MANUFACTURING PROCESS OF CURRENT TRANSFORMER (LIVE TANK)

First of all, Aluminium rod is used as shown below:

 Paper insulation and Aluminium foil is wrapped one over another as per
design with the help of CNC machine as shown below :

 Now for making secondary winding, following material circular in shape

is used.

 Over this part, white paper and copper coil wrapping is done.

 Copper coil is wrapped over white paper and secondary tapping is taken
out as per design which is shown as under:

 Now to enclose above part, one metal part called girt is used as shown
below:

 Now the complete secondary winding assembly look like as under with
the secondary winding terminals taken out as shown:

 Now both the aluminium rod (Bushing) and the above secondary winding
assembly will join and complete wrapping is done over the joint to give
the fig as below. Now these are put in oven to remove moisture from
insulation paper :

 The secondary winding terminal is taken to bottom part as shown in fig:

 Now Capacitance (Cx & CY) and tan delta points are taken out as
follows:
1.) For capacitance( Cx ) point, following procedures are being followed:-

 For CY point, one lead is taken directly from aluminium rod (from
bottom hole as shown above) such that it can calculate Capacitance of
whole CT.
Cx and CY point is taken as shown below:

 At the end both the points are taken out to secondary terminals as shown
below:

2.) Tan-Delta Point: Epoxy block is inserted at the end of aluminium rod and from that two
leads are taken out to the secondary terminal box which is termed as tan
delta point.
Below fig shown these points in secondary terminal box.

How Auxiliary core is connected??

Auxiliary core is inserted in measuring core in order to saturate CT faster
if load current is increased to avoid damaging the connected measuring
equipment.
Below fig shown the auxiliary core and connection for the same is also
shown.

 The above core is rest at the bottom of CT as shown below. Paper and
other insulation is given over it before final installation of this core:

 Below fig show the disassembled part in which top portion of CT is

placed.

 After doing proper welding, it look like as below fig:

 The below insulator are used to cover the bushing portion of CT. welded
to the primary winding part

 These two portions are welded to give complete CT assembly as shown

below:

 Complete assembly look like as under:

 Different sections of secondary terminal box are available and as per

design these are fixed to the bottom part of CT:

Below fig is the Primary terminal of CT

 The primary terminal connector is inserted through middle portion of

secondary winding and stainless steel bellow is placed at top of CT and
after doing oil filling, final CT look like as shown below: