High Voltage Prefabricated Transformer Substation
The High Voltage Prefabricated Transformer Substation is a fully integrated power distribution system designed for high-voltage transmission and medium-voltage distribution applications in utility networks, renewable energy facilities, industrial plants, and infrastructure projects. The system integrates high-voltage switchgear, power transformers, low-voltage distribution equipment, intelligent protection devices, and automation systems within a compact modular enclosure to provide reliable and efficient electrical power transformation. Engineered for demanding outdoor operating conditions, the substation features a reinforced corrosion-resistant enclosure, advanced insulation technology, optimized thermal management systems, and intelligent safety protection structures. The prefabricated modular design significantly reduces civil construction requirements, shortens installation time, and improves transportation efficiency while maintaining high operational reliability and electrical safety performance. The High Voltage Prefabricated Transformer Substation supports flexible voltage classes, transformer capacities, and smart-grid communication interfaces, making it suitable for modern utility distribution systems, renewable energy integration projects, mining operations, oil and gas facilities, and industrial manufacturing plants. With customizable electrical configurations and intelligent monitoring functions, the substation delivers scalable and energy-efficient power distribution performance for complex electrical infrastructure applications.
- Primary Voltage Ratings 35kV / 66kV / 110kV
- Type Prefabricated Substation
- Standards IEC, ASTM, UL
- Application remote mining sites, oil & gas exploration areas
- Power Rating 630kVA – 20000kVA
- Certificate UL, CESI, IEEE
- Cooling Method AN / ONAN / ONAF
Technical Specifications
Customization Optional
Packing and Shipping
Manufacturer Test
Routine Testing
Application
Technical Specifications
High Voltage Prefabricated Transformer Substation
High Voltage Prefabricated Transformer Substation Data Sheet
| Parameter | Specification |
| Product Type | High Voltage Prefabricated Transformer Substation |
| Rated Voltage | 35kV / 66kV / 110kV |
| Transformer Capacity Range | 630kVA – 20000kVA |
| Rated Low Voltage Output | 400V / 690V / 11kV |
| Frequency | 50Hz / 60Hz |
| Transformer Type | Oil-Immersed / Dry-Type / Ester-Filled |
| Cooling Method | ONAN / ONAF / OFAF |
| High Voltage Switchgear | GIS / AIS / Vacuum Circuit Breaker |
| Rated Current | Up to 5000A |
| Rated Short Circuit Current | 25kA – 50kA |
| Insulation Level | 170kV – 550kV BIL |
| Protection Degree | IP44 / IP54 / IP65 |
| Enclosure Material | Stainless Steel / Galvanized Steel / Composite Structure |
| Surface Treatment | Heavy-Duty Outdoor Anti-Corrosion Coating |
| Busbar Material | Copper / Aluminum Alloy |
| Ventilation System | Intelligent Natural & Forced Ventilation |
| Ambient Operating Temperature | -45°C to +60°C |
| Maximum Installation Altitude | ≤ 5000m |
| Humidity Resistance | ≤ 98% RH |
| Communication Protocol | IEC 61850 / Modbus / DNP3 |
| Smart Monitoring System | Remote SCADA Compatible |
| Earthing System | TN-S / TT / IT |
| Cable Entry Method | Underground / Side Entry |
| Noise Level | ≤ 68dB |
| Seismic Resistance | Up to 9 Degree |
| Operational Lifetime | More than 35 Years |
| Applicable Standards | IEC 62271 / IEC 60076 / IEEE / ANSI |
Customization Optional
High Voltage Prefabricated Transformer Substation
The High Voltage Prefabricated Transformer Substation can be extensively customized according to transmission voltage levels, grid protection requirements, environmental conditions, and regional utility standards. Customers may select high-efficiency oil-immersed transformers, dry-type transformers, ester-fluid transformers, or low-loss energy-saving transformer technologies depending on project operating conditions and environmental objectives. The high-voltage section can be configured with gas-insulated switchgear, air-insulated switchgear, vacuum circuit breakers, disconnectors, load break switches, and intelligent protection relays to support various utility distribution architectures and network protection schemes. The low-voltage and control sections may additionally integrate intelligent energy metering systems, harmonic filtering devices, capacitor banks, automatic transfer systems, and advanced automation equipment for smart-grid power management applications.
The enclosure and structural system can also be optimized for harsh outdoor environments including coastal regions, high-altitude installations, desert climates, mining operations, petrochemical facilities, and heavy industrial pollution areas. Optional features include intelligent ventilation systems, anti-condensation heaters, thermal insulation structures, arc fault protection systems, fire suppression systems, remote monitoring modules, and fiber optic communication interfaces. Customers may further customize enclosure dimensions, cable routing methods, maintenance access layouts, ventilation openings, paint colors, company branding, and renewable energy integration interfaces to improve operational flexibility and simplify installation procedures. These advanced customization capabilities ensure the high-voltage substation can fully adapt to complex industrial, infrastructure, and utility power distribution projects.
Packing and Shipping
High Voltage Prefabricated Transformer Substation
The High Voltage Prefabricated Transformer Substation is packaged using industrial heavy-duty export protection methods to ensure safe transportation, secure storage, and reliable international shipment under demanding logistics conditions. Prior to packaging, the complete substation undergoes comprehensive structural inspection, enclosure sealing verification, anti-corrosion coating analysis, and electrical component protection procedures to minimize transportation risks and environmental exposure. Sensitive devices including intelligent protection relays, communication modules, monitoring systems, and switchgear accessories are additionally protected using moisture-proof and vibration-resistant industrial packaging materials.
The transformer compartment, high-voltage switchgear section, and low-voltage distribution chamber are internally reinforced using heavy-duty steel support structures and transportation locking systems to prevent component movement during road, railway, or sea transportation. External surfaces are protected with industrial waterproof wrapping film, anti-scratch covers, reinforced edge guards, and impact-resistant fastening systems to preserve enclosure integrity throughout long-distance transportation operations. Integrated lifting lugs and forklift access structures simplify loading, unloading, and on-site installation procedures at ports and project locations.
Depending on project dimensions, shipping conditions, and customer logistics requirements, the high-voltage substation may be transported using skid-mounted systems, steel-frame export packaging, fumigation-free wooden crates, or direct container securing methods compliant with international transportation regulations. Additional anti-condensation protection systems, anti-vibration reinforcement measures, and marine-grade corrosion protection solutions are available for offshore projects, coastal environments, mining facilities, desert regions, or remote installation sites requiring extended transportation durations.
Shipping documentation generally includes factory inspection certificates, packing lists, electrical schematics, wiring diagrams, operation manuals, export compliance certifications, and quality inspection reports. Customers may additionally request multilingual labels, customized shipping marks, installation guidance documents, and project-specific logistics coordination services. The complete packing and shipping process is designed to maintain equipment quality, reduce transportation risks, and ensure safe delivery to the final installation destination.
The transformer compartment, high-voltage switchgear section, and low-voltage distribution chamber are internally reinforced using heavy-duty steel support structures and transportation locking systems to prevent component movement during road, railway, or sea transportation. External surfaces are protected with industrial waterproof wrapping film, anti-scratch covers, reinforced edge guards, and impact-resistant fastening systems to preserve enclosure integrity throughout long-distance transportation operations. Integrated lifting lugs and forklift access structures simplify loading, unloading, and on-site installation procedures at ports and project locations.
Depending on project dimensions, shipping conditions, and customer logistics requirements, the high-voltage substation may be transported using skid-mounted systems, steel-frame export packaging, fumigation-free wooden crates, or direct container securing methods compliant with international transportation regulations. Additional anti-condensation protection systems, anti-vibration reinforcement measures, and marine-grade corrosion protection solutions are available for offshore projects, coastal environments, mining facilities, desert regions, or remote installation sites requiring extended transportation durations.
Shipping documentation generally includes factory inspection certificates, packing lists, electrical schematics, wiring diagrams, operation manuals, export compliance certifications, and quality inspection reports. Customers may additionally request multilingual labels, customized shipping marks, installation guidance documents, and project-specific logistics coordination services. The complete packing and shipping process is designed to maintain equipment quality, reduce transportation risks, and ensure safe delivery to the final installation destination.
32
32 years of industry experience
Manufacturer Test
High Voltage Prefabricated Transformer Substation
Progress Test
The manufacturing progress testing procedure for the High Voltage Prefabricated Transformer Substation is implemented throughout all major production stages to ensure structural integrity, electrical reliability, and assembly precision. Initial inspections focus on raw material verification including enclosure steel thickness measurement, insulation material testing, high-voltage busbar conductivity analysis, and anti-corrosion coating inspection to confirm compliance with engineering specifications and international manufacturing standards. During enclosure fabrication and equipment assembly, engineers inspect welding quality, compartment alignment, grounding continuity, ventilation structures, cable routing systems, and enclosure sealing performance. The installation of high-voltage switchgear, transformers, low-voltage distribution equipment, and auxiliary systems is carefully monitored to ensure proper electrical clearances, operational safety, and maintenance accessibility. Internal wiring systems are additionally verified according to approved technical drawings to reduce installation errors and improve commissioning efficiency.
Design Tests
All transformers will be tested after finishing the production, test items as follows:
♦ Insulation Power Factor
♦ Ratio, Polarity, and Phase Relation
♦ Winding Resistance
♦ Impulse Tests
♦ On load Loss Test
♦ No Load Loss Test
♦ Transformer Turns Ratio/TTR (All Tap Voltages)
♦ Impedance Voltage & Load Loss (Rated Voltage)
♦ Polarity, 1-Ph / Phase Relation, 3-Ph (Rated Voltage)
♦ Excitation & No-Load Loss (Rated Voltage)
♦ Applied Voltage
♦ Induced Voltage
♦ Lightning Impulse
♦ Insulation Resistance (Rated Voltage)
♦ Temperature Rise
♦ Dielectric Withstand (Hipot)
Factory Acceptance Test
The transformer Factory Acceptance Test program for the High Voltage Prefabricated Transformer Substation is designed to guarantee manufacturing quality consistency and dependable field operation in utility and industrial power distribution systems. The testing procedure begins with visual inspections and dimensional verification of the transformer tank, bushings, cooling radiators, grounding terminals, enclosure coating quality, and accessory installation to confirm conformity with approved engineering drawings. The transformer insulation system is evaluated using insulation resistance testing, polarization index analysis, dielectric withstand testing, and induced overvoltage testing to verify insulation stability under high electrical stress conditions. Additional electrical performance tests include transformer ratio measurement, impedance voltage testing, polarity confirmation, load loss analysis, and winding resistance measurement to ensure accurate voltage regulation and efficient transformer operation.
Routine Test - Transformer Turns Ratio/TTR (All Tap Voltages)
Purpose of Testing
The purpose of the transformer turns ratio (TTR) test is to confirm whether the voltage ratio between each tap of the transformer meets the design requirements and ensure that the transformer winding is connected correctly. By measuring the voltage ratio of each tap, it is possible to detect whether there is a fault or deviation in the transformer winding.
Testing Equipment
TTR tester: such as Doble, Megger, Omicron and other brands of transformer winding ratio tester.
Voltage source: usually AC 10 V to 30 V , used to test different voltages for each tap.
Temperature and humidity meter: used to record environmental conditions during the test to ensure test accuracy.
Current probe: used to measure the load current of the winding and ensure the accuracy of the test results.
Voltage source: usually AC 10 V to 30 V , used to test different voltages for each tap.
Temperature and humidity meter: used to record environmental conditions during the test to ensure test accuracy.
Current probe: used to measure the load current of the winding and ensure the accuracy of the test results.
Pre-Test Preparation
Disconnect all transformer tap-changers from the power supply and ensure that all equipment is properly grounded and discharged.
Perform the test under suitable environmental conditions: relative humidity below 75% and no rain (recommended temperature: 20-30°C). Avoid high humidity or bad weather that may affect the test accuracy.
Perform the test under suitable environmental conditions: relative humidity below 75% and no rain (recommended temperature: 20-30°C). Avoid high humidity or bad weather that may affect the test accuracy.
Test Progress
Perform the test under suitable environmental conditions: relative humidity below 75% and no rain (recommended temperature: 20-30°C). Avoid high humidity or bad weather that may affect the test accuracy.
Measure and Record
Start the test and record the following parameters:
The voltage ratio between the windings
Deviation of the measured value from the rated ratio
The voltage ratio between the windings
Deviation of the measured value from the rated ratio
Temperature Correction
If necessary, perform temperature correction on the measured turns ratio data (especially when testing at higher or lower temperatures). Generally, the standard reference temperature for temperature correction is 20°C.
Repeat Testing (if necessary)
Test the transformer's windings of different voltage levels (high voltage, medium voltage, and low voltage) separately to ensure that the turns ratios of all windings are normal.
Evaluation Criteria (Reference)
Turns ratio error ≤ 0.5% (pass)
0.5% < Turns ratio error ≤ 1% (caution)
Turns ratio error > 1% (further inspection or corrective action required)
0.5% < Turns ratio error ≤ 1% (caution)
Turns ratio error > 1% (further inspection or corrective action required)
*These comprehensive tests ensure that each transformer meets performance standards and operates
reliably under various conditions.
Application
Suitable for utility transmission networks, renewable energy plants, mining operations, petrochemical facilities, industrial manufacturing zones, transportation infrastructure, and municipal electrical modernization projects.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
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What is a Transformer?A transformer is an electrical device used to change the voltage of alternating current (AC). It works on the principle of electromagnetic induction, converting high-voltage current into low-voltage current or low-voltage current into high-voltage current. Transformers are widely used in power transmission, distribution systems, and various electronic devices.
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Do you have UL listed?Yes, our transformer has UL listed. We have exported to America many pad mounted transformer,substation transformer and HV.
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