Placed on Light Duty at the Power Plant — Repost

Originally posted July 19, 2013:

In another profession being put on light duty may mean that you don’t have to work as hard as everyone else.  When an electrician is put on light duty it means something else entirely.  I think I calculated the number of lights at the plant and it was well over 10,000 light bulbs in the coal-fired power plant in North Central Oklahoma.  Ideally you would think that everyone of the lights should be in good working order.

Electricians don’t call a light bulb a light.  The light is the fixture.  The bulb is called a “lamp”.  So, for the rest of this post I’ll call the light bulbs lamps.

You may think that it’s pretty straight forward to go change out lights (oh.  I mean… lamps), but it’s not.  You see, it isn’t like in your house where you have the regular light bulbs everywhere with just different shapes and wattage.  Sure, there were different Watts for the different lamps, but for a good number of the lights, they varied by voltage as well.   Not only that, but these lamps were different types of lights.  Most of which are not incandescent (well… now that the government has seen fit to force the lighting industry to stop making incandescent lamps altogether, I guess it wouldn’t seem odd to the younger folks).

A descriptive picture of an Incandescent lamp found at www.techlinea.com

A descriptive picture of an Incandescent lamp found at http://www.techlinea.com

In the office areas and places like the main switchgear 4 foot fluorescent lamps were used.  Each 4 foot fluorescent lamp is 40 watts.  Just because it is 40 watts, it doesn’t mean that the voltage is low.  It can take up to 650 volts to start up a fluorescent lamp.  A Fluorescent lamp actually has a gas in it that causes a coating on the glass to glow when a current flows across the gas.

A fluorescent Lamp

A fluorescent Lamp

Besides the typical fluorescent lamps, the majority of the rest of the lamps in the plant were various sizes of Mercury Vapor lamps.  (now replaced with Sodium Vapor).

Before you become all twisted about using Mercury Vapor to light up a power plant because of the environmental impact, I think I should point out that even though a fluorescent lamp is filled with an inert gas like argon, it is mixed with Mercury vapor as well, and the phosphorous coating on the glass has mercury in it also.  So, if you have fluorescent lamps in your house…. Well, there you go.  And you know those lamps that are used to replace your old incandescent light bulbs….. Yep… and they have other kinds of hazardous metals as well.

The thing about using Fluorescent lamps and Mercury Vapors and Sodium Vapor lamps is that they all use different voltages.  So, in order for them to start up and stay running, the voltages have to change from the start up voltage to the operating voltage.  Each lamp has it’s own transformer designed just for that one type of lamp.  It is placed in the light fixture for the lamp.

You can tell this is a 100 Watt Mercury Vapor lamp because of the 10.  If it had a 25, then it would be a 250 watt lamp.   Following the same logic if it has a 75 on it, then it is a 75 watt lamp..... oh...well.. the logic is there somewhere

You can tell this is a 100 Watt Mercury Vapor lamp because of the 10. If it had a 25, then it would be a 250 watt lamp. Following the same logic if it has a 75 on it, then it is a 75 watt lamp….. oh…well.. the logic is there somewhere

If the light glows blue, then it is mercury vapor.  If it is orange then it is a sodium light.  Your street lights are the same way.  Well.  Now there is also Halogen lamps which shine white.

Besides these different type lamps, we also had some super special lights.  We have the flashing lights on the smoke stack and the red blinking light on the top of the radio tower.  The lights that flash on the smoke stacks are really flashbulbs.

A flash tube used in a smoke stack beacon that can easily be seen 50 miles away at night.  Especially when the day time setting is still on

A flash tube used in a smoke stack beacon that can easily be seen 50 miles away at night. Especially when the day time setting is still on

Our smoke stacks are 500 feet tall with beacons at the 250 foot level and the 500 foot level.  Not only did you have to change out the bulb, but you often had to change out the large capacitors and the circuit boards that had been fried by a passing lightning storm.

You may have heard that with the older style Television sets that had a picture tube (before the flat screen TVs came around), that you could electrocute yourself by taking the cover off the back of the TV and working on it, even though you unplugged the set from the wall before you started.  A few movies used this in the plot.  Robert T. Ironside even used it once in an episode during the first season.

Robert T. Ironside played by Raymond Burr

Robert T. Ironside played by Raymond Burr

Well.  The Stack lights are like that.  When we opened up the light fixture to work on the flash tube or the circuits inside the first thing you did was take a metal rod with a wooden handle and a wire attached with a clip on the end and clipped the wire to the handrail.  Then turning your head the other way, you placed the metal rod across each of the large capacitors in the box.   Invariably, one of the capacitors would let out a loud pop that would echo across the lake…. oh, and leave your ears ringing.

Once the voltage was discharged from all the capacitors, you knew it was safe to go to work fixing the light.  The lights had a day and a night mode, and the difference was how many times the flash tube flashed when it discharged.  What I mean to say is that it wasn’t just one flash.  It is really a series of flashes closely timed to look like one flash.  The number of flashes and the timing between the flashes determine how bright the flash is.

At night the flash was much dimmer because it didn’t need to be so bright.  When it was stuck in the day mode at night the farmers for a 30 mile radius would be calling saying they can’t sleep because every 6 seconds their bedroom would light up as the smoke stack lights would blink.

The Lake on a hill with the power plant in the distance at sunset

The Lake on a hill with the power plant in the distance at sunset

I thought I would just put that picture in there so you could see how pretty the plant looked from across the lake at sunset.  To me it looked like a big ship on the horizon.

I mentioned above that there was a radio tower that had a light on it that needed to be changed when it burned out.  The actual lamp looked a lot like a regular incandescent bulb in your house, but it was different.  It was designed just for this job.  It didn’t burn out very often.  Ok.  I can see your look of disbelief, so here is a picture of one:

A radio tower light bulb

A radio tower light bulb

Yeah, looks just like something in your house.  Doesn’t it?

Anyway.  I changed out the light at the top of our radio tower which is only about 200 feet tall.  It looked like the following picture:

Our tower was like this only it didn't have a safety pole up the side for a lanyard.

Our tower was like this only it didn’t have a safety pole up the side for a lanyard.

I had to climb to the top of this tower to replace the red flashing light.  I was by myself when I did it.  Bill Bennett handed me the bulb that had been specially ordered and asked me if I would do it.  If not, they could call Oklahoma City and have the line crew come down and change it.  I told him I could do it.  The tower wasn’t that tall, and I had shimmied around the top of the smoke stack before at 500 feet with only a slight urge to panic.

I changed the lamp out without incident.  I know that some people have a much more interesting job changing these lights out than I had.  Our radio tower was only 200 feet tall.  Here is a video of someone that had to climb a tower 1768 feet high.  You can see the beacon when they reach the top of this radio tower:

Ok.  That is crazy!  Wouldn’t dropping someone from a helicopter onto the tower using a safety line be safer?

My last story about being on light duty at a power plant is about when Ted Riddle and I were working at the gas-fired power plant near Mustang, Oklahoma.  I talked about the time that Ted and I worked at this plant in the post “Working Power Plant Wonders with Willard Stark

While we were there after they found out that we were electric conduit running fools, they gave us all sorts of jobs running conduit all over the plant.  One job they showed us was in an area that was dark.  All the lights were out in this area.  The foreman explained where the light bulbs were kept.  They were just the regular incandescent lights like the normal lights you would have in your house.

Well… Ted and I had both been put on Light Duty at our plant, and we knew that when we went to change out one light, we were supposed to change out all the lights.  So, Ted and I each grabbed a box and a ladder and headed up to the boiler enclosure to change lights.

After lunch, the foreman came running up to us yelling, “What did you do?  You used up all of the light bulbs!”  Well.  Yes.  We had used up the lights, but now when you go up on the boiler you can see where you are going.  The foreman then explained to us  that this little plant didn’t have the same kind of budget that the new big plants had.  They couldn’t afford to just go around replacing all the lights whenever they burned out.  They only put in a light when someone has to work in that area.  We had lit the entire place up like a Christmas tree.

Ok.  Take a note Jan… Don’t replace all the lights if they are incandescent.

Ok (again), that wasn’t quite the last story.  Let me tell you some more about replacing Fluorescent lamps in our Coal-fired power plant.  When we were placed on Light Duty, we would grab a couple of boxes of 30 lamps from the pallet in the main switchgear and go to work.

In the main switchgear the lights were up high, so we used a 10 foot ladder with a stand on the top of it (No.  I don’t mean like a Deer stand…. geez… Power Plant men…. always thinkin’ ’bout huntin’).  Actually it is called a Platform ladder:

This is a 6 foot platform ladder.  Ours was 10 foot and very wobbly

This is a solid 6 foot platform ladder. Ours was 10 foot and very wobbly

I didn’t like using this wobbly ladder when I was by myself.  besides being wobbly, the thing weighed a ton.  So, I would take a smaller ladder and put it on top of the breaker cabinets and climb on top of them.  The only problem here was that I couldn’t get directly under the lights, so I would end up reaching out to one side to change a light while I was standing on a ladder on top of a seven foot cabinet.  Not a pretty sight if someone safety minded walked in.

I felt safer doing this than standing way up in the air on a 10 foot wobbly platform ladder.  I always had the feeling that if I sneezed, the ladder would topple over.

When we were done changing out fluorescent lamps, we usually had a stack of boxes of burned out lamps.  We couldn’t just throw them in the dumpster because they were a safety hazard as they were.  We had to break each bulb.  We found that we could take a box of 4 foot fluorescent lamps and back the truck over it and it would let out a low but loud boom that sounded like a cannon going off.

The ingenious electricians invented a bulb busting barrel where you slid one 4 foot bulb into a tube and then lifted a handle quickly, and it would explode the lamp in the safe confines of the metal barrel.  The end of the lamp may at times come shooting out the end of the tube, so you never wanted to be standing to that side of the barrel.  I would show you a picture of one, but I’ve never found another one like it.

So, if you were into breaking glass, this was the best part of being placed on Light Duty.  After a hard day of changing out lamps all over the plant, you could stand around in front of the electric shop and slide the lamps down a tube like mortar shell and pull the rod and…. Boom! A puff of Mercury Vapor released into the atmosphere a small cloud of dust…. repeat.

A Day in the Life of Power Plant Man and the Sign Hangin’ Chain Gang — Repost

Originally Posted July 21, 2012:

No one knows more about having to put up with the antics of Summer Help than the Power Plant Man Jim Heflin.  Though Jim wasn’t completely a True Power Plant Man, he was nevertheless certified as a Bonafide Caretaker of Summer Help Helpers.  I understood after a couple of years of being a Summer Help myself that the reason that Summer Help were called by that name was because they really did indeed need help.  Though some may think that this help could best be found in the company of a licensed Therapist, most of the time what they really needed was a good dose of Summer Help chores to keep them out of trouble and to teach them the fine art of labor in its most tedious and repetitious form.

Though I’m not sure, but it could have been Jim Heflin that talked Stanley Elmore into allowing the summer help to attach the signs to the barbed wire fence that surrounded the Electric Company property that enclosed the Power Plant itself as well as the lake that was built to be used as cooling water in the condenser.  I say that because it didn’t seem like it was a long time after I had answered the phone one day in the garage and I found Jim Heflin’s wife on the other end of the line calling to talk to Jim that we were assigned to the task of installing the signs.  Jim wasn’t in the shop at the time so she told me to tell Jim that his wife Brenda had called.

Well.  It just so happened that my girlfriend at the time (who I later married and lived happily ever after) and I had a joke character that we would talk about named “Brenda Bulldog”.  It is a long story to tell about Brenda Bulldog, so I’ll just say that it has to do with “Otto” in the Beetle Bailey Comic Strip, and his girlfriend “Polly Bulldog” who is always suspicious of another bulldog named “Brenda Bulldog”.  I’m sure that you all have the same sort of characters that you talk about in your family… um… don’t you?

Otto from the Beetle Bailey Comic Strip

So, obviously, when she told me that her name was Brenda, I just had to respond as Otto would respond.  So I said in a gruff but excited voice (rolling the “R” in the word Brenda in my throat), “Brenda Bulldog?!?”  Jim’s Wife responded by asking what I had said, so I responded back exactly as I had the first time, “Brenda Bulldog?!?”  Well, I guess she misunderstood my intentions because she sounded obviously disgruntled as she explained to me in no uncertain terms that she was not a bulldog.  I answered back by insisting that this was, “Brenda Bulldog!” She repeated again that she was not a bulldog and told me to just tell Jim to call her at home when he returned to the garage.

When Jim came back from the Maintenance Shop I told him that his wife had called, and I added, “By the way.  I called her “Brenda Bulldog”.  I explained to him that I just couldn’t help it when I heard her name was Brenda, I just had to say “Brenda Bulldog”.  I couldn’t help it.  It just came out.  He looked a little mystified by my explanation and quickly went into the office to call home.

I guess in hindsight, after having met Brenda in person it probably wasn’t a good idea to have called her “Brenda Bulldog”.  First of all, not only did Jim Heflin have the face that reminded you of a likable Basset hound, but Brenda really did kind of remind you of a bulldog.  If I had known that earlier, I am sure I would have insisted that she was Brenda Poodle.  That would be the most logical response given the circumstance.

Kind of like this

A couple of days later a pickup truck was backed up to the garage and in the back were bundles of thin metal signs.  Each sign was about the size of a piece of paper.  the sign was white and had red lettering.  There were two different signs.  One that indicated that this was the Property of the Electric company and that a person should only enter at designated areas.  The other had a set of warnings or rules, which I can’t remember anymore.

There were 4,500 of each type of sign.  It was our job to take the signs and to bolt them together with small nuts and bolts that were supplied in buckets.  As we bolted them together we placed them in boxes and put them in the truck, where we went around the fence line surrounding the lake and the plant and every third section of fence (about 30 feet) we would mount the sign onto the barbed wire fence.  It would take about 4,500 of each of the signs to completely cover the perimeter of the property.

In the back of my mind I could hear Jim Heflin say to Stanley Elmore after he hung up the call with his wife, “Stanley.  Wouldn’t it be a good chore for the summer help to hang all those signs around the 25 mile perimeter of the electric company property?”  And Stanley replying, “Jim!  That’s a brilliant idea!”

So began the long trek of hanging signs.  We had a small blue Mitsubishi Tractor that we used to travel around the fence line in areas where the truck couldn’t easily go.

A tractor just like this

It had a small trailer on the back of it that we would pile a bunch of sign assemblies (the two signs bolted together).  Then we would walk or ride behind the tractor as we went from fence post to fence post mounting the signs evenly between the posts every third section.

This was a brilliant way to teach the young and inexperienced summer help the art of patience as well as the art of subservience.  This way, later in life when the summer help became a Power Plant Man-in-Training, or even a mechanic or electrician and was asked to do something that may seem boring to the average citizen, all the summer help had to do was remember the time they had to hang 4,500 signs on barbed wire fences and even the most boring tasks seemed like an exciting ride on a roller coaster in comparison.  For those power plant men who knew me as a janitor, now maybe they can understand how I could find so much enjoyment sweeping the turbine room floor (about the size of a football field) over and over with a red dust mop.

Like this only with a mop handle

Anyway, during our time while traversing the wilds along the fence line, it gave the summer help time to think.  I was working with a good friend of mine by the name of Tim Flowers.  We had become friends while I had attended Oklahoma University in Norman my first year in college (before going to Missouri University in Columbia for my last 3 years).  So, my fourth year as a summer help, Tim came to work alongside me.

Jim Heflin and Ken Conrad (as well as Opal Ward — or was it Opal Brien at the time) used to take turns shuffling us around the fence line.  When we were with Jim Heflin we would spend our time in the intellectual pursuit of inventing new “Burning Cat” jokes.  This was a skill I had picked up from my father who was a Veterinary Professor at Oklahoma State University in Stillwater.  He had come home one day from work with the latest copy of a Veterinary journal.  In the journal was a set of “Burning Cat” jokes that he read to me.  I’m sure you must already know them.  There were jokes like, “Why did the Burning Cat cross the road?” “So that it could burn on the other side.”  Or “Knock, Knock”  “Who’s there?”  “Burning”, “Burning who?”  “Burning Cat.”  Or “What did one burning cat say to the other burning cat when he met him in a bar?”  “That’s silly.  Everyone knows that a burning cat can’t talk when they’re on fire.”

We made it a goal to come up with at least one new burning cat joke every day.  This came in handy later on when I was in my last year in college and I became known as the “Burning Cat Man” in Columbia, Missouri as I would tell burning cat jokes to the workers at the Subway every time my friend Ben Cox and I would go there to eat a sub sandwich.  And then I would be introduced as “The Burning Cat Man” when customers would come in while we were there.

When we were with Ken Conrad we would think about more esoteric subjects like, “What does a cow think about while it is chewing it’s cud?”

Hmmm…. What does he think about?

We would go on and on speculating “Maybe the cow is meditating about the full meaning of life and whether or not the self is the center of his being or is it somewhere else, or is it just that he’s thinking that his ear itches and he can’t reach it with his tail.  He can only twitch it”  We would think about these things as we would be passing some cows standing opposite across the fence.   We would wonder if they stood around trying to think up jokes that would entertain themselves since they had to stand out in the hot sun all day.  Maybe they thought about burning cats, or even chickens crossing the road.

At first we couldn’t tell if Ken was even listening to us until one time, the tractor started to swerve a bit and he pulled it to a stop so that he could turn around and tell us that we were the strangest bunch of kids he had ever run across.  But I could tell that we had started him thinking about it.  I’m pretty sure that it was on his mind for quite a while.  “What is that cow thinking about?”  Every once in a while I knew that Ken Conrad had gained some enlightenment because he would suddenly turn to me and say, “Hey Sweet Pea!”  And then he would grin real big.  Yep.  He knew.  The meaning of life was within his grasp.

Anyway, long story short, before all the signs were hung by the barbed wire with care, I went up to the main office and asked Eldon Waugh if I could talk to him.  He was the plant manager.  The one I often have referred to as the “Evil Plant Manager”.  Mostly because I think he would have liked that title.  He worked so hard to obtain it.

I asked him if he had an opening at the plant because I would like to go to work there permanently.  He said there was a janitor position opening up and if it was all right with Ken Scott he would hire me.  So he paged Ken and asked him to come up to his office.  When he arrived, Eldon asked Ken if he thought they ought to hire me because I wanted to work at the plant full time.  Ken said that he would be happy to hire me on as a janitor.

I don’t know if Ken realized at the time how much trouble I would cause in the years that followed, because I always had come across as a fairly decent person up to that point.  So I don’t know if he ever regretted his decision.  I’m pretty sure that Eldon did and I know that Bill Moler regretted it when he returned from his summer vacation to find me standing in the janitor closet across from his office.  He was none too happy about it.  Especially since he considered it his job to do the hiring for people in the maintenance shop.  Bill knew that I had already expressed my willingness to open my mouth and reveal my innermost thoughts right to someone’s face at the most inappropriate moments.  I used to explain that I took after my Italian Mother who always spoke twice before thinking.

That was how I was able to escape the sign hangin’ chain gang and became the Janitor that I was always meant to be!  Years later the words had worn off of the signs, but the white signs were still hanging from those barbed wire fences for as long as I can remember.  Now that I think about it, I wonder what Jim Heflin was thinking when I became a janitor and he still had to tote babbling summer helps around the wilderness in the hot sun with an endless supply of Burning Cat Jokes.  Was he wishing that he had thought twice before he spoke about having us hang the signs?  Or maybe he didn’t and I just imagined that he was slightly upset all because I had said those two impulsive words….. “Brenda Bulldog!”

 

Comment from previous Repost

  1. Ron   July 24, 2013:

    Good Story!
    I still remember my first job as a “Summer Student” at the Mustang Plant (1967). Ben Snow and I worked from the top of the turbine room crane and changed out all the burned-out light bulbs (1,000 watt incandescent). Boy – that was one HOT job!

What’s That Strange Power Plant Smell?

Given that a large Coal-fired Power Plant is like a small city complete with a water treatment system to supply drinking water to thirsty Power Plant Men, and it’s own complete sewage system to handle the volumes of human waste and toxic run-off, when I ask, “What is that strange smell?”  You may expect the answer to be something like “Honeysuckle ”   If you thought, rotten fish,  diesel oil, ozone or sweaty arm pits, you would, of course, be wrong.  Those are all the usual smells found in a Power Plant.  Every so often, a smell would come by that would make you stop in your tracks and wonder…. “What’s that strange smell?”

Over the course of the 20 years I worked in the Coal-fired Power Plant in North Central Oklahoma, there were times when a new smell would just come out of no where.  There were other times when they would sneak up on me gradually, so that I wouldn’t even notice them until they were gone….  Then I would wonder why it was that I didn’t notice them when they were there.

One such smell that stung me like a bee would happen when I was on overhaul and I was walking out to the precipitator all covered in a fly ash suit from head-to-toe wearing a full face respirator with duct tape around all of the seams.

 

This isn't me, this is just some other fortunate soul I found on Google Images

This isn’t me, this is just some other fortunate soul I found on Google Images

I was walking in the breezeway between the two boilers when I suddenly smelled a sharp sort of smell.  It was a strange chemical I hadn’t ever noticed before.  I looked around to see where it was coming from.  There wasn’t anyone around, and I didn’t see anything chemical spill in the area that would account for it.

As I walked toward the precipitator, I looked up as I walked under the surge bin tower in time to see an operator coming down the stairs.  He was smoking a cigarette.  Besides that, everything else looked normal, except that the smell was almost overwhelming me at that point.

I went and climbed in the precipitator where I worked until break.   When I came out, I blew myself off with a tiny instrument air hose that we kept on either side of the precipitator for just such an occasion.  After the fly ash had been blown off of my suit, I leaned forward and pulled my respirator off of my face and breathed the fresh air.

Later that week, when I was heading back out to the precipitator and had just left the electric shop all dressed up in my suit, I had a whiff of that same smell.  I couldn’t mistake it.  It was a unique chemical smell.  looking around, there wasn’t anyone or anything near me that would have been emitting such a toxic smell.

As I walked around the condenser to head toward the boiler, I saw that a couple of mechanics were carrying some planks of wood and laying them by the condenser in order to build a scaffold once they opened the condenser.  One of the guys was smoking a cigarette.  I wondered… Could it be a cigarette that smells so rancid?  It didn’t seem likely, since I began detecting the smell when I was more than 40 yards away from the operator when he was descending from the Surge bin tower.  I shouldn’t be able to smell a cigarette from that distance.

After a few more instances, I realized that it was cigarettes that I was smelling.  I was amazed by how far away I could detect a cigarette when I was wearing my respirator.  I figured that after it had filtered out all the particles bigger than 2 microns, the only particles and odors that were entering my respirator were easily detectable by my nose.  And they didn’t smell anything like a cigarette.

I became so astute at detecting smokers, that one time I was walking through the breezeway with an unfortunate contract worker that  had been commandeered to work with me, I was dressed in my fly ash suit and respirator. My helper wasn’t because he was going to be my hole watch while I was inside.  I suddenly smelled that, now familiar, scent.  I spun around once and then turned to the guy walking with me, who hardly knew who I was, and said, “Someone is smoking a cigarette!”

He looked around and no one was in sight.  He said, “There isn’t anyone here.”  I said, “Oh, there’s someone with a cigarette all right.”  About that time a truck pulled around the end of the precipitator about 50 yards away with a couple of welders pulling a welding machine behind.  Their windows were open, and hanging out of the driver side window was an arm, with a hand on the end holding a cigarette.  As it drove by us, I pointed to the cigarette and said, “See.  Cigarette.”  He kept insisting I couldn’t have smelled that cigarette that far away… But with my respirator on, I could easily smell it.

One of the other strange Power Plant smell that I encountered during my tenure at the Power Plant was also while I was wearing my respirator and working in the precipitator.  Only, I didn’t pay much attention to it until it was gone.  Then I did everything I could to find the source of that smell, because to me, it was a sweet smell of success, even though it smelled more like a sweaty arm pit, or maybe even something worse.

I mentioned this smell in the post: “Moonwalk in a Power Plant Precipitator“.  The precipitator is what takes the smoke out of the exhaust from the boiler, and collects it in hoppers and then blows it a half mile to a silo on a hill by the coal pile, where it is trucked away to be made into concrete.

It was my job during an outage to repair the inside of the precipitator, and I was always looking for ways to improve the efficiency of the ash gathering abilities of this large piece of equipment.

The plant has a similar electrostatic precipitator, only ours is twice as long

The plant has a similar electrostatic precipitator, only ours is twice as long

I knew at certain times during an outage that the ash that had built up on the plates would all of the sudden decide to cake up and fall off in chunks leaving a perfectly clean plate.  When that happened, then the odds of the precipitator running real well when we came back online was a lot better.

I also knew that after working long hours in the precipitator for a couple of weeks, I would feel all worn out like I had a flu.  I would have to drag myself out of bed in the morning and I would even catch myself falling asleep on my feet inside the precipitator while I was inspecting it.  I always figured it was just because we were working 10 or 12 hour days and I was getting older.  Yeah…. 30 years old, and I was feeling every bit of it.

Then one day when I went to the tool room to get a couple of boxes of respirator filters Bud Schoonover told me that he couldn’t give me the regular hepa filter that I was used to using.  I already knew that the regular filters weren’t good enough, so I asked him what else he had.  He said, “Well…… I have some of these here…”  I have mentioned that if Bud had been African American and a little bit skinnier and shorter, he would have been the spittin’ image of Aunt Esther from Sanford and Son’s.  He would make this same expression:

Aunt Esther from Sanford and Son

Aunt Esther from Sanford and Son

Bud handed me a box of filters labeled:  Organic Vapor Filter:

 

Like This filter, only without the purple plastic guard.  It had a cotton looking filter on the top

Like This filter, only without the purple plastic guard. It had a cotton looking filter on the top

It wasn’t exactly what I was looking for, but I didn’t have much choice.  I could see that it had a carbon filter on it as well as the regular filter, so I thought it would be all right.

The first thing I noticed when I stepped into the precipitator wearing the Organic Vapor filter was that the air inside the precipitator didn’t smell any different than the air outside.  I wasn’t used to that.  I was used to smelling a “boiler” sort of smell.  After a couple of weeks that smell would turn more rancid.  Sort of a sour smell.  When I noticed that I wasn’t smelling the sour smell I quickly broke the seal on my filter and sniffed the air to verify that the filter was really blocking the stench that built up in the precipitator the past few weeks.  Sure enough.

Then I noticed that I was no longer feeling tired in the morning.  I was able to work all day without feeling fatigued.  I came to the conclusion that whatever that smell was that was being blocked by this respirator had been causing me to feel ill.  Now that it was gone I was beginning to believe that 30 years old wasn’t that old after all.

I was already curious about the smell in the precipitator because I had noticed that after a day or so after it showed up, the ash would just flake off of the plates in the precipitator.  If we could find out what it was, maybe we could inject something in the inlet of the precipitator when it was online and needed to be cleaned after a bad start-up or after it had been running a while to make it run more efficiently.

So, I went to our resident Doctor of Chemistry, George Pepple.  I wrote a post about him, see “Power Plant Doctor Does a Jig in a Puddle of Acid“.  I explained to him about the smell and about how this particular filter filtered it out when a Hepa filter didn’t.  And the effect it had on the ash on the plates.  He listened intensely and I could tell that I had made him excited.  There are only so many chemicals a plant chemist deals with on a normal basis, so when Dr. Pepple had an opportunity to explore something new, he jumped at the opportunity.

When I took him to the precipitator, he could smell the odor even before we began climbing the stairs up to the open hatchways.  He described it as a sewage type of odor.  Which I hadn’t really thought of before, but come to think of it, that would explain why an organic vapor filter would work on it.  I suggested that the sulfur in the ash might be giving it that.

I had analyzed the chemicals that made up the coal that we received at our plant from Wyoming and I had tried to figure out how it might combine with moisture to create a new chemical.  George explained that when the coal burns under such a high temperature, a lot of the chemicals are sort of encapsulated in ways that are not easily predictable.

George suggested that we approach this as a Safety issue and contact the Safety Department in Oklahoma City and have them see if they can put an analyzer in the precipitator to detect the chemical.  When I contacted them, I talked with a lady called Julia Bevers (thanks Fred for reminding me of her last name).  She told me to call her when the odor was strong during the next outage and she would bring some chemical detectors to the plant and I could place them in there and let them run overnight to collect samples.

Julia had said that she had heard that I was known as “Mr. Safety” at the plant.  I don’t know why.  Maybe it was because I was in the habit of complaining.  And a number of the things I would complain about were safety issues.

Anyway, during the next outage as soon as I smelled the smell emanating from the precipitator I gave her a call and the next morning I received a call from Toby O’Brien, the Plant Engineer  Extraordinaire called me and told me that Julia the Safety Lady was there in his office looking for me.

Power Plant Engineer and Good Friend - Toby O'Brien

Power Plant Engineer and Good Friend – Toby O’Brien

So, I went to Toby’s office and met “The Safety Lady.”  I know I didn’t look at all like she expected.  I was in a worn tee-shirt, not tucked in (on purpose) and worn out steal-toed boots.   When I took her out to the Precipitator, I decided to take her through across the Turbine Generator room and out the Third floor to the boiler where we walked through the boiler and over to the precipitator up and down ladders.

When we walked across the Turbine Floor, I didn’t have my usual pair of ear plugs hanging around my neck (they were in my pocket).  As it was rather loud, Julia turned and said, “Shouldn’t we be wearing earplugs?”  I replied, “Huh?”  As if I couldn’t hear her.  – I just love playing Power Plant Jokes on people that don’t even know what you’re up to…  I’m sure when we were done, she went straight back to Toby and told him how shocked she was to find out how unsafe I was.  – Me trying to keep a straight face the entire time.

Earplugs on a cord that can be draped over your shoulders when not in use.

Earplugs on a cord that can be draped over your shoulders when not in use.

To shorten a longer story, Julia gave me some indicators that would detect two different types of chemicals that she thought may be the culprit.  I let the detectors in the precipitator overnight and then sent them back to Oklahoma City for analysis.  They both came back negative leaving us with a mystery chemical.

Anyway, I never did find out what was causing that strange smell….

There was another strange smell that used to pop up in the Electric Shop when I had first become an electrician, but that just turned out to be one of our fellow electricians that liked to walk up to a group of electricians standing around talking, and then let loose a “silent but deadly” and then walk away and stand from a distance to see our reaction.

I won’t mention who that was, unless someone would like to leave a comment about that below…..  Anyway.  we all knew who it was when that happened as the electricians would yell out his name as the crowd quickly dispersed.

I decided to take a different approach.  I would stand there thinking, trying to analyze the odor to see if I could tell what exactly this person had for supper the night before.  I could tell one day when I said “Beef Stroganoff” and his face turned red that I had guessed pretty close to the mark…..  That was the last time this noble Power Plant Man did that to a crowd of electricians….. at least when I was standing there… I can’t attest to any other time…. as I wasn’t there.

But I suppose that is proof that even early in my career I was interested in finding the source of that “strange smell”.

Power Plant Lock Out – Tag Out or Just Tag Out — Repost

Originally Posted July 12, 2013:

All safe electricians worth their salt know about OSHA regulation 1910.147(c)(3).  Only Power Plant electricians have learned more about OSHA regulation 1910.147(a)(1)(ii)(C).  Section 147 has to do with locking out and tagging a power source in order to protect the employees working on the circuit.  147(a)(1)(ii) says that Power plants are exempt from section 147.  In other words, if you are working in a power plant it is all right to have a less stringent lock-out/tag-out procedure in place than if you didn’t work in a power plant.

One of the first things I learned from Charles Foster, my foreman when I became an electrician was how to remove the “heaters” from a breaker relay in order to protect myself from an “unauthorized” operation of the breaker.  That means…. in case someone accidentally turned on the breaker and started up the motor or whatever else I was working on.  “Heaters” are what we called the overloads that trip a 480 volt breaker when the circuit uses more power than it is supposed to be using.  They are called heaters, because they literally “heat up” in order to trip the breaker.

typical 480 volt overload heaters

typical 480 volt overload heaters

Charles Foster told me the following story about my bucket buddy Diana Lucas (later Diana Brien):

Dee was wiring up a sump pump at the bottom of the coal dumper.  The motor had been taken out while the pump had been repaired.  Once back in place Dee was sent to wire it back up.  The proper clearance had been taken to work on the motor.  That is, she had gone to the Shift Supervisor’s office in the Control Room to request a clearance on the motor.  Then later she had witnessed the operator opening the 480 volt breaker and place the clearance tag on the breaker.

A typical Clearance Tag.  Our tags had the word "Clearance" at the top

A typical Clearance Tag. Our tags had the word “Clearance” at the top.  We called them a “Hold Tag”

the tag is signed by the Shift Supervisor and is only to be removed by an operator sent by the Shift Supervisor.  It is place through a slot in the handle on the breaker that keeps the breaker from closing unless the tag is removed first…. well… that’s the theory anyway.

Dee had just finished hooking the three leads in the junction box together with the cable coming into the box using two wrenches.  She reached down into her tool bucket that she was using as her stool to get some rubber tape to begin wrapping the connections.  The three bare connections were sticking out in front of her face.

A large vertical pump motor

A large vertical pump motor

The Junction box is the box on the right side of this motor.  At this point the cover would be off and the wires would be sticking straight out.  As she reached into the bucket, the motor turned on and began running.

Startled, Dee stopped what she was doing.  I suppose she also pinched herself to make sure she wasn’t dreaming.  Then I suppose she checked her diaper to make sure it was still dry.  Then I suppose she may have said a few choice words whether anyone was around to hear them or not.  Maybe not all in that order.

For those of you who don’t realize what this meant.  It meant that if the motor had started running about 5 to 10 seconds later, someone, some time later may have made their way down to the west end of the dumper sump only to find one charred Diana Lucas (who never would have later become Diana Brien).  They might not have recognized her at first.  I can assure you.  It wouldn’t have been pretty.

You see… someone had removed the Hold Tag and purposely started up the motor totally disregarding the clearance.  I won’t mention any names, but his initials were Jerry Osborn.

So, after Charles told me this story, he showed me what to do to prevent this from ever happening to me.

Charles and I went to the Shift Supervisor’s office to take a clearance on a motor.  Then we followed the operator to the breaker and watched him open the breaker and put the tag on the handle.  Then we signed something and the operator left.

After the operator left, Charles told me to open the breaker and slip the hold tag through the slot in the door so that the door could open without removing the tag.   I followed his directions.

Once the door was open, he told me to remove the three heaters on the bottom of the relay and hide them at the bottom of the breaker  box.

480 volt relay with the 3 heaters at the bottom.  That white square is an overload reset button. in front of the first heater

480 volt relay with the 3 heaters at the bottom. That white square is an overload reset button. in front of the first heater

You see… with the heaters removed, even if someone were to close the breaker and try to start the motor, the electricity would never leave the breaker box because I had just created an open circuit between the relay and the wires going to the motor.

Well… If you don’t learn from history you are bound to repeat it.  No.  I’m not going to change subjects and start talking about making it illegal to own guns.

Anyway, there is always a chance for something to go wrong.  The Peter Principle demands it.  So, at one point, someone forgot to replace the heaters in the relay before returning their clearance.  When the motor was tested for rotation, it didn’t work.  At that point the electrician knew that they had forgotten to re-insert the heaters.  So, they had to return to the breaker to install the heaters before the motor would run.

This didn’t set well with the Shift Supervisor, who has supreme power at the power plant…. well… besides the janitor who had total control over the toilet paper supply.  Technically we were not going around the hold tag by removing the heaters because they were downstream from the breaker handle which cut off the power to the relay.  The Shift Supervisor on the other hand believed that the hold tag included everything in the breaker box, including the relay and heaters (which really was stretching it).

An argument ensued that pitted the shift supervisors and the supervisor of operations, Ted Holdges with the electricians.  Ted argued that we should not be removing the heaters to keep ourselves from becoming electrocuted accidentally when someone inadvertently removes a hold tag and turns the breaker on and starts up a motor.  Electricians on the other hand argued that if we were going to be exposed to the possibility of being electrocuted, we would rather not work on any circuit.  Without being completely assured that we would not occasionally be blown to pieces when someone or something accidentally caused the circuit to become hot, we concluded it wasn’t worth it.

So, a compromise was reached.  We could remove the heaters, but they had to be put in a plastic bag and attached to the hold tag on the outside of the breaker.  That way, when the clearance was returned, not only were the heaters readily available the operator would know to contact the electrician to re-install the heaters.  The electricians didn’t really like this alternative, but we agreed.  We were assured that there wasn’t any way that a breaker was going to be turned on and operated with the heaters in them when someone was actually working on a circuit.

Fast forward three years.  1992.

Bill Ennis and Ted Riddle were working on replacing a large electric junction box on the stack out tower.  The Stack Out Tower is the tower that pours the coal out on the coal pile.  Halfway up this tower there is a large junction box where most of the electric cables passed through going to the top of the tower.  Bill Ennis had taken a clearance on a number of motor and control breakers.

Bill returned from lunch one day to work on the junction box, removing the old cables.  Putting new lugs on them and placing them in the new junction box. As he began working, he decided to take out his multimeter and check the wires he was about to work on….

We had a couple of these Simpson Analog Multimeters in the shop

We had a couple of these Simpson Analog Multimeters in the shop

Bill was surprised to find that one set of cables were hot.  They had 480 volts on them.  Everything in this box should have been dead.  I suppose he pinched himself to make sure he wasn’t dreaming.  Then I suppose he checked his diaper to make sure it was still dry.  Then I suppose he said a few choice words that Ted may have heard if he was standing close by.

What had happened was that there had been two clearances on this one particular motor.  One of the electricians had returned his clearance, and had installed the heaters that were in the plastic bag on the front of the breaker and the motor had been tested for rotation and put back in service.   The operator had taken both clearances off of the breaker by mistake.

Ok.  It was time for another meeting.  Something had gone wrong.  If it had not been for the guardian angels of both Diana Brien and Bill Ennis, at this point we would have had at least two dead electricians, and believe me…. I know that when an operator had later climbed the stack out tower to check the equipment, if he had run across the body of Bill Ennis… it definitely wouldn’t have been pretty (even on a good day).

I attended this meeting with Ted Holdges as did most of the electricians.  I began by telling Ted that when we had met three years earlier I was newly married and wouldn’t have minded so much if I was killed by being electrocuted because I was young and only had a wife who knew how to take care of herself.  But now it was different.  I had a little girl at home and I need to be around to help her grow up.

Ted looked surprised by my remark.  I had just told him the way I felt about this whole situation.  The argument that we were making was that we should be able to place locks on the breakers just like OSHA demanded from the other industries.  We had demonstrated that we didn’t have a system that would protect us from human error.  We needed something that definitely kept us safe.

We told Ted that even if we had locks, and for some reason the breaker just had to be closed and the electrician had forgotten to remove his lock, the shift supervisor could keep a master key in his office to remove the lock.  He finally agreed.  His problem was a loss of control.  The thought was that the Shift Supervisor had ultimate power.

If you don’t learn from history you are bound to repeat it.  No.  I’m not going to change subjects and talk about socialized healthcare and how it destroys all concepts of quality and privacy.

So, as electricians, we weren’t really happy with this situation.  We had a secret weapon against human error.  Sure we would place a lock on the breaker.  But after the operator would leave, before we placed our lock on the breaker, we might just open up the breaker box and remove the entire face off of the relay.  It was similar to removing the heaters only it was bigger.  It completely opened the circuit no matter what.

I hadn’t really planned on talking about this next story for a couple more years, but I’ll tell it now because it fits with this story.

In the month of May, 2001.  I had already given my notice to leave the plant to work for Dell as a software developer.  I was asked to work on a job with my old bucket buddy Diana Brien.

The problem was that there was a grounded three phase circuit up on the Surge Bin tower.  It had been tracked down to the dust collectors located below the surge bin conveyor floor.

Dee and I walked up to the Gravimetric feeder deck to look at the breaker to make sure it was turned off.  It had a Danger tag on it that had been placed by the Shift Supervisor.

A typical Danger tag used at the plant

A typical Danger tag used at the plant

The breaker was open and the message on the tag said “Do not close this breaker.  The circuit is grounded”.

Ok.  We walked up to the surge bin tower through the counter weight room for belts 18 and 19.  We opened up the big junction box that fed the power to the two large dust collector motors on the landing behind us.  After taking the cover off of the box, I took out my multimeter and checked the circuit.

Like this.  Ok.  So the multimeters had become more sophisticated over the years.

Like this. Ok. So the multimeters had become more sophisticated over the years.

The big copper bus was dead (that means, there was no electricity present).

So, Dee and I worked on locating the grounded circuit.  I had just removed the cover to the junction box on one of the motors while Dee was removing some wires from the control panel when  Larry Tapp arrived on the landing through the same route we had taken from the gravimetric feeder deck.

Larry asked us what we were doing.  We told him we were tracking down the ground on the Dust Collectors.  Larry looked surprised.

You see… Larry explained that he had just come from the Gravimetric feeder deck where he had just closed the breaker for the dust collectors.  This particular breaker didn’t have a relay, as it was controlled by the control panel where Dee had been working.

So, I rechecked the copper bus with my multimeter and it was hot.  480 volts hot.

I had just been looking through my tool bucket for two wrenches to remove a piece of the bus work just to make sure the ground wasn’t in the box itself when Larry had arrived.  In other words, if Larry had arrived 5 to 10 seconds later, he would have probably arrived to find Dee looking down at my body, stunned that I had just been electrocuted by a circuit that we had just tested and found dead.

If you don’t learn by history you are bound to repeat it.

You see… there is a difference between a Hold Tag and a Danger Tag.  A hold tag is placed on a breaker after someone has requested a clearance by signing a form in the Shift Supervisor’s office in the control room.  A Danger tag can be placed and removed at anytime by the person that placed the tag on the breaker.

So, I personally wrote this up as a “near” accident.  We could have wiped our brow, pinched ourselves to make sure we weren’t dreaming.  We could have checked our diaper to make sure it was still dry and then Dee could have said a few choice words that Larry Tapp would have agreed with (I have always had a mental block against expressing myself in that manner…. I found other ways).  And we could have left this incident as a secret between Larry, Dee and I.

I thought it was a good time to remind the electricians throughout power production to follow the clearance procedures when working on high voltage circuits.  Sure.  Dee, Bill Ennis and I have powerful guardian Angels looking out for us…. but gee… I think we should be expected to look out for ourselves.  So, I wrote up this incident to warn the rest of the team….. If we don’t learn from history, we are bound to repeat it.

I met with my roomie Steven Trammell, a month and a half later in Perkins Restaurant in Stillwater, Oklahoma to discuss his performance plan.  I was a 360 Degree Assessment Counselor and my favorite roommate from 17 years earlier had chosen me to review his performance appraisal.   During this meeting I asked Steven, who had driven from Harrah, Oklahoma from another power plant to meet with me, if he had read the near accident report about the dust collector at our plant.

My roomie told me that he had, and that he thought it seemed to unduly blame the electrician.  I told him I was the electrician and that I wrote the report.  After 18 years of being an electrician, I had become so relaxed in my job that I had become dangerous to myself and others.  So, after I did a cause-effect analysis of the near accident, most of the cause had come from my own belief that I could circumvent clearance procedures and save time and still believe that I was being safe.

On my drive back to the plant after the meeting with my favorite roomie of all time, I had time to think about this…. I was going to be leaving the power plant in a little over a month to work for Dell as a programmer.  I knew this when I had been negligent with the Danger tag.  I could have caused the death of both Dee and I.  I will sure be glad to be in Texas.  – Only..  I will miss my friends most of all.

I leave the Power Plant with this one thought…. If you don’t learn from history, you are bound to repeat it.  I mean it… This time I really do.

 

Comments from the original post:

  1. Ron Kilman July 13, 2013:

    This is a great story. I thank God for His guardian angels and I thank you for taking responsibility. It was always difficult investigating accidents because people are a little reluctant to share their mistakes with the world. But a wise man knows it’s better to have a bruised ego than a fried friend.

Larry McCurry July 13, 2013:

Kevin,

  1. As an old time operator and having follows in my fathers footsteps as a Shift Supervisor, The answer to all of these problems to add steps to the clearance procedure to make sure the heaters were removed and then replaced. The second was definitely an operator error, and I agree with you about it, The Shift supervisors did argue for it however the hubris of certain power hungry people managed to intimidate and control the situation. You do not ever work on equipment with out your own clearance or a plan that includes the SS, as you mentioned He is the operating authority, or was until a person by the initials of Jim Arnold rewrote the procedures and made himself the Authority.

Jack Curtis August 12, 2013:
Good Story Indeed.
There is, I’m sure, a gene in human DNA labeled: “Murphy” that assures that anything that can happen, does. And in total ignorance, I’ll bet that some constant percentage of plant electricians were fried. I suppose the onset of computer controls has reduced that but that it still happens at a lower rate. The way you and your friends sort of automatically reached for your multimeters is a clue! These are shocking, highly-charged stories…

Fast And Furious Flat Fixin’ Fools Fight the Impact of the Canine Parvovirus — Repost

Original Posted on July 13, 2012:

Three of the four years that I was a summer help working at the Coal-Fired Power Plant, I worked out of the garage.  Not only were we responsible for mowing the grass and cleaning up the park areas around the lake, we were also the Automotive Garage.  That is, we changed the oil and other fluids, charged dead truck batteries and washed the pickup trucks that were used at the plant and various other truck related jobs.  We also Fixed Flat Tires.

Something had happened the first summer when I worked out of the garage that greatly impacted the need for us to fix flats fast and furious.  It was a disease that was rapidly killing dogs in Oklahoma during the summer of 1980.  It was known as the Canine Parvovirus.  We had a puppy at home named Oreo that died that summer from this disease.  By the time the dog showed the symptoms of the disease, it was just about too late to save the life of the dog.  This leads me to introduce you to Doug House  (No, not Dog House.  I know you were thinking that because I had just mentioned the Parvovirus killing dogs and you may have thought I misspelled Dog).

It was Doug House that taught me the fine art of “Fixin’ Flats”.  Doug House and Preston Jenkins had been hired because of their automotive skills more so than their Power Plant Man Prowess.  Doug House was a few years older than my dad and his son was about the age of my younger brother.  He was from Louisiana.  He didn’t have a Cajun accent or anything like that (or maybe he did and I just didn’t know it).  He sounded like an interesting mix between Winnie The Pooh and Frosty The Snowman (if you can imagine that).  So, those power plant men that remember Doug, listen to these two voices and think of Doug (and I don’t mean Jimmy Durante who is singing the Frosty the Snowman song.  I mean the guy that asks “What’s a lamp post?”):

Winnie the Pooh

Watch the Video Here:

Frosty The Snowman

Watch the video here:  

The Power Plant was still under construction when I started working in the garage (my second summer) and this meant that there were plenty of nails, screws welding rods and other pieces of shrapnel strewn over the roadways, giving ample opportunity for flat tires.  We would often come into work in the morning to find one of the operators’ trucks that had developed a flat tire during the night shift parked in front of the garage waiting patiently for the flat to be fixed.

It seemed like the garage was filled with all the latest equipment for automotive maintenance, however, the flat fixing tools were mostly manual.  We did have air powered tools so that we could quickly remove the lug nuts from the tire.  From there we would add air to the flat tire so that it was pressurized enough to find the leak.  Then we would put it in a half barrel trough full of soapy water to see if we could see the air leaking, blowing soap bubbles.  Once the leak was found and marked with a yellow paint pen, the wheel was placed on a special stand that was used to remove the tire from the rim called a “Tire Dismounter”.

The stand used to remove the tire from the wheel

So, I became a Flat Fixin’ Fool.  And during the three summers that I worked repairing flats, I became pretty fast.  I loved fixing flat tires.  We used patches the first two years instead of plugs, which means that we fixed the flat from the inside of the tire by placing a patch over the hole inside the tire using special patches and rubber cement.

Tire Patch Kit

It wasn’t until the third summer working in the garage that I learned about plugs when my dad and I brought my uncle’s wheel to a garage to repair a leak and I was all ready to watch the repairman take the tire off of the wheel and repair it.  But instead, as soon as he found the hole, he just reached up to a shelf, pulled this black worm looking gooey thing and splashed some rubber cement on it and jammed it in the hole using some small kind of awl. Then took out his big pocket knife and cut off the part sticking out and handed the tire back to us and said, “No Charge”.  I was shocked.

Tire Plug Kit

My first thought was that I couldn’t figure out why someone wouldn’t go through all the fun of wrestling with the tire to remove it from the rim, then clamping it down so that you could easily reach the hole inside the tire with a wire brush so you could buff the spot clean, and then applying the patch and rolling over it with another special Tire Patch rolling pin.  My second thought was, “Why don’t we have those at the plant?”

So when I arrived for my last summer as summer help a couple of weeks later, I asked Stanley Elmore why we didn’t use Tire Plugs.  The next thing I knew, we had them.  Trucks could practically line up outside with their flat tires and you could run up to them with an air hose, fill the tire up with air, spray some soapy water on it until you found the hole, pulled out the nail and jammed a plug in it.  Take out your pocket knife, cut off the tail sticking out, and then yell “Next!”  At least that is what I dreamed about doing.  There was a little more work when it actually came down to it.

So, what does all this have to do with Canine Parvovirus?  You see, the Jackrabbit population in Oklahoma was being controlled by the ever elusive wily coyote.

No. Not this one. Real Coyotes.

The coyotes had caught the parvovirus and were being destroyed almost to the point of distinction by 1980.  The Coal-Fired Power Plant ground in north central Oklahoma became a veritable Shangri-la for Jackrabbits.  The plant grounds are in the middle of a wildlife preserve created by the Electric Company that not only made the wildlife preserve, but the entire lake where all sorts of animals lived.  None were more proliferate than the Jackrabbits.

Genuine Flying Jackrabbit found at http://www.richard-seaman.com

I learned a lot about wildlife working at this power plant.  For instance, This may be a picture of a Jack Rabbit, but Larry Riley could tell at 75 yards whether or not it was a Jack Rabbit or a Jill Rabbit.  Yep.  That’s what they called the female Jackrabbit.  There were Jack and Jill Rabbits.  I couldn’t tell the difference, but then half the time while Larry was pointing out a rabbit to me I not only couldn’t tell if it was a male or female, I couldn’t even see the rabbit because it was camouflaged in the dirt and weeds.

So, at this point you are probably wondering, “What does the multiplication of jackrabbits have to do with fixing flat tires?”  I was recently reminded by one of the most stellar of Power Plant Men Shift Supervisors, Joe Gallahar (notice how his name is only one letter away from “Gallahad” as in “Sir Galahad”), that the night crew of operators that brave the weather better than any mail carrier ever did, as one of their formidable duties had to perform Jackrabbit Roundup while riding three-wheel All Terrain Vehicles (ATVs).

A Honda Three-wheeler used by Power Plant Men in 1980

It was important that the Jackrabbits not become too complacent around humans in this wholesale bliss, so the operators obviously felt it was their duty to see that they received their proper quota of daily (or nightly) exercise by being chased by ATVs.  There were enough thorny plants spread around the grassless dirt that inevitably at least one three-wheeler would end up with a flat tire by the end of the night.  And that is how the Canine Parvovirus impacted the flat fixin’ focus of the garage crew.  Fixing three-wheeler balloon tires was a slightly different animal altogether, plugs didn’t work as well on these tires, but the patches did.

I seem to remember another Power Plant A-Foreman that reads this post that used to take his three-wheeler out by the blowdown water ponds during lunch time and hone his skills maneuvering around the berm surrounding the two ponds.  His tires often needed a quick patch job later in the day.  We later went to Four-Wheelers as the added stability proved to be a much needed safety improvement.

There was also a clandestine group of Coyote hunters at the Power Plant, though I didn’t know it at the time.  Before (and many years after) the Parvovirus took its toll on the Coyotes, a group of Coyote Hunters would patrol the wilderness looking for signs of the highly elusive coyote.  I first realized something was up years later when I was a passenger in a company truck on our way to the river pumps when the driver slowed the truck down to a crawl as he looked out the window at something in the middle of the road.  He put the truck in park, climbed out and picked something up next to the truck.  He showed it to me.  It was fecal matter left behind by some creature.  Andy Tubbs was sure it was Coyote Dung and he wanted it for some reason.

The True Power Plant Electricians, Andy Tubbs and Ben Davis were the “fearless Coyote Hunters”, who were on a constant vigil for Coyotes.  This also gave them a chance to give their Greyhounds an opportunity to stretch their legs and get some exercise as a trapdoor to the large wooden box in the back of the truck was sprung open and the Greyhounds went to work chasing down the coyotes and bringing them back to the truck waiting for them at the next mile section.  Stretched Coyote skins were sometimes hung up in front of the cooling fans on the main power transformer to dry.

Here is a motivational video of a man named John Hardzog (Not a Power Plant Man) that hunts Coyotes with Greyhounds:

http://video.nytimes.com/video/2010/04/26/sports/1247467638442/coyote-vs-greyhound-one-man-s-sport.html

Anyway.  the last I heard about Doug House was that he had moved back to Louisiana and is still there to this day.  I don’t really know what he’s doing these days as he would be in his low 80′s.  I do know that I enjoyed the sport that he taught me, and that was how to be a “Flat Fixin’ Fool”.

Another Interesting factoid is that by the time I finished writing this blog, it became July 14, 2012.  Bill Moler, the Assistant Plant Manager during the time that I was a summer help became 80 years old today (now 81. Since this post was originally posted a year ago).

Printing Impossible Power Plant Fast News Post

Tom Gibson, the Electric Supervisor at the Coal-fired Power Plant in North Central Oklahoma didn’t have a clue the large can of worms he opened the day in 1988 when he told me to find out all I could about the company computer in Corporate Headquarters…. The one that ran all the important financial systems for the company.  I remember going straight down to the Electric Shop office and sending a request for a username on the Honeywell Mainframe to the IT department, with Tom’s approval.

A Honeywell Mainframe computer

A Honeywell Mainframe computer

This story is a continuation of two previous stories…. Last week I wrote a post called: “Power Plant Customer Service Team Gone Wild“.  This is the next shoe that dropped in that story….  Earlier this year I wrote a post called:  “Toby O’Brien and Doing the Impossible“.  Well, this is the second story in the list of “Impossible Things” Power Plant Electricians were able to accomplish when others said it couldn’t be done.

As a reminder… and in case you didn’t read last week’s post…. as a summary….. let me just say that I had printed out a form on every printer in the company as part of a “Quality Idea” our team was investigating.  In doing so, I sent commands to the printers to change their quality settings, as well as the Font Size and a few other settings.  When I ran the little known command that sent the document to every printer listed on the mainframe, I didn’t realize that this included all the billing, paycheck and work order printers that all had their special kinds of paper and setting for those particular jobs to run.

This was probably the biggest “Faux Pas” (pronounced “Foe Paw” — yeah…. French… which literally means:  “False Step”) of my 18 years as an Electrician. Before I tell you about how the second shoe dropped… Let me explain that a few weeks before I had hit enter on the keyboard sending the disastrous command to the Mainframe, In September, 1993, I had found an interesting program on the Honeywell mainframe called “Magna 8″.

It had to do with creating reports from the main database.  This was the entire database that ran the Electric Company Business! I thought this would be a great program to learn in order to create all kinds of reports for our plant that would help us understand where our efforts were being spent.  I thought I might actually be able to tie our Maintenance Orders to the time the employees spent on them to their wages, and to the cost of the parts used….  Nothing like that existed at the time, and the little I was able to read from the Magna 8 User Manual on the mainframe, this seemed like just the ticket..

We had never heard of SAP, or other ERP systems at the time. — Oh… sorry… ERP stands for “Enterprise Resource Planning”.  It does just that.  It combines all the company’s business together in one application so that you can account for all the costs down to each machine, person, and part.   If I could learn more about Magna 8, maybe I could start piecing these pieces together from the database. I was having one problem…. When I would page down in the user manual, it kept skipping the bottom half of every page….

I couldn’t figure out how to stop it from scrolling past the second half of each page.  So, I called in a favor from the IT guys downtown and asked them if they could send me a printed copy of the Magna 8 User’s Manual.  They said they could be glad to send me a copy. About a week later, I received the User Manual through company mail.  It was about 4 inches thick.

There were different sections.  One was called:  “The Update Module”.  Yeah…. That’s right…. It was used to enter data into the database….  I thought about that module for about 2 seconds and decided I best stay away from that one.   Then there was the “Reporting Module”.

That was the one I was looking for. — on a side note…. I know “for” is a preposition, and I know you aren’t supposed to end a sentence in a preposition, however, who doesn’t say, “That’s what I was looking for”?  In these circumstances, I figure that I better approach it from a whole different angle…. like…. “That’s the section I really wanted.”  – End side note.

A couple of weeks after I received the copy of the Magna 8 User Guide, I sent the infamous form to all the printers in the company, and that’s when I was sort of had all my “atta boys” taken away with that one “Uh Oh”.  I was all prepared to watch my step while on the mainframe. About a week after the episode in Tom’s office when he told me not to send anything outside the plant without Ron Kilman’s permission, my foreman, Andy Tubbs came in the office and told me that in two days, I was supposed to go to some training in Oklahoma City.

“Oh.  Training!”  One of my favorite things!  I always liked to learn new things.  I asked Andy what the training was for (Oh geez… did I really say that?  “For” at the end of the sentence again! — how about “I asked Andy what kind of training would I be taking” — yeah…. that’s what I said…).  Andy replied, “Something called ‘Magna 8′”.

Oh No!  I hadn’t asked for training!  I had just asked for the user guide!  Now I was scheduled to go to training in Oklahoma City and I knew that no one at the plant had “okay-ed” it.  Now what was I supposed to do?  I did the only thing I could think of at the time…. I asked Andy where I was supposed to go at Corporate Headquarters for the class.

Since I knew that this class hadn’t been approved by Tom Gibson or even our A Foreman Bill Bennett, I decided that I was going to go on my own dime…. that is, I wasn’t going to expense anything.  I would pay for my own mileage and lunch, etc.  Hopefully, no one would notice that I was gone that day.  — Anyway, I could always fall back on the fact that my own Foreman Andy had told me to go….

So, when the day came, I drove to Oklahoma City and entered Corporate Headquarters dressed in my cleanest steel-toed work boots and my cleanest tee-shirt!

I chose this picture because they look like my boots, only I never wore the toes out so that you could see the steel toes.

I chose this picture because they look like my boots, only I never wore the toes out so that you could see the steel toes.

Yeah.  Just like this

Yeah. Just like this — not not really

When I introduced myself to the instructor I told him I was surprised that I had been scheduled for this class.  He told me that since I had requested the User Guide that he figured that I should attend this course so that I would know how to use Magna 8 to create reports.  – Well, that explained it.

The classroom was short on computers so we had to share one computer between two people.  I sat in the back row on the right side if you are facing the instructor.  A young lady sat next to me.  Her name was something like Laura Burghart (I’m not sure I am spelling that right).  We didn’t introduce ourselves right off the bat. We spent the morning learning about how our database was structured.

Our database was not what is referred to as a “relational database”.  I’m not even sure if that term was being used at the time…. anyway, we had what is called a “Hierarchical Database”.  The relationships are more like a family tree.  If you needed to connect the data, you had to go up the tree to where you could go back down another branch… sort of like if you were into Genealogy and you were looking for your 3rd cousin twice removed.  This was all new to me.

I found this diagram of a simple Hierarchical Database model on Wikipedia

I found this diagram of a simple Hierarchical Database model on Wikipedia

Anyway, this isn’t an important part of this story, so don’t strain your brain trying to figure it out.

When noon came around and we were just breaking for lunch, Laura Burghart said to me, “You’re Kevin Breazile!  You’re the guy that printed out that form on everyone’s printers!”  I replied, “Yeah, that’s me.  I sure was in trouble for that one.”

She replied that they had been trying to do something like that for a long time.  Then she explained… “I work in the Communication Department and we create the Fast News Bulletins that are sent out to the printers….”

You see…  this was what you had to do before e-mail was available…. When there was some news about the company that they wanted to disseminate to all the employees quickly, they would send out a Fast News bulletin to the printers and we would post it on the bulletin board in our area.

She continued to explain….. We have asked IT to give us a list of printers that we should send the Fast New Bulletins, because we know that our list is old and we are sending some to printers that messes up billing jobs and other things…. I said, “Yeah.  I know all about those.”

She continued to explain some more…. IT told us there isn’t any way to tell which printers are good printers and which ones we shouldn’t be sending Fast News Bulletins.  I replied,  “Well…. I know which ones are good and which ones are not.  I have all the forms that were sent to me.  You can tell right away by the paper they are printed on, and if that’s not enough to give you a hint, just read the ‘colorful’ notes they wrote to me trying to convince me not to print on their printers anymore…”

Laura said it would be a great help if I could send those forms to her.  I said I would do it as soon as I was back at the plant.

When I arrived at the plant the next morning, and Andy Tubbs told me that Tom Gibson was upset when he found that I had gone to Oklahoma City for training when Bill Bennett had mentioned it to him the day before.  He had been all hot because he hadn’t approved any training and here I was going off on my own to Oklahoma City.  I told Andy…. Well…. You did tell me to go….

Anyway, after that I gathered up the stack of around 500 forms and carried them up to the mail room where Denise Anson helped me put them in a small box to mail them to Laura Burghart.

A few weeks went by and Laura called me on the phone.  She asked me how I had created the header on the forms.  You see, I had created a header with the name of the company and part of the name was normally smaller and had one word over the top of another so….. well…… let me just show you…..

An example of the Company Memo Header on our Dot Matrix Printer

An example of the Company Memo Header on our Dot Matrix Printer – without the “Quality” turned on

Notice the “GAS/AND” in the middle of the name of the company….  – This doesn’t look like anything to you today, because we now have laser printers and Publishers and all sorts of Word Art at our fingertips.  But back then, printing this from a mainframe document took some work…. let me explain, just to give you an idea.

First, I had to space all the way out to where the word GAS starts, then I had to turn on the underline and decrease the font size to the size of the small letters and print out the word GAS then I had to turn off the underline and backspace the three characters, change the font back to the large size, then backspace all the way back to the beginning of the line, then print out the word Oklahoma and a space, then change the font back to small and print out the word AND then change the font back to the large size, and continue with the rest of the line.  Yeah… I had to send backspace commands to the printer….  I was pretty proud of my header.

You can see by the Memo above that I had been using it for almost a year.  The picture above isn’t even using the “Quality” setting on the printer which even made it look a lot sharper.

Anyway, on with the story…… The Fast News Bulletin’s header had a simple design.  The “F” in Fast was created using a bunch of F’s.  The A using a bunch of A’s.  Like this:

Fast-old-news

Yeah… pretty embarass… um… I mean exciting huh?  Laura was looking for a way to add some Quality to the Fast News Bulletin.  I told her that I could create large block letters using the graphic commands on the printer  I asked her what her printer ID was and I quickly created a Fast News Bulletin for her with a real header: Fast-News-Header Laura was excited and said that she may be getting back to me soon…. which she did a few weeks later.  She asked if I could attend the first meeting of a new Task Force they had created to enhance the Fast News.  I said I would be glad to attend, but I would first have to have permission from my Electric Supervisor before I could go.

She said she would take care of it…. and she did. So, one day I showed up at Corporate Headquarters again.  Laura Burghart was there to greet me.  She told me where to sit along a big long table in a meeting room.  I was to sit about halfway down the table, while she sat on one end of the table.

When others came in, the IT person that was on the committee… I believe his name was Mike Russell sat on the far end from Laura. Laura opened the meeting by explaining the reason for the task force and when she finished she said, “For starters we were thinking that instead of using the ugly Fast News header we have been using, we would like to have a header like this…. And she passed a copy of the Fast News Bulletin I had printed out on her printer that day when she called me.

When Mike Russell saw it, he replied, “Our Printers can’t print a header like this.”  Laura looked over at me, as if she wanted me to reply to Mike’s remark.  So, I said, “This was printed out on the standard IBM network printer.”

Mike replied by saying, “No.  Our printers can’t print like this.  It’s impossible.”  I repeated that this Fast News was printed out on Laura’s IBM printer from the mainframe just like the regular Fast News is printed out.   I even told him that I could send him a copy of the header so that he could print it out and see for himself.

He said,  “There’s no need to do that.  Our printers can’t print this out.” — Though he held a bulletin in his hands that was printed out on our Standard IBM printer.

At then end of the meeting Laura thanked me for coming.  She said, “See.  This is what we have been dealing with.  They probably weren’t going to be able to go anywhere with this.”  I just nodded….  I thanked her for inviting me and I returned to the plant 75 miles north.

I guess it didn’t matter too much.  A few months later and we were all being introduced to E-Mail, as I had been running telephone cable all over the plant so that we could set up a new NT Server network using Netware 4.0.  Which used Novell’s GroupWise for e-mail.  Fast News then just showed up in our Inbox.

It’s funny how things work out. What are the odds?  I wreak havoc by sending a “rogue” form to printers that should be left alone, only to have those forms become useful to another department after I was “accidentally” enrolled in a training course where I happened to sit next to the one person in the company that could benefit from that printing blunder.  Which then led her to look at ways to improve the Fast News Bulletin that she was responsible for creating….

Then the IT department refused to listen, but it didn’t matter anyway because new Technology quickly came along which began the process of weaning us off of the mainframe and onto a new state of the art network that later allowed us to use SAP a real ERP system that made the Magna 8 application that I went to learn in the first place obsolete.

I guess the Fast News Bulletin for the day is that Technology Moves Fast…. If you aren’t on for the ride, then you will be making statements like “That’s Impossible” and having a student in the 8th grade proving you wrong.  It reminded me of what my dad always said when I was growing up… “Don’t ever say you can’t. — There’s always a way.”

Working Power Plant Wonders with Willard Stark — Repost

  1. Originally posted on July 6, 2013:

We were working for an “Acting” foreman named Willard Stark during an overhaul at the plant outside Mustang, Oklahoma the spring of ’86.  Willard seemed much older than he was.  I would have guessed he was in his late 60′s or early 70′s, but it turned out he was only in his mid to lower 50′s.  I found out why as the overhaul unfolded. I heard some slight grumblings from a few in the shop when Bill Bennett told me that I was going to the plant near Mustang, Oklahoma that spring.  I suppose it was because since I had become an electrician in the Fall of 1983, this was already going to be my third overhaul away from our plant, and all of them ended up being major overhauls. The reason others were grumbling about this was because when you were able to go on a an extended overhaul at another plant, it meant that you were going to earn not only a lot of extra overtime, but you also received travel time, mileage and a per diem (a daily amount of money for expenses).  I believe at the time the Per Diem rate was $32.00 each day.  This was supposed to pay for your hotel room and your meals while you were away from your family.  We lived in trailers to cut down on costs.   Others believed that I had received more than my share of the piece of this pie. I had been sent on every available overhaul since just before I had reached my first year as an electrician.  So, by this time, most people would have saved up quite a sum of money.  I, however, was making around $7.50 my first year, and by the time 1986 had rolled around, I was still making just under $10.00 an hour.  So, overtime amounted to $14.50 an hour.  When you compared this to the first class electricians that were making around $19.00 an hour at the time, they would have been making $28.50 an hour overtime.  This was about twice what I was making.  So, I was a cheap date. On December 21, 1985 I had been married (the day following my last day at Horseshoe Lake overhaul — see the post:  A Slap in the Face at a Gas-Fired Power Plant), and I had used every cent I had in the world to pay for our honeymoon.  I was even relying on paychecks I was receiving while I was away to finish paying for it.  So, it helped to come back and find that we were on a major overhaul at our plant on Unit 1 doing the 5 year checkout.  Then finding that I was going to a major overhaul at the plant in Mustang, Oklahoma where I could live with my wife in her apartment in Oklahoma City while she finished her last semester to obtain her nursing degree from Oklahoma University. I went on the overhaul with Ted Riddle.  Ted was hired into the electric shop the previous summer.  He wasn’t on my crew so I hadn’t worked much with him.  He was a farmer that had an electric background.  He was a bigger man that I was and had a good sense of humor.  He had a steady temper and didn’t let much bother him.  He would laugh at things that might bother others. I appreciated working with Ted, because his steady mood helped to teach me that blowing my top about little things did little to help the situation.  So, for this overhaul, I decided that I would try to emulate Ted Riddle by keeping up with his easy-going-ness (I know…. the dictionary couldn’t find that one).  Bob Kennedy was on this overhaul as well.  He had been my acting foreman during the  overhaul at Horseshoe Lake.  I had described our relationship in the post:  “Bobbin’ Along with Bob Kennedy“.  I was glad to be working with Bob again. As I mentioned, Willard Stark was our acting foreman.  For those that don’t know…. an acting foreman is someone that normally isn’t a foreman, but is appointed to lead a crew for a particular job.  These men usually are the best foremen to work for, because they haven’t attended any official “manager training”.  This usually made them better foremen, as the manager training had a tendency to destroy one’s character and moral integrity.  – I never could figure that one out.  Some people came back unscathed, but others came back with PTMD (Post-Traumatic Manager Disorder). The plant at Mustang was the smallest gas-fired power plant that had people permanently working there.  It had some smaller units that they wouldn’t run when the newer larger units weren’t running because the water treatment plant (that creates the boiler water) used more power than the small units could generate.  – That amazed me.  So, while we were there, I don’t think any of the units were running so they didn’t have to run the water treatment plant. Willard Stark had spent a good portion of his life working at the plant and had a lot of stories about our plant manager and assistant manager.  He had been an electrician when Bill Moler had first come to the plant as a new green electrician like me.  I enjoyed sitting during lunch in Mark Thomas’s electric lab as Willard told us stories.  Willard had an incredible memory.  He could remember what he was doing on any specific day decades before. We would listen to Paul Harvey on the radio during lunch, and whenever Paul would say, “….noon news and comment.”  Willard would always finish the sentence by saying “…mostly comment.” I had spent a good part of my childhood listening to Paul Harvey on the radio because when I was young, we always had a radio playing in the house and the car.  So, Paul Harvey’s voice was always a comfort to me.  I was saddened a few years ago when he passed away.

Paul Harvey was one of a kind radio personality.  No one will ever fill his shoes.

Paul Harvey was one of a kind radio personality. No one will ever fill his shoes.

Working with Ted Riddle cracked me up.  He would notice things that I was totally oblivious to.  For instance, one day while we were working, Ted asked me if I ever noticed how Bob Kennedy drinks water out of his jar.  I told him I hadn’t noticed.  You see, Bob had this jar that looked like a pickle jar that he brought to work each day filled with water.  During lunch, he would drink out of this jar.  Ted said, “Watch Bob during lunch today.  Tell me what you think.” So as I was sitting next to Bob during lunch listening to Paul Harvey, and Willard Stark telling us what he did on any particular date in the past that Paul Harvey might mention, I kept one eye on Bob.  As Bob lifted his jar to his mouth I watched as he began to drink.  I immediately knew what Ted had wanted me to see. As Bob took a drink, he  slowly tilted the jar up until the water reached his mouth.  As the jar was being tilted, Bob’s upper lip would reach way into the jar as far as it could, quivering in anticipation of a cool drink of fresh water.  The upper lip of a camel came to my mind.

Bob Kennedy's upper lip reaching into the water jar...

Bob Kennedy’s upper lip reaching into the water jar…

With all my might, I struggled to keep a straight face as I turned my head slowly to look over at Ted who had a grin from ear-to-ear….. ok.  I’ll show you the picture of Andy Griffith again that I included in my post from last week, just so you can see what I saw when I looked over at Ted:

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

I think I almost choked on my ham sandwich as I swallowed while trying to keep my composure. Another day while Ted and I were cleaning ignitors on the shop work bench Ted asked me if I had noticed what Randy Oxley and Jimmy Armafio were working on.  I told him I hadn’t noticed.  Ted said that if he’s not mistaken Randy Oxley has been coming into the shop all morning with the same piece of conduit.  He bends it, then cuts a little off the end and re-threads it. So, the next time Randy came into the shop I noticed he had a piece of  one and a half inch conduit in his hand.  It was about 3 1/2 feet long and had a couple of bends in it.  Randy hooked the conduit up in the large conduit bender and using his measuring tape carefully lined it up.  He bent the conduit a little, then put it in the bandsaw and cut off a few inches.  Then he put it in the vice on the work bench and proceeded to thread the end of the conduit.  Then Jimmy and Randy left. Ted said that if he wasn’t mistaken, that’s the same piece of conduit Randy has been working on all morning.  So, as we continued the boring job of cleaning the 30 or so ignitors piled on our workbench, I told Ted about the time I was at the plant at Horseshoe Lake and Randy had told a Mechanical A foreman Joe Balkenbush (I think his first name was Joe), who was Randy’s uncle on his mom’s side, that Randy was the best electrician at the plant at Mustang, only he was the only one that knew it.  I mentioned this meeting and the reason for it in the post:  “Bobbin Along with Bob Kennedy” (See the link above). Sure enough, a little while later, Randy came back to the shop with the same piece of conduit and performed the same procedure of bending, cutting and threading and scadoodling.  A little while later the electrical B foremen came out into the shop (I can’t remember his name for the life of me… I can see his face), and asked us if we knew how to run conduit.  We assured him that we did.  I had been thoroughly trained by Gene Roget and Ted, well, as it turned out, Ted was a crackerjack conduit hand. The foremen took us up onto the boiler and asked us if we could run some conduit from one place to another.  He sounded apologetic when he asked if that would be all right.  We assured him it was no problem.  We would get right on it.  On the way back to the shop, as we were coming down from the boiler, Ted tapped my shoulder and pointed down to the bottom of a light fixture.  He said, “Hey!  Isn’t that the piece of conduit that Randy has been working on all morning?”  Sure enough.  There is was.  He finally bent it and cut it to fit! Well… The rest of this part of the story is that instead of running back and forth to the shop to bend and cut and thread conduit, Ted and I grabbed a conduit stand, and the appropriate tools and hauled them up on the boiler.

Conduit threader stand

Rigid Conduit threader stand

We carried about 40 foot of conduit up there and began bending, cutting and threading and mounting the conduit.  We finished just before lunch.  As I mentioned above, Ted was a heck of a conduit person.  He knew exactly what he was doing.  We carried all the equipment back to the shop. After lunch Ted and I went back to cleaning ignitors.  The foreman saw us out of the window of the office and came out and asked us why we weren’t working on the conduit.  When we told him we were done, he had a look of disbelief.  He left the shop (to go check out our work).  Ted and I smiled at each other.   A little while later the foreman returned with the electric supervisor. The electric supervisor asked us if we wouldn’t mind working on some more jobs to run conduit.  Ted told him that we were there to do whatever they needed.  I nodded in agreement.  During the rest of the overhaul we worked to repair broken conduit, pull wire and install new conduit where needed. Mark Thomas, the electric specialist, that was about my age, asked if he could use us to pull and mount some new controls.  He said he wouldn’t let the others in the shop touch it because he would just have to follow through and redo it when they were done.  So, we did that also. I had mentioned in an earlier post called Resistance in a Coal-fire Power Plant that Bill Rivers had been given a bum deal when another person had accused him of cutting off the leads of electronic components so that no one could check them to see if they were really bad (which doesn’t make any sense given that you could still check them no matter how short the leads are).  Well, I found that the same situation had existed in this plant. There was this one guy that sat in the electric shop Lab (not the same electric shop lab where Willard and Mark Thomas hung out), working on Gray Phones all day.  Ted had asked me if I had noticed how many gray phone boxes were missing gray phones (gray phones are the PA system in a plant.  You could go to any one of them and page someone).

Gaitronics Gray Phone

Gaitronics Gray Phone

Ted would point to empty gray phone boxes as we walked through the plant.  He told me that they have one electrician that doesn’t do anything else but sit in the electric lab working on gray phones.  That is all he does.  When we asked Willard about it, he told us this story. Mark Thomas used to work on all the gray phones, and kept them all running in good order.  When Mark worked on a gray phone, sometimes to make sure it is working, he would page himself.  Just to make sure that part worked.  I understood this.  When I was working on gray phones with Bill Rivers, he would page me, or I would page him, just to test it.  If you were working by yourself, it would make sense that you would page yourself instead of bugging someone else several times a day while you went from one gray phone to the next. Anyway, people accused Mark Thomas of trying to make himself more important by making others think that he was being paged all the time by paging himself.  Now, anyone with any sense would know how lame of an idea that is.  I mean, anyone would recognize Mark Thomas’s voice.  The plant wasn’t that big.  There weren’t that many people working there.  Everyone knew everyone else.  Mark was obviously just working on gray phones. So, after the foreman accused him of trying to promote his self importance by paging himself several times a day, Mark said, “Fine!  Let someone else work on the gray phones!”  Mark was by far the most intelligent person at the plant.  He obviously didn’t need to artificially promote his reputation by making a fool of himself. So, they gave the job of gray phone maintenance to someone that didn’t understand electronics.  They even bought an expensive gray phone test set to help him out.  So each day he would sit in the lab smoking his pipe staring at an ever-growing pile of gray phones.  At one point, Ted and I offered to fix them all for him.  He said, “That’s ok.  It keeps me in the air conditioning. I know in later times, Mark Thomas went on to greater successes within the company.  I believe that Willard stayed around until there was a downsizing and he was able to early retire. I mentioned at the beginning that Willard looked a lot older than he really was.  Willard brought this to my attention.  He showed me a picture of himself a few years earlier.  It was of him standing by a car wearing a suit.  He reminded me of an actor from an old movie, though, I can’t remember the actor’s name at the moment. Willard said that in the past few years he aged rapidly.  It happened when the previous foreman had retired.  Willard had seniority in the shop and had been at the plant most of his life.  He knew what he was doing, and had filled in as foreman many times.  He really expected to become the foreman.  Nevertheless, they gave the job to someone from somewhere else who didn’t know the plant, or even much about being a foreman. This upset Willard so much that he said he just gave up.  He said the stress from that experience aged him.  Mark Thomas agreed.  Mark had his own encounter with this attitude when he decided to retreat to his lab off and away from the electric shop.  Willard and Mark, the two electricians that really knew what they were doing at the plant had sequestered themselves in their own hideaway where they would sit each day listening to Paul Harvey at lunch and biding their time until the next phase of their life came around.

Psychological Profile of a Power Plant Control Room Operator — Repost

Originally posted on July 6, 2012:

I suppose that many parents while raising their children would hear them say, “Dad, can you read that story to us again about the pirates that go to the island to find the treasure but Jim Hawkins fights them single-handed?”  Or their children might say to their mother, “Will you tell us the story again about how you met daddy?”  In my household, my children would say, “Dad, tell us another story about how you played a joke on Gene Day when you were working at the Coal-Fired Power Plant in Oklahoma?  Those are always the best!”

As I pointed out in my third post this year called “Power Plant Humor And Joking With Gene Day” the first time I met Gene Day, I could tell that he was the type of person that would take a joke well, or so I thought….  One of the favorite stories my daughter would like for me to tell her as she was growing up was the one where I had created a Psychological Profile of Gene Day, who at that time, an Auxiliary Operator.

It began one day when I was leaving the electric shop through the Turbine Generator (T-G) building ground floor.  A very noisy location as large steam pipes wound around under the Turbines where the steam caused a rumbling or whining sound.  It was normal when walking through this area to reach up to the ear plugs that were draped over your shoulders and put them in your ears because the decibels were dangerously high if you were exposed earplugless too long.

Earplugs on a cord that can be draped over your shoulders when not in use.

I stepped from the landing leading from the electric shop and started toward number 1 boiler when I spied Gene Day making his way around the  first floor of the T-G building inspecting equipment and marking his documents indicating that they were operating correctly.  As I saw him turn toward my direction I quickly dodged behind the nearest metal pillar (I-Beam).  I peaked my head out from behind the pillar and took out the notepad that was in my back pocket, and the pen from my vest pocket pocket protector.

A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.

Gene saw me and gave me a suspicious look as I began feverishly writing in my notepad while looking from my notepad back to Gene and then back to what I was writing.  After I had done this for about 10 seconds or so, I put my pad away, my pen back in the pocket protector and strolled away toward unit 1 to continue my work.

A notepad like this

It happened that this particular week was Gene’s week to monitor the equipment in the T-G building, so throughout the week he would be making his way somewhere around the T-G building with his clipboard in hand.  Each time I encountered him I would do the same thing.  I would visibly hide behind a beam and write notes in my notepad.  I saw Gene rather frequently during the week because the majority of the time, I left the electric shop by going through the T-G room to one of the boilers and then to the precipitators, where I spent most of my time working at this time in my career (but that is another story for a later time).

Each time, Gene would watch me suspiciously knowing that I was just messing with him, but not exactly sure what I was “up to”.  At the time, I wasn’t sure either.  So I just wrote down what I saw Gene doing, that way, if he ran over and grabbed my notepad from me, it wouldn’t say anything other than what I saw.

It had happened at the plant a few years earlier when I was a janitor that the company had hired an efficiency expert to monitor the employees at the plant.  He would walk around the plant with a stopwatch observing the employees.  When he saw them he would write notes on his clipboard.  It became very unnerving because you would walk around the corner and there he would be standing writing something down about you.

I went to the Assistant Plant Manager Bill Moler and told him that this creepy guy keeps showing up in the main switchgear by the janitors closet.  And every time he sees me, he writes something down.  I told Bill that it really bothered me.  He explained that he is an efficiency expert and he has a certain path that he takes throughout the day and takes a snapshot of what the workers are doing at that moment and writes it down.  By doing that he calculates how efficient we are.  It seemed pretty silly to me, because most mechanics when they saw him coming put their tools down and did nothing while he walked by until he was out of sight again.

When I was on the labor crew a few weeks later, and I was blowing coal dust off of all the I-Beams above the bowl mills with a high pressure air hose, I looked down, and through my fogged up goggles I could see this guy standing directly under me.  I was about 50 feet above him crawling across an I-Beam with the air hose blowing black dust everywhere.  He had crossed my barrier tape to go into the bowl mill area to see how efficient I was being.

This is the type of barrier tape I was using. It is made of woven plastic fibers.

I was so mad I turned off my air hose, climbed down the wall Spiderman-like (no.  not head first) and went straight into the A-Foreman’s office and told Marlin McDaniel that the Efficiency Expert had crossed my barrier tape and was standing directly under me as I was blowing down the beams with air.  It turned out that the Efficiency Expert had gone upstairs to complain that some guy in the bowl mill had dumped a bunch of coal dust on him while he was monitoring him from below.  Evidently, he wasn’t expert enough to know you weren’t supposed to cross someone’s barrier tape without permission, as was indicated on the caution tags that were tied to the barrier tape.  From that point on, the efficiency expert (now in lowercase) had to be accompanied by someone from the plant to make sure he wasn’t breaking any safety rules and putting himself at harm.

Long side story short, we turned out to be so efficient, people came from all over the world to study us.  Somebody downtown hired the efficiency expert full time, but later he was laid off during the first downsizing.  He reminds me of a person on an episode of Star Trek The Next Generation where this guy  Lieutenant Commander Remmick comes aboard the Enterprise and he walks around inspecting everything and asking everyone questions that make them uncomfortable and at the end asks Picard if he could come work on the Enterprise.  He looked so much like him, that I thought maybe our efficiency expert went to Hollywood to become an actor.

Lieutenant Commander Remmick

Back to Gene Day.  I suppose the thought of the efficiency expert may have been going through my mind as I was taking notes about Gene Day at work.  Like I said, at the time, I didn’t know what I was going to do with it.

It finally came to me on Thursday morning.  This was the last day that Gene was going to be on the day shift, so I figured I might as well do something about it.  So when I entered the shop that morning, I sat down at the desk of my foreman Andy Tubbs and began to write.  The title at the top of the page was:  “The Psychological Profile of Gene Day”.

Using the notes I had taken during the week, I wrote things like the following:  “Gene Day walks around the Turbine Generator building with a clipboard in his hand trying desperately to look like he’s doing something important.  He constantly hopes that someone is watching him because he dislikes doing so much work to act busy for no reason.  At times Gene Day gets paranoid and believes that he sees people spying on him from behind every corner (especially I-Beams).  Sometimes Gene Day stands in the middle of the T-G floor staring up into space as if he forgot what he was supposed to be doing.”  I’m sure I wrote more, but I don’t remember everything… but I do remember the second from the last sentence.  I will save that for a couple of paragraphs from now.

I took my Psychological Profile of Gene Day and went up to the Control Room.  I noticed out of the corner of my eye that Gene had just walked over toward the break room behind the Auxiliary Control Panel so I walked over by the Shift Supervisor’s office and I leaned against the top of the large Blue Monitor and placed the Psychological Profile on the top of the monitor in front of me.

Less than a minute later Gene came walking around behind me and seeing the paper on the top of the monitor came up behind me and looked over my shoulder and began to read…..  He wasn’t trying to hide the fact that he was reading the paper, and I obviously knew he was there, and the title in large bold letters did say, “The Psychological Profile of Gene Day”.  So, he read on.

I heard a few chuckles as he read through my interpretation of what he had done during the week.  Then he came to the “Second from the Last Sentence”, as I could hear him reading quietly in my ear…  The sentence read, “Gene Day sneaks up behind people and reads their private material over their shoulder!”  —  Bingo!  I had him!  When he read that he grabbed me by the throat and started to Throttle me!  Shaking me back and forth.  This would have been a humdinger of a joke at that point, but I had one more sentence up my sleeve… ur… I mean on the paper….

As I was waivering (is that a word?) back and forth between life and death I managed to eke out something like:  “Wait!  There’s More!”….  Gene Day let up on me a little and looked down at the page and read the last sentence…… It read….. “Gene Day tries to strangle people who are only trying to help him by creating his Psychological Profile.”  That was all it took.  Another perfect joke played on Gene Day, and I was able to live to tell about it.  When Gene read that he was stunned into dismay.  Giggling as hard as he could he retreated shaking his head in defeat.

Now, I know that Gene reads these posts, and he may remember this story a little differently, and I’ll give him that  because Gene is older than dirt and his memory isn’t that good.  But I was the one that was being strangled, and I still have a vivid image of those few moments.  Not only do I, but so do my children, who will one day tell their children, who will say, “Mommy, will you tell us that story again about how Grandpa was strangled by Gene Day that time in the Control Room at the Coal-Fired Power Plant in Oklahoma?”

Power Plant Customer Service Team Gone Wild

I never would have guessed that playing Power Plant Man jokes on Gene Day would have led me to the “Uh Oh!” moment I later encountered when I was told in no uncertain terms that the President of the Electric Company, James G. Harlow Junior was personally upset with something I had done.  I had learned my first year as a summer help at the coal-fired Power Plant in North Central Oklahoma that “One ‘Uh Oh’ wipes out all previous ‘Atta Boys’!”  I could tell by the way the Electric Supervisor, Tom Gibson’s ears were glowing red that this was considered a little more serious than I had first realized.

I have mentioned in previous posts that playing jokes on Gene Day was one of my favorite Power Plant Man Pastimes.    See the post, “Power Plant Humor and Joking With Gene Day“.    Also see, “Psychological Profile of a Power Plant Control Room Operator“.  My lunch breaks were usually consumed with learning more about how to program the Honeywell mainframe computer used by just about all the company processes that actually ran the company from payroll, to billing, to work orders and Inventory.  I figured that as I learned more about the computer system, the more elaborate jokes I would be able to play on Gene.

Already I had learned about the escape codes used by the large IBM printers that were used throughout the company at the time.

IBM Dot Matrix Network Printer

IBM Dot Matrix Network Printer

Besides the telephone and inter-company mail, printers were the only other way to communicate to non-present Power Plant Men in 1989.  We had not yet been introduced to e-mail.  I was one of the few people in the company that had an e-mail address, and the only other person that I knew that I could write to was Craig Henry, a Corporate Engineer downtown.

 

Craig Henry.  Engineer and Gentleman

Craig Henry. Engineer and Gentleman

Much like the first time when I met Gene Day, when I first encountered Craig Henry, I could tell right away that he was a down-to-earth person that would shoot straight.  Craig probably wouldn’t remember this far into the future that I would reach out to him occasionally just to say “Hi” and to pick his brain about how the corporate IT infrastructure was setup.  I figured since he was one of the few people in the company that even knew what an e-mail address was at the time, he most likely had more knowledge about such things than the average person in Corporate Headquarters.

After finding out that Gene Day would go work out at the Rock Gym in Stillwater, Oklahoma after work, and I had played the joke on him with the notes from the private investigator, I used my knowledge of Printer Escape codes to write documents on the mainframe that when printed out would turn on the graphic commands on the printer so that I could print out pictures.  I don’t mean that I would have a saved picture that I would send to a printer like we might do today.  No.  I had to create these pictures one pixel at a time using commands in a UNIX document on the mainframe.  It was all codes that would not make sense to anyone that didn’t know the graphic commands of the IBM printers.

I had been teasing Gene Day about meeting up with a young “coed” from the University at the Gym each day.  I would do this by printing out messages on the Control Room printer by the the Shift Supervisor’s office when I knew that Gene Day was there filling in as the Shift Supervisor.  They were usually notes from someone that called herself “Bunny”.  Usually they were short notes or “love letters” from Bunny just saying something about how she enjoyed her time with Gene at the Gym.

At the bottom I would sign it “Bunny”  then under it, the printer would read the graphic commands and create a small Playboy Bunny symbol under the name.  At the end, the document would send a command that would put the printer back into the text mode.

Of course.  Whenever I walked into the control room shortly after, just to see how the precipitator was doing, Gene Day would confront me about the notes.  With a grin on his face he would say, “This isn’t funny!  What if my wife found one of these notes?”  – Like that was ever going to happen…. unless he was like me, and like to save everything.

In the last couple of weeks I have written about how the Power Plant Men were introduced to the “Quality Process” (otherwise known as “Six Sigma”).  We had created teams with our crews and we met once each week to come up with Quality ideas.  In August, 1993, I had received my official Certificate Certifying that I had completed all the QuickStart training and was on my way to making a difference in the Power Plant World!

My Customer Service Team Certificate.  This made me official!

My Customer Service Team Certificate. This made me official!

So, what do these two events have in common and how did this lead the President of the Electric Company to send out a search warrant on a lowly Plant Electrician in North Central Oklahoma?  Well.  This is what happened…

First you have to remember that in 1993, the Internet was not easily accessible by the general public.  Company e-mail was still not a reality in our company.  We had dumb terminals and large IBM printers.  That was the extent of most employees interaction with a computer.  Each printer had a designation.  It was a four character ID beginning with a “P”.  So, the  printer in the Electric Shop Office might be…. P123.  I needed to know this number if I wanted to send  something to it.

At the time, the only thing people had to send to each other were requests for things from the mainframe systems that were used to run the company.  So, for instance, if you wanted to request some parts from the warehouse at our plant, we would send over a list of parts to the warehouse printer where Dick Dale and Darlene Mitchell would pick it up and go retrieve the parts.  So, the people that used the terminals and computers with mainframe emulators on them knew the most commonly used printer numbers in the plant.

If you wanted to send something to someone in Oklahoma City, or to the Power Plant in Muskogee, then you would have to call over there and ask the person what their Printer ID is so you can be sure you are sending your request to the appropriate computer.  Without e-mail, and any other form of computerized communication.  This was the only way at the time.

So, after our Customer Service Team was formed, we would meet once each week to brainstorm new ideas that would benefit the company.  Andy Tubbs was our team leader, as he was our foreman.

Andy Tubbs - True Power Plant Electrician

Andy Tubbs – True Power Plant Electrician

The other members of our Customer Service Team were Diana Brien, Scott Hubbard, Sonny Kendrick, Ben Davis and Gary Wehunt.  I haven’t properly introduced my bucket buddy Diana Brien in a post before.  I have recently obtained a photograph that I can share:

My Bucket Buddy Diana Brien

My Bucket Buddy Diana Brien

We were called bucket buddies because we carried tool buckets with us whenever we went to work on something.  They doubled as our stool and tripled as our trash can.

Thursday, October 14, 1993 during our Quality Brainstorming session, while we were pouring out ideas like…. “What if we changed out the street lights at the plant so that they would be different colors…. wouldn’t that help morale?….   and “How about if we wrapped fluorescent Christmas lights around the high voltage electric lines between here and Oklahoma City so that they could light up the night with colorful lights during the Christmas Season?”….. And other ingenious Brainstorming ideas that are bound to pull up an occasional brilliant idea….. well.  One such idea popped up!

I don’t remember which one of our brilliant brainstorming ideas conjured up this idea, but Andy Tubbs suddenly blurted out…. “What if we had the Printer IDs added as a column in the Corporate Directory? —  You see, each quarter we received an updated copy of the Corporate Phone Book.  It included the names and phone numbers of all the Electric Company employees.  It also included their mail code.  So, if you wanted to send something through inter-company mail to them, you would know where to send it.  Our mail code was PP75.  That was the code for our power plant.

So, what if we added a column where we had the printer ID that each person would use for people to send printed requests, among other things?  This was Brilliant!  We could just make this proposal and send it downtown to Corporate Headquarters where it would be lost in the “mail”.  Or we could do more research to prove that it was a possible proposal that was really doable.

So, I suggested….  Well… I can print a form out on every printer in the entire company requesting that they include all the names of all the people on that use that printer and mail it through inter-company mail back to me at PP75.  – I had recently uncovered a special printer command that allowed me to do this hidden away on the Honeywell mainframe.  So, we took a vote and it was decided that we would pursue this proposal.  I set to work on creating the form that I would send to every printer.  If we could not only send the proposal to the Communications department downtown, but also a list of everyone and their printers, the work would already have been done for them.

I wanted to send a real fancy letter because I had already created a header using the Quality print settings on the printers.  I had created a Company Logo that (I thought) ingeniously used the backspace command to create two words with one word on top of the other in the middle of a sentence….  Our company began as Oklahoma Gas and…..  in the logo, I wanted the word Gas to be on top of the word And as it was in our company logo in smaller letters than the others.  So… after playing around with it for a while, I created the logo and had it saved on the mainframe.

After attaching the header to the form, I included a message that told the person that discovered the form on the printer to add the names of all people who used the printer below and to send the form to Kevin Breazile at PP75.  As I mentioned.  In order to make the form look pretty, I turned on the Quality Print settings on the printer at the beginning of the document.  Like the story of the Sorcerer’s Apprentice….. I didn’t know a good way to turn off all the settings I changed to revert the printers back to their original settings.

I ran the command to send the document to every printer on the print server and away they went…. A copy printed out on the  printer in the Electric Shop office so I knew it was working.  Copies printed out on the other 12 printers at our plant.  They also printed out on the 500 other printers throughout Oklahoma.  – With the thought that “My work here is done.”  I went back to work repairing plant electric equipment.

The following Monday was my birthday, so in normal Power Plant Fashion, I had the day off.  When I returned to work on Tuesday, Denise Anson called me from the front office.  She said that I had a large stack of mail.  I thought, “Oh good!”  Results from our request on Thursday have arrived!  I hurried up to the front office.

When I entered the mail cubicle I was surprised to see how big the pile of envelopes were.  The stack of inter-company envelopes was over two feet high.  “Um…. Thanks….”  I said to Denise.  I picked up the stack and headed back to the Electric Shop to sort out the forms.

After opening the first few envelopes.  I suddenly came to an astonishing discovery.  Not only did the form print out on the large mainframe IBM printers used in office areas, it also had printed out on other types of printers….  I opened one envelope and found the form printed out on a “Work Order” printer.  The paper size was different than the standard paper size, and I hadn’t put a page feed at the end of the document, so, it had left the paper in the middle of the page…. “Uh Oh”.

My “Uh Oh” changed to “UH OH!” after opening a few more of the inter-company envelopes.  I found that the form had printed out on Pay Check Printers!  And Billing Printers!  “UH OH!”  quickly changed to “OH NO!”  When I read comments like “Under no circumstances print anything on this Printer Again!!!!” I realized I had really messed things up.  By changing the font size and the quality settings, the billing, payroll and work order printers all had to be manually reset and the jobs that printed out paychecks, customer bills and employee work orders had to be re-run!

After taking all the forms out of their envelopes, the stack of papers was over 4 inches thick, just to give you an idea about how many responses we had.

A couple of hours later, Tom Gibson called me to his office. “Uh Oh.”  (remember… One “uh oh” erases all previous “atta boy”s).  When I entered Tom’s office, I could tell that something was definitely wrong.  Like I mentioned earlier.  Tom’s ears were beet red…. and in case you don’t know what a beet looks like.  Here is one:

The same color of Tom Gibson's ears

The same color of Tom Gibson’s ears

Of course… I knew what this was all about, only I didn’t know yet, how Tom had found out about it….  Tom began by saying…. “Ron Kilman just received a call from James Harlow asking him who is Kevin Breazile and why is he printing something out on my printer?  Ron didn’t like the fact that he wasn’t aware that you had sent something to the President of the Company’s printer.

 

James G. Harlow Jr.

James G. Harlow Jr.

Sorry.  That’s the biggest picture I could find of James Harlow….

Um what could I say?  So, I said this…

Well.  This was a quality idea that our team had.  We wanted to collect the names of people that used each printer so that we could send in a proposal to have the printer ID added in the Corporate Directory.

I didn’t mention that Harlow’s Secretary had returned the form with all the people that used his computer as I had requested, because I knew that the President of the Electric Company was not asking because he was upset that I had printed something out on his printer.   No.  He had probably been told that the reason the bills were late being sent to the one million customers that month was because some kook had messed up their printers and the jobs had to be run over again causing the delay.  So, I thought it was best not to go that route…

So, I stuck with my story, which was the truth…. I had printed out the forms on all the printers as part of a quality idea by our CST. — I also didn’t mention that three years earlier, Tom had asked me to learn everything I could about the company computer, because he believe that the computer was going to be the wave of the future.

Even though Tom believed my explanation, he told me…. “Kevin, Ron never wants this to happen again, therefore, you are never to send anything out of this plant without Ron Kilman’s personal approval.  Is that clear?”

I replied to Tom that this was unreasonable.  I send things to other departments all the time.  I send Substation Inspection forms, and blueprint revisions and all sorts of other forms downtown all the time.  Ron Kilman wouldn’t want to waste his time approving all those things….

Tom thought about it and revised his statement…. “Then, don’t ever send out anything that isn’t part of your normal daily job without Ron’s approval first.”  – Ok.  I thought…. this works, since everything I do is part of my normal daily job…. Even printing out forms on all the printers in the company… since that was part of our normal “Quality Process” Customer Service Team activity….  So, I happily agreed.  And I left Tom’s office happy that I hadn’t joined the ranks of the unemployed.

That was one thing about working at the plant at this time.  As long as your heart was in the right place….  That is, you tried your best to keep the electricity humming through the electric lines…. then the chances of being fired for messing up, even as big of a mess up as this, most often didn’t end up by losing your job.

I sometimes think that this was my biggest mess up of all time… however…. after this episode was over… there was a part two to this story….. Believe it or not…. Someone else in the company was overjoyed about what I had just done.  They had been trying to do something similar for a long time, only to be told that it was impossible. — Doing the Impossible… I was good at that… Part two of this story is a story for another day…

Importance of Power Plant Backup Battery Preventative Maintenance — Repost

The very last thing I ever learned in High School was the importance of Backup Battery Preventative Maintenance.  In fact, the entire senior class of 1978 at Rockbridge High School in Columbia, Missouri learned this lesson at the same time.  It was during the graduation ceremony in May while the students were walking across the stage to receive their diplomas.

I had already received mine and I was back in my seat sitting between Tracy Brandecker and Patrick Brier (we were sitting alphabetically.  My name is Breazile).  Pat was sitting on my left and Tracy was on my right.  We were grinning from ear-to-ear to be graduating.  My friends from the second grade, Mark Schlemper, Russell Somers and Brent Stewart had just walked across the stage in the gymnasium while a storm raged outside.  As my friend from the fifth grade forward, Matt Tapley  was walking across the stage there was a loud crack of thunder and the sound of an explosion as the lights went out.

Matt Tapley has albinism, giving him white hair and skin.  In his black robe, the entire class witnessed Matt’s head bobbing up and down in the faint light given off from the emergency lights to either side of the stage as he was bowing to his classmates.  We all clapped.  The clapping soon turned to laughter as the emergency lights quickly dimmed and went entirely out within a minute.

An emergency light

An emergency light

As we sat in total darkness waiting for some resourceful faculty member to make their way to the hidden fallout shelter in the basement of the school to retrieve the portable generator and a spotlight, I was amazed by how quickly the emergency lighting had failed.  The transformer to the school had been destroyed by the lightning strike so we finished the ceremony by the light of the large spotlight from the back of gym.  My thought was that the school is only 4 years old and already the emergency lighting is too old to stay lit long enough to even begin evacuating the building, if that was what we had intended to do.

Fast forward to the spring of 1984.  I had become an electrician a few months earlier.  As I was learning the electrical ropes, I learned the importance of Preventative Maintenance in a power plant setting.  The majority of an electrician’s job when I first joined the electric shop was doing “Preventative Maintenance”.  I have some horror stories of bad preventative maintenance that I will share much later.  I will point out now that most Americans know of some stories themselves, they just don’t realize that the root cause of these major failures were from a lack of preventative maintenance.

A power plant, like the emergency lights in the High School, has a battery backup system, only it is on a grand scale.  There are backup batteries for every system that needs to remain online when there is a total blackout of power.  These batteries needed to be inspected regularly.  We inspected them monthly.

At first, I had done battery inspections with various electricians.  Some people didn’t seem to take this task very seriously.  I remember that when I did the inspections with Mike Rose, he usually finished by taking a gallon of soda water (a gallon of water with a box of baking soda dissolved into it) and pouring it all over the batteries.

My bucket buddy, Diana Lucas (Dee), on the other hand, took a different approach.  We carefully filled each cell with just the right amount of distilled water.  Then she showed me how to meticulously clean any corrosion from the battery posts  using a rag soaked in the soda water, and then she would paint the area on the post where the corrosion was with No-Ox grease.

A jar of No-Ox Grease (No-Ox means No Oxide)

A jar of No-Ox Grease (No-Ox means No Oxide)

When I say batteries, you may think that I’m talking about batteries like you have in your car, or even in a large piece of equipment like a big dirt mover.  Some of the batteries were the size of a battery used in a large dozer or dirt mover:

A battery used in a large dozer

A battery used in a large dozer

Some of the batteries that we inspected were of this type.  They were usually hooked up to generators that could be started up in case all the power was out and we needed to start up a diesel generator.  However, this was just the puppies when it came to the Station Power Batteries.  These were some serious batteries:

The battery shown on the left is about the size of a small file cabinet

These are the type of UPS Station batteries used at the plant.  The battery shown on the left is about the size of a small file cabinet

As big as these batteries are, it takes 58 of them for each system to come up with a 130 volt circuit.  That’s right.  58 of these batteries all in a series.  The station batteries are all in rooms by themselves known as….  “Unit 1 and Unit 2 Battery rooms”.  Smaller station battery sets are found at different locations.  Today, those places include the relay house in the main substation, the Microwave room on the roof of #1 boiler.  The River pumps, the radio tower building, the coalyard switchgear, Enid Turbine Generators and the Co-Generation plant in Ponca City.  I’m sure I’m leaving some out.  Maybe a current electrician at the plant can remind me of the others in a comment below.  Each of these locations have approximately 58 station batteries.

While I was still a novice electrician, one morning in May I was told that I was going with Dee and Ben Davis to Enid to a Battery training class  at an electric company office where the manufacturer (C&D) was going to go over the proper maintenance of the station batteries.  Ben drove the pickup.  I remember sitting in the middle between Dee and Ben both going and coming back from our lesson on Battery Preventative Maintenance….

Interesting that Ben was sitting to my left and Dee to my right that day… just like Pat and Tracy during the graduation ceremony 6 years earlier to the month when we first learned the impact of bad preventative maintenance on backup batteries.  This time we were learning how to prevent the problem I had witnessed years before.  I don’t know why I draw parallels like that.  It just seem to make life a little neater when that happens.  I don’t remember Ben and Dee grinning ear-to-ear like Pat and Tracy were the night we graduated from High School, but I can assure you, I was the entire 45 minutes going to Enid and the 45 minutes going back to the plant.

Since I had been trained for battery maintenance, I suppose it was like Andy Griffith becoming the Permanent Latrine Orderly (PLO) in the movie “No Time For Sergeants”.  I was able to go to town inspecting all kinds of backup batteries.

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Gene Roget (pronounced with a french accent as “Row Jay” with a soft J) was a contract electrician when I first became an electrician in the shop.  I wrote about him in the post New Home in the Power Plant Electric Shop.  He was a great mentor that taught me a lot about how to be an electrician.  He taught me how to use all the different tools in my tool bucket.  He taught me how to bend conduit and make it come out the right length on both ends…

He especially taught me the importance of doing a “pretty” job when running wire or conduit or just rewiring a motor.  I remember Gene stopping one day when we were walking to the precipitator and he paused to look up at the transfer tower.  I asked him  where he was looking.  He said, “I’m just admiring the wonderful job someone did bending that set of conduit.  that’s a perfect job!  Just perfect!”

Anyway, Gene and I were given the task of checking all the batteries in the emergency lights throughout the plant.  It happened that the emergency lights at the plant were all about 5 years old.  Probably about the same age as the lights were in the high school the night of our graduation.  The lights in the plant had wet cells.  Which meant that you had to add distilled water to them like you do in your car, or in the station batteries.  This amounted to a pretty large task as there were emergency lights stationed throughout the plant.

We found many of the lights that would never have been able to light up enough to cause a cockroach to run for cover.  We took the bad ones back to the shop to work on them.  A lot of the batteries had gone bad because they had never been checked.  They have a built-in battery charger, and some of the chargers were not working.  I drew a wiring diagram of the charger so that we could troubleshoot them and replace components that had gone bad.

All of this was like a dream to me.  At the time I couldn’t think of any other place I would rather be.  I loved taking things that were broken and fixing them and putting them back into operation.  Eventually we decided to change the emergency light batteries to dry batteries.  Those didn’t need water.  We could pull out the six wet cells from each emergency light box and just plug the new batteries in place.  This made a lot more sense.  Who has time to go around regularly and check 50 or 60 emergency lights every 3 months?  Not us.  Not when we were trying to save the world.

Back to the Station Batteries:

Just to give you an idea of how important these batteries are, let me tell you what they are used for….  Suppose the power plant is just humming along at full power, and all of the sudden, the power goes out.  It doesn’t matter the reason.  When there is a blackout in a city, or a state, be assured, the power plant itself is in a blackout state as well.  After all, the power plant  is where the electricity is being created.

In the plant there is large equipment running.  The largest and most valuable piece of equipment by far in a power plant is the Turbine Generator.  The entire plant exists to spin this machine.  As big as it is, it spins at 3600 revolutions per minute, or 60 times each second.  In order to do that, oil has to be flowing through the bearings otherwise they would burn up almost instantly.  This would cause the generator to come to a screeching halt — and I mean “screeching!”

A turbine Generator Room at a nuclear plant with a waxed floor!

A turbine Generator Room at a nuclear power plant with a waxed floor!

So, in order to stop a turbine generator properly, when a unit is taken offline, once it has coasted to a smooth stop, the turbine has to be engaged to something called a “Turning Gear” which slowly rotates the turbine generator.  This is turned off only when the shaft has cooled down.  Without this, you might as well call General Electric and order a new one.

So, one of the most important things the station batteries do is run emergency oil pumps that engage immediately when the power is cutoff from the plant.  This allows the turbine generator and other important equipment throughout the plant to slowdown and come to a stop gracefully in case the power is instantly gone.

I will write a story later about a day when this happened at our plant.  The moments of confusion, and the quick decisions that had to be made to keep the unit 1 boiler from melting to the ground.  Rest assured that throughout this time, the emergency oil pumps had kicked in.  The station batteries did their job when they were called upon.  While the control room operators were performing their emergency tasks to the letter and the electricians were scrambling to come up with a workable solution to an unforeseen problem, the turbine-generator, the PA (Primary Air) fans, the FD (Forced Draft) Fans, the ID (Induction) fans were all coasting down as the groundwork was being laid to quickly restore power.

Someone in an office in the middle of Oklahoma City may have noticed their lights flicker for a moment.  Maybe they dimmed slightly…

If not for the proper maintenance of the power plant station batteries, the lights would have possibly gone dark.  Someone would have had to go looking for the portable generator and the spotlight.  Ceremonies in progress may have to continued under candlelight.

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