Blog Vibration Monitoring for the Steel Industry

Vibration Monitoring for the Steel Industry

Vibration Monitoring for the Steel Industry

Download the printer-friendly Vibration Monitoring for the Steel Industry Application Note

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.

A steel factory worker in a blue jumpsuit and protective glove pushes a steel I-beam along a machine inside a steel factory

 

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

Stainless steel, standard size, AC102-1A top exit and AC104-1A side exit accelerometers A compact size, stainless steel, top exit AC292-1D accelerometer next to a compact size, stainless steel, side exit AC294-1D accelerometer. A stainless steel, mini size, top exit UEB332 ultrasound sensor next to a stainless steel, mini size, side exit UEA332 ultrasound sensor. A standard size, top exit AC133-1D low frequency vibration sensor next to a standard size, side exit AC134-1D side exit vibration sensor.
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):

A standard size, top exit, AC207-1D high temperature accelerometer next to a standard size, side exit, AC208-1D high temperature accelerometer. A TXEA331-HT side exit, triaxial high temperature accelerometer engraved with the CTC line logo, part number, serial number, and Z, X, and Y axis labels.
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:

A standard size, top exit TA202-1A dual output sensor next to a standard size, side exit TA204-1A dual output sensor. A standard size m12 top exit TR102-M12A dual output sensor next to a standard size, M12 side exit TR104-M12A dual output sensor. A standard size, top exit VT202-1A dual output sensor next to a standard size, side exit VT204-1A dual output sensor.

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:

A black SC310 Series signal conditioner with stainless steel screws holding case together at four corners, and engraved with the CTC line logo, part number, and other product information. A stainless steel SC200 Series signal conditioner enclosure with the front panel open to show four mounted SC300 Series signal conditioners and wiring. A fiberglass SCD100 series relay and display enclosure with front panel closed to show the 4 display screens and 4 BNC connections.

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.

A front and side view of a black PPS, two-socket A2R connector with stainless steel locking ring above a front and side view of a black PPS, three-socket A3R connector. A front and side view of a black nylon, two-socket, right-angle A2Y connector with stainless steel locking ring above a front and side view of a black nylon, three-socket, right-angle A3Y connector. A front and side view of a black Viton, two-socket V2N connector above a front and side view of a black Viton, three-socket V3N connector. A front and side view of a black Viton, two-socket V2R high-temperature connector with stainless steel locking ring above a front and side view of a black Viton, three-socket V3R high-temperature connector.
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

 

A segment of a CB111 yellow FEP jacketed cable with two conductor wires (red, black) and a drain wire showing on the left side of the cable. A segment of a CB206 stainless steel armor jacketed cable with two conductor wires (red, black) and a drain wire showing on the left side of the cable. A segment of a CB602 stainless steel armor jacketed cable with two conductor wires (red, black) and a drain wire showing on the left side of the cable. A segment of a CB502 black hydraulic hose jacketed cable with two conductor wires (red, black) and a drain wire showing on the left side of the cable.
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
A stainless steel JB210 junction box with 48 sensor inputs, with front panel open to show four panels with BNC connectors. A stainless steel SB202 switch box with front panel open to show 4 terminal block panels and 4 sensor location cards. A stainless steel MX200 Series BNC connection box shown above a fiberglass MX300 series BNC connection box. A stainless steel CR202 cable termination box with front panel open showing terminal block plugs.

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:

A stainless steel, top exit LP202 loop power sensor next to a stainless steel, side exit LP204 loop power sensor. A stainless steel, top exit LP302 loop power sensor next to a stainless steel, side exit LP304 loop power sensor.
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:

A render of a CTC PMX1500 enclosure with four digital displays.

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.

A FFv 5 mm proximity probe driver with a silver faceplate, surrounded by a 5 mm proximity probe on a coiled, blue extension cable. A black 8 mm proximity probe driver with navy blue faceplate surrounded by an 8 mm proximity probe on a blue extension cable. A black 11 mm proximity probe driver with purple faceplate surrounded by an 11 mm proximity probe on a blue extension cable. A black 25 mm proximity probe driver with a yellow faceplate, surrounded by a 25 mm proximity probe on a blue extension cable.
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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