Why spend three days when you can manage with just one?

Factory-assembled compact secondary substations (CSS) dramatically reduce both installation time and the risk of errors for Caverion Denmark A/S. Where it previously could take 3-4 days to install and equip a technical cabinet on site, it is now delivered as a plug-and-play solution. “Everything is assembled, tested, and approved, so we are up and running from day one,” explains department head Thomas Holm Bjerregaard from Caverion.

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Caverion in Denmark represents a leading international group in fields including installation, project consulting, building automation, management, and operation. Caverion plays a significant role in the establishment and operation of buildings and infrastructure that must function 24/7. Here, there is no margin for error, and budgets for installation, service, and operation must be adhered to.

“We are constantly trying to optimize our offerings to the market, including our choice of turnkey solutions for substations and technical buildings,” explains Department Manager Thomas Holm Bjerregaard from Caverion Denmark. “Factory-assembled stations can be delivered complete as actual plug-and-play. They are lifted into place and connected, which significantly reduces installation time. Why spend three days when you can manage with just one?”

The department head summarizes the advantages:

Quality – all components are assembled, tested, and approved under controlled conditions and indoors. This reduces the risk of errors.
Time savings – the need for on-site assembly and adjustment is minimal. We disrupt the area for the shortest possible time and ensure rapid commissioning.
Documentation – all tests, approvals, and certifications are in place upon delivery. We know that the solution meets all current standards and customer needs.
Aesthetics – the substations come in the color specified by the customer or local plan. We can also clad the station with wood.

“At Caverion, we want to lead the way to intelligent solutions,” asserts Thomas Holm Bjerregaard and continues: “For us, pre-assembled CSS, ready for installation, is an intelligent way to save time and resources without compromising on quality. And in Følsgaard, we have found a partner that works closely with us throughout the entire process from the bid to execution. We collaborate to find the best solutions for our customers, and Følsgaard is very responsive, even when requirements extend beyond standard solutions.”

Increasing Interest Across the Utility Sector

It’s not only Caverion that recognizes the benefits of pre-assembled technical stations. The entire utility sector is subject to stringent requirements, which no longer make it viable to construct outdoor enclosures on site with subsequent installation and testing of components, involving significant time consumption and challenges related to weather conditions and transportation.

Today, utility companies are subject to entirely different requirements. These include quick and smooth installation of necessary facilities, budget control, extensive testing procedures, and minimal margin for error.

In addition, there is a desire from both companies and affected citizens for substations to be integrated into the local area in a discreet and aesthetically pleasing manner. Alongside the other requirements, this has led to increased demand for pre-assembled technical buildings and transformer stations.

Partnership Ensures Flexibility and Customisation

“As a technical partner, our goal is to be frontrunners when it comes to ready solutions that can be adapted to the task, reduce installation time, and ensure trouble-free operation for many years,” says Rasmus Davidsen, Product Engineer, Powertech, Hans Følsgaard.

The lineup includes the so-called secondary compact switch substations, which convert 10/15/20/30 kV medium voltage to 800/400 V, which can be distributed to users, and transformer stations up to 4,000 kVA. Thanks to flexible equipment, almost anything is possible.

“The delivery to Caverion is a good example. These are complete stations, delivered and craned into place on site, and fitted with a transformer, MV-SWG, and low-voltage board, all made according to customer requirements and wishes,” informs Rasmus Davidsen.

A Secure Shell around Custom Components

A prefab substation is delivered complete with a concrete (alternatively steel) base, with cutouts for cables. The cabin is a robust frame construction with sides in aluzinc, which has a long lifespan and good adhesion for paint. The roof can be a saddle roof or a flat roof, and both types of roofs can be easily lifted off for assembly and service. From the factory, lifting eye bolts are mounted, so a crane can lift the entire cabin into place when delivered.

There is foam mounted under the roof construction, and the cabin is designed with na-
tural, passive ventilation. Ventilation primarily occurs in the roof construction, on the sides of the roof, under overhangs, and through filters in the doors. Ventilation is essential for continuous airflow and transformer cooling.

The busbar systems comply with EN 61 439, 1 and 5, and overall, the substation is EN 62271-200 A/B approved. Finally, they can be locked with a robust 3-point locking system. The lock housing is prepared for use with a padlock, but other locking systems can also be installed, including the unique CyberKey® locking sys-
tem supplied by Følsgaard.

“For us, pre-assembled CSS, ready for installation, are an intelligent way to save time and resources without compromising on quality. And in Følsgaard, we have found a partner that works closely with us throughout the entire process from the bid to execution. We collaborate to find the best solutions for our customers, and Følsgaard is very responsive, even when requirements extend beyond standard solutions”

Thomas Bjerregaard
Department Manager, Caverion Denmark

Aesthetics and Integration are Important

Many places in cities and landscapes, there are pump stations, technical cabinets, and utility facilities of old age. They are not always adapted to the urban surroundings or the landscape they are erected in. Often, they were designed and built according to a specific template, as a ‘one size fits all’.

“That no longer works. Today, substations must match the immediate surroundings,” says Rasmus Davidsen “Additionally, they need to be adapted to the operator’s or company’s design line, and they must be long-lasting and require minimal service over their lifespan. This necessitates careful selection of materials and post-treatment processes.”

“The substations are powder-coated with UV-resistant paint in corrosion class C5 and delivered as standard in three colors. If there are special wishes, they can be accommodated with optional colors, wood cladding, or individual adjustments,” explains Product Engineer Rasmus Davidsen and concludes:

“This freedom in design ensures that the wishes of customers and local citizens can be met, and if there are collisions or vandalism, damaged parts can be replaced. We go far to ensure many years of trouble-free operation.”