outage staffing

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

Power Plant Shut Down Work

We all know that shutdown work is critical to all customers, how- ever, when we are working for a powerplant the stakes are even higher. Bert Serak sold a lot of shutdown work for a powerplant located in southeastern Ohio. The first job was a 1000 HP motor that had to be rebuilt and returned in 5 days. This motor looked like a UFO when it was lifted by a crane to the rooftop of the plant. The next opportunity was to rebuild a dozen fans and drive motors in 5 days. We sent two trucks to pickup the fans and [...]

Power Plant Shut Down Work2024-11-15T12:56:34-05:00

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

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

Cement Season at Horner

It’s cement outage season in Indiana with Horner doing work in Greencastle, Louisville, Logansport, Speed, and Mitchell IN. A Central Indiana cement plant is conducting their largest Maintenance and Repair outage in 20 years. They needed to replace an entire section of both the kiln and raw mill. The company brought in a 700-ton mobile crane to the plant site requiring 78 semi loads of support to set up. The time needed for these extended kiln and mill repairs allowed the customer to do all other outage work in the same 6-week timeframe. Washington Street, Terre Haute and HMS are all [...]

Cement Season at Horner2021-02-18T18:28:09-05:00

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

Power Plant 7000 HP ID Fan Motors

          A Power Plant Customer’s Generating Station is located outside of Sullivan Indiana about 45 minutes South of Terre Haute. This coal fired plant went on line in 1982 operating two units producing 1080 megawatts. Horner’s shop in Terre Haute has been doing repair work for them since before the plant was operational. They continue to be a strong customer after almost 40 years. Each year they shut down one unit for maintenance so motors come into our shops for repair and Horner’s field service divisions are involved with removals and installations. Most motors are on a [...]

Power Plant 7000 HP ID Fan Motors2019-09-10T16:00:16-04:00

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

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