electric motor repair

EMDS Motion Camera Alerts Cement Plant

EMDS was called to evaluate the E51FN05 Fan, at an aggregate plant, which had been running smoothly until a defect in the fan bearings necessitated their replacement. Continued abnormal motion was detected around the unit, prompting EMDS to acquire and analyze Motion Amplification Video, alongside traditional velocity and acceleration vibration data. The motor and fan were mounted on a substantial concrete base, supported by below- grade caissons, and surrounded by a concrete apron serving as a walk and work platform. Moisture pressing out around the expansion joints while the fan was operating, and noticeable vibrations underfoot raised concerns. An earlier attempt [...]

EMDS Motion Camera Alerts Cement Plant2025-07-24T11:51:42-04:00

Manufacturing Partnership Winding Motor Stators

Typically, the work we receive at the Springfield Division is electromechanical components that our customers use as tools to create their own products with. In the Spring of 2019, we started a partnership to aid one of our local manufacturing facilities in producing and testing the products they make for their customers. This relationship has grown, and we are called upon in times when their orders are greater than their staff can produce. The Springfield and Indianapolis divisions have worked with this customer in the past, primarily winding motor stators. Our customer has recognized the value of having Horner as a [...]

Manufacturing Partnership Winding Motor Stators2025-07-23T13:46:39-04:00

Coffee Creamer Bottle Motor/Gearbox Repair

In a coffee creamer plant, the blow molding machine was the backbone of the operation, producing 16oz and 32oz bottles. The process started with plastic pellets being fed into the machine through a hopper or screw. These pellets were heated and melted due to the combined effects of external heat bands and the friction generated by a rotating screw. The melted plastic was then shaped into a parison, a hollow tube with an opening at one end, which was clamped securely inside a mold designed to form the bottle. Compressed air was then forced into the parison, causing it to expand [...]

Coffee Creamer Bottle Motor/Gearbox Repair2025-07-23T13:36:11-04:00

Plant Outage Inspection Identifies Big Problem

Horner Indy Field Service was on site at a plant outage in Blytheville Arkansas. This customer is a compressed gases company that supports a steel plant. During the inspection and testing, we identified an insulation problem in a 6,000 HP compressor motor. When we reported the findings to the customer, he asked us to change the motor out for the spare. The spare was in storage in Texas, and they got the spare on the road to Arkansas. Meanwhile, we did not go there with the tools, equipment and the required manpower to do a motor swap of this size. We [...]

Plant Outage Inspection Identifies Big Problem2025-07-23T12:24:35-04:00

7000 HP ID Fan Motors

In the dynamic landscape of energy production, Horner has been a steadfast partner in ensuring the operational excellence of a prominent coal-fired generating plant. This success story revolves around the maintenance and reconditioning of two critical 7000 HP induced draft fan motors, integral components of the plant’s power generation process. A real life example: (Not our customer) Kingston Fossil Plant near Knoxville, TN rely on the combustion of coal in a boiler to produce high-pressure steam. This steam, at temperatures exceeding 1,000 degrees Fahrenheit, propels turbines connected to genera- tors, generating electricity at an impressive 20,000 volts. The Kingston plant, with [...]

7000 HP ID Fan Motors2024-11-15T12:55:33-05:00

Crusher Motor: Car Shredding Application

A car shredder operates as a spectacular example of brute force engineering and recycling innovation. At its heart, the key player is the crusher electric motor, a powerhouse of energy conversion. The process begins as a scrapped vehicle is positioned on a conveyor belt, slowly moving towards its impending doom. As it approaches, the crusher motor roars to life, driving massive hammers, blades, or rotating drums to tear into the vehicle. The relentless electric motor generates immense torque, smashing through the car’s structure with a deafening sound. Simultaneously, powerful magnets and eddy current separators help remove non-ferrous materials like aluminum and [...]

Crusher Motor: Car Shredding Application2024-11-15T12:58:32-05:00

Chassis Dyno Failure

Horner received a call from a diesel engine company regarding a chassis dyno that had failed. If you do not know, a chassis dyno is a test cell in which a vehicle is driven into and the tires ride on a roll to simulate driving. This particular test cell is a four wheel drive test cell and the customer is measuring emissions of the vehicle. The customer was experiencing issues with the rear assembly. Horner was on-site several times helping the customer identify the problem and determined it would be best for the unit to be pulled and the motor sent [...]

Chassis Dyno Failure2024-11-15T12:59:05-05:00

Agricultural Seed Plant Drying Facility

A company that raises seed corn has two large locations in Northern Indiana. They bring in the corn during harvest season every August to October when its on the ear, which means its wet. The company dries the corn and shells it on site. The company then sells the seed to farmers to grow the following year. These facilities have a bunch of large belt driven fans that are used for the drying process. One plant has 24 and the other 48. Since the facilities only run a few months a year, they sit idle the rest of the year. They [...]

Agricultural Seed Plant Drying Facility2024-11-15T12:59:44-05:00

Horner Springfield: Sulzer Pump Company Repair Center

          There is an old saying that when you mix water and electricity, water will always win. Judging from the amount of submersible work that the Horner Springfield division has been receiving, I would say that the old saying is very true. We have seen a substantial increase in the number of underwater submersible pumps and agitators that have a motor, gearbox and fan. Part of the reason for the increase in this line of repair work is the long lead time for replacement units. Underwater submersible equipment that our division has repaired ranges in size from [...]

Horner Springfield: Sulzer Pump Company Repair Center2024-02-28T09:37:03-05:00

Terre Haute Industrial Equipment Repair Working The Weekend

Terre Haute has been busy with a lot of work from great customers. Recently a plastics recycling customer called about high vibration on a dryer auger. This customer recycles the plastic processing it into industrial resins that are used to make plastic bags. The stainless-steel auger is used to convey plastic pellets during the washing process, prior to drying and packaging. Due to high vibration the auger was pulled and sent to the Terre Haute shop for repair. Jeremy Brown, machinist, dynamically balanced the auger and sent it back the recycling facility to be put back into production. Another project that [...]

Terre Haute Industrial Equipment Repair Working The Weekend2023-06-16T13:28:51-04:00

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