Favorites Post #28
Originally posted on 1/14/2012:
What sets power plant men apart from your regular mechanic, lineman or men of other occupations is that they are a semi-captive group of people with a lot of freedom to move about the plant and the plant grounds. This provides for the opportunity to play jokes on each other without resorting to “horseplay”. There is no room for horseplay at a power plant. The power plant man lives among dangerous equipment, poisonous chemicals, carcinogenic dust, asbestos gloves and purely evil plant managers who would love to catch one of his minions engaging in horseplay.
The more elaborate yet simple joke seems to have the best effect on those who find themselves the victim. First of all, the joke must be essentially harmless. That is, no one is left injured (this rule seems to be more of a suggestion since I seemed to end up on the short end of the stick a few times). Secondly, the longer the joke takes to completion, the better.
If the joke goes on for a week or longer, then the final impact of the joke is much greater. For instance. A person that you are going to play a joke on sits in a chair that is raised and lowered by turning the chair upside down and twisting the wheel bracket around (which is how you lowered office chairs before the fancier spring and air cushioned chairs arrived). Say you were to gradually lower a person’s chair each day by 1/8 of an inch or so.
Eventually, in a couple of weeks, the person will be sitting lower and lower at their desk until one day they get frustrated at sitting so low that they turn their chair over and raise the chair higher. But each day, you keep lowering the chair by just a little bit until they are sitting so low again that they complain about it again and raise the chair up. This can go on indefinitely. The more people that know the joke is being played, the better in this instance.
The first time I met Gene Day, I knew that he was someone that would be fun to play jokes on. I don’t know what it was about him exactly. It wasn’t that he appeared to have a lower IQ. On the contrary. He seemed to be very knowledgeable as Control Room operators go. Maybe it was because he seemed like a happy person that took most things rather lightly.
He wouldn’t be the type of person that would hold something against you just because you made him look foolish in front of his peers (or you posted it on a blog for the entire world to see. — Right Gene?). It seemed like the first time I noticed Gene Day from across the room, he was standing in the Control Room and I gave him a look like I was suspicious of him and he returned the look with one that said that he knew that I might be the type of person that would play a joke on him. This surprised me, because I thought I had masked that look pretty well.
Throughout my 20 years of power plant life I played many jokes on Gene Day, and each time it seems that I was throttled to the edge of extinction, which meant that I had executed the joke perfectly. It seemed that each person had a different way of expressing their joy of finding out that they have been the victim of a power plant joke. Gene’s general reaction was to place his hands carefully around your neck and start rapidly shaking your head back and forth.
My favorite Gene Day joke was not one that took a long time to execute, and from the time that I conceived the idea to the time that I was being strangled by Gene Day was a mere 15 hours.
It began when I was driving home from work one day on my way down Sixth Street in Stillwater Oklahoma where I lived on the west end of town at the time. Gene Day was an operator and their shift was over an hour and a half before the rest of the plant. As I drove down Sixth Street about a block ahead of me, I saw Gene Day’s truck pull away from the Rock House Gym travelling in the same direction. Gene had a black pickup with flames on the side…. Something left over from High School I think… The only one in town like it.
I kept an eye on his truck to see where he went, and as he passed the Stillwater Hospital he pulled into an Eye Clinic and parked in the parking lot. I drove on past and pulled into my driveway about 3 blocks further on. As I checked my mail I decided to go to the bank to deposit some checks I had received. I returned to my car and pulled my car out of the driveway and headed back toward downtown.
Gene Day just happened to turn onto Sixth Street in front of me again as he left the Eye Clinic and proceeded to go down Sixth street in front of me. So again I watched him to see where he went.
Just as I came to Duck Street, I saw Gene Day pull his truck into the Simon’s Gas Station on the corner of Duck and Sixth. He had pulled his truck up to the garage instead of the pumps, so I figured that he was getting his truck inspected. I turned on Duck street to go to the bank drive-thru about a block away from the gas station.
After taking care of my banking business, I left the bank and headed back home toward Sixth Street. I arrived at the corner of Sixth Street just in time to see Gene Day pulling out of the gas station and heading off in the opposite direction toward his house. I thought that he hadn’t been at the gas station very long so he probably had just had his truck inspected.
The next morning when I arrived at the plant I walked by Gene Day’s truck on the way to the electric shop and I looked to see if he had a new Safety Inspection sticker. He didn’t have any Safety Inspection sticker which meant that his truck had failed the inspection.
Armed with this information when I arrived in the electric shop I took out a yellow pad of paper and proceeded to write the following:
Private Investigator’s Notes for Gene Day:
3:05 Gene Day leaves work.
3:45 Gene Day arrives at Rockhouse Gym where he works out with a young college coed named Bunny.
5:05 Gene Day leaves Rockhouse Gym.
5:07 Gene Day arrives at Cockrell Eye Care Center where he meets with a nurse in his pickup truck in the parking lot.
5:20 Gene Day leaves Eye Care Center.
5:25 Gene Day arrives at Simon’s Garage at the corner of Sixth and Duck and has them clean his pickup seats to remove the perfume scent. While he was there, he tried to have his pickup inspected, but it didn’t pass inspection.
5:33 Gene Day leaves Simon’s Garage and goes home.
I folded the paper in half and after I began work, I headed to the Control Room to see how the Electrostatic Precipitator was doing. I sat at the computer by the Control Room door that opened up to the Turbine Generator room. After a while Gene Day walked by on his way to pick up the mail from the front office.
I waited about 30 seconds and followed him out onto the Turbine Generator (T-G) floor. The T-G floor at Sooner Plant is painted bright red and the floor is kept clean so that the lights overhead reflect off of the floor.
The Control Room is halfway across this large room about 200 yards long. The office area is at one end. I walked over to the door that leads to the Office area and laid the half folded paper in the middle of the floor.
I figured that Gene wouldn’t be able to resist picking it up to see what it said. Then I went back to the Control Room and leaned against one of the big blue monitors used by the Control Room Operators to view alarms.
After a few minutes, Gene Day walked into the Control room. In one arm he carried various parcels of mail. In the other hand, he was carrying the yellow paper I had left for him to find. He was violently shaking it at me yelling, “How did you do this?!?!”
I acted surprised as if I didn’t know what he was talking about. Somehow he figured I was behind this, but for the life of me I don’t know why…. He tried to explain to me that he had stopped to see his wife who is a nurse at the Cockrell Eye Care Clinic, and that there wasn’t any girl named Bunny. He couldn’t figure out how I would know that he tried to get his truck inspected and it failed inspection….
I insisted that I didn’t know what he was talking about. About that time, the room became blurry as my head was shaking back and forth, and I came to the realization that this joke had been performed perfectly.
Favorites Post #25
Originally posted January 24, 2015
The Electric Shop had tried for three years to win the Safety Slogan of the Year award. Not because we thought we were safer than any of the other teams at the coal-fired power plant in North Central Oklahoma, but because we really liked pizza (see the post: “When Power Plant Competition Turns Terribly Safe“) . When the plant was downsized in 1994, the electric shop no longer existed as it had before. We had become cross-functional teams (See the post: “Crossfunctional Power Plant Dysfunction“). It looked as if our dream of winning the Power Plant Safety Pizza was no longer in our grasp.
My carpooling buddy, Toby O’Brien had moved from our plant as a Plant Engineer to the Safety Department in Oklahoma City. He was working with Julia Bevers and Chris McAlister. Chris had also moved from our plant as a labor crew hand to the Safety Department (This was a great opportunity for Chris!).
Bill Green our new plant manager introduced a jar of beads during his first safety meeting. We each picked a bead randomly from the jar through a small hole in the top. Then Bill Green pointed out that the color of bead represented the result of doing something unsafe.
The green color meant that nothing happened. The other colors reach represented a different type of accident that occurred. The ratio of beads in the jar represented the likelihood of each type of accident happening. There was one black bead in the jar. That meant that you died when you did something unsafe. I used to keep the number of each color of marble in my wallet, but that piece of paper disintegrated over the years.
The types of accidents were something like: First Aid Case, Reportable Accident, Lost Work Day Accident, Hospitalized, and Death.
A couple of months after the downsizing, the Safety department announced that they were going to have a Safety contest. The contest would be held at each plant and it involved each of the supervisor’s computers. The prize for the contest was that the winning team would be able to eat a free lunch with complements from the safety team.
Great! Shortly after the electric shop is busted up and we were scattered to the wind, we finally had one last chance to win the ever illusive Power Plant Safety Pizza! Only, how were we going to do it? I was working on Alan Kramer’s team. My old foreman Andy Tubbs (not old in the sense that he was an old man… old in that he was my former foreman) was now one of the other supervisors with only my old bucket buddy (you know what I mean… not “old” old) Diana Brien as the electrician on his team.
Before I go further to explain my conflict during this contest, let me explain how the contest worked.
The supervisors had new computers that ran using Windows 3.1. Back then, the screensaver on the computer didn’t just shut down the monitor like most of them do today. Instead, they showed some kind of message, or picture or something animated that kept moving around so that your monitor didn’t get burned in with an image that was constantly on your screen, such as your wallpaper and your icons.
The Safety Department said that each team should come up with some way to display the idea of “Safety” using a screensaver. They suggested using the screensaver that let you type in a message that would scroll across the screen when the screensaver was turned on. That was a simple built-in screensaver that came with Windows 3.1.
Then the Safety Department would come to the plant on a particular day and judge each of the computer’s screensaver and announce the winner. Sounds simple enough.
We first heard about the Safety Slogan Screensaver contest in our Monday Morning Meeting with our team. Alan Kramer said we should come up with a good slogan that we could put on our scrolling message screensaver. I kept my mouth shut at the time, because I didn’t know exactly how to proceed. I was having a feeling of mixed loyalty since my old Electric Shop Team with Andy Tubbs as our foreman had written over 300 safety slogans and had purposely been blocked from winning the Prized Pizza each year.
Not long after the morning meeting, Andy Tubbs came up to me in the Electric Shop and said, “We have to win this contest! That Pizza should be ours! I need you to come up with the best screensaver you can that will blow the others away.” I gave him my usual answer when Andy asked me to do something (even when he was no longer my foreman). I said, “Ok, I’ll see what I can do.”
I went down our list of safety slogans looking for the best slogan I could find. Here are a few of them:
“Having an accident is never convenient, So always make Safety a key ingredient.”
“Take the time to do it right, Use your goggles, save your sight.”
“To take the lead in the ‘Safety Race’, You must pay attention to your work place.”
“Unsafe conditions can be resolved, If we all work together and get involved.”
After thumbing through the entire list, I knew we really needed something else. So, I began to think of alternate screen savers. One caught my attention. It was called “Spotlight”. It came with the “After Dark 2.0 Screensavers” (best known for the “Flying Toaster” screensaver). I had found a freeware version that did the same thing. You can see how the spotlight works at 7:15 on the video below (just slide the time bar over to 7:15):
For those who can’t view YouTube videos directly through the above picture, here is the direct link: “After Dark Screensavers“.
The spotlight screensaver basically turns your screen dark, then has a circle (or spotlight) where you can see the background screen behind it. It roams around on your desktop showing only that portion of your wallpaper at a time. You can adjust the size of the circle and the speed that it moves around the screen.
Taking our safety slogans, I began creating a wallpaper for the computer screen by filling it with little one liner safety slogans. I also added yellow flags to the wallpaper because that was a symbol for safety at our plant (for more information why see the post: “Power Plant Imps and Accident Apes“).
With the help of Charles Foster and Scott Hubbard (both Power Plant electricians), when I was finished the wallpaper looked like this:
I printed this out in black and white, but the slogans were written in different colors.
I arranged Andy’s icons on his desktop so they were around the edge of the screen. That way they didn’t cover up the safety slogans. I set the speed of the spotlight to very slow and and the size of the spotlight so that it was just big enough to see each safety slogan. The effect worked out real well. Imagine a dark screen with a spotlight moving randomly around the screen exposing each safety slogan (and yellow flag… don’t forget about those) as it went.
Besides the electricians, no one else knew that I was working on this for Andy. As far as Alan Kramer knew, I was on his side in this contest. I even kept Toby O’Brien in the dark about it, because I knew that he was going to be one of the judges and even though he knew how much winning the Safety Pizza meant to me. I didn’t want to influence his decision. Besides, this Safety Screensaver was going to win. It was the coolest screensaver around. The trick was to keep it hidden from the other teams until it was time for the Safety Department to judge it.
I had the impression from Toby that he had purposely talked the Safety Department into this contest to give me a chance to win the Safety Pizza at our plant. Scott Hubbard and I had carpooled with Toby throughout the years we were trying to win that pizza, and I think he just felt our pain enough that when he was in the position, he was trying to pay us back for our effort.
The screensaver judging was done during the morning, and was going to be announced that afternoon during the monthly safety meeting. A short time before the Safety Meeting began, Toby O’Brien came up to me and in an apologetic manner told me that the safety slogan winner probably wasn’t going to be who I thought it was. I figured that was because he thought I was hoping Alan Kramer’s team was going to win since that was my team. I just smiled back and told him that it was all right.
It was announced during the safety meeting that Andy Tubbs’ team won the contest, and all the electricians were happy. I think it was at that point that Alan Kramer realized that I had helped Andy with his screensaver. He looked at me as if I had betrayed him. I said something like, “Andy Tubbs has been trying to win a safety contest for years. It’s about time.”
The following week, when Andy’s team was given their prize for winning the safety screensaver contest, he brought two pizzas to the electric shop and we all sat around the table relishing in the pepperonis. We had finally received our Power Plant Safety Pizza! Even though I really like pizza anytime, the pizza that day tasted especially good.
I don’t know if we ever told Toby that when Andy Tubbs team won, we all won. Maybe some day he will read this story and know…. “The Rest of the Story”.
In case you can’t read all the little safety slogans on the wallpaper, here is a list of them:
Safety First. Be Safe. Safety begins here. Watch your step. Check your boundaries. Have Good Posture. Haste makes waste. Bend your knees. Avoid Shortcuts. Be Safe or Be Gone. Know your chemicals. Check O2 before Entry. Use Safety Guards. Know your limit. Report Spills. Safety is job #1. Beware of Pinch Points. Buckle up. Safety is no accident. Impatience kills. Strive to Survive. Protect your hearing. Use the right tool. Keep your back straight. Drive friendly. Keep Aisles clear. Don’t take chances. Prevention is the cure. Safety is your job. Communicate with others. Always tie off. Don’t cut corners. Wear your glasses. Act safe. Barricade Hazards. Use your respirator. Be responsible. Lock it out. Plug your ears. Stay fit. Safety never hurts. Don’t block exits. Be aware of your surroundings. Safety is top priority. Don’t be careless. Pick up your trash. Think Ahead. Slippery When Wet. Think Safety. Don’t hurry. Report Hazards. Wear your gloves. Save your eyes. No Running. Wear your Safety Belt. Plan Ahead. Avoid Backing. Use your Safety Sense. Good Housekeeping. Get Help. Keep Cylinders Chained. Protect your hands. Don’t improvise. Beware of hazards. Get the Safety Habit. Be Prepared. Gear up for Safety. Use your PPE. Do not litter. Zero Accidents. Don’t be a Bead (a reference to Bill Green’s jar of beads). Eat Right. Keep Floors clean. Watch out. Safety Pays. Drive Safely. Take Safety Home. Know Safety, use Safety. Read the MSDS. Cotton Clothes Prevents Burns. Follow the rules. Wear your hard hat. Watch out for your buddy. Test your Confined space. Remember the Yellow Flag. Safe Mind, Sound Body. Clean up your spills. Don’t take risks. Beware of Ice. Watch out for the other guy. Obey the rules. Don’t tailgate. Circle for safety. Safety Me, Safety You. Protect your Toes. Knowing is not enough. When in doubt, Check it out. Falls can kill. Be Alert! Avoid slick spots. Safety is a team event. Almost is not enough. Avoid the Noise. Give Safety your all. And finally… This Space for Rent.
Favorites Post #24
Originally posted: June 27, 2015
When I think back about the Power Plant Men and Women that I worked with for the 20 years I spent working at the coal-fired Power Plant in North Central Oklahoma, I still see them as they were back when I first knew them. I was able to see them come to work each day willing to give all they had in order to keep the plant running smoothly. I would find out sometimes that behind their stoic behavior of heroism was a person bearing enormous pain.
I will not go into the private lives of each of the Power Plant Men and the personal struggles in their lives beyond those that we all shared at the plant. Some were bearing such enormous pain that all the Power Plant Men and Women shared their pain. Others bore their pain in silence leaving the rest of us oblivious to the grief as they sat next to you in the truck or beside you tightening bolts, or checking electric circuits.
I remember a time when one of my best friends seemed to be acting short tempered for a while. I figured something was eating at him. Finally after almost a year he confided in me what had been going on in his personal life, and it broke my heart to think of the pain this person had been experiencing all along, while I had been annoyed at his quick temper.
It is an eye opening experience when the person I talked to every single day at work is being torn apart with worry and I didn’t even have a clue. Well, the clues were there only I was too blind to see.
I began this post on a rather ominous note because one of the great Power Plant Men of his day, Larry Riley, died this past Wednesday, June 24, 2015.
A few weeks ago I wrote a post about my Power Plant Friend Bud Schoonover passing away. (See the post: “Dynamic Power Plant Trio — And Then There Was One“). I mentioned some of the special times we had while we carpooled back and forth to Ponca City, Oklahoma. I knew Bud was getting along in years, so when I heard about his death, I was not surprised. I immediately pictured him back together again with Richard Dale, our travelling companion.
On Wednesday night when I was contacted by a number of Power Plant Men and Women who all wanted me to know right away that Larry had passed away, I was suddenly hit with a wave of shock. I was overwhelmed with grief. I broke out in tears.
Larry had been important to me from the very first day I worked in the Power Plant. I worked with Larry and Sonny Karcher before I worked with anyone else. My original mentors have both passed away now.
Of the 183 Power Plant Stories I have written thus far, the story about Larry Riley was one of the first stories I couldn’t wait to tell others. You can read it here: “Power Plant Genius of Larry Riley“.
Through my first years at the Power Plant Larry was there looking out for me when he had no other reason to do so than that he cared for others. Some pseudo-Power Plant Men mocked him secretly for being a noble person. Others didn’t have a clue what lengths Larry went to help out a person in need.
Since Larry’s death I have heard a couple of stories that Power Plant Men wanted to share with me about how Larry helped them out when there was nowhere else to turn. Stories I heard for the first time. I encourage any Power Plant Men who knew Larry to leave a comment below about him.
Larry was one of those people who used to bear his pain in secret. He did the same thing with his love for others. I had mentioned in the post about the Genius of Larry Riley that “…he performed acts of greatness … with complete humility. I never saw a look of arrogance on Larry’s face. He never spoke down to you and he never bragged about anything.”
Though Larry did his best to conceal it, there was always a hidden sort of sadden about him. Since he had the wisdom and knowledge well beyond his years when he was only 24 years old, I figured he must have had a rough childhood that caused him to grow up quickly. He was humped over as if he carried a burden on his back. I thought maybe his sadness grew out of that experience. Of course, I was only guessing.
After I first posted the story about Larry Riley, I was told by a Power Plant Man that Larry had been forced to accept an early retirement because he had a drinking problem. The Plant Manager was kind enough to let him retire instead of outright firing him, which would have caused him to lose his retirement benefits.
When I heard that Larry was no longer at the plant and under what circumstances he left, my heart sank. The sadness that Larry Riley had been trying to hide all those years had finally caught up with him in a big way and his world came crashing down.
I know that I am more like an “armchair observer” in the life of Larry Riley. There were family members and friends that I’m sure were devastated by Larry’s downfall in a lot more ways than one. Where I sit back and idolize the Power Plant Men as heroes, others are down in the trenches coming face-to-face with whatever realities happen in their lives.
Where others may look at Larry as a failure for developing a drinking problem that brought him to his knees, True Power Plant Men know full well that Larry Riley has a noble soul. He has always been meant for greatness.
In the post about my last day on the Labor Crew, I wrote the following about Larry, who was my foreman while I was on the Labor Crew (see the post: “Last Days as a Power Plant Labor Crew Hand“): “…Most of all, I knew I was going to miss Larry Riley… Larry was a hero to me. I love him dearly and if I had ever had an older brother, I would have liked someone with the character and strength of Larry Riley. He remains in my prayers to this day.”
I know I am not the only person that remembers Larry the way I do. When Larry died this past Wednesday, as soon as the Power Plant Men found out, several of them sent me e-mails, and reached out to me on Facebook to let me know. I think some of them wanted me to share Larry’s greatness with the rest of the world through this post.
As I felt the outpouring of grief from the Power Plant Men, I was overwhelmed by their sorrow. I happened to be sitting alone in a hotel room in Detroit, Michigan when I first found out. My phone kept buzzing (as I had it on vibrate) as one-by-one Power Plant Men sent messages letting me know of Larry’s death. I could feel the sadness hanging over my phone like a fog.
As each message buzzed my phone, my sorrow over Larry’s death grew until I had to just sit on the corner of the bed and cry. I have never felt more sorrow over the death of a Power Plant Man than I did for Larry Riley.
As I pictured Bud Schoonover meeting up again with Richard Dale after Peter open the gate for him, I pictured Larry Riley somewhat differently. I envisioned him walking down a dirt road by himself.
In my mind this is what I saw:
As Larry walks away from me down the road humped over with bad posture, struggling to take each step, in pain from the cancer that killed him, seemingly alone, he pauses suddenly. From the distance in my vision, I can’t quite tell why. He turns to one side.
Almost falling over, as he walks like an old man to the edge of the road where the ditch is overgrown with weeds, he stumbles down into the brush. Thinking that Larry has had a mishap, I move closer.
Suddenly I see Larry re-emerge. This time standing more upright. Alongside Larry is another Power Plant Man. I recognize his gait, but his back is turned so I can’t tell for sure who he is. He is much bigger than Larry. Larry has his arm across the man’s back holding him up as the other Power Plant Man has his arm wrapped around Larry’s neck as Larry pulls him up onto the road.
The two continue walking down the road toward the sun rising on the horizon. The Saints Go Marching On.
This is the Larry Riley I knew.
His funeral service will be held on his 61st birthday, July 3, 2015.
I know that those who really knew Larry will take a moment of silence to remember him. Not for the sorrow that he felt through his life as I originally felt when I heard of his death, but take a moment of silence to remember a great man. One who secretly inspired others toward goodness. A man who went out of his way to lift up someone who had fallen along the side of the road. My personal hero: Larry Wayne Riley.
Favorites Post #23
Originally post 2/21/2015
Don’t let the title fool you. I love testing Power Plant Protective Relays. There is a sense of satisfaction when you have successfully cleaned, calibrated and tested a relay that is going to protect the equipment you have to work on every day. With that said, I was hit with such an unbelievable situation when testing Muskogee Relays in 1995 that I was left with a serious pain in the neck.
On August 14, 2003 the electric power in the Northeast United States and Canada went out. The Blackout lasted long enough to be a major annoyance for those in the that region of the United States.
When I heard about how the blackout had moved across the region, I immediately knew what had happened. I was quickly reminded of the following story. I told my wife Kelly, “I know exactly why such a large area lost power! They hadn’t done proper preventative maintenance on the Protective Relays in the substations! Just like….” Well…. I’ll tell you that part now:
I have mentioned in a couple of earlier posts that something always seemed a little “off” at the Muskogee Power Plant. I had decided early on that while working there I would stick to drinking sodas instead of water. See the post: “Something is in the Water at the Muskogee Power Plant“. Even with that knowledge, I was still shocked at what I found while testing relays at the plant.
This story really begins one Sunday at Muskogee when one of the Auxiliary Operators was making his rounds inspecting equipment. He was driving his truck around the south edge of the Unit 6 parking lot on the service road. He glanced over at a pump next to the road, and at first, he thought he was just seeing things. After stopping the truck and backing up for a second glance, he was sure he wasn’t dreaming. It’s just that what he was seeing seemed so strange, he wasn’t sure what was happening.
The operator could see what appeared to be silver paint chips popping off of the large pump motor in all directions. After closer examination, he figured out that the motor was burning up. It was still running, but it had become so hot that the paint was literally burning off of the motor.
A motor like this would get hot if the bearings shell out. Before the motor is destroyed, the protective relays on the breaker in the 4,000 Volt switchgear shuts the motor off. In this case, the relay hadn’t tripped the motor, so, it had become extremely hot and could have eventually exploded if left running. The operator shut the motor down and wrote a work order for the electricians.
Doyle Fullen was the foreman in the electric shop that received the work order. When he looked into what had happened, he realized that the protective relay had not been inspected for a couple of years for this motor.
I couldn’t find a picture of Doyle. In his youth he reminds me of a very smart Daryl in Walking Dead:
In fact, since before the downsizing in 1994, none of the Protective Relays at the plant had been inspected. The person that had been inspecting the relays for many years had moved to another job or retired in 1994. This was just a warning shot across the bow that could have had major consequences.
No one at Muskogee had been trained to test Protective Relays since the downsizing, so they reached out to our plant in North Central Oklahoma for help. That was when I was told that I was going to be going to Muskogee during the next overhaul (outage). I had been formally trained to inspect, clean, calibrate and test Protective Relays with two of my Power Plant Heroes, Ben Davis and Sonny Kendrick years earlier. See the post: “Relay Tests and Radio Quizzes with Ben Davis“.
Without going into too much detail about the actual tests we performed as I don’t want to make this a long rambling post (like… well…. like most of my posts…..I can already tell this is going to be a long one), I will just say that I took our antiquated relay tester down to Muskogee to inspect their relays and teach another electrician Charles Lay, how to perform those tests in the future. Muskogee had a similar Relay Test Set. These were very outdated, but they did everything we needed, and it helped you understand exactly what was going on when you don’t have a newfangled Relay Test Set.
You need to periodically test both mechanical and electronic protective relays. In the electronic relays the components change their properties slightly over time, changing the time it takes to trip a breaker under a given circumstance (we’re talking about milliseconds). In the mechanical relays (which I have always found to be more reliable), they sit inside a black box all the time, heating up and cooling as the equipment is used. Over time, the varnish on the copper coils evaporates and settles on all the components. This becomes sticky so that the relay won’t operate at the point where it should.
In the picture above, the black boxes on the top, middle and right are mechanical relays. This means that something actually has to turn or pick up in order to trip the equipment. The electronic relays may have a couple of small relays, but for the most part, they are made up of transistors, resistors, capacitors and diodes.
So, with all that said, let me start the real story…. gee…. It’s about time…
So, here I am sitting in the electric shop lab just off of the Unit 6 T-G floor. We set up all the equipment and had taken a couple of OverCurrent relays out of some high voltage breakers in the switchgear. I told Charles that before you actually start testing the relays, you need to have the test documents from the previous test and we also needed the instruction manuals for each of the relays because the manuals will have the diagrams that you use to determine the exact time that the relays should trip for each of the tests. So, we went up to the print room to find the old tests and manuals. Since they weren’t well organized, we just grabbed the entire folder where all the relays tests were kept since Unit 6 had been in operation.
When we began testing the relays at first I thought that the relay test set wasn’t working correctly. Here I was trying to impress my new friend, Charles Lay, a 63 year old highly religious fundamental Christian that I knew what I was doing, and I couldn’t even make a relay trip. I was trying to find the “As Found” tripping level. That is, before you clean up the relay. Just like you found it. Only, it wouldn’t trip.
It turned out that the relay was stuck from the varnish as I explained above. It appeared as if the relay hadn’t been tested or even operated for years. The paperwork showed that it had been tested three years earlier. Protective Relays should be tested at least every two years, but I wouldn’t have thought that the relay would be in such a bad condition in just three years. It had been sitting in a sealed container to keep out dust. But it was what it was.
I told Charles that in order to find the “As Found” point where the relay would trip, we would need to crank up the test set as high as needed to find when it actually did trip. It turned out that the relay which should have instantaneously tripped somewhere around 150 amps wouldn’t have tripped until the motor was pulling over 4,000 amps. I could tell right away why the Auxiliary Operator found that motor burning up without tripping. The protective relays were stuck.
As it turned out… almost all of the 125 or so relays were in the same condition. We cleaned them all up and made them operational.
There is an overcurrent relay for the main bus on each section of a main switchgear.
When I tested the “As Found” instantaneous trip for the main bus relay, I found that it was so high that the Unit 6 Main Turbine Generator would have melted down before the protective relay would have tripped the power to that one section of switchgear. The entire electric bus would have been nothing but molten metal by that time.
As I tested each of these relays, I kept shaking my head in disbelief. But that wasn’t the worst of it. The mystery as to why these relays were all glued shut by varnish was finally solved, and that reason was even more unbelievable.
Here is what I found….. The first thing you do when you are going to test a relay is that you fill out a form that includes all the relay information, such as, what it is for, what are the settings on the relay, and what are the levels of tests that you are going to perform on it. You also include a range of milliseconds that are acceptable for the relay for each of the tests. Normally, you just copy what was used in the previous test, because you need to include the time it took for the Previous “As Left” test on your form. That is why we needed the forms from the previous test.
So, I had copied the information from the previous test form and began testing the relay (one of the first overcurrent relays we tested)… Again… I was a 34 year old teacher trying to impress my 63 year old student. So, I was showing him how you mechanically adjust the relay in order for it to trip within the acceptable range. No matter how hard I tried, I couldn’t adjust the relay so that it would even be close to the desired range for the longer time trip times…. like the 2 second to 25 second range. It wasn’t even close to the range that was on the form from the last test.
The form from the last test showed that the relay was in the right range for all the levels of test. When I tested it, like I said, it wasn’t even close. So, I went to the diagram in the instruction manual for this type of relay. The diagram looks similar to this one used for thermal overloads:
See all those red lines? Well, when you setup a relay, you have a dial where you set the range depending on the needs for the type of motor you are trying to trip. Each red line represents each setting on the dial. Most of the relays were set on the same number, so we would be using the same red line on the diagram to figure out at different currents how long it should take for a relay to trip….
Here is the clincher….The time range that was written on the previous form wasn’t for the correct relay setting. The person that tested the relay had accidentally looked at the wrong red line. — That in itself is understandable, since it could be easy to get on the wrong line… The only thing is that as soon as you test the relay, you would know that something is wrong, because the relay wouldn’t trip in that range, just like I had found.
I double and triple checked everything to make sure we were looking at the same thing. The previous form indicated the same settings on the relay as now, yet, the time ranges were for a different line! — Ok. I know. I have bored you to tears with all this stuff about time curves and overcurrent trips… so I will just tell you what this means…
This meant that when the person completed the forms the last time, they didn’t test the relays at all. They just filled out the paperwork. They put in random values that were in the acceptable range and sat around in the air conditioned lab during the entire overhaul smoking his pipe. — Actually, I don’t remember if he smoked a pipe or not. He was the Electrical Specialist for the plant. I remembered seeing him sitting in the lab with a relay hooked up to the test set throughout the entire overhaul when I had been there during previous overhauls, but I realized finally that he never tested the relays. He didn’t even go so far as try to operate them.
I went back through the records to when the plant was first “checked out”. Doyle Fullen had done the check out on the relays and the test after that. Doyle had written the correct values from the manual on his forms. I could see where he had actually performed the tests on the relays and was getting the same values I was finding when I tested the relays, so I was certain that I wasn’t overlooking anything.
As I tested each of the relays, I kept shaking my head in disbelief. It was so unbelievable. How could someone do such a thing? Someone could have been killed because a protective relay wasn’t working correctly. This was serious stuff.
One day while Charles and I were working away on the relays, Jack Coffman, the Superintendent of all the Power Plants came walking through the lab. He asked us how we were doing. I swiveled around in my chair to face him and I said, “Pretty good, except for this pain in my neck” as I rubbed the back of my neck.
Jack stopped and asked me what happened. I told him that I had been shaking my head in disbelief for the last two weeks, and it gave me a pain in the neck. Of course, I knew this would get his attention, so he asked, “Why?” I went through all the details of what I had found.
I showed him how since the time that Doyle Fullen last tested the relays more than 10 years earlier, these relays hadn’t been tested at all. I showed him how the main bus relays were so bad that it would take over 100,000 amps to have tripped the 7100 KV switchgear bus or 710 Megawatts! More power than the entire generator could generate. The main generator was only rated at about 550 Megawatts at the most.
Jack stood there looking off into space for a few seconds, and then walked out the door…. I thought I saw him shaking his head as he left. Maybe he was just looking both ways for safety reasons, but to me, it looked like a shake of disbelief. I wonder if I had given him the same pain in the neck.
That is really the end of the relay story, but I do want to say a few words about Charles Lay. He was a hard working electrician that was nearing retirement. People would come around to hear us discussing religion. I am Catholic, and he went to a Fundamental Christian Church. We would debate the differences between our beliefs and just Christian beliefs in general. We respected each other during our time together, even though he was sure I am going to hell when I die.
People would come in just to hear our discussion for a while as we were cleaning and calibrating the relays. One day Charles asked me if I could help him figure out how much he was going to receive from his retirement from the electric company. He had only been working there for three years. Retirement at that time was determined by your years of service. So, three years didn’t give him too much.
When I calculated his amount, he was upset. He said, “Am I going to have to work until I die?” I said, “Well, there’s always your 401k and Social Security.” He replied that he can’t live on Social Security. I said, “Well, there’s your 401k.” He asked, “What’s that?” (oh. not a good sign).
I explained that it was a retirement plan where you are able to put money in taxed deferred until you take it out when you retire. He said, “Oh. I never put anything in something like that.” My heart just sank as I looked in his eyes. He had suddenly realized that he wasn’t going to receive a retirement like those around him who had spent 35 years working in the Power Plant.
When I left the plant after teaching Charles Lay how to test the relays, that was the last time I ever saw him. I don’t know what became of Charles. I figure he would be 83 years old today. I wonder if he finally retired when he reached the 80 points for your age and years of service. He would have never reached enough years of service to receive a decent amount of retirement from the Electric Company since he didn’t start working there until he was 60 years old. That is, unless he’s still working there now.
As I said earlier in this post, Charles Lay was a very good worker. He always struck me as the “Hardworking type”. I often think about the time we spent together, especially when I hear about a power blackout somewhere. — A word of caution to Power Companies…. keep your protective relays in proper working condition. Don’t slack off on the Preventative Maintenance. — I guess that’s true for all of us… isn’t it? Don’t slack off on Preventative Maintenance in all aspects of your life.
Added note: On 7/6/2019, 3 weeks after re-posting this story, look what happened: Con Edison says cause of NYC blackout was substation’s faulty relay protection system
Comments from previous posts:
Favorites Post #22
This story was originally posted on February 11, 2012:
There are five main power plants in the electric company in Central Oklahoma, and maintenance men from each plant would work at other plants when there was an overhaul. An overhaul is when a generator was taken off line for the purpose of doing maintenance on major parts of the plant that can only be done when the unit isn’t running. Such as repairing boiler tubes, and working on the turbine and generator.
Because employees would work at other plants for months at a time, living in camping trailers or cheap hotel rooms to save money, most people were able to work with and had the opportunity to know the Power Plant Men from the other four plants.
I have noticed that most non-plant people have a general misconception about Power Plant Men when they first meet them. As a young 18 year old entering my first job with real men, I learned very quickly that they each possessed a certain quality or talent that made them unique and indispensable Sure there were some “bad apples”, but they were never really and truly Power Plant Men. They either left because of incompatibility or were promoted to upper management.
I know more than once the plant hired someone new only to have them work one day and never show up again. There were few if any real Power Plant Men that ever left the plant where the character of the plant and its ability to be maintained properly wasn’t instantly changed.
While I am writing this post this evening a wake service is being held at the First Methodist Church in Moore, Oklahoma for a true Power Plant man; Jimmy Armarfio. He was an electrician at Mustang plant. I had heard some stories about Jimmy before I actually met him; most of them about humorous things that had happened to him at one time or other.
Everyone liked his African accent (Jimmy was from Ghana, a country in Africa) as they would imitate his voice while telling the stories. It seems that Bill Bennett our Electrical A foreman had more than a few stories to tell.
Jimmy came to our plant on an overhaul and worked out of our electric shop. The first time I talked to Jimmy, he was leaning against a counter during lunch just finishing a book. I happened to notice when I was walking by that the book was titled “One Day in the Life of Ivan Denisovich” by Aleksandr Solzhenitsyn. I had read that book not too long before, so I stopped and asked him what he thought of it.
He said that it was interesting how this man who was in a prison camp in Siberia living in a miserable state could go to bed at night thinking that he had a pretty good day. I think I said something like, “Yeah, sort of like us working in this Power Plant.”
Then he said something that has always stuck in my mind. He said that in the English language there are many words that mean the same thing. For instance, for a rock, there is pebble, rock, stone and boulder. In his native language there is one word. It means “rock”. You may say, large rock, small rock, smooth rock, but there is only one word for rock. It made me reflect on the phrase, “In the beginning was the Word…” Suppose there was one word that included everything.
What I didn’t know at that time was that not only was Jimmy Armarfio from Ghana but he was the king of his tribe. Steven Trammell said that his friends referred to him as “King Jimmy” after he was elected King of his tribe.
When I heard that Jimmy had died, I looked at the funeral home site and saw that one of his coworkers George Carr said the following: “Jimmy was a beloved coworker and one of my personal heroes.”
Another friend, Jack Riley wrote: “It was my blessing to work with Jimmy. The most cheerful person I have had the privilege of knowing.” I have included his picture below. Jimmy Armarfio…. Take a good long look at A True Power Plant Man! A Hero and a King!
Favorites Post #21
Originally posted February 25, 2012. I added Larry’s Picture at the end:
When I first began working at the power plant (in 1979), one of the people I spent a good deal of time with was Larry Riley. I was 18 and knew very little about tools, equipment, power plants and how to speak in the Power Plant language. I quickly found out that in those early days, when the plant was still under construction, a lot of people turned to Larry Riley when they were faced with an obstacle and didn’t know how to approach it.
Larry Riley was a 24 year old genius. I was amazed by his vast knowledge of seemingly disparate areas of expertise. When he was asked to do something, I never heard him say that he didn’t know how. He just went and did it. So, after I asked Larry how old he was, I asked him how long he had been at the plant. He hadn’t been there very long, but he had worked in the construction department before transferring to the power plant.
Larry Riley already at the age of 24 had a beat up hard hat full of hard hat stickers. One indicating that he was a certified industrial truck driver. I think he had about 5 safety stickers and various other hard hat stickers. He was a thin clean cut dark haired young man with a moustache that sort of reminded me of the Marlboro Man’s moustache. He walked like he had a heavy burden on his back and he was rarely seen without a cigarette in his mouth.
I worked with Larry off and on throughout my years as a summer help and during that time Larry taught me the following things (to name a few): How to drive a tractor. How to mend a fence. How to bleed the air out of a diesel engine’s fuel line (which is more important than you would think). How to operate a brush hog (a large mower on the back of a tractor). How to free a brush hog from a chain link fence after you get one of the bat wings stuck in one. Tie rebar, and pour concrete and operate a Backhoe.
I remember asking Larry why a backhoe was called a backhoe. I think Sonny Karcher was in the truck at the time. You would have thought I had asked what year the War of 1812 was fought! I’m sure you are all chuckling while reading this (especially all the power plant men). But for those of you who are as green as I was, I’ll tell you. A Backhoe is called a Backhoe because the Hoe is on the Back. Gee. Who would have thought?
Later when I was a full time employee and had worked my way from being a Janitor to being on the Labor Crew, Larry Riley became my foreman. At that point on occasion I would call him “Dad”. He would usually disown me and deny that he had anything to do with it. On occasion when he would own up to being my dad, he would admit that when I was real little I was dropped on my head and that’s why I acted so odd (though, I don’t know to what behavior he was referring).
There was this other guy at the plant the first summer I was there that had the unique title of “Mill Wright”. His name was Gary Michelson. He evidently had gone to school, taken some tests and been certified as a Mill Wright and this probably brought him a bigger paycheck than the other regular workers as well as a much bigger ego.
Gary would spend days at a time at a band saw cutting out metal wedges at different angles so that he would have them all in his pristine tool box. I worked with him a few times during my first summer as a summer help. I will probably talk more about Gary in a later post, but just to put it plainly… I could tell right away that he wasn’t a real “power plant man”.
The rest of the power plant men I’m sure would agree with me. I wouldn’t have traded Larry Riley for ten Gary Michelsons unless I was trying to help some engineers change a light bulb (actually. I have met some good engineers along the way. Some of them very good. But they were not the norm. At least not those assigned to power plants).
I have mentioned some different things that Larry had taught me and if you remember, he was the person that I worked with on my second day at the plant when Sonny Karcher and Larry had taken me to the coalyard to fix the check valve (in my post about Sonny Karcher “In Memory of Sonny Karcher – Power Plant Man“). There will always be one day that first comes to my mind when I think about Larry. This is what happened:
I drove a truck down to the Picnic area on the far side of the lake from the plant. Jim Heflin drove a Backhoe down there. I believe he was going to dig up some tree stumps that had been left over after the “engineers” in Oklahoma City had decided where to put all the trees in the area.
What the engineers in Oklahoma City did was this: They cut down all of the trees that were in the picnic area and planted new trees. Some of them not more than 15 or 20 feet away from a tree that had been there for 30 years and was a good size. So, there were a lot of stumps left over from the big hearty trees that had been cut down that needed to be removed so that the sickly little twigs that were planted there could prosper and grow without feeling inadequate growing next to a full grown he-man tree.
Anyway. I had climbed out of the truck and was making my way around the picnic area picking up trash and putting it in a plastic bag using a handy dandy homemade trash stabbing stick. As Jim was making his way across the “lawn” (I use the word “lawn” loosely, since the area was still fairly new and was not quite finished) when he hit a wet spot. The Backhoe was stuck in the mud.
There wasn’t much I could do but watch as Jim used the hoe to try to drag himself out. He rocked the backhoe back and forth. Use the stabilizers to pick up the backhoe while trying to use the scoop to pull it forward. I would say he worked at it for about ten minutes (even though it seemed more like half an hour). Eventually it was time for us to head back to the plant to go to break.
Back at the plant, Jim told Larry about his predicament and asked him if he would help him get the backhoe out of the mud. Larry said he would come along and see what he could do. At this point, I was thinking that he would jump in the Wench Truck and go down there and just pull him out. Instead we just climbed in the pickup truck and headed back to the park (notice how it went from being a picnic area to a park in only three paragraphs?).
When we arrived, Larry climbed into the Backhoe after making his way across the vast mud pit that Jim had created while trying to free himself before. He fired up the Backhoe…. cigarette in mouth… then the most fascinating thing happened… using both feet to work the pedals, and one hand working the controls in the front and the other hand working the levers in the back, Larry picked up the backhoe using the scoop and the hoe and stabilizers and cigarette all simultaneously, he walked the backhoe sideways right out of the mud pit and onto dry land just as if it was a crab walking sideways. I would say it took no longer than three minutes from the time he started working the controls. Jim just looked at me in amazement. Patted me on the back, shook his head and said, “And that’s how it’s done.”
Now that I’m on the subject of Larry Riley on a backhoe, let me tell you another one. I have seen Larry digging a ditch so that we could run some pipe for irrigation. Now picture this. The bucket on the backhoe is digging a hole in the hard red clay of Oklahoma, and Larry suddenly stops and says….. “I think I felt something”. What? (I think) Of course you did, you are operating this machine that has the power to dig a big hole in the ground in one scoop like it was nothing and Larry said he felt something?
He climbed off of the backhoe, jumped down into the ditch he was creating, kicked some clods of dirt around and lo and behold, he had just scraped clean a buried cable. He hadn’t broken it. He had come down on it with the bucket and had somehow “felt” this cable buried under all that dirt. I wonder what it felt like that told him he had encountered something that wasn’t just dirt. Maybe the electromagnet forces from the electricity in the cable caused the backhoe to be slightly magnetized and it tugged on his key chain. I think the entire labor crew just went down on one knee before his greatness for a moment of silence – all right, so we didn’t really. But we were somewhat impressed.
The one thing that makes Larry a True Power Plant Man with all the rest is that he performed acts of greatness like what I described above with complete humility. I never saw a look of arrogance in Larry’s face. He never spoke down to you and he never bragged about anything. To this day, I still picture Larry Riley working at the power plant working feats of magic that would amaze the rest of us as he thinks that he’s just doing another day’s work. That’s the way it is with True Power Plant Men.
Since I first created this post two years ago, I have found a picture of Larry Riley taken many years after this story:
Since I first posted this story about Larry, he has passed away. I described the day of his passing in the post: “Power Plant Saints Go Marching In“