High Reliable Lead Wire System of the Rotor Winding in Pumped Storage Power Stations

Hydro-generators in pumped storage power stations (PSPSs) consist of multiple rotor windings connected by lead wires, which are consistently subjected to large stress due to the frequent starting and stopping, making fatigue fractures of these lead wires common. This paper proposes a fault early warning system featuring a dual-connection lead wire and a real-time fracture monitoring system to ensure high reliability of the lead wire. A fatigue testing machine is developed and the reliability of real-time fracture monitoring mechanism is proved through the validity test on this machine. Subsequently, through analysis based on the
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model, the relationship between the fatigue life of the lead wire and the displacement amplitude of the external force it withstands was studied. This relationship can be used to predict the redundant time of dual-connection lead wires, providing reference for maintenance personnel to schedule shutdowns for generators. Conversely, this relationship can also guide lead wire designers to quantitatively adjust the expected redundant time by adjusting the lead wire’s structure, to meet the needs of practical applications.