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):

A stainless steel, top exit AC102 Condition Monitoring Sensor and a stainless steel, side exit AC103 Condition Monitoring Sensor

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:

Standard size, top exit TA202 Vibration Monitoring Sensor next to a Standard size, side exit TA204 Vibration Monitoring Sensor

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):

standard size, top exit AC207 high temperature condition monitoring sensor next to standard size, side exit AC208 condition monitoring sensor

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%

CTC's TREA331-HT standard size, side exit triaxial sensor in square stainless steel case

TXEA331-HT High Temperature Triaxial Accelerometer
Premium 100 mV/g, Side Exit 4 Pin Connector, ±5%

Pair the sensors above with our PPS connectors and recommended cabling:

Side view of CTC's A2R Black PPS molded industrial connector with a stainless steel knurled locking ring

A2R Standard Accelerometer Compatible Connector

High Temperature 2 Socket MIL-Style, PPS Molded Connector, Permanent Mount, 392 °F (200 °C) Max Temp

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

side view of CTC's CB206 red FEP jacketed cable with stainless steel outer armor

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

side view of CTC's CB218 red FEP jacketed cable with stainless steel outer armor

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:

a stainless steel, standard size, top exit AC133 condition monitoring sensor

AC133 Low Frequency Accelerometer
Top Exit 2 Pin Connector, 500 mV/g, ±10%

AC134 Low Frequency Accelerometer

Side Exit 2 Pin Connector, 500 mV/g, ±10%

a standard size, side exit TXFA331 triaxial sensor in a square stainless steel case

TXFA331 Low Frequency Triaxial Accelerometer
Side Exit 4 Pin Connector, 500 mV/g, ±5%

Recommended Connector Offerings:

For non-submersible application, CTC recommends choosing rugged connectors for optimal chemical compatibility and heat resistance.

Our Viton™ Series (V Series) Seal-Tight Boot Connectors are available in both single axis, dual output, and triaxial compatible options. V Series Connectors offer the best chemical resistance, an IP69 connection, and a high heat resistance.

side view and front view of CTC's V2N Black Viton® Boot Connector on a yellow cable

V2N Standard Accelerometer Compatible Connector
2 Socket MIL-Style, Seal-Tight Viton™ Boot Connector with Nylon Insert, Permanent Mount, 250 °F (121 °C) Max Temp

side view and front view of CTC's V3N Black Viton® Boot Connector on a yellow cable, with 3 pin connector

V3N Biaxial and Dual Output Accelerometer Compatible Connector

3 Socket MIL-Style Seal-Tight Viton™ Boot Connector with Nylon Insert, Permanent Mount, 250 °F (121 °C) Max Temp

side and front view of CTC's V2R black Viton Boot with molded PPS insert on a yellow cable

V2R Standard Accelerometer Compatible Connector

High Temperature 2 Socket MIL-Style Seal-Tight Viton™ Boot Connector with PPS Insert, Permanent Mount, 350 °F (177 °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

Our A Series Connectors are also a great options for mining applications, with a variety of material options. CTC recommends PPS or Nylon A Series Connectors for chemical resistance purposes.

side and front view of CTC's A2R black PPS molded connector with stainless steel knurled locking ring, on a black cable

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

A2Y Standard Accelerometer Compatible Connector

2 Socket MIL-Style, Right Angle, Nylon Molded Connector, Permanent Mount, 250 °F (121 °C) Max Temp

side and front view of CTC's A3Y black Nylon molded right angle connector with stainless steel knurled ring, on a black cable

A3Y Biaxial and Dual Output Accelerometer Compatible Connector
3 Socket MIL-Style, Right Angle, Nylon Molded Connector, Permanent Mount, 250 °F (121 °C) Max Temp

Hazardous-Rated Options
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:

hazardous rating logos - CSA, EX, CE, PESO, IECEx, ANZEx, EAC

CTC also offers a variety of hazardous-rated compatible accessories for a complete system:

side and front view of a CTC Q Series black connector with stainless steel knurled locking ring on an armored cable

Q2A Standard Accelerometer Compatible Connector

2 Socket MIL-Style Connector with Grounded Backshell for Class I, Division 2 Locations, Polycarbonate Molded, Permanent Measurements, 250 °F (121 °C) Max Temp

CB190 Class 1, Division 2 Approved Cabling

Twisted, Shielded Pair Cable, Blue Thermoplastic Elastomer (TPE) Jacket, 0.25 in. (6.4 mm) OD, 221 °F (105 °C) Max Temp

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

There are several other considerations for mining applications:

Motors

Fin-cooled motors present a unique challenge to sensor mounting if a flat surface cannot be achieved. As a result, CTC offers a variety of motor fin mounting pads.

Motor Fin Mount Pad Offerings:

four MH118 Series stainless steel motor fin mount pads lined up for size comparison

MH118 Series Motor Fin Mount Pads
Available in a variety of widths and heights to fit your specific application

Conveyors

In harsh mining environments where falling debris, dust, and dirt are common, armor-jacketed cables help address durability concerns. Armor-jacketed cables are commonly used in conveyor applications where conductive dust and sediment can penetrate and disrupt continuity in a standard cable and connector combination.

Jacketed Cable Offerings:

A CTC stainless steel armor jacketed cable with inner red FEP jacket and red and black conductor wires exposed on one end.

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

CTC's CB618 cable with exterior stainless steel armor jacket, and red inner jacket with exposed red, white, black, and green connector wires
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

CTC's CB802 cable with stainless steel braided armor jacket and inner red cable with red and black conductor wires exposed on one end
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:

a CTC stainless steel modular enclosure with a sloped top, with door open to show grey interior modular panel with black BNC connector, silver switch, and black dial
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

stainless steel switch box with open front panel showing the interior black panel with green T-plugs
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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