5 sensor technologies for value-driven grid data management
Digital transformation
29 November 2023
6 min
banniere-cinq-technologies-de-detection

The necessary transformation of grids, in a context of a world’s transition to renewable energy and of a growing demand for decarbonized electricity, requires an infusion of digital intelligence.

In this context, sensors are essential. They are the ‘eyes and ears’ of the modern power grid, providing invaluable data critical to the reliability, efficiency, and adaptability of tomorrow’s grid data management.

Five sensor data technologies are transforming today’s power grids.

1. Smart meters for an effective energy measurement

compteurs-intelligents

Smart meters have quickly become the innovative solution of choice to metering energy effectively. In the past decade, they have overwhelmingly replaced traditional meters and transformed the interaction of utilities and consumers with energy resources. According to the International Energy Agency, more than one billion smart power meters are globally in use, a ten-fold increase since 2010.

They allow consumers to monitor their consumption smartly and energy providers to analyze better usage patterns and forecast future energy consumption needs. They enable a reliable, efficient, and resilient network.

Smart meters come in three variations, each with different features:

  • Standard smart meters accurately measure electricity consumption and enable remote meter reading, eliminating the need for manual readings. They often support time-of-use pricing, allowing consumers to save money by using electricity during off-peak hours.
  • Intermediate models add two-way communication between consumer and utility. They offer load profiling, providing detailed data for optimizing grid operations and load management. They may also support outage detection, helping utilities respond promptly to power interruptions. These meters may incorporate tamper detection mechanisms, alerting utilities of potential electrical energy theft, which can result in important non-technical losses to the operator.
  • Advanced meters often support demand response programs, enabling utilities to control or adjust electricity demand remotely during peak times. As power quality sensors become the standard, it will help to identify voltage fluctuations and sags. Grid monitoring capabilities offer insights into the health and performance of the distribution grid, such as low voltage arcing or faults, allowing utilities to take proactive maintenance measures.

2. Single and multi-conductor current sensors

To meet ambitious net zero targets and avoid volatile and rising energy costs, grids must reduce unnecessary energy wastage.

Sarah Marie Jordaan, Assistant Professor of Energy, Resources, and Environment at Johns Hopkins University, says 500 million metric tons of carbon dioxide can be cut by improving global grid efficiencies. These savings represent more than one percent of the worldwide CO2 annual emissions. But as Scottish-Irish physicist William Thomson, better known as Lord Kelvin, wisely said, ‘If you cannot measure it, you cannot improve it.’

Solutions such as single and multi-conductor current sensors are a game changer for process and plant managers. They are field-proven solutions that can be installed directly around conductors and cable feeders to selectively and rapidly deploy audit sessions. They enable installation without operation interruption so as to build concrete energy-saving strategies leading to energy consumption reduction of up to 20 percent.

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3. Energy harvesting: converting small amounts of energy from the environment

In remote or challenging-to-access locations, the deployment of sensors poses sustainability and operational expenditure challenges, primarily concerning battery management.

With the industry set to witness over 25 billion connected objects in the sector by 2025, energy harvesting emerges as a pivotal technology to facilitate the expansion of sustainable sensors and Internet of Things (IoT) solutions.

As a concept, energy harvesting involves capturing and converting small amounts of energy from the environment or nearby power sources, such as cables. The most prevalent energy harvesting method is photovoltaic, which transforms light into electrical energy. Cost-effective and customizable for indoor lighting applications, it is an ideal fit for IoT solutions.

Inductive technology is another popular choice for cable systems. It empowers devices to operate independently by harnessing energy from power cores or terminations. This approach offers sensor functionality without the need for maintenance, delivers environmental benefits, and extends the system’s lifespan.

Recent advancements in electronic devices, including processing units and low-power wireless technologies, enhance overall efficiency and thus establish the harvesting approach as a reliable power source.

4. Edge-to-cloud: a revolution in maintenance practices

Edge-to-cloud integration is continuously revolutionizing maintenance practices, making them smarter and more efficient, particularly in the context of power grids.

At the edge, innovative hardware, including microcontroller technologies, such as advanced FPGAs (Field-Programmable Gate Arrays), are strategically placed along the grid to collect real-time cable system health data parameters such as load, temperature, humidity, vibration, or electromagnetic transient.

They enable real-time feature extraction, allowing fast processing of critical data patterns from raw information at the edge. This capability enhances the quality and relevance of the data transmitted to the cloud for further analysis and storage.

Edge AI, driven by supervised machine learning, aids in raw data filtering, such as noise reduction and early detection of deviation from standard operating conditions.

This data is then transmitted to on-premises or cloud maintenance applications such as Nexans’ Asset Monitoring Platform designed to bring decision making insights to asset managers and maintenance teams.. The seamless connectivity between the edge and the cloud empowers grid operators to implement predictive and condition-based maintenance strategies. By harnessing the power of this technology, they can identify early warning signs of asset failures, optimize maintenance schedules, and reduce costly downtime.

Edge-to-cloud technology plays a pivotal role in making grid maintenance proactive and data-driven, ultimately leading to increased reliability, enhanced safety, and cost savings, all while ensuring uninterrupted power supply.

5. Fiber optics: minimizing power disruptions

Optical fiber can be applied for remote data acquisition or as distributed sensor applications where traditional techniques are impractical or costly to deploy.

The emergence of fiber optic sensing technology is providing grid operators with a more cost-effective and accurate way of acquiring data compared to punctual sensors.

Distributed fiber optic sensing is the ability to continuously measure activity throughout the power grid, helping operators to quickly pinpoint the exact location of potential or actual disruptions and thus minimize or even avoid costly power outages.

fiber-optics

Sensitivity of fibers to temperature and mechanical strain offer a comprehensive approach to distributed sensor applications:

  • Distributed Temperature Sensing (DTS) enables the early detection of abnormal events such as hotspots and thermal bottlenecks due to condition changes in the surrounding laying environment of the cable. When combined with real time temperature rating algorithm, DTS systems allow to assess the operational condition and circuit power rating, allowing safer operation of the cable to its real conditions.
  • Distributed Acoustic Sensing (DAS) offers precise fault detection, localization and third-party interference detection both onshore (e.g., cable theft, digging, and drilling) and offshore (e.g., anchor drops and drags). Thus, providing efficient power cable condition monitoring by listening 24/7 to acoustic signatures.
  • Distributed Strain Sensing (DSS) continuously measures strain and deformation along the cable’s length. It enables the assessment of cable structural health data, ensuring that cables are not subjected to excessive mechanical stress (bending, stretching, etc).

Nexans has been at the forefront of distributed fiber optic sensing measurement technology for high-voltage (HV) cables since the early 1990s, beginning with the installation of a Distributed Temperature Monitoring (DTS) system used for the Skagerrak 3 link between Norway and Denmark. Since then, these technologies have undergone continuous enhancements in length, precision, efficiency, and cost-effectiveness.

With the emergence of innovative new technologies, sensors play a vital role in shifting to smart electrical grids. Sensors provide invaluable data critical to the reliability, efficiency, and adaptability of tomorrow’s grid data management.

Aymeric André

Authors

Aymeric André works as New Solutions Manager at Nexans within the Sales & Marketing department of the Generation & Transmission Business Group.

In 2019 he joined Nexans Services and solutions team within the Innovation Service and Growth Department as a Design Lab Manager for asset monitoring to help enhance the company’s digital offers.

He has previously worked at the SuperGrid Institute where he led a research program on high voltage subsea technologies.

Samuel Griot

Samuel Griot is the head of electrical engineering department within Nexans Innovation.

He leads a team of experts developing new innovative solutions for low, medium and high voltage applications in order to answer the future needs for the electrical grids. Samuel joined Nexans in 2021 and has a strong background in electrical grid architecture and switchgears.

He holds a Master degree in electrical engineering from INSA of Lyon, France.

Industry 1, 2, 3, 4… and 5.0
Circular economy
08 November 2023
10 min
banner-industrie-5-0

Nexans aligns its data with business operations

A shift is under way. Many countries, including the USA and France, are turning away from the factory-free economy – the dominant model of the past last 30 years – to rediscover the advantages of manufacturing at home. This shift creates a unique opportunity to promote the development of new-generation plants, reflecting new economic, social and environmental challenges. Local for local has always been the watchword at Nexans, which is seizing this opportunity to take a new step forward in its development. By integrating its rigorous management model with its international production base, the company will be in industry 4.0 mode by 2026.

When we talk about the digital revolution, we tend to think first of the glut of the information inundating our lives, every day of every week, announcing a new revolutionary smartphone, a new multi-cooker or the latest mind-boggling breakthroughs in artificial intelligence (AI). It’s a subject that has only recently come to the fore in the business world, with the fierce debate around the impact of AI on business activities and the rapid automation expected in many areas, from programming to accounting, medicine and law.

Paradoxically, industry has attracted far less interest as a subject of discussion. And yet it is a subject of key importance, not only in terms of jobs, innovation and value creation, but also in terms of sovereignty. The Covid-19 pandemic was a wake-up call for European countries, which became aware of the scale of their economic and strategic dependence, in the light of the tensions between China and the United States. Factories have a key role to play in adapting our economies to the new technological order.

industrie-reinvente

How industry is reinventing itself with industry 4.0

This comes as no surprise, since changes in the workshops have always been associated with breakthroughs in technology, continuing a cycle that began with two industrial revolutions. The steam engine and the first factories were followed by the arrival of electricity, machine tools and mass production, and then – in the 1950s – by electronics, automation through programming, numerical control machinery, industrial robots and the first supervisory software packages.

The fourth revolution, currently unfolding, directly continues the ongoing process of computerization, while taking it to a whole new level. The first step is to establish a new energy base, moving away from the fossil fuels that powered the previous three revolutions. The second step is to maximize the use of a key new resource – corporate data – by building on a powerful high-tech mix that has now reached maturity: very high-speed infrastructure (fiber for fixed connections and 5G for mobile), combined with data hosting and mass processing (Cloud, Big Data, AI), decentralized intelligence and smart objects (IoT) and new forms of human-machine interaction (mixed reality, digital twinning, avatars).

This avalanche of innovations is paving the way for a complete rethink of the way companies work, with particular emphasis on all the processes involved in production. For many industrial powers, this is now a priority. It is no coincidence that Germany was the first to launch an Industry 4.0 plan in 2011, with an eye to maintaining the excellence of its industrial base. Pursuing the same objective, China is investing in high value-added factories in order to retain its industrial might and address a growing labor shortage. France adopted a similar strategy in 2015, with its Alliance for the Industry of the Future, an association of 32,000 companies meeting every year at the Global Industry trade show. This year, Nexans was in the spotlight claiming two Golden Tech awards in the Designer and Maker categories at the 2023 event, held last March in Lyon.

Nexans 4.0 on course for 2025

These goals are part of a new commitment involving everybody at Nexans. The Group is moving towards the global digital integration of all areas of the company and its ecosystem in order to simplify processes, improve performance and response, boost productivity and safety, limit unnecessary operations, as well as to anticipate and plan for events (predictive maintenance, inventory management, customer satisfaction, etc.).

nexans-horizon-2025

In a recent survey of French business, 98% of the companies interviewed said that they have already planned or deployed initiatives relating to Industry 4.0 (7th edition of the Wavestone barometer on Industry 4.0, conducted in partnership with Bpifrance and France Industrie).

The main motivations cited are industrial performance (for 30% of respondents) and data control (27%). Note that ecological impact and energy performance were in third place this year (15%).

The Nexans Group took the first step towards change in late 2020, when it teamed up with Schneider Electric, a company with proven experience in transforming its own industrial base. The process initiated by Schneider Electric places the emphasis on reliability, productivity, improved availability through predictive maintenance, energy efficiency and protection against cyber-attacks. The first step in the partnership involved major investments at pilot sites in Autun, France and Grimsås, Sweden. The process will be deployed at eight more sites by the end of 2023, with the aim of upgrading all 45 Group plants on four continents by late 2025, at a pace of between 12 and 15 sites every year.

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Nexans plants upgraded
by the end of 2023

45

Nexans plants upgraded
by late 2025

12 to 15

Nexans plants upgraded
pe year

These fundamental changes involve the mobilization of Group data: the raw material of this new industrial revolution. Although the proportion of data used by the Group rose from 5% to 10% between 2019 and 2023, the aim is to reach 70% by 2026.

Vincent Dessale

We are approaching the Group’s digital transformation on two levels, first by integrating new technologies into our operations, and second by creating a collaborative environment.

Vincent Dessale

Chief operating officer, Nexans

This approach connects production tools using IoT and AI resources, while allowing employees to take back control through dashboards, decision-support indicators, and quality and safety monitoring. It also supports efforts to cut response time and time to market.

Reasons for a revolution: what actually changes in the field

First, we will see changes in the way we work every day. Because the transformation is not just about technology, even though connected machines, AI-powered robots are becoming an increasingly common site in factories, along with self-driving forklift trucks roving the aisles of the logistics centers ​​by day and by night. However, the most spectacular changes concern human workers, with workshops packed full of screens, tablets and connected goggles.

This is a sensitive subject, since the success of the transformation will depend on how well people are able to work alongside machines. This is precisely the aim of Industry 5.0, as it is sometimes called. The objective is to expand and strengthen the digital transformation by supporting better collaboration between people and machines, while ensuring that creativity and well-being are not overlooked.

​​This aspect is taken into account from the outset in the Nexans project:

  • Real-time dashboards monitor the smooth running of production lines, currently in each plant and soon across the Group’s entire global industrial base. Real-time data supervision boosts industrial performance and quality control, while also reducing the consumption of energy and raw materials, and cutting energy costs by 15%.

Predictive maintenance

Discover with Chao Li, Digital Development Engineer, and Tobias Karlsson, Predictive Maintenance Operator in Grimsås how predictive maintenance has been put in place in our Swedish factory. The objective is to monitor the main production indicators such as temperature, pressure, traction, to detect evolution on the trends of these parameters.

We can now pick up on many errors before they occur. It’s a bit like being able to see into the future with all the data collected.

Tobias Karlsson

Predictive maintenance operator at Nexans in Grimsås, Sweden

  • A corporate social network gives operators access to video modules and tutorials, along with a chat forum. The forum is invaluable for discussing best practices and finding solution fast, since users are able to post questions directly for the online community. It is also a way to keep track of past actions, contributing to the sharing of information between operators, staff and management and the smooth running of day-to-day operations, while also helping workers to be more self-reliant.

Operator mobility

This digital transformation program supports our operators and make their life easier facilitating access to all needed documents and supporting remote production.

Discover with Chao Li, Digital Development Engineer, and Mylène Iller, Production Operator in Autun (France), how operators’ lives is made easier.

When we get back from vacation, for example, all we have to do is look at the news feed to find out what’s been happening while we’ve been away, on our line and on the site in general.

Mylène Iller

Production operator at Nexans in Autun, France

  • Connected goggles are used to reduce workplace stress, establishing a direct line between experts and operators at any time, to manage sensitive production phases or urgent production problems, through the use of augmented reality.

General program introduction

Lionel Fomperie, Nexans Group Industrial Strategy Director and Thomas Wagner, Nexans IS Performance Director give a general program overview and explain how Operations are working together with IT/OT to generate IT/OT and Cybersecurity platforms.

At this key stage in the process, the aim is for digitization to free operators from repetitive work, so that they can focus on tasks with higher added value. The digital transformation will also play a role in increasing the appeal of our business for the younger, digital-native generation, while creating opportunities for us to enrich job profiles, reduce the time spent on machines, and enhance skills through appropriate training programs.

To harness its full power, this new approach to managing the production base must be integrated with the company’s strategic objectives. Taking this process as far as possible, Nexans is making sure that its industry 4.0 plan is consistent with the E3 management model, underpinning the transformation of the group by supporting the goals of economic performance, environmental virtue and employee commitment.

Focus on 3 use cases

Lionel Fomperie, Group Industrial Strategy Director, Chao Li, Digital Development Engineer and Olivier Ameline, Nexans Excellence Way Director drive us through three use cases: Unified Operation Cockpit (UOC), MES Performance (Manufacturing Execution System) and SQDCE Digital board: S for Safety, Q for Quality, D for Delay, C for Cost & E for Environment.

Sustainable buildings for a brighter future
Electrification of tomorrow
12 October 2023
6 min
Sustainable buildings

Today, governments from around the globe with bold commitments to reduce greenhouse gas (GHG) emissions are pressuring the construction and building sector to reduce its carbon emissions and consumption of raw materials.

And for good reason. Commercial and residential buildings are responsible for almost 40% of greenhouse gas emissions (GHG) and consume 30% of final energy globally. Decarbonizing the building and construction sector is critical to achieving net zero emissions by 2050. Doing so will need fundamental changes in how buildings are designed, built, and operated worldwide. This shift will require the sector to favor more environmentally friendly building materials and practices, institute better material efficiency strategies, and reduce raw material usage.

Innovative construction materials

The move to innovative low-carbon building materials is essential to reduce the building and construction sector’s environmental impact. Concrete is not only the most commonly used building material but is responsible for 8% of global GHG emissions.

A viable alternative to traditional concrete is low-carbon brick made from recycled materials or traditional clay bricks fired in a low-carbon process using biogas from waste, biomass methanation, or solar and wind power.

Construction materials company Saint-Gobain, for example, is leading the way in the production of sustainable, low-carbon products. Earlier this year, the global company announced the production of zero-carbon plasterboard at its modernized plant in Fredrikstad, Norway. Decarbonizing the manufacturing process was possible by switching from natural gas to hydroelectric power, thus avoiding 23,000 tons of CO2 emissions annually. In addition, the company is the first in the industry to produce zero-carbon flat glass, made possible by using 100% recycled glass (cullet) and 100% green energy produced from biogas and decarbonized electricity.

Eco-friendly materials such as hemp and flax are viable alternatives for reducing the sector’s environmental impact. Cavac Biomatériaux, specializing in the industrial application of plant fibers, manufactures insulation from hemp and flax.

Better material efficiency strategies

The 2022 Global Status Report for Buildings and Construction foresees global consumption of raw materials to double by 2060. By implementing better material efficiency strategies, there is a massive potential for the building sector to reduce its GHG emissions, according to the report’s panel.

Furthermore, material efficiency strategies, including recycled materials, in G7 countries could reduce emissions in the material cycle of residential buildings by more than 80% in 2050. Globally, the Ellen MacArthur Foundation estimates that the circular economy would reduce CO2 emissions from building materials by 38% in 2050.

A key initiative within the European Union’s Circular Economy Action Plan (CEAP) is the Digital Product Passport (DPP). This initiative aims to make sustainable products the norm in the EU by facilitating transparency throughout the value chain and boosting circular business models. Instituting a circular business model in the building and construction sector is key to reaching important sustainability targets.

Reducing raw materials usage

Construction materials and products are estimated to consume 50% of all raw materials extracted from the Earth’s crust, and demolition activities represent 50% of all waste generated. To reduce its cables’ environmental impact, Nexans increasingly uses low-impact materials throughout the production value chain.

It is projected that the availability of important raw materials will continue to decrease in the years to come. An example is copper, an essential component of electrical cables and wiring due to its high conductivity and strength. Because copper mining can no longer meet global demand, 40% of copper production comes from recycled copper.

For over 35 years, Nexans has been recycling copper and aluminum scrap as part of its Sustainable Development policy to reduce raw material usage and promote a circular business model. In 2008, Nexans and SUEZ launched RECYCÂBLES, France’s leading recycler of cables and non-ferrous metals. The joint venture processes 36,000 tonnes annually of cables, generating 18,000 tonnes of metal granules and 13,000 tonnes of plastic. The combination of leading-edge technologies enables the generation of 99.9% pure copper granules.

Today, Nexans uses up to 15% of recycled copper in new cable manufactured and is on target to use recycled aluminum by 2024. Employing recycled copper, aluminum, and plastics provides Nexans’ customers a sustainable product without compromising quality.

Environmentally friendly building materials

With the global floor area expected to double by 2060, implementing energy-efficient and environmentally friendly building materials and practices is vital.

Nexans is working to improve the impact of its products by sourcing components that meet reduced energy usage guidelines established by the company’s Corporate Social Responsibility (CSR) directives. In addition, Nexans’ R&D product development aims to protect the environment and human health by managing the chemical substances used in its manufacturing processes and ensuring that all new projects take into account the end product’s environmental footprint. For example, starting in 2025, a large part of cables manufactured at the Nexans facility in Autun, France, will be halogen-free to reduce their toxic gas emissions in the event of a fire.

Energy-efficient, zero-carbon buildings will require looking at how building materials are designed, made, and used. This will mean examining the value chain and changing how we make, use, and reuse all materials—from the actual product to the packaging and transportation—to reduce the industry’s overall environmental impact.

Christophe Demule

Author

Christophe Demule is the Building Innovation Director at Nexans, working within the Innovation Service and Growth Department. Previously, he held the position of Engineering VP for our Business Group Industry Solutions & Projects, bringing with him extensive experience in manufacturing. In 2021, he designed and launched the implementation of the Building Innovation Strategy with the creation of six Design Labs worldwide. With a focus on User experience by using the Design Thinking Methodology, Innovations are solving pain points of our customers and bringing added value to all stakeholders.

Superconducting cables, miracles of electrical connectivity
Electrification of tomorrow
06 September 2023
5 min
Superconducting cables

Superconductivity is currently the subject of intense interest and debate, fuelled in particular by research into superconductors at ambient temperature and pressure, the discovery of which would trigger a technological revolution. The many questions raised by this work are reminiscent of the scientific challenges researchers had to overcome when they discovered high-temperature superconductors in 1986. A look back at this crucial technology for the cable industry, exploring recent advances, persistent challenges, but also how Nexans is providing the world’s very first superconducting cable system integrated into a rail network.

As we move towards an all-electric future, the need to increase power supply in cities becomes ever more urgent. Equally important is the need for resilience: as electricity becomes the main source of energy, supply will need to be 100% reliable. Downtime is not an option.

Why superconductors?

Superconducting cable are electrical connectivity miracles. They have unique qualities that make them perfectly suited to modern, high-capacity electrification projects in cities.

First, superconducting cables can carry extraordinarily high currents – far greater than conventional copper or aluminium cables. This makes it possible to transmit and distribute electricity at relatively low voltages. In practical terms, this means there is less need for substations in city centres – a major cost saving.

Second, superconductors can transmit a huge amount of power relative to their size. For example, a single superconducting cable with a diameter of just 17 cm can transmit 3.2 GW – enough to power a large city. Corridors for superconducting cables can be as narrow as one metre, meaning they can be deployed with minimal disruption.

Third, superconducting cables do not produce heat and can be fully shielded on an electromagnetic standpoint, so there is no interference with power, telecom and pipe networks which typically criss-cross cities. Many of the constraints that govern cable routing do not apply when superconductors are used.

On top of this, superconductors are incredibly efficient. Superconducting cables have extremely low resistance when an AC current is carried and no resistance when the current is DC, so losses are minimal.

superconductor-cable-nexans

A first for rail

Nexans is working with SNCF, France’s national rail company, on a pioneering project to boost power supplies to Montparnasse station in Paris using superconducting cables.

Montparnasse is one of the busiest railway stations in France and handles more than 50 million passengers a year. This figure is expected to exceed 90 million by 2030. Handling new demand will require extra trains – and extra power.

As with any city-centre power upgrade, the big challenge at Montparnasse was finding a way to bring in a new power supply without the need to dig up the surrounding roads – which can be a long, expensive and disruptive process.

Fortunately, the existing cable route between Montparnasse railway station and the substation that serves it had spare conduits available. Unfortunately, there were only four of them. Using conventional copper cables to deliver the required power would require a dozen of cables. What could be done?

Superconducting cables are the answer. Nexans’ solution uses just two cables, each less than 100mm in diameter so they can be easily threaded through the existing conduits. Despite their small dimensions, each cable is capable of handling 5.3 MW, or 3500 A at 1500 VDC – a huge amount of electrical energy.

What makes this project so significant is that it is the first-ever use of superconducting cables in France, and the first time superconductors are integrated in a railway grid anywhere in the world. The new power supply at Montparnasse will be commissioned in 2023.

What does the future hold?

The Montparnasse project underlines the massive potential superconducting cable systems have for boosting power supplies in cities – particularly where site constraints place limits on the use of conventional copper and aluminium cabling.

Rail transport aside, superconducting cable systems are likely to play a bigger and bigger role in satisfying the rising demand for electricity. This is being driven by new commercial uses – such as data centres – and by new sources of domestic consumption, which include electric vehicle charging, heat pumps and air conditioning.

In addition to meeting increased demand for bulk power, superconducting systems will play a critical role in boosting the resilience of urban electricity networks.

The Resilient Electric Grid (REG) project in Chicago, USA, underlines the direction of travel. Nexans designed, manufactured and installed a superconducting cable for the REG system, which helps to prevent power outages by interconnecting and sharing excess energy capacity from nearby substations, and by preventing high fault currents.

Nexans is the global leader in superconducting cable systems. Our unique capabilities in R&D, innovation, testing, manufacturing and deployment mean that we are perfectly placed to assist our customers, partners and stakeholders as they prepare to electrify the future.

Unleashing the power of DC buildings
Electrification of tomorrow
25 July 2023
7 min
Direct current powered buildings

With the global demand for electricity expected to increase 20% by 2030 and the increasing pressure to transition to renewables, the War of the Currents is once again in the spotlight.

Back in the 1880’s, when Westinghouse and Edison were battling for their respective approach to electricity distribution, the infrastructure to transmit direct current (DC) power was at the time inefficient and expensive. And as such, Nikola Tesla’s approach using alternating current (AC) ultimately won. And since that time, our current electrical infrastructure is dominated by AC technology. But times have changed since then.

Today, over 70% of devices in a building need DC to operate. A conversion from AC to DC results in energy wastage of upwards to 20%, according to EMerge Alliance. Reducing the need to convert has profound implications regarding energy savings and environmental impact. And this is why eliminating or reducing AC to DC conversion in buildings is critical.

The International Energy Agency reports that in 2021 the operation of buildings accounted for 30% of global final energy consumption and 27% of total energy sector emissions. As a result, governments are placing increasing pressure on the building sector to move towards ambitious energy performance directives to reduce the carbon footprint of buildings. Directives such as “nearly zero-energy buildings” in the U.S. and in Europe aim for buildings to require a low amount of energy provided by renewables produced on-site or nearby.

Directives like these, along with the growing usage of self-consumption, onsite battery storage and DC-powered devices from LED lighting and heating, ventilation and air-conditioning (HVAC) systems to electric vehicles (EV) and electronic devices, are driving the building industry to switch to DC power distribution.

The move towards to reliable DC cable systems for DC microgrid

In terms of electric power distribution, there is a progressive shift towards DC due to the growing interest in low voltage (LV) and medium voltage (MV) microgrids reflecting the fundamental changes in how electricity is generated, stored, and consumed. We are convinced that AC and DC networks will coexist with a significant share.

However, expert knowledge of the behavior of the insulation system is vital to ensuring the reliability of LV cables and accessories in buildings.

The behavior of LVAC cable systems is largely known but not for LVDC.

One of the focuses of Nexans’ R&D center AmpaCity is to optimize our cable design: we perform this optimization, which is achieved by understanding the electrical behavior of insulation systems under DC stress conditions and the impact of DC current on cable breakdown, ageing and corrosion. We’re also committed to investigate on more effective polymers for DC cable insulation with lower environmental impact than AC classical solution.

DC building transformation is a Fact

As mentioned earlier, power generation is moving closer to demand. Rooftop solar photovoltaics are becoming more commonplace. According to the EU Solar Energy Strategy, EU will make compulsory the installation of rooftop solar in new public and commercial and residential buildings. Furthermore, PV panels produce natively DC. In addition to the widespread implementation of on-site battery storage for uninterrupted power supplies (UPSs) used by businesses and data centers to maintain supply security, along with the growing deployment of battery energy storage systems (BESSs) for grid balancing.

Another major change in recent years is the growth of electric vehicles (EVs) and the need for DC charging stations in commercial, residential, and office buildings. With global policies encouraging and mandating the move to EVs, the market for chargers is growing rapidly, at an estimated compound annual growth rate (CAGR) of 29% from 2023 to 2050.

Local DC-power distribution

Distributing DC power locally throughout a building provides important benefits in safety, costs, and device reliability.

From a safety point of view, AC power is inherently more dangerous. In fact, the risk of electrocution of the human body by DC is considered to be lower than with AC, as the total impedance of the human body decreases as the frequency increases. And for high growth categories such as EV chargers, the move to DC versus AC chargers means better overall safety.

The data center sector accounts for around 4% of global electricity consumption, and is set to continue growing. Improving energy efficiency in this sector is crucial. For example, cost savings in electricity-intensive buildings such as DC-powered data centers can represent savings of 4-6% compared to conventional AC installations.

In addition to the reduction in electrical losses linked to the transport of electricity in cables, there is also the reduction in AC-DC conversion losses.

Providing DC devices (loads) with DC power eliminates power losses incurred through conversion and thus eliminates an estimated 5 to 20% in energy waste. In addition, the AC to DC conversion process at the device level can shorten its operating life. For example, distributing DC power directly to a LED fixture (thus avoiding the AC to DC conversion) can substantially extend its operating life. Plus, distributing DC power locally reduces the cost and footprint of AC to DC adapters and converters.

Transition to DC-powered buildings

In conclusion, DC power distribution in buildings is on the horizon, but change will take time. Even with a move to DC microgrids, there are other significant challenges to be addressed in the coming years, notably the uptake by industry professionals, many of whom need to become more familiar with DC power and its benefits. This is due to the long experience and knowledge of AC power.

Furthermore, advancement in building standards and codes which address specifications for DC-powered devices is required, as with the further analysis of the cost-effectiveness of DC power distribution in retrofit and new construction.

Cables are a fundamental part of a building’s electrical infrastructure and are a critical player in the transition to DC-powered structures. The buildings of tomorrow will be smart, connected, sustainable, and powered by DC. Nexans is committed to this transformation by manufacturing specific cable systems compatible with these new infrastructures. And our strategic partnerships and involvement in key industry groups are helping to make the transition to DC-powered buildings a reality.

Lina Ruiz

Author

Lina Ruiz is responsible for the LVDC, MVDC and new architectures technical platforms for Nexans within the Research and Territories Techno Centre.

She previously worked as a project manager and technical innovation team leader in the field of renewable energies. In 2023, she joined Nexans to accelerate the exploration program on direct current for low and medium voltage. In her current role, she is responsible for providing new and differentiated solutions in the field of direct current.

Digital solutions for building construction: A path to progress
Electrification of tomorrow
18 July 2023
5 min
Digitalization in building construction

A wave of change is happening in the building industry. As we’ve witnessed in the last couple of years, the sector once referred to as “brick and mortar” is bracing itself for a digital revolution. Traditionally slow to embrace new technologies, resulting in decades-long productivity stagnation, digitalization of the $7.5 trillion building construction market is long overdue.

In the 2022 McKinsey global survey of over 500 executives in the building products sector, an overwhelming 70% expected to increase their investment in innovation and R&D. So much so that survey respondents ranked digital design tools such as building information modeling (BIM), software solutions and automation ahead of sustainability.

Investing in innovation and R&D is expected to be the key market differentiator in the next three to five years – rippling across the entire value chain and driven in part by climate change and productivity.

Digitalization of the construction and building sector

Productivity has long been a major issue in the construction sector, with the average capital project running 20 months behind schedule and a staggering 80% over budget. The industry is increasingly applying digital tools across the entire spectrum, from design and construction to operations, but at varying levels depending on the construction phase.

Improving productivity necessitates closing the gap between product and document management systems to simplify and increase technician productivity.

Even as gains have been made, there is vast potential to further improve productivity through increased usage of digital technologies in all phases of the processes—design, construction, and operations.

With increasing government regulation for the industry to decarbonize, digitalization is a crucial enabler in reducing the environmental impact of construction projects globally.

Electrification of buildings

As the electrification of buildings grows and expands in the years to come, ensuring efficient implementation of cabling solutions is essential to safety and productivity gains. Narrowing the gap between productivity management tools and document management systems is one key to easing the work of electricians. As skilled labor shortages continue, further enhancements in information access and traceability are vital.

The digital connection between the physical product and its accompanying documentation is lacking in the industry. This is often the case with electrical products, where installers seldom have easy access to up-to-date documentation. The lack of traceability means details such as who installed the product are often lost once the initial work is completed.

As buildings move from fossil fuels to renewable energy, the demand for skilled electricians will increase, along with the need for tech-related professionals to manage the influx of digital systems and tools required to meet this industry shift.

Foundation of the digital revolution

As the building sector moves forward in its digital transformation, Building Information Modeling (BIM) will increasingly become the standard and foundation of construction projects. This bridging of physical building elements with their accompanying digital format (referred to as BIM content) facilitates the working processes throughout a building project’s value cycle from planning and design to construction and operations.

BIM content provides architects, designers, and builders easy access to essential product information such as installation instructions, energy consumption, eco-labels, operation costs, and product lifecycle. Nexans is working with BIM providers to integrate its offerings so as to facilitate electrical cable installation, maintenance, and safety.

As newer technologies such as drones, robotics, and 3D printing become more commonplace on construction sites, ensuring that BIM is the foundation of the construction industry’s digital strategy is critical. According to McKinsey, the move to 5D BIM, combining 3D physical models of buildings with cost, design, and scheduling data, could result in a 10% savings in contract value by detecting clashes, reducing project life span, and potentially reducing material costs by 20%.

Navigating analog to digital

The shift from analog to digital documentation and traceability is key to moving the building products market forward. And thus, reversing the industry’s fragmentation to ensure better productivity, cost efficiency, and safety. This is especially important in the electrification of buildings to provide safe installation and operations.

Thanks to its cloud-based app, Evermark™, Nexans provides its clients easy access to information about the physical product installed, such as follow-up of maintenance, electrical drawings and product data. Thanks to NFC tags, Evemark™ provides a digital connection between the physical product and the necessary documentation, and ensure full traceability of the electrical installation throughout the product’s lifecycle—from implementation phases to maintenance and replacement. It provides immediate access to pertinent information on- and off-site, reducing cost and time while increasing productivity.

With new technologies come new possibilities. The key is ensuring that future digital tools integrate seamlessly for a heightened level of customer satisfaction.

Jenny Nyström

Author

Jenny Nÿstrom is Nordics Design Lab & Innovation within Nexans. She has been working in the cable industry since nearly 20 years, being involved in the domain of product marketing and product management, mainly for Building, Telecom and Utility sectors.

Fire safety in buildings: Holistic certification for enhanced protection
Electrification of tomorrow
04 July 2023
7 min
Fire safety and buildings

Today, a fire breaks out every 30 seconds in Europe. 25% of fires are due to electrical failures, representing 275,000 fires yearly. With more than half of the world’s population living in urban areas and the demand for electricity increasing, ensuring the electrical safety of buildings is critical.

A vital step to ensuring the fire safety of buildings is taking a holistic approach to testing and certifying electrical cables with their associated components.

A key to this holistic approach is understanding how the shifts in electrical consumption and increased load requirements impact the fire safety of both new and older buildings. An estimated 25% of fires are caused by electrical failures or obsolete, overloaded installations. And this statistic worsens in emerging markets where 80% of building fires are due to non-compliant cables.

In essence, fire safety is a growing concern globally, and ensuring the safety of the building’s occupants is vital.

Electrification of buildings

Electrical cables are the backbone of buildings. The typical office building houses more than 200 kilograms of electrical cables per 100 square meters. Despite their omnipresence, they are unfortunately often forgotten. In older buildings, this can and often does lead to negligence in retrofitting outdated electrical cables and systems to ensure modern safety standards are met. And, with increasing electricity demand, installations in older buildings are often undersized and thus increase the risk of electrical fires.

Today, most older buildings require significant renovations to ensure their electrical systems are compliant with the rules and can adequately handle the loads required in offices, and residential, public and government buildings.

When it comes to new usages, the electrical architecture has to be considered at the early stage to ensure safety is tackled as a whole. There are still too much datacenters burning all over the world putting at risk the economy and sometimes life despite the availability of integrated solutions. Furthermore, photovoltaic installations are also at risk…

Most buildings run on several fuels. They obviously use electricity for lighting systems and electrical appliances, but they also consume fossil fuels such as natural gas or propane for heating systems. This persistent dependence on fossil fuels makes buildings one of the biggest sources of the pollution that is warming the planet.

The terms “electrification of buildings” and “decarbonization of buildings” all describe the transition from fossil fuels to the use of electricity for heating and cooking. In addition to heating and cooling systems using the latest generation of electric heat pumps, there will also be charging points for electric vehicles, which will systematically equip buildings in the future and help to reduce a major source of carbon emissions in developed economies: mobility.

The goal of such a transition: all-electric buildings powered by solar, wind and other zero-carbon electricity sources. In other words, it’s not just a question of increasing the level of electrification of buildings, but also the reliability of their electrical networks.

Fire safety starts with a holistic approach to certification

Cables are seldom the source of a fire, but due to the inherent nature of electrical arcs, their interconnections with electrical equipments and components are prone to igniting a fire. Understanding the interactions between these components is instrumental in ensuring better fire safety in buildings.

Today, most standards and certification bodies focus on validating each component in isolation. This lack of a holistic view of the interactions between electrical components within a building structure must be a concern within the industry. Fortunately, frameworks such as the National Fire Protection Association (NFPA) & Life Safety Ecosystem™ aim to identify the components that must work together to minimize fire risk.

Changing the industry mindset from the certification of each component to consider the interactions of components is fundamental to ensuring their compatibility and overall safety. This holistic and systems approach ensures that proper testing is done to validate that the overall system performance is achieved and certified. And that testing takes into account the usage of components in a real-life setting.

Moving to a systems approach for certification will require suppliers to work together in bringing to market thoroughly tested integrated system offerings that match the performance requirements of customers and failsafe installation processes. This will mean implementing plug and play and modular electrical products that reduce the risk of on-site installation errors and ensure component compatibility.

Nexans’ Fire Safety compatibility approach

Nexans aims to provide the highest electrical and fire safety levels by ensuring its cables and wires combat fire propagation, reduce smoke and hazardous emissions during a fire, and maintain the continuous operation of fire safety systems. These are the fundamental pillars of Nexans’ Fire Safety solutions and services.

To reduce hazardous emissions, for example, Nexans Fire Safety’s offering focuses on Low Fire Hazard (LFH) cables and forgoing outdated materials such as PVC.

Our mission to provide innovative products and solutions that meet the safety needs of our customers extends to our dedication to moving the industry to systems compatibility testing and certification. This is an increasingly important opportunity to ensure the fire safety of new solutions.

For example, Nexans recently took a system approach in developing an electrical vehicle (EV) charging infrastructure offering. To do so, we selected key partners to build the integrated solution, thus proving this approach’s viability.

The challenges and opportunities

Creating safer buildings will mean fundamental mindset shifts. For customers, it will mean moving their purchasing decisions from solely component cost to a total cost-of-ownership (TCO) approach encompassing fire risk management.

The industry must also encourage collaboration between key partners to ensure an overall benefit to all stakeholders, in addition to industry certification and performance standards with an active participation of insurance organizations.

In the coming years, new offerings must take a solutions approach to further demonstrate their benefits to customers. These benefits include better fire protection, safety, and ease of installation.

In addition, an integrated fire safety system approach to electrical components aligns with the industry’s move to Building Information Modeling (BIM), digital twins, and IoT technologies.

Franck Gyppaz

Author

Franck Gyppaz is the head of the Fire Safety Systems Design Lab at AmpaCity, the Nexans Innovation Hub. He has been working in the cable industry since more than 20 years, being involved in the domain of fire safety and developing innovative technologies, cable designs and a fire test lab with the ISO17025 accreditation and UL certification. He is also active in the field of standardization members of different groups at national and international levels.His position leads him to manage relationships with all the actors of the fire safety ecosystem to propose integrated systems to our customers.

Transforming buildings industry with
3D printing and modular construction
Electrification of tomorrow
27 June 2023
9 min
3D printing & modular wiring in buildings

The building and construction industry is increasingly embracing newer technologies and solutions to meet rising floor space demand, stricter sustainability and safety standards, increasing costs, and skilled labor shortages.

As the demand for residential, commercial, industrial, and high-safety buildings is projected to grow in the coming years, meeting demand will require more efficient building construction methods. Those gaining in popularity are 3D printing, drones, robotics, and modular construction.

At the heart of this evolution in the building and construction industry is the increasing demand for electricity, which is expected to grow by 20% by 2030. This means future construction must take into account more electrical cables, connectors, systems, and subsystems, while ensuring smarter and safer installation and operations.

3D printing – from novelty to mainstream in reshaping buildings

Going from curiosity to a viable tool of the building trade, 3D printing, also known as additive manufacturing, is reshaping the industry and demonstrating its viability to dramatically reduce construction time and costs. Moreover, the benefits extend beyond on-site but to off-site (prefabrication) of building components, adding yet another major application and appeal to its uses.

One of the more progressive moves to 3D printing technology is the Dubai 3D Printing Strategy which aims for one-quarter of Dubai’s buildings to be 3D printed by 2030. Examples include the 2,600-square-foot office complex housing the Dubai Future Foundation (DFF) headquarters and the Dubai Municipality completed by robotic construction company Apis Cor.

Benefits of 3D printing in construction have been highlighted during the 2023 Construction Technology ConFex:

  • Speed and efficiency: The layer-by-layer additive manufacturing process of 3D printing can dramatically reduce construction time compared to conventional approaches, enabling the project to be completed more quickly.
  • Reduced costs: By optimizing the use of materials and reducing labour requirements, 3D printing can reduce construction costs.
  • Customization: 3D printing makes it possible to create custom designs and complex architectural elements that would be difficult to achieve using traditional construction methods. Complex and unique shapes can be easily created using 3D printing, allowing architects and designers to explore innovative design possibilities.
  • Sustainable construction: Additive manufacturing can minimize material wastage by using only as much material as is needed, promoting sustainability in construction.

However, a number of challenges remain:

  • Limits of scale and size: Scaling up 3D printing for large-scale buildings or infrastructure projects remains a challenge. Current technologies may not be able to efficiently produce structures beyond a certain size.
  • Structural integrity and quality assurance: It is essential to guarantee the structural integrity and long-term durability of 3D printed components. Rigorous testing and quality assurance processes are required to meet safety standards.
  • Integrating electrical systems and other services into 3D-printed structures requires careful planning and co-ordination to ensure their smooth operation.
  • Regulatory and legal considerations: As 3D printing in construction becomes more widespread, regulatory frameworks and legal standards must be established to meet safety, liability and compliance requirements.

Robots and drones—redefining the building construction site

The construction robotic technology is going from sci-fi to reality in record-breaking time. A report from MarketsandMarkets expects the construction robots market to reach $166.4 million by 2023, representing a 16.8% compound annual growth rate (CAGR) from 2018 to 2023. And an IDC report published in January 2020 forecasts that demand for construction robots will grow about 25% annually through 2023.

Applications range from robots that can lay bricks and weld to self-driving diggers and drones that can survey and map construction sites and monitor progress. Most foresee robots assisting construction workers in repetitive and dangerous tasks while helping the industry tackle productivity and labor shortage challenges.

An example is Hilti’s semi-autonomous job site robot, Jaibot. Designed to assist mechanical, electrical, and plumbing (MEP) contractors, Jaibot uses BIM data to locate and drill holes for interior electrical and plumbing installations.

In the past couple of years, technologies not immediately embraced by the construction industry are now rightly finding their place, going from curiosity to a viable tool in the building trade.

Modular wiring—transforming the electrical landscape

With its roots dating back to the mid-’90s, Modular wiring revolutionizes the electrical landscape by replacing traditional installation methods with a convenient plug and play technology. It provides a quick, safe, and easy solution for connecting lighting and power circuits from the distribution board to the final connection point. Initially used in high-safety buildings like healthcare facilities, modular wiring is now widely utilized in schools and government buildings due to challenges such as labor shortages and increased infrastructure demands.

Over the past 30 years, modular wiring has gained popularity as a cost-effective and user-friendly alternative to traditional electrical installation. It offers numerous benefits throughout the entire construction process, from conception and design to operation and end-of-life. This has instilled confidence in governments, builders, and electrical contractors regarding its safety, cost-effectiveness, and efficiency for both new construction and upgrades.

To meet the increasing demand for floor space, architects and builders are relying more heavily on modular building techniques. According to a recent study by MarketsandMarkets, the global Modular Construction Market size is projected to grow from $91 billion in 2022 to $120.4 billion by 2027, up 5.7% from 2022 to 2027.

This trend is driven by the need for innovative approaches and the ongoing shortage of skilled labor. Modular wiring, along with other subassemblies and components, plays a vital role in enhancing productivity and performance while providing a comprehensive view of costs that includes factors like end-of-life, waste, and safety. With the construction industry shifting towards prefabrication and off-site construction, modular wiring will continue to grow in importance to meet government requirements, reduce costs, enhance quality and safety, and minimize environmental impact.

Wiring the future

Moving forward, the industry’s biggest challenges are changing attitudes about adopting newer construction technologies and methods and more encompassing metrics.

This means that electrical cables are not seen as a commodity and, as such, not only selected on price but on type, materials, safety, and more. This changing of metrics sees performance, risk, and sustainability as essential criteria in the overall measurement of a building project.

In Oceania, Nexans supports its customers as they embark on the energy transition journey, offering a complete modular wiring solution. This solution is an efficient and sustainable way to minimize electrical site waste and reduce the cost of installation. Moreover, it encompasses switchboards, corridor wiring, and in-room wiring through to end-of-circuit accessories.

With building information management and design moving to more detailed phases earlier in the conception stage, the inclusion of modular wiring is gaining its place. In addition, supply concerns and rising material costs are increasingly driving electrical contractors to include modular wiring in bids and the design phase.

The future of modular wiring solutions is strong and will continue to gain in popularity due to the benefits of cost-savings, reliability, ease of installation, safety, quality, and sustainability.

 

Often regarded as a commodity industry, the construction sector is no exception to the trend towards new technologies and innovations. It has a multitude of tools and solutions that are revolutionizing not only processes, but also ways of working and preparing a site. Numerous innovations are already proving indispensable in improving the organization of worksites, the quality of work and the efficiency of teams. The result is a whole new way of designing projects and completing them in record time.

Sustainable development, improved worksite safety, technological solutions to save time and money, digital tools to build more environmentally-friendly structures… Innovation in the building industry is everywhere.

Christophe Demule

Author

Christophe Demule is the Building Innovation Director at Nexans, working within the Innovation Service and Growth Department. Previously, he held the position of Engineering VP for our Business Group Industry Solutions & Projects, bringing with him extensive experience in manufacturing. In 2021, he designed and launched the implementation of the Building Innovation Strategy with the creation of six Design Labs worldwide. With a focus on User experience by using the Design Thinking Methodology, Innovations are solving pain points of our customers and bringing added value to all stakeholders.

IoT and electrification: Innovations shaping the future
Digital transformation
18 April 2023
8 min
Internet of Things IoT

The Internet of Things and connected objects: the stakes ahead

By 2030, there will be 30 billion connected objects worldwide, including 244 million in France, according to estimates by ADEME (the French Agency for Ecological Transition) and Arcep (the country’s electronic communications authority). Some will be everyday objects, others will be used in professional applications.

The Internet of Things (IoT) is briming with development potential and exciting possibilities for homes and businesses. As it expands, the IoT also brings new innovative solutions for electrification. It will help industrial companies increase their productivity and help people reduce their energy consumption at home. And it is growing 15% to 20% a year across the board.

Let’s deep dive into the IoT concept, the prospects for harnessing electrification, and the issues and challenges surrounding it.

The Internet of Things: how does it work?

The IoT is a network of connected devices with built-in microprograms, sensors and connectors enabling them to interact with the Internet. Examples range from household appliances to electricity meters and on to cable drums.

The IoT, in a nutshell, makes things smart. They can collect data, process it onsite and share it online or with other devices to analyze it in more depth. Then they can take measures to improve operations or automate tasks.

When you transfer data online, you can build an intelligent ecosystem where you can use devices in more sensible and more modular ways. You can upgrade a home into a smart home, a city into a smart city and a grid into a smart grid. In France, with 35 million smart meters, electrification is among the sectors that have reached the most advanced stages of digitalization with the IoT. And it will reach even further as Enedis, which operates the country’s electricity distribution system, has announced plans to install 250,000 sensors throughout its grid over the next 5 years.

The possibilities on the operation side are opening up numerous opportunities. For example, home automation environments will be able to manage energy consumption. For connected objects to communicate effectively, however, they need specific systems. These include radio-wave modules, sensors, cellular routers and gateways, and they are all essential to manage data flows and tackle the related challenges.

IoT and innovative electrification solutions

The IoT is bringing in an array of electrification solutions that create value in homes and companies:

  • Managing energy consumption: the IoT can help consumers keep an eye on their energy consumption and manage it more efficiently using real-time electricity and gas meter readings. Smart connected objects can also be programmed to switch off automatically when they are not being used, which also reduces energy costs.
  • Monitoring equipment: companies can use the IoT to monitor their solar panels, wind turbines and other systems remotely, to make sure they are running properly and optimize their output.
  • Storing energy: the IoT can also help to monitor and manage storage levels, and optimize battery charging-discharging cycles.
  • Reducing costs: the IoT can also help to reduce operation and servicing costs by enabling predictive maintenance, shortening downtime, and optimizing supply chains and use of resources.
  • Optimizing grid operation: the IoT does this by tracking demand for energy in real time and adjusting supply accordingly, which can help to reduce power production costs and optimize distribution.

Issues and challenges around connected products

There are several practical and economic issues and challenges surrounding IoT operation.

IoT communication

When you have objects scattered around the globe, the first challenge is to interconnect them. Some of them may be in city centers, others may be in out-of-the-way places that telecom networks barely reach. To tackle this challenge and improve scalability, Nexans uses a variety of communication protocols and teams up with telecom operators worldwide.

Then you must integrate the routers, sensors and other devices mentioned earlier. Three main notions come into play in IoT rollout:

  • the reach of the equipment and connected objects you use;
  • energy consumption;
  • bandwidth requirements and capacity.

In other words, you must adapt the available resources to match the complexity of the infrastructure—and that infrastructure can span a local area, a country or the globe. That is why it is important to partner up with other experts, as Nexans started doing with Orange in 2020.

Cybersecurity for the IoT

Cybersecurity is as central to the IoT as its efficiency. The more connected objects, the greater the risk of cyberattacks, because the objects collect sensitive data and can provide hackers with a back door into a company’s information system. The entry point can be a computer as much as a connected object.

Even something as simple as a camera can be a way into the core system. A casino in London, for example, was hacked through an Internet-connected fish-tank thermometer linked to the rest of the system. Ironclad security protocols are an absolute must for the IoT: a device can be a risk however harmless it may seem.

The IoT business model

Large-scale IoT rollout is viable even when you factor in all the complexity associated with integration. It for instance provides several advantages in industrial production and supply chains:

  • smoother goods flows and real-time monitoring and updates;
  • more efficient collaboration between departments;
  • better goods tracking and transit;
  • swift and secure data collection;
  • tighter control over stock.

Besides all of the above, customer service teams can respond faster, especially when they have to deal with delivery delays or other problems.

Ultracker: the Nexans solution to optimize supply chains

Here at Nexans, we have developed Ultracker, a pioneering digital solution to harness the possibilities in the data collected by IoT sensors, combined with artificial intelligence and cloud storage.

With this solution, our customer installers and utilities can:

  1. optimize their working capital and logistics flows;
  2. shrink their carbon footprint by shortening drum rotation cycles;
  3. reduce losses and prevent cable theft.

The IoT trackers embedded in our cable drums and transportation fleets, and our cable-related products, enable customers to track drum status more closely, see a clearer picture of their stock levels and supervise jobsites remotely. This cuts raw material and supply wastage.

Nexans’ IoT expertise, and the solutions we have set up with our partners enable cable system and cable life cycles management, range from delivery on site to measuring how much cable there is left on a drum before pick-up. A leading European electricity distributor that adopted Ultracker to monitor its cables via the IoT is saving over €1 million a year.

Big data and AI in energy: Electrification’s game changer
Digital transformation
01 March 2023
10 min
Big data & AI

Artificial Intelligence (AI) has been around for a while. The first models date back to the 70s but these concepts remained theoretical until we were actually able to teach computers to think for themselves. Today, Artificial Intelligence is everywhere. It allows computers and cloud connected devices to reproduce human-related behaviours such as reasoning, planning and creativity. Artificial Intelligence is primarily dependent on the quantity of data it is given. This is where big data plays an active role. With the increased collection and analysis of digital data, big data and AI are now emerging as rich areas of opportunity for electrification professionals.

Electricity 4.0 : Big data and AI for smarter power management

Big data is a major trend in the energy industry. The Electrical network become smart grid due to Data collected from a variety of sources, such as smart meters, sensors, twin digital. Once stored, this data is an invaluable resource for the industry to make better decisions about energy production and consumption.

Electricity was deployed extensively in the late 19th century, which was the First Wave of Electrification from 1880 to 1920. This period saw the widespread adoption of electrical power in industry and the development of the first electrical grid. Then the Second Wave of Electrification took place between 1920 and 1950 with the expansion of the electrical grid into homes and the development of new electrical appliances such as refrigerators, washing machines… During the third wave of Electrification from 1980 to present, we have seen the growth of the digital revolution and the development of new technologies such as computers, the Internet, and mobile phones.

Today the fourth wave of electrification so-called Electricity 4.0 is characterized by the integration of digital technologies such as Artificial Intelligence (AI), the Internet of Things (IoT), and advanced data analytics into the electricity infrastructure.

The aim of Electricity 4.0 is to create a smarter, more efficient, and more sustainable electricity system that can respond to the fast changing demands (+20% by 2030, +40% by 2040).

Electricity 4.0 is expected to optimize the use of existing assets, integrate renewable energy sources into the grid, increase energy efficiency, reduce greenhouse gas emissions, improve grid stability, reduce costs for customers and provide more reliable and flexible energy services to customers.

Moreover, generative AI and adjacent models are changing the game. Indeed, support technology reaches a new level, application development time is reduced, and powerful capabilities are brought to non-technical users.

Just recently, we saw the buzz around ChatGPT and what it can achieve. For instance, if we ask the question “how do big data and AI impact electrification”, we have to admit ChatGPT answer might not be perfect but is still very impressive.

Explain how big data and AI impact electrification - ChatGPT

These technologies will definitely have an impact on the world of electrification. But AI is mainly dependent on the quantity and quality of the data that will be used to learn. Big data provides the storage and processing capabilities necessary to educate the AI by feeding it with a lot of information.

Machine Learning and AI are the winning combo to efficiently exploit big data. This involves identifying patterns via data mining and data science more generally.

Big data: The cloud has won

In the age of big data, the famous wave 2 of “move to cloud” announced by providers is underway and is accelerating. As a reminder, the first phase of a migration to the cloud is a discovery phase that allows to analyze the strengths and weaknesses of an infrastructure and to determine future needs.

The number of detractors is getting smaller every day, privacy and sovereignty issues are both solved by the strategic commitments of clouders and swept away by the ease of use… All sectors – banking, telecoms, insurance, etc. – are rapidly adopting cloud-hosted big data solutions.

The first paradigm shifts are appearing in the world of electrification, driven in particular by operators such as Total Energie or Schneider. We can also note the predominance of the estimated Azure services of Microsoft Vs Aws of Amazon in the field of public cloud related to big data.

Exploring the challenges of generative AI and Big Data in 2023

Generative AI promises to make 2023 one of the most exciting years for AI and, by extension, Big data!
Keep in mind that ChatGPT’s prowess is based on the net recorded in 2021, but, as with any new technology, we must always proceed with pragmatism and measurement, because the technology now presents many challenges:

  • Ethics: what sovereignty for data? What protection for personal data? What commitment to transparency and readability by the players?
  • Environment: AI and Big Data are a paradox in that they are both a solution for optimizing energy consumption and resource mobilization, but also a cause of this increase;
  • Cybersecurity: AI and Big Data in the field of energy is largely based on measuring instruments, therefore on IOT, offering an ever increasing security surface;
  • Business Model: if the value of AI in the energy field is no longer to be demonstrated, the business model associated with services is very complex. For example, if we take the residential segment, the Chat GP virtual assistant has made the buzz as has Amazon with the announcement of a massive layoff, including the Alexa division (Amazon’s virtual assistant), in the same week;
  • Talents: the development of digital services requires the onboarding of excellent technical skills, but not only. It’s the entire operating model that needs to be rebuilt. The human dimension is one of the biggest challenges brought by AI and Big Data: attractiveness, meaning of work, conditions, etc.

Big Data analysis combined with artificial intelligence also involves various risks. Key concerns include unintended consequences of automated decision-making, increased risk of cyber-attacks due to reliance on technology, inaccurate predictions leading to poor decisions, over-reliance on algorithms instead of human judgement, lack of transparency in the development process, etc…

AI and big data for Nexans

As previously expressed, AI in the energy domain is most often carried by a phygital system, meaning software + hardware.

To this end, an important part of our work in terms of AI and big data concerns the implementation of learning based on neural networks. The latter’s role is to translate images or text from measuring instruments (thermometers, drones, etc.) into numbers. The aim of these approaches is to understand recurrences, date them, predict them and locate them. We are in the AI for grid sensing.

One of the important activities in the field of electrification is the monitoring of networks for all segments: generation, transmission, distribution and use of electricity in buildings and industries. this requires the development and implementation of sensors that measure electrical activity along the value chain.

This is already the case in developed economies at home or in industry with Smartmeters. High voltage transmission lines are also systematically monitored for temperature and voltage. Medium-voltage electricity distribution networks and the connection networks of distributed renewable energies are less frequently monitored.

It is therefore essential to obtain data on the entire electricity deployment chain.

A second important activity is the analysis of data in order to optimise products or systems. this is at the heart of artificial intelligence and Big data.

In technical terms, we mobilize the techniques developed essentially for the field of natural language processing with recurrent neural networks and more precisely convolutional neural networks. In other words, the technology stacks of ChatGPT & DALL-E.

A long-term energy transition

Big Data is a hot topic with huge implications for the energy sector. It is a powerful tool that can be used to improve the efficiency of energy systems, production and consumption. In addition, it can also be used to improve electrical networks and smart technology.

Thanks to Big Data, it is possible to explore various scenarios and objectives related to the energy transition. In particular, this technology makes it possible to analyze how different systems and supply sources are interconnected and how they could be optimized in the long term. Thus, it offers an invaluable perspective to achieve a certain autonomy in a long-term energy transition objective.

The 3S (smart, small & selectivity) are challenges for the years to come. Addressed in a disorganized way today, they will become the real challenges for AI applications tomorrow:

  • Smart data: Understanding and monitoring local ecosystems
  • Small data: Limit the use of energy-intensive big data
  • Selectivity: optimize the resources needed.