HKYBW-40.5 Prefabricated Compact Substation

Product Overview

Huanghua Group’s HKYBW-40.5 and HKYBW-12 series prefabricated compact substations are factory-integrated power distribution units that consolidate medium-voltage switchgear, power distribution transformer, and low-voltage switchgear into a single outdoor-rated enclosure. Engineered as a turnkey alternative to conventional civil-engineered substations, the compact substation delivers identical capacity in just 1/10 to 1/5 of the footprint , drastically reducing design workload, construction volume, and total project cost.
Each unit is pre-assembled, pre-wired, and routine-tested at our factory, then shipped as a single lift-and-place module — eliminating on-site civil works and compressing commissioning from months to days. The HKYBW series is fully compliant with IEC 62271-202 (AC prefabricated substations up to 52kV) , IEC 60076 (power transformers), and IEC 61439 (low-voltage switchgear assemblies), qualifying it for EU tenders, utility distribution networks, and global EPC projects.
With rated voltages up to 40.5kV and capacities from 100 to 2500 kVA , the HKYBW series serves ring network distribution systems, dual-power radial end distribution, urban and rural grid expansion, renewable integration, industrial parks, and temporary/mobile power scenarios.

General Specifications

Technical Data by Voltage Class

Up to 12kV Class

Up to 24kV Class

Up to 40.5kV Class

All data above sourced from Huanghua HKYBW series technical datasheet .

Integrated Functional Modules

1 MV Switchgear Compartment

The high-voltage compartment integrates all primary and protection equipment:

MV Switchgear: Vacuum circuit breaker as standard

Relay Protection: Comprehensive protection against transformer faults, through-faults, and overloads

Current Transformers: For measurement and protection

Optional RMU: Ring Main Unit configuration available

Optional LBS Protection: Load Break Switch protection

Optional CTs/PTs: For metering and synchronization

Basic Impulse Level: Adjustable on request

Protection Degree: IP65

2 Transformer Compartment

The core step-up/step-down unit, engineered for reliability and environmental resilience:

Winding Material: Copper winding standard; aluminum winding optional

Transformer Types: Oil-immersed or dry-type (optional per application)

Core & Coil Losses: Various loss solutions available (lower losses on request)

Short-circuit Withstand: External short circuits withstanding ≥ 0.5 seconds

Animal/Bird/Vermin Protection: Sealed design minimizes accidental short-circuit risk

Options: Non-standard HV taps, special impedance, special noise levels

Noise Level: Oil type ≤ 55 dB; Dry type ≤ 65 dB

Protection Degree: IP54

3 LV Switchgear Compartment

A full IEC 61439-compliant low-voltage distribution assembly:

Provision for LV Panel: Compatible with Huanghua MNS / GCS / GCK platforms

Incomer: ACB and MCCB provisions

Current Transformers: For instrument operation

Power Distribution Function: Full provision for downstream distribution

Optional Reactive Power Compensation: Up to 30% of rated power

Optional Energy Metering: Energy metering and measurement function

Optional LV Panel Types: Various configurations per customer specification

Protection Degree: IP23 (IP54 available on request)

Circuit Count: 4 – 30 circuits

Structural Design Highlights

1 Three Independent Compartments

Physically segregated MV switchgear, transformer, and LV switchgear compartments ensure safe maintenance access, fire containment, and operational isolation. Each compartment operates under its own optimized protection class (IP65 / IP54 / IP23 respectively).

2 Anti-Misoperation Interlocking

Mechanical and electrical interlocks prevent incorrect operating sequences, protecting personnel and equipment during switching operations.

3 Lift-and-Place Mobility

Integrated lifting lugs allow the entire unit to be transported and positioned as a single module — no disassembly, no on-site civil works. This mobility characteristic makes the HKYBW series ideal for temporary power, emergency restoration, and rapidly deployable infrastructure.

4 Weather-Resistant Housing

Engineered for outdoor installation with anti-corrosion treatment as standard. The enclosure withstands diverse environmental conditions — from coastal salt-spray to desert solar radiation to grassland humidity — making it suitable for beaches, grasslands, deserts, and high-UV regions .

5 Intelligent Thermal Management

Natural ventilation as standard; forced ventilation with automatic temperature control device available. The system activates/deactivates based on setpoint temperature, ensuring optimal thermal performance without manual intervention.

6 Reduced Dimensions & Minimal Footprint

Compact structure occupies only 1/10 to 1/5 of the area required by conventional civil-engineered substations , dramatically reducing land acquisition costs and enabling deployment in space-constrained urban and industrial environments.

7 Aesthetic Integration

Diverse external decoration options allow the substation to harmonize with surrounding architectural and environmental contexts — a critical advantage for urban and commercial deployments.

Engineering Options & Accessories

Routine & Type Tests

Routine Tests for Each Unit

Visual & dimensional inspection per IEC standards

Wiring continuity & terminal torque verification

Insulation resistance test

Power frequency withstand voltage test (1 min) per voltage class

Lightning impulse withstand voltage test

Functional operation test of circuit breakers, interlocks, and protection relays

Temperature rise verification

As-built schematic vs. actual wiring validation

Type Tests

Dielectric Test: Power-frequency withstand (42kV / 50kV / 95kV per class) and lightning impulse (95kV / 125kV / 250kV per class)

Short-time Withstand (Icw): 25 kA @ 1s on HV side; 30–80 kA on LV side

Peak Withstand (Ip): 62.5 kA on HV side; up to 176 kA on LV side

IP Verification: IP65 (MV) / IP54 (Transformer) / IP23 (LV)

Mechanical Operation: Circuit breaker endurance and interlock sequence

Internal Arc Classification: Available upon request

Transport Simulation: Lifting lug load test

Full type test reports available upon request

Applications