Compact Substation
Compact Substations are suitable for residential areas, urban public substations, busy streets, construction power sources, etc. Users can choose Compact Substations according to different usage conditions and load levels. We can provide quotation and technical support for the compact substation.
Compact Substation, abbreviation CSS, also known as Box type substation or prefabricated substation,or prefabricated substation. It is a factory prefabricated indoor and outdoor compact distribution equipment consisting of high-voltage switchgear, distribution transformers, and low-voltage distribution devices arranged according to a certain wiring scheme. It organically combines the functions of transformer voltage reduction and low-voltage distribution, and is installed in a moisture-proof, rust proof, dust-proof, rodent proof, fireproof, anti-theft, heat-insulating, fully enclosed, and movable steel structure box. It is particularly suitable for urban network construction and renovation, and is a new type of substation that has emerged after civil engineering substations. Compact Substations are suitable for mines, factories, oil and gas fields, and wind power stations. They replace the original civil power distribution rooms and substations and become a new type of complete set of transformer and distribution equipment.
Compact Substations are suitable for residential areas, urban public substations, busy streets, construction power sources, etc. Users can choose Compact Substations according to different usage conditions and load levels. Since its inception, Compact Substations have developed rapidly, accounting for 70% of distribution transformers in developed European countries and 90% in the United States. The rapid development of modernization construction in Chinese cities and the continuous updating and renovation of urban distribution networks have accounted for over 80% according to statistics.
Compact Substation (referred to as Compact Substation) is a compact complete set of distribution equipment that combines high-voltage switchgear distribution transformers, low-voltage switchgear, energy metering equipment, and reactive power compensation devices in one or several boxes according to a certain wiring scheme.
The Compact Substation is mainly composed of multiple circuit high-voltage switch systems, armored busbars, substation comprehensive automation systems, communication, remote control, metering, capacitor compensation, and DC power supply electrical units. It is installed in a moisture-proof, rust proof, dust-proof, rodent proof, fireproof, anti-theft, heat-insulating, fully enclosed, and movable steel structure box, with electromechanical integration and fully enclosed operation. It mainly has the following characteristics:
Advanced technology, safe and reliable.
The Compact Substation produced by Shanghai Zhiyou Company adopts leading domestic technology and processes for the box body. The outer shell is generally made of aluminum zinc coated steel plate, and the frame is made of standard container materials and manufacturing processes, which have good anti-corrosion performance and ensure that it will not rust for 20 years. The inner sealing plate is made of aluminum alloy buckle plate, and the interlayer is made of fireproof insulation material. Air conditioning and dehumidification devices are installed inside the box, and the equipment operation is not affected by natural climate environment and external pollution, ensuring normal operation in harsh environments of -40 ℃ to+40 ℃. The primary equipment inside the box adopts fully enclosed high-voltage switchgear (such as XGN type), dry-type transformers, dry-type transformers, vacuum circuit breakers, spring operated mechanisms, rotary isolating switches and other domestically advanced technology equipment. The product has no exposed live parts and is a fully enclosed and insulated structure, which can completely achieve zero electric shock accidents. The whole station can achieve oil-free operation with high safety. The secondary equipment adopts a microcomputer comprehensive automation system, which can achieve unmanned operation.
High degree of automation
The whole station is designed with intelligence, and the protection system adopts a substation microcomputer integrated automation device, which is installed in a decentralized manner and can achieve "four remote", namely telemetry, remote signaling, remote control, and remote adjustment. Each unit has independent operation functions, complete relay protection functions, and can remotely set operating parameters, control humidity and temperature inside the box, and remotely sound smoke alarms, meeting the requirements of unmanned operation; Remote image monitoring can also be achieved as needed.
Factory prefabrication
When designing, as long as the designers make a main wiring diagram and design the equipment outside the box according to the actual requirements of the substation, they can choose the specifications and models of the box transformer provided by the manufacturer. All equipment can be installed and debugged in the factory in one go, truly realizing the industrialization of substation construction and shortening the design and manufacturing cycle; On site installation only requires box positioning, cable connection between boxes, outgoing cable connection, protection setting verification, transmission testing, and other debugging work. The entire substation only takes about 5-8 days from installation to operation, greatly shortening the construction period.
Flexible combination method
Compact Substations, due to their compact structure, each box forms an independent system, which makes the combination methods flexible and versatile. On the one hand, we can use all Compact Substations, which means that 35kV and 10kV equipment can be installed inside boxes to form a full Compact Substation; It is also possible to install only 10kV switch boxes, 35kV equipment outdoors, and 10kV equipment and control and protection system boxes. This combination method is particularly suitable for the renovation of old stations in rural power grids, where the original 35kV equipment is not moved and only one 10kV switch box is installed to meet the requirement of unmanned operation. In short, there is no fixed combination mode for Compact Substations, and the user can freely combine some modes according to the actual situation to meet the needs of safe operation.
Investment savings yield quick results
Compact Substations reduce investment by 40% to 50% compared to conventional substations of the same scale. Calculated based on a 35kV single main transformer and a 4000kV substation, Compact Substations save more than 1 million yuan in civil engineering (including land acquisition costs) compared to conventional substations; If analyzed from the perspective of completion and production, it is conservatively estimated that if each station is put into operation 4 months in advance, if the average load is 2000kw and the electricity sales profit is 0.10 yuan/kw. h, the net profit can be increased by more than 600000 yuan in three months; From an operational perspective, in a Compact Substation, the use of advanced equipment, especially oil-free equipment, fundamentally solves the problem of equipment leakage in conventional substations. The substation can implement condition based maintenance, reduce maintenance workload, and save about 100000 yuan in annual operation and maintenance costs. The overall economic benefits are considerable.
Small footprint
Taking a 4000kva single main transformer substation as an example, constructing a conventional 35kv substation would require an area of approximately 3000m and extensive civil engineering work; Choosing a Compact Substation, the minimum footprint of the main transformer box and switch box can be up to 100m, and the total footprint of other equipment including 35kV can reach up to 300m, which is only 1/10 of the footprint of a substation of the same scale. It can fully utilize the corners of the street, square, and factory to install and put into operation, in line with the national policy of land conservation.
Beautiful appearance
The outer shell of the box is made of aluminum zinc steel plate and container manufacturing technology, with a beautiful appearance design. By selecting the color of the outer shell of the Compact Substation, it is easy to coordinate with the surrounding environment while ensuring power supply reliability. It is particularly suitable for urban construction, such as residential areas, stations, ports, airports, parks, green belts and other densely populated areas. It can be used as a fixed substation or a mobile substation, with the function of embellishing and beautifying the environment.
Execution standards:
GB/T 17467-2020 High/Low Voltage Prefabricated Substations
GB/T 6451-2020 Technical Parameters and Requirements for Oil immersed Power Transformers
GB/T 10228-2015 Technical Parameters and Requirements for Dry type Power Transformers
GB/T 1094.1-2013 Power Transformers Part 1: General Principles
GB 4208-2017 Degrees of Protection Provided by Enclosures (IP Code)
GB/T 19939-2005
GB/T 50063-2017 Technical Requirements for Grid Connection of Photovoltaic Systems
GB/T 4208-2017 Electrical Design Specification for Power Equipment
Note: The above Chinese national standards are higher than or equivalent to the corresponding IEC standards.
Operating procedures:
1、 Operation of Transformer
a、 The external primary voltage of the transformer can be higher than the rated voltage, generally not exceeding 5% of the rated voltage of the operating tap.
b、 When the transformer is in operation, the gas relay protection should be activated with a signal and connected for tripping.
c、 Before putting the transformer into operation, the duty officer should carefully inspect and confirm that the transformer is in good condition and has the conditions for live operation (whether the grounding wire is removed, check the position of the tap changer, and measure the insulation resistance).
d、 After major repairs, accident repairs, and oil changes, it is advisable to stand still for 48 hours until the bubbles in the oil are eliminated before putting it into operation.
e、 When the transformer pressure relief device generates extreme pressure during operation, the release device will automatically release. After the oil tank pressure returns to normal, the valve cover of the release device should automatically close. If the release device is activated, the valve cover will lift the indicator rod, and manual reset is required. At this time, the micro switch will be activated, and the wrench must be moved to reset the mechanical device, in preparation for the next signal to be sent. The release contact should act on the signal.
2、 Operation of circuit breaker
3、 Operation of isolation switch
Application prospects:
Compact Substations are the main direction of current rural power grid renovation and future substation construction, but there are still some shortcomings in certain aspects, specifically manifested in:
(1) Fire prevention issue: Compact Substations are generally operated in a fully sealed unmanned manner. Although all equipment operates without oil and is equipped with a remote smoke alarm system, there are still fire hazards inside the box, such as cables, compensating capacitors, etc. Once a fire breaks out, it is not conducive to ventilation or firefighting. Therefore, automatic fire extinguishing systems should be considered, but this will increase the manufacturing cost of Compact Substations.
(2) Expansion issue: Due to limitations in size and manufacturing costs, the expansion margin of the outgoing line spacing in Compact Substations is small. It is difficult to add 1-2 additional outgoing line spacing in the original box, and it is necessary to add more boxes to achieve this.
(3) Maintenance issue: Due to the consideration of manufacturing costs and limited box volume during the manufacturing of Compact Substations, the maintenance space of Compact Substations is relatively small, which is not conducive to equipment maintenance, especially emergency repairs. This is an inherent deficiency of Compact Substations that cannot be overcome.
In short, looking ahead to the future, Compact Substations will be widely used in cities, rural areas, industrial and mining enterprises, and public building facilities in China. With their advantages of high quality and low price, they will be increasingly used by more and more people, taking the operation level of China's power grid to a new level.
Functional Integration and Target User Scope
The Compact Transformer Substation serves as a prefabricated, modular solution designed primarily for electrical utilities, industrial sites, and infrastructure developers requiring reliable power distribution systems. It consolidates critical electrical substation equipment including transformers, high-voltage switch cabinets, and low-voltage switchgear into a single enclosed unit. This equipment integration supports seamless electrical and electronic engineering workflows, targeting operations demanding compact, robust, and transportable solutions to optimize installation time and reduce site footprint. The product suits both urban and rural deployments where space and system continuity are essential.
Technical Composition and Operational Specifications
Incorporating advanced components, the Compact Substation features fully enclosed high-voltage switchgear and dry-type transformers combined with vacuum circuit breakers for enhanced protection. It supports operational temperatures between -40℃ and +40℃, ensuring reliability across diverse environments. Key specifications include a steel enclosure with fireproof, moisture-resistant insulation and automation systems enabling remote telemetry, control, and alarm functions. The solution enables automated monitoring and switching without on-site personnel, thus increasing system efficiency. Factory prefabrication and testing compress installation time to under two weeks, delivering reduced commissioning costs.
Industrial Applications and Operational Benefits
This integrated substation solution finds deployment in high-density urban power grids, industrial plants, mining operations, and renewable energy setups like wind farms. The compact design facilitates installation in constrained sites, supporting network modernization and emergency power supply roles. By combining switch gear and transformers within one enclosure, it reduces civil works and enhances fault isolation capabilities. The equipment is engineered to comply with major Chinese and international standards, thereby supporting global electrical and electronic engineering requirements for power quality, safety, and operational monitoring.
Product Advantages
Structural and System Design Strength
The system architecture of the Compact Transformer Substation employs a modular design with an aluminum zinc-coated steel plate enclosure, offering corrosion resistance and durability. Integration of low-voltage switchgear and high-voltage motor starting devices within a compact footprint optimizes space and improves maintainability. Enclosure design includes fireproof insulation with aluminum alloy buckles for added mechanical strength. This prefabricated structure enables rapid deployment and system scalability via flexible box combinations, suiting variable load demands while maintaining compliance with strict electrical standards.
Performance, User Efficiency, and Operational Value
The Compact Substation offers superior operational reliability through oil-free transformers and vacuum breakers, minimizing maintenance and risk of leakage. Its embedded automation enables "four remote" functions: telemetry, signaling, control, and adjustment, which optimize monitoring and ensure prompt fault response. Enhanced safety arises from a fully enclosed system protecting against environmental challenges such as dust and moisture. The compact configuration reduces civil engineering demands and associated costs while maintaining system integrity, thereby providing measurable ROI and improved end-user confidence.
Use Scenarios
Urban Power Distribution Upgrade
In metropolitan environments where land availability is limited, the Compact Transformer Substation acts as an ideal solution for upgrading aging infrastructure. It integrates seamlessly into urban grids, providing a consolidated unit that mitigates spatial constraints while delivering stable voltage regulation through embedded voltage regulators. Its robust design withstands pollution and environmental stressors, supporting uninterrupted electricity distribution to residential and commercial buildings. Installation speed and remote monitoring capabilities facilitate quick adaptation to changing urban power demands and maintenance schedules.
Industrial and Remote Site Power Management
For sectors such as mining, oil and gas, and renewable energy, this substation supports dependable distribution in challenging terrains. It houses high-voltage grounding resistor cabinets and incorporates adjustable voltage regulators, enhancing system protection and voltage stability amid fluctuating loads. The compact unit’s capacity for unmanned operation leverages remote control to maintain safety and operational continuity under harsh conditions. Furthermore, the modular and prefabricated nature reduces the logistical footprint of on-site assembly, promoting efficient integration within complex industrial power networks.
FAQ
What materials are used to construct the Compact Substation’s enclosure?
The Compact Substation outer shell uses aluminum zinc coated steel plates with fireproof insulation inside, ensuring moisture-proof, rust-proof, and fire-resistant protection. This sturdy design supports reliable operation across harsh environments, meeting high standards for electrical substation equipment durability.
Can the Compact Substation be tailored to specific voltage and load needs?
Yes, the modular structure allows flexible combinations of high-voltage switchgear, transformers, and low-voltage devices customized for various load and voltage requirements. This adaptability ensures optimal configuration for your compact transformer substation installation.
How quickly can a Compact Substation be installed on-site?
Thanks to factory prefabrication and testing, on-site installation of the Compact Substation typically completes within 5 to 8 days, significantly reducing project time and costs. The modular design facilitates rapid positioning, connection, and commissioning in both urban and remote locations.
What maintenance practices are recommended for reliable operation?
The oil-free and fully enclosed design of the Compact Substation minimizes routine maintenance. Condition-based maintenance is supported by integrated microcomputer automation and remote monitoring systems, allowing real-time diagnostics and reducing the need for frequent manual inspections.
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