IPS MegaSeal – Checklist

MegaSeal high-voltage Rewind Checklist

MegaSeal is our premium, high-voltage global VPI electrical insulation system for stator rewinds from 6.6 kV to 15KV. It is designed for a 40-year lifecycle providing the highest reliability and lowest total cost of ownership (TCO) in a high-voltage rewind. We’ve installed it in hundreds of electric motors and generators over the last 25+ years, in continuous process plants throughout North America, with zero winding failures. Use this comparison chart to make sure that you’re getting the best and most reliable high-voltage stator rewind for your electric motor or generator.

MEGASEAL Other
Experience
No. of Years 25+
No. of High-Voltage Rewinds 500+
No. of MegaSeal Winding Failures 0
Industries All
Winding Warranty 5 Years
Engineering & Technology
Voltage Rating 6.6 kV – 15 kV
Life Cycle Design 40 Years
Log Life Aging Curve (Available)
Vacuum Pressure Impregnation (VPI)
100% solids epoxy resins
IPS Stator Coil Specification
IPS Rewind Specification
Efficiency Gain Capability
Power (HP) Up-Rate Capability
Insulation Qualification Testing
Available Arrhenious Log Life Aging Curve
Thermal Insulation Class @ 10 Years Class H (180°C)
Thermal Insulation Class @ 20 Years Class F (155°C)
Thermal Insulation Class @ 30 Years Class F (155°C)
Thermal Insulation Class @ 40 Years Class F (155°C)
IEEE 43 – Insulation Resistance > 1 GΩ
IEEE 43 – Polarization Index (PI) Ratio > 4
IEEE 522 Surge Test >5.0 p.u. @ 0.1µs
Partial discharge reading typically < 150 mv
AC Hi-Pot 80+ kV
IEEE 1043 voltage endurance
— 400 Hours @ 120˚C
— 250 Hours @ 120˚C
— 50 Hours @ 120˚C
IEEE 1310 thermal cycling
IEEE 1776-2008 sealed insulation system
VPI Resin and Insulation tape compatibility
Coil Manufacturing
Stator coil specification type Material & Process
Superior Turn Insulation
Superior Ground Wall Insulation:
— Higher Mica Content
— Denser Ground Wall
Sealed Lead Exits
Taped Coil Leads
Surge Test & Hi-Pot Testing
Sacrificial stator coils per Job Qty. 2+
Rewind Process
Typical lead time 7 Weeks
Rush lead time 4 Weeks
Dedicated High-Voltage Resources:
— Winding Clean Room
— Dedicated HV technicians
— Dedicated HV engineers
Calibrated Shop Equipment
Core Loss Testing with Thermography
— Before Stator Burnout
— After Stator Burnout
— Full burnout oven cycle reports
Superior Winding Techniques
— Insulating Materials
— Spacing between coils
— Blocking, Bracing & Lashing
— Series, Pole & Jumper Connections
— Lead Cable Material
— Lead Cable Connections
— Circuit Ring Construction
Vacuum Pressure Impregnation (VPI)
— Calibrated VPI tank
— Full VPI process documentation
— 100% solids epoxy resin
— Resin Viscosity Check
— Sacrificial VPI Coils
Bake Oven Cycle Reports
In-Process Testing:
— Megger™ per IEEE 43
— Surge Test per IEEE 522
— DC Hi-Pot per IEEE 95
— No-load testing
Optional Rewind Testing
Load testing To 4,500 HP @ 15 kV
IEEE 1776-2008 underwater AC hi-pot
IEEE 1043 voltage endurance
IEEE 1434 Corona (TVA) Probe
Doble®
Partial Discharge (PD)
Blackout Test with UV Camera
PdMA Motor Circuit Evaluation (MCE)
ABB Life Expectancy Analysis Program (LEAP)
Available post-installation testing
Insulation Resistance – PI Test
AC and DC Hipot Test
Surge Comparison Test
DC Conductivity Test
Capacitance/Capacitance Tip Up
Dissipation Power Factor Tip Up
Inductive Impedance Test
PdMA MCEmax
ABB LEAP
On-line and Off-line PD Testing
LARGE MOTOR CAPABILITY
— Lifting Capacity 145-tons
— Core Loss Tester 500 kVA up to 30,000 HP
— Burnout Oven 16′ x 15′ x 20′
— Balancing Capability 40+ tons
— VPI tank 14′ dia. X 17′ Deep
— Bake Oven 14′ x 15′ x 20′
— No-load testing To 37,500 HP @ 13.8 kV
— Load testing To 4,500 HP @ 13.8 kV

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