IPS PowerSeal – Testing

Quality Assurance —
Documented and ready for verification

For every PowerSeal rewind, IPS conducts in process and post rewind testing on every motor and generator. Every PowerSeal rewind comes with the following testing and documentation:

Extensive PowerSeal design qualification testing
  • IEEE 1043 Voltage Endurance Testing
    (Simulates 40 years of life cycle)
    — 400 Hours @ 120˚C
    — 250 Hours @ 120˚C
    — 50 Hours @ 120˚C
    — Minimal visual insulation degradation after test completion
  • IEEE 1310 Thermal Cycle Testing
    (Simulates the impact of temperature fluctuations)
  • After thermocycling, the turn to turn insulation meets and exceeds the IEEE 522 Surge Testing (see video)
  • AC Hi-Pot to Destruction
    — 4,160 VAC at 40+ kV (see video)
    — 6,600 VAC at 65+ kV (see video)
  • IEEE 1776-2008 Sealed Insulation System
    (Water immersion AC Hi-pot test)
In-process testing for all PowerSeal stator rewinds
  • Core loss test with IR thermography
    — Max. 500 kVA up to 30,000 HP
    — Before and after burnout process
  • Insulation Resistance per IEEE 43 specification
    — Insulation resistance (Megger® Test)
    — Polarization Index (PI)
  • Turn insulation test (surge test)
    — per IEEE 522 specification
  • DC Hi-Pot Test
  • Phase balance test
  • Burnout & bake oven temperature cycle reports
  • Full VPI Process Cycle Documentation
    • dry vacuum
    • wet vacuum
    • pressure
    • sacrificial coil wet check
    • temperature
    • cycle time
    • resin viscosity
Optional tests available for PowerSeal rewinds
  • No-Load and Load Testing up to 13.8 kV
  • AC Hi-Pot Test
  • IEEE 1776-2008 Sealed Insulation System
    (underwater AC Hi-pot at 1.15 X Rated Voltage)
  • IEEE 1043 voltage endurance test
  • Partial Discharge (PD) testing
  • Power Factor Tip Up/Dissipation Factor per IEEE 286
    (Doble® Test)
  • Partial Discharge Testing to IEEE 1434
    — Corona (TVA) Probe
    — Blackout test
    — UV Camera testing
  • PdMA Motor Circuit Evaluation (MCE)
  • ABB Life Expectancy Analysis Program (LEAP)
Available post-Installation testing for PowerSeal rewinds
  • 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 Motor Circuit Evaluation (MCEmax) Testing
  • ABB Life Expectancy Analysis Program (LEAP)
  • On-line and Off-line Partial Discharge (PD) Testing
High Voltage Surge Testing IEEE 522 working group standards committee

PowerSeal medium-voltage stator coil testing conducted by IEEE 522 working group standards committee (surge test)

Test Stand 37,500 HP @ 13.8 kV

No-load testing available up to 37,500 HP @ 13.8 kV
Load testing available up to 4,500 HP @ 13.8 kV

IEEE 1776-2008 water immersion testing

EEE 1776-2008 water immersion testing – underwater AC hi-pot test of a 400 HP, 4 kV, 1,800 RPM motor

IEEE-1043 voltage endurance life test

PowerSeal coils under voltage endurance test per IEEE 1043

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