CBC TECHNICAL SERVICES - CBC Bearings

IMPROVING UPTIMECBC TECHNICALSERVICESASSET PERFORMANCE OPTIMISATIONPROGRAMCBC TECHNICAL SERVICESIMPROVING UPTIMEAND INCREASING OPERATIONAL EFFICIENCIESFOR AUSTRALIAN INDUSTRY

Design CentreCBC Design centre is a dedicated information website providing CBC customers with ready accessto key product and operational data associated with the design, selection and specifications forbulk material handling equipment, conveyors and related components.Included are mounted bearing plummer blocks, wire rope sheaves, shaft locking assemblies, fluidcouplings, brakes and gear reducers. The information package extends to slewing bearings andstructural bearings.The website provides design and operational guidelines, selection and calculation tools, 2Ddrawings and 3D models downloads, and applicable technical documents.The CBC Design centre is being continuously enhanced, with expanded product and supportingdata to meet particular industry requirements, including and beyond the current scope.Register online at cbcdesigncentre.com.au

Engineering DesignCBC’s team of over 40 qualified Technical Service Engineers work closely with our customers todevelop unique, fit for purpose solutions. Our Engineers have a long history of assisting customersto design solutions with specialised features which meet tough application requirements and solvefunctional problems.Our vast range of product options and in-house design capability for specialty housings andmanufactured seals for tough applications provide a complete service. Coupled with the fullsupport of CBC’s Technical Service Engineers and manufacturer resources in bearing and housingdesign, power transmission drive design, application engineering, lubrication and sealingtechnologies, we effectively deliver optimised performance and cost avoidance for our customersfrom the start.CBC is a capable, proven solutions supplier, committed to the current and future needs of ourcustomers. Our in-house capabilities offer our customers some of the best total cost of ownershipsolutions available in the market today.Your local CBC representative can show you some of our most recent “Cost Avoidance” solutions,demonstrating the huge variety of problems our initiatives have overcome for customers.

ManufacturingTransmission Bearing Company (TBC) is CBC’s manufacturing Division. TBC’s total machine shopcapability provides customised engineering solutions not available from any other Australianbearing company. From initial evaluation of requirements through to design, manufacturing andinstallation, TBC and CBC offer more than just bearings. Our experienced Engineers can assist youto design a complete customised solution that incorporates our suppliers and their expertise inbearings, housings, sealing technology and lubrication.From single piece manufacture to volume runs - no job is too small - or too large.TBC has developed solutions for a number of specialised applications, including conveyor pulleys,tunnelling cutter heads, track rollers, swing gear cases, sealing assemblies and housings.TBC can provide:• A wide range of standard solid bearing housings• GLH brand split plummer block housings• Customised solid and split housing solutions to meet specific requirements• Wire rope sheaves• Machined components assembled with bearings and seals, providing complete customised solutions• 3D CAD Solidworks drawing capability• Contract machining for medium to high volume runs• Project management capability• Machining capability - CNC and manual lathes, drilling, milling and vertical boring

TrainingIn today’s highly competitive environment, businesses are becoming more aware of theneed to invest in skills training. Equipment productivity and reliability depends on the skilfulaccomplishment of maintenance practices and there is a clear relationship between maintenancepractices, equipment productivity and bottom-line profit.Bearings and Power Transmission products are critical components in production efficiency; andfitting and maintenance practices are critical in ensuring their design life is achieved.Evidence suggests that 95% of premature equipment failure is caused by improper installationof replacement parts and maintenance practices. CBC staff are factory trained by the productmanufacturers in correct installation procedures.CBC offers a range of options for customers to access our training expertise in the correct fitting andmaintenance of bearings and power transmission components. An accredited training course anda wide variety of module specific maintenance training courses have been designed to meet thedemand for skills training in maintenance practices.CBC can tailor a complete training package to meet customer’s individual needs and time framesfor presentation on or off site.All CBC training courses incorporate world’s best practice, up-to-date techniques and information;include the use of hands-on training equipment; are conducted by qualified workplace trainers; andare offered Australia-wide for the convenience of our customers.

Alignmentof Shafts, Pulleys & DrivesKeeping rotating equipment in line is critical to achieving its optimum lifespan. Misalignedmachinery will eventually cause bearing, shaft, seal and coupling failures; and it has been identifiedas a cause of increased energy consumption.CBC Technical Services can now help you keep your rotating equipment in line with a PC-basedshaft alignment system - the FAG Top-Laser INLINE2 - enabling you to align accurately andsignificantly increase machine availability. It is suitable for precise shaft alignment of motors,gearboxes, fans, pumps and compressors.Correct alignment can minimise the risk of unplanned shutdowns, prevent critical vibration due tofriction, avoid damage to bearings and shafts, minimise wear on couplings and seals and optimisethe efficiency of your equipment through improved uptime.The system is accurate, easily mounted and operated, is compatible with all notebooks, laptops, orcan be equipped with a wireless connection.CBC Technical Services can assist with training to ensure maintenance staff are competent inthe use of the equipment, improving your organisation’s alignment standards and increasingequipment reliability.

Installation& CommissioningEquipment failures are often caused by contamination of the product before they are installed, orby failure to follow the correct installation techniques essential for larger bearings, seals and powertransmission components.Proper installation ensures maximum service life. CBC can provide engineering expertise for criticalapplications or for large components that necessitate correct installation first time, to reduce therisk of early failures.CBC’s Technical Service Engineers and representatives have experience in commissioningequipment in a variety of industrial applications; and if necessary, they can draw on our close andlong-standing association with the world’s major bearing and power transmission manufacturersfor full range product support.CBC can also provide commissioning advice on the most appropriate installation techniques as wellas offering a full range of maintenance and installation tools and training.

Bolt TensioningCBC is an authorised agent of Technofast Industries Pty Ltd - Australian manufacturer of state ofthe art hydraulic bolt tensioning equipment. The Technofast Industries range of bolt tensioningequipment enhances maintenance programs with solutions for critical bolting applications.Accurate in applying bolt load and very fast, they are easy to use, lightweight and eliminate anumber of safety concerns like pinch points and weight of tooling associated with traditionaltorque methods.Hydraulic tensioning has many advantages over traditional torque wrenches. This method issuitable for use in confined spaces and only requires access to the site with a hydraulic hose toapply or release a bolt load.By applying the bolt load with an hydraulic bolt tensioning device, the load is applied in a straightline eliminating frictional loss and allowing greater accuracy to design specification.Technofast Industries are world leaders in the resolution of bolting problems and are accreditedwith many new and innovative solutions to bolting issues in power generation (nuclear andthermal), mining and material processing industries.CBC and Technofast specialists are available for:• Onsite inspections and training• Audits of critical equipment• Compilation of a data base from audits• Simplification and standardisation of maintenance practices for tensioning• Specialised onsite bolting services including design and implementation of critical bolting tasks

Support Products& ServicesCBC is the authorised Australian distributor of specialised maintenance products which areavailable for hire or sale and are backed by local service and repair agencies.Prüftechnik Eddytherm® Eddy Current Induction Heaters are used for the safe and reliable shrinkfittingof ball and roller bearings, couplings and connectors, gears and shaft spacers. The fitting ofbearings using eddy current induction heating is the recommended method for fitting bearingswith interference fits by all major bearing manufacturers worldwide. Prüftechnik Eddytherm® unitscan be used for fitting bearings from 1kg to 4,000kg with bores from 15mm to 600mm.Hydraulic Nuts can be used to press bearings and components with a tapered bore onto theirtapered seat. They are primarily used when the drive-up forces required cannot be applied usingother devices, eg shaft lock nuts or pressure screws. Used for the mounting of rolling bearings witha tapered bore and the mounting of couplings, gears, ship propellers, etc, they are available inmetric thread sizes from 50 to 380mm.Gates have a complete range of tools and kits for the installation and maintenance of belt drives,including:• Belt drive maintenance kits containing all the tools required to install and maintain belt drives• Sonic tension meters for fast, accurate readings on all synchronous belt drive systems and V-belt drives• Laser AT-1 which accurately gauges angular and parallel misalignment• EZ-Align, a laser alignment tool that checks both angular and parallel planes simultaneously• Tensioning tools to accurately measure the tension of individual or joined belts at installation orduring maintenance

Site Surveys& Mincom LinkOneIdentifying components of equipment and ensuring they are available when necessary is a criticalpart of plant uptime. Site surveys are the first step to improving efficiency in maintenance, energyconsumption and inventory, and the first step toward achieving the longest possible life ofequipment without unexpected breakdowns.CBC’s complete surveys of plant and equipment provide the customer with a comprehensivedossier of a site’s major mechanical componentry in application order; and it cross-references OEMpart numbers to CBC part numbers and lists a full range of spare parts for that componentry. Itdetails product numbers (including interchanges) and identifies commonality amongst equipment,allowing rationalisation of inventory. Surveys are carried out by experienced CBC Technical Servicesstaff and product specialists in collaboration with customer personnel and are ideally conductedduring scheduled shutdown periods.This dossier is either distributed in hard copy to maintenance management or the informationuploaded to Mincom LinkOne.Mincom LinkOne is an innovative web-based software system which integrates SAP, OpenCatalogue Interface (OCI) compliant applications and Webview for creating and delivering graphicalparts catalogues that help users to find the right part, first time, every time. Mincom LinkOnelinks graphics with parts lists and rich text to easily produce electronic catalogues and graphicalmaintenance manuals.Mincom LinkOne’s publishing, distribution and viewing systems make all forms of electronic partsand service information available at the touch of a key via the Internet, intranet, or CD, includingparts catalogues, repair manuals, operating and commissioning instructions, maintenance andrepair procedures, visual operational aids, product alerts, safety bulletins and product updates.

StandardisationStandardisation of equipment and components is one of the most important areas a site needsto consider. Many suppliers use generic numbering systems for the same style items. These itemsare usually replaceable as a complete unit but can have different components that can affectperformance and reliability. These differences can include (but are not limited to) material and sealing.Replacement components for these items are often not interchangeable, resulting in difficulty atsite, avoidable downtime and stock duplications. Purchasing and correct stock levels also becomemore complex as the variations grow.CBC offers extensive help in the area of standardisation where both the technical and commercialrequirements are addressed, offering high dollar cost savings. An example where standardisationoffers a huge benefit is conveyor bearing housings.

Condition MonitoringCBC Technical Services and AzimaDLI reliability services are designed to provide you with allthe benefits of a condition based maintenance program without the investment in equipment,software and personnel.The purpose of our program is to deliver the maximum productivity for the life of your capital asset,through world’s best practice diagnostic expertise.The increased cost of buying new assets alone demands their greater utilisation through wellplanned, non-disruptive, condition monitoring collection services.Our technical solutions cover subscription based vibration analysis services, online remotemonitoring and onsite corrective technical services.Here is what sets us apart:• Industry leading machine condition analysts• The most advanced and reliable analytical software and remote monitoring capability in the industry• A sustainable set of solutions tailored to your condition monitoring requirements and guaranteedto deliver actionable maintenance advice• A secure and accessible web portal that allows everyone access to the same critical informationat exactly the same time, focusing your staff’s attention on urgent problems and connecting youdirectly with our expert analysts

Oil AnalysisAs part of our condition monitoring service, CBC Technical Services provides a NATA accredited oil,grease and fluid analysis program. Maximising plant uptime and efficient operation requires themonitoring of operational factors such as friction, lubrication condition, wear, temperature anderosion using oil analysis techniques. Engines, turbines, fuel systems, compressors, water quality,gears, pumps, hydraulic systems, and electro-hydraulic controls are all areas where fluid analysis byCBC Technical Services can benefit your organisation.Our oil analysis program provides you with information on the condition of your oil and themachine from which it came, as well as advice on what to do about it.At the most basic level, a CBC Technical Service oil analysis determines if the oil in a given piece ofmachinery is dirty, contaminated, diluted, or fit for continued use. A more detailed analysis will tellyou the life expectancy of the oil before an oil change is required. It also offers you a glimpse insideyour equipment to identify alignment problems, pending mechanical failure, and the cause of anywear and contaminants.An oil analysis program from CBC Technical Services will help you to avoid the cost of not knowingthe condition of your critical equipment - by decreasing mechanical failure rates, increasingproduction, and improving energy consumption in your organisation.CBC Technical Service provides fast and reliable email and web based oil analysis reports. We canhelp you increase equipment uptime, reduce safety risks, and enhance maintenance planning foryour organisation for optimum serviceability of equipment.

Thermal AnalysisAs part of our condition monitoring service, CBC Technical Services provides a thermal analysisprogram which includes thermography and digital temperature recording. Thermal analysis canreveal problems in a vast range of mechanical and electrical applications precisely, quickly andeffectively. Thermal measurement and analysis programs make information accessible withouthaving to make contact with equipment, creating a safer workplace. They can assist in identifyingpotential failures or inefficiencies in time to prevent loss of production, breakdown of equipment orfire hazards. Their use is virtually unlimited; detecting the presence of heat or even cold anywherecan help in making a determination of equipment performance condition.Thermography uses cameras to measure infrared radiation, creating thermal images of equipmentwhich show variations in temperature as brightly coloured patterns, providing crucial informationfor many applications, both electrical (for high & low voltage systems) and mechanical.Digital temperature recording is a stand-alone time and temperature tracker in a stainless steelbutton, which is affixed to equipment to record temperature at regular, adjustable intervals.Humidity tracking is also available. Data is downloaded to specialised software for analysis of results.Used in conjunction with CBC’s vibration analysis and/or oil sampling programs, these highlyeffective plant awareness programs can improve plant uptime and reduce the cost of not knowing.

LubricationEffective predictive and preventative maintenance programs rely on scheduled lubrication,sampling and analysis programs to provide an accurate indication of equipment and lubricantcondition. Monitoring, control and management of the operating condition of lubricating oils inequipment such as diesel engines, generators, turbines and gearboxes is an essential part of day today maintenance routines.CBC’s Technical Services team works closely with our specialist lubrication and oil and greaseanalysis service partners to provide a range of services including detailed equipment surveys andlubrication management recommendations, sampling and analysis of lubricants and oils, as well aslubrication manpower and management.The benefits include improved productivity, increased equipment reliability, reduced manpowerand maintenance costs, reduced in-service lubricant contamination, waste and inventoryminimisation, reduced used oil disposal costs and reduced lubricant consumption costs.CBC can supply specialised lubricants where necessary for warranty as well as training in ourlubrication products and equipment.One Eye Industries magnetic filtration equipment offers CBC customers significant machine uptimeand lubricant life improvements by the effective filtering and removal of ferrous and non-ferrouscontamination in lube oil, hydraulic fluid, fuel, coolant, gear oil, glycol, process/effluent water and amines.CBC’s user-friendly electronic lubrication selection programs for bearings provide re-lube volumeand frequency standards for hand lube and single point lubricators. These can also be supplied aslaminated or block mounted wall charts, providing easy workshop reference for conveyor pulleybearing blocks.

Lubrication SystemsCBC stocks an extensive range of single and multi-point automatic lubrication systems to suit yourevery need. Our suppliers include Alemite, Grease Max, Memolub, perma, Simalube and Tecalemit.Automatic lubricators eliminate the need for manual lubrication by cumbersome applicators. Theyreduce valuable maintenance team hours as an inspection is all that’s required to ensure all is inworking order.Automatic lubricators provide constant positive pressure, reducing the likelihood of lubricantcontamination. They also guarantee that all points are lubricated and that the correct amount ofgrease is applied.Consistent greasing of a point keeps friction levels down and increases component life. Equipmentuptime is improved, reducing breakdowns and maintenance costs.Remote mounting and quick connections allow automatic lubricators to service difficult to reachgrease points, making maintenance simpler and safer.Most automatic lubricators operate throughout a wide range of ambient temperatures, haveadjustable grease flow rates and come in a wide range of sizes, making them suitable for just aboutany application where regular greasing is essential to smooth operation.

Slewing BearingsCBC Australia Pty Ltd are the Rothe Erde GmbH authorised Foreign Sales Representative for theAustralian Sales Territory.The CBC Rothe Erde Division factory trained Engineers can provide the following technical servicesfor Rothe Erde bearings sold by the CBC Australia Pty Ltd group of companies:• Preliminary selection of slewing bearings• Information enabling the correct mounting of slewing bearing with regards to analysis ofcompanion structure flatness survey results, correct bolt pre-tensioning, correct gear/pinionbacklash setting plus lubrication regime to conform to warranty requirements of the bearingmanufacturer, Rothe Erde GmbH• Information regarding the proper lubrication type, amount and interval for raceway and gear• Information regarding the correct monitoring of bearing wear via axial reduction or tiltingclearance measurement and interpretation of results• Interpretation of grease sampling analysis results• Factory approved rewrapping of spare slewing bearings supplied by CBC with optional long termstorage treatment and vacuum packaging for a maximum period of 5 years internal storageThe following publications can be downloaded from www.rotheerde.com and are also available bycontacting our Rothe Erde division:• KD114 Mounting Greasing & Maintenance Brochure• KD125/1 Bearing Inspection for different applications Brochure• Grease Sampling Set Brochure• Integrated Wear Measuring Device (IWM) Brochure• Rothe Erde Slewing Bearings Catalogue

Root Cause AnalysisUnfortunately, in real-world operations, all conditions rarely will be satisfied and mechanicalservice life will be threatened regularly by the effects of abrasive wear, corrosion, electrical erosion,fractures or a combination of these or other factors. When bearings and other mechanical itemssustain damage and must be replaced, profit loss follows due to equipment downtime and lostproductivity. Unless the root cause of failure can be detected, history may repeat itself with more ofthe same after a new bearing is installed and the rotating machinery resumes operation.In determining root cause, practical lessons can be learned by inspecting and analysing bearing,seals and mechanical components, which can be read like a "crime scene." Telltale signs are oftenapparent. Root cause analysis affords practical insights into the causes of premature failure and thecondition of the rotating machinery.Once we know accurately the root causes, we can provide the most suitable products or evenengineer a solution to your individual needs as part of a corrective action plan.

Bearing RefurbishmentCBC Technical Services can refurbish bearings in partnership with experienced providers, whetherit’s a bearing with damaged packaging, the re-working of a bearing to keep production going, or acritical spare.Our experienced Technical Services Engineers can diagnose and repair large roller bearings that arecommonly used in rolling mills, paper machines, mining equipment, crushing machines and largeindustrial plant and equipment. Refurbishment of bearings takes 2-6 weeks depending on the extentof the repairs. Major remanufacturing can be achieved in 3-6 months utilising overseas expertise.Damage assessment is offered at minimal cost, and if repairs are undertaken, will be included in therepair cost.The benefits of reconditioning bearings include maximising the productive life of bearings’ costavoidance of up to 70% of the price of replacement bearings, short lead times and peace of mind.Our services include:• Bearing assessments (all brands)• Raceway and rolling element polishing and regrinding• Bearing repackaging and crating• Bearing modifications• Bearing ring drilling and special machining• Precision bearing spacer assemblies• Precision grinding• Housing re-sleeving• Leveller bearing repairs

GearboxesCBC has extensive experience in gearbox upgrades and has assisted many customers in designupgrades for a variety of applications and in root cause analysis reports on gearbox failures.CBC has a Sydney-based workshop where gearboxes can be assembled to specific ratios.Gearbox overhauls are carried out by CBC’s team of skilled service providers, who are committed tofinding the best possible solution and work to manufacturer’s specificationsCorrect storage and maintenance of spare gearboxes is critical to ensuring they are kept in aserviceable condition and therefore ready for immediate use when required. CBC’s structuredprogram provides long term corrosion protection and ongoing service including the inspection,rotation and lubrication of critical components during storage to manufacturer’s specifications.

RedesignOEM components and machines can fail prematurely in harsh environments and conditions. CBCTechnical Services can provide an application redesign and standardisation service, utilising thedepth of product and application knowledge of CBC’s Engineers and supporting manufacturertechnologies, to provide you with alternative solutions to address premature failures.The expertise of CBC’s trained technical staff can assist you to design and re-engineer to yourspecific requirements. We begin with your objectives and recent experience; and work to ensurethat your business benefits from our knowledge and experience.Our solutions allow for the standardisation of products across your site, ensuring consistency inmaintenance skills and the rationalisation of spare parts.Whether the problem is in your equipment’s manufacture or design, we can help, withimprovements based on existing specifications or with a redesign, delivering you more efficient andprofitable equipment.

Inventory ManagementCBC’s warehousing and inventory management solutions are customised to assist our BusinessPartners to rationalise inventory while maintaining the necessary levels of availability to sustainoperations at single sites or across multiple sites.Warehousing and inventory management solutions for our bearings, power transmission andrelated product include:• Identification of critical items required to run the business• Identification of spare parts for equipment• Identification of parts required in routine maintenance• Rationalisation of spare parts inventory and the utilisation of spares across multiple sites• Reduction of obsolete inventories• Reduction of excess inventories• Reduction of duplicate inventories• Correct storage and handling of bearings and components, ensuring that stock is in prime condition• Identification and refurbishment of damaged items or those in poor condition• Sales or disposal of surplus items.• Store surveys to identify costly OEM purchased parts• On site and vendor held stock programs• Strike rate measurement/performance

IMPROVING UPTIMECBC TECHNICALSERVICESCBC TECHNICAL SERVICESIMPROVING UPTIMEAND INCREASING OPERATIONAL EFFICIENCIESFOR AUSTRALIAN INDUSTRYTo learn more about our wide range of technical and support services designed to improve uptime and your bottom line performance, contact us:CBC Bearings Power Transmissionwww.conbear.com techservices@conbear.comNEW SOUTH WALES3 The CrescentKingsgrove NSW 2208T 02 9947 9200F 02 9954 1333E techservices-nsw@conbear.comNEWCASTLE4/585 Maitland RdMayfield West NSW 2304T 02 4968 4000F 02 4968 4040E techservices-ncl@conbear.comQUEENSLAND865 Kingsford Smith DriveEagle Farm QLD 4009T 07 3866 2111F 07 3866 2177E techservices-qld@conbear.comSOUTH AUSTRALIA479-481 South RoadRegency Park SA 5010T 08 8348 2100F 08 8340 0491E techservices-sa@conbear.comAUSTRALIAN CAPITAL TERRITORY57 Kembla StreetFyshwick ACT 2609T 02 6280 4288F 02 6239 1332E techservices-nsw@conbear.comVICTORIA174 Fairbairn RoadSunshine West VIC 3020T 03 9313 2050F 03 9313 2099E techservices-vic@conbear.comWESTERN AUSTRALIA789 Marshall RoadMalaga WA 6090T 08 6363 8200F 08 6363 8222E techservices-wa@conbear.comNORTHERN TERRITORYUnit 4/ Lot 1554 Stuart HwyWinnellie NT 0820T 08 8984 3558F 08 8984 4852E techservices-sa@conbear.comPT CBC INDONESIA Registered OfficeJalan Alexindo Km. 28 Rt.005/Rw.016Kel. Harapan JayaBekasi Utara 17124T 62 21 8895 4647E techservices-ind@conbear.com