Tag Archives: Clearance procedures

Power Plant Men Learn to Cope with “Boring”

One of the most exhilarating moments a Power Plant Man may experience is when, while wearing a pair of high voltage gloves, they crank the handle of a High Voltage Switch closed in a substation.  The booming sound of the electricity crackling overhead and the echoing off of the hills and trees a mile away comes rumbling back!  I never could understand why the training required to be a certified substation switchman had to be the most boring class a Power Plant Man had to sit through.

An Electric Substation. Who would ever want to damage at something so beautiful?

An Electric Substation. Isn’t it beautiful?

I remember when I was young, every child had their own trampoline in their bedroom.  When your mom or dad confined you to your room, you could always find entertainment by jumping on the bed.  Then throwing up the blanket and letting it fall in a way that created a big blanket bubble, then you could plop yourself down in the middle as the mushroomed bed sheet burped the air out.

Once when I was young, my dad took my brother and me to Saint Louis because he was attending a meeting.  He was in the meeting most of the day, as we stayed in the hotel room.  This was back when you didn’t have 24 hour cable TV.  The day whizzed by as my brother and I jumped around between the two beds.  Leaping as high as we could, and pouncing from one bed to the other.  When our dad arrived after a day in meetings, he didn’t find a couple of young boys staring at the walls, he found two worn out kids who had just had one of the funnest days we could remember…. being cooped up in a hotel room all day long.

Contrast that to the first time I attended Substation Switchman Certification training.

The instructor explained at the beginning of the day long class that he was required to read through the company policies and procedures on substation switching before we were allowed to take the test.  There were a number of procedures that were practically duplicates of each other, so we had to listen to the same boring documents being read to us over and over again throughout the day.  This didn’t include just the switching procedures in the switchyard.  It also included the clearance procedures required before and after the switching has occurred.

Six hours later, I thought my eyelids had grown little lead weights on the end of every eyelash (and if you have ever seen how many eyelashes I have, you would know how serious of a situation this was).

That wasn’t the worst of it.  Switchman training back then was required every two years.  Think about this.  I was an electrician for 18 years.  During that time, I had to take Switchman training 7 times!  Each time the instructor had to read the entire text of the switchman policies and procedures.  Think of the most boring lecture or sermon you ever had to sit through, then multiply it by six, and you will understand the agony we had to endure each time to receive the Certified Switchman card for our wallets.

During the summer of 1995, after we had downsized to where we only had 7 electricians at the large coal-fired power plant in North Central Oklahoma, we decided we needed to train more operators to be switchman.  After all, they had the clearance part down already, and basically did lower voltage switching in the switchgears.  It made a lot of sense.

We told the switchman trainer that we wanted to add some hands-on practical training to the course to try to make training more exciting.  Andy Tubbs, the foreman who was also an electrician and long time switchman, worked to arrange it so that we could have the operators switch out a section of the substation after they had learned the boring part of their training.

Andy Tubbs - True Power Plant Electrician

Andy Tubbs – True Power Plant Electrician

After an entire day of sitting in a classroom.  The switchmen trainees had a real life opportunity to watch and experience switching out a real section of the substation.  They could wear the high voltage gloves and open the switches.

High Voltage gloves like this

High Voltage gloves like this

We also took switching orders and added some errors to them, and asked the students to review the orders to see if they would approve the switching before they went to the substation and to make any corrections necessary.  This is one of the steps a switchman is required to do before going out to switch.  They have to review each step of the switching and approve them.

Two years later in 1997, I was asked to go to Oklahoma City and become certified as a Switchman Trainer.  I remember going to the training center just north of Norman Oklahoma where I met our instructor, Harry McRee.  He was a trainer in his early 50’s.  He had been a safety trainer for years.

Harry McRee's Business Card

Harry McRee’s Business Card

Harry explained to us that he would like to make the switchman training more interesting, but the company’s requirements demanded that all of the documentation be read through entirely every time a person was re-certified.  Since the documentation took most of the day to read, his hands were sort of tied when it came to making the class more interesting.

To give you an idea… here is how many steps it takes just to take a clearance on a breaker in a plant…. We had to review each step of the process:

Clearance Procedures

Clearance Procedures

As a side note… In 1993, I had received a Masters in Religious Education from Loyola University in New Orleans.  My emphasis was on Adult Education.  So, when I went back to the plant and began developing the class for our plant, I thought I should be able to come up with some way to make the class more interesting.

I also thought that if it was possible for a couple of kids to keep themselves entertained all day just with a couple of beds in a hotel room, then something should be able to be done to make this ultra-boring class, more entertaining.

Since I was the “computer person” at the plant, I decided that I would use my computer as a learning aid.  I went to our substations and took pictures of everything I could find, so I could add them to a PowerPoint Project.  PowerPoint was fairly new at the time, so I decided to dazzle the class with animated fly-ins and popups, and cool transitions.  I also consolidated the various documents so that I wasn’t repeating myself throughout the day.  I brought my computer from home and set it up in the conference room.

I also employed my daughter Elizabeth to help me.  I figured if she could teach some of the training, and the students could see that even a seven year old can learn this, then maybe they would be a little more interested.  I had recently bought a new Ball Camera for my computer.  It was a new thing to have a camera on your computer.  They weren’t really used for things like Skype back then, since you only had 28,800 baud modems, which doesn’t give you very much bandwidth.  So needless to say.  No one in the room knew what that little white ball was.

White ball computer camera

White ball computer camera

I had my daughter dress up in one of my wife’s lab coats and wear over-sized glasses to give her the look of a teacher.  Then we created a number of short film clips that gave specific instructions.  Here are a few screenshots from the short videos we made:

Elizabeth, The Switchman Trainer

Elizabeth, The Switchman Trainer

At any moment her video would come flying in and she would often say….. “Look Class!  I know this is boring, but you HAVE to learn it!”

She would also fly in and say, “Pay Attention!  This is on the test!”

There were still a couple of videos that the switchmen-in-training had to watch that were boring, especially since we had all watched them many times in our careers.  I knew that during the videos, many would be falling asleep, so, I took my ball camera with me and kept it sitting on the table while we went through the training.  No one really knew what it was.

While we were watching the first boring video, I sat looking at my computer monitor, which no one in the room could see.  What I was doing was acting like I wasn’t paying any attention to anyone when I really was.  I had the ball camera in my hand.  I was looking for anyone who was dozing off.  Then I would take a movie clip of them nodding off.  Some fighting to keep their eyes open.  Others leaning way back in their chair with their mouth hanging wide open fast asleep.

I took the movie clips and put them about 5 slides later in the next section we were going to cover.  Just when they were ready to be bored from the next section of the class, I would present a slide to them with movie clips of them sleeping during the videos and Elizabeth would slide in from the bottom of the slide and say, “Look Class!  I know this is boring, but you HAVE to learn it!”

People Sleeping in Chairs. Just random pictures from Google. Not actual Power Plant Men

People Sleeping in Chairs. Just random pictures from Google. Not actual Power Plant Men

That was the clincher.  Once they realized that I had taken movie clips of them sleeping in the class just a few minutes earlier, they were all wide awake the rest of the day.  No one dared to nod off again.  It worked great!  When the second video was playing, you can be sure that everyone in the room was wide-eyed and wide awake.

When it came to the part where they took their test, they could use any notes they had taken.  Since Elizabeth had popped in and notified them about the parts that were going to be on the test, they were all prepared.  Here is a copy of the test they took:

Switchman Training Final Exam

Switchman Training Final Exam

Isn’t it funny that back then, you regularly used your Social Security Number for things like this?  We wouldn’t think of doing that today.

Later, after the class was over, Harry McRee, the trainer that had trained me in Oklahoma City, had heard how I had made the class interesting. So, he called me and asked if he could come out to our plant and see what I had done.  When he arrived I showed him all my material and gave him a copy of the PowerPoint and videos.  I told him he was free to use them however he wanted.

Because of this, I was asked to train the Power Plant Man in some other areas including general Windows training.  When a job to be the “official” trainer opened up at the plant, I applied for it…. but that is a topic for another post.  See the post “Power Plant Train Wreck“.

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How Many Different Power Plant Man Jobs?

In the morning when a Power Plant Man drives through the gate at the plant, with the boilers and smoke stacks looming ahead of them, they know that whatever lies ahead for them can be any one of over 20,000 different Power Plant Man Jobs!  Yes.  That’s right.  There are over 20,000 separate jobs that a person can be assigned on over 1,000 different pieces of equipment.

Power Plant at sunset

Power Plant at sunset

The bravery brings to mind the “Charge of the Light Brigade” (by Alfred Lord Tennyson), where “…All in the Valley of Death rode the six hundred”… only there were about 44 He-men and Women to repair whatever was in need of repair that day.  And as in the commemorative poem about the Battle of Balaclava where “… Cannon to the right of them, Cannon to the Left of them, Cannon in front of them… Into the Jaws of Death, Into the Mouth of Hell Rode the Six Hundred.”  Or 44 in the case of the Power Plant Men and Women.

The Charge of the Light Brigade

The Charge of the Light Brigade

It is true of the bravery possessed by True Power Plant Men and Women as they go about their daily quest for perfection.  Unlike the Charge of the Light Brigade, who through an error in the command structure was ordered to perform a suicide mission, Power Plant Men go into daily battle well prepared using the correct tools, Safety Gear, Clearance Procedures and the knowledge of how to perform any one of the 20,000 jobs that could be assigned to them on any given day.  (wait!  Did I just create an extremely long run-on sentence? — No wonder I could never get an A in English class!).

As Lord Tennyson Memorialized the Battle of Balaclava in 1854 by writing the poem, “The Charge of the Light Brigade”, one day when I showed up to work during the spring of 1998, I was assigned a similar task at the Coal-fired Power Plant in North Central Oklahoma.  “What’s that you say? Similar to writing the Charge of the Light Brigade?”  Yeah.  You heard me.  I was given the job of chronicling each and every task that a Power Plant Man or Woman could possibly ever perform at the Power Plant.

For the next three years, I spent 50% of my time at the plant sitting in front of a computer in the Master Print Room (where the master blueprints for the entire plant are kept) entering each task into the program called SAP.  You may have heard me mention this program before.

SAP Logo

SAP Logo

We had started using SAP a year earlier at the Electric Company.  The benefit of using this product was that it connected all of the functions of the company together into one application.  So, as soon as a Power Plant Man took a part out of the warehouse, it was reflected in the finance system on the Asset Balance sheet.  When our time was entered into SAP, the expense was calculated and charged to the actual piece of equipment we had been working on during that day.  It gave us a lot of visibility into where and how the company was spending their money.

This became even more useful if we were able to tell SAP more and more about what we did.  That was where Ray Eberle and I came in.  Ray was assigned to enter all of the Bill of Materials for every piece of equipment at the plant.  I was assigned the task of entering all of the possible jobs that could be performed at the plant into SAP.

I entered jobs into a section called “Task Lists”.  When I created a task about a specific job, I had to tell SAP all about how to perform that job.  This is referred to as “Expert Data” in the world of Enterprise Software. (sorry to bother you with all these boring technical terms).

Each task had to include any Safety Concerns about doing the job.  It included a list of instruction manuals for the equipment that needed to be repaired and where to find them.  I had to the include the Safety clearance procedure that needed to be performed in order to clear out the equipment before working on it.

The Task also included all the parts that could be used to fix the equipment if something was broken along with the warehouse part number.  Then I would add a list of tools that would be used to perform the job.  This would include every wrench size, screwdriver, soft choker, come-along, pry bar, and nasal spray that might be needed for the job (well, you never know… there could be job that required the use of nasal spray).  Ok.  You have me… I only threw that in there because I found this great picture of Nasal Spray on Google Images and this was the only way I think of to show it to you:

Nasal Spray

Nasal Spray

Finally I would list each of the steps that a person would take to fix the equipment they were assigned to repair.  This was a step-by-step procedure about how to perform the job.

My first thought when I was assigned the job of chronicling every possible job a Power Plant Maintenance Man could perform was “Great!  I will get to work on the computer!  Everyone will be glad to help me with this task as it will make their lives easier!”  Well… After I began the task of collecting information about the jobs, I unexpectedly found a lot of opposition to the idea of listing down each of the steps that a Power Plant Man performed to do their job. — Can you guess why?

Well… Yeah.  It’s true that I have an annoying personality, and sometimes I may come across as unpleasant, but that wasn’t the main reason.  Here is what happened….

When a Maintenance Order was created, one of the planners, Either Ben Davis (Planner 3) or Tony Mena (Planner 4) would flag the work order as needing a Task created for that particular job.

Ben Davis

Ben Davis

I would pull up the list of work orders and start creating the task list for that job.  I could tell who was assigned to it, so I figured I would just go up to them and ask them how they were going to fix the equipment.

I remember going up to the first person on my list (Earl Frazier) the first day and explaining to him what I was doing.  I asked him if he could tell me the steps to replacing the tail roller on belt 18 in the Surge Bin Tower.  His response was, “Why should I tell you?  You will just put all of that into the computer and then when you have described how to do all of the jobs, they can just get rid of us and hire some contractors to do our jobs.”

A conveyor Drum Roller similar to the one on the coal conveyor belts

A conveyor Drum Roller similar to the one on the coal conveyor belts

Oh… I hadn’t thought about that.  It seemed unlikely, because there is a big difference between having a low wage contractor working on something and a dedicated Power Plant Man.  There just isn’t any comparison.

In order to write up the task for this job, I just waited until the men were up in the Surge Bin Tower pulling the roller off of the belt, and I went up there and watched them.  I took notes of all of the tools and equipment they were using, and asked one of them the steps they were taking to get the new roller up to the tower, and how they were taking the old one out, etc.

Ok… I wasn’t going to do this… but I can feel your anticipation clear from here while I am writing this, that you really want to know what kind of tools it took to pull the roller from the Surge Bin Tower Conveyor belt….  Here is a list of just the tools needed….  just warning you… reading this list of tools just may cause you to drop whatever you are doing and drive out in the country to your nearest Power Plant and apply for a job…. just to warn you… if you don’t think that would be good for you, you may want to skip this next paragraph.

One 9 Foot Extension Ladder.  Two 1-1/2 ton come-alongs, and one 3/4 come-along. Two large pry bars, a 15/16 in. and 3/4 inch sockets, an air or electric impact wrench (to be used with the sockets).  An 8 foot step ladder.  One can of WD-40.  a 3/8 in. screwdriver.  Oxygen-Acetylene tanks with Torch, a Welding machine, two 8 ft. 2 by 4’s (that’s two pieces of wood).  A hammer, a 1/8 in. wrench.  One small pipe wrench.  One hook to hold up the roller.  Three extension cords, with adapters for the coal-handling safety plug-ins.  One 4 in. electric grinder.  Two 6 in. C Clamps and four 6 ft. Steel Chokers.

I decided that I would make things easier for myself up front by working on all of the electrician maintenance jobs first since I knew how to do most of those already.  So, I spent the first year almost solely working on Electrical and Instrument and Control jobs.  I could easily write the task lists for these, because I new all of the steps.

For instance… If I needed to take a clearance on the A Tripper Drive motor, I knew that the breaker was on the Motor Control Center (MCC) 13B Cubicle 1C already.  I didn’t have to even look that one up. (I often wondered what they were thinking when they put Tripper B on MCC 13B Cubicle 2B.  Why not put it in the same place (1C)  on the next Motor Control Center?  It would make things less confusing  — Just things I think about when I’m sitting on my “thinkin’ chair”).

Power Plant Thinkin' Chair

Power Plant Thinkin’ Chair

Some tasks were short and easy.  Others were novels.  Take “Elevator is Malfunctioning” Maintenance order.  I included all sorts of troubleshooting tips for that one.  I even drew a sort of diagram of relays showing how they should be picked up and dropped out as the elevator went up and down…   When the elevator was going up, I put in a table of relay positions like this (U means the relay is picked up, D means it is dropped out).  Those names at the top are the names of the relays.

Elevator DA UA HS 2LC LR LRD LRU
At Rest D D D D U D D
At Start up D U D U D D D
Running Up D U U U D D D
Slowdown up D D D U D D D
Slowdown 2 up D D D D D D U
Slowdown 3 up D D D D U D U
At Stop up D D D D U D D

I wrote a similar one for when the elevator was going down.

Anyway….I mentioned a couple of weeks ago that Ray Eberle and I worked together side-by-side for most of the three years while I was writing the task lists (see the post “Tales of Power Plant Prowess by Ray Eberle“).  After I had written a number of novels about different Electrician jobs in the form of task lists, I began working on the general maintenance tasks.

After a while the Mechanics came around and saw the benefits of the task lists.  I remember one of the men who had been the most vocal about not telling me how to do his job (yes.  Earl Frazier) came up to me after I had written a task list about changing out the number 2 conveyor belt gear box and he asked me to add another wrench to the list.  He said, that they had to go all the way back down the belt at the coal yard, drive back to the shop and retrieve the wrench, all because they hadn’t taken it with them the first time.  I added it in a heartbeat and he left smiling.

Earl-Frazier

Earl Frazier

Every once in a while I would run across a Maintenance Order where I could be somewhat creative.  For instance, I had to write a task list about how to inspect the railroad tracks and right-away from the plant to where the tracks entered the town of Red Rock, Oklahoma about 5 miles away.

After explaining how the person connected the railroad truck to the tracks and drove on the tracks toward the growing Metropolis of Red Rock (population 282).  I explained about how they were to make sure that all the wildlife was being treated well.  I also said that when they arrived at Red Rock, they should go into the feed store and build up our public relations by striking up friendly conversations with the “locals”.

After completing over 10,000 different task lists…..  I had begun to get into a routine where I felt like my creativity was becoming a little stifled.  Then one day, Ray Eberle suggested that when I’m writing my task lists, I should think about how Planner 4 (Tony Mena) would like to see something a little more exciting than the usual…. “this is how you fix this piece of equipment” task list…

One day I remember writing a task list about something called a “Sparser Bar”.  A sparser bar is something that sprays water at the bottom of a sump to stir up the coal when the pump is running so that it doesn’t build up or maybe on a conveyor belt for dust suppression.  Anyway… One of the tasks I needed to write was for a person to “create a new Sparser bar”.

An iron pipe like this with holes in it

An iron pipe like this with holes in it

I wish I had the exact Task List that I wrote.  I know that many years later, Ray Eberle sent me a copy of it when he ran across it one day, but I don’t have it readily available, so I’ll just go by memory (until someone at the plant wants to print it out and send it to me).  I don’t know… I may be able to write a better one now…. let me see….

Here are the instruction:

  1. Cut a one and a quarter inch pipe 30 inches long.
  2. Drill 1/8 inch holes along the pipe so that you have exactly 24 holes evenly distributed across the pipe leaving at least 3 inches on either side of the pipe.
    1. If you accidentally drill 23 holes, then you should add an extra hole so that you end up with exactly 24 holes.
    2. If you drill 25 holes, then you should discard the pipe and start over again.
    3. Note:  Do not drill holes that are larger than 1/8 inches in diameter as this will be too big.  If you drill holes bigger than 1/8 inches, then discard the new sparser bar and begin again.
    4. Another Note:  Do not drill the holes smaller than 1/8 inches in diameter.  If you drill holes that are smaller than 1/8 inches, then obtain a 1/8 inch drill bit and use that to increase the diameter of the holes that you have drilled.
  3. Once you have exactly 24 holes in the new Sparser Bar, then rotate the pipe 30 degrees and drill 24 more holes in the exact same positions as the holes that are now 30 degrees from where you are going to drill the new holes.
    1. Note:  Do not drill the second set of holes at a 40 degree angle from the first set of holes as this is not the correct angle.  Only drill the holes at a 30 degree angle from the first set of holes.
    2. Also Note:  Do not drill the holes at a 20 degree angle, as this is also not the correct angle from the first set of holes.
    3. Caution:  If you find that you have drilled the second set of holes at an angle other than 30 degrees, please discard the sparser bar and begin again.
  4. Once you have exactly 48 holes (count them… 24 + 24) in the sparser bar, thread both ends of the pipe.
  5. After you have threaded both ends of the new sparser bar, put a metal cap on one end of the sparser bar.
    1. Note:  Do Not under any circumstance put a metal cap on both ends of the sparser bar as this will render the sparser bar useless because there will not be any way to attach the sparser bar to the water line.
    2. Caution:  If you find that you have accidentally put a metal cap on both ends of the sparser bar, then remove the metal cap from one end (and only one end) of the sparser bar so that it can be attached to the water line.
  6. After you have completed creating the new sparser bar with two rows of 24  1/8 in. holes each at an angle of exactly 30 degrees, then using a medium pipe wrench attach the new sparser bar to the water line.
  7. Align the holes on the sparser bar so that they will have the maximum desired affect when the water is turned on.

See?  Only 7 easy steps.  I think Tony Mena said he fell asleep trying to read my “Sparser Bar Task List”.  I seem to remember Ray Eberle telling me that Tony said, “Kevin’s a nut!”

So, I have one more story to tell you about writing task lists, and then I will conclude this post with the proper conclusive paragraph….

At the plant, every piece of equipment had their own “Cost Center”.  This came in handy when you were looking for spending trends and things like that.  The structure of the cost center was like this:  SO-1-FD-A-FDFLOP   — I just made that up.  It’s not a real cost center… I just wanted to show you the structure…. The first two characters SO represent the plant.  The following “1” represents the unit.  We had 2 units.  The FD represents a “functional area” like “Force Draft Fan.  The “A” represents the number of the piece of equipment, like A or B or C, etc…. depending on how many there are.  The FDFLOP is the piece of equipment.  In this case it might be a Forced Draft Fan Lube Oil Pump.

I’m explaining this apparently boring aspect of Power Plant Life, because I made an attempt to make it a little more interesting. Here is what I did…. The Ultra Clean water that goes in the boilers and are used to turn the turbine are stored in a couple of large water tanks in front of the main power transformer.  The code for their functional area just happened to be: “AM”.  So, when you were creating a task for working on a piece of equipment on the first of the two tanks, the Functional area would look like this:  SO-1-AM-A…..

See where I’m going with this?  It looks like it is saying… “So I am a….”  This quickly reminded me of Jim Arnold, who was the Superintendent of Maintenance.  The guy that had assigned me to write all of these task lists in the first place.  He always seemed like he was king of the jungle, so I thought I would have a little fun with this….

I created a completely new Functional Area Cost Center for this water tank for a non-existent piece of equipment…. I called it the “Gould Outdoor Detector”.  So, when I created the Cost Center string, it looked like this:  SO-1-AM-A-GOD.  For the Gould Outdoor Detector.  — I know… I was being rotten.

Jim Arnold in all of his awesomeness

Jim Arnold in all of his awesomeness

Then using this cost center (that looked like “So, I am a God”), I created a Task List called:  “How to be Superintendent of Maintenance”.  I added a lot of steps to the task about how you can humiliate your employees and over work them, and kick them when they are down, and stuff like that.  I don’t remember the details.  Anyway, that was a lot of fun.

I created task lists up until the day before I left the plant.  At my going away party Jim Arnold asked me how many task lists I had created in the last three years… the count was something close to 17,800 task lists.  Yeah.  That’s right.  I wrote over 17,000 descriptions of Power Plant Man jobs in three years.  Our plant had over three times more task lists in SAP than the rest of the entire electric company put together.

You can see that I was proud of some, like my the novel I wrote about Elevator Maintenance.  You can also tell that working side-by-side with Ray Eberle kept us both entertained during those years.  We were the best of friends when I left.  I don’t know how many times I just about passed out because I was laughing so hard while we worked together.

Ray Eberle

Ray Eberle

If I were to write Power Plant Tasks today, I think I would write the ones that aren’t assigned to a Maintenance Order… they would be more like “How to be a True Power Plant Man”.  It would be a novel that would describe the tremendous character of each and every True Power Plant Man and Woman that I learned to love during my stay at the “Power Plant Palace.”

Power Plant Men Learn to Cope with “Boring”

One of the most exhilarating moments a Power Plant Man may experience is when, while wearing a pair of high voltage gloves, they crank the handle of a High Voltage Switch closed in a substation.  The booming sound of the electricity crackling overhead and the echoing off of the hills and trees a mile away comes rumbling back!  I never could understand why the training required to be a certified substation switchman had to be the most boring class a Power Plant Man had to sit through.

An Electric Substation. Who would ever want to damage at something so beautiful?

An Electric Substation. Isn’t it beautiful?

I remember when I was a young, every child had their own trampoline in their bedroom.  When your mom or dad confined you to your room, you could always find entertainment by jumping on the bed.  Then throwing up the blanket and letting it fall in a way that created a big blanket bubble, then you could plop yourself down in the middle as the mushroomed bed sheet burped the air out.

Once when I was young, my dad took my brother and I to Saint Louis because he was attending a meeting.  He was in the meeting most of the day, as we stayed in the hotel room.  This was back when you didn’t have 24 hour cable TV.  The day whizzed by as my brother and I jumped around between the two beds.  Leaping as high as we could, and pouncing from one bed to the other.  When our dad arrived after a day in meetings, he didn’t find a couple of young boys staring at the walls, he found two worn out kids who had just had one of the funnest days we could remember…. being cooped up in a hotel room all day long.

Contrast that to the first time I attended Substation Switchman Certification training.

The instructor explained at the beginning of the day long class that he was required to read through the company policies and procedures on substation switching before we were allowed to take the test.  There were a number of procedures that were practically duplicates of each other, so we had to listen to the same boring documents being read to us over and over again throughout the day.  This didn’t include just the switching procedures in the switchyard.  It also included the clearance procedures required before and after the switching has occurred.

Six hours later, I thought my eyelids had grown little lead weights on the end of every eyelash (and if you have ever seen how many eyelashes I have, you would know how serious of a situation this was).

That wasn’t the worst of it.  Switchman training back then was required every two years.  Think about this.  I was an electrician for 18 years.  During that time, I had to take Switchman training 7 times!  Each time the instructor had to read the entire text of the switchman policies and procedures.  Think of the most boring lecture or sermon you ever had to sit through, then multiply it by six, and you will understand the agony we had to endure each time to receive the Certified Switchman card for our wallets.

During the summer of 1995, after we had downsized to where we only had 7 electricians at the large coal-fired power plant in North Central Oklahoma, we decided we needed to train more operators to be switchman.  After all, they had the clearance part down already, and basically did lower voltage switching in the switchgears.  It made a lot of sense.

We told the switchman trainer that we wanted to add some hands-on practical training to the course to try to make training more exciting.  Andy Tubbs, the foreman who was also an electrician and long time switchman, worked to arrange it so that we could have the operators switch out a section of the substation after they had learned the boring part of their training.

Andy Tubbs - True Power Plant Electrician

Andy Tubbs – True Power Plant Electrician

After an entire day of sitting in a classroom.  The switchmen trainees had a real life opportunity to watch and experience switching out a real section of the substation.  They could wear the high voltage gloves and open the switches.

High Voltage gloves like this

High Voltage gloves like this

We also took switching orders and added some errors to them, and asked the students to review the orders to see if they would approve the switching before they went to the substation and to make any corrections necessary.  This is one of the steps a switchman is required to do before going out to switch.  They have to review each step of the switching and approve them.

Two years later in 1997, I was asked to go to Oklahoma City and become certified as a Switchman Trainer.  I remember going to the training center just north of Norman Oklahoma where I met our instructor, Harry McRee.  He was a trainer in his early 50’s.  He had been a safety trainer for years.

Harry McRee's Business Card

Harry McRee’s Business Card

Harry explained to us that he would like to make the switchman training more interesting, but the company’s requirements demanded that all of the documentation be read through entirely every time a person was re-certified.  Since the documentation took most of the day to read, his hands were sort of tied when it came to making the class more interesting.

To give you an idea… here is how many steps it takes just to take a clearance on a breaker in a plant…. We had to review each step of the process:

Clearance Procedures

Clearance Procedures

As a side note… In 1993, I had received a Masters in Religious Education from Loyola University in New Orleans.  My emphasis was on Adult Education.  So, when I went back to the plant and began developing the class for our plant, I thought I should be able to come up with some way to make the class more interesting.

I also thought that if it was possible for a couple of kids to keep themselves entertained all day just with a couple of beds in a hotel room, then something should be able to be done to make this ultra-boring class, more entertaining.

Since I was the “computer person” at the plant, I decided that I would use my computer as a learning aid.  I went to our substations and took pictures of everything I could find, so I could add them to a PowerPoint Project.  PowerPoint was fairly new at the time, so I decided to dazzle the class with animated fly-ins and popups, and cool transitions.  I also consolidated the various documents so that I wasn’t repeating myself throughout the day.  I brought my computer from home and set it up in the conference room.

I also employed my daughter Elizabeth to help me.  I figured if she could teach some of the training, and the students could see that even a seven year old can learn this, then maybe they would be a little more interested.  I had recently bought a new Ball Camera for my computer.  It was a new thing to have a camera on your computer.  They weren’t really used for things like Skype back then, since you only had 28,800 baud modems, which doesn’t give you very much bandwidth.  So needless to say.  No one in the room knew what that little white ball was.

White ball computer camera

White ball computer camera

I had my daughter dress up in one of my wife’s lab coats and wear over-sized glasses to give her the look of a teacher.  Then we created a number of short film clips that gave specific instructions.  Here are a few screenshots from the short videos we made:

Elizabeth, The Switchman Trainer

Elizabeth, The Switchman Trainer

At any moment her video would come flying in and she would often say….. “Look Class!  I know this is boring, but you HAVE to learn it!”

She would also fly in and say, “Pay Attention!  This is on the test!”

There were still a couple of videos that the switchmen-in-training had to watch that were boring, especially since we had all watched them many times in our careers.  I knew that during the videos, many would be falling asleep, so, I took my ball camera with me and kept it sitting on the table while we went through the training.  No one really knew what it was.

While we were watching the first boring video, I sat looking at my computer monitor, which no one in the room could see.  What I was doing was acting like I wasn’t paying any attention to anyone when I really was.  I had the ball camera in my hand.  I was looking for anyone who was dozing off.  Then I would take a movie clip of them nodding off.  Some fighting to keep their eyes open.  Others leaning way back in their chair with their mouth hanging wide open fast asleep.

I took the movie clips and put them about 5 slides later in the next section we were going to cover.  Just when they were ready to be bored from the next section of the class, I would present a slide to them with movie clips of them sleeping during the videos and Elizabeth would slide in from the bottom of the slide and say, “Look Class!  I know this is boring, but you HAVE to learn it!”

People Sleeping in Chairs. Just random pictures from Google. Not actual Power Plant Men

People Sleeping in Chairs. Just random pictures from Google. Not actual Power Plant Men

That was the clincher.  Once they realized that I had taken movie clips of them sleeping in the class just a few minutes earlier, they were all wide awake the rest of the day.  No one dared to nod off again.  It worked great!  When the second video was playing, you can be sure that everyone in the room was wide-eyed and wide awake.

When it came to the part where they took their test, they could use any notes they had taken.  Since Elizabeth had popped in and notified them about the parts that were going to be on the test, they were all prepared.  Here is a copy of the test they took:

Switchman Training Final Exam

Switchman Training Final Exam

Isn’t it funny that back then, you regularly used your Social Security Number for things like this?  We wouldn’t think of doing that today.

Later, after the class was over, Harry McRee, the trainer that had trained me in Oklahoma City, had heard how I had made the class interesting. So, he called me and asked if he could come out to our plant and see what I had done.  When he arrived I showed him all my material and gave him a copy of the PowerPoint and videos.  I told him he was free to use them however he wanted.

Because of this, I was asked to train the Power Plant Man in some other areas including general Windows training.  When a job to be the “official” trainer opened up at the plant, I applied for it…. but that is a topic for another post.

How Many Different Power Plant Man Jobs?

In the morning when a Power Plant Man drives through the gate at the plant, with the boilers and smoke stacks looming ahead of them, they know that whatever lies ahead for them can be any one of over 20,000 different Power Plant Man Jobs!  Yes.  That’s right.  There are over 20,000 separate jobs that a person can be assigned on over 1,000 different pieces of equipment.

Power Plant at sunset

Power Plant at sunset

The bravery brings to mind the “Charge of the Light Brigade” (by Alfred Lord Tennyson), where “…All in the Valley of Death rode the six hundred”… only there were about 44 He-men and Women to repair whatever was in need of repair that day.  And as in the commemorative poem about the Battle of Balaclava where “… Cannon to the right of them, Cannon to the Left of them Cannon in front of them… Into the Jaws of Death, Into the Mouth of Hell Rode the Six Hundred.”  Or 44 in the case of the Power Plant Men and Women.

The Charge of the Light Brigade

The Charge of the Light Brigade

It is true of the bravery possessed by True Power Plant Men and Women as they go about their daily quest for perfection.  Unlike the Charge of the Light Brigade, who through an error in the command structure was ordered to perform a suicide mission, Power Plant Men go into daily battle well prepared using the correct tools, Safety Gear, Clearance Procedures and the knowledge of how to perform any one of the 20,000 jobs that could be assigned to them on any given day.  (wait!  Did I just create an extremely long run-on sentence? — No wonder I could never get an A in English class!).

As Lord Tennyson Memorialized the Battle of Balaclava in 1854 by writing the poem, “The Charge of the Light Brigade”, one day when I showed up to work during the spring of 1998, I was assigned a similar task at the Coal-fired Power Plant in North Central Oklahoma.  “What’s that you say? Similar to writing the Charge of the Light Brigade?”  Yeah.  You heard me.  I was given the job of chronicling each and every task that a Power Plant Man or Woman could possibly ever perform at the Power Plant.

For the next three years, I spent 50% of my time at the plant sitting in front of a computer in the Master Print Room (where the master blueprints for the entire plant are kept) entering each task into the program called SAP.  You may have heard me mention this program before.

SAP Logo

SAP Logo

We had started using SAP a year earlier at the Electric Company.  The benefit of using this product was that it connected all of the functions of the company together into one application.  So, as soon as a Power Plant Man took a part out of the warehouse, it was reflected in the finance system on the Asset Balance sheet.  When our time was entered into SAP, the expense was calculated and charged to the actual piece of equipment we had been working on during that day.  It gave us a lot of visibility into where and how the company was spending their money.

This became even more useful if we were able to tell SAP more and more about what we did.  That was where Ray Eberle and I came in.  Ray was assigned to enter all of the Bill of Materials for every piece of equipment at the plant.  I was assigned the task of entering all of the possible jobs that could be performed at the plant into SAP.

I entered jobs into a section called “Task Lists”.  When I created a task about a specific job, I had to tell SAP all about how do perform that job.  This is referred to as “Expert Data” in the world of Enterprise Software. (sorry to bother you with all these boring technical terms).

Each task had to include any Safety Concerns about doing the job.  It included a list of instruction manuals for the equipment that needed to be repaired and where to find them.  I had to the include the Safety clearance procedure that needed to be performed in order to clear out the equipment before working on it.

The Task also included all the parts that could be used to fix the equipment if something was broken along with the warehouse part number.  Then I would add a list of tools that would be used to perform the job.  This would include every wrench size, screwdriver, soft choker, come-along, pry bar, and nasal spray that might be needed for the job (well, you never know… there could be job that required the use of nasal spray).  Ok.  You have me… I only threw that in there because I found this great picture of Nasal Spray on Google Images and this was the only way I think of to show it to you:

Nasal Spray

Nasal Spray

Finally I would list each of the steps that a person would take to fix the equipment they were assigned to repair.  This was a step-by-step procedure about how to perform the job.

My first thought when I was assigned the job of chronicling every possible job a Power Plant Maintenance Man could perform was “Great!  I will get to work on the computer!  Everyone will be glad to help me with this task as it will make their lives easier!”  Well… After I began the task of collecting information about the jobs, I unexpectedly found a lot of opposition to the idea of listing down each of the steps that a Power Plant Man performed to do their job. — Can you guess why?

Well… Yeah.  It’s true that I have an annoying personality, and sometimes I may come across as unpleasant, but that wasn’t the main reason.  Here is what happened….

When a Maintenance Order was created, one of the planners, Either Ben Davis (Planner 3) or Tony Mena (Planner 4) would flag the work order as needing a Task created for that particular job.

Ben Davis

Ben Davis

I would pull up the list of work orders and start creating the task list for that job.  I could tell who was assigned to it, so I figured I would just go up to them and ask them how they were going to fix the equipment.

I remember going up to the first person on my list (Earl Frazier) the first day and explaining to him what I was doing.  I asked him if he could tell me the steps to replacing the tail roller on belt 18 in the Surge Bin Tower.  His response was, “Why should I tell you?  You will just put all of that into the computer and then when you have described how to do all of the jobs, they can just get rid of us and hire some contractors to do our jobs.”

A conveyor Drum Roller similar to the one on the coal conveyor belts

A conveyor Drum Roller similar to the one on the coal conveyor belts

Oh… I hadn’t thought about that.  It seemed unlikely, because there is a big difference between having a low wage contractor working on something and a dedicated Power Plant Man.  There just isn’t any comparison.

In order to write up the task for this job, I just waited until the men were up in the Surge Bin Tower pulling the roller off of the belt, and I went up there and watched them.  I took notes of all of the tools and equipment they were using, and asked one of them the steps they were taking to get the new roller up to the tower, and how they were taking the old one out, etc.

Ok… I wasn’t going to do this… but I can feel your anticipation clear from here while I am writing this, that you really want to know what kind of tools it took to pull the roller from the Surge Bin Tower Conveyor belt….  Here is a list of just the tools needed….  just warning you… reading this list of tools just may cause you to drop whatever you are doing and drive out in the country to your nearest Power Plant and apply for a job…. just to warn you… if you don’t think that would be good for you, you may want to skip this next paragraph.

One 9 Foot Extension Ladder.  Two 1-1/2 ton come-alongs, and one 3/4 come-along. Two large pry bars, a 15/16 in. and 3/4 inch sockets, an air or electric impact wrench (to be used with the sockets).  An 8 foot step ladder.  One can of WD-40.  a 3/8 in. screwdriver.  Oxygen-Acetylene tanks with Torch, a Welding machine, two 8 ft. 2 by 4’s (that’s two pieces of wood).  A hammer, a 1/8 in. wrench.  One small pipe wrench.  One hook to hold up the roller.  Three extension cords, with adapters for the coal-handling safety plug-ins.  One 4 in. electric grinder.  Two 6 in. C Clamps and four 6 ft. Steel Chokers.

I decided that I would make things easier for myself up front by working on all of the electrician maintenance jobs first since I knew how to do most of those already.  So, I spent the first year almost solely working on Electrical and Instrument and Control jobs.  I could easily write the task lists for these, because I new all of the steps.

For instance… If I needed to take a clearance on the A Tripper Drive motor, I knew that the breaker was on the Motor Control Center (MCC) 13B Cubicle 1C already.  I didn’t have to even look that one up. (I often wondered what they were thinking when they put Tripper B on MCC 13B Cubicle 2B.  Why not put it in the same place (1C)  on the next Motor Control Center?  It would make things less confusing  — Just things I think about when I’m sitting on my “thinkin’ chair”).

Power Plant Thinkin' Chair

Power Plant Thinkin’ Chair

Some tasks were short and easy.  Others were novels.  Take “Elevator is Malfunctioning” Maintenance order.  I included all sorts of troubleshooting tips for that one.  I even drew a sort of diagram of relays showing how they should be picked up and dropped out as the elevator went up and down…   When the elevator was going up, I put in a table of relay positions like this (U means the relay is picked up, D means it is dropped out).  Those names at the top are the names of the relays.

Elevator DA UA HS 2LC LR LRD LRU
At Rest D D D D U D D
At Start up D U D U D D D
Running Up D U U U D D D
Slowdown up D D D U D D D
Slowdown 2 up D D D D D D U
Slowdown 3 up D D D D U D U
At Stop up D D D D U D D

I wrote a similar one for when the elevator was going down.

Anyway….I mentioned a couple of weeks ago that Ray Eberle and I worked together side-by-side for most of the three years while I was writing the task lists (see the post “Tales of Power Plant Prowess by Ray Eberle“).  After I had written a number of novels about different Electrician jobs in the form of task lists, I began working on the general maintenance tasks.

After a while the Mechanics came around and saw the benefits of the task lists.  I remember one of the men who had been the most vocal about not telling me how to do his job (yes.  Earl Frazier) came up to me after I had written a task list about changing out the number 2 conveyor belt gear box and he asked me to add another wrench to the list.  He said, that they had to go all the way back down the belt at the coal yard, drive back to the shop and retrieve the wrench, all because they hadn’t taken it with them the first time.  I added it in a heartbeat and he left smiling.

Earl-Frazier

Earl Frazier

Every once in a while I would run across a Maintenance Order where I could be somewhat creative.  For instance, I had to write a task list about how to inspect the railroad tracks and right-away from the plant to where the tracks entered the town of Red Rock, Oklahoma about 5 miles away.

After explaining how the person connected the railroad truck to the tracks and drove on the tracks toward the growing Metropolis of Red Rock (population 282).  I explained about how they were to make sure that all the wildlife was being treated well.  I also said that when they arrived at Red Rock, they should go into the feed store and build up our public relations by striking up friendly conversations with the “locals”.

After completing over 10,000 different task lists…..  I had begun to get into a routine where I felt like my creativity was becoming a little stifled.  Then one day, Ray Eberle suggested that when I’m writing my task lists, I should think about how Planner 4 (Tony Mena) would like to see something a little more exciting than the usual…. “this is how you fix this piece of equipment” task list…

One day I remember writing a task list about something called a “Sparser Bar”.  A sparser bar is something that sprays water at the bottom of a sump to stir up the coal when the pump is running so that it doesn’t build up or maybe on a conveyor belt for dust suppression.  Anyway… One of the tasks I needed to write was for a person to “create a new Sparser bar”.

An iron pipe like this with holes in it

An iron pipe like this with holes in it

I wish I had the exact Task List that I wrote.  I know that many years later, Ray Eberle sent me a copy of it when he ran across it one day, but I don’t have it readily available, so I’ll just go by memory (until someone at the plant wants to print it out and send it to me).  I don’t know… I may be able to write a better one now…. let me see….

Here are the instruction:

  1. Cut a one and a quarter inch pipe 30 inches long.
  2. Drill 1/8 inch holes along the pipe so that you have exactly 24 holes evenly distributed across the pipe leaving at least 3 inches on either side of the pipe.
    1. If you accidentally drill 23 holes, then you should add an extra hole so that you end up with exactly 24 holes.
    2. If you drill 25 holes, then you should discard the pipe and start over again.
    3. Note:  Do not drill holes that are larger than 1/8 inches in diameter as this will be too big.  If you drill holes bigger than 1/8 inches, then discard the new sparser bar and begin again.
    4. Another Note:  Do not drill the holes smaller than 1/8 inches in diameter.  If you drill holes that are smaller than 1/8 inches, then obtain a 1/8 inch drill bit and use that to increase the diameter of the holes that you have drilled.
  3. Once you have exactly 24 holes in the new Sparser Bar, then rotate the pipe 30 degrees and drill 24 more holes in the exact same positions as the holes that are now 30 degrees from where you are going to drill the new holes.
    1. Note:  Do not drill the second set of holes at a 40 degree angle from the first set of holes as this is not the correct angle.  Only drill the holes at a 30 degree angle from the first set of holes.
    2. Also Note:  Do not drill the holes at a 20 degree angle, as this is also not the correct angle from the first set of holes.
    3. Caution:  If you find that you have drilled the second set of holes at an angle other than 30 degrees, please discard the sparser bar and begin again.
  4. Once you have exactly 48 holes (count them… 24 + 24) in the sparser bar, thread both ends of the pipe.
  5. After you have threaded both ends of the new sparser bar, put a metal cap on one end of the sparser bar.
    1. Note:  Do Not under any circumstance put a metal cap on both ends of the sparser bar as this will render the sparser bar useless because there will not be any way to attach the sparser bar to the water line.
    2. Caution:  If you find that you have accidentally put a metal cap on both ends of the sparser bar, then remove the metal cap from one end (and only one end) of the sparser bar so that it can be attached to the water line.
  6. After you have completed creating the new sparser bar with two rows of 24  1/8 in. holes each at an angle of exactly 30 degrees, then using a medium pipe wrench attach the new sparser bar to the water line.
  7. Align the holes on the sparser bar so that they will have the maximum desired affect when the water is turned on.

See?  Only 7 easy steps.  I think Tony Mena said he fell asleep trying to read my “Sparser Bar Task List”.  I seem to remember Ray Eberle telling me that Tony said, “Kevin’s a nut!”

So, I have one more story to tell you about writing task lists, and then I will conclude this post with the proper conclusive paragraph….

At the plant, every piece of equipment had their own “Cost Center”.  This came in handy when you were looking for spending trends and things like that.  The structure of the cost center was like this:  SO-1-FD-A-FDFLOP   — I just made that up.  It’s not a real cost center… I just wanted to show you the structure…. The first two characters SO represent the plant.  The following “1” represents the unit.  We had 2 units.  The FD represents a “functional area” like “Force Draft Fan.  The “A” represents the number of the piece of equipment, like A or B or C, etc…. depending on how many there are.  The FDFLOP is the piece of equipment.  In this case it might be a Forced Draft Fan Lube Oil Pump.

I’m explaining this apparently boring aspect of Power Plant Life, because I made an attempt to make it a little more interesting. Here is what I did…. The Ultra Clean water that goes in the boilers and are used to turn the turbine are stored in a couple of large water tanks in front of the main power transformer.  The code for their functional area just happened to be: “AM”.  So, when you were creating a task for working on a piece of equipment on the first of the two tanks, the Functional area would look like this:  SO-1-AM-A…..

See where I’m going with this?  It looks like it is saying… “So I am a….”  This quickly reminded me of Jim Arnold, who was the Superintendent of Maintenance.  The guy that had assigned me to write all of these task lists in the first place.  He always seemed like he was king of the jungle, so I thought I would have a little fun with this….

I created a completely new Functional Area Cost Center for this water tank for a non-existent piece of equipment…. I called it the “Gould Outdoor Detector”.  So, when I created the Cost Center string, it looked like this:  SO-1-AM-A-GOD.  For the Gould Outdoor Detector.  — I know… I was being rotten.

Jim Arnold in all of his awesomeness

Jim Arnold in all of his awesomeness

Then using this cost center (that looked like “So, I am a God”), I created a Task List called:  “How to be Superintendent of Maintenance”.  I added a lot of steps to the task about how you can humiliate your employees and over work them, and kick them when they are down, and stuff like that.  I don’t remember the details.  Anyway, that was a lot of fun.

I created task lists up until the day before I left the plant.  At my going away party Jim Arnold asked me how many task lists I had created in the last three years… the count was something close to 17,800 task lists.  Yeah.  That’s right.  I wrote over 17,000 descriptions of Power Plant Man jobs in three years.  Our plant had over three times more task lists in SAP than the rest of the entire electric company put together.

You can see that I was proud of some, like my the novel I wrote about Elevator Maintenance.  You can also tell that working side-by-side with Ray Eberle kept us both entertained during those years.  We were the best of friends when I left.  I don’t know how many times I just about passed out because I was laughing so hard while we worked together.

Ray Eberle

Ray Eberle

If I were to write Power Plant Tasks today, I think I would write the ones that aren’t assigned to a Maintenance Order… they would be more like “How to be a True Power Plant Man”.  It would be a novel that would describe the tremendous character of each and every True Power Plant Man and Woman that I learned to love during my stay at the “Power Plant Palace.”

How Many Different Power Plant Man Jobs?

In the morning when a Power Plant Man drives through the gate at the plant, with the boilers and smoke stacks looming ahead of them, they know that whatever lies ahead for them can be any one of over 20,000 different Power Plant Man Jobs!  Yes.  That’s right.  There are over 20,000 separate jobs that a person can be assigned on over 1,000 different pieces of equipment.

Power Plant at sunset

Power Plant at sunset

The bravery brings to mind the “Charge of the Light Brigade” (by Alfred Lord Tennyson), where “…All in the Valley of Death rode the six hundred”… only there were about 44 He-men and Women to repair whatever was in need of repair that day.  And as in the commemorative poem about the Battle of Balaclava where “… Cannon to the right of them, Cannon to the Left of them Cannon in front of them… Into the Jaws of Death, Into the Mouth of Hell Rode the Six Hundred.”  Or 44 in the case of the Power Plant Men and Women.

The Charge of the Light Brigade

The Charge of the Light Brigade

It is true of the bravery possessed by True Power Plant Men and Women as they go about their daily quest for perfection.  Unlike the Charge of the Light Brigade, who through an error in the command structure was ordered to perform a suicide mission, Power Plant Men go into daily battle well prepared using the correct tools, Safety Gear, Clearance Procedures and the knowledge of how to perform any one of the 20,000 jobs that could be assigned to them on any given day.  (wait!  Did I just create an extremely long run-on sentence? — No wonder I could never get an A in English class!).

As Lord Tennyson Memorialized the Battle of Balaclava in 1854 by writing the poem, “The Charge of the Light Brigade”, one day when I showed up to work during the spring of 1998, I was assigned a similar task at the Coal-fired Power Plant in North Central Oklahoma.  “What’s that you say? Similar to writing the Charge of the Light Brigade?”  Yeah.  You heard me.  I was given the job of chronicling each and every task that a Power Plant Man or Woman could possibly ever perform at the Power Plant.

For the next three years, I spent 50% of my time at the plant sitting in front of a computer in the Master Print Room (where the master blueprints for the entire plant are kept) entering each task into the program called SAP.  You may have heard me mention this program before.

SAP Logo

SAP Logo

We had started using SAP a year earlier at the Electric Company.  The benefit of using this product was that it connected all of the functions of the company together into one application.  So, as soon as a Power Plant Man took a part out of the warehouse, it was reflected in the finance system on the Asset Balance sheet.  When our time was entered into SAP, the expense was calculated and charged to the actual piece of equipment we had been working on during that day.  It gave us a lot of visibility into where and how the company was spending their money.

This became even more useful if we were able to tell SAP more and more about what we did.  That was where Ray Eberle and I came in.  Ray was assigned to enter all of the Bill of Materials for every piece of equipment at the plant.  I was assigned the task of entering all of the possible jobs that could be performed at the plant into SAP.

I entered jobs into a section called “Task Lists”.  When I created a task about a specific job, I had to tell SAP all about how do perform that job.  This is referred to as “Expert Data” in the world of Enterprise Software. (sorry to bother you with all these boring technical terms).

Each task had to include any Safety Concerns about doing the job.  It included a list of instruction manuals for the equipment that needed to be repaired and where to find them.  I had to the include the Safety clearance procedure that needed to be performed in order to clear out the equipment before working on it.

The Task also included all the parts that could be needed to fix the equipment if something was broken along with the warehouse part number.  Then I would add in a list of tools that would be used to perform the job.  This would include every wrench size, screwdriver, soft choker, come-along, pry bar, and nasal spray that might be needed for the job (well, you never know… there could be job that required the use of nasal spray).  Ok.  You have me… I only threw that in there because I found this great picture of Nasal Spray on Google Images and this was the only way I think of to show it to you:

Nasal Spray

Nasal Spray

Finally I would list each of the steps that a person would take to fix the equipment they were assigned to repair.  This was a step-by-step procedure about how to perform the job.

My first thought when I was assigned the job of chronicling every possible job a Power Plant Maintenance Man could perform was “Great!  I will get to work on the computer!  Everyone will be glad to help me with this task as it will make their lives easier!”  Well… After I began the task of collecting information about the jobs, I unexpectedly found a lot of opposition to the idea of listing down each of the steps that a Power Plant Man performed to do their job. — Can you guess why?

Well… Yeah.  It’s true that I have an annoying personality, and sometimes I may come across as unpleasant, but that wasn’t the main reason.  Here is what happened….

When a Maintenance Order was created, one of the planners, Either Ben Davis (Planner 3) or Tony Mena (Planner 4) would flag the work order as needing a Task created for that particular job.

Ben Davis

Ben Davis

I would pull up the list of work orders and start creating the task list for that job.  I could tell who was assigned to it, so I figured I would just go up to them and ask them how they were going to fix the equipment.

I remember going up to the first person on my list the first day and explaining to him what I was doing.  I asked him if he could tell me the steps to replacing the tail roller on belt 18 in the Surge Bin Tower.  His response was, “Why should I tell you?  You will just put all of that into the computer and then when you have described how to do all of the jobs, they can just get rid of us and hire some contractors to do our jobs.”

A conveyor Drum Roller similar to the one on the coal conveyor belts

A conveyor Drum Roller similar to the one on the coal conveyor belts

Oh… I hadn’t thought about that.  It seemed unlikely, because there is a big difference between having a low wage contractor working on something and a dedicated Power Plant Man.  There just isn’t any comparison.

In order to write up the task for this job, I just waited until the men were up in the Surge Bin Tower pulling the roller off of the belt, and I went up there and watched them.  I took notes of all of the tools and equipment they were using, and asked one of them the steps they were taking to get the new roller up to the tower, and how they were taking the old one out, etc.

Ok… I wasn’t going to do this… but I can feel your anticipation clear from here while I am writing this, that you really want to know what kind of tools it took to pull the roller from the Surge Bin Tower Conveyor belt….  Here is a list of just the tools needed….  just warning you… reading this list of tools just may cause you to drop whatever you are doing and drive out in the country to your nearest Power Plant and apply for a job…. just to warn you… if you don’t think that would be good for you, you may want to skip this next paragraph.

One 9 Foot Extension Ladder.  Two 1-1/2 ton come-alongs, and one 3/4 come-along. Two large pry bars, a 15/16 in. and 3/4 inch sockets, an air or electric impact wrench (to be used with the sockets).  An 8 foot step ladder.  One can of WD-40.  a 3/8 in. screwdriver.  Oxygen-Acetylene tanks with Torch, a Welding machine, two 8 ft. 2 by 4’s (that’s two pieces of wood).  A hammer, a 1/8 in. wrench.  One small pipe wrench.  One hook to hold up the roller.  Three extension cords, with adapters for the coal-handling safety plug-ins.  One 4 in. electric grinder.  Two 6 in. C Clamps and four 6 ft. Steel Chokers.

I decided that I would make things easier for myself up front by working on all of the electrician maintenance jobs first since I knew how to do most of those already.  So, I spent the first year almost solely working on Electrical and Instrument and Control jobs.  I could easily write the task lists for these, because I new all of the steps.

For instance… If I needed to take a clearance on the A Tripper Drive motor, I knew that the breaker was on the Motor Control Center (MCC) 13B Cubicle 1C already.  I didn’t have to even look that one up. (I often wondered what they were thinking when they put Tripper B on MCC 13B Cubicle 2B.  Why not put it in the same place (1C)  on the next Motor Control Center?  It would make things less confusing  — Just things I think about when I’m sitting on my “thinkin’ chair”).

Power Plant Thinkin' Chair

Power Plant Thinkin’ Chair

Some tasks were short and easy.  Others were novels.  Take “Elevator is Malfunctioning” Maintenance order.  I included all sorts of troubleshooting tips for that one.  I even drew a sort of diagram of relays showing how they should be picked up and dropped out as the elevator when up and down…   When the elevator was going up, I put in a table of relay positions like this (U means the relay is picked up, D means it is dropped out).  Those names at the top are the names of the relays.

Elevator DA UA HS 2LC LR LRD LRU
At Rest D D D D U D D
At Start up D U D U D D D
Running Up D U U U D D D
Slowdown up D D D U D D D
Slowdown 2 up D D D D D D U
Slowdown 3 up D D D D U D U
At Stop up D D D D U D D

I wrote a similar one for when the elevator was going down.

Anyway….I mentioned a couple of weeks ago that Ray Eberle and I worked together side-by-side for most of the three years while I was writing the task lists (see the post “Tales of Power Plant Prowess by Ray Eberle“).  After I had written a number of novels about different Electrician jobs in the form of task lists, I began working on the general maintenance tasks.

After a while the Mechanics came around and saw the benefits of the task lists.  I remember one of the men who had been the most vocal about not telling me how to do his job came up to me after I had written a task list about changing out the number 2 conveyor belt gear box and he asked me to add another wrench to the list.  He said, that they had to go all the way back down the belt at the coal yard, drive back to the shop and retrieve the wrench, all because they hadn’t taken it with them the first time.  I added it in a heartbeat and he left smiling.

Every once in a while I would run across a Maintenance Order where I could be somewhat creative.  For instance, I had to write a task list about how to inspect the railroad tracks and right-away from the plant to where the tracks entered the town of Red Rock, Oklahoma about 5 miles away.

After explaining how the person connected the railroad truck to the tracks and drove on the tracks toward the growing Metropolis of Red Rock (population 282).  I explained about how they were to make sure that all the wildlife was being treated well.  I also said that when they arrived at Red Rock, they should go into the feed store and build up our public relations by striking up friendly conversations with the “locals”.

After completing over 10,000 different task lists…..  I had begun to get into a routine where I felt like my creativity was becoming a little stifled.  Then one day, Ray Eberle suggested that when I’m writing my task lists, I should think about how Planner 4 (Tony Mena) would like to see something a little more exciting than the usual…. “this is how you fix this piece of equipment” task list…

One day I remember writing a task list about something called a “Sparser Bar”.  A sparser bar is something that sprays water at the bottom of a sump to stir up the coal when the pump is running so that it doesn’t build up or maybe on a conveyor belt for dust suppression.  Anyway… One of the tasks I needed to write was for a person to “create a new Sparser bar”.

An iron pipe like this with holes in it

An iron pipe like this with holes in it

I wish I had the exact Task List that I wrote.  I know that many years later, Ray Eberle sent me a copy of it when he ran across it one day, but I don’t have it readily available, so I’ll just go by memory (until someone at the plant wants to print it out and send it to me).  I don’t know… I may be able to write a better one now…. let me see….

Here are the instruction:

  1. Cut a one and a quarter inch pipe 30 inches long.
  2. Drill 1/8 inch holes along the pipe so that you have exactly 24 holes evenly distributed across the pipe with leaving at least 3 inches on either side of the pipe.
    1. If you accidentally drill 23 holes, then you should add an extra hole so that you end up with exactly 24 holes.
    2. If you drill 25 holes, then you should discard the pipe and start over again.
    3. Note:  Do not drill holes that are larger than 1/8 inches in diameter as this will be too big.  If you drill holes bigger than 1/8 inches, then discard the new sparser bar and begin again.
    4. Another Note:  Do not drill the holes smaller than 1/8 inches in diameter.  If you drill holes that are smaller than 1/8 inches, then obtain a 1/8 inch drill bit and use that to increase the diameter of the holes that you have drilled.
  3. Once you have exactly 24 holes in the new Sparser Bar, then rotate the pipe 30 degrees and drill 24 more holes in the exact same positions as the holes that are now 30 degrees from where you are going to drill the new holes.
    1. Note:  Do not drill the second set of holes at a 40 degree angle from the first set of holes as this is not the correct angle.  Only drill the holes at a 30 degree angle from the first set of holes.
    2. Also Note:  Do not drill the holes at a 20 degree angle, as this is also not the correct angle from the first set of holes.
    3. Caution:  If you find that you have drilled the second set of holes at an angle other than 30 degrees, please discard the sparser bar and begin again.
  4. Once you have exactly 48 holes (count them… 24 + 24) in the sparser bar, thread both ends of the pipe.
  5. After you have threaded both ends of the new sparser bar, put a metal cap on one end of the sparser bar.
    1. Note:  Do Not under any circumstance put a metal cap on both ends of the sparser bar as this will render the sparser bar useless because there will not be any way to attach the sparser bar to the water line.
    2. Caution:  If you find that you have accidentally put a metal cap on both ends of the sparser bar, then remove the metal cap from one end (and only one end) of the sparser bar so that it can be attached to the water line.
  6. After you have completed creating the new sparser bar with two rows of 24  1/8 in. holes each at an angle of exactly 30 degrees, then using a medium pipe wrench attach the new sparser bar to the water line.
  7. Align the holes on the sparser bar so that they will have the maximum desired affect when the water is turned on.

See?  Only 7 easy steps.  I think Tony Mena said he fell asleep trying to read my “Sparser Bar Task List”.  I seem to remember Ray Eberle telling me that Tony said, “Kevin’s a nut!”

So, I have one more story to tell you about writing task lists, and then I will conclude this post with the proper conclusive paragraph….

At the plant, every piece of equipment had their own “Cost Center”.  This came in handy when you were looking for spending trends and things like that.  The structure of the cost center was like this:  SO-1-FD-A-FDFLP   — I just made that up.  It’s not a real cost center… I just wanted to show you the structure…. The first two characters SO represent the plant.  The following “1” represents the unit.  We had 2.  The FD represents a “functional area” like “Force Draft Fan.  The “A” represents the number of the piece of equipment, like A or B or C, etc…. depending on how many there are.  The FDFLP is the piece of equipment.  In this case it might be a Forced Draft Fan Lube Oil Pump.

I’m explaining this apparently boring aspect of Power Plant Life, because I made an attempt to make it a little more interesting. Here is what I did…. The Ultra Clean water that goes in the boilers are stored in a couple of large water tanks in front of the main power transformer.  The code for their functional area just happened to be: “AM”.  So, when you were creating a task for working on a piece of equipment on the first of the two tanks, the Functional area would look like this:  SO-1-AM-A…..

See where I’m going with this?  It looks like it is saying… “So I am a….”  This quickly reminded me of Jim Arnold, who was the Superintendent of Maintenance.  The guy that had assigned me to write all of these task lists in the first place.  He always seemed like he was king of the jungle, so I thought I would have a little fun with this….

I created a completely new Functional Area Cost Center for this water tank for a non-existent piece of equipment…. I called it the “Gould Outdoor Detector”.  So, when I created the Cost Center string, it looked like this:  SO-1-AM-A-GOD.  For the Gould Outdoor Detector.  — I know… I was being rotten.

Jim Arnold in all of his awesomeness

Jim Arnold in all of his awesomeness

Then using this cost center (that looked like “So, I am a God”), I created a Task List called:  “How to be Superintendent of Maintenance”.  I added a lot of steps to the task about how you can humiliate your employees and over work them, and kick them when they are down, and stuff like that.  I don’t remember the details.  Anyway, that was a lot of fun.

I created task lists up until the day before I left the plant.  At my going away party Jim Arnold asked me how many task lists I had created in the last three years… the count was something close to 17,800 task lists.  Yeah.  That’s right.  I wrote over 17,000 descriptions of Power Plant Man jobs in three years.  Our plant had over three times more task lists in SAP than the rest of the entire electric company put together.

You can see that I was proud of some, like my the novel I wrote about Elevator Maintenance.  You can also tell that working side-by-side with Ray Eberle kept us both entertained during those years.  We were the best of friends when I left.  I don’t know how many times I just about passed out because I was laughing so hard while we worked together.

Ray Eberle

Ray Eberle

If I were to write Power Plant Tasks today, I think I would write the ones that aren’t assigned to a Maintenance Order… they would be more like “How to be a True Power Plant Man”.  It would be a novel that would describe the tremendous character of each and every True Power Plant Man and Woman that I learned to love during my stay at the “Power Plant Palace.”

Power Plant Men Learn to Cope with “Boring”

One of the most exhilarating moments a Power Plant Man may experience is when, while wearing a pair of high voltage gloves, they crank the handle of a High Voltage Switch closed in a substation.  The booming sound of the electricity crackling overhead and the echoing off of the hills and trees a mile away comes rumbling back!  I never could understand why the training required to be a certified substation switchman had to be the most boring class a Power Plant Man had to sit through.

An Electric Substation. Who would ever want to damage at something so beautiful?

An Electric Substation. Isn’t it beautiful?

I remember when I was a young, every child had their own trampoline in their bedroom.  When your mom or dad confined you to your room, you could always find entertainment by jumping on the bed.  Then throwing up the blanket and letting it fall in a way that created a big blanket bubble, then you could plop yourself down in the middle as the mushroomed bed sheet burped the air out.

Once when I was young, my dad took my brother and I to Saint Louis because he was attending a meeting.  He was in the meeting most of the day, as we stayed in the hotel room.  This was back when you didn’t have 24 hour cable TV.  The day whizzed by as my brother and I jumped around between the two beds.  Leaping as high as we could, and pouncing from one bed to the other.  When our dad arrived after a day in meetings, he didn’t find a couple of young boys staring at the walls, he found two worn out kids who had just had one of the funnest days we could remember…. being cooped up in a hotel room all day long.

Contrast that to the first time I attended Substation Switchman Certification training.

The instructor explained at the beginning of the day long class that he was required to read through the company policies and procedures on substation switching before we were allowed to take the test.  There were a number of procedures that were practically duplicates of each other, so we had to listen to the same boring documents being read to us over and over again throughout the day.  This didn’t include just the switching procedures in the switchyard.  It also included the clearance procedures required before and after the switching has occurred.

Six hours later, I thought my eyelids had grown little lead weights on the end of every eyelash (and if you have ever seen how many eyelashes I have, you would know how serious of a situation this was).

That wasn’t the worst of it.  Switchman training back then was required every two years.  Think about this.  I was an electrician for 18 years.  During that time, I had to take Switchman training 7 times!  Each time the instructor had to read the entire text of the switchman policies and procedures.  Think of the most boring lecture or sermon you ever had to sit through, then multiply it by six, and you will understand the agony we had to endure each time to receive the Certified Switchman card for our wallets.

During the summer of 1995, after we had downsized to where we only had 7 electricians at the large coal-fired power plant in North Central Oklahoma, we decided we needed to train more operators to be switchman.  After all, they had the clearance part down already, and basically did lower voltage switching in the switchgears.  It made a lot of sense.

We told the switchman trainer that we wanted to add some hands-on practical training to the course to try to make training more exciting.  Andy Tubbs, the foreman who was also an electrician and long time switchman, worked to arrange it so that we could have the operators switch out a section of the substation after they had learned the boring part of their training.

Andy Tubbs - True Power Plant Electrician

Andy Tubbs – True Power Plant Electrician

After an entire day of sitting in a classroom.  The switchmen trainees had a real life opportunity to watch and experience switching out a real section of the substation.  They could wear the high voltage gloves and open the switches.

High Voltage gloves like this

High Voltage gloves like this

We also took switching orders and added some errors to them, and asked the students to review the orders to see if they would approve the switching before they went to the substation and to make any corrections necessary.  This is one of the steps a switchman is required to do before going out to switch.  They have to review each step of the switching and approve them.

Two years later in 1997, I was asked to go to Oklahoma City and become certified as a Switchman Trainer.  I remember going to the training center just north of Norman Oklahoma where I met our instructor, Harry McRee.  He was a trainer in his early 50’s.  He had been a safety trainer for years.

Harry McRee's Business Card

Harry McRee’s Business Card

Harry explained to us that he would like to make the switchman training more interesting, but the company’s requirements demanded that all of the documentation be read through entirely every time a person was re-certified.  Since the documentation took most of the day to read, his hands were sort of tied when it came to making the class more interesting.

To give you an idea… here is how many steps it takes just to take a clearance on a breaker in a plant…. We had to review each step of the process:

Clearance Procedures

Clearance Procedures

As a side note… In 1993, I had received a Masters in Religious Education from Loyola University in New Orleans.  My emphasis was on Adult Education.  So, when I went back to the plant and began developing the class for our plant, I thought I should be able to come up with some way to make the class more interesting.

I also thought that if it was possible for a couple of kids to keep themselves entertained all day just with a couple of beds in a hotel room, then something should be able to be done to make this ultra-boring class, more entertaining.

Since I was the “computer person” at the plant, I decided that I would use my computer as a learning aid.  I went to our substations and took pictures of everything I could find, so I could add them to a PowerPoint Project.  PowerPoint was fairly new at the time, so I decided to dazzle the class with animated fly-ins and popups, and cool transitions.  I also consolidated the various documents so that I wasn’t repeating myself throughout the day.  I brought my computer from home and set it up in the conference room.

I also employed my daughter Elizabeth to help me.  I figured if she could teach some of the training, and the students could see that even a seven year old can learn this, then maybe they would be a little more interested.  I had recently bought a new Ball Camera for my computer.  It was a new thing to have a camera on your computer.  They weren’t really used for things like Skype back then, since you only had 28,800 baud modems, which doesn’t give you very much bandwidth.  So needless to say.  No one in the room knew what that little white ball was.

White ball computer camera

White ball computer camera

I had my daughter dress up in one of my wife’s lab coats and wear over-sized glasses to give her the look of a teacher.  Then we created a number of short film clips that gave specific instructions.  Here are a few screenshots from the short videos we made:

Elizabeth, The Switchman Trainer

Elizabeth, The Switchman Trainer

At any moment her video would come flying in and she would often say….. “Look Class!  I know this is boring, but you HAVE to learn it!”

She would also fly in and say, “Pay Attention!  This is on the test!”

There were still a couple of videos that the switchmen-in-training had to watch that were boring, especially since we had all watched them many times in our careers.  I knew that during the videos, many would be falling asleep, so, I took my ball camera with me and kept it sitting on the table while we went through the training.  No one really knew what it was.

While we were watching the first boring video, I sat looking at my computer monitor, which no one in the room could see.  What I was doing was acting like I wasn’t paying any attention to anyone when I really was.  I had the ball camera in my hand.  I was looking for anyone who was dozing off.  Then I would take a movie clip of them nodding off.  Some fighting to keep their eyes open.  Others leaning way back in their chair with their mouth hanging wide open fast asleep.

I took the movie clips and put them about 5 slides later in the next section we were going to cover.  Just when they were ready to be bored from the next section of the class, I would present a slide to them with movie clips of them sleeping during the videos and Elizabeth would slide in from the bottom of the slide and say, “Look Class!  I know this is boring, but you HAVE to learn it!”

People Sleeping in Chairs. Just random pictures from Google. Not actual Power Plant Men

People Sleeping in Chairs. Just random pictures from Google. Not actual Power Plant Men

That was the clincher.  Once they realized that I had taken movie clips of them sleeping in the class just a few minutes earlier, they were all wide awake the rest of the day.  No one dared to nod off again.  It worked great!  When the second video was playing, you can be sure that everyone in the room was wide-eyed and wide awake.

When it came to the part where they took their test, they could use any notes they had taken.  Since Elizabeth had popped in and notified them about the parts that were going to be on the test, they were all prepared.  Here is a copy of the test they took:

Switchman Training Final Exam

Switchman Training Final Exam

Isn’t it funny that back then, you regularly used your Social Security Number for things like this?  We wouldn’t think of doing that today.

Later, after the class was over, Harry McRee, the trainer that had trained me in Oklahoma City, had heard how I had made the class interesting. So, he called me and asked if he could come out to our plant and see what I had done.  When he arrived I showed him all my material and gave him a copy of the PowerPoint and videos.  I told him he was free to use them however he wanted.

Because of this, I was asked to train the Power Plant Man in some other areas including general Windows training.  When a job to be the “official” trainer opened up at the plant, I applied for it…. but that is a topic for another post.