Addressing Escalating Circuit Failure: A Proactive Approach

Electrical connectors, fundamental components of any power distribution system, are subject to inevitable aging and degradation. The only exception to this is a thermal-fusion weld, which effectively eliminates the electrical interface by creating a homogenous connection. The effective electrical interface, responsible for current transmission, represents a fraction of the apparent interface, typically ranging from 1.5% to 7% of the surface area. The discrete contact points facilitating current flow are known as “a-spots,” with the remaining surface areas rendered ineffective due to factors such as chemical reactions and corrosion, most notably the formation of aluminum oxide, a potent electrical insulator.

Connectors are engineered with materials and methodologies to mitigate these chemical effects and maximize the percentage of functional a-spots. However, a natural chemical aging process occurs, leading to corrosion and subsequent separation of the a-spots. This process is accelerated by thermal energy; elevated temperatures directly correlate with an increased rate of electrical interface degradation.

To evaluate connector performance, a metric known as the “k factor” is employed. It’s a comparison of how much resistance the connector has compared to the wire it’s connected to. Ideally, you want this k factor to be less than 1:1. When it exceeds that, especially hitting the point where the connector’s temperature matches the conductor’s, things are considered “failed” by industry standards. Even if it’s slightly above 1:1, the connector might still seem okay because it can get rid of heat better than the wire, but that won’t last. Eventually, it’ll just overheat and go into “thermal runaway.”

Empirical data suggests a typical service life of 40-70 years for utility-class overhead connectors; however, this is contingent upon the quality of workmanship during installation. Suboptimal installation practices lead to premature failure. Additionally, operational temperatures significantly impact connector lifespan. Originally designed for applications with conductors not exceeding 75°C, connectors are now frequently exposed to higher temperatures due to increased grid demand, accelerating the aging process.

To address these challenges without resorting to complete system replacement, Engineered Electrical-Mechanical Shunts with the trade name ClampStar® provide a robust solution. ClampStars are not merely a temporary fix but offer superior performance compared to original connectors, particularly in aged and weathered conductor environments. Designed specifically for such conditions, ClampStars restore mechanical integrity and significantly increase current capacity, well above the original connectors when newly installed.

ClampStars are designed to withstand high temperatures, undergoing testing at significantly elevated levels, and are proven to maintain resistance stability during extended thermal cycling. When compared to traditional, non-shunted splices via infrared thermography, ClampStars demonstrate superior thermal performance and reliability, particularly in aged conductor scenarios.

With installation times of approximately 4 minutes on the smallest units for distribution size conductors to 8-10 minutes for transmission class units for the largest conductors, ClampStar installations are efficient and require minimal tooling, typically an impact driver and a wire brush. Pre-loaded with a proprietary high-temperature inhibitor known as CC² (pronounced as CC Squared) allowing their use on 250°C conductors, and equipped with torque-limiting fasteners, ClampStars are readily deployed on energized conductors, minimizing downtime.

In conclusion, utilizing ClampStars for overhead splices, deadends, and suspension clamps represents an efficient, cost-effective, and technically sound approach to extending the life of aging electrical systems, enhancing performance, and meeting ever-evolving energy demands. This strategy offers a prudent alternative to large-scale replacements while ensuring reliable power delivery.  

ClampStars offer a simple, rapid, and cost-effective way to fully restore mechanical and electrical integrity, meeting today’s growing demands. It’s a smarter way to keep the lights on without breaking the bank.