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) |  |
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| 100% solids epoxy resins | |
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| IPS Stator Coil Specification | |
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| IPS Rewind Specification | |
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| Efficiency Gain Capability | |
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| Power (HP) Up-Rate Capability | |
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| Insulation Qualification Testing | ||
| Available Arrhenious Log Life Aging Curve | |
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| 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 | |
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| — 400 Hours @ 120˚C | |
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| — 250 Hours @ 120˚C | |
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| — 50 Hours @ 120˚C | |
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| IEEE 1310 thermal cycling | |
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| IEEE 1776-2008 sealed insulation system | |
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| VPI Resin and Insulation tape compatibility | |
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| Coil Manufacturing | ||
| Stator coil specification type | Material & Process | |
| Superior Turn Insulation | |
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| Superior Ground Wall Insulation: | |
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| — Higher Mica Content | |
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| — Denser Ground Wall | |
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| Sealed Lead Exits | |
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| Taped Coil Leads | |
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| Surge Test & Hi-Pot Testing | |
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| Sacrificial stator coils per Job | Qty. 2+ | |
| Rewind Process | ||
| Typical lead time | 7 Weeks | |
| Rush lead time | 4 Weeks | |
| Dedicated High-Voltage Resources: | |
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| — Winding Clean Room | |
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| — Dedicated HV technicians | |
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| — Dedicated HV engineers | |
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| Calibrated Shop Equipment | |
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| Core Loss Testing with Thermography | |
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| — Before Stator Burnout | |
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| — After Stator Burnout | |
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| — Full burnout oven cycle reports | |
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| Superior Winding Techniques | |
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| — Insulating Materials | |
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| — Spacing between coils | |
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| — Blocking, Bracing & Lashing | |
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| — Series, Pole & Jumper Connections | |
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| — Lead Cable Material | |
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| — Lead Cable Connections | |
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| — Circuit Ring Construction | |
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| Vacuum Pressure Impregnation (VPI) | |
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| — Calibrated VPI tank | |
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| — Full VPI process documentation | |
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| — 100% solids epoxy resin | |
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| — Resin Viscosity Check | |
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| — Sacrificial VPI Coils | |
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| Bake Oven Cycle Reports | |
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| In-Process Testing: | |
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| — Megger™ per IEEE 43 | |
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| — Surge Test per IEEE 522 | |
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| — DC Hi-Pot per IEEE 95 | |
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| — No-load testing | |
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| Optional Rewind Testing | ||
| Load testing | To 4,500 HP @ 15 kV | |
| IEEE 1776-2008 underwater AC hi-pot | |
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| IEEE 1043 voltage endurance | |
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| IEEE 1434 Corona (TVA) Probe | |
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| Doble® | |
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| Partial Discharge (PD) | |
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| Blackout Test with UV Camera | |
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| PdMA Motor Circuit Evaluation (MCE) | |
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| ABB Life Expectancy Analysis Program (LEAP) | |
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| Available post-installation testing | ||
| Insulation Resistance – PI Test | |
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| AC and DC Hipot Test | |
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| Surge Comparison Test | |
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| DC Conductivity Test | |
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| Capacitance/Capacitance Tip Up | |
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| Dissipation Power Factor Tip Up | |
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| Inductive Impedance Test | |
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| PdMA MCEmax | |
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| ABB LEAP | |
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| On-line and Off-line PD Testing | |
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| 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 | |
