Tubular busbar terminal clamp connector for aluminum tube conductors
Tubular busbar insulator support clamp with mounting base plate
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Tubular Busbar Support Clamp for High Voltage Substations | YiHaoPower

The Tubular Busbar Support Clamp is a heavy-duty high-voltage substation fitting engineered for mounting and securing rigid aluminum tubular busbars onto post insulators and switchgear terminals.

  • Cast Aluminum Alloy Construction: Fabricated from high-strength, non-magnetic aluminum alloy to eliminate electrical hysteresis losses and prevent eddy current heating.
  • Smooth Anti-Corona Contours: Radiused edges and smooth surface profiling minimize electric field gradient concentration and prevent corona discharge in extra-high-voltage (EHV) substations.
  • Fixed & Expansion (Sliding) Configurations: Available in rigid fixed clamps and sliding expansion supports to accommodate thermal expansion and contraction of long tubular conductors.
  • Short-Circuit Mechanical Restraint: Heavy-duty clamping bolts and robust hinge pins deliver exceptional mechanical shear strength against electro-dynamic short-circuit forces.

Need Custom Busbar Diameters, Insulator Pitch Circles, or Flexible Terminal Jumpers? Contact the YiHaoPower engineering team today for technical data sheets, dimensional drawings, and direct factory wholesale quotes.

SKU: YHP-EP-TBCSERIES Categories: , Tags: , ,

Product Overview: Tubular Busbar Support Clamp

The Tubular Busbar Support Clamp (TBC Series High-Voltage Busbar Hardware) is an essential power substation connection fitting designed to support rigid seamless aluminum tubular conductors on post insulators. Manufactured by YiHao Power, our busbar support clamps are cast from high-purity aluminum alloys. Engineered to satisfy international manufacturing and safety standards for extra-high-voltage substation hardware, each Tubular Busbar Support Clamp provides superior electrical conductivity, anti-corona protection, and structural rigidity under extreme wind loads and short-circuit fault conditions.

Technical Specifications

Parameter Specification
Product Series TBC Series Tubular Busbar Clamps & Support Fittings
Body Material High-Strength Corrosion-Resistant Cast Aluminum Alloy (A356 / ZL101)
Support Function Rigid Fixed Type / Sliding Expansion (Expansion Joint) Type
Fasteners & Pins Hot-Dip Galvanized Steel / Stainless Steel (A2-70 / A4-70) with Cotter Pins
Tube Outer Diameter Range 50mm, 70mm, 80mm, 100mm, 120mm, 150mm, 200mm, 250mm
Standard Compliance UL / BS / IEC / ISO International Standards Compliant
Application Scope Substation Post Insulator Supports, Transformer Terminals, EHV Switchyards

Key Performance Features of Our Tubular Busbar Support Clamp

  • Non-Magnetic Design Eliminates Power Losses: Cast aluminum alloy construction is non-ferrous, preventing magnetic flux loops and inductive heating around heavy AC current-carrying tubular conductors.
  • Corona-Free Geometry for EHV Systems: Smoothly rounded body edges and recessed hardware pockets reduce electric field intensity, preventing radio interference and corona loss in high-voltage substations.
  • Thermal Expansion Accommodation: Sliding-type support clamps feature smooth internal bearing surfaces that allow rigid aluminum tubes to expand and contract linearly during temperature shifts without over-stressing post insulators.
  • High Short-Circuit Resistance: Heavy-wall cast clamping jaws and high-tensile hardware prevent conductor deformation or dislodgement under violent electromagnetic forces during short-circuit faults.

Installation Guidelines for Substation Tubular Busbars

Proper selection and mounting of a Tubular Busbar Support Clamp system ensures structural integrity and electrical reliability across substation switchyards. Follow these standard field practices:

  1. Fixed vs. Sliding Clamp Placement: Install one fixed support clamp at the center of each long tubular busbar section and sliding expansion clamps on all remaining post insulators to allow symmetrical thermal movement.
  2. Insulator Base Mounting: Bolt the lower mounting base plate to the top cap of the post insulator using matching metric bolts and spring washers.
  3. Tube Alignment & Clamping: Lower the aluminum tubular conductor into the cushioned clamp bed. Attach the upper half-clamp and torque clamping bolts evenly to specification.

Primary Application Scenarios Across Substation Facilities

Our premium busbar support clamps and terminal hardware are widely installed across global electrical power projects, including:

  • Outdoor high-voltage transformer yards, circuit breaker bays, and disconnect switch connections.
  • Main rigid tubular busbar runs mounted on porcelain or composite post insulators.
  • Gas-Insulated Switchgear (GIS) outdoor bushings and surge arrester connections.
  • Industrial power plant main bus ducts and heavy-current distribution switchyards.

Frequently Asked Questions (FAQ)

Q1: Why are both fixed and sliding Tubular Busbar Support Clamps used on long busbar runs?

A1: Fixed clamps anchor the busbar in position, while sliding clamps allow the aluminum tube to expand or contract with temperature changes, preventing severe bending forces on post insulators.

Q2: What feature prevents corona discharge on high-voltage busbar clamps?

A2: Smooth, well-rounded outer contours and recessed bolt pockets eliminate sharp metal points where high electric field stress accumulates, thereby suppressing corona discharges.

Quality Assurance & Factory Testing

Every batch of Tubular Busbar Support Clamp products manufactured by YiHao Power undergoes rigorous quality control inspection before dispatch. Our testing protocols include aluminum alloy chemical spectro-analysis, mechanical cantilever load testing, micro-ohm contact resistance checks, and corona/RIV testing for high-voltage ratings.

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