Prefabricated Substation
The Prefabricated Substation is a fully integrated, factory-built power distribution solution that combines high-voltage switchgear, transformer, low-voltage switchgear, protection systems, metering, and auxiliary equipment into a compact, modular enclosure. Designed for rapid deployment, it significantly reduces on-site civil works, installation time, and overall project costs. Built with premium materials and advanced manufacturing techniques, these substations deliver exceptional reliability, safety, and efficiency in a weatherproof, aesthetically pleasing package. Available in both skid-mounted and containerized configurations, they support a wide range of voltages and capacities while incorporating intelligent monitoring and remote control capabilities for modern smart grid applications.
- Primary Voltage Ratings 11 kV / 22 kV / 33 kV / 35 kV
- Secondary Voltage Ratings 0.4 kV / 0.69 kV / 6.6 kV / 11 kV
- Type Prefabricated Substation
- Standards IEC, ASTM, UL
- Application remote mining sites, oil & gas exploration areas
- Certificate UL, CESI, IEEE
- Cooling Method AN / ONAN / ONAF
Technical Specifications
Customization Optional
Packing and Shipping
Manufacturer Test
Routine Testing
Application
Technical Specifications
Prefabricated Substation
Prefabricated Substation Data Sheet
| Parameter | Specification |
| Rated Capacity | 500 kVA – 8000 kVA |
| Primary Voltage | 11 kV / 22 kV / 33 kV / 35 kV |
| Secondary Voltage | 0.4 kV / 0.69 kV / 6.6 kV / 11 kV |
| Short Circuit Withstand | 25 kA / 31.5 kA (3 seconds) |
| Protection Degree | IP54 (outdoor) |
| Cooling Method | AN / ONAN / ONAF |
| Ambient Temperature | -40°C to +55°C |
| Service Life | ≥ 30 years |
| Seismic Resistance | Up to Zone 4 |
| Communication Protocol | IEC 61850 / Modbus / DNP3 |
Customization Optional
Prefabricated Substation
The Prefabricated Substation offers extensive customization to meet diverse project requirements, environmental conditions, and operational needs. Customers can select voltage levels, capacity, transformer type (dry-type or oil-immersed), and switchgear configuration (GIS, AIS, or RMU). The enclosure can be designed as skid-mounted, trailer-mounted, or containerized (20ft/40ft), with options for single-room or multi-compartment layouts. Advanced features such as intelligent monitoring systems, SCADA integration, automatic power factor correction, and diesel generator synchronization are available upon request.
For special environments, we provide enhanced corrosion protection for coastal areas, reinforced structures for high seismic zones, low-noise designs for urban locations, and hybrid solutions integrated with solar or energy storage systems. Additional customization includes fire suppression systems, CCTV and access control, custom color schemes, and internal HVAC systems. These flexible options enable clients to receive a complete tailor-made substation solution that optimizes space, performance, and long-term reliability while meeting local grid codes and international standards.
Packing and Shipping
Prefabricated Substation
The Prefabricated Substation is packaged with heavy-duty protection to withstand long-distance transportation. The entire module is securely fixed on a reinforced transport base with anti-vibration mounts and multiple locking points. All external bushings, doors, and movable components are braced with custom wooden supports and protective covers. Sensitive electrical and electronic parts receive additional foam padding and anti-static wrapping. The substation is then covered with heavy-duty waterproof tarpaulin and secured with industrial-grade strapping for maximum safety during transit.
We provide reliable global shipping solutions tailored to project schedules. For international deliveries, sea freight using flat-rack, open-top containers, or Ro-Ro vessels ensures safe handling of oversized loads, typically taking 25–60 days. Air freight is available for critical spare parts. Domestic and regional transport utilizes specialized low-bed trailers with hydraulic systems and professional escort services where required.
Complete export documentation is prepared in advance, including commercial invoices, packing lists, certificates of origin, test reports, and transportation permits to streamline customs clearance. Sustainable logistics practices are followed by using recyclable materials and optimizing load configurations to minimize environmental impact. Customers receive real-time GPS tracking and dedicated logistics support throughout the journey.
Upon arrival, we offer optional professional supervision for unloading, site positioning, and initial inspection. For large projects, we support consolidated multi-unit shipments and phased delivery scheduling to reduce on-site congestion and logistics costs. This meticulous packing and shipping process ensures the prefabricated substation arrives safely and is ready for rapid installation and commissioning.
We provide reliable global shipping solutions tailored to project schedules. For international deliveries, sea freight using flat-rack, open-top containers, or Ro-Ro vessels ensures safe handling of oversized loads, typically taking 25–60 days. Air freight is available for critical spare parts. Domestic and regional transport utilizes specialized low-bed trailers with hydraulic systems and professional escort services where required.
Complete export documentation is prepared in advance, including commercial invoices, packing lists, certificates of origin, test reports, and transportation permits to streamline customs clearance. Sustainable logistics practices are followed by using recyclable materials and optimizing load configurations to minimize environmental impact. Customers receive real-time GPS tracking and dedicated logistics support throughout the journey.
Upon arrival, we offer optional professional supervision for unloading, site positioning, and initial inspection. For large projects, we support consolidated multi-unit shipments and phased delivery scheduling to reduce on-site congestion and logistics costs. This meticulous packing and shipping process ensures the prefabricated substation arrives safely and is ready for rapid installation and commissioning.
32
32 years of industry experience
Manufacturer Test
Prefabricated Substation
Progress Test
Early manufacturing progress testing for the Prefabricated Substation includes structural frame load-bearing and welding quality verification. High-voltage and low-voltage switchgear components undergo individual mechanical operation, dielectric, and insulation resistance tests. Transformer core and winding tests confirm no-load loss, impedance, and insulation integrity. Preliminary module integration checks proper alignment of busbars, cable connections, and earthing systems. Control and protection panels are calibrated for metering accuracy and relay settings. These early-stage inspections, supported by digital quality records, establish solid mechanical stability and electrical foundation. Partial discharge and power frequency withstand tests are performed on the high-voltage section. Cooling system performance and thermal distribution are evaluated under simulated load conditions. Intelligent control system simulation tests all monitoring, protection, and communication functions.
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
Advanced FAT includes full-load temperature rise simulation, short-circuit withstand verification, and automatic control logic testing under various operating scenarios. Remote communication and SCADA integration are validated for data accuracy and command response. Mechanical operation tests cover doors, earthing switches, and movable components. Noise level measurement, fire suppression system (if equipped), and overall assembly workmanship are thoroughly inspected. Complete test reports with calibration certificates and optional customer witness records are provided, certifying the substation’s readiness for deployment. High-voltage and low-voltage switchgear undergo operation, interlock, and dielectric withstand tests. Protection relays, metering devices, and automatic control systems are calibrated and functionally verified.
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
Extensively used in utility distribution networks, industrial parks, renewable energy plants, and large-scale commercial developments, providing flexible, reliable, and cost-effective power solutions for both temporary and permanent applications.
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)
Transformers Packaging (4)
Transformers Packaging (5)
Transformers Packaging (6)
Transformers Packaging (7)
Transformers Packaging (8)
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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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