Sterlite Power Transmission: Conductors, OPGW & Cables for Future-Ready Power Infrastructure

Backed by robust investments and ongoing capacity expansion, Sterlite Power Transmission Limited (SPTL) is aiming to position itself among the top 10 global wire and cable companies in the near future. Mr. Reshu Madan, Chief Executive Officer, Global Products & Services (GPS) Business, Sterlite Power Transmission Limited, revealed during an exclusive interaction with Wire & Cable India that SPTL is focusing on increasing its manufacturing capacity for conductors to 1,50,000 MT; enhancing its HVAC and HVDC cable capacity through a state-of-the-art greenfield facility and introducing solar cables in its portfolio.The company is strategically aligned to support the evolving energy landscape by offering high-ampacity and fibre integrated power cables, energy-efficient innovative products, and space-efficient transmission solutions.

Wire & Cable India: What types of EHV cables or conductors do you manufacture for power transmission & distribution systems. How do they differ in terms of properties & performance?

Reshu Madan: Sterlite Power Transmission manufactures two main types of products: overhead transmission products (conductors & OPGW) and underground transmission products (power cables).

Our overhead conductors vary from conventional ACSR, AL59 and AAAC conductors to high performance conductors. The product range spectrum is defined on the basis of current carrying capacity and efficiency. It is used in both new lines and reconductoring of existing lines.

Offerings under the OPGW category encompass products like central steel tube design OPGWs used in low wind load areas and PBT-central core aluminium sheathed tube design OPGWs used for higher wind load areas.

The underground power cables portfolio is classified on the basis of voltage range and specialized applications with usages across data centres and metro segments. The medium voltage cables range from 6.6kV to 45 kV and high voltage cables range from 66 kV to 220 kV. Both these categories use conductors made up of copper and aluminium. Additionally, we also make specialized cables like high ampacity cables, which have enhanced the current carrying capacity compared to traditional cables.

WCI: Tell us about your recent technological innovations or advancements for enhanced efficiencies in power transmission. Have you incorporated these into your products? How do you improve their performance or reduce costs?

RM: The construction of new transmission infrastructure at higher voltage levels is challenged on account of land scarcity. To tackle this constraint, utilities have been increasingly opting for high-performance conductors and reconductoring existing infrastructure. This enables transmission lines to carry higher ampacity without expanding the physical footprint. Sterlite Power Transmission has consistently been at the forefront of innovation to enhance efficiency in power transmission. One of our key advancements has been on developing high performance conductors that deliver high-ampacity and energy-efficient transmission solutions. This technology significantly reduces line losses and supports the integration of renewable energy into the grid, thereby improving overall efficiency and sustainability.

In addition to the above, we have made substantial progress in Optical Ground Wire (OPGW) technology, introducing high-fibre count variants such as 144-fiber OPGW. This facilitates enhanced data capabilities, grid intelligence and reliable communication within power infrastructure. Our patented products like high ampacity cables and fibre integrated power cables are a testimony to Sterlite’s continued commitment on developing innovative solutions that enable optimized performance, minimize operational costs and ensure future-ready infrastructure capable of meeting evolving energy demands. With the shift towards renewable energy, we are expanding our portfolio with new-age products like solar cables, which demonstrate our preparedness in providing future-ready offerings.

Watch: Top Cable Companies in India

WCI: What quality control processes have been initiated by Sterlite Power Transmission to ensure that EHV cables and conductors meet industry standards, as well as reliability and safety benchmarks for various environmental conditions?

RM: At Sterlite Power Transmission, we ensure a robust quality control mechanism to ensure that our EHV cables and conductors meet industry standards and are reliable across various environmental conditions. Our quality control and assurance process encompasses rigorous testing right from raw material to the finished product, be it the incoming inspection to ascertain raw material defects, the in-process quality checks to monitor process quality or the final pre dispatch check. We conduct comprehensive testing for electrical, mechanical and thermal properties to ensure durability and safety. Type testing is done for all new variants at NABL accredited labs to ensure that our products consistently meet the reliability and safety benchmarks required for power transmission systems globally.

Additionally, we conduct online FAT for our clients. We also have periodic reviews and audits to ascertain adherence to our Quality Control Plan. All these measures ensure that we remain fully committed to delivering reliable quality products which abide by all safety rules and regulations.

WCI: What is the typical lifespan of your EHV cables or conductor? What value-added services do you provide to customers in the field?

RM: The lifespan of conductors and EHV cables depends on the type of materials forming up the product. Overhead conductors typically have a life span of around 30 years, whereas cables have a lifespan of around 25 years. We offer engineering support for conductors, which aids in technical evaluation for customers. Additionally, the customers are offered detailed installation manuals and SOPs.

Our specialized EPC business provides solutions on reconductoring of the existing lines and helps in delivering higher efficiency without considerable line stoppage. In EHV cables, we have dedicated and well-experienced teams, equipped with the latest tools, plans and testing facilities, to conduct route and utility surveying. We also extend support on providing optimal techno commercial and feasible EHV cable installation solutions, along with speedy fault identification & restoration services. In addition to cable supply, we also provide complete EPC solutions, which can be tailored according to customer needs.

WCI: What is your total production capacity and what target are you eyeing? To what markets do you majorly cater?

RM: Sterlite Power Transmission is on a strong growth trajectory with continued investments in augmenting its production capacity. We have an existing manufacturing capacity of 1,00,000 MT for conductors; 22,000 km for OPGW and 2,000 km for power cables. Our aim is to continue investments in capacity expansion through brownfield and greenfield projects, positioning us to meet the rising global demand for advanced transmission solutions. Through these investments, we are eyeing an increase in conductor capacity by 50,000 MT, introduction of new products like solar cables and increase in power cables capacity of HVAC and HVDC cables (+/-550 kV) via a planned state-of-the-art greenfield facility.

Sterlite has a strong market presence both in the domestic and international market. Our global footprint consists of customers in more than 70 countries spanning across all major regions like North America, Europe, LATAM, Middle East, Africa, SEA, CIS and Oceania. Our target markets primarily include regions where the demand for innovative and space-efficient transmission solutions is growing due to the integration of renewable energy and urbanization. With our ongoing capacity expansion, we are strategically aligned to support the evolving energy landscape by offering high-ampacity, energy-efficient innovative products.

WCI: Tell us about your major orders that you have bagged recently.

RM: Over the last two quarters, Sterlite Power Transmission has bagged orders cumulating to INR 2,700 crore across our Global Products and Services (GPS) business. This growth is driven by high-performance conductors, optical ground wires (OPGW) and power cables across both domestic and international markets. In the overhead conductors segment, major orders are towards supply of conductors for Tariff Based Competitive Bidding (TBCB) transmission projects and green energy transmission projects. We have also received India’s first 144-fiber count OPGW cable order from a state utility. In power cables, the major orders secured are for supply of Medium Voltage (MV) cables under the Government of India’s disaster management scheme which is aimed at providing uninterrupted and reliable power supply in disaster-prone areas.

Additionally, the specialized EPC services business which focussed on providing upgrade and uprate solutions for existing transmission lines has bagged a significant order to upgrade two vital 66kV lines for a state utility. With a strong order pipeline and increased demand, Sterlite Power Transmission is set to continue its upward trajectory.

WCI: Please walk us through your unique manufacturing setup. What new technologies have you invested in to cater to the demanding market?

RM: Our world-class manufacturing setup is designed to meet the evolving demands of the power transmission sector. We manufacture products ranging from conventional conductors to high performance conductors, power cables and OPGW at our state-of-the-art manufacturing facilities located in Silvassa, Jharsuguda and Haridwar. To cater to the evolving market needs, we have made significant investments in capacity expansion and new age technologies. Digitization in the production process, driving automation and in-process monitoring of production metrics like OEE are some of the initiatives which have invested in. These initiatives will enable us to march towards our philosophy of having a lean production system.

Moreover, our commitment to sustainability remains a central pillar of our strategy. Our investment in green technologies is also reflected in our manufacturing facilities, where we have implemented rooftop solar systems, water harvesting and waste recycling initiatives. These measures not only contribute to a reduced carbon footprint, but also ensure that our operations are environmentally responsible and sustainable. By embracing new age technologies and sustainability, we continue to drive the power transmission industry forward, positioning ourselves as leaders in an ever evolving global market.

Also Read: Powering the Future: APAR’s Innovations in Energy Transmission

WCI: What are some of the major challenges you are experiencing in the market?

RM: The major challenges which we have been experiencing primarily stem from the rapidly evolving energy landscape and the growing demand for infrastructure that supports the integration of renewable energy. One of the key challenges is the need for grid modernization to accommodate the increasing transmission capacities required for renewable energy sources. This often involves overcoming limitations posed by legacy infrastructure and navigating regulatory complexities, especially in regions with stringent environmental regulations or land acquisition hurdles. In India, for instance, right-of-way (ROW) and land scarcity significantly impact the expansion of high-voltage transmission networks.

Additionally, the aging infrastructure in rural and remote regions is proving inadequate to meet the surging energy demands, which is putting immense pressure on existing grids.

As India continues its renewable energy transition, the need to upgrade the grid infrastructure to accommodate intermittent renewable energy sources becomes a critical challenge. This evolution demands modernization across both high-voltage and distribution networks, addressing the constraints of legacy systems.

Another challenge is around global supply chain disruptions, particularly in securing raw materials and managing lead times for critical components which continue to pose operational challenges.

With the right technological innovations, strategic investments and strong partnerships, we are well-positioned to address these market hurdles, while contributing to the development of a more resilient and sustainable energy infrastructure for the future.

WCI: Where do you see the market headed in the next 5 years, in terms of growth, innovations, technology integration and new challenges? How do you see yourself in that landscape?

RM: The wire and cable market is set for a robust growth with a projected compound annual growth rate (CAGR) of 8-10 percent in India and 6-8 percent globally. The demand will be primarily driven by expansion of renewable energy integration, grid modernization and urban infrastructure development.

In terms of innovation, we expect a surge in the adoption of high-performance conductors and specialty cables, which can provide higher ampacity and efficient transmission solutions. These technologies are pivotal in enhancing transmission capacity, supporting grid resilience and facilitating the integration of renewable energy. With the growing complexity of grid infrastructure and the need for space-efficient solutions, especially in densely-populated or environmentally-sensitive regions, we foresee the demand for products that optimize grid capacity, while reducing environmental impact.

Sterlite’s commitment to innovation and the constant endeavour to offer solutions which can address the modern-day problems ensures that we continue to remain pioneers in the industry. Our product portfolio consists of a wide variety of products ranging from traditional conductors and cables to high-performance conductors, specialized cables and OPGW, proving our mettle to cater to varied requirements. Our specialized EPC service wing enables reconductoring of the existing infrastructure and delivering higher efficiency without significant line stoppage. Looking ahead, we are confident that our commitment to innovation, technology-driven solutions and a focus on sustainability will position us as leaders in the evolving energy landscape and eventually realize our goal of becoming one of the world’s top 10 wire and cable companies.