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2June 18th, 2008
The Bourg factory, established in 1956, has two core businesses :
- The manufacturing of insulated cables from 6 to 132 kV
- The manufacturing of bare overhead lines and earthing conductors
It is organised in two manufacturing halls :
- Conductors
- Cables
Bourg-en-Bresse Factory
4June 18th, 2008
Area : 150 000 m² of which 40 000 m² built (10 000 m² for Conductors and 30 000 m² for Cables)
Headcount : 270 people, of which 70 managers,
engineers and technicians
Electrical power : 15 MVA
Manufacturing 7 days per week (40 000 T/year)
Certified ISO 9001 Version 2000
COFRAC Accredited Laboratory
Fixed assets : 20 M.Euros
Bourg-en-Bresse Factory
5June 18th, 2008
Bourg-en-Bresse Factory : History
1956 Paper insulated cables
1973-81 Move to XLPE insulation (installation of CV lines)
1981 Manufacturing of strippable semi conducting compound
1996 Manufacturing of insulation compound
2002 Manufacturing of bonded semi conducting compound
2004 Move to HV cables manufacturing ( up to 132 kV)
Cables
6June 18th, 2008
Bourg-en-Bresse Factory : History
Conductors
1962 Transfer of the conductors workshop from Lyon to Bourg
1978 Extension to supply the Autun factory
1990 Transfer to Lens of flexible conductors manufacturing
2005 Transfer of bare overhead lines manufacturing from Lens
to Bourg and transfer from Bourg to Lens of conductors for Autun
8June 18th, 2008
Conductors : Manufacturing Tool
2 copper rod breakdown drawing machines (of which 1 two wire machine)
1 copper medium wire drawing machine5 aluminium & aluminium alloy drawing machines2 heat treatment ovens for aluminium alloy wires
7 stranding machines : 7, 12 (x2), 18, 37, 78, and 91 wires
1 Control laboratory1 40 T bench for tensile strength measurement on
conductors
11June 18th, 2008
Conductors Manufacturing
OUTPUT 2007 :
Copper conductors : 6 400 T (9 600 T in 2006)
Aluminium conductors : 5 600 T
Aluminium alloy conductors : 2 700 T
13June 18th, 2008
MV & HV Cables
Voltage 6 to 132 kV
XLPE Insulation
Cross sections50 to 1600 mm² Aluminium50 to 1200 mm² Copper
StandardsNFC 33-226 BS 7870 NBN 33-323 UNE 211620-5E VDE 0276 IEC 60502 NFC 33-252 IEC 60840 Any specification on demand
14June 18th, 2008
Main HomologationsFrance : EDF, French Railways Spain : AENOR, ENDESA, Union FENOSABelgium : EANDIS (ex-Electrabel )Germany : VDEUnited Kingdom : EDF Energy, Scottish Power, NEDLIreland : ESBRussia : GOSTAlgeria : SONELGAZTunisia : STEG
MV Cables
15June 18th, 2008
Main Homologations
Type-tests of 66 and 132 kV cables according to IEC 60840 :
• for 132 kV, we have type-tested early 2006 a cable according to DEWA specification (630 mm2 Cu 132 kV lead sheath + cws) : this type-test was witnessed by Bureau Veritas
• for 66 kV, we have type-tested in 2006 a cable according to Kahramaa (Qatar) specification (800 mm2 Cu 66 kV lead sheathed + cws) : this type-test was witnessed by Loyds
HV Cables
16June 18th, 2008
Main Homologations
RTE (French Power Grid) in 63 & 90 kVDEWA (Dubaï) in 132 kVUnion Fenosa (Spain) in 132 kVEDF Energy (U.K.) in 132 kV
Main CustomersSonelgaz & Siemens (Algeria)
Balfour Beatty (U.K.)Kahramaa (Qatar)Union Fenosa (Spain) EDF Energy (U.K.) RTE (France)
HV Cables
17June 18th, 2008
In-house compounding
XLPE suitable up to 150 kV
Strippable semiconductor
Bonded semiconductor suitable up to 150 kV
Semi conductive skin for outer sheath
18June 18th, 2008
Cables : Manufacturing Tool
Insulation4 CV lines under nitrogen with triple head
Screening2 screening machines for
copper wire screens
Assembling3 assembling machines
Sheathing3 sheathing machines
1 Lead press
19June 18th, 2008
Cables : Control LaboratoryTanks for corrosion test
Breakdown ramp up test up to 350 kV
Insulation and sheath shrinkage test
Rheometer
20June 18th, 2008
Cables : Long duration tests
Beyond routine tests, we can carry out long duration tests according toNFC, VDE or CENELEC standards
VDE / CENELEC 2 year test in water under voltage5000 h test on a buried cable under
voltage with thermal cycles
24June 18th, 2008
High Voltage : Faraday Cage
Useful space in the shielded room : 20 m x 10 m x 7 m
Electrical characteristics :
• Voltage – Current up to 325 kV – 40 A
• Noise below 1 pC
Automatic regulation controlled via a PC
Practically, we can test cables up to 150 kV
25June 18th, 2008
2007 Output
Insulation & semiconductors compounds : 6 250 T, of which 1 000 T sold to other Nexans units
12 000 core km (14 000 in 2006)
26June 18th, 2008
Sales
In M.Euros 2006 2007 2008YEO
EDF 35 29 33
RTE 4 5 7
Installers 18 24 21
Export 25 25 27
Internal sales 7 6 7
TOTAL at standard metals 89 89 95
TOTAL at current metals 110 115 121
27June 18th, 2008
Bourg plant : Organization Chart
Plant ManagerEric FRANCEY
Commercial Xavier BROSSE
TechnicalEric SIMEON
Supply ChainStéphanie BAGNON
ManufacturingLaurent MOREAU
Maintenance Dominique GEFFROY
Quality – Security - Environment Jean-François PLANCON
Human ResourcesFranck HERBRETEAU
ControllerPhilippe ROBERT