Project Overview
A glass manufacturing plant in Cuautla, Mexico, needed to upgrade its existing 13.8 kV backup power infrastructure. The legacy system relied on obsolete controls that required manual operation, causing extended downtime during utility outages which directly impacted continuous melting furnaces and thermal processes.
Orange Power Systems was selected to engineer and integrate a complete control system modernization (retrofit) without replacing the expensive medium-voltage switchgear, minimizing both capital investment and plant downtime.
System Overview
| Feature | Detail |
|---|---|
| Location | Cuautla, Mexico |
| Industry | Glass manufacturing |
| Application | Brownfield modernization, MV synchronization |
| Voltage | 13.8 kV (Medium Voltage) |
| Backup generation | 2 × 2,000 kW (13.8 kV) |
| Utility connection | 1 × 13.8 kV Incomer |
| Project type | Turnkey control system retrofit |
The Challenge
Glass manufacturing requires strict temperature control. Prolonged power outages not only halt production but can cause catastrophic equipment damage if molten glass solidifies within the processing equipment.
The challenge involved:
- Replacing obsolete mechanical relay logic with modern automation
- Implementing automatic synchronization and closed-transition with the utility grid
- Avoiding the replacement of the existing medium-voltage switchgear and power cabling
- Executing the complete modernization during very short maintenance windows
- Providing operators with a modern SCADA interface for monitoring and control
The Solution
Instead of proposing new power equipment, Orange Power Systems engineered a controls upgrade package that integrated directly into the existing medium-voltage cubicles.
The solution included:
- Master synchronization controllers integrated into the existing switchgear
- Upgraded control systems for the two 2,000 kW diesel generators
- Local HMI interfaces installed on the switchgear doors
- Plant-based SCADA integration for remote operation
- Rewiring of control circuits while keeping the medium-voltage buses intact
How the System Operates
The modernized system operates entirely automatically. During a utility failure, the control system starts the two 13.8 kV generators, synchronizes them together on a parallel bus, and safely feeds the critical plant load.
When utility power returns, the control system synchronizes the generator bus with the utility grid, performs a closed-transition transfer without power interruption (bumpless transfer), and seamlessly unloads and shuts down the generators to return to normal standby state.
Scope of Work
- Reverse engineering of the existing system
- Control and instrumentation design
- Fabrication of automation panels and retrofit doors
- On-site mechanical and electrical installation
- PLC and HMI software development
- SCADA monitoring system
- Medium-voltage commissioning and synchronization
Results
- Guaranteed continuity — Automatic transitions ensure thermal processes and glass melting remain stable during utility events.
- Capital savings (CAPEX) — The retrofit approach saved significant capital compared to replacing the 13.8 kV switchgear entirely.
- Minimal downtime — The project was phased during scheduled plant shutdowns to avoid impacting production.
- Modern operation — Operators now have full plant visibility through a state-of-the-art SCADA platform.
