Vibration Monitoring for the Steel Industry

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A steel mill undergoes some of the harshest conditions when creating and processing steel. The machines are put through brutal conditions, including hot temperatures, dangerous chemicals and toxins, and heavy usage. As a result, vibration monitoring is critical to ensure operational uptime, human safety, product efficacy, and machine longevity.

Common machinery found within steel mills includes:

• Blast furnaces
• Rolling mills
• Quench boxes
• CCM (Continuous Casting Machine)
• Straightening machines
• Loopers
• Girders
• Conveyors
• Motors
• Heaters
• Boilers
• Pumps
• Pipelines
• Cranes

Common failures within steel mills include:

• Improper lubrication of machinery
• Roll bearing failures
• Hydraulic pump failures

There are several challenges of monitoring within a steel mill, including:

• Hot temperatures
• Safety concerns
• Toxic chemicals and gases
• Limited accessibility
• What needs to be continuously monitored?
• Selecting the proper equipment for harsh environments

Due to the diversity of processes in steel manufacturing, CTC recommends tailoring your vibration monitoring hardware to the specific process and environment. Permanent Monitoring is the preferred method for a lot of these processes, both for repeatability as well as human safety concerns for hard-to-reach places and hot, caustic environments.

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 will 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 will require permanently mounted loop power sensors 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.

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 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 steel industry applications.

 

Standard Accelerometer Offerings (for environments up to 250 °F):

AC102 & AC104 Multipurpose Accelerometer, 2 Pin Connector, 100 mV/g, ±10%, ±80 g, Dynamic Range	AC292 & AC294 Premium Compact Accelerometer, 2 Pin Connector, 100 mV/g, ±5%, ±80 g, Dynamic Range	UEB332 & UEA332 Dynamic Vibration IEPE Ultrasound Sensor, 1/4-28 Mounting, 2 Pin mini-MIL Connector, 100 mV/g, ±10% ±50 g, Peak	AC133 & AC134 Low-Frequency Accelerometer, 2 Pin Connector, 500 mV/g, ±10%, ±50 g, Peak

 

High-Temperature IEPE Offerings (for environments up to 325 °F):

AC207 & AC208 High-Temperature Accelerometer, 2 Pin Connector, 100 mV/g, ±10%	TXEA331-HT High-Temperature Triaxial Accelerometer, Side Exit 4 Pin Mini-MIL Connector, 100 mV/g, ±5%

 

Dual Output Vibration & Temperature Offerings:

TA202 & TA204 Dual Output Sensors, Temperature & Acceleration Options: 25 mV/g and10 mV/°C 100 mV/g and 10 mV/°C 500 mV/g and 10 mV/°C	TR102-M12A & TR104-M12A RTD Sensors, Temperature & Acceleration Options: 100 mV/g and 10 mV/°C 500 mV/g and 10 mV/°C	VT202 & VT204 Dual Output Piezo Velocity Sensors, Velocity & Temperature Options: 100 mV/in/sec and 10 mV/°C

 

Signal Conditioners & Enclosures:

SC300 Series USB configurable Signal Conditioners are offered in single-band vibration or dual-band vibration output options. All SC300 Series Signal Conditioners come equipped with an optional temperature output, which can be utilized with CTC TA200 Series Dual Output Vibration and Temperature Sensors.	SCE210 Series Nema 4X, stainless steel enclosure for up to eight SC300 Signal Conditioners.	SCD100 Nema 4X, Fiberglass Vibration Relay & Display System for up to four SC300 Signal Conditioners, with the option to include switch relay or display only.

 

Recommended Cabling & Connector Offerings:
For the steel industry, CTC recommends choosing rugged cabling and connectors for optimal chemical compatibility and heat resistance.

Our Viton® Boot Series (V Series) 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 high heat resistance.

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

A2R & A3R PPS Molded Standard MIL Connector, 392 °F (200 °C) Maximum Temperature	A2Y & A3Y Nylon Molded Right Angle Connector, 250 °F (121 °C) Maximum Temperature	V2N & V3N Molded Nylon Viton® Boot, 250 °F (121 °C) Maximum Temperature	V2R & V3R Molded PPS Viton® Boot, 350 °F (177 °C) Maximum Temperature

 

CB111 Yellow FEP Jacketed Cable, 0.19 in. (4.8 mm) OD, 392 °F (200 °C) Maximum Temperature	CB206 Stainless Steel Armor Jacketed Cable, 0.27 in. (6.9 mm) OD, 392 °F (200 °C) Maximum Temperature	CB602 Stainless Steel Armor Jacketed Cable, 0.27 in. (6.9 mm) OD, 392 °F (200 °C) Maximum Temperature	CB502 FEP Jacket with Hydraulic Hose Outer Armor, 0.5 in. (12.7 mm) OD, 212 °F (100 °C) Maximum Temperature

 

Junction Box Offerings:
Junction Boxes can be used for local measurements or the transmission of data to online vibration monitoring systems. Junction Boxes can also be used for cable reduction purposes or for switched outputs during manual route data collection of the vibration signals. Due to the harsh environments present in steel manufacturing, stainless steel Junction Boxes are recommended.

JB200 Series	SB200 Series	MX200 & MX300 Series	CR202 Series
Premium Switch Box with IEPE bias indicator light and convenient flip-down panel for wiring	Legacy Switch Box Series	Enclosed BNC Connection Boxes	Cable Reduction Box for consolidating cables and reducing costs
Available in single-axis, dual input & output, and triaxial input & output configurations	Available in single-axis and dual input & output configurations	Available in single-axis, dual input & output, and triaxial input & output configurations	Single-axis sensor inputs
Minimum channel count: 4 sensor inputs Maximum channel count: 48 sensor inputs	Minimum channel count: 4 sensor inputs Maximum channel count: 48 sensor inputs	Minimum channel count: 1 sensor input Maximum channel count: 12 sensor inputs	Minimum channel count: 8 sensor inputs Maximum channel count: 16 sensor inputs

Loop Power Sensor Offerings for Process Monitoring:

LP202 & LP204 4-20 mA Output Proportional to Vibration in Velocity	LP302 & LP304 4-20 mA Output Proportional to Vibration in Acceleration

 
Relay & Display Equipment for Use with Loop Power Sensors:

PMX1500 Fiberglass, 1-4 channel process control enclosure with display and relay. These enclosures are designed for loop power sensor input, and the relays can trigger alarm or shutdown.

Predictive Maintenance for Fluid Film Bearings:
Many large motors, generators, and gearboxes will incorporate fluid film bearings to support their rotating shafts. These shafts require monitoring, which can be done through the use of X and Y radial proximity probes.

CTC’s PRO Line Proximity Probes are non-contact eddy current sensors that measure the vibration of the shaft relative to the case of the machine, and the location (gap) of the shaft in the bearing. CTC offers FFv™ 5 mm, 8 mm, 11 mm, and 25 mm probes in both standard and armor-jacketed cables. Compatible drivers and extension cables are available for all systems.

FFv™ 5 mm Proximity Probe Set	8 mm Proximity Probe Set	11 mm Proximity Probe Set	25 mm Proximity Probe Set

CTC offers a wide variety of driver output options as well as driver calibration materials, including:

• 4140 Steel
• 1045 Stainless Steel
• 17-4 Stainless Steel
• 420 Stainless Steel
• 304 Stainless Steel
• 316 Stainless Steel
• 360 Brass Alloy
• AL7075-T6
  
  

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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.