Metals and Steel Mill Motor Repair

IPS combines single-source capabilities and deep experience in metals and steel mill motor repair. Our coast-to-coast network of regional service centers place us in every major steel market in the U.S., for immediate-response emergency repair services and outage support.

We supply electric motor and generator repair services, field services and new product sales, as well as remanufacturing, in-house stator coil manufacturing of B-Stage fully cured coils and VPI engineered insulation systems. Whether we’re working within a planned outage window or fast-tracking emergency services, we deliver with turn times the competition can’t come close to matching (IPS Lean, our company-wide continuous improvement culture, continues to improve the industry’s leading turn times).

Large DC motor and generator repair

Much of our work in steel mills focuses on large DC armatures and field frames. Most mills run their large DC motors at 250% overload — over time, this results in predictable problems. We have extensive experience in reconditioning and rewinding large DC motors. We also diagnose and correct ground issues and carbon buildup on brushes, correct burning on leading and trailing edges, and remove surface contamination, such as pickling and acid damage.

We can transport large DC motors (up to 145-tons) to our service centers via supercarrier or rewind on site. Our DC rewinds offer significant improvements in dielectric and thermal performance, as today’s insulating materials are superior to those used by OEMs in the 20th century.

AC motor and generator rewind technologies

Developed in the research laboratory and backed by decades of use in motors and generators around the world, IPS engineered insulation systems provide the reliability and performance for your most demanding applications. IPS rewind technologies are available with electric motor redesign or uprates, and mechanical modifications to enclosures, shafts, seals, fans and bearings:

• IntegraSeal™ B-stage coils up to 15 kV
• MegaSeal™ VPI engineered insulation systems from 6.6–15 kV
• EnduraSeal® VPI engineered insulation systems up to 6.6 kV

In-house coil manufacturing

IPS Glassport manufactures a wide range of stator, rotor, armature and field coils up to 15 kV. In-house manufacturing means better QA and quick turn times for emergency repairs. Combining control of coil manufacturing with the rewind process ensures superior quality and performance with minimal downtime.

We have extensive engineering and manufacturing experience with all major OEM coil designs, plus an engineering form coil database with over 100,000 design configurations, including all Allis Chalmers designs.
 

Comprehensive Testing

IPS has the industry’s most advanced array of diagnostics, to validate recommendations, document “as received” and “as shipped” performance, and support one standard for quality coast to coast.

• AC test panel to 7.5 MVA / 15 kV
• DC test panel to 1,750 A / 1,000 VDC
• No-load testing to 37,500 HP
• Dynamometer load testing to 4,500 HP
• 500 kVA Core loss testing
• IEEE 429 water immersion
• IEEE 1043 voltage endurance
• Additional in-shop/ on-site diagnostics:
   • Doble®
   • Partial discharge
   • EL CID
   • Corona probe
   • MCE

Field services

IPS field services deliver coast-to-coast resources and capabilities to you. Whether we’re mobilizing for an emergency or working within a planned outage, we bring more experienced technicians and more tools to the job.

We supply a complete range of field-services for AC and DC motors (including specialty motors and older, unsupported units), embedded generators and mechanical components — gearboxes, pumps, compressors and fans. Over time, we can help move your operation from a reactive, repair-focused approach to more cost-efficient, planned maintenance.

Our dedicated field service teams have spent years on-site in mills and metal plants, troubleshooting, developing highly engineered solutions and keeping downtime to a minimum. They’re backed by some of the industry’s leading thinkers in testing, maintenance and repairs.

Mechanical repairs

We specialize in mechanical services and mill work on large, highly engineered components. IPS repair technicians have spent years working on the mechanical power transmission components in mills and metals manufacturing. We also rebuild gearboxes, pumps and blowers. Our machining services include:

• Lathes: up to 126” x 384”
• Vertical milling
• Horizontal milling
• Planer milling
• Pressing up to 600 tons
• Diamond burnishing
• Nickel brush plating
• Flame spray metalizing
• Sub-Arc/MIG/TIG welding
• Bearing rebabbitting

Custom Manufacturing

Have an old synchronous or adjustable speed motor you can’t replace? IPS remanufactures both, along with large and extralarge DC motors, generators, transformers and rectifiers — all to OEM spec. We also uprate for more power density and reliability.

IPS reverse engineers older, unsupported assets and has national repair and service agreements with the leading OEMs. This gives our engineers and technicians access to OEM drawings, parts and engineering support, when you need a replacement motor and a substantially shorter lead time (thanks to IPS Lean, we can deliver remanufactured units with turn times in months or even weeks).

Base Fan Motor Exchange Units

Deep inventory of critical spares, rebuilt to OEM specifications and available for delivery. For more information, contact IPS Chicago at 800.978.4559
or IPS Detroit at 800.992.9466.

Mill-Duty Motor Exchange Units

Deep inventories of mill-duty motors available, plus replacement parts such as carbon brushes and brush holders.

To learn more about our single-source capabilities for metal manufacturing, talk to your regional IPS sales representative or contact us.