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Compact Substation Manufacturer & Custom OEM Supplier

Anhui Yanyue Intelligent Technology manufactures factory-assembled, enclosure-protected compact substations (11kV to 33kV, up to 2500 kVA). Designed to IEC 62271-202 standards, each unit integrates high-voltage switchgear, a power transformer, and low-voltage distribution switchboards into a weather-resistant, compartmentalized steel or GRC structure.

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Construction & Environmental Adaptability

Applicable Standards

Fully compliant with IEC 62271-202 for high-voltage/low-voltage prefabricated substations and IEC 60076 for distribution transformers.

Ingress Protection

IP54 for HV/LV electrical compartments; IP33/IP43 for transformer cooling louver sections.

Corrosion Resistance

Enclosure structural frames are fabricated from 2.0mm to 3.0mm hot-dip galvanized steel sheet or stainless steel, finished with electrostatically applied polyester powder coating (thickness >= 100 um) to meet ISO 12944 C4/C5 atmospheric corrosion categories.

Thermal Management

Double-layer insulated roof structures reduce solar radiation heat transfer, complemented by thermostatically controlled forced-air ventilation systems.

Product Selection

Technical Parameter	Standard Specification Range
Rated High Voltage (HV)	11 kV / 22 kV / 33 kV (up to 38.5 kV)
Rated Low Voltage (LV)	400 V / 415 V / 690 V
Rated Capacity Range	100 kVA to 2,500 kVA
Rated Frequency	50 Hz / 60 Hz
Transformer Impedance (Uk)	4.0% - 6.0% (standard per IEC 60076)
Transformer Vector Group	Dyn11 / Yyn0 (or per utility specification)
HV Switchgear Type	SF6 Gas Insulated Switchgear (GIS) / Air Insulated (AIS) / Solid Insulated RMU
Transformer Type	Hermetically Sealed Oil Immersed (ONAN) / Cast Resin Dry Type (AN/AF)
Short-Circuit Withstand Current	20 kA / 25 kA / 31.5 kA for 1 second
Enclosure Material	Hot-Dip Galvanized Steel / Stainless Steel 304/316 / Glass Fiber Reinforced Cement (GRC)
Degree of Protection	IP43 (Transformer Compartment) / IP54 (HV & LV Switchgear Compartments)
Internal Arc Classification (IAC)	IAC-AFLR 20 kA 1s

OEM / Custom Configuration

We engineer compact substations tailored to project-specific electrical single-line diagrams, physical site constraints, and ambient environmental conditions.

Engineering Process Flow:
(1)Single Line Diagram (SLD) Submission -> (2) Electrical & Structural Engineering Review -> (3) Compartment Layout & Busbar Routing Optimization -> (4) Mechanical Fabrication & System Interlock Wiring -> (5) Factory Acceptance Testing (FAT)

Customization Options
HV Primary Equipment: Load break switches (LBS), vacuum circuit breakers (VCB), SF6-free or SF6 insulated ring main units, and zinc-oxide surge arresters.

Transformer Configuration: Copper or aluminum windings, off-circuit tap changers (OCTC), on-load tap changers (OLTC), PT100 temperature sensors, and winding temperature controllers.

LV Metering & Distribution: Multi-function digital energy meters, RS485/Modbus or Ethernet RTU telemetry modules, automatic transfer switches (ATS), and detuned capacitor banks for harmonic mitigation.

Site Adaptations: Anti-condensation space heaters, tropicalized winding insulation, sand-trap louvers, and heavy-duty structural channel skid bases for mobile or temporary mining setups.

Applications

Renewable Energy Integration

Utility-scale solar PV facilities and onshore wind farms requiring step-up transformation before grid interconnection.

Industrial Manufacturing

Chemical processing units, steel mills, and heavy industrial plants requiring decentralized MV-to-LV power transformation.

Infrastructure & Commercial Real Estate

Data centers, healthcare facilities, commercial complexes, and urban substations where land area is constrained.

Public Utilities & Microgrids

Urban/suburban power distribution network reinforcement and remote site electrification projects.

Procurement, Testing & Delivery

Manufacturing & Quality Assurance
Sheet Metal Processing: High-precision CNC laser cutting, CNC press brake bending, and robotic welding ensure dimensional repeatability and structural integrity.

Surface Pretreatment & Coating: Multi-stage degreasing, zinc phosphating, and powder baking qualified under 1,000-hour neutral salt spray testing (ASTM B117).

Interlocking Mechanisms: Integrated mechanical and electrical safety interlocks prevent access to live transformer compartments before HV earthing is engaged.

Factory Acceptance Testing (FAT)
Every compact substation undergoes full routine factory testing in accordance with IEC standards prior to dispatch:
Power frequency withstand voltage tests on HV and LV switchboards.

Transformer voltage ratio, vector group verification, and winding resistance measurement.

Insulation resistance testing and main loop resistance checks.

Functional tests of mechanical door interlocks, circuit breaker tripping, and safety key systems.

Continuity verification for secondary wiring and protection relay setting checks.

Packaging & Transport

High voltage and low voltage cabinets are separately packed in fumigated wooden export cases with independent protection for precision components.

Support EXW factory pickup and FOB designated port shipment.

Export packages are marked with high voltage/low voltage, waterproof, and shockproof labels.

Modular packaging reduces shipping volume and minimizes damage risks during transportation and installation.

Our Certificate

FAQ

Q: What thermal control measures prevent transformer derating in high ambient temperatures?

A: Substations incorporate thermostatically controlled forced-air exhaust fans paired with double-walled insulated roof panels and natural ventilation louvers. Forced cooling activates automatically at preset temperature thresholds to maintain transformer output within rated kVA limits under elevated ambient conditions.

Q: Can you fabricate compact substations according to customer-supplied Single Line Diagrams (SLD)?

A: Yes. Our engineering department reviews your SLD, dimensional footprint restrictions, and local utility regulations to generate 3D general arrangement drawings and schematic diagrams for customer sign-off prior to production.

Q: How is internal arc safety handled within the enclosure?

A: Compartments feature top-mounted pressure relief flaps. In the event of an internal arc fault, arc pressure and hot gases are directed upward away from operating personnel pathways, maintaining compliance with IAC safety requirements.

Q: What surface treatments are used to prevent corrosion in marine or industrial coastal zones?

A: Standard enclosures utilize 2.0mm to 3.0mm hot-dip galvanized steel sheet with a 100 to 120 um electrostatically applied polyester powder finish. For severe offshore or coastal environments (C5 corrosion category), we supply Grade 316L stainless steel enclosures.

Q: Are the high-voltage, transformer, and low-voltage sections physically segmented?

A: Yes. Grounded steel barrier plates divide the housing into three completely isolated compartments: HV Switchgear, Transformer, and LV Distribution. Each compartment includes separate lockable doors with key-interlock systems.

Q: What test documentation is supplied with the shipment?

A: Shipments include a comprehensive Factory Acceptance Test (FAT) report, approved schematic and dimensional drawings, operating & maintenance manuals, and factory material test certificates for key component assemblies.

Request a Quote

Submit your project specifications or Single-Line Diagram (SLD) to receive a customized technical proposal and Bill of Materials (BOM) quote within 24 hours.

Email: 15955042303@163.com

Direct Line / WhatsApp: +86 18255095123

Factory Address: Room 307, 3rd Floor, Building B, Entrepreneurship Center, East of Jingsan Road and North of Tianchu Road, Anhui Economic Development Zone, Tianchang City, Anhui Province, China

As one of the leading high voltage switchgear manufacturers and suppliers in China, we specialized in providing high quality customized products to global clients. Please feel free to buy bulk advanced high voltage switchgear for sale here from our factory. Contact us for pricelist.

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