Not a Fan of French Power Plant Fan Filters — Repost

Originally posted August 2, 2013:

I had only been an electrician a couple of months before I heard about Power Plant Louvers. My first thought was that this was a mispronunciation of the word “Louvre”.  I remembered how Marland McDaniel would pronounce the word “Italian”.  He pronounced it “It-lee-un”.  The first time he said that I asked him what he had said, and he said, “So, You’re an It Lee Un Huh?  An It-Lee-Un from It-Lee.  Meaning “An Italian from Italy”.

So, when I heard the word Louver, I immediately said to myself “ok.  They are probably trying to say the word “Louvre” (pronounced “Loove” which rhymes with “move”).  Why shouldn’t they be trying to say the name of the most famous museum in the world.  After all.  When Sonny Karcher wanted to say there were a lot of things, he would say that there were “boo-coos” of them, When I asked him what “Boo-coos” meant he explained that it was French for “A lot”.  Then I understood that he was mispronouncing the word “Beau-coup” (pronounced: “Bo Coo”).  I suspected that everyone knew about the Louvre in Paris, France.  I had first visited the Louvre in 1974 when I was 13 with my father on our way from Rome to Liverpool which I mentioned in the post “Power Plant Snitch“.

The Louvre in Paris France.  The home of the Mona Lisa and the Venus De-Milo.

The Louvre in Paris France. The home of the Mona Lisa and the Venus De-Milo.

It didn’t surprise me that they may have named a motor after the Louvre (as we were told to go replace a Louver Motor when we were doing filters).  I half expected it.  I figured it was somewhere up in the Tripper Gallery which is where the coal feeds into the coal silos above the bowl mills.  I explained about the Tripper Gallery in the post “Power Plant Painting Lessons with Aubrey Cargill“.  I have expected to see painting lining the walls when I first entered the Tripper Gallery.

So.  I mentioned that we were supposed to replace a Louver Motor while we were “Doing Filters”.  As a new electrician (which in my head an electrician was a vision of “elitism” going about the plant fixing electric circuits and running conduit and pulling wire), I soon learned from my foreman Charles Foster that as an electrician we were responsible for anything that had a wire going to it.  That meant… well.  Just about anything, one way or another.  From water fountains, to elevators, to air filters.

Air Filters?  Really?  Not that I minded changing out air filters.  It was just the connection to being an electrician that was confusing me.  Ok.  I could understand the filters that were on motors.  Since motors were something we worked on all the time.  It was the air handling filters that I was having a trouble connecting.  Needless to say.  within a few months my expectations of what an “electrician” meant was much more down to earth.

Even though we were the “elite” group of magical maintenance men (and woman), we were also the team that was looked to for all sorts of other tasks that was too involved for the labor crew, and too vague to fit under Mechanical Maintenance, because somewhere, there was a wire attached.  God forbid if a labor crew hand was electrocuted while changing out a bank of paper air filters.  — Ok.  It’s not like me to complain… — or maybe in my old age, it is becoming more common… I’m not sure.

So.  In most houses there are two types of filters.  There is what I would call a “Paper Filter”, and there is a “Metal Filter”.  The paper filter is found in the air conditioner intake.  You probably don’t change it out as often as you should, but you know what I’m talking about.  The metal filter is probably over your stove in your oven vent. — Oh…. You didn’t think about that one?  Better go clean it then….

The Power Plant is the same.  There are both paper filters and metal filters, and things we would call “Bag Filters”. — Oh.. yes.  and coffee filters… but I’m not going to talk about Coffee filters in this post other than to say that, “yes.  We did have coffee filters also.”

Power Plant Coffee Maker Coffee Filter

Power Plant Coffee Maker Coffee Filter

Ok.  A short side story… The person that was appointed to drive the truck was responsible for making sure the coffee maker was ready to go by break time.  Only, when I was the designated truck driver I told everyone that I was not going to make the coffee.  My reason was that I don’t drink coffee, and I wouldn’t know how to make a good cup of coffee and they could be sure that if I made it, it was going to be as thick as syrup.  — The rest of the Electric shop agreed that it would not be a good idea for me to make their coffee, so either Andy or Dee made the coffee when I was on Truck Driver Duty. — End of side story.

So, when we were placed on Filter Duty… That meant that we went around the plant and changed out filters for air handlers, and we cleaned and coated the metal filters that were used on motors.  This task took about a week.  “A week?” you say?  Yep.  I don’t remember the exact numbers, though at one point in my career I had counted everyone of the them just to amuse my self… but just one air handler for the main switchgear had about 50 large paper filters and if I remember correctly had another 50 bag filters behind them.

Industrial Paper Air Handling Unit Filter

Industrial Paper Air Handling Unit Filter.  They kind of look like Modern Art I suppose

Here is the bag filters that usually were attached to the back side of the paper filters:

Industrial Air Handler Bag Filter

Industrial Air Handler Bag Filter.  Except ours weren’t pink and they weren’t on a beach.

First we had to remove the old filters that were often crawling with various kinds of flying insects that had been stuck to the filters since they flew too close and were sucked onto the filter.  Then we installed the new filters in their place on a wall made of a large metal frame designed specifically for these filters.  I think the reason they have a picture of the beach with this bag filter is because usually when you are trying to fit the bag filter into the basket you often thought that you would rather be at the beach than doing this task.

So.  In the coal-fired power plant in North Central Oklahoma, there were a set of very large motors that spun the large fans that blew air into the boiler and that blew the exhaust up the smoke stack.  Each of these motors (and we have two of each kind), had a set of large metal filters on them.  You had to remove a large panel bolted to the side of the motors to remove the filters. — The motors were almost always running when this was being done.  After all.  We can’t stop lighting Oklahoma City just because it’s time to clean the motor filters on the fans on the boilers….

The metal filters reminded me of the filters over the stove when i was a cook at Sirloin Stockade.  We would have to take them out each night and run them through the dishwasher after all the dishes had been washed after closing.  Then the dishwasher was put in a self-cleaning mode to clean out all the gunk from the filters.

Galvanized, Stainless Steel Framed Air Filter used in large motors.  This is a about 2 feet by 2 feet square.

Galvanized, Stainless Steel Framed Air Filter used in large motors. ours is a about  2-1/2 feet by 2 feet in the largest motors.

Then we had pump motors around the plant and down at the river that had smaller versions of these metal filters.  Each of these metal filters were taken to the shop where we used a high pressure washer (one that would take the paint off of your car), and we would disintegrate the bugs that were stuck to these filters using the high pressure washer until the filters were cleaned.    Then after letting them dry, we would coat them with a “filter coat” that would collect dust so that we wouldn’t have to wait too long before they were dirty again.

Well.  There were some that didn’t like using the filter coat.  Especially if they thought they might have to be cleaning the same filters themselves the next time.  This happened when we decided to split the Filter Duty up between teams once.  We decided that one team was going to be responsible for Unit 1 and the other team was going to be responsible for Unit 2, and we split up the air filters so that they were pretty evenly divided.

When we did this, an incredible thing happened.  Each time we had to clean our filters, they were really dirty.  Half the time the other team cleaned their filters they were not very dirty.  It was obvious what was happening…. someone wasn’t using the filter coat.  We all knew that it was “Ain’t My Mota” (translated “not my motor) Michael Rose.  There was nothing anyone could really do about it.  His foreman tried and tried to reform him, but there was really only one cure.

Talking about “Ain’t My Mota” Michael reminds me of one guy that was on our crew, Gary Wehunt.  It wasn’t that he cut corners.  It’s just that he always wanted to do the easiest jobs first and work his way up to the worse jobs.  I was the other way around.  I always wanted to get the tough jobs over with right away, and then cruise on down to the easier jobs.

So, when I was working with Dee (Diana Brien) cleaning motor filters, we would start with the bowl mill motors and then work our way over to the big fan motors.  Then we would end up down at the river cleaning the river pump motor filters.  When I was working with Gary, he always wanted to go straight to the river pumps.  I always had the feeling that he thought that there might be a chance that by the time the Bowl Mill motors (which were always caked with Coal Dust) he would be called off to go work on an air conditioner instead.  To each their own.

So.  What is a Louver?  I guess I forgot to mention that.  A Louver is the metal flap that opens to let the air in.  When the air handler is off, the louver closes.  Before it starts up, the Louver opens so the air can pass through the filters.  It is like a set of blinds on a window.  The Louver Motor opens and closes the Louvers:

Large Metal Louvers for an Industrial Air Handler

Large Metal Louvers for an Industrial Air Handler

Today I am not able to change out the filter for my air conditioner in my house without having a flashback to the time I spent replacing filters at the plant covered with dirt, coal dust, fly ash and bugs.  I had reminded myself often early on after I joined the electric shop as an electrician what Charles Foster had told me when i was still a janitor.

In my new job I sit in a clean office area with people sitting all around typing away on their computers or talking to one another.  But out of the corner of my ear I can hear the noise every so often up in the ceiling above the false ceiling of the air handler louvers adjusting the air flow as the climate control detects that more air is needed in another area.

My coworkers may think I’m sort of strange (for a lot of reasons, but one of them may be) because as I’m working away on the computer apparently oblivious to what is going on around me, I may suddenly break out in a big smile.  Why?  They may wonder.  Because I can hear that louver slowly changing position.  They sound like they are pneumatically controlled, but there is no mistaking the distinct low grind of the flaps as they slowly change.  So, without stopping what I’m doing, a grin may appear on my face.

Charles had come up to me when I was a janitor while I was working on the floor scrubber in the main switchgear and asked me if I would think about becoming an electrician.  He said that a lot of being an electrician was cleaning things.  He had noticed that I took a lot of pride in the way I cleaned and that he thought I would make a good electrician.

I did enjoy being a Janitor and having someone encourage me to become an electrician was all I needed to pursue the honorable trade of “Electrician”.  It didn’t take me long once I joined the shop to learn that Charles wasn’t stretching the truth when he said that a lot of what an electrician does is clean things.

I spent 18 years as an electrician at the Power Plant before moving on.  Throughout that time, my wife never knew what to expect when I came home from work.  My clothes could be just as clean as when I left in the morning, or (most likely), they would be covered with Soot or Coal Dust from the Coal-Fired Power Plant in North Central Oklahoma.   One thing she could usually count on when I walked in the door was that I would have a smile on my face for having the privilege to spend a day at work with such a great group of Power Plant Heroes.

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