Big Iron Brochure Brochure

BIG IRONLarge and Extra-Large Motors and GeneratorsINTEGRATED POWER SERVICESINTEGRATED POWER SERVICESIPS is the leading independent provider of power services for big iron—large and extra-large rotating equipment—for one reason. We have more ways to test, repair, rewind, remanufacture and reverse engineer than anyone else in the business.Whether we’re working within an outage window, or providing emergency response and outage support, we minimize downtime.For specific details on our experience with your industry’s big iron and the IPS single-source approach to delivering reliability, talk to your regional IPS sales representative or visit us at www.ips.us.BIG-TIME EXPERIENCE WITH BIG IRONWe keep electric motors and generators runningRoughing Mill Motor: A 214,000-lb. armature for a Westinghouse 6,000 HP 700 VDC roughing motor arrives via a 26-axle supercarrier (we delivered a turnkey rewind in 32 days, or three weeks faster than the nearest competitor would commit to).Hydroelectric Generator: Technicians complete on site IntegraSeal™ rewind of a 10 MW, 6.9 kV stator.IPS maintains a strong corporate comittment to a safe work environment and also offers ISO-compliant quality management systems at all sixteen IPS regional service centers.-IPS offers repair services, field services and product sales for the following critical continuous process applications:Air Separation• Main compressor motors Power GenerationFossil• Circulating water pump motors• Boiler pump feed motors• Condensate pump motors• ID fan motors• FD fan motors• PA fan motors • Pulverizer and crusher motors• Steam turbine generatorsNuclear• Circulating water pump motors• Reactor coolant pump motorsHydro• Hydroelectric generators• Main shaftsPetrochem• Main compressor motors• Pipeline booster station motors• Pipeline compressor station motors• Oil rig anchorsPaper, Pulp & Wood• Chipper motors• Refiner motors• Pump motors• Steam turbine generators• Pulp grinder motorsMetals• Main drive motors• Roughing mill motors• Finishing mill motors• Tandem mill motors• Cold strip mill motors• Compressor motors• Piercer mill motors• Mandrel mill motorsMining• Compressor motors• Slope belt conveyor motors• Fan motors• Dryer motors• Main hoist motors• Main generators• Large excavation motorsAggregate & Cement• Crusher motors• Raw mill motors• Finish mill motorsWater / Waste water• Main pump motorsRubber• Banburry mixer motorsGlass• Compressor motorsScrap Metals• Shredder motorsMain Compressor Motor: 22,500 HP, 13.8 kV, 35,000 lb. statorCirculating Water Pump Motor: 2,500 HP, 6,600 V, 52,000 lbs.ID Fan Motor: 13,600 HP, 13.2 kV and 84,000 lbs.INTEGRATED POWER SERVICESReliability. Delivered.Engineered rewind technologiesDeveloped in the research laboratory and backed by decades of use in motors and generators around the world, IPS engineered insulation systems provide the reliability and performance for your most demanding applications. IPS rewind technologies are available with motor redesign or uprates, and mechanical modifications to enclosures, shafts, seals, fans and bearings:• IntegraSeal™ B-stage coils up to 15 kV• MegaSeal™ VPI engineered insulation systems from 6.6–15 kV• EnduraSeal® VPI engineered insulation systems up to 6.6 kV• Industry-leading warrantiesIPS technicians complete an IntegraSeal™ B-stage hard coil high-voltage rewind on a large stator.BIG IRON SERVICESYour single source for in-shop repair, field services and product salesComprehensive testingIPS has the industry’s most advanced array of diagnostics, to validate recommendations, document “as received” and “as shipped” performance, and support one standard for quality coast to coast.• AC test panel to 7.5 MVA / 15 kV• DC test panel to 1,750 A / 1,000 VDC• No-load testing to 37,500 HP• Dynamometer load testing to 4,500 HP• 500 kVA ore loss testing• IEEE 429 water immersion • IEEE 1043 voltage endurance• Additional in-shop/on-site diagnostics » Doble® » Corona probe » Partial discharge » MCE » EL CIDIEEE 429 water immersion test (underwater AC hi-pot test) performed on the stator of a nuclear reactor coolant pump.cThe quality and delivery advantages of in-house coil manufacturingIPS PennCoil manufactures a wide range of stator, rotor, armature and field coils up to 15 kV. In-house manufacturing means better QA and faster turn times for breakdowns and emergency repairs. Combining control of coil manufacturing with the rewind process ensures superior quality and performance with minimal downtime.We have extensive engineering and manufacturing experience with all major OEM coil designs, plus an engineering form coil database with over 100,000 design configurations, including all Allis-Chalmers designs. PENNCOILINTEGRATED POWER SERVICESReliability. Delivered.Main compressor synchronous motor (15,000 HP, 13.8 kV, 96,000 lbs.) on test. Test stand is capable of no-load test up to 37,500 HP and load tests up to 4,500 HP - both at 15 kV.Technicians lower a MegaSeal™ high-voltage rewind into the 14’ diameter VPI tank—the biggest in a U.S. service center.sCryogenic cleaning—one of the many IPS Big Iron services designed to deliver reliability.BIG IRON SERVICESYour single source for in-shop repair, field services and product salesPredictive maintenanceIPS predictive services supply the data you need to see developing trends. We recommend multiple diagnostic technologies, for more accurate predictions of your equipment reliability.• Vibration and modal analysis• Motor Circuit Evaluation (MCE)• Doble® testing• Partial discharge testing• EL CID testing• Corona probe• Baker surge testing• Operational Deflection Mode Shape (ODMS)• Finite Element Analysis (FEA) software• Synchronous rotor diagnostics• Current analysis trending• Thermography• Ultrasonic testing• Oil analysis• Motor efficiency testingPreventive maintenanceWe offer the following preventive services to minimize or eliminate unplanned outages:• Precision laser alignment• Cryogenic “dry ice” cleaning• On-site balancing• Commutator and slip ring service• Filter replacements• Lubrication programs• Equipment inspections• Motor, pump and gearbox management• Maintenance assessments• Training programsWe offer complete machining capabilities for Big Iron motors and generators.• Lathes: up to 76” x 564” and 126” x 384”• Vertical milling: up to 84”• Horizontal boring mill: up to 72” x 100”• Planer mill: 6’ wide x 6’ high x 26’ bed• Pressing up to 600 tons• Diamond burnishing• Nickel brush plating• Flame spray metalizing• Sub-Arc/MIG/TIG welding• Bearing rebabbittingMechanical repairs and machiningWe specialize in mechanical services and mill work on large, highly engineered components. IPS repair technicians have spent years providing mechanical repair and machining in your industry. We also manufacture CNC precision-machined parts in-house for improved quality and faster delivery. Our machining services include:IPS technician profiles a large DC commutator.IPS field service technicians work on a 44 MW GE hydrogen-cooled generator.Commissioning of a 21,000 HP main air compressor motor in the outheast.Installation of 7,000 HP synchronous rotor at a west coast refinery.Comprehensive on-site servicesOur dedicated field service teams of big iron professionals mobilize a complete set of resources, focusing on predictive and preventive services that extend service life, improve reliability and efficiency, and eliminate unplanned downtime.• Equipment removal and installation• Emergency and outage support• Disaster assessment/recovery programs• AC & DC motor and generator repair• Stator and armature rewinding• Mechanical machining and repairProduct SalesWe keep electric motors and generators running. There are times, however, when it’s more economical to replace a unit than repair it. As part of our single-source commitment to delivering reliability, we back our repair and field services with product sales and remanufacturing.Custom ManufacturingWe manufacture all types and sizes of AC and DC motors and generators to meet specific needs. We reverse engineer exist-ing equipment, create new assembly and parts drawings, manufacture all parts and then assemble new units — to improve reliability and decrease downtime.INTEGRATED POWER SERVICESReliability. Delivered.SYour Single Source for Big Iron Repair Services, Field Services and New Product SalesIPS is an independent power services company, providing premium-qualitymotor, generator and mechanical services on all OEM brandsto a wide range of customers. We’re also an authorized reseller anddistributor for leading OEMs.IPS regional service centers give you 24/7 dependability, withtrained professionals offering years of experience in your industry.They’re backed by unmatched technical resources and capabilities,plus a national network for coast-to-coast coverage and documentedstandards for workmanship and materials.To explore your options, talk to your regional IPS sales engineer or visit www.ips.us. www.ips.us©2010 Integrated Power Services10/10Birmingham, AL 800.978.2212Chicago, IL 800.978.4559Cincinnati, OH 800.998.8447Cleveland, OH 800.433.7801Denver, CO 800.448.0899Detroit, MI 800.992.9466Glassport, PA 800.394.7366Houston, TX 800.221.3698Indiana, PA 800.537.0097Litchfield, MN 888.694.6200Philadelphia, PA 800.451.5718Portland, OR 800.366.4951Rock Hill, SC 800.868.3702Rock Springs, WY 866.256.4798Shreveport, LA 800.366.6030Washington, PA 800.441.2553C O A S T - T O - C O A S T C O V E R A G E F O R 2 4 / 7 B I G I R O N S E R V I C E A N D D E L I V E R YINTEGRATED POWER SERVICESINTEGRATED POWER SERVICESTRICOELECTRO-MEC PENNCOIL