OTPL
Orissa Transformer Private Limited (OTPL), Bhubaneswar, is a leading manufacturer of oil and dry-type transformers, catering to government bodies, utilities, and enterprises across Odisha. With a strong reputation for quality, OTPL sought to enhance post-installation support and strengthen long-term client relationships.
At a glance
By deploying Babble with IoT-enabled gateways, OTPL gained real-time visibility into transformer temperature, load, and voltage across the field. Centralized dashboards allowed both OTPL and their clients to remotely monitor transformer health with role-based access, reducing downtime, preventing failures, and enhancing customer trust.
Challenges
OTPL needed a cost-effective, secure, and scalable monitoring solution that provided them oversight of all transformers while enabling clients to monitor their own units independently.
OTPL faced recurring challenges with field- installed transformers:
Uneven load distribution led to frequent overheating, reduced efficiency, and even transformer failures.
Lack of visibility into winding temperature and electrical parameters caused delays in diagnosing issues.
Clients had no access to independent monitoring, creating trust gaps and disputes during failures.
Existing designs occasionally suffered from air-gap issues in transformer windings, causing temperature overshoots and efficiency losses.
Solutions
OTPL needed a cost-effective, secure, and The system not only improved transformer monitoring but also gave OTPL credible data to validate warranty or service disputes with clients.
Inclue deployed a standalone IoT-enabled monitoring system powered by Babble with the following features:
Installed high-precision temperature sensors to track transformer heat in real time.
Integrated energy meters to capture load, voltage, and other electrical parameters.
Deployed an IoT edge gateway (IP65/IP68 rated enclosure) communicating securely via RS485 to the cloud.
Set up a dedicated Babble Cloud instance for OTPL, ensuring encrypted data storage and role-based access.
Developed custom dashboards so OTPL could view the entire fleet while end customers saw only their respective transformer data.
60%
Downtime reduction
100%
Remote visibility
<5%
Transformer burnouts
100%
Client satisfaction
Results
Automated QR code reading under tough conditions.
Reduced downtime and transformer failures by identifying uneven load distribution early.
Discovered design inefficiencies in winding gaps, enabling corrective action.
Enhanced transparency and trust with clients through role-based monitoring access.
Value-added service increased customer satisfaction and opened new business opportunities.
“Babble has made it easy for us to monitor transformer health in real time. It reduced disputes, improved efficiency, and built stronger trust with our customers. ”
Conclusion
Through Babble’s IoT-enabled monitoring system, OTPL successfully shifted from reactive maintenance to proactive transformer management. With improved visibility, reduced downtime, and stronger customer engagement, OTPL positioned itself not only as a reliable manufacturer but also as a trusted technology partner. Future plans include advanced Dissolved Gas Analysis (DGA) integration for even deeper health insights
