Leveling Up

Gallatin Fossil Plant’s New Digital Control System Improves Reliability

When it comes to technology, change is inevitable. But with change comes new capabilities.

In keeping with a focus on continuous improvement, TVA launched a new digital control system for units at Gallatin Fossil Plant. The scope of the project included the replacement of network servers, workstations and network switches.

At its core, a digital control system manages and monitors the units. But this upgrade came with some enhancements that will allow the team to play back short segments of operation.

“This enhancement allows operators to pull that timeframe if there are any issues,” Brad Shultz, regional engineering manager, said. “It can simulate the exact operation of all the processes and actions operators took. Ultimately, it helps with advanced troubleshooting.”

The digital control system software has a life cycle of around eight to 10 years before reaching obsolescence. This is Brad’s third iteration of the upgrade, so he’s witnessed a lot of improvements over the years.

“We replace equipment and software so our units remain reliable,” Shultz said. “Also, there are a tremendous number of redundancies built into the system – an effort to keep the unit from getting to an unsafe position.”

The handoff between the old and new system is a complex process, involving many facets of plant operations. To streamline the upgrade, Shultz and his team devoted ample time to preemptive planning, ensuring they had workarounds for every process.

Alex Mendoza, an electrical engineer on the project, analyzed the impacts of taking down digital control system networks simultaneously – particularly how such a shutdown would affect plant processes.

“I developed alternate methods to control critical systems during the transition period,” Mendoza said. “Each project brings unique problems to solve, and I appreciate the chance to grow through collaboration with experienced colleagues. I find it fulfilling to contribute to a team that’s working toward improving operations and delivering results that matter.”

Shultz attributed the upgrade’s success to the seamless communication and efforts of his team.

“After the upgrade, we handed it back to the operators with complete confidence that there would be no disruption,” Shultz said.

Shultz’ attention to detail has left its mark in various places around the plant. From the cabling of motors to setting up the raceway belt in the coal yard, he has a propensity for spearheading improvements.

From his desk, he pulled a sheet of paper that showed something he felt particularly proud of – a complex diagram of plant activities. He had created it as a timeline to visually illustrate the careful coordination of unit outages, network outages and how they overlap.

“What I love about working at TVA is being able to design things like this,” Shultz said. “Overseeing technical construction and the fulfillment of seeing that in service – it’s amazing knowing you made a difference in a project.”