IPS engineers have spent 30+ years working on our global VPI and B-stage hard coil stator rewinds. They’ve designed, improved, and validated these technologies with in-house and third-party design qualification testing.
We’ve rewound over 20,000 medium- and high-voltage motors running in the toughest industrial applications, with zero failures.
IPS recommends the right rewind to mitigate electrical, thermal, mechanical, and environmental stress on your stator windings. We also customize windings to increase motor efficiency or uprate horsepower.
MegaSeal is the high-voltage stator rewind that delivers the lowest total cost of ownership. It also offers uprating or efficiency gains, plus additional key benefits that include:
PowerSeal™ is our patented, premium global VPI engineered insulation system for stators from 1 kV to 7.2 kV and up to 14-ft. in diameter. PowerSeal delivers better-than-new performance, backed by our industry-leading 5-year warranty.
This medium-voltage rewind powers over 10,000 electric motors and generators running in severe-duty environments where reliability is critical. This industry list includes:
PowerSeal delivers the lowest total cost of ownership of all medium-voltage rewinds. It also offers uprating or efficiency gains, plus additional key benefits that include:
PowerSeal is available through every North American IPS location, made with one set of stator coil materials and process specifications.
WindGuard™ is our Class H rewind for wind turbine generators, offering a 60-year log life aging curve. It has the dielectric and mechanical strength to withstand the conditions that cause premature generator failure.
IPS engineers addressed specific failure modes with this next generation insulation system:
WindGuard combines the dielectric strength of PowerSeal VPI mica tapes with the additional surge resistance of polyimide film. We apply this combination directly to the conductors, using an advanced polymerization process for unmatched surge protection.
Zero thermal aging during rapid thermal cycling makes WindGuard the most robust VPI rewind available in the wind power industry.
IntegraCoil™ is our standard on-site high-voltage rewind. It’s also available for in-shop high-voltage rewinds for stators too big to fit in our largest VPI tank (14’ diameter).
This B-stage, resin-rich stator coil is an option for rewinds from 6.6 kV to 15 kV. The North American installed base includes:
IntegraCoil offers these benefits:
Our premium B-stage stator coil for hydro generator rewinds up to 15 kV and 50MW. HydroCoil® offers improved dielectric performance and heat dissipation, exceeding IEEE 1553-2002 and IEEE 1147-2021 testing and rehabilitation standards.
In tests, HydroCoil exhibited superior mechanical properties and thermal dissipation in thermal cycling and thermal aging tests. It also exceeded all industry standards in voltage endurance testing.
We use advanced, resin-rich tapes and construction to increase groundwall density and ensure complete resin migration. The result — a void-free coil that prevents the delamination and micro-voids causing partial discharge and eventual insulation failure.
HydroCoil delivers the improved reliability you need, with a higher generator rating for more power output in the same footprint:
This is a legacy GE high-voltage insulation system that IPS acquired with the acquisition of ABB Hydro Services in 2022. It’s service-proven for rewinds of hydro generators from 7 kV to 15 kV.
A Class F insulation system, HV600 uses qualified materials and ISO 9001 accredited procedures. 100% final testing includes:
Stator winding components include support rings, circuit rings, and connections using the same insulation system. The corona suppression system consists of slot armor tape and grading tapes fully processed during manufacturing.
This is a legacy GE medium-voltage insulation system that IPS acquired with the acquisition of ABB Hydro Services in 2022. It’s suitable for low-voltage hydro generators and industrial motors rated up to 6.9 kV.
LV400 is a flexible, rugged insulation providing a barrier against moisture, oil, solvents, or other aggressive materials. It’s manufactured at qualified coil manufacturing facilities in strict compliance with IPS insulation system requirements.
This system is 100% tested to IPS and IEEE standards for turn and groundwall insulation integrity, during manufacturing and after installation.
PowerLok™ is our industry-standard global rewind for stators from 1-4.1 kV. It’s competitively priced, similar to other rewinds in its class, and suitable for general-duty motor applications.
This rewind powers over 10,000 electric motors & generators in general-duty (non-harsh and non-severe) applications. The North American installed base includes: