All coils IPS Newcastle manufactures meet the relevant electrical standards, such as IEC 60034, BS EN 50209 and IEEE 1553 & 1043. We also carry vigorous in-house coil testing, which includes:

• Surge comparison or turn-to-turn test (2 UN) + 1000
• Tan δ / Tip Up
• Hi-pot (AC and DC flash) test (2 UN + 1000)1.2
• Lamination test
• Partial Discharge test
• VE test

We can also test to customer specifications as required.

Voltage Endurance Testing

VE is a test that quantitatively measures the capability of an insulation system to withstand partial discharge (corona) at operating temperature, which in turn is a measure of the quality of the design of the materials and the manufacturing process.

High voltage stress causes the ageing of stator winding insulation, eventually leading to insulation failures. Our voltage endurance testing is an accelerated life cycle test that is used as a measure of quality by applying a much higher than normal machine-operation stress to coils/bars within a short period to accelerate insulation ageing, which occurs during machine service.

We ensure coils are manufactured to maximise performance and reduce the risk of partial discharge, preventing premature failure.

Partial Discharge Coil Testing

We also carry out Partial Discharge testing on our coils.

Corona discharge activity at the core exit is designed using a proven process using the highest grade of corona stress grading tapes. The corona discharge activity at the slot portion is overcome using hot-pressed corona protection tape, which provides a resilient, continuous corona protection shield.

We keep the PD below 300 pC to ensure longer life expectancy and minimise security risks from PD in wound motors and generators.

If required, we can PD test each coil as it is manufactured, which gives increased confidence in the quality of the coils and their ability to maximise the life of the asset once rewound.

Independent Coil Testing

HiFLEX™ coils were subjected to the following tests by a leading independent Canadian testing laboratory, with satisfactory results:

• Visual inspection and tap tests on the coils before and after VE test
• Partial discharge (PD) analysis at 7.3kV before the VE tests, as per IEEE Standard 1434-2000
• Dissipation factor (DF) measurements as per IEEE Standard 286-2000 from 2kV to 16kV in 2kV steps before the VE test
• Turn to turn insulation test before VE test as per IEEE Standard 522-2004
• Voltage Endurance Test as per IEEE Standard 1043-1996 at 31.7kV, 90°C for 500 hours
• Dissection and microscopic examination of the coil after VE test
• Insulation thickness measurements of one coil after VE test

Independent Testing Results

Turn Insulation Test complies with the following:

• As per IEEE Standard 522-2004
• 5 successive voltages were applied to the coils with both polarities before the VE test

Voltage Endurance Coil Test

• Coils subjected to an accelerated insulation-ageing program
• As per IEEE Standard 1043-1996 and IEEE Standard 1553-2002
• Test parameters were 31.7kV at 90°C for 500 hours
• Both coils passed the 250 hours required by IEEE 1553
• Coil 1 passed by 161%, and Coil 2 passed by 182%

Further Specialist electro-mechanical engineering support

We provide specialist electro-mechanical engineering support based on our experience and requirements. Our skilled team has worked on various machines worldwide and offers training on motor data, insulation services, and performance upgrades.

Our engineers are also skilled in reverse engineering, where your data cannot be provided. We can work backwards from a sample coil to provide detailed coil specifications and accurate fits.

AutoCoil design software

Our bespoke AutoCoil design software utilises the latest technology to offer 3D coil design and slot build drawings for improved design and accurate fit.

AutoCoil extrapolates data sheet information into 3D drawings, which can be supplied alongside the quotation to illustrate the design and present a projection view of the cross-section of the slot build.

The 3D model supports the design process by allowing customers to visualise their coil requirements and improves communication with the end user, supporting quote acceptance.

Worldwide in situ support services

In addition to supplying the coils, we can provide additional support to assist with carrying out the rewind. Our engineers routinely work both on-site and at our customer’s premises, either carrying out the full rewind or simply providing high-voltage expertise to support the engineers carrying out the work.

We also provide in situ inspection, testing, and fault diagnostics, including air gap checks and partial discharge testing. Our condition monitoring services enable maintenance and rewinds to be planned in line with pre-arranged shutdowns, helping to reduce unexpected downtime.