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Horner Industrial, Springfield OH division, has recently acquired two large customers from one competitor, who fell from grace by not meeting the service expectations of the customers. One of these customers is a large cement processing facility. After firing our competitor, our new customer sent in orders for two 1000 HP motors. One was a large, low speed crusher motor for rebuild and reconditioning.
The other order was for a replacement spare fan drive motor that was obsolete and no longer produced. Bill Roper, our salesman in northern OH, located a used motor that was the correct frame and RPM. The only problem was that it was rated at 575 volts so we had to do a redesign to 4160 volts, per the customer’s specification. Our coil vendor assisted with the redesigned formed coils. I assisted Lisa Keyton to produce the winning quotation and Bill Roper closed the deal with the customer. Lori Beam ordered the materials and the Springfield division winders completed the medium voltage rewind work. Horner Washington Street shop performed the vacuum pressure impregnation process to seal the windings with epoxy and ensure 100% penetration of the coils.
Another hurdle was that this motor was originally a forced draft cooling design. The customer needed a totally enclosed, fan cooled (TEFC) design motor to match the other fan motors that are in service. Our machine shop supervisor, Kim Shellabarger, designed a bolt on shaft extension to accommodate a TEFC cooling fan, on the opposite drive end of the motor. After determining that a new cooling fan was obsolete, Jim Delawder and Kim Shellabarger visited the customer’s site on a shutdown day to remove the fan cover and record measurements to produce a dimensional drawing of the original fan design.
The TEFC cooling fan information was sent over to Horner Fan & Fab to produce an identical fan. Darrell Cothran’s team at Fan & Fab also had to modify the fan cover by reducing the length by 11” to match the original TEFC design. The motor was assembled by Springfield division mechanics, under the direction of Dave Howard, for a successful test run. The motor was then epoxy painted and will be shipped for installation during the customer’s August shutdown. After installation, we expect to receive the removed 1000 HP fan motor, so the customer will have a viable spare motor for this critical application. This is how we create customer value.
It takes a talented team to successfully pull off a project like this one. Just like a winning sports team, we utilize the strengths of each of our talented team members to produce a successful outcome for our customers. This is how Horner Industrial gains and retains a strong customer base, providing job security for all employees.