IPS MegaSeal – Testing

Quality Assurance —
Documented and ready for verification

IPS conducts complete inspections and testing on every motor and generator we receive for a MegaSeal rewind. Your MegaSeal rewind comes with the following testing and documentation:

Extensive MegaSeal 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 Partial Discharge 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 (see video)
  • AC Hi-pot to Destruction, typically above 80+ kV (see video)
  • IEEE 1776-2008 Sealed Insulation System
    (Water immersion AC Hi-pot test)
In-process testing for all MegaSeal stator rewinds
  • Insulation Resistance per IEEE 43 specification
    — Insulation resistance (Megger® Test)
    — Polarization Index
  • Core loss test with IR thermography
    — Before and after burnout process
    — Max. 500 kVA up to 30,000 HP
  • Turn insulation test (surge test)
    — per IEEE 522 specification
  • Partial Discharge Test Measurements (mV)
  • 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 MegaSeal 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
  • 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 MegaSeal 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)
  • On-line and Off-line Partial Discharge Testing
High Voltage Surge Testing IEEE 522 working group standards committee

MegaSeal high-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

IEEE 1776-2008 water immersion testing of a 400 HP, 4 kV, 1,800 RPM motor

IEEE-1043 voltage endurance life test

MegaSeal coil 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.