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dc motor repair

3000 HP Cement Motor

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 [...]

3000 HP Cement Motor2023-03-15T10:11:23-04:00

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

Aluminum Foil Plant Preventative Maintenance

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 [...]

Aluminum Foil Plant Preventative Maintenance2023-03-13T10:55:03-04:00

Power Generation Plant Water Pump Motors

A coal fired power generation plant had a planned outage to maintain equipment and Horner was onsite to remove 2 1250HP vertical pump motors. These motors pull water from the reservoir for cooling purposes and heat exchangers. These motors were taken out for routine maintenance, basic reconditioning and to replace bearings. Onsite to help with the removal was Indianapolis Field Service Don Pence, Louisville Field Service Joe Dupont and Terre Haute’s Eddie Piper and Jeremy Brown. Crane service had to be scheduled and coordinated to pull the motors out. The bearings for these motors are specialized thrust bearings and were replaced [...]

Power Generation Plant Water Pump Motors2023-03-13T10:23:54-04:00

Slip Ring Rebuild

A customer called overnight because they had a slip ring failure on one of two synchronous motors and that halted production. Horner was on site in the morning to assess the situation and it was determined that an on site repair was not feasible. The unit was disassembled and transported to the Terre Haute shop for rebuild. By securing customer supplied brushes, brushholders (which are now obsolete), Horner stock to fabricate insulators and with the help of Horner Machining Services, we were able to have the unit back on site within just a few days. Horner was onsite for the eight [...]

Slip Ring Rebuild2023-03-03T11:44:31-05:00

Powerplant Turbine Vent Fan/Motor

A power plant’s combined cycle generating station contacted Horner Salesperson Joseph Motz on Friday 12/16/22 regarding one of the Turbine Vent fan motors which had failed and was going to need to be replaced or repaired. As this motor is not accessible while the Turbine generator is running, Horner could not verify Motor dimensions for the possible replacement of the original OEM motor. The Station had a spare fan, but it did not come with a motor. Upon inspection of the fan and Impeller in the customers storeroom, it was noted that the base could accommodate the metric frame motor but [...]

Powerplant Turbine Vent Fan/Motor2023-03-03T11:34:10-05:00

1937 DC Stainless Steel Manufacturer Motor

A good customer who manufacturers stainless steel had a power outage recently. When power was restored, the motor failed due to condensation from the unheated building. This motor was built by the Army Corp of Engineers in 1937 and came out of a boat from WWII. Field Service came onsite to inspect the motor and found that the fields were grounded and the armature was not far behind. Luckily, this customer had a spare in their warehouse. They decided it was the quickest to take that spare motor out and send it to Horner to repair and get it running. Due [...]

1937 DC Stainless Steel Manufacturer Motor2023-03-03T11:26:56-05:00

Compressor Room Electric Motor

A call came in late Friday from a customer planning to have their maintenance team do an onsite bearing change on a production compressor motor. We had the bearings in stock and set aside for them, however, Monday morning I received a call letting me know that they weren’t able to complete the work in house and requested Horner Field Service to come assist as soon as possible. We sent a team that morning to pull the motor and get it in to the shop for evaluation. Once onsite, they found that the compressor room is not accessible with a forklift. [...]

Compressor Room Electric Motor2022-05-16T11:51:07-04:00

Sawmill DC Motor

Last summer, we received a call from the maintenance manager of a large sawmill. To get an idea of equipment size, this large bandsaw cuts 6’ diameter tree trunks into quarter pieces. A large carriage carries the log and feeds it into a large bandsaw with a blade that is 12” wide. The quarter pieces then go to smaller saws to cut slab boards. The complaint was that the large DC mill motor was making noise. Our field service supervisor, Jim Delawder, investigated and found that the banding on the commutator end of the armature had fractured and was flopping against [...]

Sawmill DC Motor2022-01-28T17:14:56-05:00

Complex Motor Rewind – DC Mill Motor

Horner Louisville had the opportunity over the Holidays to service a customer who is a plastics extrusion company. The motor came in on an overtime basis, so it was given top priority. The customer sent in a 75Hp FUJI DC Motor that, after disassembly, inspection and testing required a full rewind and machine work that included coatings work on the armature. However, this wasn’t your every day run of the mill DC motor. The motor was a random wound compound design which is known to be a little tricky to wind. Louisville’s winder, Charlie Mings, looked at the winding and was [...]

Complex Motor Rewind – DC Mill Motor2022-01-28T15:33:09-05:00

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