Transportation and Installation Guide for E-house

From: FATENG Electric Author: Ethan

Introduction

As global industries accelerate toward renewable energy, digitalization, and smarter electrical infrastructure, the demand for E-house (Electrical House) modular substations continues to rise. Compared with traditional brick-built substations, E-house solutions offer shorter construction periods, higher reliability, better environmental control, and significantly reduced on-site labor.

However—despite their advantages—successful E-house deployment depends heavily on proper transportation, lifting, positioning, and commissioning procedures. Because an E-house integrates MV switchgear, LV switchboards, protection relays, HVAC, fire systems, communication panels, and more into a single prefabricated module, the structure must be transported and installed with great care.

This guide provides a complete, practical, and engineering-focused overview of how to transport, place, and install an E-house safely and efficiently. It is designed for EPC contractors, project managers, field engineers, and renewable energy developers deploying E-house substations in solar farms, wind farms, oil & gas facilities, data centers, mining operations, and large industrial plants.

1. Understanding the Structure of an E-house

Before planning transportation and installation, it is essential to understand how an E-house is built. A typical E-house consists of:

1.1 Structural Components

Welded steel frame
External steel wall panels (corrosion-protected)
Reinforced floor frame with equipment mounting rails
Lifting lugs and forklift pockets
Roof ducts, cable penetrations, ventilation openings

1.2 Internal Systems

MV switchgear (IEC or ANSI/UL)
LV switchboards or MCCs
UPS system
Bus ducts and power distribution cables
Lighting, emergency lighting, small power outlets
Fire detection and suppression system

1.3 Environmental Control

HVAC system
Thermal insulation
Pressure relief panels (if required)

1.4 Additional Features

Battery compartments
Control panels and SCADA
Cable trays and access flooring
Main doors and maintenance access panels

Because these components are fully assembled and tested before shipment, maintaining structural integrity during transportation is critical.

2. Pre-Transportation Preparation

Proper preparation ensures that the E-house arrives safely and ready for installation.

2.1 Dimensional and Weight Verification

Before loading, verify:

Overall dimensions (height, width, length)
Lifting point locations and rated loads
Total shipping weight
Center of gravity (CoG)

This will determine the suitable transportation vehicle and lifting method.

2.2 Equipment Securing Inside the E-house

All internal electrical equipment must be secured:

Lock switchgear panels
Fix drawers, breakers, and accessories
Secure loose tools and consumables
Lock or brace HVAC units
Protect cable entry points

For long-distance transport, shock sensors may be installed.

2.3 Weather Protection

Depending on climate:

Use waterproof shrink wrap if required
Seal all ventilation openings
Add protective covers to exposed connectors

2.4 Documentation Checklist

Transport drawings
Lifting plan
Structural analysis data
Packing list
Test reports (FAT)

E-house projects normally undergo a Factory Acceptance Test to ensure reliability before transport.

3. Transportation Methods for E-house

Choosing the right transportation method is key to minimizing risk.

3.1 Road Transportation

This is the most common method.

Vehicle Requirements

Low-bed or flatbed trailers
Wide-load permitting (if applicable)
Escort vehicles for oversized loads
Air-ride suspension for vibration control

Securing the E-house

Use chains, ratchet straps, and corner protectors
Secure at designated tie-down points
Maintain balanced weight distribution

Road Clearance Checks

Bridge heights
Road width
Curves and turning radius
Slopes or unpaved sections
Local transportation regulations

3.2 Sea Transportation

For global projects, E-houses are shipped as break-bulk cargo or in open-top containers.

Key Considerations

Marine-grade corrosion protection
Vibration and movement protection
Humidity control inside the E-house
Lashing according to IMO standards

Port Handling

Ports must be capable of:

Heavy-lift crane operation
Oversized cargo handling
Safe storage areas prior to onward transport

3.3 Rail Transportation

Less common but useful in landlocked regions.

Considerations

Check loading gauge restrictions
Confirm vibration impact limits
Ensure sufficient securing and weight distribution

Rail routes often require special scheduling for oversized modules.

4. On-site Receiving and Positioning

Once the E-house arrives, precise site handling is crucial.

4.1 Site Preparation

Foundation pads or steel platforms completed
Anchor bolts and embedded plates installed
Cable trenches opened and clear
Access roads reinforced for crane entry
Ground compacted to required density

Use geotechnical data to ensure stability.

4.2 Offloading Procedures

Depending on size and weight, offloading may involve:

Crane Lifting

Mobile crane or crawler crane
Lifting from designated lifting lugs
Use of certified slings, shackles, and lifting beams

Forklift Offloading

Suitable for small E-houses only.

Skidding System

For restricted spaces.

Lifting Safety Requirements

Review lifting plan
Inspect lifting accessories
Prevent workers from standing under loads
Maintain wind speed limits (usually < 10 m/s)

4.3 Positioning the E-house

Once lifted, the E-house is placed on its foundation.

Steps

Align with GPS or laser markers
Lower gently to avoid shock
Check for level alignment (using laser level)
Bolt to foundation frame
Install anti-vibration pads if required

5. Electrical and Mechanical Connections

After positioning, the E-house must be integrated into the site system.

5.1 External Cable Connection

MV incoming/outgoing cables
LV power and control cables
Communication and fiber-optic connections

Cable glands or entry boxes must be properly sealed.

5.2 Bus Duct Connection

Some E-houses connect to transformers via:

Sandwich bus duct
Air-insulated bus duct

Ensure proper support structures.

5.3 Grounding and Bonding

Grounding must comply with local standards:

IEC 60364
IEEE 80
NEC Article 250

5.4 HVAC and Ventilation

Connect external power supply for HVAC
Verify airflow direction
Check temperature and humidity settings

6. Testing and Commissioning

Before energization, the E-house must undergo thorough onsite testing.

6.1 Mechanical Checks

Door alignment
Fire system test
Ventilation and HVAC performance
Lighting and emergency lighting

6.2 Electrical Tests

MV switchgear testing (HIpot, insulation, functional test)
LV switchboard testing
Protection relay programming
SCADA/communication checks

6.3 Integrated System Performance

Interlock tests
Load test
Emergency shutdown test

A Site Acceptance Test (SAT) is usually conducted with client representatives.

7. Common Challenges and Best Practices

7.1 Handling Oversized Loads

Plan routes months in advance.

7.2 Weather Sensitivity

Avoid lifting during high winds or heavy rain.

7.3 Foundation Mismatch

Always verify anchor positions before shipment.

7.4 Vibration Damage During Transport

Use shock absorbers and limit long off-road travel.

7.5 Coordination Among Contractors

Communication between logistics, civil works, electrical team, and crane operators is essential.

Conclusion

E-house modular substations offer rapid deployment, reduced on-site labor, and reliable performance for a wide range of industries—particularly renewable energy, oil & gas, mining, and utilities.

However, their success depends heavily on proper transportation and installation. By following the guidance outlined in this article—covering preparation, shipping, lifting, positioning, electrical connections, and commissioning—project teams can significantly reduce risks, avoid delays, and ensure that the E-house operates safely and efficiently from day one.

As a professional manufacturer of medium- and low-voltage switchgear and modular substations, FATENG ELECTRIC provides custom E-house solutions built to IEC, ANSI, or UL standards, complete with engineering support from design to onsite commissioning.