IPS PowerSeal – Testing

For every PowerSeal rewind, IPS conducts in process and post rewind testing on every motor and generator. Every PowerSeal rewind comes with the following testing and documentation:

Extensive PowerSeal 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 insulation degradation 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 Surge Testing (see video)
• AC Hi-Pot to Destruction
  — 4,160 VAC at 40+ kV (see video)
  — 6,600 VAC at 65+ kV (see video)
• IEEE 1776-2008 Sealed Insulation System
  (Water immersion AC Hi-pot test)

In-process testing for all PowerSeal stator rewinds

• Core loss test with IR thermography
  — Max. 500 kVA up to 30,000 HP
  — Before and after burnout process
• Insulation Resistance per IEEE 43 specification
  — Insulation resistance (Megger® Test)
  — Polarization Index (PI)
• Turn insulation test (surge test)
  — per IEEE 522 specification
• DC Hi-Pot Test
• Phase balance test
• 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 PowerSeal 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
• Partial Discharge (PD) testing
• 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 PowerSeal 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) Testing
• ABB Life Expectancy Analysis Program (LEAP)
• On-line and Off-line Partial Discharge (PD) Testing