Motor Vibration: Things Are Not Always As They Appear

Three pumps sat beside one another on a concrete foundation. Two of the motors on the pumps operated with low levels of vibration. The third motor had high levels of 120Hz vibration. As with the previous case, when the good motors were put in the third location, the 120 HZ vibration was high. A resonance test was performed and it was discovered that where the vibration levels were high that the foundation had a 120Hz vertical resonance that was not present under the other two motors. When the foundation under the bad location was jack hammered out, it was discovered that [...]

Motor Vibration: Things Are Not Always As They Appear2019-09-10T16:00:16-04:00

Marine Field Service Work: Riverboat

The first week of July is always the busiest week for our field service group. As luck would have it, I received a call from two customers for field service work – on the water. Service Call #1: I consulted with Rich Streitmarter, Ralph Coonce and Jim Delawder and of course, our field service resources were tapped out. Jim offered to pull a new field tech, Gabe Mercuri, from a job if I could assist him as Gabe has only been with us for about a month. The good news was that Gabe has a lot of mechanical and hydraulic experience [...]

Marine Field Service Work: Riverboat2019-09-10T16:00:16-04:00

1500 HP Aggregate Mill Motor

A large aggregate company in Southern Indiana that Horner Industrial has serviced for years contacted Horner as they had a 1,500 HP 180 rpm Open Frame AC Wound Rotor/Synchronous motor that needed to be removed, rewound, and reinstalled. This motor was manufactured in the 1950’s and it was one heavy piece of iron. (42,000lbs) Once it was removed, transporting it posed a challenge to Horner’s Logistics Department as it had to be transported on a special “low-boy” semi-trailer due to its size. We had to make sure that it would pass under all the overpasses on I-65 from Louisville to Indianapolis. [...]

1500 HP Aggregate Mill Motor2019-09-10T16:00:16-04:00

Power Plant 7000 HP ID Fan Motors

          A Power Plant Customer’s Generating Station is located outside of Sullivan Indiana about 45 minutes South of Terre Haute. This coal fired plant went on line in 1982 operating two units producing 1080 megawatts. Horner’s shop in Terre Haute has been doing repair work for them since before the plant was operational. They continue to be a strong customer after almost 40 years. Each year they shut down one unit for maintenance so motors come into our shops for repair and Horner’s field service divisions are involved with removals and installations. Most motors are on a [...]

Power Plant 7000 HP ID Fan Motors2019-09-10T16:00:16-04:00

Asphalt Plant Exhaust Fan and VFD Project

When you think of Asphalt you think of Roads. And if you’re in the Midwest you know how important it is to have these plants up and running with all the pot holes. The asphalt plant is mainly composed of cold aggregate supply system, drum dryer, coal burner, coal feeder, dust collector, hot aggregate elevator, vibrating screen, filler supply system, weighing and mixing system, asphalt storage, bitumen supply system. All these components have characteristics that impact not only the overall quality of the asphalt but also the effect on the environment. The plant had recently added a new line and had [...]

Asphalt Plant Exhaust Fan and VFD Project2019-09-10T16:00:17-04:00

Cooling Tower Emergency

One Saturday evening in March I received a call from a plastic fabrication company in Indianapolis that both the motors on their cooling tower had failed. The plant operates several water-cooled extruders and compressors and without the cooling towers their operation would be shut down. They had one spare motor but needed a second and they needed it installed ASAP. I called Ralph Coonce to arrange a field service crew and crane for Sunday morning and went to the plant to get a better eye on the situation. Once at the plant I called Kerry Fork (Inside Sales Indy) and he [...]

Cooling Tower Emergency2019-09-10T16:00:18-04:00

1000 HP Challenge

We have a saying that “if you are not making mistakes, you are not doing much.” Well, that holds true for our customers, as well. Recently, a customer connected a 1000 HP DC motor improperly and the motor was operated until the field and interpole coils failed. Dan Sneary inspected the motor out on-site and determined the windings had failed. The customer did not have a spare motor so this job turned into a full overtime repair job. Bill Roper handled all of the customer communications so our shop could concentrate on the repair work and meeting a one-week deadline. This [...]

1000 HP Challenge2019-09-10T16:00:18-04:00

Aluminum Manufacturer Exhaust Fan Build

Horner Fan & Fabrication had been involved with the rebuild and repair of an existing furnace fan earlier in 2018 at an Aluminum Manufacturer. The project was stressful due to time constraints and very expensive for the customer. This experience led Horner Sales to suggest to the customer that they needed a back-up plan in the event they had another fan go off line. This led the customer to approach Horner about building them a fan that could be used for just such occasions. The existing furnace units used at the plant were manufactured in Germany. Although the plant had many [...]

Aluminum Manufacturer Exhaust Fan Build2019-09-10T16:00:18-04:00

Horner Gearbox Repair: Cutting Down Customer Costs and Turn Around Time

There are a lot of motor shops in the Midwest but there are very few gearbox repair firms. Most customers send their large and expensive gearboxes back to the manufacturer to repair them for 50 – 75% of the price of a new replacement gearbox. This repair practice has created some opportunity for our division to repair special, expensive gearboxes for less than a manufacturer’s repair and we can offer a shorter delivery timeframe. We recently received five plastic extrusion drive gearboxes from one customer, thanks to John Baumann’s sales effort. We dismantled all five gearboxes and quoted them to the [...]

Horner Gearbox Repair: Cutting Down Customer Costs and Turn Around Time2019-09-10T16:00:18-04:00

Unique Shaft Manufacturing at Machine Shop

A magnetics manufacturer in Ohio makes magnetic drums that can sort metal out of material on a conveyor belt. These magnetic drums are for auto shredding, municipal solid waste, parts recovery, and iron ore cobbing just to name a few. These drums are for heavy duty ferrous separation applications. They come in sizes in diameters from 36” to 72” and widths from 36” to 120”. The magnetic manufacturer was currently looking for a company who could manufacturer these shafts for them and thanks to John Baumann he was awarded the contract along with the Machine Shop. The customer sends the material [...]

Unique Shaft Manufacturing at Machine Shop2019-09-10T16:00:18-04:00

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