The Prefabricated Substation (Compact Substation / Package Substation) integrates medium voltage switchgear, transformer, low voltage switchgear, and protection equipment into a complete power distribution unit. The technical specifications can be customized according to project requirements, grid standards, and application conditions.

General Specifications

Medium Voltage (MV) Switchgear Specifications

Transformer Specifications

Oil Immersed Transformer Option

Dry Type Transformer Option

Low Voltage (LV) Switchgear Specifications

Enclosure Specifications

Environmental Specifications

Protection & Control Options

Available options:

• Remote monitoring system
• SCADA communication interface
• Temperature monitoring
• Transformer protection relay
• Partial discharge monitoring
• Smart energy management system
• Fire detection system
• Anti-condensation heater

Typical Configuration Examples

Solar Power Plant Application

Industrial Factory Application

Factory Testing

Each Prefabricated Substation is tested before delivery:

✔ Transformer routine test
✔ MV switchgear functional test
✔ LV switchgear inspection
✔ Insulation resistance test
✔ High voltage withstand test
✔ Protection system test
✔ Wiring verification
✔ Mechanical structure inspection
✔ Complete operational test

Customization Options

Available customization:

• Transformer capacity
• MV/LV voltage level
• Frequency (50Hz/60Hz)
• Oil or dry type transformer
• Switchgear configuration
• Protection system
• Enclosure design
• Climate adaptation
• Customer logo and nameplate

Prefabricated Substation provides a complete, reliable, and customizable MV/LV power distribution solution for utilities, renewable energy projects, industrial facilities, and infrastructure developments worldwide.

The Prefabricated Substation (Compact Substation / Package Substation) can be fully customized according to different grid requirements, project conditions, installation environments, and customer specifications. Our modular design allows flexible configuration of transformers, switchgear, protection systems, and enclosure structures.

1. Transformer Configuration Customization

The transformer is the core component of the prefabricated substation and can be customized according to power requirements.

Transformer Type Options:

• Oil Immersed Transformer
  • High efficiency
  • Strong overload capability
  • Suitable for utility and industrial projects
• Dry Type Transformer
  • Fire-resistant
  • Environmentally friendly
  • Suitable for urban and indoor applications

Capacity Options:

• 100kVA
• 250kVA
• 500kVA
• 800kVA
• 1000kVA
• 1250kVA
• 1600kVA
• 2000kVA
• 2500kVA
• 3150kVA
• Customized capacity available

2. Voltage Level Customization

Different voltage configurations can be designed according to local power grid standards.

Medium Voltage Side (MV)

Available options:

• 3.3kV
• 6kV
• 10kV
• 11kV
• 13.8kV
• 15kV
• 20kV
• 22kV
• 24kV
• 33kV
• 35kV

Low Voltage Side (LV)

Available options:

• 380V
• 400V
• 415V
• 440V
• 480V
• 600V
• 690V

3. Medium Voltage Switchgear Customization

The MV section can be configured according to different protection and distribution requirements.

Optional components:

• Ring Main Unit (RMU)
• Vacuum Circuit Breaker Panel
• Load Break Switch
• Fuse Switch
• Earthing Switch
• Current Transformer (CT)
• Voltage Transformer (PT)
• Surge Arrester
• Protection Relay
• Metering Unit

4. Low Voltage Switchgear Customization

The LV distribution system can be customized based on load requirements.

Options include:

• MCCB outgoing feeders
• ACB main breaker
• Capacitor compensation cabinet
• Metering cabinet
• ATS automatic transfer switch
• Power monitoring system
• Energy management system

5. Enclosure Structure Customization

The prefabricated enclosure can be designed according to installation conditions.

Material Options:

• Galvanized steel
• Stainless steel
• Aluminum alloy

Design Options:

• Standard compact enclosure
• Containerized substation design
• Underground substation structure
• Walk-in type substation
• Non-walk-in type substation

6. Environmental Adaptation Customization

Special designs are available for harsh environments.

Desert & High Temperature Areas

Suitable for:

• Middle East
• Africa
• Mining areas

Options:

• Enhanced ventilation system
• High-temperature components
• Dust-proof design
• Sand protection structure

Coastal & High Humidity Areas

Options:

• Anti-corrosion coating
• Salt spray protection
• Stainless steel enclosure
• Moisture-resistant components

Cold Climate Areas

Options:

• Anti-condensation heater
• Thermal insulation design
• Low-temperature components

7. Protection & Monitoring Customization

Smart monitoring solutions can be integrated.

Optional systems:

• SCADA communication
• Remote monitoring
• IoT monitoring
• Transformer temperature monitoring
• Partial discharge monitoring
• Fault alarm system
• Energy management system

Communication protocols:

• Modbus
• IEC 61850
• RS485
• Ethernet

8. Renewable Energy Application Customization

Special configurations are available for renewable energy projects.

Applications:

Solar PV Projects

Options:

• PV step-up transformer
• MV switchgear
• Inverter connection cabinet
• SCADA interface

Energy Storage Systems (BESS)

Options:

• Battery interface
• PCS connection
• Fire protection system
• Monitoring system

Wind Power Projects

Options:

• High reliability transformer
• MV collection system
• Remote monitoring

9. Standard & Certification Customization

The prefabricated substation can be manufactured according to different international standards:

• IEC 62271
• IEC 60076
• IEEE C57
• ANSI
• UL
• CSA
• AS/NZS

10. Appearance & Branding Customization

For OEM customers:

Available options:

• Customer logo
• Customized nameplate
• Special paint color
• Project identification labels
• Customized drawings and documentation

11. Engineering Documentation Support

Complete technical documents can be provided:

✔ Single line diagram (SLD)
✔ Electrical drawings
✔ Layout drawings
✔ Wiring diagrams
✔ Installation manual
✔ Operation manual
✔ Factory test report
✔ Quality certificates

OEM Customization Capability

We provide complete Prefabricated Substation customization solutions, from transformer selection and switchgear configuration to enclosure design and project-specific engineering.

Flexible design + factory assembly + complete testing ensures a reliable MV/LV power distribution solution for utilities, EPC contractors, renewable energy developers, and industrial customers worldwide.

The Prefabricated Substation (Compact Substation / Package Substation) undergoes comprehensive factory testing before delivery to ensure the complete system meets international standards and project requirements.

Testing covers the transformer unit, medium voltage switchgear, low voltage switchgear, protection system, wiring connections, insulation performance, and overall operational reliability.

All tests are performed according to applicable standards, including IEC 62271, IEC 60076, IEEE C57, and ANSI requirements.

1. Transformer Routine Tests

The transformer inside the prefabricated substation is fully tested before integration and shipment.

Winding Resistance Test

The resistance of HV and LV windings is measured to verify:

• Correct winding manufacturing
• Proper electrical connections
• Conductor quality
• Balanced winding performance

Voltage Ratio Test

The transformer turns ratio is tested to confirm:

• Accurate voltage transformation
• Correct tap changer operation
• Compliance with design specifications

No-Load Loss & No-Load Current Test

This test evaluates transformer core performance.

Measured parameters:

• No-load loss
• Excitation current
• Magnetic circuit performance

Purpose:

✔ Verify core quality
✔ Confirm energy efficiency
✔ Reduce operating losses

Load Loss & Impedance Test

The transformer is tested under rated conditions to verify:

• Copper losses
• Short-circuit impedance
• Load performance
• Thermal characteristics

Insulation Resistance Test

Insulation performance is checked between:

• HV winding and ground
• LV winding and ground
• HV and LV windings

Purpose:

• Ensure insulation reliability
• Prevent electrical breakdown
• Improve operational safety

Dielectric Withstand Test

High voltage withstand testing verifies the transformer insulation system can withstand electrical stress.

2. Medium Voltage Switchgear Testing

The MV switchgear section is tested to ensure safe operation and protection performance.

Mechanical Operation Test

Checks:

• Switch operation
• Interlocking system
• Earthing switch operation
• Door locking mechanism

Circuit Breaker Test

For vacuum circuit breaker configurations:

Testing includes:

• Opening and closing operation
• Contact resistance measurement
• Trip function verification
• Protection operation test

Insulation Test

Verifies:

• Busbar insulation strength
• Cable connection insulation
• Switchgear dielectric performance

Protection Relay Test

Optional protection systems are tested for:

• Overcurrent protection
• Short circuit protection
• Earth fault protection
• Communication functions

3. Low Voltage Switchgear Testing

The LV distribution section undergoes complete inspection and functional testing.

Tests include:

✔ Breaker operation test
✔ Wiring inspection
✔ Terminal connection check
✔ Metering system verification
✔ Protection function test

4. Complete Substation Functional Test

After assembly, the complete prefabricated substation is tested as an integrated system.

Testing items include:

Electrical Connection Verification

Check:

• MV/LV cable connections
• Control wiring
• Grounding system
• Terminal markings

Insulation Coordination Test

Verify:

• Proper insulation distance
• Safe electrical clearance
• Protection against overvoltage

Control & Monitoring Test

For intelligent substations:

Testing includes:

• Remote monitoring system
• SCADA communication
• Temperature monitoring
• Alarm functions
• Data transmission

5. Mechanical Structure Inspection

The enclosure and mechanical structure are inspected before shipment.

Inspection items:

✔ Enclosure dimensions
✔ Steel structure strength
✔ Door operation
✔ Ventilation system
✔ Cable entry points
✔ Lifting hooks
✔ Surface coating quality

6. Environmental Protection Test

The prefabricated substation is inspected for outdoor operating conditions.

Verification includes:

• Waterproof performance
• Dust protection
• Corrosion protection
• Ventilation performance

Customized inspections are available for:

• Desert environments
• Coastal areas
• High-temperature regions
• Industrial pollution areas

7. Final Factory Acceptance Test (FAT)

Before shipment, a complete Factory Acceptance Test (FAT) is performed.

FAT includes:

Test Reports Provided

Customers can receive complete technical documentation:

✔ Factory Test Report
✔ Transformer Test Certificate
✔ Switchgear Test Report
✔ Electrical Drawings
✔ Single Line Diagram (SLD)
✔ Inspection Records
✔ Operation Manual

Quality Assurance

Every Prefabricated Substation is fully tested before leaving the factory to ensure:

✔ Safe and reliable operation
✔ Compliance with international standards
✔ Reduced installation risk
✔ Faster project commissioning
✔ Long-term service reliability

Strict manufacturer testing guarantees that each prefabricated substation delivers dependable power distribution performance for renewable energy, industrial, commercial, and utility projects worldwide.

The Prefabricated Substation (Compact Substation / Package Substation) undergoes comprehensive routine testing before shipment to verify the performance, safety, and reliability of the complete integrated system.

Routine tests are performed on each unit according to international standards, including IEC 60076, IEC 62271, IEEE C57, and ANSI requirements. Testing covers the transformer, MV switchgear, LV switchgear, protection system, wiring connections, and overall assembly quality.

1. Transformer Routine Tests

The transformer is tested individually before integration into the prefabricated substation.

Winding Resistance Test

Measures the DC resistance of HV and LV windings.

Purpose:

• Verify winding manufacturing quality
• Confirm electrical connection reliability
• Check resistance balance between windings
• Detect possible manufacturing defects

Voltage Ratio Test

Tests the transformation ratio between high voltage and low voltage sides.

Purpose:

• Confirm accurate voltage conversion
• Verify tap changer operation
• Ensure output voltage meets requirements

Polarity and Phase Relationship Test

Checks the internal winding connections.

Purpose:

• Verify correct phase relationship
• Ensure proper system connection
• Prevent installation errors

No-Load Loss and No-Load Current Test

The transformer operates under rated voltage without load.

Measured Parameters:

• No-load loss
• Excitation current

Purpose:

• Verify core performance
• Confirm energy efficiency
• Check magnetic circuit quality

Load Loss and Impedance Test

The transformer is tested under short-circuit conditions.

Measured Parameters:

• Load loss
• Short-circuit impedance

Purpose:

• Verify winding performance
• Confirm transformer efficiency
• Ensure thermal design compliance

Insulation Resistance Test

Measures insulation strength between:

• HV winding and ground
• LV winding and ground
• HV and LV windings

Purpose:

• Ensure insulation reliability
• Prevent electrical failure
• Improve operational safety

Dielectric Withstand Test

High-voltage testing is performed to verify insulation capability.

Purpose:

• Check insulation strength
• Detect internal insulation defects
• Ensure safe operation under voltage stress

2. Medium Voltage Switchgear Routine Tests

The MV switchgear section is tested according to IEC 62271 requirements.

Visual and Mechanical Inspection

Inspection includes:

• Cabinet structure
• Switch operation
• Door locking system
• Interlocking mechanism
• Component installation

Main Circuit Resistance Test

Measures contact resistance of:

• Circuit breakers
• Load switches
• Busbars

Purpose:

• Ensure low resistance connections
• Reduce power losses
• Improve reliability

Insulation Test

Checks insulation performance of:

• Main busbars
• Switchgear components
• Cable terminals

Operating Function Test

Verifies:

• Switch opening and closing
• Earthing switch operation
• Mechanical interlocking
• Protection mechanism

3. Low Voltage Switchgear Routine Tests

The LV distribution panel is tested to ensure safe power distribution.

Testing includes:

✔ Main breaker operation test
✔ Feeder circuit inspection
✔ Control wiring verification
✔ Terminal connection inspection
✔ Metering function test
✔ Protection device operation test

4. Complete System Routine Testing

After final assembly, the complete prefabricated substation undergoes integrated testing.

Wiring Verification Test

Checks:

• MV/LV connection accuracy
• Control cable wiring
• Grounding connections
• Terminal identification

Functional Operation Test

Verifies:

• Complete power flow
• Switching operation
• Protection coordination
• Control system response

Grounding System Test

Ensures:

• Correct grounding connection
• Safe fault current discharge
• Compliance with safety requirements

5. Enclosure Routine Inspection

The prefabricated enclosure is inspected for mechanical quality.

Inspection items:

• Overall dimensions
• Structural strength
• Door sealing performance
• Ventilation system
• Cable entry protection
• Surface coating quality

6. Routine Test Summary

Factory Test Documentation

After routine testing, the following documents can be provided:

• Factory Routine Test Report
• Transformer Test Certificate
• MV Switchgear Test Report
• LV Panel Inspection Report
• Electrical Drawings
• Single Line Diagram (SLD)
• Quality Inspection Records

Quality Guarantee

Every Prefabricated Substation is fully tested before delivery to ensure:

✔ Reliable electrical performance
✔ Safe operation under rated conditions
✔ Compliance with international standards
✔ Reduced commissioning time at site
✔ Long-term service reliability

Professional routine testing ensures each prefabricated substation is ready for reliable operation in utility networks, renewable energy projects, industrial facilities, and commercial power distribution systems.

1. What is a Prefabricated Substation?

A Prefabricated Substation (Compact Substation / Package Substation) is an integrated power distribution unit that combines medium voltage switchgear, transformer, low voltage switchgear, protection devices, and control systems into a factory-assembled enclosure.

It is designed to provide a complete MV/LV power distribution solution with faster installation, reduced construction requirements, and reliable operation.

2. What are the main components of a prefabricated substation?

A standard prefabricated substation typically consists of:

• Medium Voltage (MV) Switchgear
  • Ring Main Unit (RMU)
  • Vacuum Circuit Breaker
  • Load Break Switch
  • Protection devices
• Transformer Section
  • Oil immersed transformer
  • Dry type transformer
• Low Voltage (LV) Switchgear
  • Distribution panels
  • Circuit breakers
  • Metering devices
• Control & Protection System
  • Relay protection
  • Monitoring system
  • Communication interface

3. What is the difference between a prefabricated substation and a traditional substation?

Prefabricated substations are ideal for projects requiring fast deployment and reliable operation.

4. What transformer capacities are available?

The transformer capacity can be customized according to project requirements.

Common capacities include:

• 100kVA
• 250kVA
• 500kVA
• 800kVA
• 1000kVA
• 1600kVA
• 2000kVA
• 2500kVA
• 3150kVA
• 5000kVA

Higher capacities are available for special projects.

5. What voltage levels can be customized?

Prefabricated substations support different voltage systems.

Medium Voltage (MV):

• 6kV
• 10kV
• 11kV
• 13.8kV
• 20kV
• 22kV
• 24kV
• 33kV
• 35kV

Low Voltage (LV):

• 380V
• 400V
• 415V
• 480V
• 690V

Customized voltage solutions are available.

6. Can the prefabricated substation use different transformer types?

Yes.

Available transformer options:

Oil Immersed Transformer

• High efficiency
• Strong overload capability
• Suitable for utility and industrial applications

Dry Type Transformer

• Fire-resistant
• Environmentally friendly
• Suitable for urban and indoor applications

7. Is the prefabricated substation suitable for outdoor installation?

Yes. It is designed for outdoor operation with:

• Weather-resistant enclosure
• Anti-corrosion coating
• Dust and moisture protection
• Strong mechanical structure

Special designs are available for:

• Desert environments
• Coastal areas
• High-temperature regions
• High humidity environments

8. What standards does the prefabricated substation comply with?

The product can be manufactured according to international standards:

• IEC 60076 (Power Transformer)
• IEC 62271 (High Voltage Switchgear)
• IEEE C57 Series
• ANSI Standards

Other regional standards can be customized.

9. What tests are performed before shipment?

Each prefabricated substation undergoes complete factory testing.

Testing includes:

✔ Transformer routine tests
✔ Winding resistance test
✔ Voltage ratio test
✔ No-load loss test
✔ Load loss test
✔ Insulation resistance test
✔ Dielectric withstand test
✔ MV switchgear operation test
✔ LV system inspection
✔ Protection function test
✔ Complete system functional test

Factory test reports are provided.

10. Can the prefabricated substation be customized?

Yes. OEM customization is available.

Customization options include:

• Transformer capacity
• MV/LV voltage level
• Frequency (50Hz/60Hz)
• Transformer type
• Switchgear configuration
• Protection system
• Enclosure size
• Cooling system
• Monitoring system
• Customer logo and nameplate

11. What applications are suitable for prefabricated substations?

Common applications include:

Renewable Energy

• Solar farms
• Wind power plants
• Battery energy storage systems

Industrial

• Factories
• Mining projects
• Oil & gas facilities

Commercial

• Shopping malls
• Hotels
• Data centers

Utility

• Distribution networks
• Rural electrification
• Infrastructure projects

12. How long does installation take?

Compared with traditional substations, prefabricated substations require significantly less installation time.

Typical installation steps:

1. Prepare concrete foundation
2. Transport unit to site
3. Position and connect cables
4. Complete commissioning

The factory-integrated design greatly reduces field installation work.

13. What protection functions are available?

Optional protection systems include:

• Overcurrent protection
• Short circuit protection
• Earth fault protection
• Transformer temperature monitoring
• Surge protection
• Remote monitoring
• SCADA communication

14. How is the prefabricated substation transported?

Transportation options include:

• Sea freight
• Land transportation
• Railway transportation

Packing methods:

• Steel frame fixing
• Waterproof protection
• Export standard packaging
• Container transportation

15. What documents are provided with the product?

Complete technical documents include:

• Product datasheet
• Single Line Diagram (SLD)
• Electrical drawings
• Installation manual
• Operation manual
• Factory Test Report
• Quality Certificate
• Packing List

16. Why choose a prefabricated substation?

Main advantages:

✔ Integrated MV/LV power solution
✔ Factory assembled and tested
✔ Faster installation
✔ Lower project construction cost
✔ Compact footprint
✔ Flexible customization
✔ Reliable long-term operation

Prefabricated Substation is an efficient and reliable choice for modern power distribution projects, providing complete electrical solutions for utilities, EPC contractors, renewable energy developers, and industrial customers worldwide.