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5 Benefits of Factory-Built Substations for Renewable Projects

February 6, 2024

Updated:

February 6, 2024

Originally Published:

Introduction

The global renewable energy market is expanding rapidly, with countries setting ambitious targets for reducing carbon emissions and switching to cleaner energy sources. Developing renewable energy projects can often require advanced infrastructure, including upgraded high-voltage electrical substations—the interconnecting points within power and distribution systems. [1] However, designing and building these substations can be a daunting task for renewable developers and electric utility companies facing strict time and budget constraints. Therefore, it is essential to choose a design-build approach that fast-tracks construction and improves schedule certainty while keeping safety and quality at the forefront. Renewable developers and utilities can gain these 5 benefits by utilizing a design-build approach leveraging Factory-Built Substations.

What are Factory-Built Substations?

Factory-Built Substations are electrical substations designed in modular sections, built and rigorously tested in a factory setting, then transported by semitrucks to a project site for installation. From there, installation typically takes three days or less. They can also be built with voltages ranging from 34.5kV to 345kV, allowing them to meet various project needs.  

Continue reading to understand why these modular substations are gaining traction worldwide.

1) Faster Development

Ask anyone what the biggest construction hurdle is for substations and power grid projects, and they’ll probably answer: time. This is especially true in the renewable energy sector.  The longer it takes to get a project energized, the higher the risk and cost.

Utilizing a Factory-Built Substation can speed up project completion by as much as 30% because the pre-fabrication method enables substation construction in the factory to happen at the same time as site preparation. Construction in a controlled factory environment also minimizes project delays caused by weather conditions.

2) Flexibility and Scalability

Factory-Built Substations are adaptable to the needs of each unique project. Once installed, a Factory-Built Substation is just like any other substation. They meet all industry electrical standards and can be customized to fit the project’s location and voltage requirements, including up to 345kV on the high side.  

Their modular design also makes them easy to expand when needed, allowing scalability to accommodate future growth plans at a lower cost and on a faster schedule than a conventional stick-built substation expansion.

3) More Control: Quality, Schedule, and Cost

Renewable developers and electric utilities gain a higher level of control over quality, schedule, and cost with Factory-Built Substations. When the electrical substation is prefabricated, all components undergo rigorous testing prior to shipment to the site. This eliminates common on-site quality issues, schedule overruns, and helps keep costs under control.

4) Enhanced Safety

On-site construction comes with hazards to workers, equipment, and the environment. Factory-Built Substations eliminate many of these risks by providing a controlled working environment where safety measures are fully integrated into the design and construction process.

Fewer equipment lifts are necessary on site, reducing the duration of heavy machinery needed to install the project. With fewer hazards and shortened on-site construction time, renewable developers and electric utilities can reduce the possibility of safety risks by as much as 30%.

5) Reduced Environmental Impact

Factory-Built Substations are designed with environmental sustainability in mind. Their modular, prefabricated design fits on a smaller footprint, reducing land usage while facilitating a shorter installation, which in turn, leads to fewer disruptions to the surrounding environment.

Additionally, due to their prefabricated construction, Factory-Built Substations can help renewable developers and electric utilities earn LEED (Leadership in Energy and Environmental Design) credits under the Construction and Demolition Waste Management section of the material and resources category. [2]

Conclusion

Renewable developers and electric utilities can keep up with growing power demands and decarbonization goals while improving safety, quality, and budget by Factory-Built Substations. This innovative design-build approach offers schedule savings, customization, and standardization, which will be essential for the clean energy transition.

Beta Engineering has been a leading provider of engineering, procurement, and construction services in the high-voltage substation industry for almost 50 years and played an integral role in introducing modular substations to the market with Agile by Beta®—our signature-line of Factory-Built Substations. Contact our team of experts and schedule to see a Factory-Built Substation in person to learn how you can interconnect your high-voltage project to the grid faster, safer, and with less risk.

Learn more about Agile by Beta®

View our Agile by Beta® Portfolio

More Beta News

blog

5 Benefits of Factory-Built Substations for Renewable Projects

February 6, 2024

Updated:

February 6, 2024

February 6, 2024

Updated:

February 6, 2024

Originally Published:

Introduction

The global renewable energy market is expanding rapidly, with countries setting ambitious targets for reducing carbon emissions and switching to cleaner energy sources. Developing renewable energy projects can often require advanced infrastructure, including upgraded high-voltage electrical substations—the interconnecting points within power and distribution systems. [1] However, designing and building these substations can be a daunting task for renewable developers and electric utility companies facing strict time and budget constraints. Therefore, it is essential to choose a design-build approach that fast-tracks construction and improves schedule certainty while keeping safety and quality at the forefront. Renewable developers and utilities can gain these 5 benefits by utilizing a design-build approach leveraging Factory-Built Substations.

What are Factory-Built Substations?

Factory-Built Substations are electrical substations designed in modular sections, built and rigorously tested in a factory setting, then transported by semitrucks to a project site for installation. From there, installation typically takes three days or less. They can also be built with voltages ranging from 34.5kV to 345kV, allowing them to meet various project needs.  

Continue reading to understand why these modular substations are gaining traction worldwide.

1) Faster Development

Ask anyone what the biggest construction hurdle is for substations and power grid projects, and they’ll probably answer: time. This is especially true in the renewable energy sector.  The longer it takes to get a project energized, the higher the risk and cost.

Utilizing a Factory-Built Substation can speed up project completion by as much as 30% because the pre-fabrication method enables substation construction in the factory to happen at the same time as site preparation. Construction in a controlled factory environment also minimizes project delays caused by weather conditions.

2) Flexibility and Scalability

Factory-Built Substations are adaptable to the needs of each unique project. Once installed, a Factory-Built Substation is just like any other substation. They meet all industry electrical standards and can be customized to fit the project’s location and voltage requirements, including up to 345kV on the high side.  

Their modular design also makes them easy to expand when needed, allowing scalability to accommodate future growth plans at a lower cost and on a faster schedule than a conventional stick-built substation expansion.

3) More Control: Quality, Schedule, and Cost

Renewable developers and electric utilities gain a higher level of control over quality, schedule, and cost with Factory-Built Substations. When the electrical substation is prefabricated, all components undergo rigorous testing prior to shipment to the site. This eliminates common on-site quality issues, schedule overruns, and helps keep costs under control.

4) Enhanced Safety

On-site construction comes with hazards to workers, equipment, and the environment. Factory-Built Substations eliminate many of these risks by providing a controlled working environment where safety measures are fully integrated into the design and construction process.

Fewer equipment lifts are necessary on site, reducing the duration of heavy machinery needed to install the project. With fewer hazards and shortened on-site construction time, renewable developers and electric utilities can reduce the possibility of safety risks by as much as 30%.

5) Reduced Environmental Impact

Factory-Built Substations are designed with environmental sustainability in mind. Their modular, prefabricated design fits on a smaller footprint, reducing land usage while facilitating a shorter installation, which in turn, leads to fewer disruptions to the surrounding environment.

Additionally, due to their prefabricated construction, Factory-Built Substations can help renewable developers and electric utilities earn LEED (Leadership in Energy and Environmental Design) credits under the Construction and Demolition Waste Management section of the material and resources category. [2]

Conclusion

Renewable developers and electric utilities can keep up with growing power demands and decarbonization goals while improving safety, quality, and budget by Factory-Built Substations. This innovative design-build approach offers schedule savings, customization, and standardization, which will be essential for the clean energy transition.

Beta Engineering has been a leading provider of engineering, procurement, and construction services in the high-voltage substation industry for almost 50 years and played an integral role in introducing modular substations to the market with Agile by Beta®—our signature-line of Factory-Built Substations. Contact our team of experts and schedule to see a Factory-Built Substation in person to learn how you can interconnect your high-voltage project to the grid faster, safer, and with less risk.

Learn more about Agile by Beta®

View our Agile by Beta® Portfolio

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