mechanical field service

Field Service Cooling Tower Gearbox Project

Indianapolis Field Service went on site to look at a gearbox problem toward the end of last year. What we found was not one, but two cooling towers had experienced failures of the old gearboxes at the center of the cooling towers. Cranes were brought in for the material handling and the cooling tower drive train was all removed and taken to the shop for repair. When at the Indianapolis Repair Facility, the age and condition of the gearboxes added together to make repairs impractical if not impossible. A replacement drive (the drive train replaced was the drive shaft, couplings gearbox, [...]

Field Service Cooling Tower Gearbox Project2026-04-14T10:50:51-04:00

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

Underground Rock Quarry

I have previously expressed, that the unexpected challenges encountered in Field Service contribute significantly to the intrigue and appeal of the profession. My recent assignment required me to venture underground, an endeavor I found to be a genuinely remarkable experience, one that I would readily undertake again. I received a service call to balance the primary air supply fan at a local underground rock quarry. Upon arriving, I successfully completed the requisite safety training and prepared to descend below ground. To access the underground tunnel, I unloaded my van as diesel vehicles are the exclusive mode of transport permitted in subterranean [...]

Underground Rock Quarry2024-11-15T12:57:05-05:00

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

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 Motors2019-09-09T18:03:25-04:00

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 Outage2019-09-18T15:37:39-04:00

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 Thermography2019-09-09T18:04:41-04:00

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