Prefabricated Box Type Transformer Substation
The Prefabricated Box Type Transformer Substation is a fully integrated power distribution system combining medium-voltage switchgear, distribution transformer, low-voltage distribution equipment, and intelligent control systems within a compact outdoor enclosure. Engineered for modern electrical infrastructure, the substation delivers efficient, safe, and stable power transformation and distribution for industrial facilities, renewable energy projects, urban developments, and utility networks. Its modular structural design significantly reduces installation time, civil construction requirements, and overall project costs while enhancing operational reliability and maintenance efficiency. The enclosure is manufactured using corrosion-resistant materials and advanced environmental protection technologies to ensure dependable performance under harsh outdoor conditions including high humidity, dust, salt spray, and temperature fluctuations. The substation supports multiple transformer capacities, flexible voltage ratings, intelligent monitoring functions, and customizable switchgear configurations to meet different regional standards and project specifications. With compact footprint advantages and scalable integration capability, the Prefabricated Box Type Transformer Substation is an ideal solution for modern smart grid systems and distributed energy applications.
- Primary Voltage Ratings 6kV / 10kV / 13.8kV / 35kV
- Type Prefabricated Substation
- Standards IEC, ASTM, UL
- Application data centers, oil and gas facilities, ports, hospitals
- Certificate UL, CESI, IEEE
- Cooling Method ONAN / Dry Type Air Cooling
- Opeartion --
Technical Specifications
Customization Optional
Packing and Shipping
Manufacturer Test
Routine Testing
Application
Technical Specifications
Prefabricated Box Type Transformer Substation
Prefabricated Substation Data Sheet
| Parameter | Specification |
| Rated System Voltage | 6kV / 10kV / 13.8kV / 35kV |
| Transformer Capacity Range | 100kVA – 6300kVA |
| Rated Frequency | 50Hz / 60Hz |
| Rated Current | 400A – 4000A |
| Protection Degree | IP34 / IP44 / IP55 |
| Cooling Type | ONAN / Dry Type Air Cooling |
| Short Circuit Withstand Time | 1s / 3s |
| Rated Short Circuit Current | 16kA – 40kA |
| Lightning Impulse Withstand Voltage | 75kV / 95kV / 170kV |
| Transformer Vector Group | Dyn11 / Yyn0 / Yd11 |
| Temperature Rise Limit | 60K / 65K |
| Noise Level | ≤ 58dB |
| Enclosure Material | Stainless Steel / Galvanized Steel |
| Surface Treatment | Powder Coating / Anti-Corrosion Painting |
| Ventilation Mode | Natural / Forced Ventilation |
| Operating Temperature | -45°C to +50°C |
| Installation Environment | Indoor / Outdoor |
| Relative Humidity | ≤ 95% |
| Communication Interface | RS485 / Ethernet |
| Intelligent Monitoring | Optional Remote SCADA |
| Cable Entry Direction | Bottom / Side |
| Fire Resistance Level | Customized Optional |
| Busbar Material | Copper / Aluminum Alloy |
| Internal Arc Protection | Optional |
| Seismic Resistance | Up to 8 Degree |
| Service Life | ≥ 30 Years |
Customization Optional
Prefabricated Box Type Transformer Substation
The Prefabricated Box Type Transformer Substation can be tailored according to project voltage levels, installation environments, power consumption characteristics, and regional electrical standards. Customers may select oil-immersed transformers, cast resin dry-type transformers, or energy-saving amorphous alloy transformers depending on efficiency targets and installation conditions. Medium-voltage sections can be configured with ring main units, vacuum circuit breakers, gas-insulated switchgear, or load break switches to support different grid architectures and protection strategies. The low-voltage compartment may include intelligent metering devices, capacitor compensation systems, harmonic filtering units, automatic transfer switches, and advanced protection relays for smart power management applications.
The enclosure structure can be customized using stainless steel, galvanized steel, composite materials, or concrete-type housing for coastal, mining, desert, or high-humidity environments. Additional options include thermal insulation systems, anti-condensation heaters, intelligent temperature monitoring, remote communication interfaces, internal lighting systems, arc fault protection, and fire suppression systems. Customers can also customize dimensions, cable routing methods, access door layouts, corporate branding, paint colors, ventilation structures, and integrated renewable energy interfaces to optimize installation flexibility and long-term operational performance.
Packing and Shipping
Prefabricated Box Type Transformer Substation
The Prefabricated Box Type Transformer Substation is packaged using reinforced industrial-grade protection methods to ensure maximum safety during storage, transportation, and international shipment. Prior to packaging, each substation undergoes detailed cleaning, structural inspection, and anti-corrosion treatment to prevent mechanical damage and environmental exposure during transit. Sensitive electrical components including protection relays, meters, communication modules, and monitoring devices are secured using vibration-resistant and moisture-proof protective materials.
The transformer chamber, medium-voltage compartment, and low-voltage distribution section are internally reinforced to reduce movement and vibration during road transportation or container shipment. External surfaces are protected using waterproof wrapping materials, anti-scratch protective films, and heavy-duty corner reinforcements. Lifting lugs, forklift channels, and transportation fixing points are integrated into the base structure to facilitate efficient loading and unloading operations at ports and construction sites.
Depending on project size and shipping conditions, the substations may be packed using steel-frame packaging, export wooden crates, skid-mounted structures, or direct container fastening methods compliant with international logistics standards. Additional packaging protection can be provided for projects located in coastal regions, tropical climates, desert environments, or remote installation areas requiring extended transportation durations. Anti-vibration reinforcement and anti-condensation packaging solutions are also available for oversized or high-capacity equipment.
Shipping documentation generally includes factory inspection certificates, electrical schematics, operation manuals, packing lists, product labels, warranty documents, and export compliance certifications. Customers may request customized shipping marks, multilingual operation instructions, installation guidance documents, and project-specific logistics coordination services. The complete packing and shipping procedure is designed to maintain product integrity and ensure reliable delivery under demanding international transportation conditions.
The transformer chamber, medium-voltage compartment, and low-voltage distribution section are internally reinforced to reduce movement and vibration during road transportation or container shipment. External surfaces are protected using waterproof wrapping materials, anti-scratch protective films, and heavy-duty corner reinforcements. Lifting lugs, forklift channels, and transportation fixing points are integrated into the base structure to facilitate efficient loading and unloading operations at ports and construction sites.
Depending on project size and shipping conditions, the substations may be packed using steel-frame packaging, export wooden crates, skid-mounted structures, or direct container fastening methods compliant with international logistics standards. Additional packaging protection can be provided for projects located in coastal regions, tropical climates, desert environments, or remote installation areas requiring extended transportation durations. Anti-vibration reinforcement and anti-condensation packaging solutions are also available for oversized or high-capacity equipment.
Shipping documentation generally includes factory inspection certificates, electrical schematics, operation manuals, packing lists, product labels, warranty documents, and export compliance certifications. Customers may request customized shipping marks, multilingual operation instructions, installation guidance documents, and project-specific logistics coordination services. The complete packing and shipping procedure is designed to maintain product integrity and ensure reliable delivery under demanding international transportation conditions.
32
32 years of industry experience
Manufacturer Test
Prefabricated Box Type Transformer Substation
Progress Test
The Prefabricated Box Type Transformer Substation undergoes a multi-stage production testing program designed to maintain high manufacturing consistency and long-term operational reliability. The testing process begins with structural inspections including enclosure dimensional verification, anti-corrosion coating thickness checks, steel structural integrity analysis, and transformer tank fabrication evaluation. Electrical verification procedures include dielectric testing, secondary control circuit simulation, relay protection configuration checks, breaker synchronization testing, and communication protocol verification. Functional simulations are carried out to evaluate system response during overload, grounding faults, short circuit conditions, and emergency shutdown operations. Transformer protection accessories including pressure relief devices, oil indicators, and thermal alarms are also inspected for reliable operation. Engineers confirm all assembly procedures, electrical drawings, testing reports, and component certifications are accurate and traceable. This comprehensive progress testing system significantly improves equipment safety, manufacturing quality, and long-term service performance.
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 Prefabricated Box Type Transformer Substation is designed to ensure consistent manufacturing quality and reliable field performance in industrial and utility power distribution systems. The testing process begins with visual and dimensional inspections of the transformer tank, bushings, grounding terminals, cooling radiators, and external protective coatings to verify structural compliance with approved engineering drawings. The transformer insulation system is then evaluated using insulation resistance testing, polarization index measurement, dielectric withstand testing, and induced overvoltage testing to confirm insulation stability under high electrical stress conditions. Winding resistance measurements, transformer ratio testing, polarity checks, and impedance voltage testing are additionally conducted to verify electrical performance and voltage regulation accuracy. The Factory Acceptance Test process ensures the transformer substation meets customer performance expectations and international quality standards before shipment and site installation.
Routine Test - Insulation Power Factor
Purpose of Testing
The purpose of testing the insulation power factor is to evaluate the dielectric loss of the insulation system in electrical equipment, and to determine whether issues such as moisture ingress, aging, or contamination are present. A high power factor value usually indicates insulation deterioration.
Testing Equipment
Insulation power factor tester (e.g., brands like Doble, Megger) Voltage source (typically 1 kV, 2.5 kV, or 10 kV or as the customer request standard) Temperature and humidity meter (for recording environmental conditions)
Pre-Test Preparation
De-energize tap changer the equipment and ensure it has been properly grounded and discharged. Make sure the bushings and terminal connections to prevent surface contamination from affecting test results. Perform the test under suitable environmental conditions: relative humidity below 75% and no rain (recommended temperature: 20–30°C).
Test Progress
Connect the Test Instrument: Connect the test equipment to the bushings or terminals of the equipment under test and ensure proper grounding. Apply Test Voltage: Select the appropriate test voltage according to the rated voltage of the equipment (e.g., 25 kV for high-voltage windings or as the request of the pad mounted transformer).
Measure and Record
Start the test and record the following parameters: Capacitive current (IC) Power current (IW) Power factor (PF) or dissipation factor (Tanδ) Capacitance Ambient temperature and humidity at the time of testing
Temperature Correction
Correct the measured power factor to the reference temperature (typically 20°C) for accurate evaluation.
Repeat Testing (if necessary)
Measure different windings (high-voltage, medium-voltage, low-voltage) and bushings separately for comparative analysis.
Evaluation Criteria (Reference)
Insulation power factor ≤ 0.5% (Excellent) 0.5% < Power factor ≤ 1% (Good) 1% (Further inspection or corrective action required)
*These comprehensive tests ensure that each transformer meets performance standards and operates
reliably under various conditions.
Application
Widely applied in data centers, oil and gas facilities, ports, hospitals, transportation hubs, utility substations, smart grid systems, temporary construction power supply projects, manufacturing plants, and renewable energy integration systems.
Technical Advantages
● 30+ years of manufacturing experience
● ISO and UL certified production
● Customized cable and transformer solutions
Product Packaging
Transformers Packaging (1)
Transformers Packaging (2)
Transformers Packaging (3)
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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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What are the main uses of a transformer?The main use of a transformer is voltage conversion. Transformers are used in power transmission systems to help transfer electricity from power plants to consumers. In addition, transformers are also used in electronic devices such as chargers, televisions, power adapters, etc., to adjust the voltage to meet the requirements of different 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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