Display

Substation Steel Pipe Support Case Sharing

Publish Time: 2025-09-17

Project Background and Challenges

The Inner Mongolia Energy Group's Zhunda Power Plant 2x1,000 MW coal-fired power integration project is a key component in building a regional smart grid. This project places extremely high demands on the station's structural support: it must not only support large, new intelligent equipment (such as GIS switchgear and ultra-large capacity transformers), but also be compactly arranged to conserve space and possess extremely high seismic performance (designed for seismic fortification intensity 8). Traditional angle steel supports are no longer able to meet the demands of such a high-end project in terms of aesthetics, load-bearing capacity, and wind and earthquake resistance.

Our Customized Solution

Our company was deeply involved in the project design phase, collaborating with the design institute to provide a one-stop steel pipe structural support solution, from design optimization and intelligent manufacturing to anti-corrosion treatment.

Advanced Materials and Structural Design

All primary materials are Q355C or higher high-strength seamless steel pipe or longitudinally welded pipe. Compared to traditional angle steel, these offer superior cross-sectional properties, reduced wind resistance, high load-bearing capacity, and a modern and aesthetically pleasing appearance. Utilizing 3D building information modeling (BIM) for collision detection and load simulation, we optimized the joint design to ensure that strength, rigidity, and stability meet requirements under various operating conditions, including equipment installation, operation, and maintenance. This ensures an optimal balance between structural safety and economic efficiency.

Precision Manufacturing Process

The intersection lines of the main and branch pipes are cut entirely using CNC cutting machines. The highly precise cuts provide perfect grooves for subsequent welding, ensuring penetration and quality of the joint welds.

Flanges are machined using a dedicated machine to ensure a smooth flange contact surface and precise bolt hole placement, enabling stress-free, rapid, high-altitude assembly on-site, significantly improving installation efficiency and accuracy.

Excellent Long-Term Corrosion Protection

To address the project site's unique corrosive environment, we employed a combined anti-corrosion system combining hot-dip galvanizing and high-performance anti-corrosion coatings. Components undergo pickling, rust removal, and hot-dip galvanizing, followed by a highly weather-resistant fluorocarbon paint or polysiloxane topcoat. This system provides a double barrier of protection, with a designed corrosion protection lifespan exceeding 40 years, far exceeding conventional hot-dip galvanizing.

Strict quality control throughout the entire process

All raw steel pipes undergo ultrasonic flaw detection (UT) testing, all primary and secondary welds undergo 100% visual inspection and spot ultrasonic flaw detection (UT), and finished product dimensions undergo three-dimensional inspection to ensure the inherent quality and installation accuracy of every product leaving the factory.

Core Value for Customers

Safety Guarantee: The highly reliable structural design provides an absolutely secure "home" for the core electrical equipment within the station, valued at hundreds of millions of yuan, completely eliminating customer concerns about structural safety.

Schedule Guarantee: Factory prefabrication and a high degree of standardization, carried out in parallel with civil construction, significantly shortened on-site installation time, saving valuable time for the project's on-schedule commissioning.

Value Enhancement: The simple and sleek steel pipe structure perfectly complements the technological aesthetic of modern smart substations, enhancing the station's overall appearance and value.

Life Guarantee: The long-lasting composite anti-corrosion technology significantly reduces maintenance costs throughout its lifecycle, achieving the design goal of "maintenance-free and long life."

Project Achievements

A total of 525 tons of various steel pipe supports were delivered for this project. All components were installed on-site with zero hole expansion and cutting, resulting in a successful first-time installation. All performance indicators exceeded design requirements, earning high praise from the client, supervisor, and contractor, making it a model project for regional power grid construction.

Conclusion

Our company is committed to providing the safest, most reliable, and most advanced steel structure system solutions for modern substations. We are not only a manufacturer of supports, but also your trusted structural partner, contributing our strength to building a strong smart grid.