predictive maintenance

Horner Electro-Mechanical Diagnostic Group – Coal Fired Power Plant Vertical Motor

At Horner Industrial Group, we take pride in our commitment to excellence and preventative maintenance solutions. Recently, our EMDS department had a significant impact on the operations of a coal-fired power plant, showcasing the vital role of hands-on data collection and analysis in preventing potential disasters. Our client, a coal-fired power plant, relies heavily on rotating equipment to maintain its operations. Every month, our vibration technician Joe Roseberry, performs vibration data collection and analysis on all rotating equipment at the plant. One critical piece of equipment under Joe’s watchful eye is an agitator, which plays a crucial role in an environmental [...]

Horner Electro-Mechanical Diagnostic Group – Coal Fired Power Plant Vertical Motor2025-01-15T11:05:08-05:00

500 MW Generator Failure: Lesson Be Observant

          A 500 MW generator failed catastrophically, it had an internal short that resulted in a phase to phase short. The generator stopped so suddenly that it sheared off 24 2 ½” bolts in the coupling between the generator and the turbine. The problem was traced to the phase leads resonance shifting to 120HZ as the generator aged. This problem resulted in the annual testing of the phase leads for the unit that had the failure and also on its sister machine. One of the key lessons learned during many hours of testing these generators was that [...]

500 MW Generator Failure: Lesson Be Observant2024-02-28T09:55:34-05:00

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

Advanced Diagnostic Services and Preventative Maintenance

A major steel mill was looking to upgrade their maintenance practices thru predictive maintenance vibration analysis. There were several meetings with Brad Barton of Horner’s Electrical Mechanical Diagnostics Service (EMDS) group to identify equipment and understand their expectations. The EMDS reporting was covered in depth, a vibration collection route was laid out and frequency of reporting established. The machines identified ranged from 10,000 hp AC motors to smaller AC and DC motors in the range of 100hp up to 1250 hp as well as gearboxes. Horner’s field service group installed remote accelerometers on equipment deemed not safe for personnel to enter [...]

Advanced Diagnostic Services and Preventative Maintenance2022-01-26T23:19:34-05:00
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