field service

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+00:00

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+00:00

2000 HP DC Shredder Motors

A recycling scrapyard in Dayton, OH had a few problems with one of two 2000 HP DC motors. The outboard motor was going through brushes and they were having flash-over issues causing field coil damage. The 2 motors are coupled together to run a shredder that shreds anything from cars, and scrap iron, to office furniture etc. The customer’s spare motor was sent to our shop at Washington Street to make sure the motor was ready to go when it was switched out with the motor needing repair. Washington Street bought and installed a new coupling and then sent the motor [...]

2000 HP DC Shredder Motors2019-09-09T18:03:25+00:00

Cabinet Manufacturer “Boxed In”

When our customers are “boxed” in, Horner has the unique ability to assemble resources from Multiple Horner locations to get them back up and running. In this case, our customer literally makes thousands of boxes a year in the form of Kitchen and bathroom cabinets. As a major supplier to the (2) largest home improvement chains in the United States, that makes for a lot of Boxes! In this case, our customers largest exhaust fan drawing air off of their paint booths failed the Dodge 3-15/16 bearings on the 52” diameter fan. The air off the booths is run through a [...]

Cabinet Manufacturer “Boxed In”2019-08-29T16:18:44+00:00

Power Plant Outage

A power plant in Indiana had Horner recondition 6 large motors during an outage they had in April. The Power Plant is a coal fired electric generation plant. The key component of the power generation plant is the boiler, and is also called the steam generator. The essence of the power generation plant is to create the steam in boilers. This steam is sent at high pressure to a turbine that generates electricity. The coal is first crushed into small particles using equipment called pulverizers. A joint effort between the Terre Haute Shop, the Washington St. shop, and field service helped [...]

Power Plant Outage2019-09-18T15:37:39+00:00

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+00:00

Steel Manufacturer Learns Value of Thermography

        One of the services offered by Horner Mechanical Field Service is thermography inspections. It is primarily used to inspect energized electrical systems. We look for electrical equipment that is hotter than it is rated for, as well as for balanced temperatures. Temperature imbalance can occur due to uneven current flow, or a loose connection causing heat. It is another one of those “black box” technologies that some people are very skeptical about the validity of paying for. Matt Brown is one of the guys who perform these inspections and recently had the opportunity to make a new convert [...]

Steel Manufacturer Learns Value of Thermography2019-09-09T18:04:41+00:00

1500 HP DC Drive Changeout

One of our Horner customers had a mid 70’s Reliance Engineered Drive with an AB PLC-5, it was operating a Banbury Mixer application. The existing drive was damaged in a minor fire and was only operating on 3 out of 6 caps. Due to the damage and loss of pertinent feedback to monitor quality, our customer made the decision to replace the existing drive with a new Bardac DC drive. Bardac was chosen due to the availability of the drive which was 2 weeks out on an expedited basis. No other drive company could provide delivery inside 16-18 weeks. David Whited, [...]

1500 HP DC Drive Changeout2019-08-29T16:27:42+00:00

Maintaining the Cleanliness of the Exterior of the Motor, the Fan and the Fan Cover Grill/Screen is Critical to Getting the Most Life Out of Your Motors.

Keeping the exterior of motor frames free of debris and buildup is necessary to achieve the normal lifespan of the winding. On a TEFC motor, the fins on exterior of motor are made to direct the air flow over the motor frame for heat dissipation. When they become restricted or filled with foreign material, it may cause the motor to run at an elevated temperature creating a thermal deterioration of the winding insulation. For every 10 degrees C that you increase the temperature of the motor, it cuts the insulation life in half. Of course the air will originate with the [...]

Maintaining the Cleanliness of the Exterior of the Motor, the Fan and the Fan Cover Grill/Screen is Critical to Getting the Most Life Out of Your Motors.2017-03-13T17:44:57+00:00