1、 Product Overview

High voltage fully insulated copper tube busbar is a transmission equipment with high conductivity copper tube as the core conductor and high-performance insulation material wrapped on the outer layer. It has the characteristics of high current carrying capacity, excellent insulation performance, and high mechanical strength. Its design voltage level usually covers 35kV to 252kV, suitable for complex power scenarios, and is an upgraded alternative to traditional rectangular busbars, cables, and aluminum alloy busbars.

2、 Core application areas

1. Ultra high voltage substations and switch stations

In substations with voltage levels of 500kV and above, fully insulated copper tube busbars are used to connect the high-voltage circuit between the main transformer and the circuit breaker. Its compact cylindrical structure can optimize spatial layout, reduce inter phase distance, and the fully insulated design avoids bare conductor exposure, reducing the risk of pollution flashover. For example, in coastal areas with high salt spray, fully insulated structures can effectively prevent insulation failure caused by salt deposition.

2. New energy generation system

-Hydroelectric power station: The outlet of large hydroelectric units needs to withstand high short-circuit current impact. The high mechanical strength (able to withstand dynamic stable current of 4 times the rated current) and low resistance characteristics of copper tube busbars can reduce the electric power damage during faults.

-Photovoltaic power station: In harsh environments such as high temperatures and sandstorms, fully insulated copper tube busbars have better resistance to UV aging than cables, and do not require additional protective measures. They can be directly laid overhead or underground.

-Wind Farm: The humid salt spray environment of offshore wind power is highly corrosive to conductors, and the corrosion resistance of copper materials is significantly better than that of aluminum materials. Combined with fully insulated design, it can extend the service life of equipment.

3. Urban underground pipe gallery and compact distribution network

In underground utility tunnels in cities, the small cross-section of copper tube busbars (which reduces the cross-sectional area of copper tubes by 30% to 50% compared to rectangular busbars under the same current carrying capacity) can save passage space. Its fully insulated characteristics do not require additional insulation brackets, simplifying the installation process, especially suitable for multi circuit shared corridor scenarios.

4. Industrial load intensive areas

The internal power grids of large enterprises such as steel and petrochemicals have high requirements for power supply reliability. The low resistance characteristics of copper tube busbars (with a copper conductivity of 108% IACS at 20 ℃) can reduce line losses, while the fully insulated structure can resist the invasion of chemical corrosive gases, ensuring long-term stable operation.

3、 Analysis of Core Advantages

1. Efficient conductivity and energy efficiency

The resistivity of copper is only 60% of that of aluminum, and under the same current carrying capacity, the loss of copper tube busbar is reduced by more than 40% compared to aluminum alloy busbar. Taking a 100MVA transformer as an example, using copper tube busbar can save about 120000 kWh of electricity per year, significantly improving energy utilization efficiency.

2. Mechanical properties

-The cylindrical structure makes its bending strength 2-3 times that of a rectangular busbar, and can withstand external impacts such as earthquakes and wind strikes.

-Tubular conductors have no eddy current effect and exhibit better skin effect under alternating magnetic fields, making them particularly suitable for high-frequency harmonic environments.

3. Lifecycle reliability

-The outer layer is insulated with silicone rubber or epoxy resin, with a weather resistance of C5 level (the highest anti-corrosion level), and maintains elasticity even at special temperatures ranging from -40 ℃ to+105 ℃, eliminating the risk of cracking.

-The sealed structure has passed the IP68 protection level test and can operate in water immersion, suitable for wet scenarios such as water conservancy hubs.

4. Convenience of installation, operation and maintenance

-Modular design supports factory pre assembly, with only lifting and docking required on site, shortening the construction period by 50% compared to traditional busbars.

-The maintenance free cycle is up to 30 years, which reduces the overall cost by 30% compared to the 10-15 year replacement cycle of cables

5. Environmental adaptability

-Outstanding ability to resist electromagnetic interference, it can be installed closely to communication equipment without generating signal interference.

-Copper materials can be 100% recycled, meeting the requirements of green power grid construction.