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At Horner Industrial Group, we take pride in our commitment to excellence and preventative maintenance solutions. Recently, our EMDS department had a significant impact on the operations of a coal-fired power plant, showcasing the vital role of hands-on data collection and analysis in preventing potential disasters. Our client, a coal-fired power plant, relies heavily on rotating equipment to maintain its operations. Every month, our vibration technician Joe Roseberry, performs vibration data collection and analysis on all rotating equipment at the plant. One critical piece of equipment under Joe’s watchful eye is an agitator, which plays a crucial role in an environmental process that prevents pollutants from entering the air. This agitator, like a giant mixer in a large tank, is integral to the plant’s operation. Without it, the plant cannot function due to strict regulations imposed by the Environmental Protection Agency (EPA). During one of his routine inspections, Joe noticed something amiss with the vertical motor of the agitator. With his experience, he recognized that the motor’s movement indicated a potential slurry buildup in the mixer’s paddles. This observation underscored the importance of hands-on data collection, as remote monitoring would not have detected this issue. Moreover, the location of the equipment, positioned high above ground level, meant that the movement would have gone unnoticed by others. Joe’s keen eye and proactive approach averted a looming disaster.
Had this problem gone undetected, the consequences would have been dire. A non-scheduled emergency shutdown would have ensued, resulting in significant losses in time, money, and electricity production. However, the issue was caught in its infancy, allowing the new maintenance manager to devise a plan to rectify the situation swiftly. This success story exemplifies the invaluable contributions of our EMDs department. Time and again, their meticulous data collection and analysis have saved the day for our clients. Joe Roseberry’s experience serves as a reminder of the importance of addressing seemingly simple maintenance issues before they escalate into major set- backs. As he aptly puts it, “simple things like bolts, torque, alignment, and pipe strain cause big problems.” Unfortunately, these fundamental maintenance principles are often overlooked in today’s industry, high- lighting the need for comprehensive training programs. Horner remains committed to delivering exceptional service and proactive solutions to our customers. Our EMDS department stands as a beacon of reliability, ensuring the smooth and efficient operation of critical equipment across various industries.