Vibration Monitoring for the Mining Industry
Download the printer-friendly Vibration Monitoring for the Mining Industry Application Note
Equipment used in the mining industry is subject to heavy use, dirty environments, and often high temperatures. These factors can result in increased wear and tear on rotating components, creating the threat of premature failure.
Condition monitoring programs can be used to monitor the vibration of the bearings throughout the plant and improve the reliability of the overall process.
Other important equipment to be monitored within the mining industry includes:
- Crushers
- Mills
- Conveyors
- Precipitators
- Kilns
- Silos
Common faults which can be detected include:
- Unbalance
- Misalignment
- Blade Pass
- Vane Pass
There are several challenges to monitoring mining equipment, including:
- Safety concerns
- Limited accessibility
- What needs to be continuously monitored?
- The impacts of corrosion, dust, and debris
The first consideration is whether or not Process Monitoring or Dynamic Vibration Analysis is right for your condition monitoring program.
Process Monitoring requires 4-20 mA loop power sensors, which provide the overall vibration level of the machine so that it can be trended and alarmed using the plant DCS, PLC, or SCADA system. Process Monitoring requires permanently mounted loop power sensors like LP200 and LP300 Series that output a 4-20 mA signal proportional to velocity or acceleration. Process Monitoring will provide an overall understanding of machine health, but cannot provide the same level of detailed, diagnostic data as Dynamic Vibration Analysis.
Loop Power Sensor Offerings for Process Monitoring:
LP202 Loop Power Sensor
4-20 mA Output Proportional to Vibration in Velocity, Top Exit 2 Pin Connector
LP204 Loop Power Sensor
4-20 mA Output Proportional to Vibration in Velocity, Side Exit 2 Pin Connector
LP302 Loop Power Sensor
4-20 mA Output Proportional to Vibration in Acceleration, Top Exit 2 Pin Connector
LP304 Loop Power Sensor
4-20 mA Output Proportional to Vibration in Acceleration, Side Exit 2 Pin Connector
Dynamic Vibration Analysis allows for trended data and machine health diagnostics. However, Dynamic Vibration Sensors can be paired with CTC’s SC300 Series Signal Conditioners to create a hybrid approach for both Process Monitoring and Dynamic Vibration Analysis.
A signal conditioner converts the signal from a dynamic sensor into a 4-20 mA output, so it can be trended and alarmed using the plant DCS, PLC, or SCADA system but also used for more in-depth predictive maintenance. Regardless of whether or not a signal conditioner is the right choice for your program, CTC has a variety of accelerometers for use in mining applications.
In general, CTC multipurpose 100 mV/g sensors can be used for the majority of mining applications.
Standard Accelerometer Offerings (for environments up to 250 °F):
AC102 Multipurpose Accelerometer
Top Exit 2 Pin Connector, 100 mV/g, ±10%
AC104 Multipurpose Accelerometer
Side Exit 2 Pin Connector, 100 mV/g, ±10%
AC292 Premium Compact Accelerometer
Top Exit 2 Pin Connector, 100 mV/g, ±5%
AC294 Premium Compact Accelerometer
Side Exit 2 Pin Connector, 100 mV/g, ±5%
UEB332 Dynamic Vibration IEPE Ultrasound Sensor
1/4-28 Mounting, Top Exit 2 Pin Mini-MIL Connector, 100 mV/g, ±10%
UEA332 Dynamic Vibration IEPE Ultrasound Sensor
1/4-28 Mounting, Side Exit 2 Pin Mini-MIL Connector, 100 mV/g, ±10%
For applications where temperature monitoring is necessary, CTC also offers a variety of Dual Output Vibration and Temperature Sensors.
Dual Output Vibration and Temperature Sensor Offerings:
TA202 IEPE Dual Output Sensor
Temperature & Acceleration, Top Exit 3 Pin Connector, 100 mV/g, 10 mV/°C, ±10%
TA204 IEPE Dual Output Sensor
Temperature & Acceleration, Side Exit 3 Pin Connector, 100 mV/g, 10 mV/°C, ±10%
TR102-M12A RTD Dual Output Sensor
Top Exit 4 Pin M12 Connector, 100 mV/g, ±10%
TR104-M12A RTD Dual Output Sensor
Side Exit 4 Pin M12 Connector, 100 mV/g, ±10%
VT202 Dual Output Piezo Velocity Sensor
Velocity & Temperature Output, Top Exit 3 Pin Connector, 100 mV/in/sec, 10 mV/°C, ±10%
VT204 Dual Output Piezo Velocity Sensor
Velocity & Temperature Output, Side Exit 3 Pin Connector, 100 mV/in/sec, 10 mV/°C, ±10%
For high-temperature environments, CTC also has a variety of high temperature resistance sensors that can operate up to 350 °F.
High Temperature IEPE Offerings (for environments up to 350 °F):
AC207 High Temperature IEPE Accelerometer
325 °F (162 °C) Max Temp, Top Exit 2 Pin Connector, 100 mV/g, ±10%
AC208 High Temperature IEPE Accelerometer
325 °F (162 °C) Max Temp, Side Exit 2 Pin Connector, 100 mV/g, ±10%
TXEA331-HT High Temperature Triaxial Accelerometer
Premium 100 mV/g, Side Exit 4 Pin Connector, ±5%
J4R Triaxial Accelerometer Compatible Connector
4 Socket Mini-MIL Connector for CTC 4 Pin Triaxial Accelerometers, PPS Molded, Permanent Mount, 392 °F (200 °C) Max Temp
CB206 Armor Protected Cabling
Low Cost, Twisted, Shielded Pair Cable, Lightweight Red FEP Jacket with Stainless Steel Outer Armor, 0.27 in. (6.9 mm) OD, 392 °F (200 °C) Max Temp
CB218 Armor Protected Cabling
4 Conductor Shielded Cable, Red FEP Jacket with Stainless Steel Outer Armor, 0.27" (6.9 mm) OD, 392 °F (200 °C) Max Temp
For low-frequency applications (12 CPM to 30 CPM [0.2 Hz to 0.5 Hz]) like gearboxes, often used in fans and conveyors, 500 mV/g sensors should be used.
Low Frequency Application Offerings:
AC133 Low Frequency Accelerometer
Top Exit 2 Pin Connector, 500 mV/g, ±10%
2 Socket MIL-Style, Seal-Tight Viton® Boot Connector with Nylon Insert, Permanent Mount, 250 °F (121 °C) Max Temp
V3R Biaxial and Dual Output Compatible Connector
High Temperature 3 Socket MIL-Style Seal-Tight Viton® Boot Connector with PPS Insert, Permanent Mount, 350 °F (177 °C) Max Temp
A2R Standard Accelerometer Compatible Connector
High Temperature 2 Socket MIL-Style, PPS Molded Connector, Permanent Mount, 392 °F (200 °C) Max Temp
A3R Biaxial and Dual Output Compatible Connector
High Temperature 3 Socket MIL-Style, PPS Molded Connector, Permanent Mount, 392 °F (200 °C) Max Temp
3 Socket MIL-Style, Right Angle, Nylon Molded Connector, Permanent Mount, 250 °F (121 °C) Max Temp
Since many mining applications have hazardous environments due to gas, oil, or dust that could create a combustible atmosphere in around machines, CTC offers hazardous-rated sensors by certifying organizations including:
CB296 Armor Protected Cabling
Class 1, Division 2 Approved, Twisted, Shielded Pair Cable, Lightweight Red FEP Jacket with Stainless Steel Outer Armor, 0.27” (6.9 mm) OD, 392 °F (200 °C) Max Temp
MH118 Series Motor Fin Mount Pads
Available in a variety of widths and heights to fit your specific application
CB206 Standard Armor Jacketed Cable
Low Cost, Twisted, Shielded Pair Cable, Lightweight Red FEP Jacket with Stainless Steel Outer Armor, 0.27 in. (6.9 mm) OD, 392 °F (200 °C) Max Temp
CB618 Heavy Duty Armor Jacketed Cable
4 Conductor, ShieldedCable, Red FEP Jacket with Heavy Duty Stainless Steel Outer Armor, 0.303 in. (7.7 mm) OD, 392 °F (200 °C) Max Temp
CB802 Stainless Steel Braided Sheathing
Twisted, Shielded Pair Cable, Red FEP Jacket with Stainless Steel Braided Outer Sheathing, 0.25 in. (6.4 mm) OD, 392 °F (200 °C) Max Temp
CB502 Hydraulic Hose Jacketed Cabling
Twisted, Shielded Pair Cable, Red FEP Jacket with Hydraulic Hose Outer Armor, 0.5 in. (12.7 mm) OD, 212 °F (100 °C) Max Temp
Sloped-Top Junction Boxes
CTC's Sloped-Top Junction Boxes are specifically designed for mining applications. Due to the presence of dust and debris in mines, the pitched roof of our sloped-top boxes prohibits particles from settling on the box.
Sloped-Top Junction Box Offerings:
SSB6000 Modular Sloped-Top Box
Single Axis, Sloped Top, Modular Vibration Switch Box, Stainless Steel Enclosure, NEMA 4X (IP66) Rated, Includes SSB-MOD(X) for 1 to 12 Single Output Sensor Inputs
SB262 Sloped-Top Switch Box
Single Axis Sloped Top Vibration Switch Box, Stainless Steel Enclosure, NEMA 4X (IP66) Rated, Sensor Input Options: 4 to 12 Single Output Sensor Inputs
JB310 Sloped-Top Junction Box
IBox Single-Axis, Sloped-Top Vibration Switch Box, Stainless Steel Enclosure, NEMA 4x (IP66) Rated, Sensor Input Options: 4 to 12 Single-Output Sensors
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CTC is the world leader in the design and manufacture of industrial accelerometers and piezo velocity transducers, 4-20 mA vibration sensors, and proximity probe sets, as well as all related mounting hardware, cables and connectors, and junction boxes. Our products enable efficient vibration monitoring for predictive maintenance in a wide variety of industries. Industries served include cement, mining, petrochemical, food & beverage, auto, steel, wind, paper & pulp, power generation, water & wastewater treatment, pharmaceutical, hospitals, bottling, and more. Our mission is to offer the widest variety of accelerometers and vibration hardware products, which are compatible with data collectors and online monitoring systems, as well as the tools for installation.
The CTC product line features vibration analysis hardware for heavy industry. All CTC products are backed by our unconditional, lifetime warranty. If any CTC product should ever fail, we will repair or replace it at no charge.
CTC’s PRO Line offers the world’s most durable and reliable Proximity Probe Sets including drivers, probes, extension cables, and driver enclosures for 24/7 protection of critical machinery in the most demanding industrial environments. CTC PRO Line Proximity Probe Sets are compatible with all major data collectors. PRO Line products are covered by our best-in-class lifetime warranty on material and workmanship.
The TMP line features vibration analysis hardware for research and development. All TMP products are backed by a five-year warranty on materials & workmanship for standard sensors and a two-year warranty for all accessories, cables, connectors, and custom & private-labeled products.
CANCELLATION POLICY:
Stock, built-to-order, and private-label products qualify for free cancellation only if cancelled within 24 hours of order entry.
After 24 hours of order entry:
- Stock products will be subject to a 25% cancellation fee
- Built-to-order and private-label products will be subject to a 50% cancellation fee
Custom products are non-cancellable at any time after the order is placed.
If you wish to cancel an order, please reach out to your CTC sales representative. The timestamp of when your email requesting cancellation was received will be honored for whether or not your request meets the free cancellation window.
RETURN POLICY:
All stock products may be returned for a 25% restocking fee if returned in new and unused condition within 90 days of shipment.
Built-to-order and private-label products qualify for a 50% refund if returned in new and unused condition within 90 days of shipment.
Custom products are quoted and built specifically to the requirements of the customer, which may include completely custom product designs or private-labeled versions of standard products for OEM customers. Custom products ordered are non-cancellable, non-returnable, and non-refundable.
EXPEDITED PRODUCTS CANCELLATION & RETURN POLICY:
All expedited CTC orders are non-cancellable and non-returnable.
