ClampStar® is proud to be part of the Weather Channel's new show titled "Top 10 Extreme Jobs"

It's no surprise that Helicopter Lineman made the list! The show is currently scheduled to air on Thursday, Oct 27 at 12am EST. Just set your DVR!
Click here to watch a preview


Classic Connectors USA introduces the new ClampStar® Repair Unit

The new ClampStar® Repair Unit quickly and easily corrects damaged conductor, great for gunshot or other types of damage on conductors sized from 2/0 – 1780 kcmil. After brushing the conductor, ClampStar is placed over the damaged area and is installed with only a nut driver.

ClampStar, an engineered mechanical shunt is the industry’s only PERMANENT, life extension solution for virtually all overhead conductors of any voltage class. ClampStar easily installs with NO power interruption and NO mechanical grips, come-alongs, jumper cables or cutters are needed. ClampStar exceeds ANSI C119.4 Class AA, extra heavy duty and restores both electrical and mechanical integrity on weathered conductors.

Additional ClampStar models are also available for correcting failing splices, deadends and suspension clamps on transmission and distribution conductors from #6 AWG thru 2750 kcmil AAC and 2550 ACSR. And ClampStars are also available to handle Overhead Shield Wire and OPGW. ClampStar also increases ampacity allowing for system up-rates to help meet NERC's maximum conductor operating temperature requirements.

ClampStar® THE BEST METHOD TO PERMANENTLY REPAIR & PROTECT DAMAGED CONDUCTOR


ESMO 2016 - The Demo You May Have Missed

If you attended the ESMO show in Columbus, Ohio 2 weeks ago then you may have seen a Haverfield aerial line crew performing some fantastic demonstrations. Click the image below to see a short video of a couple of their demonstrations.

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And for those of you who stopped by the ClampStar booth, "thank you!" We appreciate your time and trust that we were able to satisfactorily answer all your questions.

As the grid ages, many electric utilities are experiencing a large increase in downed lines due to overhead connectors reaching the end of their service life. Installing ClampStars on them before they fail is the best way to prevent outages and protect the public. ClampStar provides a Life Extension solution for virtually all overhead conductors.


Here's What To Do After Finding Hot Connectors

As the grid continues to age, many utilities are increasing connector inspection frequency with a main goal of preventing outages and wire down incidents. One simple and relatively inexpensive line inspection method utilizes Infrared (IR) technology.

The above images were provided by a utility located in Pennsylvania.

Image #1 in the IR photo below shows the interface of the conductor at the entrance of the dead end body at a significantly high temperature.

Image #2 shows the same DE in the Visual Spectrum.

Image #3 shows the same DE cooled following ClampStar installation.

Image #4 shows the now corrected DE in the Visual Spectrum.

 

When helicopters are used to perform line inspections they should be equipped with appropriate ClampStar units so damaged and degraded connectors can be immediately corrected. This results in substantial cost savings compared to returning at a later date and immediately reduces the possibility of downed lines caused by failed connectors.

ClampStar....

  • Lightweight design installs in less than 10 minutes!
  • Permanent installation for deadends, inline splices, suspension clamps, OHSW and damaged conductor
  • Easily installs over existing connectors
  • No mechanical grips, Come-Alongs, jumper cables or cutters needed
  • Installs with hot sticks or barehand
  • Available for copper, composite core and all aluminum stranded conductors

ClampStar units are readily and quickly installed from any aerial platform (including helicopters, click here to see a video).

ClampStar shunts provide an excellent solution for PERMANENT mechanical and electrical upgrade to existing overhead connections. ClampStars are also used to increase the performance rating of existing splices and other connectors, clamps and fittings for the purpose of increasing line ampacity that may be presently limited by such devices.

Each unit is prefilled with proprietary CC² inhibitor to prevent galvanic corrosion and is designed with an integral fastening assembly that provides a high conductivity path and incorporates flat and Belleville washers to maintain compressive force regardless of thermal contraction and expansion.

NOTE: Safe-T-Link Tether assemblies are available for deadend and suspension clamp applications requiring additional mechanical support.

As the grid ages, many electric utilities are experiencing a large increase in downed lines due to overhead connectors reaching the end of their service life. Installing ClampStars on them before they fail is the best way to prevent outages and protect the public.

The smartest grid in the world looks pretty dumb when it is lying on the ground!


Many Utilities Ban The Use of Automatic Splices

There are estimated to be 250 million automatic splices installed on overhead power lines in North America. The majority of which were installed over 30 years ago.

A variety of reports in the field indicate the service life of automatics is as short as five years up to, and perhaps surpassing 30 years.

A recent event, where an automatic splice, installed for only 5 years, let go and dropped a line on a woman, ultimately resulting in her tragic death. The lawsuit resulted in an award of $105 Million!

Unfortunately, due to the advanced age of the power grid, overhead splice failures are increasing at a rapid rate putting the safety of the unsuspecting public at risk.

Google “Swingset Electrocution” to see a video of an overhead power line that came down on top of a metal swing set. Luckily, no children were in the area when this potential catastrophe took place.

As a result of this steadily increasing problem, many utilities have completely banned the use of automatic splices or are limiting their use only for the purpose of emergency restoration.

Many utilities are also correcting and protecting existing splices and overhead connectors by installing permanent ClampStar® shunts on them. ClampStar installs in a few minutes, is relatively inexpensive, and results in a connection of significantly higher integrity than even that of an original, properly installed connector!

CSR-0325-015 Protect with CS

ClampStar® is intended to correct and reinforce the deteriorated electrical and mechanical performance of hot-running, aged or degraded splices and other connectors.

ClampStar, along with proactive maintenance practices improves safety and prevents unplanned outages. ClampStar is the industry’s only PERMANENT solution for protecting overhead splices and connectors.

ClampStar is the least expensive insurance you can buy!


Classic Connectors USA Introduces Overhead Shield Wire (OHSW) Protection And Correction

When attending the upcoming IEEE show in Dallas, please visit the Classic Connectors booth #4736 to see the new ClampStar® for Overhead Shield Wire. This new ClampStar is designed for both tangent and deadend applications as well as splices.  Full tension on galvanized and HSS, as well as Alumoweld and OPGW!  Both insulated and non-insulated versions are available.  An option for copper is also offered. All the features you’d expect from ClampStar: prefilled with a proprietary inhibitor, torque-shear fasteners, First Class, High Integrity Solutions!

  • Lightweight design installs in less than 10 minutes!
  • Easily installs over existing connectors
  • No mechanical grips, Come-Alongs, jumper cables or cutters needed
  • Installs with a hot stick or barehand

ClampStar OHSW units are a permanent repair fitting composed of an attachment head, which connects to the OHSW and a connecting link that attaches to the tower bracket. This connecting link is available in either an insulated or non-insulated design based on the application. A custom bracket is included to anchor the assembly to the tower. This unit serves as an OSHW safety catch to prevent the shield wire from falling into the energized conductors or substation bus below.

ClampStar units are readily and quickly installed from any aerial platform (including helicopters). ClampStar units may be used for a variety of repair situations, at splices, dead-ends, suspension systems, or wherever conductor or attachment hardware damage has occurred, or may occur.

ClampStar shunts provide an excellent solution for PERMANENT mechanical and electrical upgrade to existing OSHW connections.  ClampStar will meet NERC's requirements for OHSW safety anchors without costly replacement, repair or expensive downtime.

Each unit is prefilled with proprietary CC3 inhibitor to prevent galvanic corrosion and is designed with an integral fastening assembly that provides a high conductivity path and incorporates flat and Belleville washers to maintain compressive force regardless of thermal contraction and expansion.

As the grid ages, many electric utilities are experiencing a large increase in downed lines due to overhead connectors reaching the end of their service life. Installing ClampStars on them before they fail is the best way to prevent outages and protect the public.

The smartest grid in the world looks pretty stupid when it is lying on the ground!

Other ClampStar distribution and transmission products will be on display. There will also be a hands-on demonstration. Come on by and discuss your specific application with our engineers.

We look forward to seeing you in Dallas!


Classic Connectors USA Introduces a New Transmission Class ClampStar® That Substantially Decreases Total Installation Time

This new ClampStar model CSR-1631-048 is designed to protect and thermally uprate connectors to meet n-1 contingency conditions as well as continuous service on overhead transmission lines with Aluminum and ACSR type conductors sized from 1272 Bittern to 1780 Chukar and up through 2000 kcmil Cowslip AAC

Each unit is prefilled with proprietary CC2 inhibitor to prevent galvanic corrosion and is designed with an integral fastening assembly that provides a high conductivity path and incorporates flat and Belleville washers to maintain compressive force regardless of temperature induced contraction and expansion.

ClampStar shunts provide an excellent solution for PERMANENT mechanical and electrical upgrade to existing conductor connections. And ClampStar helps meet NERC's maximum conductor operating temperature requirements without costly replacement, repair or expensive downtime. Additional sizes are available for splices, suspension clamps, deadends, and damaged conductor repair. ClampStar units are designed for use on ACSR, AAC, AAAC, ACAR, ACSS & Fiber composite core. ClampStar units are also available for use on copper conductors.

·       New lighter weight design installs in less than 10 minutes!

·       Decreases total installation time by 70 - 80%

·       Easily installs over existing connectors

·       No mechanical grips, Come-Alongs, jumper cables or cutters needed

·       Installs with a hot stick or barehand


The most cost-effective, technically superior, uprate technology alternative

In 2000, NERC began advising utilities to consider actual field conditions to confirm transmission line thermal ratings. In turn, many utilities have surveyed transmission lines to identify critical issues and determine whether their lines are capable of meeting required contingencies.

Depending on line length, utilities may have to replace dozens or even hundreds of compression dead-ends and mid-span splices. Field crews not only have to work on tight schedules, but obtaining clearances to de-energize lines may not be an option. If outages can be obtained, circumstances may require a utility to fund spinning reserve from another source to accommodate the outage if the duration of the transferred load exceeds the capacity of the alternate source. To circumvent these challenges and save a substantial amount of money and time in the field, proven technology that first became available in 2008 provides airborne power line contractors the ability to assist utilities by installing shunt technology via helicopter.

Click here to read the latest T&D World Magazine article about the most cost effective, technically superior alternative for uprating and repairing overhead transmission lines. You'll learn how to quickly restore both mechanical and electrical integrity to connectors with a single device, designed to be installed on energized lines without the need for power interruptions.

Click here to watch the Air2 aerial lineman install ClampStars.


Classic Connectors USA Introduces the Newest ClampStar®, The Latest in Connector Corrector Technology, for Use on Copper Conductor

January 15, 2015 -- Classic Connectors USA, CSR-0325L-007-P is designed to protect automatic splices on overhead, copper conductor sized from #6 - #2 AWG. In addition to torque limiting nuts, each unit is supplied with nickel-plated keepers, and is prefilled with proprietary CC² inhibitor to prevent galvanic corrosion. The unit weighs 1.75 lbs. and can be easily installed on an energized line with a hot-stick or gloves. ClampStar® helps avoid potential catastrophes and expensive lawsuits resulting from failing overhead splices. In just minutes, this eliminates risk and prevents connector failures before they occur, without costly replacement, repair, or expensive downtime. Additional sizes for use with copper are available for splices, suspension clamps, dead-ends, and damaged conductor repair. ClampStar units are also available for use on all aluminum stranded conductors, e.g., ACSR, AAC, AAAC, ACAR, ACSS & fiber composite core.


International Lineman's Rodeo Video Montage

This video pays tribute to the those highly trained and dedicated individuals that keep the lights on. They're out there in extreme conditions doing what they do best and we appreciate it!

https://www.youtube.com/watch?v=giqfz_8d4OY