor
- · Transformer trip
- · Breaker trip
- · Power failure
- · Overvoltage / Undervoltage
- · High temperature alarm
Alerts Generated
- ▸ Instant trip notification
- ▸ Real-time event log with timestamp
- ▸ Escalation to maintenance team
Why It Matters
Every undetected fault costs production time. Faster fault detection means faster response, less damage, and less cascading downtime.
Real-World Outcome
A metal fabrication plant reduced fault response time from 22 minutes (someone notices, calls supervisor) to 4 minutes (auto-alert to phone). Average production loss per incident dropped from ₹85,000 to ₹18,000.
AMC & Preventive Maintenance Management
What We Monitor
- · Service schedules
- · Oil BDV test tracking
- · Thermography inspection log
- · Spare parts inventory
- · AMC expiry dates
- · Service tickets
Alerts Generated
- ▸ AMC expiry reminder (60/30/7 days)
- ▸ Overdue service flag
- ▸ Oil test reminder
Why It Matters
Most transformer failures happen because routine maintenance was skipped or forgotten. A digital maintenance log removes that risk entirely.
Real-World Outcome
A cement plant with 12 transformers was managing AMC via spreadsheet. Two AMCs had lapsed unnoticed. After digitising maintenance schedules, all 12 are tracked, serviced on time, and insurer reduced premium by 8%.
Every plant with a transformer does.
Heavy manufacturing
Multiple large transformers, high load variation
Pharma & Food plants
Sensitive equipment, power quality critical
Textile mills
High continuous load, overheating risk
Auto & Engineering
CNC, VFDs, PLCs at risk from harmonics
Cement & Mining
Remote transformers, hard to inspect manually
Any plant with AMC
Digitise service schedules and avoid lapses
Know your transformer's health. Always.
Connect in days, not months. See every parameter live. Get alerted before something goes wrong.
Request a Demo →