"Benyue Compact Box Substation: Innovation in Electrical Efficiency"
I. Design Concept: Space Optimization and Functional Integration
Highly compact structure
It adopts a "three-in-one" closed design of high-voltage switchgear, transformers and low-voltage distribution devices. Its volume is only two-thirds of that of traditional prefabricated substations, and the occupied area is significantly reduced.
The typical layout is divided into "triangular" or "eye" shapes. The transformer room and the high/low voltage room are modularly assembled and support direct cable connection, which is suitable for space-constrained scenarios such as streets and industrial parks.
Full insulation and safety reinforcement
SF6 gas-insulated ring main units are applied on the high-voltage side, eliminating the handcart passage. With a double-row arrangement, the operation width is reduced to less than 3 meters, lowering the risk of insulation faults.
The transformer adopts a fully sealed oil-immersed structure. The vacuum oil injection process prevents moisture from entering. It is equipped with a pressure relief valve (action value 30kPa) and explosion-proof membrane to ensure overload safety.
Ii. Core Processes: Material and Manufacturing Upgrades
Anti-corrosion and durability processes
The box body undergoes eight pretreatment processes (acid washing and phosphating) and seven electrostatic spraying and baking processes, with a coating thickness of ≥150μm, making it suitable for highly polluted and high-humidity environments.
The radiator and the transformer body are designed separately: The radiator is installed at a high position, reducing the floor space occupied and keeping the noise below 45dB (the standard for Class I residential areas).
Innovation in transformer technology
Give priority to oil-immersed transformers (with a capacity of 100-1250kVA), support natural cooling, and avoid energy consumption of fans. The windings are made by cold-pressing welding process, which enhances the shock resistance and eliminates the need for core lifting inspection after transportation.
The high-voltage equipment is built-in: load switches, fuses and tap changers are integrated into the oil tank and operated through an external panel, reducing the need for independent compartments.
Iii. Intelligent and Energy-saving Upgrades
Digital control system
Integrate the "three-remote" distribution measurement and control device (remote measurement, remote signaling, and remote control) to monitor temperature, oil level and pressure in real time, and link reactive power compensation capacitors (with capacity configured at 15% - 30% of the load).
The new generation of products integrates photovoltaic-assisted power supply (solar panels + inverters) to provide energy for cooling fans and semiconductor water cooling systems, reducing operating costs.
The trend of modular production
According to the "Technical Specification for Modular Compact Intelligent Integrated Box-type Substation" in 2025, the low-voltage room is disassembled into incoming line, outgoing line and metering modules, supporting factory prefabrication and on-site rapid assembly.
Ventilation system optimization: Inclined louvers + dust-proof filters, in combination with temperature-controlled fans, achieve the dual goals of heat dissipation and preventing small animals from entering.
Iv. Application Value and Industry Promotion
Land resource conservation: Suitable for urban centers and high-rise building distribution stations, it saves 60% of land compared with traditional brick-and-mortar substations.
Full life cycle cost advantage: Installation period is shortened by 50%, maintenance cost is reduced by 30% (the design without oil storage tank reduces the frequency of maintenance).
Green Certification: Complies with GB/T17467 and DL/T537 standards, with noise ≤55dB and loss 10% lower than the national standard, and has obtained the "Energy-saving Product" certification.
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E-mail :sales@benyueelec.com
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Xinke Avenue, Pingqiao Industrial Park, Xinyang City, Henan Province
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Xinke Avenue, Pingqiao Industrial Park, Xinyang City, Henan Province