Originally posted on: June 1, 2012
The first couple of years while I worked as a summer help at the Coal-Fired Power Plant Coal Cleanup was performed on weekends by volunteer He-Men that wanted to make a few extra dollars. As a summer help, I needed all the extra money I could get. My wages during the first year (1979) were $3.89 an hour.
This jumped to $5.84 an hour when I worked on the weekend, so you can imagine the thrill I had at receiving a paycheck that included the extra money made by doing “Coal Cleanup”. Another great advantage to doing coal cleanup on the weekends was that I was able to carpool with different people. So, during the first summer instead of just riding to work with Steve Higginbotham (See the post “Steve Higginbotham’s Junky Jalopy late for the Boiler Blowdown“), I caught a lot of rides with real Power Plant Men like Dale Hull, David Hankins, Jerry Mitchell, Preston Jenkins and Marlin McDaniel (Yeah. Marlin McDaniel as an A Foreman would volunteer for coal cleanup some times. Maybe it was when we were short a few people).
Coal Cleanup really became important during the second half of the first summer because Unit 1 was getting ready to go online. There was a major flaw in the Coal Conveyor logic when the conveyors first started conveying coal from the coal pile to the coal silos just above the bowl mills. What would happen was the same thing that happens if someone were to fall down at the top of a crowded escalator going up. Everyone behind that person would be shoved right on top of them if there wasn’t an emergency stop button to stop the escalator.
All the conveyors had a safety cord alongside the entire length that could be pulled to stop the conveyor in an emergency, but this was something different.
To give you an idea… once the coal on the coal pile has been fed onto either Belts 4, 5, 6 or 7, from there the coal is dropped onto either belt 8 or 9. That carries the coal up to the coal Crusher which has a bin above the crusher that can be filled with coal. If the bin gets too full, then conveyor 8 and/or 9 would stop. When that happens, belts 4, 5, 6 or 7 should stop also…. only they didn’t. Belts 8 and 9 continued dumping coal into the crusher bin until it filled up and then coal fell out all over the top of the crusher tower around belts 8 and 9 until the coal tripped the belt by hitting the safety cord on the side of the belt. Belts 4, 5, 6 and 7 continued dumping coal onto belts 8 and 9, which caused the coal to backup and spill out all over the floor until the coal piled up high enough to trip the safety cord on the side of the belt.
In the picture of the power plant on the side of this post, there is one long conveyor that goes from the coalyard to the plant. It is about 1/2 mile long. This is where belts 10 and 11 carry the coal from the crusher, which crushes the coal down from big pieces the size of baseballs down to the size of walnuts.
At the top of the Transfer tower the coal from belts 10 and 11 are dumped onto belts 12 and 13 which carry the coal up to the Surge Bin Tower where the coal is dumped into the Surge bin. When the Surge Bin fills up, it stops belts 12 and/or 13 and it should also stop belts 10 and 11 and the feeders that feed the coal into the crusher at the bottom of the crusher bin… only they didn’t.
They continued dumping coal into the Surge bin, which filled up and spilled coal all over the surge bin until belts 12 and 13 tripped, at which point, coal began spilling out all over the transfer tower filling up both floors of the transfer tower with tons of coal. The same thing would happen at the bottom of Belt 10 and 11, where the crusher feeders kept feeding coal down to belts 10 and 11, which spilled out all over the bottom floor of the crusher tower.
I have worked in the transfer tower where the coal was higher than the windows and you had to bend over because your head would hit the ceiling on the floor at the foot of belt 12 and 13. It was almost dangerous enough to picture yourself sliding down the pile of coal and slipping right out one of the windows (which had been broken out by the pile of coal). To give you an idea of what this felt like, it was then a straight drop of 150 feet to the concrete below.
If that doesn’t seem like enough coal spills, then picture this… The coal from the Surge Bin tower fed onto belts 14, 15, 18 and 19 which in turn fed onto belts 16 and 17, 20 and 21. These last 4 belts were in what was called the “Tripper Gallery”. These 4 belts would dump coal into 12 coal silos (6 on each unit) that would feed the bowl mills. These are big silos about 5 stories tall.
The same thing would happen to these belts leaving piles of coal at the bottom of the surge bin in the surge bin tower and all along the tripper gallery because when the coal silos were full, the tripper was supposed to move to the next silo and dump coal until it was full, and keep moving until all the silos were full. Only, the tripper wasn’t working correctly, so it wouldn’t detect that the silo was full so the belt would keep dumping coal and would end up spilling coal all over the entire tripper gallery which runs about 100 feet or so.
So, our first experience with doing coal cleanup was like being on a chain gang where we shoveled coal from morning until night trying to clean up these 15 or so major coal spills from the Trippers on back to the the first belts 4, 5, 6 and 7 by shoveling the coal back onto the conveyor while it was running. In some cases, we had to shovel the coal away from the belt before the belt could even run (as was the case with belts 12 and 13). So, you can imagine how shoveling coal one scoop at a time made it seem like you were not getting anywhere fast. 3 or 4 men could all be shoveling on one pile of coal for 30 minutes and not even make a noticeable dent in the pile. That is why when I went to the tool room to choose a shovel, instead of picking a regular shovel, I picked a large scoop shovel used to scoop grain.
Even though each scoop of coal was heavier, it seemed more satisfying to see the bigger dent in the pile of coal with each shovelful. I remember one day after we had shoveled coal all day from morning until late at night only to come back into work the next morning to the new piles of coal just as big as the ones we had shoveled the day before. Once we had cleaned everything up they started up the conveyors again only to have it do the same thing as before.
After 2 years of volunteer coal cleanup which was becoming less volunteer and more rotational since the list of volunteers was growing smaller, Ray Butler pointed out that it didn’t make much sense to pay a first class machinist overtime to shovel coal when you could create a labor crew and pay them bottom dollar to do coal cleanup all the time, as well as other dirty jobs that no one really wanted to do (such as suck out sewage pits and other sump pits around the plant).
That was when the Labor crew was formed. While I was in my 3rd year as a summer help (1981). Bill Cook was a summer help then that stayed on as a labor crew hand at the end of the summer. By the 4th summer as summer help, the only time we did coal cleanup was when there was a major spill, which was only a couple of times all summer.
I will write later about coal cleanup with Dale Hull. I also remember doing coal-cleanup with Preston Jenkins one weekend. I hadn’t carpooled with him to work, but I caught a ride back to Stillwater with him because my ride left at the end of a full day, and I decided to stay behind to add a few extra dollars to my bank account. We left a couple of hours later around seven o’clock.
I climbed into the back of Preston’s Camaro. I apologized for being so dirty, as I was covered from head-to-toe in coal-dust and my clothes were soaked with coal-dust permeated sweat. Preston said that he didn’t mind. I soon found out why.
When I climbed into the backseat of his car, I noticed that the upholstery that covered the seat back of the back seat was stained with some blackish-brownish um…. something. Anyway. I decided to sit on the passenger side of the back seat instead of behind the driver side because that side wasn’t nearly as stained. As we drove down the highway toward home, I quickly learned why the seat back was so stained.
Being the “good-ol’ boy” that Preston was, when he climbed into the car, he took out his can of Skoal and put a pinch between his cheek and gums:
As we flew down the highway like a Texan heading for Stillwater, Preston would lean his head out the window and squirt out a wad of spit. It would dance in the air like a little fairy just before it would be sucked into the back window of his car and splat against the seat back of the back seat. Yep that explained it all right. I always wondered if he knew, never having to sit in the back seat of his own car.
During the first summer when I was able to catch a ride with David Hankins a couple of times. He was the crane operator at the time and drove a black Trans Am. He was a black man with a very broad chest that never seemed to tire while doing coal cleanup. From the first day he always treated me with great respect which in turn gave me a great respect for him. I had him classified as a true Power Plant Man.
The second summer when I had been back at the plant for a couple of weeks, one day when Jim Heflin and I were going somewhere in a yellow Cushman cart, I asked Jim why I hadn’t seen David Hankins around.
Jim (who hadn’t been at the plant the first summer) stopped the cart in the middle of the road and looked at me very solemnly and told me that David Hankins had died in a car accident in the spring. He had been going home from a Men’s Club event when he was killed. Because of this, alcoholic beverages were no longer allowed at Men’s Club events. As with all the people I have worked with at the power plant, I keep David Hankins in my memory and I often think about him to this day. David Hankins was a True Power Plant Man.
Comments from the original Post:
neenergyobserver June 1, 2012 as 6:28 pm
We’ve lost so many friends over the years, in the plants and on the line, especially when they were relaxing on their way home. You, and David’s family have my very belated condolences.
Somebody, somewhere, needs to teach engineers a course on Conveyor Logic 101, I’ve seen the same thing happen in nearly every plant (from automotive, rarely, to meat packing, often) I’ve been in. Or they could, just for once in their life, shut their pie-hole and listen to people like you and me.
Plant Electrician June 1, 2012 at 11:39 pm
We were often exhausted while driving home from work when we had been working a lot of overtime. It was a wonder sometimes that we were able to keep the car on the road.
My uncle Bill Breazile worked for the Utility company in Nebraska City where someone closed a breaker while he was working on a line. He was in the hospital for about 6 months healing from his burns. This was about 30 years ago. He has since passed away. It takes a special person to be a lineman. Putting their life on the line every time they reach out to do their job.
neenergyobserver June 2, 2012 at 10:42 am
Not that different from you. It’s all about planning your work, and doing it right, and safely. You and I know that 480 will kill you just as quick as 7200 if you get careless. That’s why almost all (old) linemen and electricians are in some sense stolid and unexcitable.
jackcurtis July 14, 2012 at 12:59 pm
Industrial America returns in stories and comments in places like this, from the only place it still exists: the minds of those who were part of it. Industrial America was a giant; those who manned it were giant tamers and it seems to me, very much the special breed illuminated in these posts…
Comment from last repost:
Originally Posted on August 3, 2012 (I added a picture of Walt Oswalt):
The second summer as Summer Help at the Coal-fired Power Plant, was when I first worked out of the Automotive garage. It wasn’t finished during the first summer. The second summer when I began working in the garage, Jim Heflin, Larry Riley, Doug House and Ken Conrad were the regular workers that mowed the fields using tractors with brush hogs, as I have explained in previous posts. A summer help that also worked with us from Ponca City named David Foster was also able to mow grass using one of the new Ford tractors that we painted Orange to easily identify them as belonging to the Electric Company in Oklahoma.
I learned to drive the tractors later in the summer when I worked irrigating the fields in our attempt to grow grass (as told in the post “When a Power Plant Man Talks, It Pays To Listen“). The next summer I was able to mow grass using a Brush Hog pulled behind a tractor:
It didn’t take long before I had to mow grass on the side of the dam (and other levies). The side of the dam has a very sharp incline, so while mowing grass on the side of the dam you sat more on the side of the tractor seat than on the seat itself. Heavy weights were put on the front of the tractor and the back tires on the tractor were turned around so that they were farther apart than they would be otherwise. This gave the tractor a lower, wider profile and a lower center of gravity helping to keep it from rolling over sideways down the slope.
I had watched Jim, Larry, Ken and David mow grass along some very steep inclines the summer before without any tractors tumbling over, so I felt like it must be safe, even though looking at the tractors they still seemed a little “top heavy”.
It was quite an eerie feeling the first time I actually mowed a slope this steep. I experienced the same feeling as you have on a roller coaster when it hits the top of the hill and flings you down real fast when the tractor tire on the downhill side of the tractor rolls into a washed out spot on the dam causing the tractor to roll over just a little farther than you are used to. It was definitely an adrenaline rush each time this happened, because it felt like the tractor was going to roll over.
That is when I remembered the story about the little engine that was trying to pull the train over the steep mountain, and he kept chanting, “I think I can, I think I can” over and over. So, between each decade of the Rosary that I was saying while counting Hail Mary’s on my fingers, I added in an “I Think I can…” as an added prayer before the next “Our Father”.
In the time that I worked as a summer help we never turned over a tractor while mowing on a slope. That isn’t to say that the tractors didn’t start to tip over. It’s just that if you realize that the large back tractor tire has left the ground and is spinning freely, you could quickly turn the steering wheel downhill so that the tractor would turn downhill preventing it from rolling completely over. The weight of the brush hog on the back helped to keep the tractor snug against the sloping dam.
Years later, after I left the Power Plant, in 2006, my father’s best friend, Tom Houghton, a Veterinarian in Lakeland, Florida was killed in a tractor accident at his family’s farm in Polo, Missouri. This greatly effected my father. He has not recovered from the loss of his friend still today. As I was mowing grass and picturing my sudden demise if a tractor were to roll down the hill, my main concern was the sorrow my family would have felt by my death. Needless to say… I never toppled a tractor.
It was during that same summer in 1981 that I first worked with the Power Plant Icon Walt Oswalt. Every plant must have at least one person like Walt. He is the type of person that once he has something in his mind about how to do something, nothing is going to change it. I know many different stories about Walt Oswalt that have been shared with me, but this is one of my own. Walt is a sandy-haired Irish-looking man that always reminded me of the little old man, Jackie Wright, on the Benny Hill Show.
I now have an actual picture of Walt that I found laying around….
One Saturday while I had caught a ride to the Power Plant to do “coal cleanup” the crew was asked who would like to wash down belts 10 and 11. These are the 1/2 mile long belts that go from the coalyard all the way up to the plant. You can see them on the left side of the picture of the plant on the side of this post. Finding the opportunity for a challenge, I volunteered.
I made my way up to the top of the Transfer tower where I found Walt Oswalt. He was working out of the coalyard at the time and was helping us wash down 10 and 11 belt. Wearing rainsuits and rubber boots we began at the top and worked our way down. It didn’t look like this belt had been washed down for a while. We could blast the tin enclosure with the high pressure hoses we were using to completely wash off all the coal dust that had built up over time. This looked like it was going to be a fun job.
Then Walt pointed out to me that most of our work was under the belt where the coal had built up almost solid up to the belt itself so that the coal was rubbing on the rubber Uniroyal conveyor belt. Remember, if the conveyor belt goes up, it has to go back down also. So underneath the conveyor is where the belt returns. it is a big loop.
So, Walt Oswalt and I spent the rest of the day laying on the grating so we could see under the belts washing the coal down the slope of belt 10 and 11. Under the conveyor is another set of rollers that the rubber conveyor belt rides on it’s return trip to the Crusher Tower. During this time there were two chants that came to my mind…. One was, “Whistle While you Work”, since we seemed to be in some kind of coal mine working away like the Seven Dwarfs (you know… Walt Disney… Walt Oswalt). The other one was the song, “Workin’ In a Coal Mine” (…goin’ down down).
At one particular spot the coal had built up and packed itself in there so much that one of the rollers wasn’t able to turn and the belt was just rubbing on the roller. After we had washed the coal away we could see that the roller was not able to turn still because the belt had worn it flat on one side.
Walt called the Control Room to shutdown the belt so that we could look at it. We could see that the roller was bad. For some reason the other belt (11) was out of commission so without this belt running, no coal was being sent up to the plant. The coal silos and the surge bin hold enough coal for a while but not for too long during the summer when the units need to run at their maximum rate to supply the electricity needed by the customers. We could have the belt shutdown for a while, but not for too long.
I followed Walt down the belt to the Crusher Tower wondering what he had in mind. He didn’t tell me what we were going to do, so I just gathered my clues by watching what he did. When we came out of the belt and left the Crusher I was surprised that it was already dark outside. When I had left the Maintenance Shop it had been morning. Now it was dark. We had spent the entire day (12 hours at this point) in Belt 10 and 11. I didn’t remember ever taking a break or eating lunch or even going to the bathroom. Just holding the high pressure water hose, directing the stream down under the belt… all day.
We walked over to a new building that was still being built called the Coalyard Maintenance Building. This was the new building that was going to be used by the new Labor Crew in a few months. Outside the building to one side was a Conex Box, as I have described before. This is the kind of large box that you see on the CSX train commercials that are being transported by trains.
We used them to store equipment used for specific jobs or crews. In this case, the Conex box had conveyor equipment in it. Walt found a long straight roller that is used under the Number 10 and 11 belts and tied it to a 2 wheel dolly. We rolled it back to the Crusher Tower and began the long trek back up the belt. I was pulling the dolly and Walt was carrying some large wrenches.
When we arrived at the spot where the roller had been worn, Walt called the control room to let them know we were beginning to work. We pulled the safety cords on the side of the conveyor to ensure that the belt would not start, even though we were assured that a Clearance had been placed on the breaker in the Main Switchgear (where I began my first war with the spiders a year later. See the post “Power Plant Spider Wars and Bugs in the Basement“).
Walt climbed over the belt and I stayed on the main walkway. We worked upside down for a while unbolting the roller. At one point we decided we needed some more suitable tools and headed back down the belt to the Coalyard Garage where the heavy equipment is serviced and brought back some large ratchet wrenches and sockets with an extension.
I think the chant, “I think I can, I think I can” was running through my head on our second trip back up the conveyor belt. I think it was around 10pm. We finished changing the roller and decided to leave the old one laying in the walkway for the night. Walt said he would bring it back to the coalyard on Monday morning.
We made our way back to the Maintenance shop where I took off the rain suit and rubber boots that I had been wearing all day and put my regular boots back on. I went up to the control room and asked if anyone could give me a ride to Stillwater since the evening shift of operators were just getting off at 11pm. I believe it was Charles Buchanan that gave me a ride home that night in his little beat up pickup truck.
I never worked directly with Charles Buchanan since he was an operator. The first impression that one may have is that he looks like a caricature of a construction worker in a comic strip.
Charles reaffirmed my belief that Power Plant Men are some of the nicest people you will ever meet. There were a few times when I caught a ride with Charles to or from the plant. Each time I felt honored to ride in his truck. If I think about what chant was running through my mind as we were on our way home at night, I think it would be something like the song “You’ve Got a Friend”: “Winter, spring, summer, or fall, all you have to do is call, Lord, I’ll be there, yeah, yeah, you’ve got a friend….”
That is what all real Power Plant men and linemen are like. Wherever you look in the United States, these great men and women work tirelessly to keep you safe by providing electricity to your homes. Something we take for granted until the power goes out.
Recently when the power went out in the east, the linemen from this electric company drove with pride, eager to help those in need:
Below I have included the lyrics for the song “You’ve Got a Friend” by Carole King and her husband James Taylor. See how well it fits those people that work around the clock bringing the power to your home:
You just call out my name, and you know where ever I am
I’ll come running to see you again.
Winter, spring, summer, or fall, all you have to do is call and I’ll be there, yeah, yeah,
you’ve got a friend.
If the sky above you should turn dark and full of clouds
and that old north wind should begin to blow,
keep your head together and call my name out loud.
Soon I will be knocking upon your door.
You just call out my name, and you know where ever I am
I’ll come running to see you again.
Winter, spring, summer, or fall, all you have to do is call and I’ll be there.
Hey, ain’t it good to know that you’ve got a friend? People can be so cold.
They’ll hurt you and desert you. Well, they’ll take your soul if you let them,
oh yeah, but don’t you let them.
You just call out my name, and you know where ever I am
I’ll come running to see you again.
Winter, spring, summer, or fall, all you have to do is call, Lord, I’ll be there, yeah, yeah,
you’ve got a friend. You’ve got a friend.
Ain’t it good to know you’ve got a friend. Ain’t it good to know you’ve got a friend.
Oh, yeah, yeah, you’ve got a friend.
Here is a YouTube video of James Taylor singing this song:
If your aren’t able to play youtube videos directly from the picture… here is the link: “You’ve got a Friend“
Originally Posted on August 11, 2012. Added a picture of Larry Riley:
When I was a janitor at the Power Plant there were times when we were christened by being allowed to work with the Labor Crew on jobs that needed to be done in a hurry. Larry Riley was the foreman of the Labor Crew. I had worked with Larry Riley during the summers when I was a summer help, and I always held him in high esteem.
I think he knew that, and he said he was glad to have me working for him whenever they were in a pinch to complete a job in a hurry. I have described Larry as reminding me of the Marlboro Man, as he had a moustache that looked like his.
I finally found a picture of Larry taken a couple of decades later… Here he is:
The wonderful thing about working in a Power Plant is that when you drive through the gate in the morning, you never know what you might be doing that day. Even after 20 years at the plant, I was still amazed by the diversity of jobs a person could do there. Anyone who spent those 20 years actually working instead of doing a desk job, would know a lot about all kinds of equipment and instruments, and temperatures.
When I was young I was able to go to Minnesota to visit my cousins in a place called “Phelp’s Mill”. Named after an old mill along a river that was a “self service” museum. Across the road and on the hill loomed a big foreboding house where my cousins lived during the summers. We would play hide-and-seek in that mill, which was mainly made out of wood. It was 4 stories high if you include the basement and had a lot of places to hide.
When I began working in the Power Plant, I realized one day that this was like that old mill only on a much bigger scale. You could spend half of a life time wandering around that plant before you actually knew where everything was. Each day brought something new. My first years as a summer help, most of the “emergencies” that I would take part in had to do with cleaning up coal. When I was able to work with the Labor Crew, things became a lot more interesting.
One day in the spring of 1983 while I was a janitor when I arrived at work ready to mop the floor and sweep and dust the Turbine Generators, I was told that I needed to get with Chuck Ross an A foreman over the Labor Crew at the time, because I was going to work with the Labor Crew that day. I was told to bring my respirator… Which usually had meant it was time to shovel coal. This day was different.
Chuck brought me to the Tool room and asked Biff Johnson to give me a new Rubber Mallet.
I went with the labor crew up on #1 Boiler just above the Air Preheater Baskets that I didn’t know existed at the time… The Boiler had been shutdown over night because there was a problem with the airflow through the boiler and we had to go in the duct and clean the Slag Screen.
Below the Economizer and above the air preheater in the diagram above.
“Slag Screen,” I thought… That sounds like a fancy word for something that was probably just some kind of filter or something…. I knew that Power Plant Engineers liked to give fancy words to make the Plant sound more like a Palace.
As I mentioned before… there are places like: The Tripper Gallery. Hopper Nozzle Booster Pump. Generator Bathtub. The Gravimetric Feeder Deck — I liked that one, it sounded like you were on a ship. Travelling Water Screens. There were long names for some, like “Force Draft Fan Inboard Bearing Emergency Lube Oil Pump” (try saying that with a lisp). Anyway, I could go on and on.
Larry Riley explained to us that we needed to work as fast as we could to clean the slag screen because they wanted to bring this unit back online in the evening. We couldn’t wait for the unit to cool down much, so we were only allowed to go in the hot air duct for 10 minutes at a time because of the heat.
So, in I went. The first thing I noticed as I stuck my head in the door was that there wasn’t any immediate place to stand. There was only a hole below me that went down into the darkness. So I looked around for something to grab onto to pull myself in. Once my body was in the door I was able to walk along a beam next to this big screen. It looked similar to a screen on a window at home only the wires were about 1/2 inch apart. Something like this:
Oh, and there was one more thing that I noticed…. It was incredibly HOT. I was wearing leather gloves so I could grab onto the structure to hold myself up, but if I leaned against the screen with my arm, it would burn it. I was just wearing a tee shirt. I don’t know the exact temperature, but I have worked in similar heat at other times, and I would say that it was around 160 degrees. I was wearing my hard hat with a chin strap to keep it from blowing off because there was a strong wind blowing to try and cool the boiler down.
The problem is that we were on the tail end of the air flowing out of the boiler, and it was carrying all that heat right onto us. At 160 degrees your hard hat will become soft so that you can squish it like a ball cap. I was wearing Goggles as well, and that helped keep my eyes from drying out since everything else went dry the moment I stuck my head in there.
Anyway, I threw the lanyard for my safety belt around a pipe that ran diagonal across my path, and held onto it with one hand while with my other hand I began pounding on the screen with the rubber mallet. I had to breathe very shallow because the air was so hot. Breathing slowly gave the air time to cool off a bit before it went down into my throat.
This was a new adventure for me. There are some Brave Power Plant Men that work on the “Bowl Mill” crew that have worked in these conditions for weeks at a time. I suppose you grow used to it after a while. Kind of like when you eat something with Habenero Sauce. The first time it just very painful. Then a few weeks later, you’re piling it on your tortilla chips.
After my first 10 minutes were over, someone at the door, (which was hard to see) hollered for me, so I made my way back to the door and emerged into the cool air of the morning. I noticed that Larry Riley gave me a slightly worried look and I wondered what it meant. I realized what it was moments later when I went to remove the respirator off of my face. I only had one filter cartridge in the respirator.
The other one was missing. I thought that was silly of me to go in there with only one filter. No wonder it seemed like I was breathing a lot of dust. Then I thought…. No. I know I had both filters when I went in the duct. I must have lost one while I was in there. Maybe with all that banging I knocked it off.
Anyway, 10 minutes later it was time for me to go back in there, and this time I made sure my filters were securely screwed onto the respirator. I worried in the back of my mind that I may have ruined my lungs for life by breathing all that silicon-based fly ash because I was feeling a little out of breathe (for the next 10 years).
Anyway, halfway through my 10 minutes in the duct I reached up with my hand to make sure my filters were still tightly screwed in place, and to my astonishment, they weren’t tight. I tried tightening them, but I couldn’t screw them tight. The respirator itself had become soft in the heat and the plastic was no longer stiff enough to keep the filter tight. It made sense then why I had lost my filter the first time. It must have fallen down into the abyss of darkness that was right behind me while I was banging on that slag screen.
After working on the screen for an hour or so, we took a break. When we returned the temperature in the boiler had dropped considerably, and I was able to stay in the duct the rest of the day without having to climb in and out every 10 minutes.
Larry had an air powered needle gun brought up there and someone used that for a while cleaning the screen. It is what it sounds like. It has rods sticking out the end of a gun looking tool that vibrate wildly when you pull the trigger. I don’t know what the real name is for it, but it cleaned slag screens a lot faster than my beating the screen with the rubber mallet all day.
I did beat that screen all day. When it was time to leave I brought the mallet back to the tool room, and it looked like this:
I had worn the rubber off of the mallet. When I brought the mallet back to the tool room, Biff said, “What is this?” I said I was just returning the mallet that I had borrowed that morning. He said something about how I must be some kind of a he-man or crazy. I was too worried about my lungs to think about how much my wrists were aching from taking that pounding all day.
A couple of months later I was promoted to the Labor Crew. Chuck Ross had kept saying that he couldn’t wait for me to go to the Labor Crew because he wanted me to work for him. The very day that I started on the Labor Crew, the plant had a going-away party for Chuck Ross. He was leaving our plant to go work at another one in Muskogee.
During the party Chuck presented me with the rubber mallet that I had used that day cleaning the slag screen. He said he had never seen anything like that before. He was sorry he was going to leave without having the opportunity to have me working for him.
I felt the same way about Chuck. I have always kept that rubber mallet laying around the house since 1983 when I received it. My wife sometimes picks it up when she is cleaning somewhere and says, “Do you still want this?” With a hopeful look, like someday I may say that it is all right if she throws it away.
Of course I want to keep it. It reminds me of the days when I was able to work with True Power Plant Men in their natural environment. The slag screen was later deemed unnecessary and was removed from the boiler.
It also reminds me of other things. Like how quickly something can happen that changes your life forever.
Questions from that day have always remained with me.
How much ash did I breathe in? I couldn’t see much more than a few feet in front of me as I banged on that screen knocking ash down all over me. What did it do to my lungs?
What if I had taken a step back or slipped off of that beam before I had walked to the other end to secure my safety lanyard? I know now what was below me then. I would have fallen about 20 feet down to some fins, and then down another 20 feet onto the air preheater baskets. It would have taken a while to retrieve me, once someone figured out that I was missing.
What does that much heat do to your body… or your brain?
I know these are things that go through the minds of True Power Plant Men. I worked with them for years improving the safety of the power plant. All-in-all, no one ever died when I was there, though some came close. The Slogan over the Shift Supervisor’s Office said, “Safety is job #1”. That wasn’t there to try to convince us that Safety was important. It was there as a testimony to everyone who had already made that decision.
Originally posted on August 18, 2012:
I have just finished watching the movie “Godfather II” with my son. Toward the end of the movie Fredo Corleone and Al are going fishing. There is a scene where the motor boat in the boat house is lowered down into the water. I have seen one boat house like this before where the boat is hoisted out of the water in the boat house so that it can be stored dry while hovering a few feet over the water. The Coal-fired Power Plant where I worked as a summer help had a very similar boat house.
The Power Plant had a boat house because each month during the summer months the chemist had to go to various locations in the lake to take the temperature and a water sample. He would take the water samples back to the chemist lab where they could be analyzed. Each bottle was carefully labeled indicating where in the lake the sample was taken. In order to take the samples out in the middle of the lake…. A motor boat was required. Thus the need for the boat house.
The second summer as a Summer Help (before the boathouse was built) I was asked to go along on this journey with George Dunagan, a new chemist at the time. Larry Riley usually manned the motor, as it was known that the motor for the boat had a tendency to cut out and die at random times and the best person that could be counted on to fix a stranded boat out in the middle of the lake was Larry Riley. I know I always felt safe.
I have seen Larry dismantle part of the motor out in the middle of the lake, clean a fuel filter and put the thing back together again with a minimum number of tools at his disposal. I would sit patiently as the boat rocked back and forth with the waves (Oklahoma winds usually kept a steady flow of waves) waiting for Larry to repair the motor. I didn’t have any fear of missing lunch because Larry was in the boat. So, I would just sit and watch the ducks and other birds fly by or look into the water to see what I could see.
Larry would pull something out of the motor and say, “Well, look at that! No wonder this thing died.” Right on queue. A few minutes later and he would start the boat up again and off we would go speeding across the lake.
During the time I was a summer help, there were various tragic events that took place. One man committed suicide by drowning at the park while his sister and wife waited on the shore to tell whoever was first to arrive. Summer Helps were there, but I was on an errand to Oklahoma City at the time and only heard about it when I returned. He had wrapped himself up in some brush. Evidently, he was in some kind of legal trouble at the time and was expected to show up to serve jail time the following Monday.
Another tragedy which was very sad was when a man was swimming with his son on his shoulders out to the dock that was placed out in the water so that swimmers could swim out to it, when he had a heart attack while his daughter was waiting for them on the shore. When the summer help arrived, the daughter told them that her father and brother just went under the water and never came up. One of the Summer Help, David Foster jumped in and found them both drowned. It was a traumatic experience for him, which I’m sure lives on in his memory to this day. Both the father (which appeared to have had a heart attack) and his son had drowned.
Another man was fishing where the river pumps discharged into the lake. This was a popular place to fish at a certain part of the day. A large man had waded out into the water, and at some point fell over. He could not swim (maybe because he had too much to drink) and was also drowned.
These tragic events were a constant reminder that water sports of all kinds have their dangers. Following Safety rules is very important. I believe that two of those 4 people would have not drowned if they had on a life preserver.
Another more humorous tragedy (depending on how you look at it) occurred not far from the boat ramp at the park located closer to Hwy 177. The story as I heard it was that this stubborn farmer who had become rich when they found oil on his land (and I won’t mention his name, because I don’t remember it. Heck. I can’t even remember his initials, if you can believe that), had bought his first boat. Not knowing much about boating, he wanted to make sure he was well equipped, so he attached the biggest motor he could buy to it.
He lowered it into water at the boat ramp at the park, and turned it around so that it pointed out into the lake. Then he opened it up to full throttle. The nose of the boat proceeded to point straight up in the air, and the boat sank motor first. The man swam over to the shore. Climbed in his truck and drove away. Leaving the boat on the floor of the lake. Now… I figure that someone must have seen this happen, because I’m sure that the person didn’t go around telling everyone that he met what he had done… — That is, until he had a few beers in him… maybe.
I would like to tell you some more about George Dunagan, the chemist that went with us to take the water samples. He looked like the type of person that would make a good Sergeant in the Army. A solid facial structure, and a buzz haircut reminded me of the Sergeant Carter on the Gomer Pyle TV show. Here is a picture of Sergeant Carter and George Dunagan when he was younger:
George was in his mid-40s when I first met him. He was 4 months older than my father. He went about his business as a man that enjoyed his job. Occasionally, something might get under his craw, and he would let you know about it, but you always knew that he was the type of person that was looking out for you, even when you thought you didn’t need it.
I considered George a True Power Plant Chemist. He was a genius in his own field. When I was young and I worked around George, I felt like he was passionate about his job and that he wanted to teach it to others. He would explain to me what the different chemical processes in the Water Treatment were doing. He would take any opportunity to explain things in detail. Some people would think that he was kind of grumpy sometimes, and sometimes they would be right. He cared passionately about things that involved “right” and “wrong”. When he saw something that he considered wrong, he rarely sat still.
I considered George to be a passionate teacher that loved to see others learn. I made it a point to stop and nod my head like I was really listening when he was telling me something because I could see the joy in his face that knowledge was being bestowed upon someone.
As he took the water samples in the lake, he explained to me why he was doing what he was doing. How the EPA required these for so many years to show that the lake was able to cool the power plant steam back to water without disturbing the wildlife that inhabited the lake (that the electric company had created).
At that particular time, they were still taking a baseline of how the water was with just one unit running. Later when both units are running they would see how it held up by comparing the year before when no unit was running, then this year with one, and next year with two units.
I listened intently. Not so much because the topic interested me. I wouldn’t tell George that I was struggling to pay attention because the particulars about how he had to label each sample and put them in order in the box were not as interesting as things that came to my own imagination. I imagined things like… “Wouldn’t it be neat if you could breathe under water?” Or, “If the boat tipped over, and we were in the middle of the lake, would I stay with the boat or try to swim to the shore….” “Was that my stomach rumbling? Am I getting hungry already?” I would put my own imagination aside.
I listened intently, mainly because I could see that George would brighten up to find such an attentive pupil in the boat. I was grinning inside real big to watch George with such a satisfied look. I suppose inside as George was explaining the world of water temperature and bacteria growth, I was thinking, “I wonder if George used to be a Sergeant in the Army.” “Does he teach his own children the same way he does me?”. “I wonder what George did before he came here. Was he a chemist somewhere else?”
At the beginning of this year I began writing this Power plant Man Blog because I felt a great need to capture on paper (well. Virtual paper anyway), some stories about the people I was blessed to work with at the Power Plant. Sonny Karcher, who I considered a good friend had died a couple of months earlier. I needed to write about these men, because if I didn’t, I feared these stories would be lost to the world. These are too great of men to just fade away into history without something being left behind to record at least some memorable events in their lives. 16 days after I wrote my first post this year (on January 18, 2012), George Dunagan died in the Ponca City Medical Center.
One thing I was not surprised to learn about George was that he used to be a teacher. He had a Master Degree in Education and had taught at the Chilocco Indian School for 11 years before going to work at the power plant. This explained why he seemed to go into the “Teacher” mode when he was explaining something.
I also learned that he was in the U.S. Navy where he enlisted in 1954. This didn’t surprise me either. As I mentioned above, George reminded me of the Sergeant Carter on Gomer Pyle, and not in the humorous way, but in the way he carried himself like someone in the military. George Dunagan reached the rank of Master Sergeant in the Army Reserves where he retired in 1994, two years after retiring from the Power Plant life.
The movie Godfather II seemed to be about how one man struggled to build a secure home for his family and fellow countrymen through any means necessary, and about how his son destroyed his own family to the point where he was left completely alone with his family destroyed at the end.
Power Plant Men had their own struggles at home. They were not immune to family strife any more than anyone else. The nature of their work gave them a great sense of dignity and feeling of accomplishment. This sense of dignity helps relieve some stress in the family unit. To realize every day that the work that you perform directly impacts the lives of everyone that receives the electricity being produced at the Power Plant.
When something goes wrong and a base unit trips suddenly, the lights flicker in every school room, every store and every house of 2 million people reminding us that this fragile system is so stable because of the due diligence of True Power Plant Men with the sense to care as much as George Dunagan a True Power Plant Chemist.
Comment from previous repost:
Originally posted September 14, 2012:
I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One. I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back. I thought the hard hat made me look really cool. Especially with the safety glasses that looked like someone wore as a scientist during the 1950s. Dark and square.
I used to keep a pair with me when I went back to school. When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).
That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent. Anyway…. I diverse. I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.
The yellow hard hat made me confident that I was part of the blue collar working class. Hard hats have a suspension system in them that make them look like it is riding too high on your head. You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.
This is this because of this great suspension system that causes the hat to ride so high on someone’s head. I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.
While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground. At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast. It seemed that my legs had just buckled under me.
I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat. I was surprised by the force of the cable and how little I had felt. I became a true believer in wearing my hardhat whenever I was working. The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.
Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere. Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.
During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back. I mean… really hurt their back. I was helping to carry a very large 30 foot long section of a wooden extension ladder. There were four of us. Each on one corner. I know that Tom Dean was behind me carrying one side of the back end. I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.
As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office. The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.
Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.
When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder. By doing this, he became slightly twisted, and at once he was in terrible pain. Back pain. I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant. He was pretty well out the rest of the summer recuperating from the back injury.
The next summer when I returned to the plant, Tom was working in the tool room. Obviously a step down from being a mechanic. He was also very unhappy. You could tell by looking at him that he had lost the proud expression that he had wore the summer before.
I don’t remember how long Tom worked at the plant after that. I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth. Hurting your back is one of the most common and most serious injuries in an industrial setting. It is definitely a life changing event.
There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work. One summer there was a young man working in the warehouse and tool room. His name was Bill Engleking (thanks Fred. I didn’t remember his name in the original post). The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind. It turned out that he had a very serious case of diabetes. The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.
Then there was one of the Electricians, Bill Ennis. He would say that he was “Blind in one eye and couldn’t see out of the other one.” He was actually blind in one eye completely, and the other eye he was color blind. So, what he said was actually true.
It happened on occasion that people visiting the plant would be seriously hurt. Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.
One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse. While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.
I remember Mickey Postman explaining what happened. His crew was eating lunch in the garage when they heard someone yelling for help. When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air. They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.
It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do. This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew. I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins. Mickey would know for sure. I’ll leave it up to him to remind me.
I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One. The Power Plant Men didn’t have to be told by a safety video to know how important it was. They all knew examples of tragedies such as these.
Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting. Safety pamphlets would be read, safety videos would be watched. Campaigns would be waged to re-emphasize the importance of proper lifting techniques. Everyone in the plant had to take the Defensive Driving course.
The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course. The course was being given by Nancy Brien, Nick Gleason and Ken Couri. We learned a lot of defensive driving slogans like, “Is the Pass really necessary?” “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time). “Do a Circle For Safety” etc….
My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them. Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.
That was when I began wearing my seat belt all the time. Before that, it was not common for people to wear seat belts. They only had the lap belt before that, and those weren’t the safest things in the world. Especially since they would get lost inside the seat. I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver. There were a number of tips that I learned then, that I still use all the time today.
There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head. Whenever you are outside at the plant, you always wear your hardhat and safety glasses. When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.
During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me. Not until I had a sunburn on the top of my head. I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat. Oh, and a pair of super stylish safety glasses like those shown at the top of this post.
You know when you are young, and I’m sure this has happened to all of you at one point in your life, you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas. — Yeah. I thought you would remember that one. Well. I still have dreams of showing up at my desk job wearing a hardhat and safety glasses. I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.
Comment from previous post:
Jack Curtis January 22, 2014:
The safety meetings, Defensive Driving, safety glasses… it was the same way for telephone men, too. And they jumped in whenever there were problems as well. It is striking to me, to see the differences in attitudes from one generation to another…
Originally Posted September 28, 2012:
I have learned one thing from Power Plant Men, and the Power Plant Safety Process is that, when you become comfortable doing a dangerous job, that is when an accident is most likely to happen. Isn’t that when a young driver seems to become careless?
They drive carefully for the first couple of months when they have just learned how to drive, and then when they feel confident about their driving ability, they begin to cut safety corners, and the next thing you know an accident occurs. That was one lesson we learned in our Defensive Driving Course.
In the spring of 1986, while I was an electrician at the Power Plant in North Central Oklahoma, I went with another electrician, Ted Riddle, to work on a Major Overhaul for three months in Oklahoma City at a Power Plant just North of Mustang. While we worked there, we would eat lunch with a man well into his 50’s that was our acting foreman for the overhaul. His name was Willard Stark.
During lunch we would listen to Paul Harvey on the radio. When Paul would mention a date 20 years in the past, Willard would be able to tell us what he was doing on that day, many years earlier.
I was fascinated by his ability. I will probably talk about Willard more in a later post, but today, I mention him only because of his ability to remember what happened on dates long gone by.
Now that I am about the same age as Willard was then, I am beginning to see that certain dates hold a special significance. The more memorable the experience, either for the good or the bad, and I seem to remember what day it happened. That leads me to one of the memorable dates in my past life at the Power Plant.
The particular date was July 15, 1980. I was working at the power plant during my second summer when I was normally working out of the garage. But Stanley Elmore had told me to go to the Maintenance Shop and get with Ray Butler, because he was going to have me do some cleaning up around the shop.
When I arrived, Ray told me to go over and wait with this new hand that they had just hired the day before, and he would be over there in a few minutes when he finished what he was doing. I walked over to the young man (I say young, but he was 6 years older than I was. He was 25) named Kerry Lewallen.
I introduced myself to him, and we waited together for a few minutes until Ray came over and told us to get a forklift and move some crates that were nearby over to the Warehouse, and then meet him there to help build some shelves in the warehouse to store the larger material on pallets.
The reason I remember this day so well was because of what happened right after Ray walked away. Kerry looked at me and asked me if I wanted to drive the forklift. Well. I really did want to drive the forklift, because I thought it would be fun, but from my experience at the plant, I noticed that people like Larry Riley had a Hard Hat Sticker that said: “Certified Operator Industrial Powered Trucks”.
So I explained to Kerry that I wasn’t Certified to drive a forklift. Kerry had only worked there one day before that day, and even though he probably had a lot of experience driving a forklift (as most Power Plant Men did), he didn’t feel comfortable driving the forklift either.
So, we waited for Ray to come back and Ray asked if we were going to go get the forklift. Then Kerry said something that I have never forgotten, and that I have used repeatedly throughout my career at the Power Plant, as well as my current career. He explained to Ray, “I would like to, but I haven’t been circumcised to drive the forklift.”
I watched Ray as he listened, and I noticed a very faint smile as he realized what Kerry meant to say. Ray agreed, and said he would take care of it. I believe that was the day he took us to the warehouse and circumcised both of us to drive the forklift right then and there.
I couldn’t wait to get home and show my parents. As you can see, I was so proud of my new hardhat sticker, I didn’t put it on my hardhat, I just brought it home and framed it and hung it on the wall. That was July 15, 1980. Being Circumcised to drive the forklift was kind of like my “Come to Jesus” moment in my Power Plant journey.
Kerry Lewallen, as it turned out was a great welder, as were all the True Power Plant Welders. He stayed on at the plant to become one of the True Power Plant Men that worked side-by-side with the other great welders in the boilers welding boiler tubes, or in the bowl mill welding inside them in the tremendous heat that mere mortals like myself found totally unbearable.
As with Jerry Mitchell, my wife came home one day and told me about this very nice person that she worked with as a Nurse in the Stillwater Medical Center. She described her as being a very honest and pleasant person to work with. She also told me that her husband worked at the Power Plant. Her name was Vicki Lewallen, Kerry’s wife.
Through the years, there were many opportunities where we received Hardhat stickers. Most of them were safety related. Each year we would receive a safety sticker, if we hadn’t had an accident. It would indicate how many years in a row it has been that we have been accident free. I received my last safety sticker the last day I worked at the Power Plant during my going away party.
I didn’t place this on a hardhat either. Well. I was walking out the door leaving my hardhat behind (so to speak). I don’t remember how long the Plant Manager Eldon Waugh had worked for the electric company, (about 40 years) but just a couple of months before he retired, while driving back to the plant from Oklahoma City, he took an exit off of I-35 behind a semi-truck.
The truck stopped on the ramp realizing that he had taken the wrong exit and proceeded to back up. He ran into the company truck that Eldon was driving causing an accident. This was enough to ruin Eldon’s perfect safety record just months before he retired. The thought was that Eldon should not have pulled up so close to the truck, or have kept the truck in line with the driver’s side mirror so that he knew he was there.
Throughout the years that I worked at the plant we would have different Safety programs or initiatives that would help to drive our safe behavior. Since back injuries were a major concerned, we would watch films about lifting properly. Since we worked with heavy equipment we would watch videos about people being injured while working with dozers, and other big tractors.
One video that we watched was called: “Shake Hands With Danger”. You can watch it here on YouTube:
This is a classic Safety film shown at the Power Plant periodically. I always thought we should have been provided with popcorn when we watched these. Harry in this film reminds me of a cross between Ken Conrad and Darrell Low. The “Old timer” reminds me of Mike Lafoe. I could go on.
When our new plant manager Ron Kilman arrived after Eldon Waugh, he had us watch a film where there was a near fatal race car accident. When they looked more closely at the accident, it turned out that there were many things that had to happen wrong that led up to the accident.
When an accident occurs on the race track, a Yellow Flag is raised, and everyone gets in line and takes it slow around the track until the accident is cleared. In the movie, the thought was that it would have been helpful if the yellow flag had come out each time someone was about to do something wrong “Before” the accident happened.
The foremen at the plant were given yellow flags to put on their desks as a reminder to see yellow flags whenever you see something that has the potential to be dangerous. We were even given yellow flag stickers to put on our hardhat. — By now, you probably know what I did with mine. Yep. I have it right here. I keep it by my bedside as a reminder:
At one point during the years at the plant, we created a Safety Task Force. When Bill Gibson was the head of the Task Force, he used his Safety imagination to come up with some customized Hardhat Safety Stickers that people at our plant would appreciate. One of the more patriotic Hardhat Safety Stickers looked like this:
I didn’t receive one of the stickers that he came up with that I really liked because I was away at the time on an overhaul when they were being handed out. Many years later, when I mentioned it to the guys at the plant in an e-mail, I was given a stack of them by Randy Dailey the next time I visited the plant.
Randy Dailey the Plant Machinist that was known as “Mister Safety” himself. Thanks to Randy Dailey I am able to show you a hardhat safety sticker that was created based on a particular phrase that was going around the plant at the time:
That really says it all doesn’t it. The real truth about Power Plant Men. They really do care about each other. The close bond between the Power Plant Men is what kept us safe. In the “Shake Hands with Danger” at one point, it mentions that each person should “Watch out for the other guy.”
That is how our plant remained as safe as it did throughout the years that I was there. When I received the Hardhat Safety Sticker for working 20 years without an accident, it wasn’t because I was always being safe in every job I was doing, because that wasn’t always true. It was because there were enough Power Plant Men and Women looking out for me that decreased my odds of being injured by decreasing the number of times that I would end up doing something stupid and getting myself hurt or killed.
So, not only do I thank all the True Power Plant Men and Women that I worked with throughout those years, but so does my wife and my two children. One little mistake at the wrong time. One extra time of Shaking Hands with Danger, and I might not have come home one day from work. It was more than luck that kept me safe. I thank each and everyone of the Power Plant People that I worked with throughout my career for watching out for the other guy.
NOTE: After posting this last year, Ron Kilman, the plant manager at our plant from 1988 to 1994 sent me a picture of his Hard hat. I thought I would post it here so you can see it:
Ron said he stacked his Yearly safety stickers on top of each other as you can see. 24 years of working safely.
Originally Posted January 4, 2013:
November 7, 1983 I walked into the electric shop from the Power Plant Parking Lot with Bill Rivers. Bill was an electrician that I had been carpooling with off and on for almost a year. I remember walking in the door and the first thing I noticed were two guys leaning against the counter by the coffee pot that I hadn’t seen before. They looked like a couple of Electrical Contract hands.
When I came in the door, Bill told them that I was the new electrician. They both looked very surprised. The tall one told me that his name was Art Hammond and that this was his first day as an electrician in the shop also. He had just been hired. The shorter guy introduced himself as Gene Roget (it is a French name pronounced “Row jay” with a soft J). I could tell by his shock and look of disappointment at my young appearance and obvious lack of experience that he had been expecting to be hired permanently along with Arthur.
My new foreman was Charles Foster, the person that had asked me to think about becoming an electrician in the first place. Charles was a calm mild mannered person that made it clear to me the first day that I could call him Charles, or Foster or even Chuck, but don’t call him Charlie. Ok. I made a note of that in my mind….. When the need arises to really irritate Charles, I should remember to call him Charlie. — Just a side note… That need never did arise. I did think it was funny that I had referred to my previous foreman Larry Riley as my Foster Father, and now I actually had a Foster for a Foreman. The electric shop had a short Monday Morning Safety Meeting and then I officially began my 18 year career as an electrician.
I could go on and on about how Charles Foster and I became the best of friends. I could fill up post after post of the things we did and the hundreds of conversations we had each day at lunch…. and um…. I suppose I will in good time. Today I just want to focus on what we did the first day. The first thing Charles told me after making it clear that “Charlie” was not the way to address him, was to tell me that he believed that the way I would become a good electrician was for him to not tell me much about how he would do something, but instead, he would let me figure it out myself. And if I made a mistake. That was all right. I would learn from it.
I really hated making mistakes, and I wished at the time that he would let me follow him around telling me his electrical wisdom. Finally, in my mind I thought, “Ok. If Charles didn’t mind my making mistakes, then I will try not to mind it either.” It was hard at first, but eventually, I found that making mistakes was the highlight of my day sometimes… Sometimes not… I’m sure I will talk a lot about those in the coming months.
I followed Charles up to Bill Bennett’s office. He was our A foreman, and there was a cabinet in his office where he kept all the new electrician tools. I was given a used black five gallon bucket and a tool pouch to carry my tools. Like my first day as a summer help, I had to learn the name of a lot of new tools that day. There were crimpers, side cutters, Lineman’s Pliers, strippers and Holding Screwdrivers. I was given a special electrician pocket knife and was told that I would have to keep it very sharp. I had all sizes of screwdrivers and nut drivers. I put all the tools including the tool pouch into the black plastic bucket.
Bill Bennett was a tall very thin black man. He was a heavy smoker. This showed on his face as he looked older than I thought he really was. He spoke with a gruff voice from years of smoking. He was a very likable person (like most Power Plant Men). He told me that they had tried really hard to get me in the electric shop because the two men in the corner offices really didn’t want me to move off of the labor crew. He explained that I owed my new career to Charles Foster who gallantly went to bat for me. I told him I was grateful.
I was also given a Pocket Protector and a pair of small screwdrivers (one a philips screw driver). Charles explained that I would probably use these small screwdrivers more than any of the other tools. I also was given a small notebook and a pen. All of this went into my pocket protector. Which went into the vest pocket on my flannel shirt.
We went back down to the electric shop and Charles introduced me to Gene Roget again and Charles asked Gene if he would help me organize my tools and teach me some of the basics around being an electrician. Gene said that the first thing I needed to do was to lubricate my new tools. It just doesn’t do to have tools that are stiff. So, we worked on lubricating them and we even went down to the machine shop to get some abrasive paste called “jewelers rouge” that we worked into the tools to loosen them up. Gene took his side cutters and threw them up in the air and as they flew up, they rapidly opened and closed making a rattling sound. He caught them as they came down as if they were tied on his hand like a YoYo.
I worked the tools back and forth. Lubricating them and rubbing the abrasive paste in the joint. I had no coordination, so when I would try throwing my pliers in the air like Gene did, they would end up on the other end of the workbench, or across the room. So, I didn’t try it too often when others were around where I might injure someone. I thought. I’ll work on that more when I’m alone or just Gene is around. He had good reflexes and was able to quickly dodge my miss-thrown tools.
After Lunch Charles said that we had a job up at the coalyard that we needed to work on. He told me to grab my tool bucket and the multimeter from the cabinet. The electricians referred to it as the “Simpson”.
This was before each of us were issued our very own digital Fluke Mulimeter a few years later. I’m sure the old electricians are chuckling to remember that we used to use these old Multimeters. Charles explained to me that when you are checking voltage with the meter, that after you turn the dial to check voltage, always touch the two leads together to make sure the meter doesn’t move before touching the electric wires. This is done because if something happens that causes the meter to still be on “Resistance”, then when you check the voltage, the meter or the leads could explode possibly causing an injury. I had observed the electricians in the shop doing this back when I was a janitor, and now I knew why.
Charles explained that we needed to find out why the heater in the small pump room on the northwest corner of the dumper wasn’t running. So, we went to coalyard and found the space heater mounted along the wall. We tested it to make sure it wasn’t running. After checking the circuits with the multimeter on a panel on the wall, we found that we needed to replace a small fuse block because it had become corroded from all the coal dust and moisture.
I had seen electrical he-men go up to a panel and hold a screwdriver in their hand out at arms length and unscrew screws rapidly, one at a time. Bill Rivers had been doing that up on the precipitator roof when I was working with him while I was still on the Labor Crew. He could unscrew screws from a terminal block faster than I could unwrap Hershey Kisses.
So, when Charles told me to remove the fuse block from the panel, I thought this would be an easy task. I pulled out a screwdriver from my handy dandy tool bucket and with one hand holding the screwdriver, and the other hand steadying it by holding onto the stem of the screwdriver I moved toward the panel. Charles stopped me by saying something like: “Rule number one. Never use two hands. Especially when you are working on something hot.” Ok. I see.. If one hand is touching the metal screwdriver, and I come into contact with the screw which is electrified, then… um… yeah. Ok. I dropped one hand to my side and proceeded to remove the fuse block. That other hand remained at my side for the next 18 years when working on something hot (something is hot when it has the electricity turned on).
I explained above that I was pretty uncoordinated when it came to flipping my side cutters up into the air trying to act impressive like I knew what I was doing. Well. I couldn’t hold a screwdriver steady for the life of me. I tried to match up the head of the screwdriver with the slot in the screw, but I was pretty wobbly. It was kind of embarrassing. The truth had come out. This guy can’t even hold a screwdriver still. How is he ever going to become a real electrician?
Using all my concentration, I fumbled about and began working the screw out of the fuse block, when suddenly the screwdriver slipped slightly and Pow! Sparks flew. I had shorted the screwdriver between the screw and the hot post on the fuse block. There was a quick flash of light and a loud pop. Geez. The first time I’m working on something, what do I do? I blew it….. literally.
Well. Charles pointed out. The electricity is off now. Go ahead and change out the fuse block, then we will find out where the source of power is for it. So, I changed it out…. Feeling a little down that my new screwdriver now had a neat little notch on the blade where the electricity had melted off a corner of my screwdriver (I carried that notched screwdriver around for the next 10 years before I replaced it). We found the breaker that had been tripped in a DP Panel (which stands for Distribution Panel) in the Dumper Air Handler room and turned it back on. We checked the heater and it was working.
At the end of the day, when Bill Bennett came down to the shop to see how my first day went, Charles told him that I had jumped right into it and already had a notch in my screwdriver to prove it. Both Bill and Charles were good-natured about it. I filled out my timecard which told a short story about my first adventure as an electrician.
As I walked to the parking lot with Bill Rivers to go home, I was thinking that even though I had been full of nerves all day, this had to be one of the most exciting days of my life. I was actually one of the electricians now. I had the feeling that somehow something was going to happen and they were going to tell me that they made a mistake and that I would have to go back to the labor crew. That was a feeling that haunted me for about 3 months after moving to the electric shop.
Comments from the original post:
Ron Kilman January 5, 2013
Your memory still amazes me. It’s like you kept a copy of every day’s time card. I’ll bet your time cards take up a whole room at Sooner!
Great article. I still have some of the tools I was given on my first day in the Results Dept. at the Horseshoe Lake Plant in June, 1970 (don’t tell the Evil Plant Manager).
NEO January 5, 2013
I’ve got a few screwdrivers like that myself. Goes with the territory. Good post
Coments from previous repost:
Originally posted January 25, 2013:
When is the appropriate time to call 911? Calling 911 in the Power Plant is when you call the Shift Supervisor to report something important. As Randy Dailey, our Safety Trainer extraordinaire, always taught us, first tap the person on the shoulder and say, “Are you all right?” Then you point your finger at someone and say, “Call 911!” That’s called “Activating the EMS” (Emergency Medical System). Besides medical emergencies, there are other reasons to call the Shift Supervisor.
I learned early on to ‘fess up when you have done something wrong.” People appreciate it when you tell them up front that you goofed. That way the problem can be dealt with directly. Dee Ball was that way. Any time he wrecked a truck, he didn’t hesitate to tell his boss. So, even as a summer help I had developed this philosophy. Never be afraid to expose your blunders. It works out better in the long run.
One example of someone not following this philosophy was Curtis Love. As I mentioned in the post Power Plant Spider Wars and Bugs in the Basement, Curtis didn’t want to tell anyone that he had been bitten by a brown recluse for the third time because he was afraid of losing his job.
His philosophy came back to bite him a year and a half later when he was on the labor crew when he was the designated truck driver. I had moved on to the electric shop by this time.
He was backing up the crew cab around a corner under the Fly Ash hoppers up at the coalyard when the side of the crew cab came into contact with one of those yellow poles designed to protect the structure from rogue vehicles. Unfortunately. This created a dent in the side of the truck.
Curtis, already on probation. worried that he would be fired if he told anyone about this mishap, failed to tell Larry Riley about this incident. Larry, on the other hand, was standing in front of the Coalyard Maintenance shop (the labor crew home), and saw the entire incident. At that moment, he turned to one of the labor crew hands and said, “I hope Curtis comes over here and tells me about that.” Unfortunately, Curtis decided to act as if nothing had happened. This resulted in his termination. As much as I cared about Curtis, I must admit that the Power Plant scene was probably not the best location for his vocation.
I had seen Dee Ball do the same thing over and over again, and he always reported his accidents immediately. He was never punished for an accident, though, for a number of years, he was banned from driving a truck. You can read more about this in the post: Experiencing Maggots, Mud and Motor Vehicles with Dee Ball.
One day during the summer of 1984 just after lunch, 1A PA fan tripped (PA stands for Primary Air). When this happened, number one unit had to lower it’s output from over 500 Megawatts down to around 200. The trip indicator on the 6900 volt breaker said that it had been grounded. Being grounded means that one of the three phases of the motor or cable had made a circuit with the ground (or something that was grounded). The trip circuits shut the fan down so fast that it prevents an explosion and saves the fan from being destroyed.
Diana Lucas (later Diana Brien), Andy Tubbs and I were given the task of finding the ground and seeing what we could do to fix it. We unwired the motor, which was no easy task, because the motor is about the size of a large van, and about 10 times heavier.
So, we spent the rest of the day unwiring the motor (in the rain), and unwiring the cable to the motor from the breaker in the main switchgear and testing both the motor and the cable with various instruments looking for the grounded wire or coil that caused the motor to trip. We used a large “Megger” on the motor. It’s called a Megger because it measures Mega-Ohms. So, it’s technically called a Mega-Ohm meter. Ohms is a measurement of resistance in an electrical circuit. We usually use a small hand cranked megger, that is similar to an old hand crank telephone that generates a high voltage (good for shocking fish in a lake to make them rise to the surface). In the case of the hand cranked Megger, it would generate 1,000 volts.
The Megger this size would have been useless with this large motor. Instead we used one that was electric, and you ran the voltage up over 10,000 volts and watched the mega-ohms over a period of 1/2 hour or so.
For the cables, we hooked up a Hypot (or Hipot). This stands for High Potential. Potential in this case is another word for “Voltage”. It would charge up and then you pressed a button and it would send a high voltage pulse down the cable, and if there is a weak spot in the insulation,The Hypot will find it. So, we hooked a Hypot up to the cable and tried to find the grounded wire. No luck.
After spending 4 hours looking for the grounded cable or motor, we found nothing. We spent another hour and a half putting the motor and the breaker back in service. The Fan was put back into operation and we went home. As I was walking out to the car with Bill Rivers, he told me, “I knew they weren’t going to find anything wrong with that fan.” He had a big grin on his face.
At first I thought he was just making an educated guess as Rivers was apt to do on many occasions (daily). It was raining and I could see where water may have been sucked into the motor or something and had momentarily grounded the motor. Just because we didn’t find anything didn’t mean that the breaker didn’t trip for no reason.
When we were in the car and on our way to Stillwater, Oklahoma with Yvonne Taylor and Rich Litzer, Bill explained that he knew why the motor tripped. He had been walking through the main switchgear with Mike Rose, and Mike, for no apparent reason other than curiosity, had opened up the bottom door to the breaker for 1A PA fan. He looked at it for a moment and then slammed the door shut. When he did this, the breaker tripped.
So, the ground relay happened to be the one that tripped. It might as well been an over-current or a low voltage trip. It just happened to trip the ground trip. Bill said that he told Mike that he should call the Shift Supervisor and let him know so they could restart the motor. Mike on the other hand told Bill that he was already on probation and was afraid of losing his job if he reported that he had slammed the door on the breaker and tripped the fan.
If there was ever a reason to call 911, it was then. All he had to do was tell them, “I accidentally tripped the PA fan when I bumped the breaker cabinet.” They would have told him to reset the flag, and they would have started the fan right back up. No questions asked… I’m sure of it. And they wouldn’t have lost their generating capacity for the remainder of the afternoon and we wouldn’t have spent 4 hours unwiring, testing and rewiring the motor in the rain with a plastic umbrella over our head.
Bill wasn’t about to tell on Mike. If Mike didn’t want to report it, Bill wasn’t going to say anything, and I understand that. I probably would have kept it to myself at the time if I was in Bill’s shoes (I’m just glad I wasn’t because I probably wouldn’t have been able to sleep soundly for the next year). But 30 years later, I might write about it in a Blog. Even though I wouldn’t have looked to Mike to teach me much about being an electrician (he was more of an Air Condition man anyway), I still loved the guy.
Mike died almost two years ago on May 29, 2011. He was from England and had lived in Canada for a time. He used to work on trains. Trains, even though they are diesel, are really electric. The Diesel engine really runs a generator that generates electricity that runs the train. I know that Mike was a good man at heart. He loved his family with all his heart. Here is a picture of the Limey:
Ok. So I know what you are thinking…. There must be a story about myself in here somewhere. Well, you would be right. First of all. I always ‘fessed up to my mistakes, as my current manager at Dell knows well (yes. I still mess up after all these years). I told my current manager the other day that CLM was my middle name. (CLM means “Career Limiting Move”). So here is my power plant “mess up” story (well one of them):
In January 1986, I returned from my Honeymoon with my new wife Kelly when I found that we had hired a new electrician. Gary Wehunt was replacing Jim Stephenson who had left the plant on February 15, 1985, which is a story all it’s own. We had just started an overhaul on Unit 1.
I remember the first Monday I spent with Gary. It was January 6, 1986 and we were working on cleaning out the exciter house on the end of the main power generator with Diana Brien (formerly Diana Lucas). We were discussing salaries and Gary was surprised to find out that I was making more than he was. Well… I had been an electrician for over 2 years and had been promoted regularly…. so I didn’t think there was anything strange about it, except that I still looked like I was only about 18 years old (even though I was 25) and Gary was about 34. I had already been promoted 4 times and my salary had gone from $7.15 to over $12 an hour.
Anyway, when that first Wednesday rolled around, Since Gary and I were assigned to Substation Inspection that week, (Some later time I may go into the details of what “Substation Inspection” entails), but for now, let’s just stick with my “911 call.” It is enough to say that we were in the main plant substation relay house on Wdnesday January 8, 1986 at 9:00 am. One of our jobs was to call other substations and perform a test called a “Transfer Trip and Carrier Test”. We had called Woodring Substation (Woodring is a town in Oklahoma and we had a 345 KV line going there), and I was talking to the man in the substation on the other end of the phone line.
At the same time I was showing Gary just how experienced I was at being an electrician. People had told me that you had to be a plant electrician for 5 years before you really became a “first class” electrician. Well. Here I was at 2 years, and I thought I was so good that I could do anything by now…. — Yeah… right. I told the guy on the other end of the line as I turned a switch…. Amber light… Back to Blue…. and I wrote down the value on the meter (paperwork… oh yes…. it’s that important. Like A-1 sauce).
Then I reached for the second switch. I said, “Carrier test”, then turned the switch. The lights in the relay house went out and we were in the dark. I told the guy on the other end of the line….. “Well. That’s not supposed to happen.” Then as I let go of the switch and it returned to it’s normal position, the lights turned back on. Okay……
I wrote the numbers down from the meter and said goodbye to the other faceless substation man on the other end of the line that I talked to over 100 times, but never met in person. He sounded like a nice guy. Then I headed for the gray phone. I heard the Shift Supervisor paging Leroy Godfrey (The Electrical Supervisor) on line 2 (we had 5 Gray phone lines. The Gray Phone was our PA system).
When I picked up the line I heard Leroy pick up the phone and the Shift Supervisor tell Leroy that we just lost station power in the main substation and it had switched over to Auxiliary power. I immediately jumped in and said, “Jim (for Jim Padgett, the Shift Supervisor), I did that. I was performing a Carrier test with Woodring and the moment I performed the carrier test the lights went out.” Leroy chimed in by saying, “That wouldn’t cause you to lose station power.”
Well, in my ‘inexperienced’ plant electrician way, I responded, “Well. All I know is that when I turned the switch to perform the carrier test, the lights went out, and when I let go of the switch, the lights came back on.” Leroy reiterated, “That wouldn’t cause you to lose station power.” I replied with, “I’m just saying….” and left it at that. I had done my job. They knew I was out here. They knew I had called 911 right away. I explained what I was doing…. they could take it from there.
I had hoped that I had showed Gary upfront that it doesn’t hurt to report your mistakes (even though I hadn’t made one as far as I could tell), but I was 100% sure I had done something to cause the relay house to lose power. Though, I couldn’t figure out why.
After lunch, Bill Bennett, our A foreman came down to the shop to tell me that they figured out how the substation lost station power. He said that a road grader had been grating the road down by the Otoe-Missouri reservation (which is actually called “Windmill road” I guess because there is a windmill down that road somewhere), and had hit an electric pole and knocked it over and had killed the power to the substation.
It turned out that the substation relay house was fed by a substation down that road where we have a radio tower. So, think about this. The exact time that I turned that switch in the substation, a road grater 2 1/2 miles away hits a telephone pole accidentally and knocks it to the ground and kills the power to the substation at the exact same time that I am performing a transfer-trip and Carrier test with Woodring Substation, and the time it takes to switch to auxiliary power is the exact time it took me to let go of the switch.
Don’t tell me that was by accident. I will never believe it. I think it was for the soul purpose of teaching me a useful lesson or two. First….. don’t be afraid to tell someone when you do something wrong. Second…. If you think you have control over the things that happen to you in your life… well, think again…… Third….. God watches you every moment, and if you let him, he will guide you to do the right thing when the time comes. Oh, and Fourth: “Doesn’t God have a great sense of humor?”
God bless you all.
COMMENTS FROM THE ORIGINAL POST:
Monty Hansen January 26, 2013
I had a similar thing happen to me, I was upgrading to shift foreman & system called to remove a tag in the switchyard & put the switch back to auto. The tag on the pistol grip was attached with a plastic zip tie & the previous operator had put it on real tight, as I was wrestling it off with my leatherman, the pliers slipped & I banged my elbow into the control panel, at that very instant there was a loud BANG as several 345 KV breakers opened simultaneously in the switchyard, I had the phone pinched between my shoulder & ear as I was wrestling with this switch & talking to the system control operator, he said a few bad words – gotta go – & hung up. The power plant lost all power & went in the black, I, of course was just sick in the pit of my stomach, after we got power restored, the plant back on etc. I called system back to see if they found the cause & fess up to causing the trip (I figured I must have caused a trip relay to close when I hit the panel) – anyway a crane at a plant down the road had got it’s boom tangled in the power line & went to ground – AT PRECISELY THE INSTANT MY ELBOW SLIPPED & HIT THE PANEL!!
Plant Electrician January 26, 2013
That’s a Great Story Monty!
Ron Kilman January 26, 2013
Some great illustrations of the truth in Proverbs 28:13 “He who conceals his transgressions will not prosper, But he who confesses and forsakes them will find compassion”.
justturnright January 28, 2013
CLM: I can relate.
My first boss 30 years ago once told me he was going to officially nickname me “I’m sorry” (and make me wear it for a name badge) if I said it one more time.
Hey, there’s worse things.
Roomy January 29, 2013
I had not thought about Mike Rose in years. He was a good guy to work with, now Rivers was a different story!!!
Sub checks, I used to love to do sub checks. I performed pilot wire & transfer trip checks for years. I hated it when they went to being done by automation.
Thanks for bringing back old memories.
Originally posted February 1, 2013:
It is vitally important that a manhole cover be round. By just being square or even oval, it could mean death to some unsuspecting electrician. You see, only a perfectly round manhole cover will never be able to fall down into a manhole. No matter how hard you try, you just can’t fit a bigger circle through a smaller circle. An oval or square cover could fall through the hole when turned just right but not a round one. A typical cast iron manhole can weigh up to 500 pounds.
Not long after becoming an electrician, and shortly after the Rivers and the Rose story that I mentioned last week (see the Post “Rivers and Rose in the Power Plant Palace“), we had a cable really go to ground between the main plant and the coalyard. The cable that went to ground was called a 500 MCM cable. What this means is that 500,000 circles of 1 mil (or one milli-inch) in diameter can be put in a circle that is 500 MCM in diameter. A typical 500 MCM cable is good for a 400 amp load at 6900 volts.
For large industrial circuits, 3 phases of electricity are used instead of just one like you have in your house. With three phases of electricity, you have a constant amount of power being applied to the entire circuit at all times. With a one phase circuit, you have zero power 120 times every second. So with any “decent” power circuit, you have 3 phases of electricity.
The cable that went to ground was the coalyard station power cable. Not only were there three phases of power, but for each phase there were two 500 MCM cables. That means that this circuit was good for 800 amps of power at 6,900 volts. Giving you a capacity of 5.5 Megawatts (or 5 million, 500 thousand watts) of power. These cables were so big that a typical industrial Wire cable chart doesn’t even go this high:
In a Coal-fired power plant, you have a redundant system for everything. So, the coalyard wasn’t completely in the dark. It had just swapped over to the redundant circuit. — This always amused me. In my English and Poetry classes in College I would have points taken off for being “redundant”, but in the power plant this was necessary to keep the plant running at all times.
As I said many times 15 years later, when I was training operators and electricians to be certified substation switchmen, “I know this is boring, but you have to learn it…” (but that is another story).
So, to make a rather boring lecture shorter, I will skip the part about how we had a hypot from the T&D (Transmission and Distribution) department brought in so big that it had to come in a van. They attached it to the cables to find where the short to ground was located. I’ll skip the part about how it was decided to replace the faulty cables going to the coalyard 1/2 mile away. I’ll also skip the part about how Charles Foster was able to finagle the use of Stanley Elmore’s precious blue Mitsubishi mini-tractor to try to pull the cables from one manhole to the next (the first time anyone outside the garage was able to operate his most beloved tractor…..).
Oh, and I’ll skip the part about how 1000 feet of this cable cost about $10,000 and we had six cable to replace for a cost of about $320,000 just for the cable… I’ll also skip the part about how this little tractor was too small to pull the cables through the manholes from manhole to manhole up to the coalyard, so we sent in for the big guns from the T&D department to use their equipment that pulled the cables through the manholes as easy as pulling the wool over Gene Day’s eyes while playing a joke on him. (Don’t get me wrong…. I know in his heart, Gene Day really appreciated a good joke. Gene Day is one of the best men I have ever been able to call “Friend” — which I would do shortly after playing a joke on him, after I returned to consciousness).
Anyway, after this episode was all over it was decided that something needed to be done about how all the manholes from the plant to the coalyard were always full of water. You see, the manholes were easily deeper than the lake level so water naturally leaked into them. Each of them had a pump in them that was supposed to keep them dry, but somewhere along the line, in the 5 years the plant had been in operation, each manhole pump had failed at one time or other… When pumping out the first manhole, it took days, because as you pumped out that first manhole, water would run from one manhole to the other as you actually ended up pumping out all the manholes down to the point where the cables went from one manhole to the other.
So, none other than the “newbie” was appointed as the keeper of the Manhole pumps. Yep. That would be me. So, for the next few months I spent almost all my times pumping out manholes and repairing all the pumps that had been submerged in water for years. This was my first real job.
This was my real introduction to becoming a real plant electrician (You can see how I really like using the word “real”). The most common job of an electrician was to take a motor that had failed or was scheduled to be overhauled and repair it and put it back in place to continue on it’s “tour of duty”. It’s amazing how you can take a motor that has failed, and you can “rebuild” it and put it back in operation. — This has come in handy at home as the cooling fan motor on the air conditioner unit on your house goes out every few years. I have yet to call an air conditioner man to my current house where I have lived for 11 1/2 years (now 18 years).
I remember that Charles Foster had told me that “paperwork” was very important when it came to motors. A history had to be kept. Certain steps had to be performed before, during and after repairing a motor. It had to be meggared properly (see the post from last week to learn more about meggars: Rivers and a Rose of the Power Plant Palace).
So, I asked Ben Davis if he could show me what I needed to do to fix a motor. His immediate indignant response was, “What? You don’t know how to fix a motor?” My response was, “No, I don’t know. Would you show me?” Ben, who up to that point had presented himself with displeasure at my presence in the shop, suddenly smiled and said, “Sure! Let me show you what you need to do!”
Ben showed me all the steps you go through to repair and “document” a motor repair in great detail. I was glad that I had found that Ben was just putting on a front of disgust at my presence in the Electric shop only to show me at the “proper” time that I had been “misjudging” him as being a grumpy person when he wasn’t really. There is a certain art to this which I describe in detail in this post: “Power Plant Art of Making a Bad First Impression“.
I had figured, before this time, that Ben really had a kind heart because I figured that if Diane Lucas and Andy Tubbs, who I both admired greatly considered Ben as a good friend, then he must really be a good guy underneath, even though he was keeping this hidden from me.
I knew the moment he smiled at my response when I told him I really didn’t know anything, that Ben had a kind heart. He couldn’t hide it any longer. If I had asked the same thing to OD McGaha, one of the other B Foremen in the shop, for instance, he would have told me to go to hell. But not Ben.
I have more to tell you about Ben, but I’ll save that for a later post. For now, I’ll just say that though Ben may not have known it during the time I spent as an electrician, he has always been close to my heart. I have always had Ben and his family in my daily prayers from the day that he smiled at me and explained to me how to repair a motor.
So, how does a lone newbie electrician pull a 500 pound lid off of a manhole by himself? Well. He uses a Manhole cover puller of course.
Ok. Our manhole cover puller wasn’t blue like this, but it had a similar shape. With a simple tool like this a 500 pound manhole cover could be popped out of the hole and dragged away. So, I used this tool as my one man crew (myself) went from manhole to manhole, where I pumped each out and lowered a ladder into each hole and disconnecting the drenched motor and brought it back to the shop where I dried it out (using the hot box in the shop that doubled as a heater for lunches), and repaired it and re-installed it.
We had all the manholes in the plant identified. I painted the numbers on each lid with orange paint. It was while I was working in the manholes 15 feet below ground that I appreciated the round manhole. I knew that as long as that manhole cover was round, it couldn’t accidentally be knocked into the hole only to crush me to death below.
Other things were of concern in the manholes where I worked… For instance, many of these holes had been underwater for at least a couple of years, and the entire manhole was covered with a kind of slime. there were also high voltage cables that had splices in some of the manholes, and I remember Gene Roget telling me that he had seen sparks flying off of some of them when they were hypoting the cables looking for the ground. The dank smell of the manholes made you think that there were probably some kind of “swamp gases” in there.
Nevertheless, when I grew weary of dragging the heavy shellacked wooden ladder from hole to hole, I devised a way to climb down into the manholes using the drain pipe from the motor. This was before OSHA had implemented all the confined spaces rules in 1994 that would have prevented me from entering a manhole alone. I was improvising and taking a risk of falling and hurting myself each time I entered a manhole.
I ran into one of the reasons for not leaving a person in a manhole alone one time when I was working in a manhole near the intake house and another crew drove up and parked their truck near the hole I was working in. I remember that while I was working there, I suddenly became nauseous. Not sure why, I climbed out of the hole.
The truck that had been left idling nearby had been emitting toxic fumes that had looked for the lowest place they could settle, and that happened to be in the manhole where I was working. After that, I always kept an ear out for any motor vehicles nearby when I was in a manhole.
Ten years later, in 1994, OHSA added some new laws to the books that made it mandatory to have a “hole watch” stand outside a hole watching you while you worked in a manhole. You even had to have a safety harness tied to a safety hoist so that if you passed out while in a manhole the hole watch could pull you out without having to enter the hole.
Needless to say. I got my feet wet as an electrician popping in and out of manholes like the gopher in the arcade that you try to bop on the head.
One interesting story that happened during this time happened when Blake Tucker, who had been a summer help with me in the garage, and then later became a summer help in the electric shop, was sitting with me while we were going to fix a pump in manhole 215 (I believe this is the number of the manhole next to the intake where the fly ash pipes go over the intake).
The hole was full of water, and the pump had naturally tripped the breaker….. For some reason I decided to go into the intake switchgear and reset the 120 volt breaker to the pump in the Distribution Panel. When I did. I returned to the hole where Blake was waiting for me. I reached down into the hole with my foot and I kicked the drain pipe that rose from the pump and made a 90 degree turn up close to the entrance.
When I kicked the pipe, the motor actually began running. We could see it 15 feet below us in the clear water running. It was an open face motor, meaning that it wasn’t sealed and made to be a submersible pump, yet it was running under water. A year later we decided that it made more sense to replace all the open motors with submersible pumps.
Blake Tucker and I watched for 1/2 hour as the pump sucked out the water from the manhole. When the level of the water reached the top of the motor, the outboard fan that had been slowly rotating all of the sudden kicked into high gear and we could see that the pump had been running at full speed all along.
This fascinated me. I figured the water must have been pure enough not to be too conductive (pure water is a natural insulator…. oddly enough). We could easily see this pump through 15 feet of water, so it must have been pretty clean. That was the only time I have ever seen an open motor happily running submersed in water… It is not something you see every day….. for instance…. It is not every day that you see a janitor with a Psychology major acting like an electrician sitting beside a manhole staring down into the darkness in a power plant either. But there you are…
Originally Posted on February 15, 2013:
My first job, where I wasn’t working for myself, was when I was 14 years old and I became a dishwasher in a German Restaurant called Rhinelanders in Columbia Missouri. It felt good feeding dishes through the dishwasher, and scrubbing pots and pans because I knew that in the scheme of things I was helping to feed the customers the best German food in a 60 mile radius. Later when I went to work for the Hilton Inn as a dishwasher, I was serving a lot more people as they would host banquets with 100’s of people at one time. After that I went to work for Sirloin Stockade as a dishwasher, busboy and finally a cook. The number of people that would go through that restaurant in one day dwarfed the number of people we would serve at the Hilton Inn.
Nothing prepared me for the massive amount of people whose lives are touched each day by a Power Plant Electrician! Or any Power Plant employee for that matter. Our plant alone could turn the lights on for over one million people in their homes, offices and factories. As a summer help mowing grass and cleaning up the park each week removing dirty diapers and rotting fish innards it never really had the impact that becoming an electrician did.
Part of the routine as an electrician was to do preventative maintenance on equipment to keep things in good working order. We performed substation inspections, emergency backup battery checks. We changed brushes on the generator exciter, performed elevator inspections and checked cathodic protection to make sure it was operational. At certain times of the year we would check out the plant freeze protection to make sure the pipes weren’t going to freeze come winter. I also worked on maintaining the precipitator equipment. All of these things were needed to keep the plant running smoothly, but, though they were each fun in their own way, they didn’t have the impact on me that fixing something that was broken did. (ok. two paragraphs ending in the word “did”… what does that tell you?).
I used to love getting a Maintenance Order that said that something was broken and we needed to go fix it. It may have been a motor that had a bad bearing, or a cooling system that had shutdown, or the Dumper that dumped the coal trains had quit working. One of my “speci-alities” (I know. I misspelled that on purpose), was working on elevators. — I will save my elevator stories for later.
When I was working on something that was broken, I could see more clearly how my job was related to keeping the lights on throughout the area of Oklahoma where our company served the public. Depending on what you were working on, one wrong slip of the screwdriver and “pow”, I could make the lights blink for 3 million people. I will talk more about certain events that happened throughout the years that I worked at the plant where things that happened at the plant were felt throughout our electric grid.
Sometimes even as far away as Chicago and Tennessee. There was a “club” for people that shut a unit down. It was called the “500 Club”. It meant that you tripped the unit when it was generating 500 or more Megawatts of power. I can say that “luckily”, I never was a member of that club.
Ok, so a broken elevator doesn’t directly impact the operation of the plant, but it was, during more than one occasion, a life threatening situation considering that a few times the elevator would pick the most opportune time to stall between 200 and 225 feet up the elevator shaft full of elderly visitors that were touring our flagship Power Plant on their way back down from experiencing the great view of the lake from the top of the boiler. (I know. My college English Professor would have a heyday with that run-on sentence). — actually, that sentence was so long, I think I’ll make it the only sentence in the entire paragraph, — well, except for my comments about it….
Charles Foster, my foreman and best friend, took me up to the top of the boiler soon after I became an electrician and showed me the “Elevator Penthouse”. I know. “Elevator Penthouse”… Sounds like a nice place…. Well. It wasn’t bad after you swept out the dead moths, beetles and crickets that had accumulated since the last Elevator Inspection. It was a noisy room on the top of the elevator shaft where the elevator motor buzzed as it pulled the elevator up and let it down. Stopping on floors where someone had pushed a button.
I told you earlier that my elevator stories will be in a later post, so for this story, I’ll just say that Charles set me down on my tool bucket (which doubled as my portable stool and tripled as my portable trash can), in front of a panel of about 100 relays all picking up and dropping out as the elevator made its way up and down. He told me to study the blueprints that hung on the side of the panel and watch the relays until I understood how it all worked.
So, one afternoon, I sat there for about 4 hours doing nothing but watching relays light up and drop out. On the other side of that panel were the main relays. There were relays there we called “Christmas Tree” relays because they looked like a fir tree. I made some notes on a piece of paper about the sequence that the relays would pick up and drop out that I kept in my wallet.
I used those notes years later (in 2000) when I was writing task lists in SAP (our Enterprise Resource Planning computer system) on how to troubleshoot the elevator controls. Anyway, that was how I learned all about how elevator logic works. You know what? It is just like writing a computer program using computer code. It is basically a set of instructions with rules built-in, only it was done with relays.
Well. Back to helping humanity…. So, usually when we were working on something that was broken there was an operator somewhere that was waiting for the equipment to be repaired so that they could go on with their job. Sometimes the Shift Supervisor would be calling us asking us periodically when we were going to be done because they were running low on coal in the silos and were going to have to lower the load on the units if we didn’t hurry up. It was times like that when you fixed the kill switch on the side of the 10 or 11 conveyor that supply the coal to the plant from the coalyard that you really understood just where you stood with your fellow man.
I am writing about this not because I want to pat myself on the back. Though I often did feel really proud as I returned to the truck with my tool bucket after coming down from a conveyor after fixing something. I would feel like taking a bow, though I was often by myself in situations like that when I wasn’t with my “bucket buddy”. At least the Shift Supervisor and the control room operators were very grateful when you would fix something critical to keeping the plant operating at full steam (and I mean that literally…. The electricity is made by the steam from the boiler that turned the turbine that spun the generator).
No. I am writing about this because it would hit home to me at times like these how much each of us depend on each other. We all know about how important it is to have a police force keeping order and having fire fighters and paramedics on standby to rush to protect families in time of distress. People in jobs like those are as obvious as the soldiers that protect our nation.
I think the majority of us have a much bigger impact on the rest of society than we realize. I think the Power Plant Men and Women that I worked with never gave it much thought. Like the person washing dishes in a restaurant, they didn’t look at themselves as heroes. But they are (I know… Sentence fragment). Each day they moved through an environment where a boiler ghost could reach out and grab them. They distinctively know that they are standing next to a dragon that could wake up at any moment and blast them from the face of the earth, but they don’t let it deter them from the immediate job at hand.
When the boilers were being brought on line for the first time in 1979 and 1980, when you walked through the boiler area, you carried a household straw broom with you that you waved in front of you like someone knocking spider webs out of the way (I called it searching for the boiler ghost). It was explained to me at the time that this was done to detect if there was steam leaking from the pipes. If steam was leaking from some of the pipes, you wouldn’t be able to see it, but if you stepped into the flow of the steam, it could cut you in half before you even realized there was something wrong. When the steam hit the broom, it would knock the broom to the side, and you would know the leak was there. Kind of like the canary in the mine.
I remember one day when everyone was told to leave Unit 1 boiler because during an emergency, the entire boiler was at risk of melting to the ground. If not for the quick action of brave Power Plant Men, this was avoided and the lights in the hospitals in Oklahoma City and the rest of Central Oklahoma didn’t blink once. The dragon had awakened, but was quickly subdued and put back in its place.
I entitled this post “Serving Mankind Power Plant Style”, but isn’t that what we all do? If we aren’t serving Mankind, then why are we here? Today I have a very different job. I work at Dell Inc., the computer company. Our company creates computers for people around the world. We create and sell a computer about once every 2 seconds. At the electric company we had about 3,000 people that served 3 million. At Dell, we provide high quality computers for a price that allows even lower income families to enter the computer age. Computers allow families to connect with each other and expand their lives in ways that were not even conceived of a few years ago.
Even though I spend my days serving my internal customers at Dell, I know that in the big scheme of things along with over 100,000 other employees, I am helping to impact the lives of over a billion people worldwide! I wouldn’t be able to do much if down the road the brave men and women at a Power Plant weren’t keeping the lights on. It is kind of like the idea of “Pay it Forward.”
So, the bottom line of this post is… All life is precious. Whatever we do in this life, in one way or other, impacts the rest of us. We go through life thinking that we live in a much smaller bubble than we really do. The real bubble that we live in is this planet and just like every cell in our body is in some way supported by the other cells, it is that way with us. Don’t discount what you do in life. It may seem insignificant, but the smile you give to someone today will be “paid forward” and will impact every one of us.
Comments from the Original Post:
Far too few understand this, very well said, my friend.
Ron Kilman February 16, 2013
I remember one time at the Seminole Plant when we had a steam leak on a Unit 2 throttle valve. You could hear it (over the roar of the turbine room) but you couldn’t see it (superheated steam is invisible). Martin Louthan and Ralph McDermott found the leak with a “red rag” on the end of a broomstick.
Life is precious, or it’s just another commodity, right? And that’s right down the center of the Left/Right divide…
Abortion debates sit astride that divide; healthcare is now crossing it as government undertakes how much to spend on various age groups.
Another side of it provided the sense of responsibility that led Power Plant Men to sacrifice and risk when those were needed. At one time, those attitudes would have been taken for granted, normal and to be expected… something that comes clear in all the Power Plant stories.
Comments from the Previous Repost:
February 20, 2014