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):

AC102 & AC104 Multipurpose Accelerometer, Top or Side Exit 2 Pin Connector, 100 mV/g, ±10%, ±80 g, Dynamic Range

A render of CTC AC292 and AC294 compact top and side exit accelerometers
AC292 & AC294 Premium Compact Accelerometer, Top or Side Exit 2 Pin Connector, 100 mV/g, ±5%, ±80 g, Dynamic Range

Render of CTC UEB332 and UEA332 mini top and side exit ultrasound sensors
UEB332 & UEA332 Dynamic Vibration IEPE Ultrasound Sensor, Top or Side Exit 2 Pin mini-MIL Connector, 1/4-28 Mounting, 100 mV/g, ±10%, ±50 g, Peak

A render of CTC AC133 and AC134 standard size top and side exit accelerometers
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, Top or Side Exit 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, Top or Side Exit 3 Pin Connector, 100 mV/g, 10 mV/°C, ±10%

TR102-M12A & TR104-M12A RTD Sensors, Temperature & Acceleration, Top or Side Exit 4 Pin M12 Connector, 100 mV/g, ±10%

A render of CTC VT202 and VT204 standard size top and side velocity sensors.
VT202 & VT204 Dual Output Piezo Velocity Sensors, Velocity & Temperature, Top or Side Exit 3 Pin Connector, 100 mV/in/sec, 10 mV/°C, ±10%

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.
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.

A stainless steel SC200 Series signal conditioner enclosure with the front panel open to show four mounted SC300 Series signal conditioners and wiring.
SCE210 Series Nema 4X, stainless steel enclosure for up to eight SC Series signal conditioners

A fiberglass SCD100 series relay and display enclosure with front panel closed to show the 4 display screens and 4 BNC connections.
SCD100 Nema 4X, fiberglass vibration relay & display enclosure for up to four SC Series 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.
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

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.
V2N & V3N Molded Viton™ Seal-Tight Boot Connector with Nylon Insert, 250 °F (121 °C) Maximum Temperature

V2R & V3R Molded Viton™ Seal-Tight Boot Connector with PPS Insert, 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.
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.

Compare some of our most popular junction box enclosures below:

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

PMX Series 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 render of a PRO Line FFv 5 mm proximity probe driver with a grey faceplate.
FFv™ 5 mm Proximity Probe Set

A render of a CTC PRO Line 8 mm Proximity Probe Driver with blue faceplate.
8 mm Proximity Probe Set

A render of a CTC PRO Line 11 mm proximity probe driver with a purple faceplate.
11 mm Proximity Probe Set

A render of a CTC PRO Line proximity probe driver with a yellow faceplate
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

Back to Blog Archive