What Coal-Fired Power Plant Electricians Are Doing at an Oil Refinery

Power Plant Men working for a large Coal-Fired Power Plant have the kind of culture where Cleanliness is next to “Leroy Godfrey-ness”.  If you knew Leroy Godfrey, then you would know that he was a perfectionist in a lot of ways.  Or… Well, he expected the Plant Electricians to be anyway.  A few years after becoming an electrician, there was some work being done by Ben Davis, one of our best electricians, at the Conoco (Continental) Oil Refinery twenty miles north of the plant in Ponca City.

Conoco (Now Philips 66) Oil refinery

Conoco (Now Philips 66) Oil refinery in Ponca City

Being a low level Electrician Apprentice, I was not included in whatever was happening at the Refinery.  I didn’t work at the refinery for many years.  When I finally did go to Conoco, I wished I hadn’t.

What was happening?  A Co-Generation plant was being built there.  It is called a “Co-Generation” plant because it serves two purposes.  Waste gas from the refinery is used to fire the boiler that produces the steam to turn the turbine.  Any steam left over is sent over to the refinery to supplement their own needs.  The electricity is used by the refinery and any left over electricity is sold by the Electric Company for a profit.  So, in a sense, it is a “Co-Existence”.

For the most part, Power Plant Men were looking for opportunities to get in a company truck and leave the plant grounds to work on something outside the confines of the plant where they work every day, week in and week out.  Trips to the river pumps or the parks on our lake were always nice, because you would see wildlife along the way.  You could look out over the Arkansas River in the morning as the sun was rising and feel the cool breeze and smell the pastures nearby.

Trips to Enid to our small peaking units were fun too, because we were able to work on some different equipment out in a quiet substation where mud daubers were the only sound until the units came online.  The drive to Enid was nice because the 45 mile trip across the countryside is pleasant and the traffic is very light.  You can go for miles without seeing another car.

After only a couple of visits to the Conoco Oil Refinery, I never looked forward to the 20 minute drive from the plant when we had to work on the Co-Generation Plant co-owned by our company and the Oil Refinery.  There were a few things about the refinery that bothered me about working there.  One annoying factor was the hideous smell.

I had lived in Ponca City for three years and the sour odor that poured out of the Oil Refinery to the south of our house generally blew right up our street.  One winter morning I remember stepping out of our rental house into the dark on my way to work, and the exhaust from the oil refinery must have been blowing directly down the street to our house where I lived because when I took a breath I gagged immediately and was at the point of vomiting on the front lawn.

The house we rented in Ponca City, Oklahoma

The house we rented in Ponca City, Oklahoma in 1986-89 with about 600 sq. ft. of living space

A side note…

My wife and I lived in this tiny house shortly after we were married.  Kelly was an RN (nurse) at the local hospital working the night shift while I was an electrician at the Power Plant during the day.  I had the philosophy that if we started by living in a dump and saved our money, then as we gradually worked our way up to a bigger house, we would feel as if life was getting better, and we never had to worry about money, since we always lived well below our means.

I figured that if we lived far below our means, our means would keep growing.  Living just below your means meant always staying in the same economic spot (how many sentences can put the words “means” and “meant” right next to each other?).  The quality of Life doesn’t get much better.  When living well below your means, life continues to get better even if your job stays the same your entire life.  I had figured that I was going to be a plant electrician until the day I retired, so, this was my way of planning ahead.

My wife endured living in this tiny house one block away from the railroad tracks traveled by the coal trains on their way to our plant (which shook our house as they passed) for three years before we moved to Stillwater, Oklahoma where we lived with more than twice the square feet and no smell from the oil refinery.

end of side note…

I started out by saying that the culture at our Power Plant was that Cleanliness was very important.  I suppose this was true at the Oil Refinery as well, only, it seemed that even though the clutter was all picked up, there was something “inherently” dirty about the oil refinery.  I’m not sure how to describe it, but you just felt like you didn’t want to touch anything because it was going to leave some sort of dirty film on you.  It was….. grimy.

Our Power Plant is in North Central Oklahoma, and during the summer going for an entire month with over 100 degree weather every day was not uncommon.  There are parts of the plant where you had to work some times where the temperature reached 160 degrees.  Of course, you can’t stay in that environment very long, and those areas are generally not the areas of choice when choosing which job to work on next.

One hot summer day in 1996, Charles Foster and I had to go to the oil refinery to our Co-Generation plant there to fix an Air Conditioner Condenser Fan Motor.

Charles Foster

Charles Foster

This isn’t like one of those fans on the side of your house in the box that you know as your “air conditioner” that blows hot air out when the air conditioner in your house is running, though it performs the same task, only on a much bigger scale.

A large air conditioner about the size of the one that Mike Rose worked on

No.  Even bigger than this air conditioner

When you entered the oil refinery you had to wear a long blue cloak or coat called “Nomex”.

A Blue Nomex Coat

A Blue Nomex Coat  which can be worn by Mexicans.  That rumor is just not true.

The reason for wearing this heavy “woolen” coat was to help save your life in case you happened to be around the next time (next time?) something exploded, blasting flames in your direction.  — Yeah…. comforting huh?  Knowing that this flame retardant coat was going to keep you from being burned alive when something exploded in the refinery.  Oh joy.

Everyone in the refinery was wearing these blue coats.  It was a requirement before you could drive your pickup through the security gate.

Once inside the gate, Charles and I checked our clearances to make sure it was safe to work on unwiring the motor that was mounted under the air conditioner coils.  Another fan was running that was turning a large fan blade blowing hot air down next to us.  We had brought our own fans to blow cooler air on us while we worked on the motor.  This particular motor weighed about 400 lbs, to give you an idea of the size of motor we were repairing.

A motor much like this one

A motor much like this one only mounted vertically

Charles and I had brought a temperature gun to check how hot everything was when we were working.

An Infrared Thermometer

An Infrared Thermometer

When we checked the temperature, we found that the area where we had to stand was 160 degrees.  The motor itself was even hotter than that.  We had to wear leather gloves just to work on it without burning our hands.  Asbestos gloves would have rendered us useless because they make you feel like you are wearing “Hulk Hands” where your fingers are about 2 inches wide.

Asbestos Gloves worn when putting hot bearings on a motor shaft (for instance)

Asbestos Gloves worn when putting hot bearings on a motor shaft (for instance)

See what I mean?

Hulk Hands

Hulk Hands

The air was too hot to breathe except for quick shallow breaths.  Even though we had a fan blowing directly on us, we took turns approaching the motor, turning some bolts a couple of times, and then quickly moving out of the area to where we could be in the cooler 105 degree temperature.

There is nothing like a mild irritation (such as working in extreme heat) to motivate you to hurry up a job.  Charles and I worked diligently to remove the motor and then lowering it down with a platform hand lift that we kept in the shop.

A platform Lift Hand Truck like the one we used

A platform Lift Hand Truck like the one we used only ours had a hydraulic lift on it.

This fan motor was on the roof of a building, so once we had removed the motor from where it was mounted, we still had to lower it down to the back of the truck which was backed up to the side of the building.  Once in the truck, we brought it back to the plant where we could work on it.

When you first went to work in the oil refinery you have to take a specially designed safety course when you are issued your Nomex coat.  During that class, you are told that if you hear the sirens go off, that generally means that there are some toxic gases being released accidentally in the plant, you are supposed to take action quickly.

The funniest (or not so funniest) instructions was that when the sirens go off, you are supposed to run in the opposite direction away from the sirens.  Which sort of reminds me of Monty Python’s Search for the Holy Grail when they had to run away from the viscous fighting rabbit. Yelling “Run Away!  Run Away!”  Great safety evacuation plan.

Battling the Killer Rabbit in the Search for the Holy Grail

Battling the Killer Rabbit in the Search for the Holy Grail

The toxic gas that everyone was worried about is called Hydrogen Sulfide or H2S.  This is the gas that smells like rotten eggs.  The only problem is that when there is more than the minimal amount of H2S in the air, you can’t smell it anymore because it quickly deadens your sense of smell.

Hydrogen Sulfide Warning Sign

Hydrogen Sulfide Warning Sign

Another fun reason to not want to go work in the Oil Refinery.

Anyway, Charles and I safely reversed the process to return the motor to its rightful place mounted on the bottom of the coils on the roof.

A few times I had to go to work at the Co-Generation plant because something was broken (like the fan motor), but most of the time that we went to the plant was to do our quarterly battery inspections.  For more information about battery inspections, you can read this post: “Importance of Power Plant Backup Battery Preventative Maintenance“.

I have told you all the reasons why I didn’t enjoy working at the Oil Refinery in Ponca City, Oklahoma.  There were reasons why I did enjoy it.  I suppose if you have been reading my posts, you will know the most obvious answer to that question (oh.  I guess I didn’t really ask a question… but if I had…).  The only redeeming factor with working at the Co-Generation plant at the oil refinery was being able to work with the best Power Plant Men and Women in the country.

I have given you an example above when I worked with Charles Foster.  I also worked with Scott Hubbard and Diana Brien.

Scott Hubbard

Scott Hubbard

My Bucket Buddy Diana Brien

My Bucket Buddy Diana Brien

Both of them top class electricians and First Class Friends.  Just to be able to work side-by-side with such terrific people made me forget about the poison gases.  I didn’t mind the heat.  I even forgot I was wearing the heavy suffocating Nomex Coat.  What’s a little grime when your friend tells you about their day?  About what they are planning for the weekend?  Or the rest of their life?

Actually, I think that’s what made everything about working both at the Oil Refinery and the Power Plant itself the most enjoyable job I can imagine.  Sure.  We had a culture of “cleanliness” at the plant.  I think it was the “friendliness” that really made all the difference.  It was also the most painful part the day I finally left the Power Plant to adventure out to find the rest of the world in 2001.

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19 responses

  1. Reblogged this on Angel 4 Light and commented:
    What a great story to share. We all have had jobs that rated 0 on a scale of 1 to 10 (10 being the highest). Having such experiences and being able to share the lighter side of it with a sense of humor and genuine admiration for our co-workers is a gift.

    I loved this story and felt compelled to share. Be blessed

    Like

  2. Whatever the conditions at a workplace, the people make all the difference.

    Liked by 1 person

  3. I love your writing style. As I have said in the past, I know nothing about power plants, but you make it seem like Disney World!! Great post as always!

    Liked by 1 person

  4. I felt that same pain 7 years earlier. It was a great environment to be a part of.

    Liked by 1 person

  5. Hello Plant Electrician, You are so blessed to have a wife who understands the principle of “living BELOW your means.” Not to be a chauvinist, but I am originally from NJ. A LOT of the “Jersey Girls” just want the super rich guy. They have no idea of the concept of “growing in social stature.” They want the fancy jewelry, the expensive car, the designer clothes; and they want them NOW! To a lot of the Jersey Girls that I’ve known, sorry if the truth hurts. You are blessed to have married a practical woman.

    Liked by 1 person

    1. Thanks Richard. I truly am blessed.

      Like

  6. You are a great writer. Thanks for your diligence.

    Liked by 1 person

  7. Wow, another wonderful story. Scary and heroic. Always interesting and informative as well. Thank you.

    Liked by 1 person

  8. You stories are so interesting and I like your writing style. You compliment your story with pictures that add even more interest. I know very little about power plants and feel like I am getting an education.

    Liked by 1 person

  9. Goodnight! What an interesting blog, I never would have guessed something like this existed. I will enjoy looking it over.

    Liked by 1 person

    1. Thanks Iowa, I look forward to reading your blog as well.

      Like

  10. Great story of life ! and a credit to you all still have a smile in your face. Worked once in side a boiler and suddenly it turn on and we have to sprint out of the boiler on a hole just enough for you to crawl. We are all pilgrims in this world and there is a better one in the next. God bless +++

    Liked by 1 person

  11. […] wrote a post about the Co-Generation Plant in a previous post: “What Coal-fired Power Plant Electricians Are Doing at an Oil Refinery“.  When it was discovered that the computer at the Conoco Oil Refinery Power Plant would […]

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