Tennessee Valley Authority Crane Modernization at Chickamauga Dam
Our team at DESHAZO has partnered with Tennessee Valley Authority (TVA) for over 25 years, modernizing aging hydro dam cranes to meet today’s demanding standards. A standout project at Chickamauga Dam involved upgrading an 80-year-old 275-ton powerhouse crane.
Tight access required innovative solutions: instead of costly roof removal, our teams engineered a method to dismantle and lower massive components through a confined hoist well. Unexpected discrepancies in historical drawings meant some parts were heavier than anticipated, demanding on-the-fly adjustments.
Despite added complexity, we delivered a modern crane system with advanced controls, ensuring reliable operation for decades to come. This project exemplifies our collaborative spirit, in-house manufacturing capabilities, and commitment to solving unique challenges — safely, cost-effectively, and the right way, every time.
Conditions inside the original operator cab were uncomfortable and offered limited views of the facility.
After modernization, the new operator cab offered increased operator visibility, internal heating & cooling unit, and a cab chair mounted control console.
Water weight load testing after the completion of all modernization ensures this crane system is both safe and efficient for every day use.
Modernizations included rebuild and repair of the crane's existing 80-year-old end trucks to ensure efficiency and safety.
The Opportunity
TVA required modernization of an 80-year-old powerhouse crane at Chickamauga Dam to meet current operational, safety, and reliability standards. The powerhouse’s confined geometry prevented conventional methods like roof removal, necessitating innovative rigging and handling techniques. TVA sought a partner capable of executing complex mechanical, structural, and electrical upgrades in restricted spaces while minimizing costs and downtime.
Our Solution
Leveraging over 25 years of partnership with TVA, we engineered a tailored solution. Instead of dismantling the roof, we developed a method to disassemble and extract heavy crane components through the powerhouse’s limited hoist well access. During execution, our team discovered discrepancies between legacy drawings and actual conditions, with some crane assemblies significantly exceeding expected weights. Our team responded in real-time, segmenting large assemblies into smaller, manageable pieces for safe rigging and transport. The project included installation of new inverter-duty motors, updated gearboxes, variable frequency drive (VFD), and complete electrical rewiring, all engineered and manufactured in-house to meet TVA’s precise specifications.
Critical innovations in this project included:
- Custom procedures for lowering massive components through confined hoist wells, avoiding costly structural demolition
- Integration of inverter-duty motors and VFD technology for improved control and efficiency
- Replacement of obsolete wiring and controls to meet modern operational and safety standards
- New operator cab assembly with operator’s chair and cab controls
Key Takeaways
This project showcases our capability to deliver highly customized, technically demanding crane modernizations, even under the most challenging physical constraints.
- Technical Ingenuity
Complex rigging solutions eliminated the need for costly structural demolition. - Real-Time Problem-Solving
We adapted to unanticipated weight variances without compromising safety or quality. - Integrated Execution
In-house engineering, fabrication, and field services ensured precise quality control and schedule adherence. - Customer Collaboration
Our team's continuous engagement with TVA enabled tailored solutions and maintained operational trust.
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