BEARING MANUFACTURE, REPAIR AND DESIGN

I n t r o d u c t i o n

KC Engineering Bearings Ltd

was originally founded in 1982 as KC Engineering Ltd.

KCEB specialises in the manufacture, repair design and

analysis of white metal lined oil film bearings and other

white metal lined components used in industries such

as power generation, mining, oil and gas, petrochemical

processing, marine and aerospace. KCEB currently operates

from the North East of England in County Durham. Our

2,500 sq.m. Facility includes, casting foundry, extensive

CNC machine shop and a dedicated service and repair

centre. We also have specialist engineering and design team.

KCEB is a brand independent, world class solution provider for white metal oil film bearings. We have over 30

years experience with service/repairs (for planned outages and breakdowns) and manufacturing that includes

our own product range or make to print in our modern CNC machine shop. With our leading edge design and

engineering team we can offer upgrades and develop customised, effective and efficient solutions. All available 24/7.

Manufacturing Services Repair Services

Standard Product Ranges Technical Services

G l o b a l R e a c h

Serving our international client base.KCEB gained its reputation and strong position in the market not only by selling quality products but

also providing support and assistance to clients worldwide. Currently we are serving clients in over

20 countries in following market sectors:

Pumps

Mining / Cement /Mineral Processing

Compressors Marine

Oil and Gas / Petrochemical

Gearboxes / Transmissions

Turbines / Generators

Power Generation

M a n u f a c t u r i n g S e r v i c e s

Standard Interchangeable range with OEM Bearing Types.

A Series Plain Journal

B Series Flange Locating Journal

C Series Flange Locating Journal with Locating Faces

K Series Pedestal Bearings ISO II687

T Series Tilt Pad Journal

Any tilt pad construction

• OffsetPivot• PreloadDesign• DirectLubrication Backing materials:

• Steel• Brass• CopperChrome

Zirconium

Journal Bearings

are our most major product and they are used in many

applications. KCEB manufacture journal bearings

for major OEMs, service companies and end users

around the world. Bearings can be manufactured

according to our client’s design / specifications,

our design solutions or re-engineered from

samples. We cover every type of journal bearing

configuration, bore profile, material and construction.

Any fixed bore profile:

• Cylindrical• Lemon• OffsetHalves• Tri-Lobe• QuadLobe

Product Range - Journal Bearings

M a n u f a c t u r i n g S e r v i c e s

Thrust Bearing Assemblies

are also produced by KCEB for major OEMs, service

companies and end users around the world. This is

part our strategic supply chain solution, offering a

service known as “make to print”. Reputation for

high quality manufacturing services and particularly

short lead times makes us the first choice supplier

for all kinds of equipment manufacturers and

industries. Our experience and expertise covers

every type of thrust bearing design and construction.

J Series Equalising Sector Thrust Bearing

L Series Leading Edge Equalising Thrust

M Series Modular Thrust Non Equalising

Q Series Modular Compact Equalising

Standard Interchangeable range with OEM Bearing Types.

Product Range - Thrust Bearings

Backing materials:

• Steel• Brass• CopperChrome

Zirconium

Available in variety of configurations:

• FixedProfile• TaperLand• TiltPadEqualising• NonEqualising• DirectandIndirect

lubrication.

Instrumentation options:

• Thermocouples• LoadCells• RTD’s

S e r v i c e a n d R e p a i r

Hydrodynamicbearingslinedwithwhitemetalalloyaretypicallydesigned

as a sacrificial component. The bearings fail in a controlled manner in

order to protect more important parts of equipment; the rotating shaft

and elements. Nearly all white metal lined bearings can be repaired

regardless of application, including critical machines such as high speed

compressors, gearboxes, boiler feed pumps, turbines and generators.

KCEB has over 30 years experience in the repair of all types

of bearing components and has reliable processes to repair

bearings to the same quality, materials and finish as new parts.

Our Repair Service:

Dedicated UK based repair team

24/7 emergency service (24 -> 48 hrs service)

Repair options: Centrifugal Casting or Gravity Casting

Standard Lead Time 2 weeks for general service and repair

Comprehensive Inspection Process - Inwards and Final

Onsite Inspection service available

ComprehensiveQualityControl:UltrasonicInspectionto

ISO 4386-1 and Dye Penetrant Inspection to ISO 4386-3

Inwards Inspection

Remove old Whitemetal alloy

Grit Blast Shells

Submerged Tinning

Centrifugal Casting

Proof Machining

Ultrasonic Inspection

Ultrasonic Inspection

Dye Penetrant Inspection

Final Dimensional Inspection

Preservation and Packaging

Standard Repair Process

D e s i g n a n d Te c h n i c a l S e r v i c e s

KCEB has engaged in bearing design for

over 20 years. Our in depth knowledge

of bearing systems, hydrodynamic

lubrication and rotor dynamics allows

us to offer the following design

and analysis service to our clients.

• Newbearingdesign

• Material&Designupgrades

• FailureAnalysis

• BearingPerformanceAnalysis

Reverse EngineeringUsing a mix of traditional methods (micro meter / Vernier /

calliper measurements) coupled with CMM Technology,

we are able to offer in house or on site scanning

solutions for reverse engineering of sample parts and

obsolete components. The data gathered is then

used for CAD modelling and identifying areas of

concern. Our engineering team will then analyse the

model, propose upgrades where applicable and then

establish manufacturing drawings. The whole process

is very robust and efficient, using the latest technology

we can complete reverse engineering within few hours.

Bearing Performance AnalysisOur design engineers perform finite element

analysis of the oil film to ensure all operating

requirements are met.

A full analysis of the bearing performance is

generated including oil temperatures, power loss,

oil flow rates, stiffness and damping coefficients.

M a n u f a c t u r i n g S e a l s

Labyrinth SealsKCEB manufactures and repairs labyrinth

seals for a variety of applications and from

various materials. Standard parts for

gas turbine seals and oil deflectors are

available from our product range or can

be manufactured / re-engineered from

samples, damaged parts or to a client’s

design/drawing and specification.

Balance Piston SealsKCEB manufactures and repairs

balance piston seals with variety

of lining materials, These linings

include pure lead, nickel graphite,

aluminium-silicon-polymer and other

abradable coatings. They are produced

to clients design and specification.

Types of Seals available:

• DeflectorSeals• LeadLinedSeals• NickelGraphiteSeals• HydrogenSealRings• Inter-stagePacking

Seals

Backing materials:

• Steel• Brass• Aluminium

Q u a l i t y

As a minimum each bearing manufactured

or repaired by K C Engineering Bearings

is tested to the following ISO standards.

When required, bearings can also

be manufactured or repaired using

customer specific quality standards.

• ISO4386-1Ultrasonic

Inspection

• ISO4386-3LiquidPenetrate

Inspection (if required)

•DimensionalInspection

•VisualInspection

KCEB has a strong reputation in

the market place for high quality

products and a responsive,

flexible service. We operate

with a “Quality First” mentality

to ensure quality products are

delivered on time to our clients.

C A S E S T U D I E S

Mill BearingsRecently repaired 2 large Mill Bearings

(Trunnion Slippers) for a UK Power Station.

The bearings were for Ø69” (1.75m) and

Ø78” (1.98m) shafts. These bearings had the

integral cooling system replaced and were

fully overhauled, the white metal was cast

using a static/gravity casting technique using

approximately 900kgs of white metal alloy.

Segmental PadsKCEB has experience in both repair

and manufacturing of this type

of large segmental pads.

The pads shown here are

a set of manufactured

pads used in a SAG

mill (Semi-Autogenous

Grinding Mill) found

in the mining industry.

C A S E S T U D I E S

Combined Thrust and Journal BearingsCombined thrust and journal bearings with precisely

machined taper lands on the white metal face produced for

European gearbox manufacturer.

These bearings have taper-land face to accommodate the

axial load developed within the gearbox during the operation.

These bearings can be manufactured using different

backing and lining materials to suit application and

customer specification.

An example of steel backed bearings produced for

customer based in Middle East with taper land face.

C A S E S T U D I E S

15” KC J Series Bearing AssemblyWithin our Thrust Bearing Product Range, Our J series is one of the most popular.

These parts are fully manufactured in house including small sub-assembly

components, all according to our quality procedures. This 15” assembly has been

manufactured in 2017 for a European customer within transmission industry.

Vertical Thrust Bearings RefurbishmentAt KCEB we overhaul vertical thrust

bearings, these parts sometimes have

almost all the internal components

replaced and re-engineered from

damaged parts depending on the

severity of the failure. As part of our

service we offer full inwards condition

inspection report, identifying all parts

and our recommendation for overhaul.

The completed assemblies are then

returned to the client “plug and play”

with new seals, gaskets, fasteners and

fully pressure tested (where required).

C A S E S T U D I E S

Re-Engineered Blower FanKCEB completed on site re-engineering of Blower Fan bearing assembly which was

then 3D modelled and manufactured in our UK facility. This is a complete sealed water

cooledThrust&JournalBearingAssembly,performanceanalysiswascarriedtoensure

the current application and operational conditions were correctly matched to the

existing design. The assembly was produced from a mix of castings and fabrications

all carefully controlled through our facility to meet exacting quality requirements.

Spherical Journal Bearing Re-EngineeringKCEB re-engineered this Spherical Journal Bearing from a sample,

manufactured and shipped to customer in Thailand within 3 weeks. The

sample bearing was shipped to the UK and within 48hrs the sample was

returned to the client, full manufacturing drawings produced and raw materials

ordered. The part was cast, bond tested, finish machined and dye penetrant

inspected and shipped to the client in time for a critical shutdown re-build.

C A S E S T U D I E S

Liner bearingsBearings used in UK Overspeed

Facility for a client within power

industry. Typically bearing sets

repaired within 5 days ready for the

next overspeed test. These bearings

range from 200 mm - 530 mm bore.

N O T E S

KC Engineering Bearings Ltd

HownsgillDrive,DelvesLaneIndustrialEstate

Consett,Co.Durham,DH89HU

United Kingdom

Tel. +44 (0) 1207 583100

Fax +44 (0) 1207 581900

Email sales@kceng.com

www.kceng.com