Tragedy Occurs During Power Plant Safety Meeting
Originally posted August 16, 2014.
I knew that we had our work cut out for us when Unit 1 was taken offline for a major overhaul on February 19, 1994 at the Coal-fired Power Plant in North Central Oklahoma. I had learned to expect the unexpected. I just never suspected this to happen. As acting foreman, I had a crew that consisted of a few of our own electricians, as well as a number of contract workers. I was also coordinating efforts between Brown & Root contractors that were going to be doing some major work inside the Precipitator (that takes the smoke out of the exhaust from the boiler) during the 12 weeks we were going to be offline and a Vacuum Truck Company that was going to vacuum ash out of the hoppers where the ash is collected and blown through pipes to the coal yard to be trucked away to make concrete.
When I inspected the precipitator during the first week, I had found numerous hoppers that had filled up with ash. One in particular hopper was so full that the ash had built up between the plates over 5 feet above the top of the hopper. Because of this, I had to coordinate with hoppers that were available for the Brown and Root contractors to begin building scaffolding, and those hoppers the vacuum truck needed to vacuum out first.
I had learned to deal with full hoppers the first time I entered the precipitator back when I was on the Labor Crew in 1983. Since that day, I had understood the potential dangers lying in wait. Especially with hoppers full of ash. See the Post “Angel of Death Passes By the Precipitator Door“.
The crew I was directly managing was on the Precipitator roof working on vibrators, insulators, transformers and rappers. I worked inside the precipitator aligning plates, and removing broken wires and cleaning insulators. The vacuum truck company vacuumed out the full hoppers by attaching a vacuum hose from a large vacuum truck to clean out pipes at the bottom of the hoppers. The Brown and Root crew climbed into the hoppers through an access door near the bottom of the hopper and constructed scaffolding in order to work at the top of the hoppers immediately below the plates.
This operation had been going on for 3 days and had seemed to be going smoothly. The Brown and Root crews and the vacuum truck crews were working shifts 24 hours a day. I would come in the morning and see the progress that had been made during the night. We kept a sheet taped to a beam in the hopper area that the vacuum truck would update when they had finished a hopper, and the Brown and Root crew indicated where they had finished building their scaffold.
On Thursday March 3, 1994, just after lunch, instead of making my way out to the precipitator to continue my work, I went up to the office area to meet in the conference room with the Safety Task Force. I was the leader of the task force, and we were meeting with upper management to work out some issues that I outlined in last week’s post. See “Taking Power Plant Safety To Task“. As you may have noticed, the last two weekly posts are a continuation of a long story.
Our meeting began shortly after 12:30 and we were discussing ways in which the Safety Task Force could work in a more cooperative way with the Maintenance Supervisor, Ken Scott. I felt that we were making good progress. We seemed to have come up with a few solutions, and we were just working out the details.
At 1:10 pm, the Electric A Foreman knocked on the door and opened it. He explained that there had been an accident at the precipitator in one of the hoppers and he thought that I might have been in the hopper at the time. He was checking to see if I was in the meeting. Once he was assured that I was all right, he left (presumably to tell the rest of my crew that I was not involved in the accident).
At this point, my head started to spin. What could have happened? None of my crew would have been in the hoppers. Maybe someone fell off of a scaffold and hurt themselves. I know I had locked out all of the electricity to the precipitator and grounded the circuits that have up to 45,000 volts of electricity when charged up, so, I’m pretty sure no one would have been electrocuted. Bill’s voice seemed real shaky when he entered the room, and when he saw me he was very relieved.
When working in a Power Plant, the Power Plant Men and Women become like a real family. Everyone cares about each other. Bill Bennett in some ways was like a father to me. In other ways, he was like an older brother. The nearest picture I have of Bill is a picture of Bill Cosby, as they looked similar:
I don’t know how long I was staring off into space counting my crew and thinking about what each of them would be doing. I was sure they were all on the roof. I knew that if a Brown & Root hand had been hurt that their own Safety Coordinator would be taking care of their injury. The thought of someone being hurt in a hopper sent flashbacks of the day I nearly dived off into the hopper full of ash ten and a half years earlier.
After about 5 minutes, Bill Bennett came back to the conference room, where we were still trying to focus on the task at hand. I don’t remember if we were doing any more good or not since I wasn’t paying any attention. Bill said that he needed for me to leave the meeting because they needed me out at the precipitator. Someone had been engulfed in fly ash!
Then I realized that the first time Bill had come to the room to check on me, he had mentioned that. I think I had blocked that from my mind. He had said that someone had been engulfed in ash, and they couldn’t tell if it was me or someone else. That was why he was so shaken up. Bill had thought that I may have died, or at least been seriously injured. The pain he was feeling before he saw me sitting in the room, alive and well, flooded my thoughts.
I quickly stood up and left the room. Bill and I quickly made our way to the precipitator. He said that Life Flight was on the way. One of the vacuum truck workers had climbed into the hopper to get the last bits of ash out of the hopper when a large amount of ash had broken loose above him and immediately engulfed him in the hopper.
When that happened there was a large boom and a cloud of ash came pouring out from the side of the precipitator. Scott Hubbard, who would have been my twin brother if I had been able to pick my own twin brother (though I never had a real twin brother)… heard the boom on the roof and when he looked down and saw the cloud of ash, immediately thought that I may have been hurt. I suppose he had called Bill Bennett on the radio and told him.
As we arrived at the precipitator, a young man was being carried out on a stretcher. A Life Flight from Oklahoma City was on it’s way, and landed just a few minutes later. I looked at the man all covered with ash. I could see how someone may have mistaken him for me. He was dressed like I was. A white t-shirt and jeans. He was unconscious.
Without going into detail as to the cause of the accident, as that will be in a later post, let me tell you about the heroic Power Plant Men and their actions before I had arrived on the scene…
James Vickers, a 26 year old vacuum truck worker, had climbed in the hopper carrying a shovel. He had a hole watch standing out the door keeping an eye on him. They had sucked out the hopper from the outside pipes and had banged on the walls in order to knock down any ash build up on the sides until they figured they had cleaned out the hopper.
James had opened the door to the hopper, and maybe because he saw some buildup on the hopper walls, he decided to climb in the hopper in order to knock it down with the shovel. While he was doing this, a large amount of ash that had bridged up in the plates above was knocked free all at once and immediately filled up the hopper probably more than half full.
James was crammed down into the throat of the hopper, which at the bottom is only about 8 inches in diameter with a plate across the middle about 2 feet above the throat of the hopper. He was immediately knocked unconscious by the impact.
The person assigned to be the hole watch was standing at the door to the hopper and when the ash fell down, he was knocked back about 6 or 7 feet when the ash came pouring out of the door. Panicking, He ran to the edge of the walkway yelling for help. Luckily, he was not also knocked unconscious, or this would pretty much have been the end of the story.
Men came running. Especially a couple of Power Plant Men working in the area. I wish I could remember who they were. When I try to think of the most heroic Power Plant Men I knew at the plant at the time, the list is about a long as my arm, so it is hard to narrow it down.
The Power Plant Men began to frantically dig the ash out of the hopper to uncover James Vickers. When they reached his head, they immediately cleared his face to where they could perform Mouth-to-Mouth resuscitation. They began breathing for James as soon as they could, and continued mouth-to-mouth as they dug out more of the ash.
As they dug the ash out, they were using their hardhats for shovels. When they tried to move James, they found that he had been crammed down into the bottom of the hopper to where he was trapped in the throat of the hopper. Heroically they continued without hesitation to breath for James, while simultaneously working to free him from the hopper. The shovel had been wedged into the bottom of the hopper with him.
Almost immediately after the accident happened, the control room became aware that someone had been engulfed in a hopper, they called Life Flight in Oklahoma City. A helicopter was immediately dispatched. By the time James was safely removed from the hopper, placed on a stretcher and carried out to the adjacent field, the Life Flight Helicopter was landing to take him to the Baptist Medical Center. I would say the helicopter was on the ground a total of about 3 or so minutes before it was took off again.
Bill and I inspected the hopper where the accident had taken place. On the ground below under the grating was a pile of ash, just like I had experienced years before when I almost bailed off into the hopper to look for my flashlight. I was suddenly filled with a tremendous amount of sorrow.
I was sorry for James Vickers, though I didn’t know who he was at the time. I was sorry for Bill Bennett who thought for a while that I had died in that hopper. I remembered hanging by one finger in a hopper only two rows down from this one, ten years ago with my life hanging by a thread, and I just wanted to cry.
So, I gave Bill a big hug as if I was hugging my own father and just started to cry. The whole thing was just so sad.
Meanwhile, in Oklahoma City….
On the roof of the Baptist Medical Center, a Triage unit had been setup waiting for the helicopter to arrive with James. Hazardous Waste protective suits were being worn by the people that were going to begin treating James. They had heard that he had been engulfed in hazardous chemicals which consisted of: Silica, Aluminum Oxide, Hexavalent Chromium, arsenic and other unsavory and hard to pronounce chemicals. The Life Flight People on the helicopter had to be scrubbed down by the Hazmat team as soon as they exited the helicopter to clean off the hazardous Fly Ash. The news reporters were all standing by reporting the incident.
Yes. The same fly ash that I went swimming in every day during the overhaul. The same fly ash that I tracked through the Utility Room floor when I came home at night. The same fly ash used to create highways all across the country. It’s true it has some carcinogenic material in it. I’m sure I have my share of Silica in my lungs today, since it doesn’t ever really clear out of there.
Besides the psychological trauma of a near-death experience, Jame Vickers was fairly unharmed considering what he went through. He came out of the ordeal with an eye infection. Randy Dailey pointed out that this was because the Safety Coordinator from Brown & Root had opened his eyes to check if he was alive when he was laying on the stretcher, and had let ash get in his eyes. Otherwise, he most likely wouldn’t have developed an eye infection.
When I arrived at home that evening I explained to my wife what had happened. She had heard something on the news about it, but hadn’t realized they were talking about our plant since the person was in Oklahoma City when the reporters were talking about it.
All I can say is… Some Safety Meetings in the past have been pretty boring, but nothing made me want to improve my Safety Attitude like the Safety Meeting we had that afternoon. I’m glad that I had to experience that only once in my career as a Plant Electrician.
Comments from the original post
I remember when this happened. I know some prayers went up for James.
They had to “decontaminate” the helicopter too. It was always amusing for me to see a hazmat worker strain at a “gnat” removing every molecule of fly ash, then take his respirator and suit off and light up his “camel” cigarette!
Hope you don’t mind I posted on my Innovative Safety Solutions facebook page along with a link back to the blog. Good article!
I remember hearing about that on the news that day. Also that Dad told us how strange it seemed that they were wearing the haz mat suits to deal with flyash.
The OSHA Man Cometh
I suppose when you are a Plant Manager, the last person you want to see at your Power Plant doorstep is the OSHA Man! That’s exactly what happened on Thursday, March 10, 1994 at the Coal-fired Power Plant in North Central Oklahoma. He was not paying a social call. He was there to conduct an investigation. One in which I was heavily involved.
In my post from last week, “Tragedy Occurs During Power Plant Safety Meeting” I described a near death accident where a contract worker was engulfed in fly ash in a precipitator hopper. The accident was all over the 5 o’clock news in Oklahoma City. The press was there when the Life Flight helicopter arrived at the hospital where they interviewed the flight crew. The OSHA office in the Federal building a few blocks from the Electric Company’s Corporate Headquarters had quickly assigned someone to the case. Armed with all the authority he needed, he began a full investigation of the accident.
The day before Gerald Young, (the OSHA Man) arrived, I had done some investigation myself into the accident. I was trying to figure out exactly what had happened. Why had someone who thought that he had emptied out a hopper so much so that he climbed inside, had suddenly become instantly engulfed in ash? Where did this large volume of ash come from, and why did it decide to suddenly break loose and fill the hopper at the particular moment when James Vickers had decided to climb into the hopper?
Larry Kuennan, the lead engineer had asked me to show him the hopper from the inside of the Precipitator, so he could have an idea of what took place. I told him he needed to put on a fly ash suit and a full face respirator in order to go into the precipitator. After we were all suited up, I took him on a tour of the inside. A sight few people have had the chance to experience. I could write an entire post just about the experience…. Oh…. maybe I already have. See “Moon Walk in a Power Plant Precipitator”
The hopper we needed to investigate was not at the edge, so, we had to squeeze our way around a few beams in order to see the hopper where the accident took place. When we arrived, I explained that when I had first inspected the precipitator, I had found that the ash had piled up five foot above the bottom of the plates because the feeder wasn’t feeding properly. So, I had figured that when they were vacuuming out the hopper, the ash that was lodged between the plates (that were 9 inches apart) must have still been there when James climbed into the hopper. Something had caused the ash to give way all at once.
Larry and I climbed down between the hoppers where we could see the bottle racks underneath the plates. The bottles are 30 pound anchors in the shape of the old style milk bottles. They are used to keep the tension on the wires, which are the electrodes that are normally charged with up to 45,000 volts of electricity when the precipitator is online.
When we sat down to look at the four bottle racks, I noticed right away that one row of bottles was about a foot and a half lower than the rest of the bottle racks. This didn’t make sense to me at first. I couldn’t think of anyway that 176 wires and bottles would be lower than the rest of the wires in the hopper. It was a paradox that took a while to soak in.
When we left, Larry Kuennen made a statement I will never forget. He said, “Until now, I thought that Plant Electricians did nothing but twist wires together. I never thought they worked on things like this.” I replied, “We work on anything that has a wire connected to it. That includes almost everything in the plant.” He replied, “Well, I have a new appreciation for Plant Electricians.”
It wasn’t until I returned to the electric shop and heard Scott Hubbard’s recount of the accident (again). Scott and his crew was working on the roof of the precipitator when the accident happened. He said that when the accident happened he heard a loud bang. Sort of like an explosion. I told him what I had found inside the precipitator. This could only mean one thing…. An electric insulator on the roof of the precipitator that held up the wires on that bottle rack had broken. When that happened, it fell the foot and half causing all the ash that had been lodged between the plates to be jolted loose, engulfing James Vickers who had just climbed in the hopper below.
After lunch, Scott went up on the roof and opened the portal on the tension house that housed the insulator that held up that row of wires. Sure enough. The three foot by 3 inch diameter ceramic insulator had broken. Something that had never happened at the plant up to that point. A tremendous load must have been put on this insulator, or it must have been defective in order to just break. These insulators are designed to hold up to 10,000 pounds of weight. the weight of the bottles and wires altogether weighed about 6,000 pounds. This meant that about 4,000 pounds of ash was pressing down from the ash above in order for it to just pull apart.
There was only one person that the OSHA man Jerry wanted to speak to when he arrived at the plant (other than to arrange things). That was me. I was the acting foreman in charge of the operations in, on and below the precipitator when the accident happened. I was also just a regular hourly employee, not so “beholden” to the company that I would participate in any kind of “cover-up”.
The first thing OSHA Jerry wanted to see was the inside of the precipitator. So, I procured a respirator for him, and we climbed up to the landing where one enters the precipitator through side doors. The first thing he did when he arrived at the door was take out a measuring tape to measure the height of the door.
I hadn’t thought about it until that moment, but a new set of OSHA regulations had a new set of Confined Space regulations 1910.146 that dealt specifically with confined spaces. It had gone into effect on April 15, 1993. Here we were almost a year later. I had always treated the precipitator as a confined space, so I had always checked the air quality before I entered it.
So, I asked OSHA Jerry why he measured the size of the door. He said, he was checking if the entrance was “restricted” or “limited”. This was the requirement of a Confined space as stated in OSHA regulation 1910.146. I asked him how small does an entrance have to be to be restricted? He said, “Well. That’s not clearly defined. We could enter the precipitator by bending over and stepping in.
That was the first time I thought that maybe the precipitator itself may not really fit into the strict definition of a confined space. The hoppers do for sure, but does the precipitator? Hmm…. I wondered…. I still do come to think of it. The hoppers were definitely confined spaces by definition… “any space with converging walls, such as a hopper…..”
Oh. I forgot to describe OSHA Jerry. He reminded me a little of the guy a sidekick in Cheers named Paul Willson:
Actually, he looked so much like him that I thought of him right away.
When we were done inspecting the precipitator, we returned to the front office where we went to Tom Gibson’s (our Electric Supervisor) office. He closed the door and locked it. And he began to interview me by explaining that anything that was said in this room would be held in confidence. He explained that I could speak freely and that the Electric Company could do nothing to me for telling him the truth.
I thought… Ok…. um…. I have always been known for speaking my mind, so he wasn’t going to hear anything that I would personally tell the Plant Manager, Ron Kilman to his face. Just ask Ron. I’m sure he would agree that I was pretty open about anything that popped into my mind.
He asked me if I had been trained how in the OSHA Confined Space regulations. I responded by saying that we had a class on it one day where we went over our new confined space requirements. That consisted of reading the company policy. I knew that I needed to have a hole watch, and I needed to check the air before I went into a confined space.
We checked to make sure there was 20.9% oxygen, that there was less than 10 parts per million Carbon Monoxide, less than 5 parts per million H2S (Hydrogen Sulfide) and that there was less than 5% explosive vapors. OSHA Jack wrote everything down.
Actually, while I was talking, Jerry asked me to pause often because he was writing everything I said word-for-word on a yellow notepad what I was saying.
While we were talking, I asked him a few questions also. I asked Jack how he decided to work for OSHA. Where he had come from (Kansas. Wichita, I think). How long he had been working for OSHA. Did he enjoy his job….. At times, I could get him to digress and tell me a story about his life.
As we continued with our interview over this grave accident that almost resulted in the loss of someone’s life, I was busy making a new friend. By the time he had asked me everything he needed to know, I knew all about how he had grown up in Kansas, and how he had gone from job-to-job until he had ended up in front of me… interviewing me.
When we had finished the interview, he explained to me that this was an official document that contained all the answers to the questions he had asked me. He said that this would be private and that the Electric Company would not be able to ever see what I said unless I wanted them to see it. I asked him if I could show it to them. He said he would give me a copy of it, and I could do whatever I wanted with it. He asked me to sign it. I did.
I took Jerry to the copy machine in the front office where he made copies for me. When he handed them to me, I shook his hand. I told him I enjoyed talking to him. I also told him that I wished him well. I showed him to the elevator, and he left the plant. I made a copy of the papers that I had signed and went directly to the plant manager Ron Kilman’s office and gave him a copy of the document I had signed.
Ron asked me how it went. I told him that it went fine. Here is everything we talked about. I had nothing to hide. It did amaze me that OSHA Jack thought I might want to “spill the beans” about something as if we were treated like peons where the King had total rule. — I guess he didn’t know that Eldon Waugh had retired in 1987.
From there, I went to Bill Bennett’s office. Bill Bennett was our A Foreman. His office was across the hall from Tom Gibson’s office where I had been interviewed for the previous 3 hours. — Yeah. 3 hours. OSHA Jerry didn’t know Shorthand.
Bill asked me how the interview went. I said it went fine. He said that Ron and Ben Brandt had been worried about me because the interview had lasted so long. Bill said he told them, “Don’t worry about Kevin. He probably has this guy wrapped around his little finger. He’s probably using his ‘psychology’ on him” I always loved Bill with all my heart. He knew me too well. I told Bill that I knew OSHA Jerry’s life story by the time we were done. Bill smiled…. just like this:
I smiled back at Bill. I returned to the Electric Shop to continue with Unit 1 Overhaul. After all. That was my “real” job. I put on my fly ash suit, my full face respirator, and my rubber boots and returned to the innards of the precipitator to continue where I had left off. I had a lot to think about as I scanned the Precipitator plates and wires in the dark with my flashlight safely strapped around my neck.
Comment from the original post
Great story! And good job interviewing OSHA Jack.
When the OSHA (EPA, OFCCP, EEOC, etc.) Man cometh, whatever was scheduled for that day (week, etc.) was suspended and you do whatever he/she wants. Cost to implement changes was not a factor and permanent effects on plant efficiency or employee morale were of little importance either. At 67 (with increasing arthritis) I’m reminded of OSHA’s “help” every time I have to use both hands to start my recip saw (one to pull the trigger and the other to push the “safety” switch), or when I have to re-start my lawnmower every time I empty the grass bag.
Power Plant Men Summoned by Department of Labor
Originally posted August 30, 2014.
When a death or a near death occurs at a workplace due to an accident, OSHA Occupational Safety and Health Administration) will investigate what happened. There are two reasons for this. If they find that the company has been negligent in following the safety regulations set down in CFR 1910, then they are fined (if the negligence is severe enough). OSHA also investigates the accident to see if changes are needed to regulations in order to protect employees due to new unsafe workplace conditions that are not currently covered under CFR 1910.
Because of the tragedy that happened at our plant that I outlined in the post: “Tragedy Occurs During Power Plant Safety Committee” and after I had met with the OSHA man (Gerald Young) to give him my deposition as discussed in the post last week: “The OSHA Man Cometh“, the plant manager, the assistant plant manager, and I were summoned to the Department of Labor building in Oklahoma City at 10 o’clock on Monday April 18, 1994.
On a side note:
The Department of Labor office in Oklahoma City is just a couple of blocks from the Murrah Federal Building that was bombed exactly one year and one day after our visit on April 19, 1995. Not that there was any connection.
I mentioned this because I went to the Murrah building later that day after the meeting with OSHA to meet my brother for lunch. He was working there in the Marine Recruiting office at the time. I think he was a Major then. He changed jobs in June 1994 and moved to Washington D.C. I think. His replacement was killed in the bombing. Here he is Greg today as a full Colonel:
End of Side Note:
I was asked by Ron Kilman our plant manager to show up at 9:00 am on Monday in the building south of our main corporate headquarters where we rented office space to meet with the guys from our own Safety Department because they were required to attend the OSHA meeting with us. The Department of Labor building was just across the parking lot and across the street from this building, so we planned to walk from there.
I drove myself because Ron said he had other meetings to attend in Oklahoma City after this meeting was over and he wouldn’t be driving back to the plant. That was why I arranged to have lunch with my brother.
When we met with the Corporate Safety Department Jack Cox told us how we should act during the meeting with OSHA. He didn’t tell us to do anything wrong, like withhold information. He just told us to answer all the questions as truthfully as we could. Don’t offer any information that isn’t directly asked by OSHA. Don’t argue with them if you disagree.
From what I understood from the conversation, we were supposed to be polite, truthful and don’t waste their time going down a rat hole with specifics. I was told that I shouldn’t have to say anything and I should be quiet unless I was asked a specific question. The Safety department would answer all the questions and make any statements that need to be made. I was assured by them that I had nothing to be worried about. I only needed to tell the truth if asked anything.
If you know my personality, I always want to throw in my 2 cents, even when I know it is wasted on the audience. But I took this seriously. We were going to be fined by OSHA for 10 different violations relating to the accident that occurred at the plant. I was there because I was directly in charge of the work that was being done when the accident occurred. It was my deposition that was used to determine about half of the violations.
After we had been briefed on how we should behave during the meeting, as a group we walked from the corporate building over to the Department Of Labor building. One of the safety guys was carrying a few binders. I think one was the company’s Policies and Procedures book (We called it the GP&P).
Upon entering the building we went to the 3rd floor where we were asked to wait in a room until OSHA was ready for the meeting. The room had a long table down the middle. As usual, I picked a seat about halfway down on one side. I remember Ron Kilman sitting across from me and about 2 seats down.
We waited and we waited….. 10:00 came and went, and no one came. We quietly discussed whether this was to make us more nervous by keeping us waiting. Then someone came to the door and apologized. They said that Robert B. Reich, the U.S. Secretary of Labor was in the office that day and that had thrown off everyone’s schedule.
This was quite a coincidence, and we wondered if Robert B. Reich (it seems like you need to put the B in his name in order to say it right) would be attending our meeting. That would sort of throw a whole new importance of me keeping my mouth shut to make sure I wasn’t putting my foot in it.
It seemed as if Mr. Reich had shown up unexpectedly. Or at least on short notice. Almost as if it was a surprise visit to check up on the place. He didn’t end up coming to our meeting. Now that I think about it. This was one day shy of being one year to the date that the Branch Davidians had burned themselves alive in Waco, which was one year and one day before the Murrah Building Bombing three blocks away from where we were sitting that morning. Aren’t coincidences interesting? Just saying…
More about why Robert B. Reich was there further below.
Around 10:30 four or five OSHA lawyers (I assume they were lawyers, they talked like they were), came in the room along with the Jerry that had interviewed me a few weeks earlier. They apologized again for being late due to the arrival of their “supreme” boss. They sort of sat at one end of the room and the people from our company was more on the other end. Jerry, the OSHA man, sat next to me in the middle.
I was saying a mantra to myself…. “Don’t say anything… just keep quiet and listen…. don’t say anything… just keep quiet and listen.
The meeting began by the Lady at the end of the table reading off the violations to us. I don’t remember all 10. I remember the most important violations. They mainly centered around the new Confined Space section of 1910. It was 1910.146 that dealt with confined spaces and it had gone into affect April 1, 1993, almost one year before the accident happened. Generally, OSHA gives companies about a year to comply to the new regulations, which kind of put us right on the edge since the accident at our plant had occurred on March 3, 1994.
Because of this, some of the violations were quickly removed. That lowered the number down to 6 violations right away. That was good. No one from our company had said a word yet, and already the OSHA lawyers seemed to be on our side. Then they read off a violation that said that our company had not implemented the required Confined Space Program as outlined in CFR 1910.146.
This was when our Safety Department leader, Jack Cox. said that we would like to contest that violation, because here is the company policy manual that shows that we implemented the Confined Space Program before the end of the year.
One of the OSHA lawyers responded by saying that we had not fully implemented it because we had not trained the employees how to follow the policy. When he made that statement, Ron Kilman contested it. He had a stack of papers that showed that each of the employees at the plant had taken the training and had signed a paper saying they had read the policy. Not only that, but the person that was hurt was not a company employee, they were an outside vendor who was hired by the company to vacuum out the hoppers.
The OSHA man said that just because they took the course did not mean that they were properly trained. Ron asked how do you know they weren’t properly trained. The OSHA man replied, “Because they didn’t follow all the rules. If they had, no one would have been hurt.” — What do you say to that? You can tell we weren’t properly trained because someone was hurt? I suppose that the OSHA rules were written in such a way that if you followed them to the letter, no matter what kind of mechanical failure happens, no one will be hurt. I could see the frustration on Ron’s face.
I was a little amused by Ron’s statement though because Jack Cox had told us to just let them answer all the questions and the first seemingly absurd thing the OSHA man had said, Ron had addressed. — I smiled and said to myself…. “Don’t say anything… just keep quiet and listen…”
One of the violations was that we didn’t have a Confined Space Rescue Team. That was true, we didn’t. There was something in the regulations that said, if a rescue team could arrive in a reasonable time from somewhere else, we didn’t have to have our own rescue team…. Well, we lived 20 miles from the nearest fire station equipped with a Confined Space Rescue team. So, there was that…. That was a legitimate violation.
The next violation was that we didn’t have a rescue plan for every confined space in the plant and each confined space was not clearly marked with a Confined Space sign. This was a legitimate violation.
The next violation was that we hadn’t coordinated efforts between different work groups working in confined spaces together. This was clearly stated in the regulations…. — Oh oh. that was me… I think I was mid-mantra when I heard that one. I had just said to myself… “…anything….just keep….” when I heard this violation. I stopped muttering to myself and immediately forgot that I was supposed to keep quiet.
I said, “But wait a minute. We did coordinate between the three groups that were working in the confined spaces. I was coordinating that. I had posted a sheet on a beam in the middle of the hopper area where the accident occurred where the Brown and Root contractors, and the vacuum truck contractors knew what hoppers were still full and which were safe to enter. I kept the sheet updated each day and so did the vacuum truck workers. They indicated when they had finished vacuuming out a hopper, and I would inspect it from above. When I deemed it safe, the Brown and Root contractors could enter the space. The accident occurred because one of the vacuum truck workers entered the confined space while still cleaning it out and before I had inspected it to make sure it was safe.”
Jerry (the OSHA man that had interviewed me turned and said, “Oh. I didn’t know that. Do you still have that piece of paper?” — Incredibly, I did. About a week after all the vacuuming had finished and all the hoppers were safe, I was walking through the hopper area under the precipitator where I found the paper with the duct tape still on it laying on the grating. Without realizing the importance, I picked it up and brought it back to the janitor closet behind the electric shop that we now used as a “Precipitator Fly Ash Cleanup Room”. I had laid it on a shelf there. The lawyers said, “Send us the original sheet and we will drop this violation.
Here is a copy of the piece of paper. The big black splotch at the top is what duct tape looks like when you make a copy of it.
Well, that worked out good. I had stepped out of line by opening my mouth before I had been asked a question, but everything worked out all right.
The final verdict was that we had four violations. We had to re-train our employees on Confined Spaces. We had to create a Confined Space Rescue Team. We had to put the correct signs on all of the confined spaces and we had to develop rescue plans for all of the confined spaces on the plant grounds. If we did that by August 1, 1994, the four remaining violations which amounted to a $40,000 fine would all be dropped. So, we had our work cut out for us. This not only impacted our plant, but all the Power Plants. The meeting was adjourned.
I already told you what I did after the meeting (I went and ate lunch with my brother). But I haven’t mentioned yet why Robert B. Reich had made a surprise visit to the Department of Labor building in Oklahoma City on April 18.
As it turned out, that morning, Labor Secretary Reich had come to Oklahoma City to hand deliver a $7.5 million fine to Dayton Tire Company. This was due to an accident that had resulted in a man, Bob L. Jullian, being crushed by a piece of machinery in the tire plant. He died a week and a half later at the age of 53.
Robert B. Reich had become so angry when he had studied the case on Friday that he wanted to hand deliver the citation himself the following Monday. That is how we ended up in the building at the same time on Monday, April 18, 1994. We resolved our dispute with OSHA on a congenial note and the citations were dropped on August 1. Dayton, however, was still fighting the conviction 18 years later, eventually paying around a $2 million penalty.
Now you know the rest of the story. Well, almost. Like I said, we had a lot of work to do in the next three and a half months.
Power Plant Grows Up in Smoke
Originally posted September 13, 2014.
I chalked it up to being a trouble maker when someone approached me in the electric shop one day to ask me if I would be an “Advocate of Change”. I figured this person asked me either because he thought I couldn’t resist fighting for a cause, or because he thought he might enjoy watching me make a fool out of myself. Either way, I accepted the challenge.
Last night I was watching TV with my son. We decided to watch a show where “If we weren’t careful, we might learn something.” It was a cartoon from my childhood called “Fat Albert and the Cosby Kids”. The episode was called “Smoke gets in your Hair”. The main theme was about the health hazards from smoking cigarettes. Nothing like Educational TV on a Friday Night. I told my son I had a Power Plant Story about that…
The coal-fired Power Plant in North Central Oklahoma had recently made a change to the “Smoking Policy” at the power plant. New rules went in place that restricted smoking in the office areas. Specifically, it made any area that had a lower ceiling and was enclosed off limit to smokers.
This may seem like a normal restriction today, but this was January, 1990. Before that, smoking in an office was not out of the ordinary. In fact, in the A foreman’s office there was such a stink about not allowing smoking that a compromise was reached (at least for a while) where probes were mounted on the ceiling that was supposed to clean the smoke out of the air by ionizing the particles, causing them to stick to the walls and ceiling, and floor, and…. well… and you…
This became evident a few months later when the walls began turning darker and the ceiling tiles turned from white to a smoky shade of gray.
The company offered smoking cessation classes for anyone who wanted to quit smoking. I think as a whole, our medical insurance rates went down if we took these measures. Back then, it was common to have an ashtray in every office and on the break room tables. It seems rather odd now to think about it after living in an “anti-smoking” culture for the past 25 years.
A few years earlier there was an electrician that had tried to make the electric shop a No Smoking area. At that time, there were 5 electricians that smoked as well as our A foreman Bill Bennett, who often came to the electric shop for his smoke break. Bill Bennett had made it clear then that the electric shop was going to remain a smoking area. Just not in the office or the lab.
Times had changed by 1991. Three smokers had retired and Diana Brien had just declared that her New Year’s resolution was that this time she was going to give up smoking for good. She had tried that a few times before, but with the encouragement from Bill, the first time a stressful situation came around, she would start back up again.
I think my fellow electrician had seen that this was the perfect opportunity to try again to make the electric shop a “No Smoking” area. With Dee giving up cigarettes, this left only Mike Rose as the only smoker in the electric shop. — Well… and Bill Bennett, but technically his office was upstairs in the main office area.
Mike Rose was not just a smoker. He was an avid smoker. When I was watching Fat Albert, there was a father of one of the characters that was a smoker. He coughed a lot, and at one point, went on a coughing jag. When I saw that, I turned to my son, and I said, “That’s when Mike Rose would reach for a cigarette.”
I used to marvel at how after having a coughing jag, barely able to catch his breath, the first thing Mike Rose would do while leaning against the counter was reach in his vest pocket and pull out a pack of cigarettes and quickly light up. — All that stress from coughing…
So, with Dee on the wagon, and only Mike on the verge of keeling over any moment from…. well…. it wasn’t only smoking that made Mike teeter… I approached Bill Bennett and told him that I thought that it was time that we made the electric shop a “No Smoking” area. Bill replied right back that it would be over his dead body before the electric shop before the electric shop would be a “No Smoking” area.
I pointed out that Dee had just decided to quit smoking and that left only Mike Rose as a smoker in the shop. Bill said, it still wouldn’t be fair to the smokers in the shop. I had polled the electricians, and there were at least 5 people would like the shop to be smoke-free. So, with only one smoker, and 5 that would rather not have smoking, what was more fair?
Bill refused to give in, so I told him I would take it to Tom Gibson, our Electrical Supervisor (Bill’s boss). Bill said, “Ok, but I’m not going to bend on this one.” Bill was a chain smoker, and I didn’t really expect him to agree, but this was only the first step.
I had found in the past that in dealing with Tom Gibson, it is best to have some facts in your back pocket. It didn’t do any good to just go up there and whine about something. So, I signed up with a group called “Oklahoma Smoke-Free Coalition”.
I called them (this was before the World Wide Web had become popular) and asked them if they could send me some information about the problems with second-hand smoke. I told them what I was trying to do, and they said they would send me some pamphlets about the hazards of smoking with statistics. I was surprised a week later when I received, not only a few pamphlets but a large tube with anti-smoking posters. I hung one up in the electric shop and would change it out each week.
One poster showed the lungs of a healthy person, then the lungs of a smoker, then the lungs of someone who had quit smoking for 10 years, to show that if you gave up smoking and lived long enough, you could clear yourself up after a while. I had 25 posters, so, I thought I could put one up a week for 6 months.
Signing up with the Oklahoma Smoke Free Coalition was a strange step for me. It gave me a strange feeling because I am normally a very conservative person who doesn’t believe in restricting individual rights whenever feasible. I believe that people should have the right to smoke cigarettes, even though I don’t like it when people smoke around me.
The problem I have with smoking is that, it’s not just an individual smoking their own cigarette. When someone smokes in a room, they are imposing their smoke on everyone else. I believe in the individual having the right to breathe smoke free air and they shouldn’t have to leave a room just because someone else comes in there with a lit cigarette.
I understood that a lot of the people that are active in groups like “Oklahoma Smoke-Free Coalition” have a liberal agenda to curb individual rights in a large range of areas. So, I felt I was straddling a fence that made me uneasy. I resolved to keep this effort focused on one thing…. making the electric shop a smoke free area.
Armed with some statistics about the hazards of breathing second hand smoke, I went to Tom Gibson’s office to make my stand… (well, to ask the question anyway). I told Tom about the situation in the electric shop. I explained that Mike Rose was the only “current” smoker in the shop and I listed the names of the people in the shop that would rather have a smoke free shop.
I told him that even though we had a high ceiling, which had made our shop exempt from the “Smoke Free” office policy, we still felt as if we were in an enclosed room. The air supply for the office and lab was in the shop, and when people smoked in the shop, the smoke ended up in the office area. I mentioned some statistics about how second hand smoke could be dangerous. I also told him I was prepared to take this all the way to Corporate Headquarters if necessary.
To my surprise, Tom didn’t push back. I told him that I had talked to Bill and that he refused to let the shop be smoke free. So, Tom said that he would talk to Bill about it. — Not wanting to lose any time, I asked Tom if we could order some No Smoking signs to put on the doors in the shop. He agreed.
I was in a hurry to get this done because I knew that any day now, Dee would be back to smoking again, and then I would lose all the leverage I had with only having one smoker in the shop. Even Dee had said that she would support a smoke free shop if that’s what we wanted. So, it really came down to Mike and Bill.
More than 20 years later, Oklahoma is still fighting the smoking fight. Mary Fallin, the Governor of the State, has said that she supports cities and towns crafting their own anti-smoking laws. Coming from a Conservative Governor, I feel like I was in good company when fighting for the shop to become smoke free.
I know a few people at the plant were upset with me for restricting their right to smoke in the electric shop. Well, they knew I was a troublemaker when they hired me…
Now it seems like the culture in the United States has shifted so that we recognize the rights of individuals are actually impaired by someone smoking in your face. Sometimes I can just pass a smoker walking down the side walk, and my clothes smell like cigarette smoke the rest of the day.
I think that either noses become more aware of cigarette smoke when you don’t breathe it every day, or the cigarette companies put something in the cigarette to make the smell stronger than before. Today, I can sit in my car with my windows up, and if a car is in front or alongside me at an intersection while we are waiting for the light to change, I can smell the cigarette being smoked in another car.
It’s not just me, my son can smell it too. We can usually smell the cigarette before we see the person smoking it. One of us will say…. “Someone’s smoking.” And we’ll whip our heads around looking for the car. I guess our noses are more sensitive these days.
I know this phenomenon hasn’t reached Europe like it has in the United States. When visiting there, it is like being back in the 1970’s here with people standing around smoking on the street corners, and in the restaurants.
On a side note… I have a story about my mom….
My mom would smoke cigarettes some times when I was growing up. She would do that when she was on a diet. So, on occasion, my brother and I would find a pack of cigarettes lying around.
We had purchased a small metal container of “Cigarette Loads”.
These are small explosives you stick down in the end of a cigarette. When the flame reaches the load, it explodes, destroying the end of the cigarette. So, we put a Load in one of our mom’s cigarettes and put it back in the pack of cigarettes.
Well, my mom didn’t smoke very often, so I was confused a couple of months later when my mom picked me up from High School one day and I found that I was in trouble. My mom’s cigarette had blown up in her face and she wasn’t too happy about it.
End of that side story…. time for one more….
I have always bragged about never smoking a cigarette in my life…. but the truth is that one time I tried to smoke a cigarette… here is what happened….
I was in the 9th grade, and I had cooked the steaks for dinner on the grill in the backyard that evening…. After dinner I went for a walk in the weeds behind my house, which was one of the favorite things I enjoyed doing while growing up.
I ended up down the road from our house where a new church was being built. I walked around the outside of the brick building looking in the windows that were all open as the glass hadn’t been installed yet….
While looking through one window, I noticed a pack of cigarettes left by a construction hand laying on the window sill. I picked it up and there was one cigarette still in the package. I realized I had a book of matches in my pocket that I had used to light the charcoal grill that evening… No one was around, and no one could see me because there were no houses around behind the church where I was standing, so I thought…. “I’ll smoke this one cigarette just to see what it’s like.”
So, I put the cigarette in my mouth, and lit the match. At that very moment, out of nowhere, it began to rain. The rain immediately soaked the cigarette and put out the match. I threw them both on the ground as if they had burned my hand and walked quickly away from the church knowing full well what had just happened. The rain stopped just as suddenly as it began. I said out loud, “I received your message God. I’m not going to try that again!” I only needed that kick in pants once.
Comments from the Original post:
What Happens When Power Plant Gremlins Bite Back
Originally Posted October 4, 2014.
I suppose many of you have seen the movie Gremlins that came out in 1984. It’s a story about a creature named Gizmo who is a Mogwai that becomes a pet of an unsuspecting young man, who inadvertently breaks certain rules that were explained to him in specific detail. The first rule was Don’t get the Mogwai wet…. The second rule was Don’t feed a Mogwai past midnight. — There was another precaution, like Mogwai do not like Bright Lights. The Mogwai is a cute little pet designed to sell toys, and I think it was probably pretty successful.
When a Mogwai get wet, it pops out some fur balls that then turn into other Mogwai. You would think this would be good, but when the boy accidentally spills water on Gizmo, the new Mogwai turn out to be mischievous, where Gizmo is friendly and has a nice smile. The new Mogwai trick the boy into feeding them past midnight. This is when the trouble really begins. The cute fuzz ball Mogwai turn into Gremlins:
Can you guess which one is the Gremlin?
So, what does this have to do with Gremlins in a Power Plant? As it turns out something like Gremlins live in Power Power Plants. I know they did at the Coal-fired Power Plant in North Central Oklahoma where I worked as an electrician. Sometimes when you least expected it, a Gremlin would jump out and bite you.
At first a Power Plant Gremlin may appear like a nice cuddly Mogwai. For instance, one day when Stanley Elmore asked Hank Black to pull up to the front of the garage with the large P&H Crane to unload a large piece of equipment from a truck, or some such thing. I’m sure to Hank, this seemed like a nice cuddly Mogwai sort of a job.
Just think about it. Operating something with so much power and the ability to do so much work by just pulling a few levers and pressing a couple of petals, flipping a few switches. Not many people at the plant were privileged enough to have the opportunity to operate the P&H Crane. So, when Stanley asked Hank to lift that load and tote that bale, he hopped right to it.
Unfortunately, Hank didn’t realize when he climbed into the cab of the crane that the little Mogwai sitting in the seat next to him had been eating after midnight the night before…. One little pull of the wrong lever at the wrong time, and a little distraction that caused Hank to forget to put his outriggers out before trying to lift his heavy load, and the crane flipped over on its side.
I wonder if Hank noticed the Gremlin jumping out of the cab just after that happened, or was he in too much of a state of shock. Though Hank appeared all right after that incident, he had injured his back in a way where he eventually had to leave permanently. I know that many years later after he left, he was still collecting a pay check from the company. Compliments of the Gremlin.
One day RD (Dick) McIntyre, Dale Mitchell, Don Timmons and George Alley were working underneath one of the four Intake Pumps, also known as the Condenser Water Pumps. These are the large water pumps that push the lake water through the condenser in order to cool the steam so that it can make another round through the boiler and end up turning the turbine once again. I believe each of these pumps can pump something like 189,000 gallons of water per minute. — One of the Power Plant Men at the plant can correct me if I’m mistaken.
The crew was putting the coupling back on the pump if I remember this correctly…. and they needed to rotate the rotor of the motor or the pump in order to line it up or check the alignment. I wish I had a team picture of these four men, because they were the nicest bunch of old men. Especially when you were able to catch them all together. It seemed like the energy of their friendship made their group larger than the sum of the individuals. I’m sure while they were working on this job, all sprawled out underneath the pump motor, they had warm cuddly feelings just as if each of them was petting a Mogwai.
That’s when the Mogwai suddenly turned into a Gremlin. The team had put a strap wrench around the rotor (correct me if the details are wrong Mickey. You would know better than I) and were attempting to rotate the rotor. Dale Mitchell told me later that suddenly something slipped and the handle of the strap wrench swung around and smacked Dick McIntyre right in the forehead. Dick and Dale were just about as inseparable as Dick Dale was with his first and last name, so you can imagine how Dale felt that he had injured Dick.
Here is an interesting coincidence…. Dick Dale worked in the warehouse across the drive from the automotive garage where Dick and Dale (McIntyre and Mitchell respectively) worked, which was where the crane had tipped over with Hank Black in the driver seat. — I could stretch the coincidence to David Hankins, who used to drive a Black Trans Am. I would have mixed up David Hankins and Hank Black, because of David’s Black Trans Am, but David died in an auto accident early in 1980, and I don’t think Hank had arrived until shortly after. Racially, David Hankins was Black, and Hank Black was not. He was Native American. Anyway. I digress (which means… I have strayed from the topic of Gremlins).
When I think about Gremlins at the plant, Yvonne Taylor comes to mind. Not because she reminds me either of a Mogwai or a Gremlin, but because she encountered a Gremlin of sorts that sort of had a similar effect of spilling water on a Mogwai. I have recently reposted a story called “How Many Power Plant Men Can you Put in a 1982 Honda Civic” where I talked about Yvonne Taylor, one of the Chemists at the Plant.
Yvonne Taylor had worked as a Chemist at the plant since around 1980. We carpooled while I was a janitor and on the labor crew, almost until I joined the electric shop. So, I knew her pretty well. She liked to talk a lot, so I knew her a lot better than she knew me. As a chemist, she worked in the water treatment plant testing water quality, as well as testing our sewage treatment pond, and ground water, etc. She worked with a lot of different chemicals.
I was always fascinated with the chemistry lab. I had my own chemistry lab set up in the basement of our house when I was young. My dad would bring home different left over chemicals from work, and I would mix them, heat them, and light them on fire, and test their chemical properties… to the point of making gunpowder and exploding them in the backyard.
I think Yvonne had worked at the plant about 10 years when she developed a rash (or something) where she would become ill when working in the lab or in the water treatment plant. It was serious enough that Yvonne would have to take sick leave at times to recover. I first learned about her condition when I went to the chemistry lab for something and she was sitting in there wearing a paper filter mask. When I asked her why, she explained to me that she was trying to figure out what was causing her to become ill. She thought there might be some particles in the air in the lab or the water treatment plant that was causing it.
I think that the effects of Yvonne’s condition sounded a lot like what happens when someone develops an allergy to Latex. Yvonne would wear Latex gloves a lot when handling chemicals, so maybe that was it.
The sad part of the story is that Yvonne’s condition was severe enough that she had to leave the Power Plant and find another job. I don’t know where she went to work when she left the Electric Company. So, you see, Yvonne Taylor who happily went to work each morning ready to cuddle up to her chemicals just as if they were Mogwai, was finally chased away by Power Plant Gremlins.
In the post about the Honda Civic I mentioned that Yvonne’s husband Patrick had died in 2012. So, I wondered how Yvonne is doing lately, so I Googled her, knowing that she lived out in the country near Perkins Oklahoma…. But an interesting thing happened when I pulled up a page from the Perkins Journal for June 9, 2011.
I became confused when I saw this page. You see, the picture in the middle at the top is Mike Rose. He was an electrician I had worked with at the Power Plant, and I had recently re-posted a story about him called “River and Rose In the Power Plant Palace” Mike Rose had his own set of Gremlins which I may have mentioned in that post, but why, when I searched for Yvonne Taylor, did I pull up the a Newspaper Obituary of Mike Rose with the same picture of Mike I had posted in my post:
Talk about a Coincidences:
I read through the entire page before I found Yvonne’s name in a totally unrelated article on the same page of the Perkins Journal! Look in the lower right corner of the screenshot of the newspaper. The picture of Kimberly Jo Taylor Wilkins. — Yep. That’s right! The daughter of Yvonne and Patrick Taylor! I don’t know how may hundreds of stories I heard about Kimberly throughout the 9 or 10 months I spent carpooling with Yvonne each morning as we drove to the Power Plant. Here she was beginning a new phase in Kimberly’s life on the same page that Mike Rose was beginning a new phase in his life. Two unrelated stories of Power Plant People I worked with on the same page of a small town newspaper (Perkins Oklahoma, Population 2,863) 10 years after I left the plant to go work for Dell. — Isn’t that neat?
Power Plant Music To My Ears
Originally posted October 25, 2014.
I’m sure just about everyone does this. When they look at someone, they occasionally hear music. Some sort of song that is inspired by the person. For instance when I look at my mom, I suddenly begin to hear Beethoven’s 5th Symphony (sorry about the advertisements. Nothing I can do about that).
For those with older browsers that are not able to view video links, I will include the link below the video: Beethoven’s 5th Symphony.
A few years ago when I was working for Dell, after I had given a thumb drive loaded with the songs I liked to listen to, to a friend of mine, Nina Richburg, when she left our team, she came up to me later and said she had never heard such an eclectic selection of music before. I told her I knew what she meant. I had included classical, rock and roll, electronic, movie soundtracks, country, easy listening, and just about every other genre in the book.
I didn’t explain to her how I can come to the point where I listened to so many different types of music. The answer of course is that I had worked at a Coal-fired Power Plant in North Central Oklahoma for 20 years and I had learned to listen to the music that played in my head while working alongside some of the most diverse set of humans that comprised the Power Plant Men and Women at the plant.
I think it began while I was a janitor working with Pat Braden. When I would work with him, I hear a certain song in my head. So, I began to associate that song with Pat. I’m sure many at the plant heard the same song playing in their heads while interacting with Pat. He was such a nice guy:
The direct link is: Sesame Street Theme Song.
I guess you can call it Power Plant Theme Songs, since the songs that usually played in my head represented the type of person. This wasn’t always the case. For instance, when I looked at the electric Foreman and my close friend, Charles Foster, I would usually hear this song:
The direct link is: GhostBusters.
I would hear this song, because when the movie came out, and the song would be played on the radio, Charles’ son Tim Foster thought the song was saying, “Who ya gonna call? Charles Foster!” So, I can’t hear this song without thinking of Charles Foster.
I have told stories about Gene Day (formally known as Victor Eugene Day — I didn’t misspell “formally), and how it was always fun to play jokes on him. The main reason is because Gene Day was always so easy going. When you look at Gene, the obvious song that pops in my mind is this:
The direct link is: Feelin’ Groovy.
Aren’t they cute? If you took Garfunkel (the tall singer) and shrank him down to the size of Simon, then you would have Gene Day. It was worth the trip to the control room just to encounter Gene Day, so that the rest of your day, you could go around the Power Plant, performing your feats of magic while you were “Feelin’ Groovy!” just for looking at Gene Day. That’s the effect he would have on passerby’s.
My bucket buddy Diana Brien had her own theme song. This song would come to mind not because the song itself reminded me of her, but because she remarked one day when the song was playing on the radio that she really liked it. So, from that point, this was Dee’s song:
The direct link is: Desperado.
I had some songs in my head when I looked at other Power Plant men because it actually sounded like they were singing the song themselves. This was the case with Bill Bennett, our A Foreman. He had a gruff Cigarette voice so I could easily hear Bill Bennett singing this song. Actually, ZZ Top was probably inspired to write this song by Bill Bennett:
Direct link to: La Grange.
The Extreme Power Plant character of some Power Plant Men that I was inclined to “Hero Worship” because of their tremendous talent led me to hear music of a more epic nature. This was true for both Earl Frazier and Andy Tubbs. Earl Frazier was a welder of such talent and when combined with his loyal country nature, even though his occupation was different than this song… This is what usually came to mind when I would look at Earl Frazier:
Direct link: Wichita Lineman.
Andy Tubbs had the same sort of “epic-ness” that Earl had. He was “Country” like Earl also. At the same time, Andy was one of the most intelligent Power Plant Man that graced the Tripper Gallery by his presence. That is probably why this song would come to mind when I would look at Andy:
Direct Link: Good Bad and the Ugly.
Notice the resemblance to Andy’s picture and the song. You could hear the Good Bad and the Ugly Song start up every time Andy would leave the foreman’s office and step out into the shop.
I have covered the “Power Plant Genius of Larry Riley” in a previous post. He was another “Epic Hero” of mine. There was not a lot that Larry couldn’t do. His epic-ness was more like a knight from the time of King Arthur. I think that’s why I would hear the song that I heard when I would look at Larry. The movie Excalibur included the perfect song for a knight riding out to meet the enemy just as Larry would step out of the Labor Crew building each morning when I worked for him as a laborer. I would hear the following epic song go through my mind (try singing along with this song):
Direct link: O Fortuna.
Flashbacks of Latin Class!
If you look at Larry’s picture while listening to O Fortuna, you can actually picture him dressed in armor riding on a backhoe just as if it was a War Horse, heading off into battle!
There were other epic characters at the plant that would inspire similar songs. Toby O’Brien, as a Power Plant Engineer, though, not “epic” in the Power Plant Man sort of way, still inspired music when in his presence. I think it was his calm demeanor even when faced with those who may disagree with him (to put it mildly), and it was his deliberate resolve to focus on tasks at hand that left me with this music running through my mind when in his presence:
Direct Link: Moonlight Sonata.
The music fits, doesn’t it?
Scott Hubbard, my partner in crime (not literally…. it felt like a crime sometimes having so much fun and getting paid for it at the same time), was always such a hard worker. Like most industrious Power Plant Men, Scott was always running around (not literally again…) with a smile on his face working away on one project or other. That’s probably why this song was always going through my head when we were working together. It always seemed like everything was going like clockwork:
Direct link: Miss Marple Theme Song.
When I would go to the tool room to get parts, if Bud Schoonover was working there, I could usually hear his song even before I arrived. I don’t know if it was some kind of psychic ability I had, or it was because I would observe the faces of others as they were leaving the tool room, that would queue me in that Bud was on Tool Room duty. Either way, when this song would start up in my head, I knew that Bud Schoonover was near:
Direct Link: Baby Elephant Walk.
It wasn’t because Bud reminded me of an elephant that this song would come to mind. I think it had more to do with Bud’s carefree attitude about things. This song just seemed to come to mind while I would wait at the tool room gate while Bud would search for the parts I had requested. I don’t have a picture of Bud. He was big like Paul Bunyan, but he had the expression of Aunt Esther from Sanford and Son, as I have often mentioned. It was the squint and the jutting jaw when he spoke…
Here is Bud:
Johnny Keys was another True Power Plant Man that had his own theme song. This one came to mind just about the first time I met Johnny. I could tell right away where he would rather be. This song actually came up with a lot of different Power Plant Men, including Ben Davis and Don Burnett. Don and Johnny were working together as machinists when I first met them the summer of 1979. Ben Davis was good friends with both Don and Johnny, so this song would come to mind whenever I encountered any of these three Power Plant Men:
Direct link: Daniel Boone.
There are some Power Plant Men that sort of reminded me of a bear. Ronnie Banks was that way, and so was Dave McClure. Ronnie reminded me of a bear because he walked like one. Dave reminded me of a bear because he was a big scruffy Power Plant Man. He was gentle like Gentle Ben in the TV show Gentle Ben. I didn’t hear the theme song for Gentle Ben when I worked around these two. Instead I heard this song because this song captured their personality much better:
Direct Link: Bare Necessities.
Ron Kilman, the Plant manager (yeah. I have a song for him too). But I wanted to say that Ron Kilman had his own clerk (secretary) that sort of acted like a receptionist when you entered his office. Her name is Jean Kohler. She was the same age as my mother. Unlike hearing Beethoven’s 5th Symphony as I do with my mom, when I would have the opportunity to talk with Jean Kohler, she was such a lady that the following song would immediately come to my mind:
Direct Link: Lady.
I don’t have a picture of Jean Kohler, so you will just have to picture a very nice prim and proper lady with a perfectly sweet smile.
Ron Kilman’s theme song was The William’ Tell Overture. I guess because of the pace that he usually had to work. I listen to this song often because it helps me work. The song is longer than most people are used to hearing, so, I’ll just send you a link to the part that most people are familiar:
Direct Link: Lone Ranger.
In the Power Plant there were a few “sour apples”. In my posts I generally like to focus on the True Power Plant Men and their accomplishments. Occasionally when the topic is right, I may mention those of a less savory character…. Without saying much more than that, whenever I would encounter Jim Arnold, who was the Supervisor over the engineers, and later the head of Operations and later, the head of Maintenance, several songs would come to mind. The theme of the songs were songs like this one:
Direct Link: You’re So Vain.
I searched everywhere for a picture of Jim Arnold and this was the only one I could find:
What more can I say? I will leave it at that. Now you can see why someone would think that I listen to an eclectic selection of music. Because I worked with such a diverse bunch of Power Plant Men and Women!
Finding and Defining Power Plant Confined Spaces
Originally posted on November 8, 2014.
OSHA defines a confined space as a place with restricted access, or a place like a hopper with converging walls where you can get stuck. When the supervisors at the coal-fired power plant in North Central Oklahoma were asked to identify the confined spaces their workers had to work in, there were a few spaces that ended up on the list that made some wonder if they had just picked up a case of lice…. In other words, they began to scratch their heads.
Earlier I wrote a story about when a person was engulfed in ash in a Precipitator hopper and almost died, (See the post “Tragedy Occurs During a Power Plant Safety Meeting“). This led to an investigation by OSHA a man from OSHA (See the post “OSHA Man Cometh“). Then we were fined and were given a list of tasks that we had to perform by August 1, 1994 (See the post “Power Plant Men Being Summoned by the Department of Labor“). One of those tasks was to create a Confined Space Rescue Team.
The first task for the Rescue team was to put signs on all the confined spaces with a warning that this was a confined space and that you weren’t supposed to go in there unless you have a Confined Spaces Entry Permit.
After that, the Confined Space Rescue Team was was tasked with developing rescue plans for each confined space.
One of the confined spaces on the list that was supplied by the supervisors at the plant was the Battery Room in the Main Switchgear. This was added to the list by Tom Gibson who was the Electric Supervisor for the plant. According to OSHA’s definition of a confined space, a room like the Battery Room, which you entered by walking through a regular door, didn’t meet the definition of a Confined Space even when trying to stretch the definition in imaginary directions.
Tom Gibson explained that he wanted to add the Battery Rooms to the list because he thought that a dangerous conditiono could arise in the battery room if the ventilation fans failed and there was a build up of toxic gases from the batteries and someone walked in there and passed out. They would need to be rescued just as if they were in a confined space.
So, the Battery Room went on the list…. but the Confined Space Rescue Team decided that we weren’t going to create a rescue plan with much detail. We decided that we would just need to open the door and turn on the vent fan. Later, we were able to remove the battery room from the list.
It is interesting how some people come up with their justification for bending the definition of something like a confined space in order that the room would be considered a more hazardous place than normal. There were other ways to make this point besides trying to fit the big rectangular door into the size of a manhole cover.
When we put together the Confined Space Rescue Team, we had the Safety Task Force send out a intra-company letter to each person asking them if they would like to join the Confined Space Rescue Team. We wanted to get a good cross-section of people from different skill sets. I thought we did pretty good.
I can’t remember every one of the original member, but those that I can remember are:
Alan Hetherington, Jimmie Moore, Mike Vogle, Randy Dailey, Ray Eberle, Thomas Leach, Paul Mullon, George Clouse, myselft and um…. I can’t remember the last one. Maybe one of you can remind me.
Once we had the list, the first thing we had to do was to be properly trained as a Confined Space Rescue Team. A company in Dallas, Texas was hired to come to our plant to train us to become Confined Space Rescuteers (I just made that word up… Sort of like Mouseketeers).
While we were taking the training, the trainers kept calling the lead trainer “Dad”, so we began to wonder if this was a family affair. The leader of the training team was much older than the others, and he did treat the young trainers like a father. At one point when one of the trainers was trying to get the lead trainer’s attention, he kept saying, “Dad! Dad!” just like a little kid would try to ask their dad if they could go outside now and play. The rest of us just kept looking at each other like…. yeah… he’s their dad.
It turned out that Dad was really just his initials. His name is David A. David, so they just called him Dad. I thought that was pretty neat and fitting since he did treat them all like he was their dad. When I later moved to Texas, I found that David David is a rather popular name down here. It seems like people named David David own a number of car dealerships in the Dallas area.
We were given special rescue harnesses to wear that was a lot like a regular safety harness, except the place where you clip on to the rope is down at your waist instead of up by your chest. This put the point where you are suspended at the center of your weight (if you are built like your average rescuer… I mean, you don’t have a shape like Santa Claus…. which, if you did, you were probably more likely to be a rescuee instead of a rescuer).
With the focal point in the center of your body, you could easily swing upside down, lay flat or sit straight up. It was pretty neat. You have probably seen someone wearing one of these before…. Tom Cruise demonstrated this technique in the first Mission Impossible movie:
We learned a lot of lessons in the Confined Space Rescue Team Training that I have never forgotten. One important statistic was that somewhere around 70 percent of people that die in confined spaces are would be rescuers.
If you stop and think about this number for a moment, it is rather shocking (if true). This meant that more people died trying to rescue someone from a confined space than actual original victims.
The reason this happens is because when someone in a confined space is found to have passed out, people tend to rush in there to pull them out, not realizing that the reason the person passed out was because there was some sort of toxic gas or a lack of oxygen in the confined space that caused the first victim to pass out.
I remember a tragedy when I was going to college at the University of Missouri in Columbia, Missouri around the year 1980. I think it was at the Rolla campus where agriculture researchers had a large pit sort of like a deep empty swimming pool where they were doing some kind of experiment.
One of the people working on the project passed out in the bottom of the pit. Three other people in the area rushed down there to help the person. When they climbed down the ladder to help, each of them passed out, and all four of them ended up dead. There was some sort of poison gas that settled down in the pit that was fatal.
We knew then that it was important that we become properly trained as confined space rescuers. We have a culture in the United States to want to help someone in trouble. In some circumstances, a person could even be held liable if they don’t come to someone’s aid in an emergency. It is called a “Duty To Rescue”.
The problem with rushing into a confined space to rescuse someone is that you may actually be putting more lives at risk if you are not properly trained. The first tool we used when we arrived at a confined space was an Air Monitor.
We checked the quality of the air in a confined space for 4 different conditions. First, there had to be enough Oxygen (20.9% hopefully). Not too much Carbon Monoxide, No Hydrogen Sulfide (smells like rotten eggs, only if you smell it briefly and then the smell goes away, it could be because it deadens the receptors in your nostrils making you think you’re safe when you’re not — that’s why you need to use a monitor instead of just your nose). Lastly, we check for an explosive atmosphere. In order to make sure we aren’t crawling into some place that is ready to explode.
The first skill we learned was to tie knots. We actually spent a lot of time learning about knot tying. We had to be able to tie them while wearing rescue gloves. Those are leather gloves that keep you from burning your hand when you are feeding a rope through your hands.
Some of the Rescue knots we learned how to tie were the Figure 8, the Figure 8 on a Bite, and a Figure 8 Follow Thtrough. We also learned to tie a Prusik Knot that could be used to climb right up another rope like you were going up steps.
We learned to tie a Water Knot if we needed to extend the lengths of straps. Other knots were the Girth Hitch, the Double Fisherman’s knot, butterfly knot, and the right way to tie a square knot to make sure that you don’t end up with a granny knot and have your knot slip right off the end of the rope.
During the Confined Space course, we had to be able to tie these knots not only wearing our gloves, but we had to tie them behind our backs in the dark. After all, it was explained to us, that when you are rescuing people from a confined space crawling on your stomach wearing an SCBA (Self-Contained Breathing Apparatus), you will not be able to see the knots you have to tie in order to pull someone safely out of the hole.
The trainers would inspect our knots and they had to be perfect, or he would take them apart and we would have to do them again. You couldn’t have one rope croxxing over another where it shouldn’t be, even if the knot was correct. The knot had to be picture perfect.”
“Dad” and the training company had a big black trailer that had a big metal maze where they could fill it with smoke. Then, they would put a safety manequin in the trailer somewhere and we would have to go in there wearing our safety equipment and rescue the dummy in the smoky dark maze during a hot summer day when it was about 100 degrees outside.
The most important thing we learned during that class was that even though our instinct is to go in and be a hero and rescue someone in trouble, we have to realize that the majority of the time when a person goes in a confined space to rescue someone they are retrieving a dead body.
The importance of this lesson is that it’s not worth risking the lives of the Confined Space Rescue Team when the person being rescued is most likely dead already. We needed to remember the statistic that 70% of people that die in confined spaces are would be rescuers.
As long as we kept that in mind, when the time came for us to dive right in and pull someone out, we would take the time to do it right and do it safely. What good is trying to rescue someone only to have our fellow rescuers die alongside the original victim?
Power Plant Janitor John Fry Standing Guard as Floors Dry
Originally posted November 15, 2014. I added an addendum at the bottom of the original post:
John Fry had a peculiar way of standing in front of the bathroom door in the electric shop after he had mopped the bathroom floor as he waited for the floor to dry. It was as if he was a sentry on duty in front of the Buckingham Palace in London because he would stand so still. I would amuse myself by picturing him dressed in the red Beefeater uniform standing at attention at the bathroom door at a coal-fired Power Plant in North Central Oklahoma.
Only John wasn’t carrying a rifle, he was holding his broom handle. He would hold the handle of the broom so that it was parked just behind his right ear. His head would be slightly bent forward and the expression on his face was one of deep thought. John didn’t speak much. I wondered if he had ever been a guard or a soldier. It would have had to been during the Vietnam War if he had given his age. He was born in 1947.
I always admired John who was doing the job I used to do when I was a janitor at the plant when I had first become a full time employee after four years of working as a summer help. Like the tourists in London, I would do subtle things to try to distract John from his stalwart sentinel position without actually talking to him. I didn’t think it would be fair to actually use words, because John, being the polite person that he was would break out of his guardian stance to say “Hello” or answer a question if I had posed one.
One day while John was standing watch over the wet bathroom floor, I silently came up alongside him with my own broom and I put the handle behind my ear just like him and tried to stand with the same interesting posture John used. I stood there for a few minutes waiting to see if John would respond to me. There was something peaceful about standing next to John meditating on the water evaporating from the tiles behind us. The wooden handle placed behind the ear, pressed up against the side of the head added a sort of stability.
He just continued standing watch. He may have had a slight smile, I’m not sure. When John smiled, it was usually very subtle. It was more in the eyes than on the mouth and since I was only looking out of the corner of my eye, I couldn’t really tell. I didn’t wait until the floor completely dried before I left. I still had to be an electrician, and I only had a few minutes to spare before I had to continue on my way.
The other interesting feature about John was that he didn’t turn his head. It was as if he was wearing an invisible neck brace. So, when he walked by, if you said “Hi John”, he might put up one hand as a slight wave, and mutter “Hi” back, but he wouldn’t turn his head toward you, unless he happened to be coming straight in your direction. He was generally looking at the floor a few feet in front of him when he walked. He would walk sort of hunched over as if he was looking for a small lost item on the ground.
I took this to mean that John had some sort of surgery on the vertebrae in his neck that fused them together so that they were immobile preventing him from looking this way or that. He was built like a boxer and looked the part, so I would imagine that in his earlier days, John was in a boxing ring exchanging blows with someone until he had to stop because of the injuries to his spine that could only be mended by fusing his neck into a permanent position of a Buckingham Palace Guard.
It was a pastime of mine to imagine what the Power Plant Men did before they ended up spending their days creating electricity for half the state of Oklahoma. That was until I had the opportunity to ask them and find out what they really did. As I mentioned, I pictured John Fry as a boxer before he became the bathroom Beefeater.
I pictured Johnny Keys as being someone who lived in the Arkansas Ozarks making Mountain Dew from a still up in the hills before he became a machinist.
You would understand that image better if you had seen him before they disallowed the wearing of beards on the plant ground. When Johnny had a beard he looked more like this:
I don’t even want to mention the number of Power Plant Men I pictured as used car salesmen before I knew them better. Ok. All right. I won’t tell you their names, but one of them has the initials: “Gene Day”.
There were a number of Power Plant Men that looked like they were Sergeants in the Army or Navy. Some that come to mind are
and Jim Arnold:
Then there is the group of Mad Scientists. You know the type… They look so normal, but you can tell that in their spare time they are playing with chemicals, or coming up with new Physics equations in order to puzzle those fortunate enough to take a college Physics course….
Before I knew what this group actually did for a living before they arrived at the plant, I immediately thought…. Mad Scientist:
and lastly Merl Wright:
Then there was the group of people that looked like they were in a Hard Rock Band. They were easy to categorize since they all wore dark glasses…. Or maybe they did that because they worked in the welding shop…
There’s Larry Riley:
and Junior Meeks:
Ok. Maybe in their spare time, they also doubled as a biker gang.
Then there was the more simple jobs… For instance, Danny Cain probably worked in a donut shop (which coincidentally… I did):
And also Coincidentally, Danny always liked Donuts.
Then there was the all around nice looking guys who would serve you in a restaurant or bag your groceries like Mike Gibbs:
or Brent Kautzman that reminded me of one of those guys that modeled fancy shirts in a J.C. Penny’s Catalog:
Ok…. I think you get my point…. Sort of like the songs I would hear whenever I was around these guys like I had discussed in the post “Power Plant Music To My Ears” I also categorized the Power Plant Men into various previous jobs… Larry Riley used to say that it was a good idea for me to not be idle because when I was, I would come up with the goofiest (my word, not his) things to do. I suppose he was right.
Anyway, I want to get back to John Fry. You see… my thought about John being an ex-boxer that could no longer box because of a neck injury gave me a sad feeling when I looked at John. I never really knew if he was married, though I didn’t think so. I knew he had a younger brother that lived in Stillwater, while John lived in Ponca City. Besides that, John’s life was a mystery to me.
So, today when I decided to write about John, I looked him up online to see what I could find. I found that he had died at the age of 58 years old on May 10, 2006 while working as a Warehouse Inventory Clerk. I couldn’t find an obituary. It seems that the Trout Funeral Home that handled his funeral either didn’t keep records that far back, or they just didn’t have anything to say about it.
I learned that the Sunset Baptist Church had a service for John but I couldn’t find anything about his funeral there either. Actually, I couldn’t even find the cemetery where he was buried. There is one John Fry in the IOOF cemetery in Ponca City, but I am not able to tell if that is him or not. It seems to me that John, whose brother had died 4 years earlier may have been alone.
I wish I knew more. Maybe someone at the plant can fill me in. Maybe I have the wrong John Fry and John is still around.
As a terrific Power Plant Man Janitor who held his post each day while the floor was drying, I want him to receive the honor that he deserves. I want him to know that there is a group of men that honored his service and respected his life. If I had his picture, I would display it here. The only picture I have is the one I carry in my memory.
About two weeks after I wrote this post last year, John Fry’s daughter Amy ran across this post and left a comment. I have included that below:
Comments from the original post:
This is about my Dad, Thank you for writing this about him. It brought back many memories about my Dad, many from out there at OG&E power plant when we would go fishing or I would pick him up from work. I am really speechless about someone writing about him and I am grateful to you for sharing your memories by writing about him in the newsletter/blog. I could not sleep tonight so I google my dad’s name and I found it. Who ever wrote this my email is firstname.lastname@example.org please feel free to contact me I would would greatly appreciate it!!!
The Power Plant Smokestack Third Rail is the Lifesaver
Originally posted November 29, 2014:
It was quite a site at the coal-fired Power Plant in North Central Oklahoma to see a 400 pound man climbing up the ladder to the 250 foot level (halfway) of the smokestack only to climb halfway down again on the track the elevator used to go up and down the smokestack. I was on labor crew then and I remember thinking, I’m sure glad that’s not me.
A small tour of people from Oklahoma City had come to the plant and one of the engineers was showing them around. I think Allen Gould may remember who it was. I’m not saying it was Allen, I’m just thinking that he was around at that time.
I think that day the wind was blowing rather hard and when the elevator was descending (going down) the stack, the power cable somehow blew over into the path of the elevator and it was caught under the roller which brought the elevator to an abrupt halt. Unfortunately. in this instance, trying to free fall the elevator manually to bring it down wouldn’t work since when the brakes were released, the elevator wouldn’t move because it was really stuck right where it was.
A person that worked for the Alimak elevator company was called in from Wichita Kansas 100 miles to the north of the Power plant, which meant that it took almost 2 hours for the person to arrive at the plant. When he did, he turned out to be the largest elevator repairman I had ever seen. He had to climb up 250 feet up a ladder to the landing, then back down again about 100 feet to the elevator to rescue the people from the elevator.
I first found out about it when someone pointed out the large figure of a man about halfway up to the first landing on the smokestack ladder. He had stopped for a rest and was leaning back on his lanyard that was attached to the ladder. When we arrived in the maintenance shop, Marlin McDaniel explained the situation to us. I think it took well over three hours for this man to take each person out of the hatch in the top of the elevator, then climb with them up the elevator track to the landing, and then take them down the ladder 250 feet to the ground. I think one of them was a lady, and two were men.
The stack elevator is a small box with a capacity to carry 3 people or a weight of 900 pounds. It is crowded enough with only two people in it, but three is always a crowd (as the saying goes, “Two’s company, Three’s a crowd”). That phrase definitely is true with the stack elevator.
At the time, I didn’t realize that one day I would be an electrician that took care of the smoke stack elevators. Actually, I never gave it a thought about what sort of equipment electricians repaired or maintained. It turned out that electricians worked on anything that had electric power going to it. That’s pretty much anything mechanical.
Electricians would work on the motors while the mechanics would work on the pumps, fans and valves attached to the end of the motors. When it came to the stack elevators, it was generally left up to the electricians to do the majority of the work. We inspected the elevators each month, and when they broke down, we were called to repair them.
When the boiler elevators broke down, it seemed as if I was the person of choice to ask to climb the boiler to the roof to fix it. The elevator controls were located on the top of the boiler, so I would usually end up climbing the stairs to the top cleaning door contacts on the way up. It happens that the boilers are 250 feet tall. So, the middle landing on the stack elevator is about the same height as the boiler as you can see in the picture above.
Bill Bennett, our A Foreman, would always add when he was telling me to go fix the elevator…. “You like climbing all those stairs anyway.” What could I say? “Sure Bill! I’ll go see what I can do.”
I think in the back of my mind I knew the day was coming when I was going to have to climb the stack elevator ladder to rescue someone. I had already climbed it a few times to fix some conduit that had come loose that ran up the smokestack next to the ladder, so I knew what it was like to go straight up a 500 foot ladder to the top of the smokestack. Luckily when my turn came around for a rescue, I only had to go halfway up. There were 4 people stuck on the smokestack.
Unlike the large elevator repairman from Wichita, I didn’t have to climb down the elevator track to reach the elevator. It had malfunctioned right at the 250 foot level when the group was ready to come back down from their semi-lofty visit of one of the Power Plant Smokestacks. My only task was to climb up, fix the elevator and bring the group safely to the ground.
I grabbed some tools from my tool bucket that I thought would be useful. A couple of different size screwdrivers (one large one and one small), my multimeter, fuse pullers, and three wrenches, (7/16, 1/2 and 9/16 inch). I put them in a bag that looked like a feed bag for a horse. It had a rope with a hook on it.
I figured I didn’t want to take anything I didn’t need, so I didn’t put all 40 pounds of tools from my tool bucket into the bag. Just those things I thought I might need. I had my handy dandy little crescent wrench in my pocket and my baby screwdriver in my pocket protector on my tee shirt.
I took a safety belt off of the coat rack by the door in the electric shop and put it on. I figured I could hook the tool bag to one of the rings while I was climbing the ladder up the smokestack. With only the safety belt and the fairly lightweight tool bag, I headed out to the Unit 2 smokestack. Oh yeah. I was carrying one other nifty device as well.
when I arrived, Doug Link was standing at the bottom with some other people. Doug explained that George Bohn and some other engineers from the City (meaning Oklahoma City) were trying to come down, but the elevator wasn’t working. Luckily they had carried a two-way radio with them when they went up (which was a regular safety precaution since smoke signals would largely go unnoticed coming from a smokestack).
I understand from watching movies that when you climb onto the tracks in a subway in New York City or some other large town with a subway, that you are supposed to avoid the “Third Rail”. After Doug Link had explained to me the problem, the first thing I did was to grab the third rail on the ladder that ran up the smoke stack.
You see. Running right up the middle of the ladder is an extra rail. This is what keeps you alive while you climb a very high ladder. Think about it. If you were to try to climb a ladder 250 or 500 feet straight up, what’s going to happen to you? Your arms and legs are going to start getting wobbly. You are going to become short of breath, and your head is going to start to swim some either from hyperventilating or the lack of oxygen… I haven’t figured out which yet.
Anyway, at some point, something is going to stop working. Your fingers are going to miss their grip on the next rung or your work boot is going to slip off of the rung and you will fall. If there is nothing to stop you, then you are going all the way to the ground.
That is why the third rail is added to the ladder. It is there so that you can tie your safety belt to it. It keeps you from falling when you slip, and it also allows you to take a rest when you need it without the worry that if some part of your body momentarily malfunctions, you won’t fall to your death.
Here is an example of a ladder with a device similar to the one we had on our stack ladders. I took the nifty device I had brought with me and hooked it into the third rail of the ladder and clipped the tool bag to the other metal loop on my safety belt (this was before we had safety harnesses). Then I began my trek to the landing.
As I ascended (went up) the ladder I told myself that this was no higher than climbing the stairs on the boiler to go to the elevator penthouse to fix the boiler elevators. I do that all the time. This should not be so hard. Just as I would help myself climb the stairs, I could use my hands to pull myself up the ladder distributing the work between my arms and legs as needed so that when one set was becoming too tired, I would have the other set do more of the work (arms and legs I mean).
I told myself it would probably be best if I didn’t stop until I arrived at the 250 foot landing, because I thought that if I did stop for a rest, my legs would get all wobbly. As long as I kept climbing, they didn’t have time for that nonsense. So, I huffed and puffed, and kept focusing on each rung of the ladder as I climbed.
When I reached the 250 foot landing, I swung my tool bag over onto the grating and unclipped my belt from the third rail and sat down with my feet still dangling off the edge of the grating where the ladder came through and rested for a few moments.
George Bohn and the other castaways were around the other side of the stack. They had not realized I had arrived yet. After I caught my breath, I climbed up to the top of the elevator and opened the control panel to see why the elevator was not working. I switched it to manual, and tried to operate it from the top of the elevator, but it didn’t budge.
I used my multimeter to check the circuits and quickly found that one of the fuses had blown out. Unfortunately, I didn’t bring a spare fuse with me, and there wasn’t one in the control box, so there wasn’t much I could do to fix the elevator controls at this point.
I hollered for George and he came around the walkway to the elevator. I explained to him that the fuse to the controls was blown and that I could either climb all the way back down the ladder to the ground to get one, or, I could manually “drop” the elevator down with them in it to the ground. The lady with them didn’t care much for that idea.
I explained that I regularly drop test the elevator and I would be able to let the brake loose long enough for the elevator to go down a couple of feet at a time. After doing that about 125 times, we would be safely on the ground. That seemed to satisfy them, so they entered the elevator and closed the door, while I remained on the top of the elevator.
I took my large screwdriver out of the tool bag and pried it between the motor and a latch on the brake. This way, I just had to pull out on the screwdriver to release the brake on the elevator until it began to free-fall toward the ground. I turned my head to look up at the elevator track so I could make sure I didn’t let the elevator drop too far. If I did, then my heroic attempt to rescue my elevator hostages would quickly turn from an “atta-boy” into an “Uh-Oh!”
You see, if I let the elevator drop more than 3 feet (or so), then the safeties on the elevator (known as “dogs”) would set. This would bring the elevator to an abrupt halt. It was designed to stop a falling elevator by instantly locking the elevator to the tracks.
If the dogs were to be set on the stack elevator, the only way to release them is to take the cover off of a gear box and start manually cranking the elevator up about 3 feet until the dogs reset. This was a slow process that usually took about 30 minutes, and if I didn’t go up far enough to actually reset the dogs, as soon as we continued going back down, the dogs would set again and I would have to repeat the process.
So, like the tortoise, I decided that slow and steady wins the race. I was not going to drop the elevator more than a foot and a half each time. We would take our time going down.
The first time I released the brakes and the elevator began to free-fall, I heard the lady below me in the elevator let out a loud gasp. I know the guys were gasping as well, they just had to be more quiet about it. I know I was gasping each time on the top of the elevator and I had done this probably 20 times before when we did the elevator drop tests (See the post “After Effects of Power Plant Drop Tests“).
After about 10 minutes the elevator was safely back on the ground and so were the engineers. Doug Link came up to me and said with an excited voice, “It took you only 4 minutes and 23 seconds to climb up the ladder! That’s incredible! I timed you!” I said, “That’s about right. One second per foot.”
I went back to the shop and found three fuses for the one that had blown on the elevator. I climbed back on the elevator and opened the control box and replaced the bad one. Then I placed the other two in the control box. I figured this way, if this fuse were to blow again, then at least the electrician could just replace it, and not have to manually ride the elevator to the ground again.
I tested the elevator by riding it up and down the stack a few times and everything worked just fine. I figured that this must have just happened because George Bohn was trying to show off to some cute engineer. That’s just George’s luck. To find out more adventures with George, you can read this post: “Bohn’s Boner and the Power Plant Precipitator Computer“.
I hadn’t thought of the “4 Imps” in years! I’m impressed (again) that you still remember them. Good story!