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Aluminum plant

Aluminum Plant Outage

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 [...]

Aluminum Plant Outage2023-03-14T11:27:59-04:00

Catastrophic Bearing Failure

An Aluminum Foil manufacturer experienced catastrophic bearing failure on a combustion air furnace fan. When the bearings failed, the fan wheel made contact with the fan housing. The combustion air fan provides air to the furnace gas burners. The furnace heats the aluminum foil rolls to burn off the oil used to manufacture aluminum rolls when the aluminum passes through mills and separators. Horner Fan received the damaged fan. The incoming inspection revealed the fan hub was cracked and along with the fan wheel damage – bent/cracked blades and ripped off back plate, Horner Fan recommended to manufacture a replacement. The [...]

Catastrophic Bearing Failure2022-01-28T15:18:37-05:00

Non Standard 2000 HP Mill Stand Motor

What makes the Horner Motor Division stick out from most motor shops besides the breadth of services it offers is its ability to fix and problem solve non-standard motors and equipment. We employ some of the best winders and mechanics whose knowledge is incomparable. We received a 2000 HP Mill Stand motor from an aluminum plant for repair. Fractures were found in the risers exiting the commutator bars with a design from Siemens that would definitely be considered “non-standard.” Many of the design characterizations were due to lots of horsepower in a fairly small frame. We replaced the commutator, windings, and [...]

Non Standard 2000 HP Mill Stand Motor2020-03-05T18:06:06-05:00

Aluminum Plant Outage

In June of 2017 an Aluminum plant contacted us to begin the early planning stages of their outage which was scheduled for January 2018. The customer was about to undertake the most involved outage on their primary mill and wanted Horner’s exclusive involvement. The outage was a success despite the very large scale and daunting tasks assigned. All work was coordinated by Ralph Coonce of field service. If you’ve ever seen Ralph in action during an outage I don’t have to explain that he doesn’t just show up. He’s elbow deep in the actual work turning wrenches or any another task [...]

Aluminum Plant Outage2019-09-09T17:28:00-04:00

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