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Integrated instrument transformers and distribution power units engineered for rigorous industrial factory continuous operation.
In modern industrial facilities such as metallurgical smelting complexes, chemical petrochemical plants, automotive gigafactories, and pulp-and-paper mills, electrical infrastructure operates under extreme continuous electrical loads and fluctuating duty cycles. Power distribution networks at medium and high voltage levels (10kV, 20kV, 35kV, up to 110kV) demand uncompromising precision for both tariff revenue metering and high-speed protection relays. The CT-VT Combined Instrument Transformer (also known as a Combined Metering Unit or JLS/MOF series) represents a pinnacle engineering solution that integrates Current Transformer (CT) and Voltage/Potential Transformer (VT/PT) active parts within a single, hermetically sealed or cast-resin encapsulation.
Traditional substation designs relied on standalone CTs and separate VTs, requiring extensive busbar layouts, duplicate mounting structures, complex secondary wiring channels, and larger footprints within switchgear rooms or outdoor substations. In contrast, the integrated CT-VT combined transformer cuts substation footprint by up to 45%, diminishes potential dielectric breakdown points, and ensures matched phase-angle calibration between current and voltage vectors. This synergy drastically minimizes metering ratio errors, optimizes harmonic distortion evaluation, and delivers real-time telemetry crucial for AI-driven energy management systems.
Equipped with class 0.2S or 0.5S metering cores for high dynamic range precision from 1% to 120% nominal current, guaranteeing compliant billing and energy accountability.
Engineered core geometry with optimized magnetic flux densities prevents core saturation and dangerous ferroresonance conditions induced by switching transients.
Independent multi-core configurations allow dedicated cores for 5P10 / 10P20 relay protection alongside 0.2S high-fidelity tariff data acquisition.
Industrial manufacturing plants present operating environments that deviate significantly from standard municipal electrical grids. The primary challenges encompass harmonic pollution caused by variable frequency drives (VFDs), rapid load swings in electric arc furnaces (EAF), inductive motor start-up surges, and harsh environmental contaminants such as chemical airborne gases, coal dust, or ambient moisture.
Steel plants and metallurgical smelting facilities experience instantaneous short-circuits during the melt-down phase, creating extreme dynamic current peaks ($I_{dyn}$) and severe voltage flickers. A CT-VT combined transformer deployed at the incoming feeder must exhibit superior short-time thermal current ratings ($I_{th}$ up to 31.5kA/3s) and reinforced epoxy resin or oil-paper insulation capable of enduring repetitive transient overvoltages without partial discharge inception.
In petrochemical processing, unscheduled power interruption can lead to catastrophic production freezing and severe financial loss. Combined metering units for these sites require hermetic enclosure sealing (IP55 to IP67 terminal boxes), creepage distances exceeding 31mm/kV for Class IV pollution zones, and dual secondary taps to ensure uninterrupted switchover to auxiliary protection circuits.
Mining operations subject equipment to severe mechanical shock, continuous vibration from heavy haulers, and restricted installation geometry inside skid-mounted mobile substations. Compact combined CT-VT transformers eliminate inter-device cabling, reducing mechanical stress points and offering superior seismic endurance exceeding 0.3g ground acceleration.
As factories integrate rooftop PV arrays, battery energy storage systems (BESS), and waste-heat turbine generators, power flows become bi-directional. CT-VT combined units with 4-quadrant measurement capability provide precise data for automated power factor correction (APFC), zero-sequence fault identification, and automated grid islanding controls.
"Integrating primary current and voltage measurement within a calibrated monolithic chamber removes cumulative external phase displacement errors, providing accurate power quality telemetry and robust fault recording essential for Industry 4.0 electrical automation."
| System Voltage Class | Rated Primary Current (A) | Accuracy Class (Metering) | Accuracy Class (Protection) | Insulation Medium | Applicable Standards |
|---|---|---|---|---|---|
| 10kV – 12kV | 5A – 1200A | 0.2S / 0.5S (10-30VA) | 5P10 / 5P20 / 10P10 | Vacuum Cast Hydrophobic Epoxy (HCEP) / Oil-Immersed | IEC 61869-1/2/3/4, IEEE C57.13 |
| 20kV – 24kV | 10A – 1500A | 0.2S / 0.5 (15-50VA) | 5P20 / 10P20 (15-30VA) | Cycloaliphatic Epoxy / Hermetic Oil Immersed | IEC 61869, GB/T 20840.4 |
| 35kV – 40.5kV | 20A – 2000A | 0.2S (30-50VA) | 5P20 / Class X / PX | Nitrogen-Cushioned Mineral Oil / Silicone Rubber Bushing | IEC 61869, ANSI/IEEE, AS 60044 |
| 66kV – 110kV | 50A – 3150A | 0.2S / 0.1 High Precision | 5P30 / TPS / TPY Transient | Hermetically Sealed Oil with SS Bellows | IEC 61869-4, DL/T 726 |
Quality excellence and customer satisfaction remain the core values that guide every aspect of XINSANHUAN’s business operations. Through strict quality assurance, reliable delivery schedules, and comprehensive after-sales support, the company has earned the trust and long-term cooperation of customers around the world. Its commitment to providing dependable products and professional services has established a strong reputation within the global power equipment industry.
Every CT-VT combined transformer and heavy distribution unit undergoes comprehensive factory routine testing, including power-frequency withstand voltage testing, lightning impulse tests, partial discharge (PD) measurements maintained below 5pC at 1.2Um/√3, and precision ratio/phase displacement verification on automated multi-tap test benches.
Today, XINSANHUAN’s products are exported to more than 30 countries and regions worldwide. Its international footprint spans Europe, Central Asia, Southeast Asia, Africa, and Latin America, with successful projects completed in countries such as Russia, Kazakhstan, Uzbekistan, Kyrgyzstan, Ethiopia, Zambia, Tanzania, Mexico, Honduras, and many others. The company’s products are widely recognized for their excellent operational performance, high efficiency, durability, and adaptability to diverse climatic and grid conditions.
Delivering ultra-low-temperature resistant equipment and high-voltage grid apparatus designed for severe winter conditions down to -45°C across Kazakhstan, Russia, and Uzbekistan.
Providing heavy-duty tropicalized transformers engineered for intense ambient heat, sandstorm resistance, and high-altitude mining networks across Ethiopia, Zambia, and Tanzania.
Supplying coastal-corrosion-resistant industrial distribution solutions with robust seismic damping for major industrial infrastructure projects in Mexico, Honduras, and South America.
Looking toward the future, Hanzhong Xinsanhuan Transformer Co., Ltd. will continue to uphold its philosophy of integrity, innovation, quality, and customer focus. By leveraging its strong technical expertise, advanced manufacturing capabilities, and global market experience, the company is committed to building long-term partnerships with customers worldwide and contributing to the development of safe, efficient, and sustainable power infrastructure. Together with its partners, XINSANHUAN strives to create greater value and shape a brighter future for the global energy industry.
Through pioneering integration of optical fiber sensors, digital IEC 61850 sampled value protocols, and eco-friendly biodegradable ester insulation fluids into the next generation of instrument transformers, XINSANHUAN is accelerating the global shift towards green, intelligent, and zero-carbon industrial power distribution.
Explore our complete product lineup tailored for heavy-duty industrial factory distribution, grid substations, and harsh environment electrical installations.
