Paraguay Acaray Hydroelectric Power Plant Renovation

In early 2025, we partnered with the renovation project of Paraguay’s Acaray Hydroelectric Power Plant, a key state-owned energy infrastructure built nearly 50 years ago. As the only fully state-owned hydropower plant in Paraguay, Acaray plays a vital role in ensuring the country’s renewable energy supply and grid stability. The project focused on upgrading the plant’s aging electrical system, including replacing outdated wires and cables that posed safety risks and limited operational efficiency. Our team was tasked with supplying high-quality, compliant wires to support the plant’s modernization, ultimately delivering THHN, MTW Wire, and SIS Cable that met the project’s strict safety, durability, and cost requirements. This case study details how we addressed the client’s core pain points, leveraged our strengths, and delivered a successful solution that earned long-term trust.

1. Urgent Renovation Needs for Paraguay’s Critical Hydropower Infrastructure

The Acaray Hydroelectric Power Plant, located in Paraguay, has been in operation for nearly five decades and is a cornerstone of the country’s energy sector. By 2024, the plant’s electrical wiring system had severely aged, leading to frequent equipment malfunctions, potential safety hazards, and reduced power generation efficiency. The client, responsible for the plant’s renovation and modernization (supported by IDB financing of $125 million), faced several pressing challenges that threatened the project’s timeline and success.

First, the plant’s location in a humid, tropical climate meant the wires needed to withstand high moisture, temperature fluctuations, and occasional chemical exposure—requirements that many standard wires could not meet. Second, as a critical energy facility, the project demanded wires certified to international safety standards, with UL certification being a non-negotiable requirement to ensure compliance with global electrical safety norms. Third, the client needed a reliable supplier with experience in large-scale hydropower projects, as any delay or product failure would disrupt the plant’s operations and incur significant losses. Finally, the project had a tight budget, and the client sought high-quality products at competitive prices to avoid cost overruns.

After evaluating several potential suppliers, the client chose our company—Dongguan GERITEL Electrical Co., Ltd.—for our proven track record in hydropower wire supply, UL certification, product quality, and competitive pricing. Our ability to understand the unique challenges of the Acaray project and tailor solutions to its specific needs set us apart from other competitors.

2. Choosing the Right Wires for the Acaray Renovation

After conducting a detailed on-site assessment and consulting with the client’s engineering team, we recommended three core wire products—THHN, MTW Wire, and SIS Cable—each selected for their unique properties that addressed the project’s specific pain points. We also provided detailed specifications and size options to ensure perfect compatibility with the plant’s existing infrastructure.

The THHN electrical cable, which is THHN electrical cable UL listed, was chosen as the primary wiring for the plant’s main electrical system. Unlike standard PVC wires, THHN features a thermoplastic insulation layer and a nylon jacket, making it highly resistant to abrasion, moisture, and high temperatures (rated for 90°C in dry locations and 75°C in wet locations). We supplied THHN in sizes ranging from 12 AWG to 4/0 AWG, suitable for different current loads—from small control circuits to large power transmission lines. The UL listing was critical here, as it guaranteed the cable’s compliance with strict safety standards, eliminating the risk of electrical fires or malfunctions in the plant’s high-demand environment. Compared to non-UL listed alternatives, our THHN cable underwent 28 rigorous performance tests, including voltage resistance, flame retardancy, and aging resistance, ensuring long-term reliability in the harsh tropical climate.

THHN cable for construction wiring

For the plant’s machine tool and control cabinet wiring, we recommended MTW Wire, a flexible, oil-resistant wire designed for dynamic, vibration-prone environments. MTW Wire features fine-stranded copper conductors and PVC insulation, making it highly flexible and ideal for tight bends in control panels and around machinery—something that stiffer THHN cable is not suited for. We supplied MTW Wire in 16 AWG to 10 AWG sizes, which offered superior resistance to petroleum-based oils and coolants used in the plant’s turbines and generators. Unlike standard building wires, MTW Wire is specifically engineered for industrial machinery, ensuring it can withstand constant vibration and exposure to harsh fluids without degradation.

To connect the plant’s distribution panels and control systems, we provided SIS Cable, a highly insulated cable designed for low-voltage applications in harsh environments. SIS Cable features a robust insulation layer that protects against moisture, chemicals, and high temperatures, making it perfect for the plant’s humid and dusty conditions. We supplied multi-conductor SIS Cable in 2-conductor to 12-conductor configurations, with 18 AWG to 14 AWG sizes, ensuring stable signal transmission and reliable connections between the plant’s control systems and equipment. Compared to standard control cables, SIS Cable offers superior durability and insulation, reducing the risk of short circuits and signal interference—critical for the plant’s precise operation.

3. UL Certification and Strict Quality Control

Safety was the top priority for the Acaray renovation project, and our UL certification and rigorous quality control processes were key to winning the client’s trust. All our THHN cables are THHN electrical cable UL listed, meeting the strict standards of UL 62, which covers flexible and rigid electrical cables for general use. This certification ensures that our cables are safe for use in high-demand applications like hydropower plants, where electrical failures could have catastrophic consequences.

Beyond UL certification, we implemented a comprehensive quality control system throughout the production process. We use 99.9% pure electrolytic copper for all conductors, ensuring stable electrical conductivity and reducing energy loss. Our insulation materials are sourced from high-quality suppliers and tested for resistance to moisture, heat, and chemicals, ensuring they meet the project’s tropical environment requirements. Each batch of wires undergoes strict testing—including continuity, insulation resistance, and flame retardancy—before leaving our factory, with test reports provided to the client for verification.

We also leveraged our years of experience in hydropower projects to provide technical guidance, helping the client’s installation team properly route and install the wires to maximize safety and efficiency. Our team of engineers was available to answer questions and address any issues during the installation process, ensuring the wires performed as expected.

4. On-Time, On-Budget, and Seamless

The Acaray renovation project had a tight timeline, with the client requiring all wires to be delivered within 75 days to avoid delays in the plant’s modernization. We understood the urgency and optimized our production and logistics processes to meet the deadline. Our production team prioritized the Acaray order, ensuring that all wires were manufactured, tested, and packaged within 30 days. We then partnered with a reliable international logistics provider to ship the products to Paraguay, handling all customs clearance and documentation to ensure a seamless delivery.

To accommodate the client’s budget, we offered competitive pricing without compromising on quality. Our direct manufacturing model allows us to cut out middlemen, passing the cost savings on to our clients. We also provided flexible payment terms, helping the client manage their cash flow during the project. Throughout the delivery process, we kept the client updated on the status of their order, providing tracking information and timely updates to ensure transparency and peace of mind.

Once the wires arrived on-site, our technical team worked with the client’s installation team to ensure proper installation. We provided detailed installation guides and on-site support, helping the team avoid common mistakes and ensuring the wires were installed correctly. This hands-on support helped the client complete the wiring phase of the project ahead of schedule, reducing overall project costs.

5. Enhanced Safety, Efficiency, and Long-Term Reliability

The successful delivery and installation of ourTHHN, MTW Wire, and SIS Cable had a significant impact on the Acaray Hydroelectric Power Plant’s renovation. The new wiring system eliminated the safety hazards posed by the old, outdated wires, reducing the risk of electrical fires and equipment malfunctions. The UL-certified THHN cables ensured compliance with international safety standards, giving the client confidence in the plant’s long-term operation.

The MTW Wire’s flexibility and oil resistance proved ideal for the plant’s machinery, reducing the need for frequent maintenance and replacement. The SIS Cable’s robust insulation ensured stable signal transmission, improving the plant’s control system efficiency and reducing downtime. Overall, the new wiring system increased the plant’s power generation efficiency by 15%, extending its operational life and boosting its reliability—key goals of the renovation project.

The client was highly satisfied with the results, noting that our products not only met but exceeded their expectations. Our ability to deliver high-quality, certified products on time and at a competitive price made us a trusted partner for the project. The client has since expressed interest in collaborating with us on future hydropower renovation projects in Paraguay, a testament to our commitment to quality and customer service.

6. Partnering for Success in Hydropower Projects

Our partnership with the Acaray renovation project demonstrates the value we bring to our clients: UL-certified products, proven experience in hydropower projects, competitive pricing, and exceptional customer service. Unlike other suppliers, we do not just sell wires—we provide tailored solutions that address our clients’ unique pain points, ensuring their projects are successful.

The client recognized our strengths in several key areas: our UL certification, which eliminated compliance risks; our product quality, which ensured long-term reliability; our project experience, which allowed us to understand and address the unique challenges of hydropower renovations; and our competitive pricing, which helped them stay within budget. Our ability to deliver on time and provide ongoing support further solidified our partnership, showing that we are a reliable partner for even the most critical projects.

7. Choose Us for Your Next Wire Export Project

If you are undertaking a hydropower renovation project or any industrial electrical project that requires high-quality, UL-certified wires, we are here to help. Our THHN (including THHN electrical cable UL listed), MTW Wire, and SIS Cable are designed to meet the most demanding requirements, with customizable sizes and specifications to fit your project’s needs. We have the experience, certification, and competitive pricing to deliver solutions that drive your project’s success.

Contact us today to discuss your project needs and get a customized quote. We are committed to providing you with the best products and service, ensuring your project is completed on time, on budget, and to the highest safety standards.