Turbine MSV Position Sensor TD-1-800: Yields Comprehensive Benefits in Unit Safety and Efficiency

I. Ensuring High Unit Startup Success Rate: Avoiding “Startup Detours,” Saving Time and Cost

Turbine startup is a delicate operation. The high-pressure MSV must open slowly to gradually heat the rotor and casing; opening too quickly causes equipment deformation due to large temperature differences, while opening too slowly prolongs startup time and wastes fuel. The prerequisite for all of this is that the position sensor accurately reflects the MSV’s opening degree.

Standard Sensors: Often “Drop the Ball” During Startup

Standard position sensors lack sufficient accuracy. During startup, if the MSV opens 5%, the sensor might feedback 3% or 7%. The control system receives the wrong signal and mistakenly adjusts the MSV. This can lead to either excessive opening, causing uneven rotor heating and requiring an emergency shutdown for cooling and restart, or insufficient opening, slowing the casing temperature rise, turning a 2-hour startup into a 4-hour ordeal. Worse yet, some sensors fail suddenly mid-startup, causing the MSV to lose control and the startup to fail directly. One power plant using standard sensors reported three consecutive failed startups, not only wasting fuel but also delaying the time of grid connection and power generation.

TD-1-800: “Successfully Reaches Position” on the First Try

The TD-1-800 displacement sensor offers significantly higher measurement accuracy than standard sensors. Even a 0.1% change in MSV opening can be accurately fed back, ensuring the control system receives the correct signal. During startup, the MSV strictly follows the preset “temperature ramp-up curve,” avoiding both rapid opening that damages equipment and slow opening that wastes time. There is no longer a need for repeated starts and stops.

If your power plant is often stuck at the startup stage due to sensor problems, contact us to see if the TD-1 series displacement sensor can be adapted to your high-pressure MSV model, ensuring a smoother startup process.

II. Enhancing Unit Operating Efficiency: Precise Steam Control, Lower Consumption, Higher Profit

During normal turbine operation, the power output is adjusted based on grid load—opening the MSV more for high load and less for low load. At this stage, the stability of the position sensor directly impacts the accuracy of steam intake, which in turn affects operating efficiency.

Standard Sensors: “Drift” During Operation, Stealthily Lowering Efficiency

Standard position sensors tend to drift over time. For example, if the actual MSV opening should be 30%, the sensor might feedback 28%. The control system, believing steam intake is insufficient, continues to open the MSV further. This wasted excess steam is not used for power generation; conversely, if the sensor feeds back 32%, the steam intake is inadequate, power generation fails to meet load requirements, and unit stability may be compromised. One power plant estimated that a 2% deviation in steam intake due to standard sensor drift resulted in nearly a thousand tons of extra coal consumption annually, translating to hundreds of thousands of Yuan in losses.

TD-1 Series: Long-Term Stability, Efficiency at “Full Value”

The TD-1-800 features anti-interference and anti-drift designs. Regardless of changes in unit vibration or temperature during operation, its measurement values remain accurate. The MSV opening precisely matches load demands—just enough steam for high loads, no waste; no excess steam for low loads, no energy waste.

Case Example: A power plant that switched to this sensor saw a 2 g/kWh drop in heat rate for power generation. The coal savings alone could amount to over a hundred thousand Yuan.

III. Preventing Unplanned Shutdowns: Fewer Failures, Reduced “Accidental Losses”

Unplanned shutdowns are a serious violation for power plants. A shutdown not only interrupts power generation but also requires extensive maintenance time, leading to losses ranging from hundreds of thousands to over a million Yuan. Many unplanned shutdowns are rooted in the sudden failure of the high-pressure MSV position sensor.

Standard Sensors: Frequent Failures, Shutdowns are “Unavoidable”

Standard sensors lack durability. The high temperatures and strong vibrations around the high-pressure MSV easily damage the sensor coils and wiring, potentially leading to sudden failure after just a month or two of operation. When the sensor fails, the MSV loses signal feedback, and the control system triggers a “safety trip”—regardless of the current load, the unit must shut down immediately. One power plant experienced four unplanned shutdowns in one year due to standard sensor failure, with accumulated losses exceeding 2 million Yuan, also affecting grid reliability.

TD-1-800: Durable with “Early Warning,” Significantly Fewer Shutdowns

The TD-1-800 displacement sensor’s casing is made of high-temperature and anti-vibration materials, and its internal coil is reinforced. It typically lasts 3 to 5 years without replacement. More importantly, it features a fault self-diagnosis function—if a minor fault occurs, it sends an early warning to the control system, rather than waiting for complete failure to trigger a shutdown. Maintenance personnel can seize the opportunity during low-load periods for replacement, avoiding emergency shutdowns.

Case Example: A power plant that switched to the TD-1-800 reported two consecutive years without an unplanned shutdown caused by the position sensor, saving millions of Yuan on this item alone.

Summary: Investing in TD-1-800 is Not “Spending Money,” It’s “Saving Money”

Many people view the high initial investment of the TD-1-800 as uneconomical. However, a full accounting clarifies its value: standard sensors incur costs from frequent replacement, startup failures waste fuel, low operating efficiency increases coal consumption, and unplanned shutdowns lead to massive losses. The TD-1-800, through a single investment, eliminates these troubles—successful startup on the first attempt saves time and fuel; accurate operation lowers consumption and increases revenue; fewer failures prevent shutdowns and reduce losses. In the long run, the comprehensive benefits delivered by this investment are simply incomparable to those of a standard sensor.

If your power plant is troubled by the “frequent failures and inaccurate measurements” of standard position sensors, and you wish to improve unit startup success rates, enhance operating efficiency, and reduce unplanned shutdowns, or if you want to know how the TD-1 series displacement sensor can be adapted to your turbine high-pressure MSV model, please contact us. We not only provide genuine TD-1-800 LVDT linear position sensors but also have a professional team to assist with installation guidance and troubleshooting, ensuring that the high-performance sensor genuinely delivers the comprehensive benefits of safety, efficiency, and cost savings for stable unit operation.

E-mail: sales@yoyik.com
Tel: +86-838-2226655
Whatsapp: +86-13618105229

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