{"id":1451,"date":"2024-06-27T18:28:59","date_gmt":"2024-06-27T17:28:59","guid":{"rendered":"https:\/\/www.weidmann-group.com\/news\/optimize-transformer-insulation-systems-a-qa-with-brad-greaves-laboratory-services-manager-at-weidmann\/"},"modified":"2026-04-29T14:03:57","modified_gmt":"2026-04-29T13:03:57","slug":"optimize-transformer-insulation-systems-a-qa-with-brad-greaves-laboratory-services-manager-at-weidmann","status":"publish","type":"post","link":"https:\/\/www.weidmann-group.com\/de\/news\/optimize-transformer-insulation-systems-a-qa-with-brad-greaves-laboratory-services-manager-at-weidmann\/","title":{"rendered":"Optimize Transformer Insulation Systems: A Q &amp; A with Brad Greaves, Laboratory Services Manager at Weidmann"},"content":{"rendered":"\n<p><strong>In this article, we explore with Brad how transformer manufacturers can optimize the insulation system to reduce cost, optimize design, and improve the supply chain.<\/strong><\/p>\n\n\n\n<p><strong>Q1. Please provide an overview of a few key insulation design concepts that can contribute to a more optimized insulation system.<\/strong><\/p>\n\n\n\n<p>Three key concepts that can improve the design of liquid-immersed core form power transformers are:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Milled spacers<\/li>\n\n\n\n<li>Calendered crepe conductor insulation<\/li>\n\n\n\n<li>Low-density pressboard barriers<\/li>\n<\/ul>\n\n\n\n<p><strong>Q2. Explain the benefits of milled spacers as a substitute for un-milled board.<\/strong><\/p>\n\n\n\n<p>There are multiple benefits of substituting un-milled board with milled spacers, such as:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Reduced thickness variation allows for a more precise and consistent winding&nbsp;height<\/li>\n\n\n\n<li>Predictable shrinkage after the drying process due to consistent material thickness and moisture compensation during the milling process<\/li>\n\n\n\n<li>Improved compressibility characteristics; reduced and consistent compressibility across all thicknesses<\/li>\n<\/ul>\n\n\n\n<p><strong>Q3. Why choose Calendered Crepe paper to wrap the conductors<\/strong><\/p>\n\n\n\n<p>The benefits of using Calendered Crepe paper as conductor insulation include:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>High dielectric strength \u2013 determined by thickness and number of layers<\/li>\n\n\n\n<li>High tensile strength and high elongation \u2013 allowing the paper to be wrapped as tightly as possible (controlling turn-to-turn thickness)<\/li>\n\n\n\n<li>Enhanced moisture resistance \u2013 the calendering process reduces the porosity of the paper, decreasing moisture absorption and improving performance with insulating fluids<\/li>\n<\/ul>\n\n\n\n<p><strong>Q4. How do Low-Density Pressboard barriers contribute to optimizing transformer design?<\/strong><\/p>\n\n\n\n<p>Low-density pressboard, manufactured from cellulose materials and impregnated with mineral oil, typically displays the following values:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Dielectric stress distribution is inversely proportional to the material permittivity for better operational efficiency<\/li>\n\n\n\n<li>Using a low-density board (instead of a high-density board) brings the relative permittivity of the solid closer to the relative permittivity of the liquid \u2013 reducing the stress in the liquid and improving insulation performance<\/li>\n\n\n\n<li>Replacing hi-lo barriers from high-density pressboard (T4) to low-density pressboard (Hi-Val) results in a shift of the dielectric stress away from the liquid and an increase in the percent margin during the Insulation Design Analysis.<\/li>\n<\/ul>\n\n\n\n<p><strong>Q5. How would you summarize this topic?<\/strong><\/p>\n\n\n\n<p>As part of the global&nbsp;<a href=\"https:\/\/weidmann-electrical.com\/transformer-services\/\">Weidmann Technical Engineering Services<\/a>&nbsp;team, we utilize these concepts, among many others, to provide Optimized Insulation Design Analysis Services.<\/p>\n\n\n\n<p>Some of the primary insulation design concepts that contribute to a more optimized&nbsp;<a href=\"https:\/\/www.sciencedirect.com\/science\/article\/pii\/S111001682200028X#:~:text=One%20of%20the%20main%20parts,2%5D%2C%20%5B3%5D.\">insulation system<\/a>&nbsp;are:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>By utilizing milled spacers, windings can be manufactured with improved sizing control and have improved compression characteristics<\/li>\n\n\n\n<li>By creping and then calendaring conductor insulation, the strength, and elongation are significantly improved, allowing for high tension during the wrapping process, which provides an improved space factor<\/li>\n\n\n\n<li>Utilizing pressboard barriers with lower relative permittivity (closer to that of the liquid) lowers the dielectric stress in the liquid, allowing for smaller oil gaps<\/li>\n<\/ul>\n\n\n\n<p>Get more insights from Brad Greaves by watching his presentation at the&nbsp;<a href=\"https:\/\/ieeet-d.org\/\">IEEE PES<\/a>&nbsp;Expo.<\/p>\n\n\n\n<figure class=\"wp-block-embed is-type-rich is-provider-embed-handler wp-block-embed-embed-handler\"><div class=\"wp-block-embed__wrapper\">\nhttps:\/\/youtube.com\/watch?v=9Kimol107yY%3Ffeature%3Doembed\n<\/div><\/figure>\n","protected":false},"excerpt":{"rendered":"<p>In this article, we explore with Brad how transformer manufacturers can optimize the insulation system to reduce cost, optimize design, and improve the supply chain. Q1. Please provide an overview of a few key insulation design concepts that can contribute to a more optimized insulation system. Three key concepts that can improve the design of [&hellip;]<\/p>\n","protected":false},"author":7,"featured_media":1079,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[34],"tags":[],"class_list":["post-1451","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-industry-insight-de"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.5 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Optimize Transformer Insulation Systems: A Q &amp; A with Brad Greaves, Laboratory Services Manager at Weidmann - Weidmann Group<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.weidmann-group.com\/de\/news\/optimize-transformer-insulation-systems-a-qa-with-brad-greaves-laboratory-services-manager-at-weidmann\/\" \/>\n<meta property=\"og:locale\" content=\"de_DE\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Optimize Transformer Insulation Systems: A Q &amp; A with Brad Greaves, Laboratory Services Manager at Weidmann - Weidmann Group\" \/>\n<meta property=\"og:description\" content=\"In this article, we explore with Brad how transformer manufacturers can optimize the insulation system to reduce cost, optimize design, and improve the supply chain. 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