IPS Nuclear Service — Service and repair capabilities that comply with all federal regulations and nuclear standards

IPS is certified to provide services and repairs for nuclear safety- and non-safety-related motors and other rotating equipment in compliance with all federal regulations and nuclear standards.

We provide these services in accordance with the IPS quality assurance manual, which meets the requirements of 10CFR50 App. B and ASME NQA-1. Our 10CFR50 Appendix B shops are located in Cleveland, OH, Shreveport, LA, and Tampa, FL.

Other commercial shops are available for non-safety-related repair, depending on customer preference.

To learn more about our fleet-level nuclear services, contact us here.

IPS low-voltage rewinds with the Reliance NUC-9 insulation system

Most U.S. nuclear plants were originally supplied with non-safety-related, safety-related, and environmentally qualified low-voltage motors using the insulation system specified in the Reliance NUC-9 and NUC-22 qualification reports. These legacy Reliance Electric® insulation systems are designated “Type RH” and “Type RN” qualified insulation systems.

IPS maintains the same materials and processes for providing like-for-like, OEM equivalent rewinds for motors certified to the original qualification report. No design change is required for any application with an existing NUC-9 insulation system.

The Reliance NUC-9 insulation system also represents a like-for-like, OEM-equivalent replacement for Reliance Type RH and Type RN insulation systems.

To learn more about our insulation systems, contact us here.

A strong culture of quality

IPS delivers consistent quality to support nuclear plants. We have decades of experience with meeting the individual specifications of all major nuclear utilities.

The IPS Nuclear Quality Assurance Manual provides the framework to ensure that the work of our engineers and technicians meets or exceeds customer specifications. We welcome compliance audits by qualified, independent third parties concerning IPS capabilities to meet or exceed customer and regulatory performance requirements.

To learn more about our quality assurance, contact us here.

The industry’s highest capacity for nuclear motor & generator repair

IPS has repaired virtually every OEM motor in the nuclear industry, including General Electric, Westinghouse, Siemens-Allis, and Baldor-Reliance. We have the industry’s largest VPI tank, to support the rewind of any nuclear motor.

Available testing and diagnostics include:

  • AC test panel to 7.5 MVA/15 kV
  • DC test panel to 1,750 A/1,000 VDC
  • AC & DC hi-pot testing
  • No-load testing to 37,500 HP
  • Dynamometer load testing to 4,500 HP
  • 500 kVA core loss testing to 30,000 HP
  • NEMA MG-1 Sealed Winding Water Immersion Testing
  • IEEE 95 High Voltage Insulation Testing
  • Partial discharge testing
  • IEEE-1799 corona camera testing
  • Doble®
  • Corona probe

IPS repair capabilities include:

  • AC motor repair up to 80,000 HP/15 kV
  • DC motor repair up to 10,000 HP
  • Low- and medium-voltage safety-related motor rewinds and refurbishment
  • Low- and medium-voltage rewinds with qualified Harsh Environment EQ insulation systems
  • 145-ton lifting capacity (max 75-ton lifting capacity at nuclear locations)
  • Comprehensive electrical and operating tests
  • Dynamic balancing up to 50 tons
  • 120” x 432” horizontal lathe
  • 250-ton horizontal press
  • 75-ton vertical press
  • MIG, TIG, and sub-arc welding
  • Shaft repair (nickel plating) and manufacturing
  • Fluid-film bearing rebabbiting

IPS has extensive experience rigging and transporting extra-large motors and generators via super-carriers.

Engineering for nuclear applications

IPS design engineers specialize in both new and legacy equipment engineering, design, and performance. We engineer for nuclear applications, including large motors and pumps, to provide purpose-built drop-in replacements, as well as like-for-like, OEM-equivalent replacements wherever possible. 

Many of our engineers have over 30 years of experience with rotating electric machinery. This  includes OEM design, engineering, and repair experience with companies such as GE, Reliance, EM, Siemens, Toshiba, Ideal Electric, Westinghouse, TECO, and others.

IPS engineering capabilities include:

  • Motor design, modification, and optimization, including maintaining form, fit, and function requirements
  • Systems modeling and finite element analysis
  • On-site and remote troubleshooting
  • Technical support
  • Failure analysis
  • Vibration analysis
  • Design change evaluations
  • Obsolescence avoidance
  • Reverse engineering for like-for-like repairs and component replacement
  • Replacement equipment or parts design and analysis

The IPS Reliance NUC-9 insulation system

NUC-9 is engineered and qualified to exceed the requirements of 10CFR50.49 and NRC Reg. Guide 1.89. Reliance Electric and IPS engineers completed extensive testing to achieve this level of performance and reliability.

Based on the requirements of IEEE-334-1974, motors with Class H type RH insulation are qualified for total radiation dosage of 2 x 10₈ rads. Class H type RN insulation has a higher rating of 1 x 10₉ rads.

Thermally, according to the requirements of IEEE-334-1974 paragraph 5.1.1, these insulation systems have a projected log life of approximately 44 years. With a commercial motor operating temperature of 130℃, the qualified life becomes 748 years. At a Class F operating temperature of 155℃, the qualified life becomes 135 years.

These qualifications also include the effects of 100% condensing humidity, thermal and log life aging, and seismic qualification, for voltage ratings up to 600 VAC. As with any type of equipment, the ultimate operation depends to a great extent on the user’s maintenance program.

Based on our qualification testing, IPS can state that these insulation systems meet the requirements of IEEE-334-19We 74 and IEEE-323-1974. NUC-9 is engineered to survive the toughest operating and accident conditions possible at a nuclear power plant.

For more information on NUC-9, contact us here.

Engineered insulation systems

IPS offers engineered insulation systems for random-wound motors up to 600V and form-wound motors up to 15 kV. Our engineers have designed, improved, and validated these technologies with in-house and third-party certified design qualification testing.

PowerSeal™— 10,000+ rewinds. Zero failures.

PowerSeal™ is our patented, premium engineered insulation system for stators from 1 kV to 7.2 kV and up to 14 ft. in diameter. PowerSeal delivers better-than-new performance, backed by our standard 5-year warranty.

This VPI rewind technology powers over 10,000 electric motors and generators running in severe-duty environments where reliability is critical. It also offers uprating options or efficiency gains, plus key benefits that include:

  • 60-year design (thermal life curve)
  • Insulation rating = Class N+ (>200° C) @ +60 years
  • Exceeds IEEE 43, IEEE 95, IEEE 1068, and NEMA MG1
  • Available sealed winding water immersion, and AC hi-pot testing
  • Expedited rewinds available

MegaSeal™— 1500+ rewinds. Zero failures.

This is our premium VPI engineered high-voltage insulation system for stators from 4 kV to 15 kV and up to 14 ft. in diameter. MegaSeal™ offers better-than-new performance and reliability, coupled with a standard 5-year warranty.

This rewind offers uprating or efficiency gains, plus additional key benefits:

  • 60-year design (available thermal life curve)
  • Insulation rating = Class H+ (>180° C) @ +60 years
  • Available dielectric designs = Up to 75 volts/mil
  • Exceeds IEEE 43, IEEE 95, IEEE 1068, and NEMA MG1
  • Available sealed winding water immersion and AC hi-pot testing
  • Expedited rewinds available

IPS has a 14’ VPI tank, the industry’s largest, and dedicated winding clean rooms for foreign material exclusion (FME). We also provide mechanical modifications for enclosures, shafts, seals, and bearings.

We provide PowerSeal and MegaSeal rewinds for nuclear safety-related, mild environment applications as well as non-safety-related applications.

For more information or a quote, contact us here.

Radiological decontamination

IPS partners with multiple decontamination facilities, depending on location and availability. This helps us minimize cost and lead times for contaminated motor repair.

Commercial-grade dedication

IPS maintains a robust commercial-grade dedication program. We procure commercial-grade components and dedicate them for safety-related use, as required via Failure Modes and Effects Analysis (FMEA) and customer requirements. This program is modeled after EPRI TR 3002002982.

IPS has expanded its 10CFR50 Appendix B quality assurance program to include commercial grade dedication of new motors for the nuclear industry.

Diversification to support the drive train

The recent growth of IPS has added extensive experience in repairing and reconditioning centrifugal pumps, including modifications and upgrades. This includes safety-related applications. 

IPS also manufactures various pump components, including:

  • Shafts
  • Shaft sleeves
  • Bearing housings
  • Collets
  • Couplings
  • Cast components
    • Impellers
    • Shrouds/bowls
    • Diffusers/guide vanes
    • Intercolumns
    • Trumpets

IPS also offers additional rotating equipment capabilities for non-safety-related applications. We repair pumps, blowers, compressors, and fans, including:

  • Vertical split-case and horizontal split-case multistage centrifugal compressors
  • Lobe blowers
  • Axial flow, mixed flow, and radial flow centrifugal fans
  • Compressor air-ends
  • Screw blowers

Technical field services and support for nuclear plants

IPS provides experienced technical field services for nuclear plant motors and rotating equipment. IPS PowerServe adds to our capabilities with NETA-certified technicians.

Our in-situ testing and maintenance for nuclear plants includes:

  • Equipment inspections
  • Vibration analysis
  • Balancing and laser alignment
  • Cryogenic cleaning
  • Commissioning and start-up services
  • Transformer services
  • Substation maintenance
  • Motor Circuit Evaluation (MCE)
  • Doble®
  • Partial discharge
  • Operational Deflection Mode Shape
  • Thermography
  • Ultrasonic testing
  • Motor efficiency
  • Laser alignment
  • Current analysis trending

We also provide condition monitoring and authorized warranty repair, plus replacement parts.

For more on IPS technical field services for nuclear plants, contact us here.

Emergency & outage support

This is where we leverage scale and experience, deploying field service teams and resources across North America. We’re on-site fast when equipment goes down with the trucks, cranes, portable generators, and critical spares you need.

IPS single-source capabilities streamline plant emergency response. You can manage one trained and certified service provider on-site instead of coordinating the work of multiple vendors.

Our size and experience also work to your advantage during planned outages. We perform inspections and testing, plus bearing replacement, balancing, and cryogenic cleaning.

For more on IPS emergency & outage support, contact us here.

Motor storage in accordance with EPRI 1009698 and ANSI N45.2.2 Level B

IPS meets all packaging, shipping, storage, and handling (PSS&H) requirements for equipment used in nuclear power plants. Our professional asset management and documented maintenance reduce unplanned downtime and capital investments.

We maintain a proven storage and asset management system with strategic warehousing across the U.S. IPS has 650,000+ square feet of temperature- and humidity-controlled storage space, free of resonant vibrations.

Our Shreveport and Cleveland service centers maintain a 10CFR50 Appendix B quality assurance program to cover safety-related motors. These storage locations also follow EPRI 1009698 and ANSI N45.2.2.

IPS Tracker – Real time updates on your equipment

Our real-time digital reporting platform lets you monitor motor repair and storage. You can also automatically receive repair milestone updates via email with all applicable job data.

Nuclear motors and replacement/spare parts

In addition to new motor dedication, IPS offers like-for-like replacements via new motor manufacturing or surplus motor remanufacturing for select end-use applications. Our internal distribution services let us leverage lower costs that we forward to the customer.

We offer multiple repair or replace options when you need new parts and equipment.

To learn more about our services for nuclear power plants, talk to your local IPS representative or contact us here.

IPS has close working relationships with OEMs