2026. VENEZUELA
Proyelec executed a set of specialized electrical engineering works at the Coca-Cola FEMSA plant located in Maracaibo, intervening across three critical fronts: cable containment and routing in the ALPLA compressor room, preventive maintenance of the Main and ALPLA substations, and preventive and corrective maintenance of the SM-6 medium-voltage switchgear unit. The interventions were aimed at ensuring operational continuity, personnel safety, and electrical system efficiency, in compliance with KOF’s internal KORE standards and national COVENIN regulations.
▶ Feeder Routing and Retrofitting: Relocation and extension of the main feeders for the ALPLA warehouse, chiller, and Blower No. 4. Wear conditions in cabling, cable tray misalignment, and reduced space in distribution panels were corrected through compression splices with 1000 V heat-shrink insulation, new conductor routing respecting proper bend radii, and torque application per manufacturer specifications.
▶ Works at Height and Blower No. 4 Power Supply: Assembly of certified modular tubular scaffolding for work at heights up to 6.5 meters. For Blower No. 4, 11 conductors (9 phase and 2 ground conductors) were successfully recovered and pulled over 7 business days, connecting them to the 460/400 V step-down transformer and verifying the correct motor rotation direction.
▶ Electrical Substation Maintenance: Execution of preventive maintenance on the Main and ALPLA substations, including 1500 and 2000 kVA oil-immersed transformers, high-voltage disconnect switches, low-voltage switchboards, capacitor banks, and metering panels. Scope of work included de-energization, deep cleaning, blowing, mechanism lubrication, contact alignment, torque-controlled connection re-tightening, and electrical testing.
▶ Low and High-Voltage Equipment Servicing: On low-voltage circuit breakers, surface oxidation, carbonized dust buildup, and loss of lubricant were addressed via dielectric solvent cleaning, blowing, and re-lubrication with dielectric grease. During re-energization following Main Substation maintenance, a fracture occurred on the mobile closing guide of Circuit No. 2. Preliminary analysis points to bakelite embrittlement due to aging or cumulative fatigue. Immediate replacement with an original spare part was recommended, along with non-destructive liquid penetrant testing on the guides of Circuits 1 and 3, and operator training on maximum allowable manual closing force.
▶ Capacitor Bank and Metering Panel Diagnostics: Infrared thermography identified hotspots up to 65 °C on contactor terminals and fuses of Circuit No. 3 within the capacitor banks. Recommended actions included torque verifications, contact wear inspections, follow-up thermographic scans at 15 days and 3 months, and enclosure ventilation improvements. In the ALPLA metering panel, conductive dust accumulation was detected on secondary current transformer (CT) terminal blocks along with two loose screw connections, prompting immediate deep cleaning and corrective torquing.
▶ Transformer Testing and Diagnostics: Transformer Turns Ratio (TTR) testing yielded maximum errors of 0.27%, well below the 0.5% regulatory threshold, resulting in approval for all transformers. Polarization Index (PI) values ranged between 1.57 and 2.20, meeting the minimum regulatory limit (>1.25); however, TX2—with a PI near 1.5—exhibited a condition consistent with incipient thermal aging or moisture absorption, warranting semi-annual monitoring. Additionally, a critical discrepancy was identified on the ALPLA transformer: the nameplate indicates vector group Dyn5, whereas the actual configuration corresponds to Dyn1; immediate nameplate replacement was recommended.
▶ Grounding System Verification: Earth resistance measurements yielded values of 0.2 ohms, reflecting excellent performance and staying well below the maximum 5-ohm regulatory limit.
▶ MT SM-6 Medium-Voltage Switchgear Maintenance: Comprehensive preventive and corrective maintenance was performed, including deep component inspection and cleaning, opening/closing mechanism verification, contact adjustment, dielectric lubrication, operational and grounding tests, and minor fault troubleshooting. No major issues were reported during the intervention. The service value was USD 9,949.55 plus VAT, totaling USD 11,541.48.
▶ Testing, Safety, and Technical Equipment: Insulation resistance tests (megger testing) yielded excellent values, confirming the dielectric integrity of the serviced circuits. Motor rotation verification for Blower No. 4 confirmed proper phase sequence and operation. Operations adhered to strict safety protocols, including LOTO, Job Safety Analysis (JSA), high-altitude work permits, personal protective equipment (PPE), and resulted in zero accidents or incidents. Diagnostics utilized calibrated equipment, including Megger MIT515, TTR310, HIKMICRO thermal imaging camera, and temperature/humidity sensors.
▶ Recommendations and Follow-Up: An action plan was established for Coca-Cola FEMSA, incorporating single-line diagram updates, a semi-annual megger testing program, thermographic inspection under 70% plant load, oil sampling for dissolved gas analysis (DGA) within 3 months, ALPLA transformer nameplate replacement, reduced maintenance intervals (semi-annual) for legacy disconnect switches, and annual predictive maintenance for the medium-voltage switchgear.
The comprehensive intervention executed at Coca-Cola FEMSA enhanced the reliability of its low- and medium-voltage electrical infrastructure, spanning feeder containment and retrofitting to the diagnosis and maintenance of transformers, disconnectors, capacitor banks, metering panels, and the MT SM-6 medium-voltage switchgear. The timely identification of critical conditions and implementation of a structured follow-up plan provide KOF with a more reliable, measurable, and sustainable electrical system over time.