After having successfully cutting coils from a stator on site four times previously, the 3,000 HP stator finally died and had to be scheduled to be rewound at a cement plant in KY. The removal of the motor is not the conventional way you think of a motor being removed, you start by removing the outside wall of the building it is in, and then sticking the boom of the crane inside the building to be able to lift the motor. standing at a safe distance from the equipment, the motor does not look all that large, but as if gets [...]
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So far Jacqueline Keen has created 154 blog entries.
Most customer accounts begin with small motor repair jobs and then graduate to larger motors and driven equipment repair work such as fans, gearboxes and pumps. A few of our customers have specialized process equipment that also needs service work to keep production rolling. One of our customers produces only one product – cellulous fiber, and they cannot make enough of it to satisfy the consumer demand for this product. Cellulose is found in all plant matter. This customer uses large rolls of white paper as their only source of cellulose. The wood pulp in the paper along with the starch [...]
The water/wastewater market can sometimes be a tough market to get into. Manufacturers build specific products that are built solely around this market to help remain competitive against other markets such as industrial/HVAC. One challenge is that manufacturers only have a few select distributors that have access to their water/wastewater products. Sometimes a customer may have an existing water/ wastewater product or wants a brand that Horner does not have direct access to. Unfortunately, this limits our ability to react quickly, quote competitively, and support the customer the way they deserve. This is why Horner continues to build relationships with other [...]
A manufacturer of insulation and commercial roofing, along with glass fibers and nonwovens recently had a project to rebuild their glass melter and scheduled to have the plant completely shut down for 60 days. Mike Croft and I met with the electrical engineering staff on-site and listened to their problems. Mike, another vendor, and I walked the entire plant taking pictures and collecting information on their electrical substations. We ended up getting the bid for right around $300,000.00. For the 3 months leading up to the outage, we met weekly (either in person or conference call/TEAMS meeting) and agreed/planned to have [...]
We were contacted by a sand and gravel producer in hopes that we could make a drive shaft that was accidentally bent and running out of balance. The original plan was for the end user to purchase the coupling hubs and have Horner Machining Services install those onto the new tubing. Once the customer finally received the Hubs from the Original Manufacturer they were incorrect. At that point, and having waited beyond the expected delivery date, our customer asked if Machining Services could machine new hubs from blank stock. Darrell Cothron and his team accepted the challenge and began the overtime [...]
A major aluminum manufacturer contracts Horner EMDS (Electro Mechanical Diagnostic Services) to perform monthly vibration data collection and analysis. EMDS identified a mill gearbox input shaft bearing issue. In 2022, the monthly vibration analysis indicated the bearing issue increasing. The vibration analysis was discussed with the customer and the vibration data collection increased to twice weekly. At the same time, customer was planning a major outage to on-site repair the gearbox. The March outage was scheduled. Horner provided 24 hour per day, 5-day work schedule. On a Monday the outage started. Mark Rosebrock was lead tech on day shift and Matt [...]
On one of our 90 degree plus summer days, Horner received a call from a major Hotel near the Indianapolis Airport. The variable frequency drive (VFD) that operates their cooling tower was faulting and preventing the cooling tower from operating. For those who may not know what a cooling tower is, it is used to cool water that is then used to cool the air in the building, and/or cool equipment. So when it is hot, it is a very important piece of equipment. Jeff Meshishnek was sent out to look at the VFD. Jeff identified that the VFD was terminal [...]
A customer who makes counter weights for fork trucks called Horner after a safety incident. One of their old exhaust fans has a failure and a blade from the prop fell to the manufacturing floor. The customer knew they not only had to replace the roof- top fans but needed to rethink the design for safety of the workers. So instead of 1 fan being repaired they decided all 4 rooftop exhaust fans would be redesigned. Fan and Fabrication came up with an aluminum safety screen that would be welded on the underside of the fans. This new custom safety screen [...]
One of Louisville’s largest customers pro- duces aluminum foil. Manufacturing foil starts with aluminum rolls up to 1/2” thick. This plant takes the ½” thick thru mill 6, which reduces the foil thickness to less than 0.100” thickness. From mill 6, the rolls are rolled thinner in mills 3-4-5. After several passes thru these mills, the rolls go to mill 1-2 to roll to thickness required for commercial or residential use. Standard household or standard duty aluminum foil is 0.00063” thick and extra heavy duty foil is 0.00094” thick. Both thinner than 1 thousandth of an inch. Rolling aluminum foil this [...]
An office building had an open atrium that went from ground level up to the roof. In the center of the atrium was a large flowing fountain. Surrounding the fountain were meeting rooms. Each meeting room had a large plate glass window approximately 8 feet tall and 12 feet wide through which the individuals in the meeting room could view the fountain. The problem was that these large plate glass windows had high levels of vibration. The frequency of the vibration was 240 cycles/minute. The floors and walls were all tested and no significant level of the 240 cpm vibration was [...]