A Comprehensive Guide to Prefabricated Substations

No doubt that the power distribution network is being upgraded, and prefabricated substations are at the forefront of the innovation! Due to their ease of installation, space-efficient design, and excellent functionality, they are changing industries around the globe. So, in this blog, we will discuss prefabricated distribution substations, their functions, main components, key benefits, applications, and much more. So, just stay connected!

Prefabricated substation

1) What is a prefabricated substation?

A prefabricated electric substation is an electric unit assembled within a factory and sealed in a protective casing for delivery to the site for use. It mainly consists of transformers together with their switchgear and even control panels, all enclosed in a protective housing. It can assist in safe and efficient electricity distribution.

Unlike conventional substations, prefabricated ones do not require onsite building structures. These substations come as complete systems, which considerably cut down installation time and the man-hours needed to set them up. They are manufactured in a controlled atmosphere, thus, these prefabricated substations are accurately built to standard and safety regulations.

What is prefabricated substation

These substations have a wide application spectrum that covers power distribution and manufacturing as well as renewable energy. They are the ideal solution in areas that need electricity fast, like remote locations and temporary project sites.

Also, there is increased flexibility. Different configurations for different voltage and power levels can be created, providing unmatched freedom for project-specific requirements.

2) Functions of prefabricated substations

A pre-fabricated substation is crucial for power distribution. It guarantees a consistent and safe flow of power for various purposes. Once it leaves the factory, all it needs is to be assembled on-site, which makes it a reliable solution for many.

• Power transformation: One of the primary functions is to transform high voltage electricity to low voltage electricity so that it can be safely used. It is equipped with a transformer that alters with the voltage needs of the distribution network.

Loring Chien, an electrical engineer, talks about substations in a Quora post. His review further assured the working applications of a prefab substation. He said that through substation, high voltage can be converted into lower voltage and be distributed in many branches.

Quora review on substations

• Power distribution: A prefabricated power substation assists in the optimal distribution of electricity to different regions. It enables electricity to flow to residential houses, industrial factories, and commercial buildings without interruption.

• Safety and Protection: These components include the switchgear and circuit breakers, which protect against electrical faults like overloads and short circuits. These safety measures reduce the risk of electrical accidents among people and the equipment being used.

• Dependable Functioning Under Diverse Conditions: The enclosed structure protects electrical parts from dust, moisture, and severe weather so that these components can function in various conditions.

• Compact Design: Being compact, it can be placed in both urban and remote settings. This makes it ideal for regions experiencing a rapid growth in electricity demand.

• Simple and Fast Assembly and Installation: Because it comes preassembled, it can be erected faster than traditional substations. This ensures that industries and businesses do not have to wait for power solutions for long periods of time.

3) Main components of prefabricated substations

A set Substation is totally an Electric Power System designed for safe and economical use of electric power. It is constructed inside a Factory and is shipped for immediate use. Now, let’s discuss electrical substation parts one by one;

Prefbricated substation

i) Transformer: Central to the substation is the transformer, which alters the voltage by changing high voltage to low voltage and vice versa, depending on what is needed within the system at the particular time.

ii) Switchgear: Switchgear also controls electric flow through the use of circuit breakers and disconnect switches to manage and shield the system from short circuits and overloading power.

iii) Protection Devices: In order to maintain safety within the substation system, relays and surge protectors are used in order to avert damages from unexpected electrical jolts or defaults, help to keep constant operation, and ensure electrical substation equipment are safe.

iv) Control Panel: The control panel oversees the management and supervision of the substation. It contains sets of functions that operators can check power levels and troubleshoot any functions.

v) Enclosure: The system is fully assembled in a strong enclosure that protects it from weather, dust, and other external damage. It ensures that all components are well-guarded and can allow the substation to work efficiently in various environments.

vi) Busbars and Cables: Busbars are metal strips that serve as the main/distribution power supply lines within a substation. Cables link the substation to external power lines and facilitate the smooth flow of electric power.

vii) Cooling System: Due to the heating effect of transformers, a cooling system is adopted in order to manage heat loads. Doing so conserves efficiency while helping to prolong equipment wear and tear.

4) Differences between prefabricated and conventional substations

Even though both types serve the role of power distribution, prefabricated and conventional electric substations differ in a number of ways. Here are the main differences:

Differences in prefab and conventional substation

a) Construction Method

• Prefabricated Substation: Constructed in a factory environment and shipped as a single piece.
• Conventional Substation: Built at the location using assembled parts.

b) Installation Time

• Prefabricated Substation: This has Fast deployment with little manual work.
• Conventional Substation: Requires a longer time because of the construction work that has to be done.

c) Space Requirement

• Prefabricated Substation: Smaller in size; takes up less area.
• Conventional Substation: Bigger in size; requires more area for devices and cables.

d) Cost Efficiency

• Prefabricated Substation: This is More economical because of mass production in the factory and less requiring of manpower.
• Conventional Substation: More expensive because of the work put into it, as well as the materials used.

e) Flexibility

• Prefabricated Substation: Can be modified, although only within the limits of the design layouts.
• Conventional Substation: Less restriction for large complex advanced Power system configurations.

f) Protection and Durability

• Prefabricated Substation: Completely sealed meaning parts are shielded from dust, rain, and outside weather conditions.
• Conventional Substation: Received by the environment which calls for more cover constructions to be set.

 g) Best Use Cases

• Prefabricated Substation: Most suited in urban settings, isolated sites, or as a temporary solution.
• Conventional Substation: Ideal for large, permanent power networks.

5) Key Benefits of Saipwell Prefabricated Substations

When it comes to efficient power distribution, Saipwell’s prefabricated substations stand out because of their reliability and sophisticated design. Some of their key features include:

Saipwell Prefabricated substation

+ Compact and Space-Saving Design: With a capacity three times larger than conventional substations, these prefabricated unit substations drastically reduce the footprint. These are very useful in areas that are heavily populated and have space constraints.

+ Fully Sealed and Insulated: Their design greatly reduces the possibility of power interruptions because Saipwell’s prefabricated substations are fully sealed and insulated. A distance for additional insulation is not required, which means personal safety is also greatly assured.

+ Substation Features: Saipwell Substations can be integrated into multiple power supply systems such as ring network power supply, dual power supply, or terminal power supply systems. This allows for greater flexibility in power distribution.

+ Reducing the effect of sunlight radiation: Double-layered thermal insulation structure of these substations protects the internal components from harmful sunrays. Moreover, there are some ventilation holes in the structure to dissipate heat.

+ Safety: These substations are safer due to double fuse protection with dual sensitive fuses, which respond to temperature as well as current, reducing operational expenses.

+ Durability: The protective enclosure of the substations is robust, which enhances the durability of the structure while preventing internal components from dust, moisture, and extreme weather conditions.

+ Cost and time-effective: The modular design of these substations makes them easier to install due to minimal site work during installation. This leads to lower labor costs and shorter project timelines.

Saipwell’s substations can be integrated into a wide range of electrical infrastructure, making them compact, efficient, and safe solutions for power distribution.

6) Applications of Prefabricated Substations

Due to their speedy deployment, reliability, and compact nature, prefabricated substations can be utilized for multiple industries. Below are some key applications:

Prefabricated substation applications

• Power Distribution in Cities

For residential and commercial areas in urban regions, power distribution is made effortless by means of prefab substations.

• Industrial Facilities

Sustained power provision is necessary for warehouses, factories, and manufacturing plants to allow the use of machinery and power workstations. So, industrial facilities make efficient use of prefab substations as they are able to handle high-power loads.

• Construction Sites

Lighting, power tools, and heavy-duty equipment all require power while construction projects are ongoing. For this reason, prefab substations are ideal as they are mobile and can be used at various locations.

• Renewable Energy Projects

These substations play a key role in connecting solar farms and wind power plants with the rest of the power grid. Controlling the smooth flow of energy transmission alongside handling fluctuating power outputs makes these substations essential to renewable energy infrastructure.

• Railways and Metro Systems

The substations are prefabricated for power supply to metro networks, railway stations and tram systems, which require power for trains, signalling, and operations around the station. Their small form factor enables them to be mounted in underground or metropolitan locations.

• Mining Operations

The remote and harsh environments of the operating mines are provided with reliable and robust power from the prefabricated substations mounted close to them. Substations of this type are constructed to endure dust and moisture along with very high and low temperatures.

• Oil and Gas Industry

Oil and gas offshore platforms and onshore drilling locations need an energized power solution that is safe and explosion-proof at the same time. Prefabricated substations provide continuous, uninterrupted power to these areas of high risk while observing all security requirements.

7) Conclusion

All these industries benefit from the versatile options available with compact, efficient, and reliable solutions from prefabricated substations. At Saipwell, we design premade sub stations with great attention so that they provide stable power distribution. With flexible design, these units can easily be integrated into urban, industrial, and renewable energy settings, which makes them a perfect solution for all. Saipwell is just a click away!