Numerical Investigation on Thermal-Mechanical Coupling Behavior and Fire Resistance Performance of Steel Structures in Substation Fires

Transformer fires within indoor substations constitute severe hydrocarbon fire scenarios characterized by rapid heat release rates and extreme peak temperatures, posing a critical threat to the structural integrity of steel frameworks and power grid stability. To rigorously assess structural safety under such conditions, this study employs a sequential thermal-mechanical coupled numerical methodology combining Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA). Focusing on a 110 kV indoor substation, the research simulates the transient, non-uniform temperature fields induced by transformer oil combustion and analyzes the thermo-mechanical response of key steel components. Furthermore, the protective efficacy of two non-intumescent coatings (Material A and Material B) with distinct thermal conductivities is systematically evaluated. Computational results elucidate significant thermal stratification, with upper-level structures sustaining exposure to temperatures exceeding 1500 K. Unprotected steel components subjected to direct flame impingement exhibit severe stress concentrations and plastic deformation, reaching their load-bearing limit within 4825 s. The application of fire-retardant coatings markedly enhances fire resistance; a 5 mm layer of Material A (λ = 0.20 W/(m·K)) extends the time to failure to approximately 9390 s. Notably, increasing the thickness of Material A to 20 mm, or alternatively employing a 10 mm layer of Material B (λ = 0.10 W/(m·K)), effectively mitigates thermal stress concentrations. This ensures structural deformation remains within safe limits throughout a 3 h (10,800 s) fire duration. This study provides a theoretical basis and quantitative engineering references for the optimal fire protection design of substation steel structures.