Rewind Technologies
Synchronous Compressor HV Motor
MegaSeal Stator Rewind and Rotor Rewind
(22,500 HP - 13.8 kV - 1200 RPM)
IPS offers three of the industry’s leading rewind technologies. Our premium engineered VPI insulation systems come with an industry-leading 5-year warranty. Their superior performance improves efficiency ratings and often permit design uprates. In addition to electrical performance improvements, mechanical modifications to enclosures, brackets, shafts, seals and bearings are available.
- MegaSeal™
— Our premium high-voltage VPI insulation systems for HV motors and generators including 13 kV, 13.2 kV, 13.8 kV and 15 kV. Available on stators up to 14’ in diameter. - EnduraSeal®
— Our premium medium-voltage VPI rewind for motors up to 6.9 kV operating in severe conditions and harsh duty environments. - IntegraSeal™
— Our premium B-stage hard coil rewind designed for large and extra-large motors and generators. Ideal for onsite rewinds of turbine and hydroelectric generators, or stators greater than 14’ in diameter that are too large for VPI processing.
IPS provides in-house coil manufacturing for its large and extra large HV motor and generator rewinding, to maintain single-source control over quality and lead time.
MegaSeal™ VPI rewinds
MegaSeal™ is our premium high-voltage VPI insulation system for HV motors and generators including 13 kV, 13.2 kV, 13.8 kV and 15 kV and is available on stators up to 14’ in diameter. MegaSeal™ is designed to provide the motor rewinding performance and durability you need, with reduction in I2R losses and thermal dissipation, making it ideal for applications where reliability, efficiency and performance are paramount.
Based on advanced Reliance Electric and Kato® Engineering technologies, vacuum pressure impregnation processes and materials, MegaSeal is a total remanufacturing system that yields performance and durability beyond “as good as new.” This stator rewind and winding insulation comes with a five-year warranty (not one of the hundreds of MegaSeal VPI rewinds performed has ever failed). Like all IPS engineered insulation systems, MegaSeal is available through and backed by the coast-to-coast network of IPS regional service centers.
- Partial discharge testing
- Water immersion testing per IEEE 429 and NEMA MG 1-20.48
- Voltage endurance testing per IEEE 1043
EnduraSeal® VPI rewinds
Our rewind insulation system for medium-voltage motors and generators, developed in the Reliance Electric Research Center Materials Laboratory and proven with over 40 years of use in new motors worldwide. This is a premium sealed Class F+ motor rewind system using vacuum pressure impregnation and features a five-year warranty, providing service life extention by reducing the effects of thermal and electrical aging (breakdown test results typically exceed eight to ten times rated voltage).
EnduraSeal® dissipation factor tests are less than 15% at 180°C. We blast our stator cores with glass beads and fly ash to prepare them for severe duty applications. Our VPI insulation systems are chemically resistant and exposure to harsh industrial contaimination produces no degredation of the winding insulation. All EnduraSeal® tests are performed according to applicable IEEE and NEMA MG1 guidelines. Depending on your requirements, we can also subject your EnduraSeal stator rewinding to the following optional tests:
- Water immersion testing per IEEE 429 and NEMA MG 1-20.48
- Voltage endurance testing per IEEE 1043
EnduraSeal® is available through and backed by the coast-to-coast network of IPS regional service centers.
IntegraSeal™ B-stage hard coils
For larger, fixed motor or generator rewinding, or stators measuring over fourteen feet in diameter, our IntegraSeal B-stage hard coil rewind system offers a proven solution. In most cases, the new coil winding substantially improves dielectric and thermal performance, as our insulating materials and processes are superior to those used by OEMs in the 20th century.
We use resin-rich insulating materials and fully cured coils with flexible knuckles in our hard coil rewinds. They’re individually pressed with forms, heated to cure the resin, and then inserted in the stator slots and side-packed to eliminate movement in the slot. Our technicians test coils individually as they are manufactured and installed, to prevent dielectric impairment in the finished unit. During production, coils are surged and hi-pot tested to voltages that far exceed the required voltages of the unit, to ensure that the completed stator winding can withstand abnormal stresses in the power system.
IntegraSeal™ is available as an in-shop or on-site rewind, available through and backed by the coast-to-coast network of IPS regional service centers.
- TVA Corona Probe Testing
- Partial Discharge Testing
- Voltage endurance testing per IEEE 1043
