Originally posted June 6, 2014;
I’m sure the plant manager at the Coal-fired Power Plant in North Central Oklahoma thought that a little competition might just do our Safety Program a little good. The maintenance crews always knew what they were going to be doing first thing on Monday morning. They were going to attend a Safety Meeting with their team. All of the maintenance crews attended a team safety meeting every Monday morning to remind them to be safe during the week. This had been going on for at least 9 years at the power plant. Every Monday morning we all looked forward to the 30 minutes we would spend reminding ourselves to be safe that week.
It didn’t seem to matter if I was on the Summer Help yard crew, or a janitor, on the labor crew or an electrician. The Monday Morning safety meetings were all pretty much the same. Someone would read from a Safety pamphlet that each of the foreman would receive once each month. We would try to read one of the articles each week in order to stretch it out so that it lasted the entire month of Monday Morning Safety Meetings. This often meant that we would be listening to a completely irrelevant safety article that really didn’t apply to us.
Some of the articles were things that reminded us to be safe in the work place. Other articles reminded us to clean up the kitchen counter after you have finished cutting up the chicken in order to cook fried chicken for dinner. The chicken juices could lead to food poisoning if they sat there for a while and then some other food was placed on the same counter if it was still soaked in juices from the chicken. We justified to ourselves that it didn’t hurt to remind ourselves about things like this because if we went home and had food poisoning by not watching our chicken juices, then it could be as serious as a lost workday accident on the job.
When I joined the electric shop, I used to keep a stack of all the Safety Pamphlets. Who knew if they would ever come in handy. Years later when I left the Power Plant to pursue another career I left the stack behind in case some other safety zealot needed some motivating safety material. I tried to find a picture of the safety pamphlets that we used to read on Google, but I could only find Safety Pamphlets that were more colorful and had more eye-catching covers. The only aesthetic difference between our safety pamphlets from one month to the other consisted of using a different color font. So, one month, the pamphlet would be written in blue. The next month, green. Then red. Maybe purple some times. The December one would have a little drawing of holly at the top. That was about as exciting as they were.
Occasionally the foreman would get a different kind of safety pamphlet on a certain topic. Instead of changing the font color, this pamphlet would change the background color to one bright solid color. I could find a picture of one of these:
In the first paragraph I mentioned that the maintenance crews generally knew what they would be doing right off the bat on Monday morning when their work day began. Yep. They would spend 15 to 30 minutes staring off into space while their foreman, or the designated hypnotist would read a safety pamphlet in a monotone voice. I think it was permitted to fall asleep as long as you didn’t snore. Once you snored it was too hard to claim that your eyes were closed only so that you could better picture how to lift with your legs and not your back.
In order to add something dynamic to the Monday Morning Safety Meeting, it was decided that some friendly competition might help. So, here is what happened:
A Safety Committee was formed and their task was to collect safety slogans from the teams and once each month they would decide which slogan was the best and then it would become the “Safety Slogan of the Month”. Then for the next month this particular safety slogan would be posted on all the bulletin boards throughout the plant. At the end of the year, a winner was selected from the 12 winning Monthly Safety Slogans. Whichever team won the safety slogan of the year award would be honored with a free Pizza (or two) for lunch.
A noble attempt at trying to add a little spice (and tomato sauce) into the safety program.
At first our team didn’t give this much thought. I was one of the first people from the electric shop on the committee and since I was on the committee, I didn’t think it would be fair to submit a safety slogan myself, because I would have to be one of the people voting on it. One person from each area was on the Safety Committee. One person from each of the three A foremen’s teams in the Maintenance shop. One person from the Instrument and Controls team and one electrician. One person from the office area. One from the warehouse. There might have been one person from the Chemistry Lab, but since there were only three chemists, I’m not sure how long that lasted.
Anyway, sometime in March, 1992, when we were sitting in a Monday Morning Safety Meeting staring blankly at the only thing moving in the room besides the lips of the Safety Article Hypnotist, a black beetle scurrying across the floor, Andy Tubbs finally broke through our hypnotic state by making a suggestion. He said, “How about we start entering safety slogans for the Safety Slogan Contest and try to win the free pizza at the end of the year? Instead of just sitting here on Monday Mornings doing the same thing over and over, let’s spend our time brainstorming Safety Slogans!”
This of course was a brilliant idea. It meant that we would actually be blurting out all kinds of goofy safety slogans until we hit on a really good one to turn in for the month. We began immediately. I was the scribe capturing all the creativity that suddenly came popping up from no where. Andy was real quick to come up with some. Others took their time, but when they spoke they usually had a pretty clever safety slogan.
By the end of the first day we had about 10 new safety slogans to choose from. We picked the best one of the bunch and turned it in at the front office. I don’t remember the specific safety slogan we started out with, but I do remember some of them that the team invented. Here are a couple unique slogans that I have always remembered – not written by me….
“Lift with your legs, not with your back, or you may hear a Lumbar crack.”
“Wear skin protection in Oklahoma or you may get Melanoma.”
I invite anyone at the plant that remembers more slogans to add them to the Comments below….
You can see that we tried to take a standard safety slogan like “Lift with Your Legs and Not your Back” and added a clever twist to it. I had taken out the stack of safety pamphlets from the cabinet and we reviewed them. Each of them had a safety slogan on the back. We weren’t going to use any that were already written, but it gave us ideas for new slogans.
We won the Monthly Safety Slogan that month. So, we figured we were on a roll. The next month we picked our next best one. By that time we must have come up with over 25 pretty good safety slogans, and we figured we would enter our best one each month. We were in for a little surprise.
After submitting a real humdinger of a Safety Slogan the second month (something like, “Wear your Eye Protection at work so you can See Your Family at Home” — well. I just made that up. I don’t remember the exact slogan 22 years later), the slogan that won that month was a much more bland slogan than our clever one. We felt slighted. So, we talked to Jimmy Moore (I believe) who was the electrician on the other team of Electricians in our shop that was on the Safety Committee selecting the safety slogans this year. He said that there were some people on the committee that thought it wasn’t good for the same team to win two times in a row. Others thought that any one team should only be able to win once a year.
As it turned out, we were able to win the monthly safety slogan only a few more times that year only because we were the only team that turned in a safety slogan during those months.
When it came time for picking the winning safety slogan for the year, Sue Schritter’s slogan from the warehouse won even though it was fairly lame compared to the clever ones we had been turning in. (Note the warehouse and the front office were all under the same manager…. so, when one of them won, they both really did). So, the front office (slash) warehouse were able to enjoy the free pizza.
After complaining about the process at the beginning of the next year, we were determined that we were going to do what it took to win every single month and that way they would have to give us the pizza at the end of the year. So, in 1993 that was our goal.
It was determined at the beginning of the year that all safety slogans would be judged without knowing who had turned them in. It was also determined that a team could turn in as many safety slogans as they wanted each month (probably because we had complained that our team was unfairly being singled out).
So, we made a concerted effort to turn in at least 15 safety slogans each month. That way, the odds of one of ours being picked would be very high, especially since our team was the only team that was really serious about wanting to win the free pizza at the end of the year.
Gary Wehunt from our team was on the committee selecting the slogans in 1993, so he would tell us about the conversations the committee was having each month when they would get together to select the slogan, and we knew it wasn’t going to be easy to win every single month.
During the year, it became a game of cat and mouse to try to win the safety slogan of the month every single month. We knew that a couple of people on the Safety Committee were doing everything they could to not pick one our our slogans. So, here is what we did… along with the best safety slogans we had, we threw in some really lame ones. I think we had some that were so bad they were nothing more than…. “Think Safety”. Our better safety slogans were more like: “Watch for Overhead Hazards! Avoid becoming Food for Buzzards” or “Wear you Safety Harness when working up high. One wrong step and you may die.” — I mean…. How could any other safety slogan compete with the likes of those?
The funny thing was that we thought that just in case the Safety Committee was trying to look for a safety slogan that our team didn’t write, they would intentionally pick a really bad one. Like “Think Safety”.
And it actually worked. Two months during 1993, the team actually chose a Safety Slogan that was really lame, just to try and pick the one that our team didn’t enter only to be surprised to find that it was from our team.
Through October our team had managed to win every Safety Slogan of the Month, and it looked like we were going to finally win the Safety Slogan of the Year and receive the free Pizza. I had written down every safety slogan our team had invented. We had over 425 safety slogans by that time. I had a folder in the filing cabinet with the entire list.
Then in November, the people who were on the Safety Committee who were intent on us not winning the yearly safety slogan was able to slip one by. They had submitted a safety slogan from their own team and had told a couple other people to vote for it. It didn’t take too many votes to win for the month since when we turned in 15 to 20 slogans the votes were spread out.
Most of the slogans that did receive a vote would only get one vote. So, any slogan that had two or more votes would usually win. So, all they had to do was throw together a safety slogan and tell someone else on the committee that was not happy about our team winning every month during the year, and they would win that month.
Louise Kalicki turned in a safety slogan in November. It was a simple safety slogan like “Be Safe for your family’s sake”. We had turned in a number of slogans that had said pretty much the same thing in the 400 or more slogans we had submitted, but that was the slogan that won during that month.
Well. That was all it took. When the winner of the Safety Slogan for the year was chosen, there was no way that everyone didn’t already know whose team the safety slogan was from because they had been posted on the bulletin boards throughout the year. So, you can guess what happened. After the electric shop had won 11 of the 12 safety slogans in 1993, The girls in the front office won the free pizza… again (just like they did every year).
So, what happened in 1994? Well…. That’s another story… isn’t it?
Comments from the original post:
Originally posted July 18, 2014
Given that a large Coal-fired Power Plant is like a small city complete with a water treatment system to supply drinking water to thirsty Power Plant Men, and it’s own complete sewage system to handle the volumes of human waste and toxic run-off, when I ask, “What is that strange smell?” You may expect the answer to be something like “Honeysuckle?” If you thought, rotten fish, diesel oil, ozone or sweaty arm pits, you would, of course, be wrong. Those are all the usual smells found in a Power Plant. Every so often, a smell would come by that would make you stop in your tracks and wonder…. “What’s that strange smell?”
Over the course of the 20 years I worked in the Coal-fired Power Plant in North Central Oklahoma, there were times when a new smell would just come out of no where. There were other times when they would sneak up on me gradually, so that I wouldn’t even notice them until they were gone…. Then I would wonder why it was that I didn’t notice them when they were there.
One such smell that stung me like a bee would happen when I was on overhaul and I was walking out to the precipitator all covered in a fly ash suit from head-to-toe wearing a full face respirator with duct tape around all of the seams.
I was walking in the breezeway between the two boilers when I suddenly smelled a sharp sort of smell. It was a strange chemical I hadn’t ever noticed before. I looked around to see where it was coming from. There wasn’t anyone around, and I didn’t see anything chemical spill in the area that would account for it.
As I walked toward the precipitator, I looked up as I walked under the surge bin tower in time to see an operator coming down the stairs. He was smoking a cigarette. Besides that, everything else looked normal, except that the smell was almost overwhelming me at that point.
I went and climbed in the precipitator where I worked until break. When I came out, I blew the dust off of myself with a tiny instrument air hose that we kept on either side of the precipitator for just such an occasion. After the fly ash had been blown off of my suit, I leaned forward and pulled my respirator off of my face and breathed the fresh air.
Later that week, when I was heading back out to the precipitator and had just left the electric shop all dressed up in my suit, I had a whiff of that same smell. I couldn’t mistake it. It was a unique chemical smell. looking around, there wasn’t anyone or anything near me that would have been emitting such a toxic smell.
As I walked around the condenser to head toward the boiler, I saw that a couple of mechanics were carrying some planks of wood and laying them by the condenser in order to build a scaffold once they opened the condenser. One of the guys was smoking a cigarette. I wondered… Could it be a cigarette that smells so rancid? It didn’t seem likely, since I began detecting the smell when I was more than 40 yards away from the operator when he was descending from the Surge bin tower. I shouldn’t be able to smell a cigarette from that distance.
After a few more instances, I realized that it was cigarettes that I was smelling. I was amazed by how far away I could detect a cigarette when I was wearing my respirator. I figured that after it had filtered out all the particles bigger than 2 microns, the only particles and odors that were entering my respirator were easily detectable by my nose. And they didn’t smell anything like a cigarette.
I became so astute at detecting smokers, that one time I was walking through the breezeway with an unfortunate contract worker that had been commandeered to work with me, I was dressed in my fly ash suit and respirator. My helper wasn’t because he was going to be my hole watch while I was inside. I suddenly smelled that, now familiar, scent. I spun around once and then turned to the guy walking with me, who hardly knew who I was, and said, “Someone is smoking a cigarette!”
He looked around and no one was in sight. He said, “There isn’t anyone here.” I said, “Oh, there’s someone with a cigarette all right.” About that time a truck pulled around the end of the precipitator about 50 yards away with a couple of welders pulling a welding machine behind. Their windows were open, and hanging out of the driver side window was an arm, with a hand on the end holding a cigarette. As it drove by us, I pointed to the cigarette and said, “See. Cigarette.” He kept insisting I couldn’t have smelled that cigarette that far away… But with my respirator on, I could easily smell it.
One of the other strange Power Plant smell that I encountered during my tenure at the Power Plant was also while I was wearing my respirator and working in the precipitator. Only, I didn’t pay much attention to it until it was gone. Then I did everything I could to find the source of that smell, because to me, it was a sweet smell of success, even though it smelled more like a sweaty arm pit, or maybe even something worse.
I mentioned this smell in the post: “Moonwalk in a Power Plant Precipitator“. The precipitator is what takes the smoke out of the exhaust from the boiler, and collects it in hoppers and then blows it a half mile to a silo on a hill by the coal pile, where it is trucked away to be made into concrete.
It was my job during an outage to repair the inside of the precipitator, and I was always looking for ways to improve the efficiency of the ash gathering abilities of this large piece of equipment.
I knew at certain times during an outage that the ash that had built up on the plates would all of the sudden decide to cake up and fall off in chunks leaving a perfectly clean plate. When that happened, then the odds of the precipitator running real well when we came back online was a lot better.
I also knew that after working long hours in the precipitator for a couple of weeks, I would feel all worn out like I had a flu. I would have to drag myself out of bed in the morning and I would even catch myself falling asleep on my feet inside the precipitator while I was inspecting it. I always figured it was just because we were working 10 or 12 hour days and I was getting older. Yeah…. 30 years old, and I was feeling every bit of it.
Then one day when I went to the tool room to get a couple of boxes of respirator filters Bud Schoonover told me that he couldn’t give me the regular hepa filter that I was used to using. I already knew that the regular filters weren’t good enough, so I asked him what else he had. He said, “Well…… I have some of these here…” I have mentioned that if Bud had been African American and a little bit skinnier and shorter, he would have been the spittin’ image of Aunt Esther from Sanford and Son’s. He would make this same expression:
Bud handed me a box of filters labeled: Organic Vapor Filter:
It wasn’t exactly what I was looking for, but I didn’t have much choice. I could see that it had a carbon filter on it as well as the regular filter, so I thought it would be all right.
The first thing I noticed when I stepped into the precipitator wearing the Organic Vapor filter was that the air inside the precipitator didn’t smell any different than the air outside. I wasn’t used to that. I was used to smelling a “boiler” sort of smell. After a couple of weeks that smell would turn more rancid. Sort of a sour smell. When I noticed that I wasn’t smelling the sour smell I quickly broke the seal on my filter and sniffed the air to verify that the filter was really blocking the stench that built up in the precipitator the past few weeks. Sure enough.
Then I noticed that I was no longer feeling tired in the morning. I was able to work all day without feeling fatigued. I came to the conclusion that whatever that smell was that was being blocked by this respirator had been causing me to feel ill. Now that it was gone I was beginning to believe that 30 years old wasn’t that old after all.
I was already curious about the smell in the precipitator because I had noticed that after a day or so after it showed up, the ash would just flake off of the plates in the precipitator. If we could find out what it was, maybe we could inject something in the inlet of the precipitator when it was online and needed to be cleaned after a bad start-up or after it had been running a while to make it run more efficiently.
So, I went to our resident Doctor of Chemistry, George Pepple. I wrote a post about him, see “Power Plant Doctor Does a Jig in a Puddle of Acid“. I explained to him about the smell and about how this particular filter filtered it out when a Hepa filter didn’t. And the effect it had on the ash on the plates. He listened intensely and I could tell that I had made him excited. There are only so many chemicals a plant chemist deals with on a normal basis, so when Dr. Pepple had an opportunity to explore something new, he jumped at the opportunity.
When I took him to the precipitator, he could smell the odor even before we began climbing the stairs up to the open hatchways. He described it as a sewage type of odor. Which I hadn’t really thought of before, but come to think of it, that would explain why an organic vapor filter would work on it. I suggested that the sulfur in the ash might be giving it that.
I had analyzed the chemicals that made up the coal that we received at our plant from Wyoming and I had tried to figure out how it might combine with moisture to create a new chemical. George explained that when the coal burns under such a high temperature, a lot of the chemicals are sort of encapsulated in ways that are not easily predictable.
George suggested that we approach this as a Safety issue and contact the Safety Department in Oklahoma City and have them see if they can put an analyzer in the precipitator to detect the chemical. When I contacted them, I talked with a lady called Julia Bevers (thanks Fred for reminding me of her last name). She told me to call her when the odor was strong during the next outage and she would bring some chemical detectors to the plant and I could place them in there and let them run overnight to collect samples.
Julia had said that she had heard that I was known as “Mr. Safety” at the plant. I don’t know why. Maybe it was because I was in the habit of complaining. And a number of the things I would complain about were safety issues.
Anyway, during the next outage as soon as I smelled the smell emanating from the precipitator I gave her a call and the next morning I received a call from Toby O’Brien, the Plant Engineer Extraordinaire. He called me and told me that Julia the Safety Lady was there in his office looking for me.
So, I went to Toby’s office and met “The Safety Lady.” I know I didn’t look at all like she expected. I was in a worn tee-shirt, not tucked in (on purpose) and worn out steal-toed boots. When I took her out to the Precipitator, I decided to take her across the Turbine Generator room and out the Third floor to the boiler where we walked through the boiler and over to the precipitator up and down ladders.
When we walked across the Turbine Floor, I didn’t have my usual pair of ear plugs hanging around my neck (they were in my pocket). As it was rather loud, Julia turned and said, “Shouldn’t we be wearing earplugs?” I replied, “Huh?” As if I couldn’t hear her. — I just love playing Power Plant Jokes on people that don’t even know what you’re up to… I’m sure when we were done, she went straight back to Toby and told him how shocked she was to find out how unsafe I was. — Me trying to keep a straight face the entire time.
To shorten a longer story, Julia gave me some indicators that would detect two different types of chemicals that she thought may be the culprit. I left the detectors in the precipitator overnight and then sent them back to Oklahoma City for analysis. They both came back negative leaving us with a mystery chemical.
Anyway, I never did find out what was causing that strange smell….
There was another strange smell that used to pop up in the Electric Shop when I had first become an electrician, but that just turned out to be one of our fellow electricians that liked to walk up to a group of electricians standing around talking, and then let loose a “silent but deadly” and then walk away and stand from a distance to see our reaction.
I won’t mention who that was, unless someone would like to leave a comment about that below….. Anyway. we all knew who it was when that happened as the electricians would yell out his name as the crowd quickly dispersed.
I decided to take a different approach. I would stand there thinking, trying to analyze the odor to see if I could tell what exactly this person had for supper the night before. I could tell one day when I said “Beef Stroganoff” and his face turned red that I had guessed pretty close to the mark….. That was the last time this noble Power Plant Man did that to a crowd of electricians….. at least when I was standing there… I can’t attest to any other time…. as I wasn’t there.
But I suppose that is proof that even early in my career I was interested in finding the source of that “strange smell”.
Originally posted October 18, 2014.
Does anyone know where the phrase, “Step on a Crack, Break Your Mother’s Back” came from? I’m sure there is a story behind that one. Maybe even a lot of different origins. I can distinctly remember a day in the Power Plant when a Power Plant Man stepped on a crack and broke his own back.
I remember looking out of the seventh floor window of my friends dorm room when I was a freshman in college watching students returning from classes about 6 months before the Power Plant Man broke his back. I was watching closely to see if any of them were purposely missing the cracks as they walked down the sidewalk toward the entrance. Out of about 20 people two of them purposely stepped over every crack in the sidewalk.
In the post “Power Plant Safety is Job Number One” I told the story about four of us were carrying a very long extension ladder through the maintenance shop at the Coal-fired Power Plant in North Central Oklahoma one summer morning in 1979 when Tom Dean stepped on a crack (well, it was a cracked piece of plywood that had been placed over a floor drain because the floor grate was missing), and when as he stepped on it, he lost his balance enough to twist himself around. By the time he stopped twirling, he was in immense pain as he had destroyed any chance for comfort for the next 6 months.
So, I could understand the dangers of stepping on cracks even when they appear to be insignificant. What that has to do with my mom I’m not sure. However, one day when my sister was walking with my mom on the campus of Oklahoma State University, my sister may have stepped on a crack at that time, as well as my mom, which sent her plummeting the five feet to the ground resulting in a broken hip.
This makes me wonder that since the times have changed, it may be time to change the saying to something else. Maybe something like “Smoke some crack, break your parent’s piggy bank” would be more appropriate for these times. Oh well, I’ve never been much of a poet.
Anyway, back to the subject of back pain.
The number one favorite topic during Safety Meetings at the Power Plant was Back Safety. We were told (and rightly so) that accidents where the back is injured cost the company and the employee more than any other injury. Once you really hurt your back, you can expect to have back pain the rest of your life. It only takes one time. — Times may have changed since 1979, so that now you can have some excellent back surgeries to help correct your back injuries. Even with these, you will never be completely free from back pain.
In the Power Plant Post, “When Power Plant Competition Turns Terribly Safe” I told a story about how our team came up with hundreds of safety slogans in an attempt to win the coveted Power Plant Safety Award Pizza at the end of the year. A Pizza that continued to allude us for 2 and a half years. During our meetings to invent the most catchy safety slogans, Andy Tubbs (or was it Ben Davis) came up with a slogan that said, “Lift with your legs, not your back. Or you may hear a lumbar crack”. — See. I wish I could come up with doozies like that! This takes the idea of a crack and a back and turns it around, if you think about it. Now instead of a crack hurting your back, its about a strain on your back creating a crack. — I know… probably just a coincidence….
One morning Sonny Kendrick, our electric specialist at the time, while sitting in the electric lab during break, let out a whopper of a sneeze. When he did, he suddenly knew what it felt like to experience tremendous back pain. One sneeze and he was out of commission for many weeks.
One day, when Charles Foster, my very close friend, and electric foreman, were talking about back pain, I realized that a good portion of Power Plant Men suffered with back pain. — At the risk of sounding like Randy Dailey teaching our Safety Class, I’m going to repeat myself, “You only have to hurt your back one time to have a lifetime of back pain.”
The company would focus a lot of their safety training around the importance of proper lifting techniques in order to prevent back accidents (not to be confused with backing accidents which is when you back out of a parking space — which is also a common accident — though usually less severe — unless you happen to be a Ford Truck). We would learn how to lift with our legs and not with our back.
You see, it wasn’t just that one sneeze that caused Sonny’s plunge into Back Pain Hell, and it wasn’t just stepping on the cracked plywood floor drain cover that broke Tom’s back (I know “Broke Back” is a misnomer since the back isn’t exactly broke). The problem is more systemic than that. This is just the final result of maybe years of neglecting your back through various unsafe activities.
The two important points I remember from watching the safety videos during our monthly safety meetings was that when you slouch while sitting, you put a needless strain on your lower back. So, by sitting with good posture, you help prevent a future of pain. The second point I remember is that you need to keep your stomach muscles strong. Strong stomach muscles take the weight off of your back when you’re just doing your regular job.
The big problem that finally causes the disc in your lumbar region of your spine to break after neglecting it through these other means is to lift a heavy object by bending over to pick it up instead of lifting the load with your legs. So, the phrase that we always heard was “Lift with your Legs. Not your Back”. You do this by bending your knees instead of just your hips.
Ok. I know you are all thinking the same thing I am thinking (right? Yeah. You are). Bending both your knees and hips saves your back. Isn’t there another word for when you bend your knees and hips at the same time? — Yeah. Yet, I don’t remember hearing it during any of our Safety Videos. — Oh. It was implied, they just never came out and said it…. What they really mean to say is, “Squat”. Yeah. “Squat”. When you bend your knees and hips, isn’t that “Squatting?”
Times have changed…. I mean….. Doesn’t everyone today have a “Squatty Potty”?
Don’t we all have “I ‘heart’ 2 Squat” tee-shirts?
To learn more, you can watch this video:
This doesn’t just work with the Squatty Potty to help you drop your loads, it also works when lifting heavy loads. So, remember the next time you are going to bend over to pick something up…. Squat instead.
Other lifting tips include keeping the load close to your body and not holding your breath but tightening your stomach muscles, and don’t lift something too bulky by yourself. Don’t twist your body when picking something up, face the load directly. A weightlifter once told me that when you lift, feel the weight on the heel of your feet, not on the balls of your feet.
Randy Dailey, the Safety Guru of our Power Plant, and an expert machinist invented a pen that you could put in your pocket protector in your shirt pocket that would alert you by beeping if you leaned over too far. It was an ingenious device to remind you to lift with your legs instead of your back.
In one of the safety videos we watched about back safety, there was a short stalky scientist that explained the dynamics of lifting and how easy it was to put a tremendous strain on your back by leaning over and picking something up. He said that “People choose the more simple way to pick something up. Not the easiest way.”
Doesn’t that sound like the same thing? Isn’t the simplest way the easiest way? Well. You would think so, but it isn’t always the case. This Doctor of Back-ology went on to explain his statement. He explained that the simplest way to pick up an object on the floor is to bend at the hip. It is one movement. Bend at the hip. — However…. The easiest way to pick up the object is to bend both your knees and your hips to pick up the object. Since you keep your back straight and you lift with your leg muscles that are the most powerful muscles in your body. He avoided using the word, “Squat”, but that’s what he meant.
In order to reduce back injuries at the plant, the company made back belts available at the plant.
Note that this picture not only shows a Power Plant Man wearing a Back Support Belt, but he also is wearing the right kind of Tee-Shirt. It has a vest pocket where you can put a Pocket Protector for your little screwdriver and your Back Alert Pen created by Randy Dailey.
The use of back belts was new around the late 1980’s. Even though we had them available through the tool room when we wanted them, few people wore them. The warehouse team wore them a lot. I suppose that is because they were lifting and moving things all day long.
In the warehouse Bob Ringwall, Darlene Mitchell and Dick Dale used to have back belts on when I would visit the warehouse to pick up a part, or to visit my friends. I don’t remember if Bud Schoonover would wear a back belt. How’s this for a slogan…. “Be a Safety Black Belt…. When Lifting, wear your Back Belt.” I know. I should stop when I’m ahead, only I’m so far behind now I may never catch up.
There was a question about whether wearing a back belt was really a good idea. It was thought that people might tend to substitute using their stomach muscles while lifting with the back belt, resulting in weaker stomach muscles. So we were cautioned not to go around wearing back belts all day long. Only when we were going to be doing a job where we had to do a lot of lifting. I suppose now, after years of research, there is a lot more data to tell us one way or the other. I haven’t heard what the latest jury has said on this subject.
Even though I titled this post “…Plain Ol’ Power Plant Back Pain”, there is nothing plain about back pain. I just thought it sounded like a catchy title.
I was lucky enough that during the 20 years I spent working at the Power Plant, I never really hurt my back. To this day, I have been able to avoid living with perpetual pain in my back. — I have been accused of causing pain in other people’s necks. Also, I don’t think the many times that people told me I was a pain in their back side, they were referring to the Lumbar region. I think they meant an area just below the tailbone. I hope that by bringing to their attention the benefits of the Squatty Potty that I have been able to relieve (or prevent) a little of that lower lumbar pain.
Now when someone says, “You don’t know Squat”, you can correct them!
Comments from the original post:
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!
Originally posted December 20, 2014:
When my children were young and the season was right and I had finished telling them all the Gene Day stories, when they were in just the right Christmas spirit, I would tell them about the Power Plant Christmas Star and how it would shine brightly over Ponca City, Oklahoma around Christmas time, calling shepherds and Power Plant Operators to come and see what technological miracle had taken place on Bonnie Drive on the North End of the thriving community known as Ponca City (Did I actually make an entire paragraph out of one sentence? — Geez. This is why my English Teacher was always slapping my hand — Catholic school…. you can imagine how that was).
The story actually begins way before the Christmas season starts, but some time after Christmas decorations have gone up in Target and Wal-Mart. That is, some time after Halloween, but before Thanksgiving. November, 1984 was the first time I had a hint that something big was going to be happening soon. At the time, I had been an electrician for one year, and since that time, a new machinist had arrived at the plant named Randy Dailey. We thought he looked a lot like Barney Fife, only he seemed to be a lot smarter. Here is a picture of the two. See what you think.
Ok. I admit it. that’s not really Randy Dailey. That really is Barney Fife’s Smarter Brother. Here is a real picture of Randy Dailey:
I happened to be walking through the machinist shop at the coal-fired Power Plant in North Central Oklahoma on my way to the tool room when I noticed a big pile of large cans stacked up next to the large press. These cans were about the size of a large can of beans.
The labels had been removed from all the cans, so I couldn’t tell if they were beans, corn, Hawaiian Punch, or what. Only Randy Dailey knew for sure. He had set up some sort of assembly line where he was punching holes through these cans in the shapes of stars and Christmas trees, and I don’t even remember what else. Ginger Bread Men maybe…. Hopefully Randy will comment at the bottom of this post to answer the unanswered questions about the can decorations and not leave a comment about how I look more like Barney Fife than he does and how he actually looks more like Cary Grant.
One could only imagine what Randy was going to do with hundreds of cans with Christmas designs punched out around them. I know that one could only imagine that, because I was one. No one else seemed puzzled about the cans, so I pretended not to be puzzled also. It seemed to work, because no one stopped me on the way to the tool room to ask me about the puzzled look on my face. Which was surprisingly not that uncommon since I walked around a lot puzzled by a great many things.
I figured that some day all this can punching (as opposed to cow punching which is something entirely different) would some day make sense to me. Each year, Randy would do the same thing. He would fill the machine shop with cans and then proceed to punch Christmas Trees and stars into them. It finally made sense to me two years later. After I had moved to Ponca City, Oklahoma.
My wife and I were sitting around one night in our luxurious two bedroom, one bath, one dog house in Ponca City trying to decide what to do for our first wedding anniversary.
I suggested that we try to solve the riddle of the Randy Dailey Christmas cans. My wife was not at all surprised, because during our wedding night a year earlier I had made up a story called “Barney Frumpkin, the Christmas Pumpkin”, so, solving a riddle like Randy Dailey’s Christmas Cans seemed right up my alley and in no way out of the ordinary.
Ok. Here is a side story about Barney Frumpkin the Christmas Pumpkin. Keep in mind that I just whipped this one out off the top of my head and it was 30 years ago tomorrow (December 21, 1985):
Once upon a time there was a pumpkin patch out in the country by a small town.
Each year the people from the town would go out to the pumpkin patch to pick out a pumpkin before Halloween,
in order to make Jack-O-Lanterns and/or Pumpkin Pie.
This one particular year, there was one pumpkin in the patch named Barney Frumpkin.
He had heard from the other pumpkins that the farmer had been talking to someone and said,
“Tomorrow the people from the town will be here to pick their own special pumpkin, so I want everything to be just perfect.”
All the pumpkins were excited about being chosen by a family, but none were as excited as Barney Frumpkin.
Barney stretched and stretched himself as much as he could to try to stand out as a very special pumpkin.
He could imagine himself shining bright orange among the green vines.
When the day finally arrived, Barney was as excited as he could be as children and parents walked through the pumpkin patch,
Each family looking for their own special Halloween Pumpkin.
As each family came near to Barney, he would wish as hard as he could wish that this would be the family for him.
Each time throughout the day, as each family walked by Barney, none of them so much as gave him a second glance.
Toward the end of the day, as the crowds began to thin, Barney suddenly came to the realization that he was all alone.
No one had chosen him to be their special Halloween Pumpkin.
What Barney didn’t know was that he had a very large black spot on one side that made him look like he was rotten.
As the sun set that day, Barney was left all alone in the pumpkin patch.
All the other pumpkins had been picked and carried away.
Barney Frumpkin sat in the patch and cried.
No one heard him except you and I.
As each day began, the sun was lower in the sky and the nights became colder.
Soon there was snow on the ground that left Barney Frumpkin rather wrinkled and dry.
Barney felt as if the world had left him behind and he wanted to die.
So, he just laid there in the withered pumpkin patch sinking slower into the ground.
Shivering in the snow one night, he thought he could hear songs coming from the village.
In the distance people were singing carols of happiness and joy.
In the darkness Barney felt as if his life was coming to an end.
Then suddenly Barney became aware of a different sound.
The sound of someone humming quietly to their self.
Unknown to Barney, it was an evil witch making her way through the pumpkin patch.
Back to the hovel she would call home if she had a heart.
The people of the town called her a witch and she had no friends.
As she approached Barney, the moon peered out from behind a cloud to take a look.
The witch was about to step on Barney Frumpkin when the moonlight appeared.
The witch stopped in her tracks and looked down at the shriveled pumpkin at her feet.
The one with the large black spot on the side.
She had never seen such a wonderful site in all the days of her life.
It was the perfect pumpkin laying right there in front of her!
Without hesitation, the witch carefully picked up the pumpkin.
She smiled a smile that was so big that the cloud covering the rest of the moon scurried away,
Allowing the moonlight to brighten up the pumpkin patch.
The witch hugged Barney Frumpkin with as much care as she could muster.
She carefully carried him home to her hovel which would now become a home.
Barney was so surprised that for a while he was in shock.
He wasn’t sure what had happened because suddenly everything had turned dark.
It wasn’t until he saw the fire in the fireplace that he realized that someone had taken him home.
The witch set Barney on a table close to the fire where Barney could look around the room.
Standing close by, he saw the witch leaning toward him.
Barney Frumpkin had never seen such a beautiful site!
Barney Frumpkin, the Christmas Pumpkin and the Witch lived happily ever after.
End of Side Story. Back to the mystery about Randy Dailey and his Christmas cans.
So, I went to the kitchen and took the phone book out of the drawer and looked up Randy’s address…. hmm…. Bonnie Drive. In 1986, we didn’t have the World Wide Web, so I couldn’t Google the address. So, I looked in the middle of the phone book to where they had inserted maps of the town, and found the street.
Kelly and I climbed into our car and drove north up Union Street to Lora Street and over to Bonnie Drive. The mystery of the Christmas Cans was immediately solved even before we had turned the corner. The entire neighborhood was lit up. Randy’s Christmas Cans were lined up and down both sides of the street, up and down each drive way on the block and each can had a light shining in it so that you could see the punched out Christmas Trees and Stars shining brightly.
Randy’s house was easy to see halfway up the street because it was all lit up.
You can see the Flag Pole in the front and the Ham Radio tower in the backyard. Well, the Ham Radio tower had a large star on the top of it, and there were strings of lights coming down on all sides. The entire street was lit up with Christmas lights and those in front of Randy’s house had a light show going that was fantastic. Randy had programmed the lights himself. The Nativity Scene on the front lawn was like none I had ever seen before. I wish Randy would send me a picture of it (I would put it in this post).
So, the Christmas story that I told my Children went something like this:
The Evil Plant Manager (Eldon Waugh) had issued a decree that no Christmas Lights would be visible on the plant grounds. And the Power Plant Men were distraught. Then there were unknown sounds coming from the machine shop. They went, “Punch, Punch, Punch. Zing. Punch, Punch, Punch, Zing…” Like that.
Cans were quietly being donated while the lone Power Plant Elf (Randy Dailey) punched out designs on cans. Careful to keep them hidden where the Evil Plant Manager wouldn’t see them. Which was easy, because he never dared to stroll through any shop where work might be happening.
Then when Christmas Eve came, and the Operators were keeping watch over the boilers at night, An Angel of the Lord appeared to them and said, “Lo! Climb to the top of Unit 2 Boiler and look yonder North toward Ponca City!”
And Lo! When the Power Plant Operators and any other Shepherds that happened to be nearby (the cattlemen were all tucked in their beds with visions of Salt Licks dancing in their heads. Apparently, cattlemen don’t need to keep watch at night like Shepherds do.. unless they are trying to catch cow tippers).
Anyway, the Operators and any other shepherds that happened to be nearby climbed up the 250 stairs (or took the elevator), and gazed upon the Conoco Oil Refinery lighting up the night sky, they became puzzled.
Then the Angel said, “No. Over that way.” And Lo! The Power Plant Men of Operator Fame gazed upon a Star shining brightly in the night! With streams of light coming down in a fantastic light show specially programmed for the occasion to elicit maximum emotions.
And the Angel said unto the Power Plant Men and any stray Shepherds, “Be not afraid! I bring you good news that will cause great joy for all the people! Know that today, this very power plant has supplied the electricity to power The Star of Ponca City! To honor the baby Jesus that was born 2,000 years ago in the town of Bethlehem! The Son of God!”
When the Angel of God had left them, the Power Plant Men said to one another, “Let us go to Ponca City (during our midnight lunch break) and see Randy Dailey’s Christmas Star and all the magical Christmas Cans for ourselves!”
So, they hurried off to their pickup trucks and created a convoy of Ford and Chevy’s and an occasional GMC and Dodge Ram and raced up Highway 177 to Ponca City. Arriving at Randy’s house, they found the Nativity Scene of Mary and Joseph and the baby Jesus and they were amazed! They spread the word to all the Power Plants letting them know how important it was to keep the Star of Ponca City burning for all to see. Then they all returned back to work.
And now you know…. The rest of the Story! Merry Christmas to all, and to all a Good Night!
The Electric Shop had tried for three years to win the Safety Slogan of the Year award. Not because we thought we were safer than any of the other teams at the coal-fired power plant in North Central Oklahoma, but because we really liked pizza (see the post: “When Power Plant Competition Turns Terribly Safe“) . When the plant was downsized in 1994, the electric shop no longer existed as it had before. We had become cross-functional teams (See the post: “Crossfunctional Power Plant Dysfunction“). It looked as if our dream of winning the Power Plant Safety Pizza was no longer in our grasp.
My carpooling buddy, Toby O’Brien had moved from our plant as a Plant Engineer to the Safety Department in Oklahoma City. He was working with Julia Bevers and Chris McAlister. Chris had also moved from our plant as a labor crew hand to the Safety Department (This was a great opportunity for Chris!).
Bill Green our new plant manager introduced a jar of beads during his first safety meeting. We each picked a bead randomly from the jar through a small hole in the top. Then Bill Green pointed out that the color of bead represented the result of doing something unsafe.
The green color meant that nothing happened. The other colors reach represented a different type of accident that occurred. The ratio of beads in the jar represented the likelihood of each type of accident happening. There was one black bead in the jar. That meant that you died when you did something unsafe. I used to keep the number of each color of marble in my wallet, but that piece of paper disintegrated over the years.
The types of accidents were something like: First Aid Case, Reportable Accident, Lost Work Day Accident, Hospitalized, and Death.
A couple of months after the downsizing, the Safety department announced that they were going to have a Safety contest. The contest would be held at each plant and it involved each of the supervisor’s computers. The prize for the contest was that the winning team would be able to eat a free lunch with complements from the safety team.
Great! Shortly after the electric shop is busted up and we were scattered to the wind, we finally had one last chance to win the ever illusive Power Plant Safety Pizza! Only, how were we going to do it? I was working on Alan Kramer’s team. My old foreman Andy Tubbs (not old in the sense that he was an old man… old in that he was my former foreman) was now one of the other supervisors with only my old bucket buddy (you know what I mean… not “old” old) Diana Brien as the electrician on his team.
Before I go further to explain my conflict during this contest, let me explain how the contest worked.
The supervisors had new computers that ran using Windows 3.1. Back then, the screensaver on the computer didn’t just shut down the monitor like most of them do today. Instead, they showed some kind of message, or picture or something animated that kept moving around so that your monitor didn’t get burned in with an image that was constantly on your screen, such as your wallpaper and your icons.
The Safety Department said that each team should come up with some way to display the idea of “Safety” using a screensaver. They suggested using the screensaver that let you type in a message that would scroll across the screen when the screensaver was turned on. That was a simple built-in screensaver that came with Windows 3.1.
Then the Safety Department would come to the plant on a particular day and judge each of the computer’s screensaver and announce the winner. Sounds simple enough.
We first heard about the Safety Slogan Screensaver contest in our Monday Morning Meeting with our team. Alan Kramer said we should come up with a good slogan that we could put on our scrolling message screensaver. I kept my mouth shut at the time, because I didn’t know exactly how to proceed. I was having a feeling of mixed loyalty since my old Electric Shop Team with Andy Tubbs as our foreman had written over 300 safety slogans and had purposely been blocked from winning the Prized Pizza each year.
Not long after the morning meeting, Andy Tubbs came up to me in the Electric Shop and said, “We have to win this contest! That Pizza should be ours! I need you to come up with the best screensaver you can that will blow the others away.” I gave him my usual answer when Andy asked me to do something (even when he was no longer my foreman). I said, “Ok, I’ll see what I can do.”
I went down our list of safety slogans looking for the best slogan I could find. Here are a few of them:
“Having an accident is never convenient, So always make Safety a key ingredient.”
“Take the time to do it right, Use your goggles, save your sight.”
“To take the lead in the ‘Safety Race’, You must pay attention to your work place.”
“Unsafe conditions can be resolved, If we all work together and get involved.”
After thumbing through the entire list, I knew we really needed something else. So, I began to think of alternate screen savers. One caught my attention. It was called “Spotlight”. It came with the “After Dark 2.0 Screensavers” (best known for the “Flying Toaster” screensaver). I had found a freeware version that did the same thing. You can see how the spotlight works at 7:15 on the video below (just slide the time bar over to 7:15):
For those who can’t view YouTube videos directly through the above picture, here is the direct link: “After Dark Screensavers“.
The spotlight screensaver basically turns your screen dark, then has a circle (or spotlight) where you can see the background screen behind it. It roams around on your desktop showing only that portion of your wallpaper at a time. You can adjust the size of the circle and the speed that it moves around the screen.
Taking our safety slogans, I began creating a wallpaper for the computer screen by filling it with little one liner safety slogans. I also added yellow flags to the wallpaper because that was a symbol for safety at our plant (for more information why see the post: “Power Plant Imps and Accident Apes“).
With the help of Charles Foster and Scott Hubbard (both Power Plant electricians), when I was finished the wallpaper looked like this:
I printed this out in black and white, but the slogans were written in different colors.
I arranged Andy’s icons on his desktop so they were around the edge of the screen. That way they didn’t cover up the safety slogans. I set the speed of the spotlight to very slow and and the size of the spotlight so that it was just big enough to see each safety slogan. The effect worked out real well. Imagine a dark screen with a spotlight moving randomly around the screen exposing each safety slogan (and yellow flag… don’t forget about those) as it went.
Besides the electricians, no one else knew that I was working on this for Andy. As far as Alan Kramer knew, I was on his side in this contest. I even kept Toby O’Brien in the dark about it, because I knew that he was going to be one of the judges and even though he knew how much winning the Safety Pizza meant to me. I didn’t want to influence his decision. Besides, this Safety Screensaver was going to win. It was the coolest screensaver around. The trick was to keep it hidden from the other teams until it was time for the Safety Department to judge it.
I had the impression from Toby that he had purposely talked the Safety Department into this contest to give me a chance to win the Safety Pizza at our plant. Scott Hubbard and I had carpooled with Toby throughout the years we were trying to win that pizza, and I think he just felt our pain enough that when he was in the position, he was trying to pay us back for our effort.
The screensaver judging was done during the morning, and was going to be announced that afternoon during the monthly safety meeting. A short time before the Safety Meeting began, Toby O’Brien came up to me and in an apologetic manner told me that the safety slogan winner probably wasn’t going to be who I thought it was. I figured that was because he thought I was hoping Alan Kramer’s team was going to win since that was my team. I just smiled back and told him that it was all right.
It was announced during the safety meeting that Andy Tubbs’ team won the contest, and all the electricians were happy. I think it was at that point that Alan Kramer realized that I had helped Andy with his screensaver. He looked at me as if I had betrayed him. I said something like, “Andy Tubbs has been trying to win a safety contest for years. It’s about time.”
The following week, when Andy’s team was given their prize for winning the safety screensaver contest, he brought two pizzas to the electric shop and we all sat around the table relishing in the pepperonis. We had finally received our Power Plant Safety Pizza! Even though I really like pizza anytime, the pizza that day tasted especially good.
I don’t know if we ever told Toby that when Andy Tubbs team won, we all won. Maybe some day he will read this story and know…. “The Rest of the Story”.
In case you can’t read all the little safety slogans on the wallpaper, here is a list of them:
Safety First. Be Safe. Safety begins here. Watch your step. Check your boundaries. Have Good Posture. Haste makes waste. Bend your knees. Avoid Shortcuts. Be Safe or Be Gone. Know your chemicals. Check O2 before Entry. Use Safety Guards. Know your limit. Report Spills. Safety is job #1. Beware of Pinch Points. Buckle up. Safety is no accident. Impatience kills. Strive to Survive. Protect your hearing. Use the right tool. Keep your back straight. Drive friendly. Keep Aisles clear. Don’t take chances. Prevention is the cure. Safety is your job. Communicate with others. Always tie off. Don’t cut corners. Wear your glasses. Act safe. Barricade Hazards. Use your respirator. Be responsible. Lock it out. Plug your ears. Stay fit. Safety never hurts. Don’t block exits. Be aware of your surroundings. Safety is top priority. Don’t be careless. Pick up your trash. Think Ahead. Slippery When Wet. Think Safety. Don’t hurry. Report Hazards. Wear your gloves. Save your eyes. No Running. Wear your Safety Belt. Plan Ahead. Avoid Backing. Use your Safety Sense. Good Housekeeping. Get Help. Keep Cylinders Chained. Protect your hands. Don’t improvise. Beware of hazards. Get the Safety Habit. Be Prepared. Gear up for Safety. Use your PPE. Do not litter. Zero Accidents. Don’t be a Bead (a reference to Bill Green’s jar of beads). Eat Right. Keep Floors clean. Watch out. Safety Pays. Drive Safely. Take Safety Home. Know Safety, use Safety. Read the MSDS. Cotton Clothes Prevents Burns. Follow the rules. Wear your hard hat. Watch out for your buddy. Test your Confined space. Remember the Yellow Flag. Safe Mind, Sound Body. Clean up your spills. Don’t take risks. Beware of Ice. Watch out for the other guy. Obey the rules. Don’t tailgate. Circle for safety. Safety Me, Safety You. Protect your Toes. Knowing is not enough. When in doubt, Check it out. Falls can kill. Be Alert! Avoid slick spots. Safety is a team event. Almost is not enough. Avoid the Noise. Give Safety your all. And finally… This Space for Rent.
I know I’m getting old when I pick up a small piece of paper and I am suddenly taken back 17 years to the day I pulled the small page from the Hunzicker Brothers Inc. Notepad sitting on the desk in the Electric Shop office. It was the day that I was finally able to come to the aid of a noble Power Plant Man that the plant generally referred to as “Stick”.
Gary McCain, or Stick, is a tall thin Power Plant Man (sort of like a stick) known for his intellect and knowledge of “Machine Language”. In this case, “Machine Language” refers to the ability to understand how machines work, not how to talk directly to computers using zeroes and ones.
Gary had just walked into the Electric Shop office at the power plant in North Central Oklahoma as lunch was ending. He was carrying a textbook, which seemed odd right off the bat. He explained that some of the machinists and mechanics had been sent to motor alignment school and they had been given this textbook in case they wanted to refer back to the material that was covered in the class.
Gary sat down next to me and set the book on the desk opening it to the page he had bookmarked (Yeah. We used to use books made out of paper, and we put pieces of paper between pages to bookmark the pages we wanted to remember… Bookmarking wasn’t something new with Internet browsers).
Gary (am I going to start all my paragraphs with the word “Gary”? Maybe the next paragraph, I’ll just say “That tall guy”) pointed to a formula on the page and asked me if it was possible to use the computer to make calculations that will help him align motors using this formula.
I told that tall guy (Gary) that we could use a program called “Excel” (from Microsoft) that could be used to solve problems just like that. So, I grabbed the small sheet of paper off of the Hunzicker Brothers Inc. notepad and wrote down the variables for the formula on one side, and the four formulas on the back side. Here is what I wrote:
Oh yeah. I think I ripped off the corner of the paper to use as a bookmark because I didn’t like the one Gary was using. It was too small.
I guess at this point I should stop and tell you what is meant by “motor alignment” and why machinists and mechanics are interested in this in the first place.
The alignment that is done with a motor is performed when you are putting a pump back in place or some other equipment like a gear box or fan shaft or… well… a lot of things. You have to make sure that the shaft on the motor is perfectly aligned with the pump otherwise it will quickly tear something up when you turn it on.
This picture shows how the motor is aligned up with the compressor so that the red coupling lines up perfectly. Once it is aligned the coupling can be bolted together to connect the motor to the pump.
Notice that the motor has bolts to mount it to the skid in the front and the back on both sides, as well as the pump. These are called “Feet”. Usually when you put the pump and the motor back in place, they don’t line up perfectly, so thin pieces of brass called “shims” are used to raise the various feet just the right amount so that the shaft on the motor and shaft on the pump are looking right at each other.
A special piece of equipment is used to check the alignment. It is called a “Dial Caliper” and it is mounted to the coupling on the motor and the pump with a magnet and it tests the alignment as it is rotated around.
I’m sorry if I’m boring those of you who don’t immediately see the beauty of Motor Alignment. Try pretending that the dial caliper is something invented by ancient aliens if you need to make this part of the post more interesting (actually, who needs ancient aliens when you have machinists?).
Gary told me that the company was looking into buying laser guided motor alignment machines for only $30,000 a piece. They would probably buy three of them that could be used between the four main plants. He said that he didn’t think we needed them if we could use these formulas to calculate exactly how to align the motors. This would save the company around $90,000 and at the same time show the mechanics the “joy of math”!
So, I made some notes on another page which simplified, (or maybe complicated) the formulas further. Then I sat down at the computer and began putting them into Excel. The idea was to have the person doing the motor alignment take some notes, then go to the computer and enter them into the Excel sheet and it would tell them right away how many shims to put under any of the 8 feet (four on the motor and four on the pump).
Here are the notes I made:
If you are Jesse Cheng (or some other old time calculator geek), you can see what I was doing with my notes. I was thinking of the next steps… which I’ll explain below…. (oh… ok… I’ll tell you… this is the code that you would use if you were creating a program for a Casio calculator).
After creating the spreadsheet, Gary headed out the door to go start aligning a motor using our newfangled motor alignment method. A little while later he came back into the shop and pulling out his handy dandy notepad he read off the notes he had taken while he put the values into Excel… When he was finished, he wrote down the results and headed back out the door to add the proper shims to the motor and the pump.
We had to tweak the program a little to work out the bugs, but after a couple of tries it worked very well and Gary was pleased. Only, there was one problem with this method… Over the next couple of weeks, Gary would come bursting into the electric shop office interrupting me and Charles Foster while we were having a deep discussion about the virtues of banana peppers on ham sandwiches.
So, I suggested to Gary that we could use a calculator to do the same thing that we were doing with the spreadsheet. That way he wouldn’t have to travel back and forth to the computer. Instead, he could just stand there at the motor and enter the information and have it display the answers that he was seeking.
Right off the bat (hmm… the second time I have used that “cliche”…. I need to read more often), Gary didn’t understand how a calculator could do this. So, I explained to him that some calculators are programmable and I can write a program on the calculator that would do just that. I said, “Let me show you”….. After all, I had grown up in Missouri (the Show Me State)… So, I took my calculator off of the top of the filing cabinet and placed it on the table.
I used the thermal printer to connect the calculator to the tape recorder to store my programs, so I didn’t have to enter them manually after I entered them once.
I took my notes and wrote the following program and entered it into the calculator.
I gave the calculator to Gary and showed him how to run the program and sent him to try it out for himself. He was very excited about this and offered some suggestions to make the program easier to use.
A few days later Gary caught me walking across the maintenance shop and showed me a catalog with various calculators for sale. He said he wanted to buy some calculators for the shop so that every person that had been trained to align motors had a calculator with a program on it. I showed him a Casio calculator that would work for about $70. So, he ordered a better one.
Even though the language for programming it was different than the Sharp calculator, it didn’t take long for me to write a program for it that did the same thing since I had sort of already written it by that time. After Gary proved to his foreman that the calculator worked, he ordered several more and when they arrived he asked me if I could program them as well.
It took almost a half hour just to type the program into each calculator, so I bought a small pigtail that connected two calculators together. This allowed me to copy the program from one calculator to another one. So, when Gary arrived one day with a box of over 20 calculators for the rest of the plants, it took me longer to open the packages than it did to copy the program from one calculator to the next.
Since the calculator was a graphic calculator, I thought about improving the program by drawing a little picture of a motor shaft and a pump shaft and showing how they were out of alignment after the information was entered, but I never took the time to do that as I was on to another computer project by that time (which I will write about later).
So, think about this. The company was willing to buy $90,000 worth of laser-guided motor alignment equipment to do something that machinists and mechanics already knew how to do. The specialized equipment would work, and it might have been faster I suppose. With the aid of a programmable calculator, however, a mechanic can stand at the motor, takes a few measurements and come up with the same results probably just as fast as the laser-guided motor alignment gizmo could do it.
Either way, the mechanic still had to install the same number of shims under the same feet whether they used the calculator and the dial caliper or the laser beam. The 26 or so calculators that were purchased for the four plants came up to less than $2,000, which is a savings of $88,000. I don’t think the laser would have saved that much time. It still had to be carried over to the motor and plugged in and mounted on the motor. My guess is that as soon as the laser was dropped on the floor accidentally, it would have been broken anyway.
The best part of this little project was that I was able to help out a True Power Plant Man Gary McCain, that I hadn’t really had the opportunity to help much before. Gary didn’t need much help as he is one of those Power Plant Men that people seek out when they need advice. So, when he came to me and asked for help with the computer, I was more than glad to do what I could to help him.
Sometimes it is a little difficult for my wife to understand why I keep scraps of paper laying around that have meaningless scribbles on them. One might be a doodle that some friend of mine created one day while talking on the phone. Another might be a fortune from a cookie that I opened when I was eating lunch with a coworker. Today the piece of paper I picked up happened to have a mathematical formula written on the back.
I think my son understands now that when I seem to be picking up trash off of the table and a tear comes to my eye, it isn’t because I have just picked up something rotten, but because I have just been transported back in time to place where I am with some people that I love. It doesn’t stop him from saying, “Dad? It’s just a piece of paper. Geez!” Well… I know I’m getting old… but that scrap of paper is poetry to me.
In the morning when a Power Plant Man drives through the gate at the plant, with the boilers and smoke stacks looming ahead of them, they know that whatever lies ahead for them can be any one of over 20,000 different Power Plant Man Jobs! Yes. That’s right. There are over 20,000 separate jobs that a person can be assigned on over 1,000 different pieces of equipment.
The bravery brings to mind the “Charge of the Light Brigade” (by Alfred Lord Tennyson), where “…All in the Valley of Death rode the six hundred”… only there were about 44 He-men and Women to repair whatever was in need of repair that day. And as in the commemorative poem about the Battle of Balaclava where “… Cannon to the right of them, Cannon to the Left of them Cannon in front of them… Into the Jaws of Death, Into the Mouth of Hell Rode the Six Hundred.” Or 44 in the case of the Power Plant Men and Women.
It is true of the bravery possessed by True Power Plant Men and Women as they go about their daily quest for perfection. Unlike the Charge of the Light Brigade, who through an error in the command structure was ordered to perform a suicide mission, Power Plant Men go into daily battle well prepared using the correct tools, Safety Gear, Clearance Procedures and the knowledge of how to perform any one of the 20,000 jobs that could be assigned to them on any given day. (wait! Did I just create an extremely long run-on sentence? — No wonder I could never get an A in English class!).
As Lord Tennyson Memorialized the Battle of Balaclava in 1854 by writing the poem, “The Charge of the Light Brigade”, one day when I showed up to work during the spring of 1998, I was assigned a similar task at the Coal-fired Power Plant in North Central Oklahoma. “What’s that you say? Similar to writing the Charge of the Light Brigade?” Yeah. You heard me. I was given the job of chronicling each and every task that a Power Plant Man or Woman could possibly ever perform at the Power Plant.
For the next three years, I spent 50% of my time at the plant sitting in front of a computer in the Master Print Room (where the master blueprints for the entire plant are kept) entering each task into the program called SAP. You may have heard me mention this program before.
We had started using SAP a year earlier at the Electric Company. The benefit of using this product was that it connected all of the functions of the company together into one application. So, as soon as a Power Plant Man took a part out of the warehouse, it was reflected in the finance system on the Asset Balance sheet. When our time was entered into SAP, the expense was calculated and charged to the actual piece of equipment we had been working on during that day. It gave us a lot of visibility into where and how the company was spending their money.
This became even more useful if we were able to tell SAP more and more about what we did. That was where Ray Eberle and I came in. Ray was assigned to enter all of the Bill of Materials for every piece of equipment at the plant. I was assigned the task of entering all of the possible jobs that could be performed at the plant into SAP.
I entered jobs into a section called “Task Lists”. When I created a task about a specific job, I had to tell SAP all about how do perform that job. This is referred to as “Expert Data” in the world of Enterprise Software. (sorry to bother you with all these boring technical terms).
Each task had to include any Safety Concerns about doing the job. It included a list of instruction manuals for the equipment that needed to be repaired and where to find them. I had to the include the Safety clearance procedure that needed to be performed in order to clear out the equipment before working on it.
The Task also included all the parts that could be used to fix the equipment if something was broken along with the warehouse part number. Then I would add a list of tools that would be used to perform the job. This would include every wrench size, screwdriver, soft choker, come-along, pry bar, and nasal spray that might be needed for the job (well, you never know… there could be job that required the use of nasal spray). Ok. You have me… I only threw that in there because I found this great picture of Nasal Spray on Google Images and this was the only way I think of to show it to you:
Finally I would list each of the steps that a person would take to fix the equipment they were assigned to repair. This was a step-by-step procedure about how to perform the job.
My first thought when I was assigned the job of chronicling every possible job a Power Plant Maintenance Man could perform was “Great! I will get to work on the computer! Everyone will be glad to help me with this task as it will make their lives easier!” Well… After I began the task of collecting information about the jobs, I unexpectedly found a lot of opposition to the idea of listing down each of the steps that a Power Plant Man performed to do their job. — Can you guess why?
Well… Yeah. It’s true that I have an annoying personality, and sometimes I may come across as unpleasant, but that wasn’t the main reason. Here is what happened….
When a Maintenance Order was created, one of the planners, Either Ben Davis (Planner 3) or Tony Mena (Planner 4) would flag the work order as needing a Task created for that particular job.
I would pull up the list of work orders and start creating the task list for that job. I could tell who was assigned to it, so I figured I would just go up to them and ask them how they were going to fix the equipment.
I remember going up to the first person on my list (Earl Frazier) the first day and explaining to him what I was doing. I asked him if he could tell me the steps to replacing the tail roller on belt 18 in the Surge Bin Tower. His response was, “Why should I tell you? You will just put all of that into the computer and then when you have described how to do all of the jobs, they can just get rid of us and hire some contractors to do our jobs.”
Oh… I hadn’t thought about that. It seemed unlikely, because there is a big difference between having a low wage contractor working on something and a dedicated Power Plant Man. There just isn’t any comparison.
In order to write up the task for this job, I just waited until the men were up in the Surge Bin Tower pulling the roller off of the belt, and I went up there and watched them. I took notes of all of the tools and equipment they were using, and asked one of them the steps they were taking to get the new roller up to the tower, and how they were taking the old one out, etc.
Ok… I wasn’t going to do this… but I can feel your anticipation clear from here while I am writing this, that you really want to know what kind of tools it took to pull the roller from the Surge Bin Tower Conveyor belt…. Here is a list of just the tools needed…. just warning you… reading this list of tools just may cause you to drop whatever you are doing and drive out in the country to your nearest Power Plant and apply for a job…. just to warn you… if you don’t think that would be good for you, you may want to skip this next paragraph.
One 9 Foot Extension Ladder. Two 1-1/2 ton come-alongs, and one 3/4 come-along. Two large pry bars, a 15/16 in. and 3/4 inch sockets, an air or electric impact wrench (to be used with the sockets). An 8 foot step ladder. One can of WD-40. a 3/8 in. screwdriver. Oxygen-Acetylene tanks with Torch, a Welding machine, two 8 ft. 2 by 4’s (that’s two pieces of wood). A hammer, a 1/8 in. wrench. One small pipe wrench. One hook to hold up the roller. Three extension cords, with adapters for the coal-handling safety plug-ins. One 4 in. electric grinder. Two 6 in. C Clamps and four 6 ft. Steel Chokers.
I decided that I would make things easier for myself up front by working on all of the electrician maintenance jobs first since I knew how to do most of those already. So, I spent the first year almost solely working on Electrical and Instrument and Control jobs. I could easily write the task lists for these, because I new all of the steps.
For instance… If I needed to take a clearance on the A Tripper Drive motor, I knew that the breaker was on the Motor Control Center (MCC) 13B Cubicle 1C already. I didn’t have to even look that one up. (I often wondered what they were thinking when they put Tripper B on MCC 13B Cubicle 2B. Why not put it in the same place (1C) on the next Motor Control Center? It would make things less confusing — Just things I think about when I’m sitting on my “thinkin’ chair”).
Some tasks were short and easy. Others were novels. Take “Elevator is Malfunctioning” Maintenance order. I included all sorts of troubleshooting tips for that one. I even drew a sort of diagram of relays showing how they should be picked up and dropped out as the elevator went up and down… When the elevator was going up, I put in a table of relay positions like this (U means the relay is picked up, D means it is dropped out). Those names at the top are the names of the relays.
|At Start up||D||U||D||U||D||D||D|
|Slowdown 2 up||D||D||D||D||D||D||U|
|Slowdown 3 up||D||D||D||D||U||D||U|
|At Stop up||D||D||D||D||U||D||D|
I wrote a similar one for when the elevator was going down.
Anyway….I mentioned a couple of weeks ago that Ray Eberle and I worked together side-by-side for most of the three years while I was writing the task lists (see the post “Tales of Power Plant Prowess by Ray Eberle“). After I had written a number of novels about different Electrician jobs in the form of task lists, I began working on the general maintenance tasks.
After a while the Mechanics came around and saw the benefits of the task lists. I remember one of the men who had been the most vocal about not telling me how to do his job (yes. Earl Frazier) came up to me after I had written a task list about changing out the number 2 conveyor belt gear box and he asked me to add another wrench to the list. He said, that they had to go all the way back down the belt at the coal yard, drive back to the shop and retrieve the wrench, all because they hadn’t taken it with them the first time. I added it in a heartbeat and he left smiling.
Every once in a while I would run across a Maintenance Order where I could be somewhat creative. For instance, I had to write a task list about how to inspect the railroad tracks and right-away from the plant to where the tracks entered the town of Red Rock, Oklahoma about 5 miles away.
After explaining how the person connected the railroad truck to the tracks and drove on the tracks toward the growing Metropolis of Red Rock (population 282). I explained about how they were to make sure that all the wildlife was being treated well. I also said that when they arrived at Red Rock, they should go into the feed store and build up our public relations by striking up friendly conversations with the “locals”.
After completing over 10,000 different task lists….. I had begun to get into a routine where I felt like my creativity was becoming a little stifled. Then one day, Ray Eberle suggested that when I’m writing my task lists, I should think about how Planner 4 (Tony Mena) would like to see something a little more exciting than the usual…. “this is how you fix this piece of equipment” task list…
One day I remember writing a task list about something called a “Sparser Bar”. A sparser bar is something that sprays water at the bottom of a sump to stir up the coal when the pump is running so that it doesn’t build up or maybe on a conveyor belt for dust suppression. Anyway… One of the tasks I needed to write was for a person to “create a new Sparser bar”.
I wish I had the exact Task List that I wrote. I know that many years later, Ray Eberle sent me a copy of it when he ran across it one day, but I don’t have it readily available, so I’ll just go by memory (until someone at the plant wants to print it out and send it to me). I don’t know… I may be able to write a better one now…. let me see….
Here are the instruction:
- Cut a one and a quarter inch pipe 30 inches long.
- Drill 1/8 inch holes along the pipe so that you have exactly 24 holes evenly distributed across the pipe leaving at least 3 inches on either side of the pipe.
- If you accidentally drill 23 holes, then you should add an extra hole so that you end up with exactly 24 holes.
- If you drill 25 holes, then you should discard the pipe and start over again.
- Note: Do not drill holes that are larger than 1/8 inches in diameter as this will be too big. If you drill holes bigger than 1/8 inches, then discard the new sparser bar and begin again.
- Another Note: Do not drill the holes smaller than 1/8 inches in diameter. If you drill holes that are smaller than 1/8 inches, then obtain a 1/8 inch drill bit and use that to increase the diameter of the holes that you have drilled.
- Once you have exactly 24 holes in the new Sparser Bar, then rotate the pipe 30 degrees and drill 24 more holes in the exact same positions as the holes that are now 30 degrees from where you are going to drill the new holes.
- Note: Do not drill the second set of holes at a 40 degree angle from the first set of holes as this is not the correct angle. Only drill the holes at a 30 degree angle from the first set of holes.
- Also Note: Do not drill the holes at a 20 degree angle, as this is also not the correct angle from the first set of holes.
- Caution: If you find that you have drilled the second set of holes at an angle other than 30 degrees, please discard the sparser bar and begin again.
- Once you have exactly 48 holes (count them… 24 + 24) in the sparser bar, thread both ends of the pipe.
- After you have threaded both ends of the new sparser bar, put a metal cap on one end of the sparser bar.
- Note: Do Not under any circumstance put a metal cap on both ends of the sparser bar as this will render the sparser bar useless because there will not be any way to attach the sparser bar to the water line.
- Caution: If you find that you have accidentally put a metal cap on both ends of the sparser bar, then remove the metal cap from one end (and only one end) of the sparser bar so that it can be attached to the water line.
- After you have completed creating the new sparser bar with two rows of 24 1/8 in. holes each at an angle of exactly 30 degrees, then using a medium pipe wrench attach the new sparser bar to the water line.
- Align the holes on the sparser bar so that they will have the maximum desired affect when the water is turned on.
See? Only 7 easy steps. I think Tony Mena said he fell asleep trying to read my “Sparser Bar Task List”. I seem to remember Ray Eberle telling me that Tony said, “Kevin’s a nut!”
So, I have one more story to tell you about writing task lists, and then I will conclude this post with the proper conclusive paragraph….
At the plant, every piece of equipment had their own “Cost Center”. This came in handy when you were looking for spending trends and things like that. The structure of the cost center was like this: SO-1-FD-A-FDFLOP — I just made that up. It’s not a real cost center… I just wanted to show you the structure…. The first two characters SO represent the plant. The following “1” represents the unit. We had 2 units. The FD represents a “functional area” like “Force Draft Fan. The “A” represents the number of the piece of equipment, like A or B or C, etc…. depending on how many there are. The FDFLOP is the piece of equipment. In this case it might be a Forced Draft Fan Lube Oil Pump.
I’m explaining this apparently boring aspect of Power Plant Life, because I made an attempt to make it a little more interesting. Here is what I did…. The Ultra Clean water that goes in the boilers and are used to turn the turbine are stored in a couple of large water tanks in front of the main power transformer. The code for their functional area just happened to be: “AM”. So, when you were creating a task for working on a piece of equipment on the first of the two tanks, the Functional area would look like this: SO-1-AM-A…..
See where I’m going with this? It looks like it is saying… “So I am a….” This quickly reminded me of Jim Arnold, who was the Superintendent of Maintenance. The guy that had assigned me to write all of these task lists in the first place. He always seemed like he was king of the jungle, so I thought I would have a little fun with this….
I created a completely new Functional Area Cost Center for this water tank for a non-existent piece of equipment…. I called it the “Gould Outdoor Detector”. So, when I created the Cost Center string, it looked like this: SO-1-AM-A-GOD. For the Gould Outdoor Detector. — I know… I was being rotten.
Then using this cost center (that looked like “So, I am a God”), I created a Task List called: “How to be Superintendent of Maintenance”. I added a lot of steps to the task about how you can humiliate your employees and over work them, and kick them when they are down, and stuff like that. I don’t remember the details. Anyway, that was a lot of fun.
I created task lists up until the day before I left the plant. At my going away party Jim Arnold asked me how many task lists I had created in the last three years… the count was something close to 17,800 task lists. Yeah. That’s right. I wrote over 17,000 descriptions of Power Plant Man jobs in three years. Our plant had over three times more task lists in SAP than the rest of the entire electric company put together.
You can see that I was proud of some, like my the novel I wrote about Elevator Maintenance. You can also tell that working side-by-side with Ray Eberle kept us both entertained during those years. We were the best of friends when I left. I don’t know how many times I just about passed out because I was laughing so hard while we worked together.
If I were to write Power Plant Tasks today, I think I would write the ones that aren’t assigned to a Maintenance Order… they would be more like “How to be a True Power Plant Man”. It would be a novel that would describe the tremendous character of each and every True Power Plant Man and Woman that I learned to love during my stay at the “Power Plant Palace.”
After I left the power plant and went to work for Dell on August 20, 2001, I wrote letters back to my friends at the plant letting them know how things were going. This is the ninety eighth letter I wrote. Keep in mind that at the time when I originally penned this letter I didn’t intend on it being posted online.
4/13/04 – The Boiler Ghost
Dear Friends from Sooner Plant and others,
Kelly was cleaning out our closet over the weekend, and she ran across some old papers from my former life at Sooner Plant. She asked me if she could throw them out, so I sifted through them, and I ran across a piece of paper that was folded up and all stained with Fly Ash. When I opened it, I found that it was a short story that I had written when I was on Labor Crew 21 years ago. I had written it for Bob Lillibridge.
When we were on Labor Crew and we had to work in the Economizer tubes cleaning the caked up ash with Cross-cut saws welded end on end, we would climb into the small crawl space halfway down the tubes to spread the tubes from below. Bob used to grab Ronnie Banks by the legs and Yell, “Boiler Ghost!!!” Ronnie Banks had Claustrophobia, and it would throw him into a panic. So I had written this story to Bob.
It went like this:
From the darkness of the boiler it came.
The Boiler Ghost, black, enormous, full of hate.
I watched with disbelief as it edged its way along.
Its eyes, red and piercing, with a stare of terror
It glanced first this way and then that.
As its eyes passed through me I was filled with
Such a terrible fright that I felt near the point of death.
The massive head hung down between two pointed
Shoulder blades vulture-like.
The most terrifying thing of all was the gaping mouth
That hung open.
It was full of such a terrible darkness,
So dark and evil as if it were the gates of Hell.
Just then I noticed its eyes had fixed on Bob.
He was pressed against the wall by the piercing stare,
His mouth open wide as if to scream.
Eyes bulging out in utter terror.
Mindless with pure fright.
I tried to scream, but felt such a choking force
On my throat I could make no noise.
With steady movement the monster advanced toward Bob.
Bob was white as ash staring into that dark empty mouth.
Smoke poured out of a flat nose on that horrid face.
It reached out a vile and tremendous hand
And grabbed Bob,
Who burst into flames at his touch.
In one movement he was gone.
Vanished into the mouth of pure darkness.
The Evil Ghost glanced first this way, then that,
And into the darkness of the boiler it went.
All was quiet,
The roar of the boiler told me I was safe once again.
Until the boiler ghost should decide to return.
Kevin James Anthony Breazile
Kevin J. Breazile