Parameter Table for Tubular Busbars

Tubular busbars are hollow conductor systems designed for high-current distribution in substations, with parameters defined by material, current rating, fittings, insulation, and structural support.

Material and Construction

Tubular busbars are typically manufactured from aluminium tubes for new installations, while copper tubes are used for extensions to existing copper systems unless a break in the system allows aluminium to be used. The choice of material affects conductivity, weight, and compatibility with fittings. Aluminium busbars are supplied with continuous current ratings of 1250 A or 2000 A.

Fittings and Connectors

Fittings for tubular busbars are designed to avoid deformation of the tube conductor and ensure reliable electrical contact. All terminal fittings employ current-carrying half clamps, with the number of clamps determined by the current rating. Fixed fittings always use two complete clamps for mechanical stability.

Special precautions are required for copper-to-aluminium connections to prevent electrochemical corrosion.

Insulation and Electrical Properties

Tubular busbars may use adhesive-coated insulation materials such as Nomex®, Tedlar®, Mylar®, Kapton®, Ultem®, or epoxy-glass to provide electrical isolation and environmental protection. Insulation affects capacitance, inductance, and impedance, which are critical for maintaining system performance and minimizing voltage drop.

Support Structures

Busbars are mounted on support insulators and structural frameworks designed to withstand short-circuit forces, wind loading, and mechanical stresses as per BS EN 61936-1. Proper spacing and support placement are essential to maintain short-circuit strength and thermal performance.

Thermal and Electrical Ratings

The permissible busbar temperature depends on current, cross-section, surface area, and ambient conditions. Centralized infeed and symmetrical load distribution optimize thermal performance. Continuous current ratings are specified according to ENA TS 41-11 for aluminium and ENA TS 41-16 for copper systems.

Standards and Compliance

Tubular busbars must comply with national and international standards, including BS EN 61936-1 for high-voltage installations and ENA technical specifications for fittings and current ratings. Compliance ensures safety, reliability, and compatibility with substation equipment.

Summary

Key parameters of tubular busbars include: Material: Aluminium (new) or Copper (extensions)Current Rating: 1250 A or 2000 AFittings: Half clamps, designed to prevent deformationInsulation: Various high-performance materials for electrical and environmental protectionSupport: Insulators and structures rated for mechanical and thermal loadsStandards: BS EN 61936-1, ENA TS 41-11/41-16Thermal Performance: Dependent on load distribution, cross-section, and ambient conditions These parameters ensure that tubular busbars provide efficient, safe, and reliable power distribution in outdoor primary substations up to 132 kV.