Prefabricated Switchgear Substation
The Prefabricated Switchgear Substation is an integrated medium-voltage power distribution system designed to provide safe, efficient, and intelligent electrical control for utility networks, industrial facilities, renewable energy projects, and commercial infrastructure. The system combines medium-voltage switchgear, transformer equipment, low-voltage distribution units, and advanced protection systems within a compact prefabricated enclosure, significantly reducing installation time and civil construction requirements. Manufactured using high-strength corrosion-resistant materials and advanced insulation technology, the switchgear substation delivers stable outdoor operation under harsh environmental conditions including high humidity, dust exposure, temperature fluctuations, and coastal environments. Its modular architecture improves operational flexibility, maintenance accessibility, and transportation efficiency while supporting scalable electrical distribution requirements. The Prefabricated Switchgear Substation supports multiple voltage classes, intelligent monitoring functions, and customized protection configurations for modern smart-grid applications. The compact design optimizes installation space while ensuring reliable medium-voltage switching, power distribution stability, and enhanced operational safety for industrial, utility, and infrastructure projects.
- Primary Voltage Ratings 3.3kV / 6kV / 11kV / 22kV / 33kV
- Type Prefabricated Substation
- BIL 250kVA – 6300kVA
- Standards IEC, ASTM, UL
- Application utility substations, renewable energy plants
- Power Rating --
- Certificate UL, CESI, IEEE
- Cooling Method ONAN / ONAF
- Opeartion --
Technical Specifications
Customization Optional
Packing and Shipping
Manufacturer Test
Routine Testing
Application
Technical Specifications
Prefabricated Switchgear Substation
Prefabricated Switchgear Substation Data Sheet
| Parameter | Specification |
| Product Type | Prefabricated Switchgear Substation |
| Rated Voltage | 3.3kV / 6kV / 11kV / 22kV / 33kV |
| Transformer Capacity Range | 250kVA – 6300kVA |
| Rated Frequency | 50Hz / 60Hz |
| Rated Current | 630A – 4000A |
| Rated Short Circuit Current | 20kA – 40kA |
| Switchgear Type | RMU / AIS / GIS / VCB |
| Transformer Type | Oil-Immersed / Dry-Type |
| Cooling Method | ONAN / ONAF |
| Insulation Level | 75kV – 170kV BIL |
| Protection Degree | IP44 / IP54 / IP65 |
| Enclosure Material | Stainless Steel / Galvanized Steel / Composite Panel |
| Busbar Material | Copper / Aluminum |
| Surface Treatment | Outdoor Powder Coating |
| Ventilation System | Natural / Forced Air Ventilation |
| Ambient Operating Temperature | -40°C to +55°C |
| Maximum Installation Altitude | ≤ 4000m |
| Humidity Resistance | ≤ 95% RH |
| Communication Protocol | Modbus / IEC 61850 / DNP3 |
| Remote Monitoring | Optional SCADA Integration |
| Cable Entry Method | Bottom / Side Entry |
| Earthing System | TN-S / TT / IT |
| Noise Level | ≤ 65dB |
| Operational Lifetime | More than 30 Years |
| Applicable Standards | IEC 62271 / IEC 60076 / ANSI / IEEE |
Customization Optional
Prefabricated Switchgear Substation
The Prefabricated Switchgear Substation can be fully customized according to project voltage levels, protection requirements, environmental conditions, and regional utility standards. Customers may select different medium-voltage switchgear configurations including ring main units, vacuum circuit breakers, gas-insulated switchgear systems, air-insulated switchgear, or load break switch assemblies depending on operational requirements and network architecture. Transformer options include sealed oil-immersed transformers, dry-type transformers, ester-oil transformers, and low-loss energy-efficient transformer designs for industrial, commercial, and renewable energy applications. The low-voltage distribution section can additionally integrate intelligent metering systems, automatic transfer switches, harmonic suppression devices, capacitor compensation units, and digital protection relays for advanced electrical management and power quality optimization.
The enclosure structure and internal layout can also be optimized for coastal environments, desert climates, mining facilities, petrochemical plants, tropical regions, and high-pollution industrial areas. Optional features include arc fault protection systems, fire suppression systems, anti-condensation heaters, thermal insulation structures, intelligent ventilation systems, remote communication modules, and maintenance lighting systems. Customers may further customize enclosure dimensions, cable routing directions, ventilation openings, paint colors, branding labels, access door configurations, and renewable energy integration interfaces to improve operational flexibility and simplify installation procedures. These customization capabilities ensure the switchgear substation can fully adapt to modern utility, industrial, and infrastructure power distribution applications.
Packing and Shipping
Prefabricated Switchgear Substation
The Prefabricated Switchgear 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 structural inspection, enclosure sealing verification, coating quality assessment, and anti-corrosion treatment to minimize the risk of transportation damage and environmental exposure. Sensitive electrical components including protection relays, intelligent communication devices, meters, monitoring systems, and switchgear accessories are additionally secured using vibration-resistant and moisture-proof packaging materials.
The transformer section, medium-voltage switchgear compartment, and low-voltage distribution chamber are internally reinforced using heavy-duty support structures and transportation locking systems to prevent movement during road, railway, or sea transportation. External surfaces are protected with industrial waterproof wrapping film, reinforced corner guards, anti-scratch covers, and impact-resistant fastening systems to preserve enclosure integrity throughout long-distance transportation. Integrated lifting lugs and forklift access channels are designed to simplify loading, unloading, and on-site installation procedures.
Depending on project dimensions, transportation routes, and customer requirements, the switchgear substation may be shipped using steel-frame export packaging, skid-mounted transportation systems, fumigation-free wooden crates, or direct container securing methods compliant with international logistics standards. Additional anti-condensation protection, anti-vibration reinforcement systems, and marine-grade corrosion protection measures are available for coastal installations, mining projects, desert regions, or remote construction sites requiring extended transportation durations.
Shipping documentation generally includes factory inspection certificates, packing lists, operation manuals, electrical schematics, wiring diagrams, quality reports, and export compliance certifications. Customers may additionally request multilingual labels, customized shipping marks, installation guidance documents, and project-specific logistics coordination support. The complete packing and shipping process is designed to maintain equipment quality, reduce transportation risks, and ensure safe delivery to the final installation location.
The transformer section, medium-voltage switchgear compartment, and low-voltage distribution chamber are internally reinforced using heavy-duty support structures and transportation locking systems to prevent movement during road, railway, or sea transportation. External surfaces are protected with industrial waterproof wrapping film, reinforced corner guards, anti-scratch covers, and impact-resistant fastening systems to preserve enclosure integrity throughout long-distance transportation. Integrated lifting lugs and forklift access channels are designed to simplify loading, unloading, and on-site installation procedures.
Depending on project dimensions, transportation routes, and customer requirements, the switchgear substation may be shipped using steel-frame export packaging, skid-mounted transportation systems, fumigation-free wooden crates, or direct container securing methods compliant with international logistics standards. Additional anti-condensation protection, anti-vibration reinforcement systems, and marine-grade corrosion protection measures are available for coastal installations, mining projects, desert regions, or remote construction sites requiring extended transportation durations.
Shipping documentation generally includes factory inspection certificates, packing lists, operation manuals, electrical schematics, wiring diagrams, quality reports, and export compliance certifications. Customers may additionally request multilingual labels, customized shipping marks, installation guidance documents, and project-specific logistics coordination support. The complete packing and shipping process is designed to maintain equipment quality, reduce transportation risks, and ensure safe delivery to the final installation location.
32
32 years of industry experience
Manufacturer Test
Prefabricated Switchgear Substation
Progress Test
The Prefabricated Switchgear Substation undergoes a comprehensive multi-stage production testing program designed to maintain strict quality control and operational safety throughout the assembly process. The testing procedure begins with enclosure structural verification, transformer tank inspection, dimensional tolerance measurement, and coating thickness analysis to ensure mechanical durability and environmental protection performance under outdoor operating conditions. Electrical verification procedures include dielectric testing, secondary circuit simulation, relay protection logic inspection, breaker synchronization testing, and communication protocol verification. Functional simulations are performed to evaluate substation response under overload, grounding fault, short-circuit, and emergency shutdown conditions. Transformer accessories such as oil level indicators, pressure relief devices, thermal alarms, and protective relays are additionally tested for operational stability and reliability.
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 Switchgear Substation is designed to guarantee manufacturing quality consistency and dependable field operation in industrial and utility 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 - Induced Voltage
Purpose of Testing
The purpose of the Induced Voltage test is to simulate the electrical stress that the equipment may encounter under actual working conditions by applying an induced voltage, thereby evaluating the tolerance and stability of the equipment's insulation system. This test helps to detect the insulation performance of the equipment under high voltage conditions and ensure its safety and reliability in operation.
Testing Equipment
Induced Voltage Tester (e.g. OMICRON, Megger, HioKI, etc.)
AC voltage source, commonly 2 kV, 5 kV, 10 kV, or customized according to test requirements.
Environmental thermometer and hygrometer, used to record the temperature and humidity of the environment for appropriate test evaluation.
AC voltage source, commonly 2 kV, 5 kV, 10 kV, or customized according to test requirements.
Environmental thermometer and hygrometer, used to record the temperature and humidity of the environment for appropriate test evaluation.
Pre-Test Preparation
Disconnect all relevant power supplies and ensure that the equipment is properly grounded and discharged.
Check the connection wires and terminals to ensure they are secure and free of contamination.
Test under suitable environmental conditions: relative humidity below 75%, no rain (recommended temperature: 20-30°C).
Check the connection wires and terminals to ensure they are secure and free of contamination.
Test under suitable environmental conditions: relative humidity below 75%, no rain (recommended temperature: 20-30°C).
Test Progress
Connect the Test Instrument:
Connect the test equipment to the appropriate terminals or bushings of the device under test, ensuring that the connections are secure and properly grounded.
Apply Test Voltage:
Select the appropriate induction voltage according to the rated voltage and standard of the equipment.
Connect the test equipment to the appropriate terminals or bushings of the device under test, ensuring that the connections are secure and properly grounded.
Apply Test Voltage:
Select the appropriate induction voltage according to the rated voltage and standard of the equipment.
Measure and Record
Start the test and record the following parameters:
Induced Voltage
Applied Current
Voltage peak, stability and waveform (waveform analysis)
Any abnormal current or voltage changes during the measurement process.
Induced Voltage
Applied Current
Voltage peak, stability and waveform (waveform analysis)
Any abnormal current or voltage changes during the measurement process.
Temperature Correction
The measured induced voltage data is corrected to the reference temperature (usually 20°C) to ensure the accuracy of the test results.
Repeat Testing (if necessary)
If necessary, test different windings (HV, MV, LV) and bushings separately and compare the results at different test points.
Evaluation Criteria (Reference)
Inductive voltage ≤ 1% (Excellent): normally and meets safety standards.
1% < Inductive voltage ≤ 3% (Good): still within acceptable range.
Inductive voltage > 3% : faulty or not meet safety requirements and requires further analysis and repair.
1% < Inductive voltage ≤ 3% (Good): still within acceptable range.
Inductive voltage > 3% : faulty or not meet safety requirements and requires further analysis and repair.
*These comprehensive tests ensure that each transformer meets performance standards and operates
reliably under various conditions.
Application
Widely applied in data centers, hospitals, railway stations, ports, petrochemical facilities, smart-grid infrastructure, temporary construction power systems, and remote industrial distribution networks.
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)
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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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