IPS IntegraCoil – Engineering

IPS IntegraCoil - Coil Drawing

IntegraCoil Stator Coils —
designed for on-site rewinds and very large AC stators

High-voltage, AC motors and generators are designed to have multi-turn, form-wound stator coils. In these cases, the stator winding has three separate but interrelated insulating barriers: strand to strand insulation, turn to turn insulation, and ground insulation. Failure of any of these barriers will prematurely terminate the service life of the machine.

All IntegraCoil B-Stage Hard Coils are manufactured to IPS specification with regards to insulation materials and manufacturing processes.  The IntegraCoil design is validated thru extensive qualification testing to prevent strand-to-strand and turn-to-turn shorts which may result from voltage surges. The ground wall insulation contains multiple layers of half-lapped, resin-rich Mica tape, engineered for your specific voltage requirements. On 6.6 kV and higher voltage ratings, we also apply conductive corona tape to the slot portion of the coil to prevent corona discharges in the slot, as well as stress grading tape to help bleed the voltage to non-damaging levels.

IEEE-1043 voltage endurance life test

IEEE 1043 Voltage Endurance Test of IntegraCoil stator coils

25+Year Rewind Design

IntegraCoil stator coils are made using Class F (155 ˚C) rated insulation materials, and meet or exceed the following standards:

  • IEEE-522 Surge Test
  • IEEE-286 Power Factor Tip-Up
  • IEEE-1043 Voltage Endurance
  • ANSI-C50.10 Standards

IPS engineers have designed IntegraCoil rewinds for a 25+year life cycle by incorporating processes and materials that increase your electric motor reliability and mitigates the following winding failures and aging factors:

  • Strand to Strand short
  • Turn to turn short
  • Phase to phase short
  • Grounding in the slot
  • Grounding at edge of slot
  • Shorted Connections or Leads
  • Corona Inception due to Partial Discharge (PD)
  • Mechanical Stresses (e.g. Vibration, Abrasion, Thermal Expansion…)
  • Environmental Stresses (e.g. Moisture, Chemicals, Dirt, Contaminants…)
  • Electrical Stresses (e.g. High-Voltage Applications, Voltage surge / transients…)
  • Thermal Stresses (e.g. Temperature Rise, Hot Spots, Insulation Material Degradation…)

To learn more about our services or to see how IPS can help you, contact your local service representative or email us.