IPS MegaSeal – Process

IPS MegaSeal™ —
Complete control of all material, coil manufacturing and rewind processes

Optimized, qualified and documented high-voltage process

MegaSeal™ is our patented, premium, global VPI electrical insulation system for high-voltage AC motors and generators from 6.6 kV to 15 kV operating in severe, dynamic conditions. It’s designed to provide the reliability and performance you need for the most demanding high-voltage applications while supporting an industry leading 5-year warranty and 40-year design life. Developed with extensive laboratory and material testing, the MegaSeal engineered insulation system consists of optimized high-voltage technologies, processes and materials which yield performance and durability that lead the industry. We test our coils, resins, tapes, lead cables and insulating materials. We calibrate every piece of equipment that touches a MegaSeal rewind — hand tools, VPI tanks, ovens and test equipment. Everything is qualified, documented and ready for your review.

Dedicated high-voltage and large motor repair resources

IPS MegaSeal high-voltage repair process includes dedicated facilities and veteran high-voltage rewind specialists. We do multiple high-voltage rewinds each month, meaning that our high-voltage technicians and engineers are truly specialists in the repair industry. They live high-voltage on a daily basis. Our facilities are also equipped and experienced in dealing with larger and extra-large motors and generators. This includes lifting capacity of 145 Tons, 14’ VPI tanks, load testing to 13.8 kV, core loss testing to 500 kVA and the largest ovens.

Environmental controls for Foreign Material Exclusion (FME)

All MegaSeal stator rewinds are conducted in clean and controlled environments to ensure optimum materials performance and rewind integrity. These environmental controls help prevent dirt or contamination throughout the process.

Coil testing before and after insertion

We surge test coils before and after insertion in the stator core, according to IEEE 522 standards. We also perform in-process proof tests on the entire winding for added assurance of winding integrity. Sample coils regularly undergo IEEE 1043 high-voltage endurance testing.

Rewinding for maximum structural integrity

With the coils inserted into stator slots and top sticks in place, IPS technicians lash the coils to surge rings, then block the coil heads by lashing Dacron® mat and polyester laminate. This ensures negligible coil movement in severe-duty applications, such as plug reversals or across-the-line starts. IPS technicians also provide superior series, pole and jumper connections that provided increased reliability to every rewind.  We also hand tape our circuit rings for increased winding reliability.

Lower vacuum—higher pressure eliminates voids and seals stator coils

Every stator undergoes computer-controlled vacuum pressure impregnation—ensuring a homogenous fill and void-free insulation for maximum durability, maximum structural integrity and maximum resistance to abrasion, chemicals and moisture.  Each PowerSeal rewind includes a minimum of two sacrificial stator coils that are “wet checked” after VPI to validate complete resin penetration and saturation of stator coil insulation tapes.

Oven curing for improved durability

We oven cure each stator after the VPI cycle. This reinforces the previous steps of lashing the coils, blocking the coil heads and vacuum pressure impregnation, to turn the winding into a solid, rugged system.  We also apply an overcoat for added environmental protection.

Reliability. Delivered.

We performance-match all MegaSeal materials and processes to deliver the reliability you need from your rewind. We offer optional testing such as IEEE 1776-2008 Sealed Insulation System (water immersion AC Hi-Pot testing to voltage rating x 1.15) to validate our MegaSeal high-voltage rewind.

IPS clean winding rooms

Dedicated clean rooms for winding and repairing high-voltage motors, applying best practices for Foreign Material Exclusion (FME).

Dedicated IPS high-voltage technicians

IPS high-voltage technicians apply best rewinding practices ensuring maximum structural integrity.

IPS Superior rewinding techniques

Superior winding techniques and materials provide increased reliability for series, pole and jumper connections.  and taped circuit rings provide increased reliability.

IPS 14' VPI tank premium rewinds

IPS can VPI high-voltage stators up to 14 feet in diameter.

VPI Oven

Oven curing forms a solid, rugged impenetrable winding.

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