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Unit 3 of the Dave Johnston Power Plant east of Glenrock, WY, USA had problems staying at or below the opacity limits set by the state. The unit makes use of a Lodge Cottrell precipitator. When the plant changed to burning Power River Basin coal, ash buildup became a significant issue as the fly ash control system was unable to properly evacuate hoppers on the unit. To overcome the problem, the PLC on the unit was replaced with a software optimization package called SmartAsh for the precipitator fly ash control system, at a cost of $500,000. After the upgrade, there have been no plugged hoppers and the opacity has been reduced from around 20% to 3-5%. 2 figs.