IPS MegaSeal – Engineering

MegaSeal Coil Drawing

MegaSeal Stator Coils —
designed to withstand the stress of severe applications

All MegaSeal coils are manufactured to IPS specification with insulation materials designed and proven thru extensive qualification testing to prevent strand-to-strand and turn-to-turn shorts which may result from voltage surges. MegaSeal stator coil ground wall insulation contains multiple layers of half-lapped high content Mica tape, engineered for your specific voltage requirements.  We apply conductive corona tape to the slot portion of the coil to prevent corona discharges in the slot, as well as stress grading tape to help bleed the voltage to non-damaging levels. Our global VPI process completely penetrates and saturates all stator coil insulation tapes in epoxy resin homogenously at the same time, while encapsulating the entire stator winding into a solid, rugged protective mass.

MegaSeal - AC Hi-Pot Test @ 80+ kV

AC Hi-pot of PowerSeal 13.8 kV stator coil @ 80+kV

40-Year Rewind Design

MegaSeal is a Class F+ (> 155 ˚C) rated insulation system that has completed extensive internal and external qualification testing. IPS engineers have designed MegaSeal to a 40-year life cycle by incorporating processes and materials that increase your electric motor reliability and mitigates the following winding failures and aging factors:

  • Strand to Strand short
  • Turn to turn short
  • Phase to phase short
  • Grounding in the slot
  • Grounding at edge of slot
  • Shorted Connections or Leads
  • Corona Inception due to Partial Discharge (PD)
  • Mechanical Stresses (e.g. Vibration, Abrasion, Thermal Expansion…)
  • Environmental Stresses (e.g. Moisture, Chemicals, Dirt, Contaminants…)
  • Electrical Stresses (e.g. High-Voltage Applications, Voltage surge / transients…)
  • Thermal Stresses (e.g. Temperature Rise, Hot Spots, Insulation Material Degradation…)

Lowest partial discharge in the industry (typically < 150 mV)

Parital Discharge (PD) is a phenomenon that if present will deteriorate the reliability of high voltage stators. PD results in microbursts that take place in air pockets and voids commonly found in the coil ground wall insulation or between the coil and the slot cavity. PD readings are generally considered acceptable in the industry if they are below 200 mV. Higher PD causes insulation degradation, leading to decreased reliability and service life of the stator.

The IPS MegaSeal technology allows for the lowest PD readings in the industry — typically 100 – 150 mV, and sometimes as low as 50 mV. MegaSeal “global VPI” rewinds typically have half of the PD readings of B-Stage high-voltage rewind performed by competing motor repair shops in North America.  The benefit is increased reliability and service life of your electric motor or generator.

MegaSeal Coil Cross section

Magnified MegaSeal coil cross section shows uniformly compressed tapes absent of puckers and voids, which is critical in minimizing partial discharge.

MegaSeal Coil Cross section drawing

Motor efficency gain and up-rate opportunity

IPS uses state-of-the-art insulation that provides higher mica content and a denser ground wall. The benefits are better coil dielectrics and superior heat transfer (allowing the motor to run cooler) — all of which extend the service life of the electric motor or generator. In addition, the improved coil insulation provides IPS engineers the opportunity to potentially increase motor efficiency and/or up-rate the motor.

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