Case Study: Using Box-Type Substation and Medium Voltage Switchgear for a Medium-Voltage Industrial Facility

Table of Contents

1. Introduction: Project Background and Industry Challenge
2. Overview of the Industrial Facility and Power Requirements
3. Challenges with Traditional Industrial Substation Solutions
4. Why a Box-Type Substation Was Selected
5. Role of Medium Voltage Switchgear in the System
6. Integration of Box-Type Substation and Medium Voltage Switchgear
7. Installation Process and On-Site Advantages
8. Operational Performance and Results
9. Why This Solution Works for Medium-Voltage Industrial Facilities
10. Key Takeaways from This Case Study
11. Conclusion: Choosing the Right Medium Voltage Power Solution
12. Customized Box-Type Substation and Switchgear Solutions

1. Introduction: Project Background and Industry Challenge

Medium-voltage industrial facilities face increasing pressure to ensure power reliability, safety, and scalability while controlling capital expenditure and construction timelines. As manufacturing processes become more automated and energy-intensive, traditional power distribution solutions often struggle to meet modern industrial requirements.

This case study examines how a box-type substation combined with medium voltage switchgear was successfully implemented to support a medium-voltage industrial facility, providing a compact, reliable, and future-ready power distribution system.

The project involved an industrial plant operating continuous production lines, where power interruptions, long installation cycles, and safety risks could result in significant financial losses. The facility required a power solution that could:

• Handle medium-voltage power distribution reliably
• Be deployed within a limited construction window
• Minimize on-site civil engineering work
• Comply with international electrical standards
• Allow for future capacity expansion

Rather than adopting a conventional indoor substation with extensive on-site construction, the project team selected an integrated box-type substation with dedicated medium voltage switchgear, enabling faster deployment and improved operational control.

From an industry perspective, this approach reflects a growing trend: industrial power users are shifting toward prefabricated, modular, and standardized medium-voltage solutions to reduce project risk and improve lifecycle performance.

2. Overview of the Industrial Facility and Power Requirements

2.1 Facility Profile

The industrial facility covered in this case study is representative of many medium-scale industrial plants, such as:

• Manufacturing factories
• Industrial processing facilities
• Logistics and warehousing centers
• Infrastructure-related industrial projects

The site operated multiple electrically driven systems, including production machinery, motor control centers, auxiliary systems, and facility services. These systems required stable medium-voltage power distribution with high operational uptime.

2.2 Power Demand Characteristics

Unlike commercial buildings, industrial facilities present unique power challenges:

• High load density within limited space
• Frequent load fluctuations due to machinery startup and shutdown
• Strict power quality requirements
• Low tolerance for downtime

The facility required a medium-voltage distribution system capable of handling these conditions while ensuring safe operation and straightforward maintenance.

Key Electrical Requirements

These requirements directly influenced the selection of both the box-type substation and the medium voltage switchgear configuration.

3. Challenges with Traditional Industrial Substation Solutions

Before selecting the final solution, the project team evaluated traditional substation designs, including indoor substations with separate switchgear rooms and transformer rooms.

3.1 Limitations of Conventional Indoor Substations

Traditional industrial substations often require:

• Dedicated buildings or rooms
• Extensive civil construction
• Long on-site installation periods
• Coordination between multiple contractors

For this project, these factors introduced several challenges:

1. Extended Construction Timeline
   Civil works and equipment installation would significantly delay power availability.
2. Higher Project Risk
   On-site wiring, assembly, and testing increased the risk of installation errors.
3. Space Constraints
   The facility had limited space available for electrical infrastructure.
4. Increased Total Cost
   While individual components may appear cost-effective, total project cost increased due to construction and labor.

3.2 Operational and Maintenance Concerns

From an operational perspective, traditional substations can present long-term challenges:

• Complex maintenance procedures
• Higher exposure of live components
• Inconsistent quality due to on-site assembly

These risks are particularly critical in medium-voltage industrial environments, where safety and reliability are non-negotiable.

4. Why a Box-Type Substation Was Selected

4.1 What Is a Box-Type Substation?

A box-type substation is a prefabricated, enclosed power distribution unit that integrates:

• Medium voltage switchgear
• Power transformer
• Low voltage distribution equipment

All components are assembled, wired, and tested at the factory before delivery. The unit is designed for outdoor installation and requires minimal on-site work.

This design approach aligns perfectly with industrial facilities seeking fast deployment and standardized performance.

4.2 Key Reasons for Selecting a Box-Type Substation

The decision to use a box-type substation was driven by both technical and operational considerations.

Primary Selection Factors

4.3 Comparison with Traditional Substation Solutions

This comparison clearly demonstrated that a box-type substation offered superior value for this industrial project, particularly in terms of time-to-operation and long-term reliability.

5. Role of Medium Voltage Switchgear in the System

5.1 Importance of Medium Voltage Switchgear in Industrial Power Distribution

Medium voltage switchgear plays a critical role in any industrial power system. It is responsible for:

• Power switching and distribution
• Fault protection and isolation
• System control and monitoring

In this case study, the medium voltage switchgear formed the operational backbone of the entire power distribution system.

5.2 Switchgear Configuration Used in This Project

The switchgear was integrated directly into the box-type substation, ensuring seamless coordination between switching, protection, and transformation.

Typical Switchgear Components

This configuration ensured high system reliability while maintaining flexibility for future system upgrades.

5.3 Safety and Protection Advantages

Medium voltage switchgear significantly enhances safety by:

• Limiting fault propagation
• Providing clear isolation points
• Reducing exposure to live components

For industrial operators, these features translate into lower operational risk and safer maintenance procedures.

6. Integration of Box-Type Substation and Medium Voltage Switchgear

The true strength of this solution lies in the integrated design of the box-type substation and medium voltage switchgear.

6.1 System-Level Integration

Instead of treating each component as a standalone unit, the system was designed as a fully integrated medium-voltage power solution.

Key integration benefits included:

• Optimized internal layout
• Reduced cable lengths
• Improved thermal management
• Simplified control logic

This level of integration is difficult to achieve with on-site-built substations.

6.2 Standardization and Compliance

The complete system was designed and tested to comply with relevant international standards, ensuring consistent quality and global applicability.

Standardization also simplified documentation, inspection, and long-term operation.

7. Installation Process and On-Site Advantages

7.1 Prefabricated Delivery and Site Preparation

One of the most significant advantages of using a box-type substation combined with medium voltage switchgear is the simplified installation process. For this project, the entire power solution was prefabricated, factory-assembled, and fully tested before shipment.

Instead of coordinating multiple contractors for civil construction, equipment installation, wiring, and testing, the industrial facility only needed to prepare a simple foundation and cable trenches prior to delivery.

This approach drastically reduced uncertainties during the installation phase and allowed the project team to maintain a predictable timeline.

7.2 On-Site Installation Workflow

The installation process followed a streamlined sequence:

1. Foundation preparation
2. Box-type substation positioning
3. Medium-voltage cable termination
4. Low-voltage outgoing connections
5. Grounding and earthing verification
6. Final commissioning and energization

Because the medium voltage switchgear was already integrated and wired inside the enclosure, on-site work was limited mainly to external cable connections.

Installation Comparison

This simplified installation model is particularly valuable for industrial facilities operating under tight construction schedules or those located in remote or labor-constrained areas.

7.3 Reduced Impact on Industrial Operations

Another key benefit was the minimal disruption to surrounding operations. Since the substation was installed outdoors and required limited on-site construction, the facility avoided prolonged shutdowns or interference with ongoing industrial activities.

For many medium-voltage industrial facilities, this advantage alone justifies the adoption of prefabricated box-type substation solutions.

8. Operational Performance and Results

8.1 System Stability and Power Reliability

Following commissioning, the power system demonstrated stable and reliable performance under varying load conditions. The integration of medium voltage switchgear ensured precise control and rapid fault isolation, preventing disturbances from spreading across the system.

Key performance outcomes included:

• Stable voltage levels under fluctuating loads
• Reliable switching operations
• Effective fault detection and isolation
• Smooth coordination between feeders

For industrial operators, this translated into higher production uptime and reduced operational risk.

8.2 Safety Improvements in Daily Operation

Safety is a critical concern in any medium-voltage industrial environment. The enclosed design of the box-type substation, combined with properly interlocked medium voltage switchgear, significantly improved overall safety.

Safety Enhancements Achieved

Maintenance personnel benefited from clearly defined isolation points and standardized operating procedures, reducing the likelihood of human error.

8.3 Maintenance and Lifecycle Benefits

From a long-term perspective, the integrated solution offered several maintenance advantages:

• Reduced inspection time
• Simplified spare parts management
• Standardized components
• Easier documentation and record keeping

These factors contribute directly to lower total cost of ownership (TCO) over the lifecycle of the power system.

9. Why This Solution Works for Medium-Voltage Industrial Facilities

9.1 Suitability Across Industrial Sectors

While this case study focuses on a single industrial facility, the solution is widely applicable across multiple industries, including:

• Manufacturing and processing plants
• Mining and resource extraction facilities
• Oil and gas infrastructure
• Data centers and energy-intensive facilities
• Logistics and transportation hubs

Each of these environments benefits from the compactness, reliability, and modularity offered by a box-type substation with integrated medium voltage switchgear.

9.2 Scalability and Future Expansion

Industrial facilities rarely remain static. Load growth, new production lines, or expanded operations often require additional power capacity.

The modular nature of this solution allows for:

• Additional outgoing feeders
• Future transformer upgrades
• Expansion without major reconstruction

This flexibility ensures that the power system can grow alongside the facility, protecting the initial investment.

Expansion Capability Comparison

9.3 Alignment with Modern Industrial Power Trends

Globally, industrial power distribution is moving toward:

• Standardized solutions
• Prefabricated equipment
• Shorter project timelines
• Higher safety standards

This case study reflects that shift and demonstrates how box-type substations and medium voltage switchgear align with modern industrial power strategies.

10. Key Takeaways from This Case Study

This project highlights several important lessons for industrial power system planning:

1. Integrated solutions reduce project risk
2. Prefabrication improves quality and consistency
3. Medium voltage switchgear is central to system reliability
4. Compact designs optimize industrial space utilization
5. Standardization simplifies operation and maintenance

These takeaways are directly applicable to other medium-voltage industrial facilities seeking reliable and scalable power distribution solutions.

11. Conclusion: Choosing the Right Medium Voltage Power Solution

Selecting the right power distribution system is a strategic decision for any industrial facility. This case study demonstrates that combining a box-type substation with medium voltage switchgear offers a balanced solution that addresses technical, operational, and economic requirements.

By leveraging factory-prefabricated equipment, integrated design, and standardized components, industrial operators can achieve:

• Faster project delivery
• Higher operational safety
• Improved power reliability
• Lower lifecycle costs

As industrial energy demands continue to evolve, modular and integrated medium-voltage solutions will play an increasingly important role in supporting efficient and resilient operations.

12.Customized Solutions for Industrial Facilities

Every industrial project presents unique challenges. Power capacity, site conditions, regulatory requirements, and future expansion plans all influence system design.

If you are planning a medium-voltage power distribution system for an industrial facility, a customized box-type substation and switchgear solution can help you achieve reliable performance with minimal project risk.

Contact our engineering team to discuss your project requirements and receive a tailored medium-voltage solution designed for safety, reliability, and long-term value.