
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 |