Original posted on January 28, 2012:
I vividly remember four events while working at the power plant where I was at the brink of death. I’m sure there were many other times, but these four have been etched in my memory almost 30 years later. Of those four memorable events, Curtis Love was by my side (so to speak) to share the wonder of two of those moments. This is a story about one of those times when you are too busy at the time to realize how close you came to catching that ride to the great power plant in the sky, until the middle of that night when you wake up in a cold sweat trying to catch your breath.
As I mentioned in an earlier post, safety is the number one priority at the power plant. But what is safe and what isn’t is relative. If you are the person that has to walk out onto a plank hanging out over the top ledge on the boiler in order to replace a section of boiler tube before the boiler has cooled down below 160 degrees, you might not think it is safe to do that with only an extra long lanyard tied to your waist and a sheer drop of 200 feet to the bottom ash hopper below (which I incidentally didn’t have to do as an electrician, but had to hear about after some other brave he-man had the privilege), you might not think that this is safe. But the Equipment Support Supervisor who has spent too many years as an engineer behind his desk doesn’t see anything wrong with this as long as you don’t fall. So, he tells you to do it, just don’t fall.
Safety is also relative to the date when something occurs. In 1994 OSHA implemented new rules for confined spaces. A confined space is any place that’s hard to enter and exit, or a place where you might be trapped in an enclosure because of converging walls. So, before 1994, there were no safety rules specific to confined spaces.
No rules meant that when I was on labor crew it was perfectly safe to crawl into a confined space and wind and twist your way around obstacles until the small oval door that you entered (18 inches by 12 inches) was only a distant memory as you are lying down in the bottom section of the sand filter tank with about 22 inches from the bottom of the section to the top requiring you to lie flat as you drag yourself around the support rods just less than 2 feet apart. Oh. and wearing a sandblast helmet…
and holding a sandblaster hose…
with a straight through Sandblast Nozzle….
Which means, the person sandblasting has no way of turning off the sand or the air on their own. If you wanted to turn off the sand, you had to bang the nozzle against the side of the tank and hope that the person outside monitoring the sandblaster was able to hear you above the roar of the Sandblaster and the Industrial Vacuum.
You also had a drop light that left you all tangled in wires and hoses that blew air on your face so that you could breathe and a 4 inch diameter vacuum hose that sucked the blasted sand and rust away, while the sandblaster blasts away the rust from all things metal less than a foot away from your face, because the air is so full of dust, that’s as far as you can see while holding the drop light with the other hand next to the sandblast hose. The air that blows through the sandblaster is hot, so you begin to sweat inside the heavy rain suit that you wear to protect the rest of you from sand that is ricocheting everywhere, but you don’t feel it as long as cool air is blowing on your face.
The week I spent lying flat trying to prop up my head while sandblasting the bottom section of both sand filter tanks gave me time to think about a lot of things…. which leads us to Curtis Love…. Not that it was Curtis Love that I was thinking about, but that he enters the story some time in the middle of this week. When I least expected it.
Curtis Love was a janitor at the plant when I first joined the Sanitation Engineering Team after my four summers of training as a “summer help”. Curtis was like my mother in some ways (and in other ways not – obviously). He was always looking for something to worry about.
For instance, one Monday morning while we were sitting in our Monday Morning Janitor safety meeting and Pat Braden had just finished reading the most recent safety pamphlet to us and we were silently pondering the proper way to set the outriggers on a P&H Crane, Jim Kanelakos said, “Hey Curtis. Don’t you have your mortgage at the Federal Bank in Ponca City?” Curtis said, “Yeah, why?” Jim continued, “Well I heard this morning on the news that the bank was foreclosing on all of their home mortgages.”
Curtis said that he hadn’t heard that, but that as soon as it was 9:00 am he would call the bank to find out what he needed to do so that he wouldn’t lose his house. About that time I gave a report on the number of fiddleback spiders I had killed in the main switchgear the previous week. It seemed like no one was listening to my statistics as Doris Voss was still pondering the P&H Crane hand signals, and Curtis was shuffling his feet in worry and Ronnie Banks was staring off into space, as if he was stunned that Monday was already here again, and Jim Kanelakos was snickering under his breath.
When the meeting was over and we were standing up, Jim told Curtis, “Hey Curtis. I was just kidding. The bank really isn’t foreclosing on their mortgages.” Curtis replied, “I don’t know. I better call them to check anyway.” Jim replied, “Curtis, I just made that up! I was playing a joke on you.” Curtis said, “I better check anyway, because it still is possible that they could be foreclosing on their mortgages”. So Jim just gave up trying to explain.
I know you wouldn’t be able to tell by looking at me now, but there were only two of us at the plant that were small enough to crawl through the portal into the Sand Filter tanks (Ed Shiever and myself), because not only was it very tight, but the entry was so close to the edge of the building that you had to enter the hole by curving your body around the corner and into the tank.
I have tried to paint of picture of the predicament a person is in when they are laying in this small space about 20 feet from the small portal that you have to crawl through. with their airline for the sandblast helmet, the sandblast hose, the drop light cord and the 4 inch vacuum hose all wound around the support rods that were not quite 2 feet apart in all directions. Because this is where I was when without my giving the signal (by banging the sandblast nozzle on the tank three times), the sand stopped flowing from the nozzle and only air was hissing loudly.
This meant one of two things. The sandblast machine had just run out of sand, or someone was shutting the sandblaster off because it was time for lunch. I figured it was time for lunch, because I didn’t think it had been more than 10 minutes since the sand had been refilled and amid the roaring blasts and the howling sucking vacuum hose, I thought I had caught the sound of a rumbling stomach from time to time.
The next thing that should happen after the sand has blown out of the sandblast hose, is that the air to the sandblaster should stop blowing. And it did…. but what wasn’t supposed to happen, that did, was that the air blowing through my sandblast hood allowing me to breathe in this sea of rusty dust shut off at the same time! While still pondering what was happening, I suddenly realized that without the air supply to my hood, not only could I not breathe at all, but my sweat-filled rain suit that I was wearing suddenly became unbearably hot and dust began pouring into my hood now that the positive pressure was gone.
I understood from these various signs of discomfort that I needed to head back to the exit as quickly as possible, as I was forced by the thick dust to hold my breath. I pulled my hood off of my head and everything went black. I had moved more than a foot away from the drop light. I knew that the exit was in the direction of my feet on the far side of the tank, so I swung around a row of support rods and dragged myself along by the rods as quickly as I could unable to see or take a breath. Working my way around the cable, the air hose, the sandblast hose and the vacuum hose as I pulled myself along trying to make out where the exit could be. Luckily, I had figured correctly and I found myself at the exit where in one motion I pulled myself out to fresh air and the blinding light of the day gasping for air.
Furious that someone had turned off my air, I ran out of the sand filter building to the sandblast machine where I found Curtis Love of all people. Up to this point, Curtis had never had the privilege to operate the sandblaster and was not aware of the proper sequence to shutting down the machine…. without shutting off the air to my hood. Incidentally, both the sandblaster and the air hose to the sandblast hood were being fed from the same regular plant air supply (which OSHA might have frowned upon back as far as 1983, and which caused you to blow black oily stuff out of your nose for a few days).
Needless to say, about the time that I came bolting out of the sand filter building Curtis had figured out that he had shut off the wrong valve. He was apologizing profusely in one long drawn out sentence….. “Kevin, I’m sorry, I’m really sorry, I’m sorry, I’m really sorry….” I stopped myself short as my hands were flying toward the area where his neck would have been, if Curtis had had a neck.
I looked over toward the crew cab parked nearby. It was full of hungry labor crew “he-men in training” all smiling and chuckling. At that moment I knew that both Curtis and I had been on the receiving end of what could be construed as a “power plant joke” (refer to the post about Gene Day to learn more about those: “Power Plant Humor and Joking with Gene Day“). So, I spent the next 30 seconds as Curtis and I piled into the crew cab telling Curtis that is was all right, he didn’t have to feel bad about it. Evidently, someone had told Curtis how to shutdown the sandblaster, but failed to tell him exactly which valve to turn off when turning off the air to the sandblaster.
Needless to say. Lunch tasted extra good that day. Possibly the rusty dust added just the right amount of iron to my sandwich.
Originally Posted on April 20, 2012. I added a couple of pictures including an Actual picture of Ed Shiever:
The Coal Fired Power Plant where I worked is out in the country and it supplies its own drinkable water as well as the super clean water needed to generate steam to turn the turbine. One of the first steps to creating drinkable water was to filter it through a sand filter. The plant has two large sand filters to filter the water needed for plant operations.
These are the same tanks I was in when I was Sandblasting under the watchful eye of Curtis Love which was the topic of the post about “Power Plant Safety as Interpreted by Curtis Love“. Before I was able to sandblast the bottom section of the sand filter tank, Ed Shiever and I had to remove all the teflon filter nozzles from the two middle sections of each tank. Once sandblasted, the tank was painted, the nozzles were replaced and the sand filter was put back in operation.
Ed Shiever and I were the only two that were skinny enough and willing enough to crawl through the small entrance to the tanks. The doorway as I mentioned in an earlier post is a 12-inch by 18-inch oval. Just wide enough to get stuck. So, I had to watch what I ate for lunch otherwise I could picture myself getting stuck in the small portal just like Winnie the Pooh after he had eaten all of Rabbits honey.
Ed Shiever was a janitor at the time, and was being loaned to the labor crew to work with me in the sand filter tank. Ed was shorter than average and was a clean-cut respectable person that puts you in the mind of Audey Murphy, the most decorated soldier of World War II. For those power plant men that know Ed Shiever, but haven’t ever put him and Audey Murphy together in their mind will be surprised and I’m sure agree with me that Ed Shiever looked strikingly similar to Audey Murphy at the time when we were in the sand filter tank (1983).
Before I explain what happened to Ed Shiever while we spent a couple of weeks holed up inside the sand filter tanks removing the hundreds of teflon nozzles and then replacing them, I first need to explain how I had come to this point in my life when Ed and I were in this echo chamber of a filter tank. This is where Ann Bell comes into the story. Or, as my friend Ben Cox and I referred to her as “Ramblin’ Ann”.
I met Ramblin’ Ann when I worked at The Bakery in Columbia Missouri while I was in my last year of college at the University of Missouri. I was hired to work nights so that I could handle the drunks that wandered in from nearby bars at 2 a.m.. Just up the street from The Bakery were two other Colleges, Columbia College and Stephen’s College which were primarily girls schools. Ramblin’ Ann attended Stephen’s College.
She had this uncanny knack of starting a sentence and never finishing it. I don’t mean that she would stop halfway through the sentence. No. When Ann began the first sentence, it was just molded into any following sentences as if she not only removed the periods but also the spaces between the words.
She spoke in a seemly exaggerated Kentucky accent (especially when she was talking about her accent, at which point her accent became even more pronounced). She was from a small town in Kentucky and during the summers she worked in Mammoth Cave as a tour guide (this is an important part of this story… believe it or not).
A normal conversation began like this: “Hello Ann, how is it going?” “WellHiKevin!Iamjustdoinggreat!IhadagooddayatschooltodayYouKnowWhatIMean? IwenttomyclassesandwhenIwenttomymailboxtopickupmymailIrealizedthatthistownisn’t likethesmalltownIcamefromin KentuckybecausehereIamjustboxnumber324 butinthetownwhereIcamefrom (breathe taken here) themailmanwouldstopbymyhousetogiveusthemailandwouldsay, “Hi Ann, how are you today?” YouKnowWhatImean? AndIwouldsay, “WellHiMisterPostmansirIamdoingjustgreattodayHowareYoudoing?”YouknowwhatImean? (sigh inserted here) SoItIsSureDifferentlivinginabigtownlikethisandwhenIthinkbackonmyclassesthatIhadtoday andIthinkabouthowmuchitisgoingtochangemylifeandallbecauseIamjustlearning somuchstuffthatIhaveneverlearnedbefore IknowthatwhenIamOlderandI’mthinkingbackonthisdayandhowmuchitmeanstome, IknowthatIamgoingtothinkthatthiswasareallygreatdayYouKnowWhatIMean?” (shrug added here)….
The conversation could continue on indefinitely. So, when my girlfriend who later became my wife came to visit from Seattle, I told her that she just had to go and see Ramblin’ Ann Bell, but that we had to tell her that we only have about 15 minutes, and then we have to go somewhere else because otherwise, we would be there all night nodding our heads every time we heard “…Know What I Mean?”
My roommate Barry Katz thought I was being inconsiderate one day when he walked in the room and I was sitting at the desk doing my homework and occasionally I would say, “Uh Huh” without looking up or stopping my work, so after sitting there watching me for a minute he asked me what I was doing and I told him I was talking to Ann Bell and I pointed to the phone receiver sitting on the desk.
I could hear the “You Know What I Mean”s coming out of the receiver and each time I would say, “Uh Huh”. So, when he told me that wasn’t nice, I picked up the receiver and I said to Ramblin’ Ann, “Hey Ann, Barry is here, would you like to talk to him?” and I handed it to him.
He sat down and asked Ann how she was doing…. 10 minutes or so and about 150 “Uh Huh”‘s later, Barry looked over at me and slowly started placing the receiver back on the desktop repeating “Uh Huh” every so many seconds.
Anyway. The reason I told you this story about Ramblin’ Ann was because after a while I began to imitate Ann. I would start ramblin’ about something, and it was almost as if I couldn’t stop.
If you have ever read the story about Dr. Jekyll and Mr. Hyde, Dr. Jekyll would transform into Mr. Hyde by drinking a potion. But eventually he started turning into Mr. Hyde randomly without having to drink the potion. Well, that is what had happened to me. In some situations, I would just start to ramble non-stop for as long as it takes to get it all out… Which Ed Shiever found out was a very long time.
You see, Ed Shiever and I worked in the Sand filter tanks for an entire week removing the nozzles and another week putting them back in. the entire time I was talking non-stop to him. while he just worked away saying the occasional “uh huh” whenever I said, “you know what I mean?”, though I didn’t say it as much as Ramblin’ Ann did. I could never match her prowess because my lung capacity just wasn’t as much.
Ed Shiever was a good sport though, and patiently tolerated me without asking to be dismissed back to be a janitor, or even to see the company Psychiatrist…. Well, we didn’t have a company psychiatrist at the time.
It wasn’t until a few years later when Ronald Reagan went to visit Mammoth Cave during the summer, that this event with Ed Shiever came back to me. You see… Ann Bell had been a tour guide at Mammoth Cave during the summer, and as far as I knew still was. My wife and I both realized what this could mean if Ronald Reagan toured Mammoth Cave with Ann Bell as his tour guide.
Thoughts about a Manchurian Candidate Conspiracy came to mind as we could imagine the voice of Ann Bell echoing through the cave as a very excited Ramblin’ Ann explained to Ronald Reagan how excited she was and how much this was going to mean to her in her life, and how she will think back on this time and remember how excited she was and how happy she will be to have those memories and how much she appreciated the opportunity to show Ronald Reagan around in Mammoth Cave… with all of this echoing and echoing and echoing….
We had watched this on the evening news and it was too late to call to warn the President of the United States not to go in the cave with Ann Bell, so we could only hope for the best. Unfortunately, Ronald’s memory seemed to be getting worse by the day after his tour of Mammoth Cave and started having a confused look on his face as if he was still trying to parse out the echoes that were still bouncing in his head.
Of course, my wife and I felt like we were the only two people in the entire country that knew the full potential of what had happened.
So this started me thinking… Poor Ed Shiever, one of the nicest people you could ever meet, had patiently listened to me rambling for two entire weeks in an echo chamber just like the President. I wondered how much impact that encounter had on his sanity. So, I went to Ed and I apologized to him one day for rambling so much while we were working in the Sand Filter tank, hoping that he would forgive me for messing up his future.
He said, “Sure, no problem.” Just like that. He was all right. He hadn’t lost his memory or become confused, or even taken up rambling himself. I breathed a sigh of relief. Ed Shiever had shown his true character under such harsh conditions and duress.
I’m just as sure today as I was then that if Ed Shiever had been with Audey Murphy on the battlefield many years earlier, Ed would have been standing right alongside him all the way across the enemy lines. In my book, Ed Shiever is one of the most decorated Power Plant Men still around at the Power Plant today.
I finally found an actual picture of Ed Shiever:
Originally published on May 25, 2012:
Either this was the luckiest day of my life, or a day where stupidity seemed to be my natural state of mind. This particular day occurred sometime during September 1983. The Main Power transformer for Unit 1 had shutdown because of an internal fault during an exceptionally hot day during the summer and was being replaced.
While the unit was offline, while I was on the labor crew, I was asked to help out the electricians who were doing an overhaul on the Precipitator. The Precipitator takes the ash out of the boiler exhaust before it goes up the smoke stack. Without it, you would see thick smoke, instead, you see only clear exhaust. At the time the electricians I worked with were Sonny Kendrick and Bill Rivers. I had already applied for a job in the electric shop and was waiting to see if I was going to be offered the job. This gave me the chance to show the electricians what a brilliant worker I was.
Bill Rivers told me to go in the precipitator and wipe down the insulators that held the wire racks in place. He showed me where they were. I wore a regular half-face respirator because the fly ash is harmful to inhale.
Just before I went in the precipitator door to begin wiping down the insulators using a Scotch Brite Pad, Bill Rivers pointed to my flashlight and said, “Don’t drop your flashlight in a hopper otherwise you will have to make sure that you get it out of the hopper before we go back online.” I told him I would be sure to hold onto my flashlight (noticing that Bill had a string tied to his flashlight which was slung over his shoulder) and I entered the precipitator door.
The inside of the precipitator was dark. 70 foot tall plates are lined up 9 inches apart. Wires hang down between the plates and when the precipitator is turned on, the wires are charged up to around 45,000 volts of electricity. The wires each have a 30 pound weight on the bottom to keep the wires straight, and the wires are kept apart and lined up by a rack at the bottom. One end of the rack which is about 25 feet long is held in place by an electrical insulator about 3 feet long. This is what I was supposed to clean. The light from the flashlight lit up the area around me because everything was covered with the fine white powder reflecting the light.
The first hopper I came to was full of ash up to the top of the hopper, but just below where the insulator was mounted to the edge of the hopper. So, I worked my way down to the ledge along the edge of the hopper and dangled my feet down into the ash as I prepared to wipe down the first of the four insulators on this particular hopper. Just as I began, the precipitator suddenly went dark as my flashlight fell from my hand and down into the hopper. — Oh boy, that didn’t take long.
I sat there for a minute in the dark as my eyes grew accustomed to the small amount of light that was coming through the doors. After I could see again, I reached my hand into the ash to feel for my flashlight. The ash was very fluffy and there was little or no resistance as I flailed my hand around searching for it. I leaned over farther and farther to reach down deeper into the ash. I was at the point where I was laying down flat on the ledge trying to find the flashlight, and it was no where to be found.
I pulled myself over to the side edge of the hopper and dropped myself down into the ash so that I could reach over where I had dropped the light, but I was still not able to find it. At that point, I was leaning out into the hopper with only my one index finger gripping the ledge around the hopper. I had a decision to make… I thought I would just bail off into the ash to see if I could find the flashlight, or I could give up and go tell Bill Rivers that I had done the one thing that he told me not to do, and in record time.
I don’t usually like to give up until I have exhausted every effort, so here was my dilemma. Do I let go and dive into this ash to retrieve my flashlight? Or do I leave the hopper and go tell Bill? I regretfully decided to go tell Bill. So, I climbed up out of the hopper, with my clothes covered with Ash (as we did not have fly ash suits at the time and I was wearing my coveralls). I made my way to the precipitator door and once I was outside, I determined which hopper I had been in when I dropped my flashlight.
I found Bill and told him that I had dropped my flashlight in a hopper full of ash. He told me to get the key for that hopper and open the door at the bottom and see if I could find the flashlight. Unlike the picture of the hoppers above, we had a landing around the base of the hoppers by the access door so you didn’t need a ladder to reach them.
Curtis Love had been watching the door of the precipitator for me while I was supposed to be wiping off the insulators. He came down with me, and we proceeded to open the access door at the bottom on the side of the hopper. When I opened the door both Curtis and I were swept backward as a stream of fly ash shot from the door. The ash fell through the grating to the ground below. We regained our footing and watched as a tremendous pile of ash grew below us. If the flashlight had come out of the doorway, it would have remained on the landing since it was too big to go through the grating, but it never came out.
After the ash had finished pouring out of the hopper as if it were water, I reached down into the remaining ash to see if I could feel the flashlight. Still I was unable to find it. There was about 4 more feet from the doorway to the bottom of the hopper, so I emptied out as much ash as I could using my hard hat for a shovel. Then I pulled my body head first into the hopper and I reached down as far as I could in the bottom of the hopper, but I couldn’t find the flashlight.
So, in my infinite wisdom, I asked Curtis Love to hold onto my legs as I lowered myself down to the throat at the bottom of the hopper. I lowered myself down until I had half of my face laying in the ash. At this point only one of the two filters on my respirator was able to function as the other one was down in the ash. I reached my hand into the top of the feeder at the bottom of the hopper and with my finger tips I could just feel the flashlight. I had reached as far as I could, but I couldn’t reach far enough to grip the flashlight.
All of the sudden my head dipped down into the ash and my hand went around the flashlight. I was not able to breathe as my respirator (and my entire head) was entirely immersed in ash. Everything went dark. I struggled to get up, as Curtis had let go of my legs and I had plunged head first into the bottom of the hopper. I had one hand free as the other one held the flashlight. I used it to push against the opposite wall of the hopper to raise my head up out of the ash. I still couldn’t breathe as my respirator was now clogged solid with ash. When I tried to inhale, the respirator just gripped my face tighter. Finally with my one free hand pushing against the hopper wall to hold my head out of the ash, I reached up with the hand that held the flashlight and pushed against my respirator enough to break the seal around my face so that I was able to get a breath of air.
Then I quickly pulled myself out of the precipitator as I heard Curtis saying the mantra that I had heard one other time (as I indicated in the post about Power Plant Safety as Interpreted by Curtis Love). He was saying over and over again, “I’mSorry,I’mSorry, KevinI’mSorry, ThoseGuysWereTicklingMe. I’mSorry,IDidn’tMeanToLetGo,ITriedToHoldOn, butThoseGuysWereTicklingMe.”
Looking around I spied a few Labor Crew hands sneaking away. As this happened before when I was sandblasting in the sand filter tank when Curtis Love had turned off my air, this wasn’t the first encounter I had with Power Plant Men In-Training playing a Power Plant joke on me. I told Curtis to forget it. I had retrieved my flashlight and everything was all right. I was covered from head-to-toe with fly ash, but that washes off pretty easily.
It dawned on me then that when I had dropped the flashlight, it had sunk clear to the bottom of the hopper and down into the throat of the feeder at the bottom. If I had dived into the ash in the hopper from up above, I would have fallen right down to the bottom of the hopper and been engulfed in ash. My feet would have been pinned down in the feeder pipe, and that would have been the end of me. It probably would have taken many hours to figure out where I was, and they would have found only a corpse.
While I was hanging on the edge of the hopper with only the tip of my index finger gripping the ledge, I was actually considering letting go. There never would have been an electrician at the power Plant named Kevin Breazile. I never would have married my wife Kelly, and had my two children Elizabeth and Anthony. I would not be writing this story right now. If it had been left to my own stupidity, none of those things would have happened.
I believe it was my guardian angel that had talked me out of letting go (or had actually been standing on my finger). As stubborn as I was, and against my nature, that day I had decided to give up searching for my flashlight and seek help. That one momentary decision has made all the difference in my life.
Since that day I have had a certain appreciation for the things that happen to me even when they seem difficult at the time. I have lived a fairly stress-free life because each day is a gift. Currently I work in a stress-filled job where individual accomplishments are seldom rewarded. From one day to the next I may be laid off at any time. I still find a lot of satisfaction in what I do because it was possible that it never would have happened. I have been kept alive for a purpose so I might as well enjoy the ride.
I find a special love for the people I work with today, because they are all gifts to me. I try to pay them back with kindness… when that doesn’t work.. I try to annoy them with my presence… Just to say….. — I am still here!
Comments from previous repost:
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 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 Bif 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 not wearing my hard hat 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 all the time.
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, Bif 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 November 17, 2012:
Louise Gates seemed reluctant to approach me to ask if I wanted to make a donation for flowers for Grant Harned’s funeral. Of course I did. He was a good friend of mine. We had many carpooling adventures before he left his job as the plant receptionist to move to Tulsa, Oklahoma where he died a little more than a year later in May 1984 in an automobile accident.
Thomas “Grant” Harned had obtained a degree in business from Oklahoma State University before accepting the job at the coal-fired power plant in North Central Oklahoma. He told me that he thought that once he had his foot in the door that he would be able to advance up the HR chain until he worked his way into a business department downtown at Corporate Headquarters. Downtown is synonymous for Oklahoma City.
Like many struggling new Power Plant men such as Ed Shiever, Dale Hull and others, Thomas lived in a modest student rental apartment near campus. Grant lived on West Miller Avenue just off of Main Street in Stillwater. Soon after I had become a janitor and the summer helps I had been carpooling with had left, I began carpooling with Grant.
Grant was a tall thin man with sandy hair and a moustache that reminded me a lot of Gary McCain (also known as Stick). I have a picture of him around here somewhere that I found many years after his death when we were cleaning out the office that Louise Gates (now Kalicki) had obtained upon becoming the supervisor over HR. It is a picture of him sitting at the receptionist desk.
Louise gave me a picture of myself that had been taken when I was a janitor, and as I filed through the other pictures I found Grant’s photo. I knew no one else at the plant would want the picture as few knew him or even remembered him by that time. So I took it as well. Some day when I find where I have placed those pictures, I will post them. (I found the picture since the original post).
As I mentioned, Grant was just out of the Business College at OSU and he was fired up, ready to make a difference. He had all sorts of ideas that he shared with me about how the plant and the company business processes could be improved.
He reminds me now of myself years later when I was carpooling with Scott Hubbard and Toby O’Brien and how I would talk about having smart electricity instead of the same dumb electricity we have had for the past 100 years. Except that Grant’s ideas were about business processes, where my ideas were about electrons moving through a conductor.
For Power Plant Men, carpooling is a way of getting into other Power Plant Men’s minds and understanding them from the inside out. Each day while driving back and forth from the plant you are basically locked into a confined space with one or more other individuals with nothing but your thoughts, or NPR or in the case of Dale Hull and Ricky Daniels… Beer.
In the case of Grant Harned, he soon became frustrated. He had graduated from school and wanted to make a difference somehow. And he wanted it to happen right away. He would tell his manager Jack Ballard his ideas about how he thought things could change, and each time Jack would shoot it down.
I’m not saying that Grant had great business changing ideas that would change the way Power Plants all over the country operated. He just wanted to be listened to, and he didn’t understand that there were built-in reasons why we did it the way we did. The most important was that “We had been doing it this way for 35 years, and we’re not going to change it now.”
For some reason that rubbed Grant the wrong way. Maybe because he couldn’t help thinking outside the box. He obviously had trouble understanding the benefit of doing something the same way for 35 years. I guess he must have missed the class where “because I said so” was a solid business case. If he had stuck around long enough Ben Brandt would have explained that to him.
Anyway. It is true that Power Plant business processes before Grant’s time and for a while after, were based on doing things the same way it has always been done. I suppose that is why electricity for all those years was the same boring thing…. 60 cycles (60 Hz or 50 Hz in Europe) Alternating Current. Regular Sine wave, perfectly generated. Each wave identical to each other. — But I’ll talk about electricity later. At this time I was still a janitor.
Grant finally decided that he was going to look for another job because he realized that he didn’t have a future at the power plant. He had been trained as a business person and there was little opportunity to display and cultivate his new found skills at a power plant in the middle of the countryside where everyone was content with the way things were.
Before he left, he gave me some cassette tapes that he used to play on the way to and from work. I kept them for years until I had worn them out listening to them in my car. Two of the tapes were The Rolling Stones, one of his favorite bands.
I said goodbye to Grant when he left, but I never forgot him. Each year on All Souls Day (November 2), I remember him and David Hankins. He, like most of the men I have carpooled with over the years was like a brother to me. Those that weren’t brothers, were fathers.
It didn’t occur to me until after I first wrote the original post that years later, I too went to Oklahoma State University while I was working at the plant to obtain a degree from the Business College, Spears School of Business. As with Grant, the Electric Company had no use for someone with my newfound skills, so I moved south to Round Rock, Texas to work for Dell. I wonder if Grant was looking down giving me a thumbs up as I walked to the podium to get my diploma.
I mentioned that I don’t know where I placed his Power Plant picture, but I do have other pictures (before I recently found it):
Evidently someone else remembers Grant as I do. I found these picture of him on a memorial site online. There is a comment there that says this of Grant: “Was known in school and by friends as Grant. He had a great sense of humor and would always make you laugh.”
I agreed with Grant. He really didn’t belong at the power plant. Power Plant life and culture at the time was not geared toward “continuous improvement” and Six Sigma. It was about coming home safely at night to your family and doing a good days worth of work and having something to show for it. He was young and ambitious.
I cherish the time I spent with Grant driving to and from work. I remember many of the conversations that we had. Many of them philosophical in nature. Some having to do with the regular questions people have about life and God. I know that he was being drawn toward something greater, and in the end I pray that he found it.
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 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 16 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….
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 July 26, 2013:
I suppose everyone at some point in their life wishes they could work at Disney World or some other place where there is one wonder after another throughout their day. Working in the Power Plant was a lot like that…. sometimes….. I have mentioned a few times that when you drove through the gate to the coal-fired Power Plant in North Central Oklahoma each morning, you never knew what was in store for that day. It was often a surprise. Sometimes the surprise was a wonder. Sometimes it was well…. surreal.
This is a story about one day in October 1986 during an overhaul while I was a plant electrician, where I entered a world totally foreign to just about anything I had encountered before. You may think this is an odd statement if you have read some of my other posts where I have found myself in oddly dangerous situations and my life was in the balance. Well…. this is one of those stories, with a new twist.
As I said, we were on overhaul. This meant that one of the two units was offline and major repairs were taking place to fix things that can only be done when the unit isn’t running. The two major areas of repair are the Turbine Generator and the Boiler. People come from the other plants to help out and get paid a lot of overtime working long hours to complete this feat.
At this time I was working on motors in the electric shop. I had been removing the fan motors from the large General Electric Transformer for Unit 1. Changing their bearings and testing them. Then putting them back in place. The transformer had 24 of these motors, so after the first few, the work was becoming pretty routine.
Somewhere between the 11th or 12th motor David McClure came into the shop. I think he may have been on the labor crew at the time. He had only been working at the plant for about 8 months. He was a welder, so I think if he had been on labor crew, they had quickly moved him into the welding shop because anybody with welding skills were always in high demand.
David told me that Bill Bennett had told him to ask me to help out with a problem in the boiler. Now. when I was on the labor crew, I had been in the boiler during an overhaul. I had worked on shaking tubes in the reheat section and cleaning the clinkers out of the economizer section. You can read about these moments of mania in the posts: “Bob Lillibridge Meets the Boiler Ghost” and “Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back“.
During those times I knew that something was taking place in the superheat section of the boiler, but I wasn’t exactly sure what it was. You see, even when I was in the bottom ash hopper when it was being sandblasted, there was a wooden floor that had been put in above the hopper so that you couldn’t see the boiler overhead. This was the first time I was going to go into the boiler to actually work on something other than laying down the floor (which I had been lucky enough to do once when I was working on the labor crew).
So, I grabbed my tool bucket and David took me up to the main entrance into the boiler which was next to the door where Chuck Ross and Cleve Smith had been blown off of the landing by the Boiler Dragon six years earlier when I was a summer help (see the post: “Where Do Knights of the Past go to Fight Dragons Today?“). About 40 feet up from the concrete floor we climbed into the boiler.
This is where I first came face to face with Boiler Rats. These rats live in a boiler when it is taken offline. Shortly after the boiler is cooled down, these “boiler rats” move in and they spend the next 4 or 10 weeks (depending on the length of the overhaul), roaming around the boiler sniffing out boiler tubes that are in need of repair.
Some lights had been placed around the bottom of the boiler to shine up the 200 feet to the top of the boiler. That is the height of a 20 story building. Yes. That’s right. The inside of the boiler is as tall as a 20 story building. I couldn’t really see what was going on up there toward the top, but there was a boiler rat standing right there in the middle of the wooden floor staring at me with the grin (or snarl) that is typical of a rat. Not a cute rat like this:
Or even a normal rat like this:
No. These rats looked like Ron Hunt wearing his hillbilly teeth. More like this:
Yep. Red eyes and all, only the whiskers were longer. I would go into how the boiler rats smelled, but I didn’t want to get too personal….
Anyway, this one boiler rat that had been waiting for me said that he had just finished rigging up this sky climber so that he could take me up into the upper reaches of the dark to work on a sky climber that was stuck. He had rigged this sky climber up so that it would pull up next to the one that was hung up by the bottom of the high pressure boiler tubes that were hanging out over the top of the boiler.
If you have ever seen Window washers going up and down the side of a building washing windows, then you know what a sky climber is.
You see, the boiler rats would ride these sky climbers up from the wooden floor to the boiler tubes hanging down from the ceiling of the boiler. One had stopped working and they needed an electrician to go up and fix it so that they could continue working. That was my job…. I carry a badge…. oh… wait… that’s Sergeant Friday on Dragnet… I carry a tool bucket that doubles as a trash can and triples as a stool.
So, I climbed into the sky climber and up we went. I could see faint lights up above me where boiler rats were working away cutting and welding boiler tubes. As we took off, one of the boiler rats said that a little while just before I had arrived, someone from above had dropped a tool that came flying down and stuck right into the wooden plank floor. It had landed about 10 feet from another boiler rat. This answered a question that I had for some time…. it turned out to be true… Boiler Rats do have Guardian Angels too.
Anyway, Up into the darkness we went. The boiler rat (I believe this one was called Rodney… as in Rodney Meeks) operated the sky climber as I just enjoyed the ride. Looking down, I saw the spot lights getting smaller and dimmer. Looking up, I saw us approaching a group of hanging boiler rats, all doing their stuff. Some were resting. Some were welding. Some were looking off into space in a daze after having been in the boiler for so long they had forgotten their name.
There were names for these rats. One was called T-Bone. Another was called ET. There was a guy there called Goosman. Another boiler rat was called Frazier. I think it was John Brien that was staring off into space at the time, or was it Butch Ellis. Oh. Now I remember. Butch was on one sky climber staring off into space at the other sky climber where john Brien was staring back at him.
There were many other boiler rats there from other plants. They were all hanging down from the top of the boiler on these sky climbers like fruit hanging from a tree in the dark. Most of them paid no attention to my arrival.
We pulled up to the sky climber that was broken. I swung over the couple of feet from the one climber to the other, with a straight drop of about 160 feet down to the floor. I looked below so that I could calculate that in case I slipped and fell, how I would try to swing my body just as i fell so as to miss any boiler rats below. I wouldn’t have wanted to upset any boiler rat families by falling on their boiler rat breadwinners.
By Swinging my tool bucket toward the other sky climber, I followed the momentum so that it carried me over to the other platform, where I swung my bucket over the railing and climbed in. Once settled, I took out my flashlight so that I could look around my new six or eight foot world.
I tried the controls, and sure enough… nothing happened. Remembering my dropped flashlight almost exactly three years earlier that had almost cost me my life (see post: “Angel of Death Passes By The Precipitator Door“), I took extra care not to drop any tools on some unsuspecting souls below.
I took out my multimeter and checked the voltage coming into the main junction box and found that the problem was in the connect where the cable came into the box. So, this turned out to be a fairly easy fix. The cord had been pulled by something (geez. It was only hanging down 200 feet. I don’t know what might have been pulling on it) and had worked its way out of the connections.
I told Rod that I would be able to fix this quickly and went to work removing the connector from the cable, cutting off the end and preparing it to be reconnected to the connector. It was about that time that I became aware of something that had been going on since I had arrived, I just hadn’t noticed it. Maybe it was a remark one of the boiler rats had said. I think it was Goosman talking to Opal. He said something like “That George Jones can sure sing.”
That was it. That was the extra amount of strangeness that I had been experiencing since I had arrived. Someone had a radio that was playing country music. The music was echoing throughout the boiler so that all the hanging boiler rats could listen to it. I realized that Butch and Brien weren’t just staring off into space at each other. They were experiencing a moment of country music meditational bliss. The moment the current song was over someone off in the distance that I couldn’t see in the dark or because they were stuck up inside a rack of boiler tubes, let out a hoot of satisfaction. Butch and Brien rose and went back to work.
I have heard that it takes a village to raise a child…. Hillary Clinton even wrote a children’s book with that title once. I experienced something similar but strangely different that day in October 1986. A village of raised boiler rats, who for a moment, it seemed, some had stopped to sit by the welder’s campfire to listen to the tales being woven by the country music singer on the radio.
There was a sincere camaraderie between these individual boiler rats. A culture had grown inside this boiler that was completely foreign to me. I suppose the same thing happens to soldiers who put their lives on the line to protect our country. When you are in a position where one wrong step and someone dies. You bond to those around you in a unique way.
I am grateful for my brief encounter with the boiler rats that day. They had invited me into their lair because they needed my help. I was glad to have been able to fix there problem and be quickly on my way.
Though I never had a desire to become a boiler rat myself, during the many years where I walked alone throughout the inside of the precipitator I would sometimes hear the sounds coming down through the economizer from the Superheat section of the boiler. Maybe a faint hint of country music. I knew that the boiler rat village had come together again like a group of nomads that meet every winter to share stories. Sometimes I would take the plate straightening tool I carried and banged on the plates wondering if any of them would hear me way back up in the boiler. I doubt anyone ever did.
Comment from previous post:
Originally Posted on August 9, 2013:
I first ran across Power Plant Men totally by accident the summer of 1979 when I was 18 and I went to work as a summer help at a Power Plant in Oklahoma. I walked into the plant, and there they were. All standing there looking at me as if I was the new kid on the block. Which, of course, I was.
I had very little in common with this group of men. It was interesting enough to watch them at work, but it was equally as interesting to observe them after hours. I didn’t spend a lot of time with them myself. I often just listened to their stories of adventure on Monday Mornings. I think that was why the Monday Morning Safety Meeting was invented.
Like I said. I had little in common with these He-men. The only thing I could relate to was around Fishing. I had been fishing my entire childhood with my Father. Most everything else they did was foreign to me. Though, the first summer it seemed like the only things to do was to go fishing and to go over to the Peach Orchard by Marland, Oklahoma and pick peaches. Well, that, and go to Men’s Club dinners.
Like I’ve said twice now, I had little in common with this sunflower eatin’ bunch of men. I had just finished my first year as a college student and the only thing I knew to do during my free time was to play Dungeons and Dragons or Pinball. Actually, I was quite a pinball wizard and could usually spend all day on one quarter. This didn’t seem to impress the likes of this bunch, so I kept my Pinball Prowess to myself.
As I learned more about the Power Plant Men, I found out that they were a diverse group of men that had many different recreational activities. I have mentioned before that the evil plant Manager Eldon Waugh was a beekeeper, and so was my good friend Sonny Karcher. Even though Sonny spent a good portion of his time away from the plant doing some sort of farming, he enjoyed raising bees.
I mentioned in a previous post “Imitations and Innovations of Sonny Karcher” that Sonny liked to choose one thing about someone else and then take on that characteristic or possess a particular item that they had. So, I figured Sonny had become a beekeeper because he had a friend that did the same thing. I never thought that it was Eldon Waugh, since Sonny usually only chose something from someone he admired and Eldon made it a full time effort to make sure no one really liked him.
While I was a summer help I learned a few of the activities that Power Plant Men liked to do. For instance, I knew that Stanley Elmore liked to spend the weekend either making his yard look like something you would find in a Home and Garden magazine, or he liked cleaning his car and waxing his engine so that you could cook an egg right on it and not have to worry about any grit or grime between your teeth.
It goes without saying that the Power Plant Men that had families spent most of their free time with them. Those that didn’t have a family spent a lot of their time trying to avoid going down that path. So, they chose activities that would take them into the wilderness somewhere or maybe a river or two.
I heard very little talk of disgruntled husbands from the true Power Plant Men. The only story I can remember off the top of my head about a husband that was upset with his wife was Marlin McDaniel. He told us one Monday morning that he had to take his wife over his knee on Saturday. He explained it like this. “I was so mad at her that I grabbed her and laid her across my knees. I pulled up her skirt to spank her. I looked down to make sure I was aiming in the right direction… Then I paused for a moment… and I suddenly couldn’t remember why I what I was mad about.”
You know… It is funny because I had always thought that Marlin McDaniel looked like Spanky, and in the story he told about his wife, he was going to spank her. What are the odds of that?
It wasn’t until I entered the Electric Shop as an electrician in 1983 that I learned more about the recreational activities of Power Plant Men. I mean. I knew that Gene Day liked to drive around campus on weekends in his black pickup truck with the flames on it to impress the college girls, even if he was 50 years older than them. But besides that, I mean…..
Outside the welding shop on the lawn was a piece of art made from metal rods that had been created by the welders to resemble a cow with horns. It was used to practice lassoing. There was a certain group of Power Plant Men that took part in rodeos. Some riding on broncos, some lassoing cows and tying them up in knots. If I remember correctly, Andy Tubbs, one of the most intelligent electricians, was a rodeo clown. If you haven’t been to a rodeo, then you might not realize what a Rodeo Clown does.
Sure they stand around in bright colored clothes. These two guys aren’t just there for laughs. Here is a rodeo clown at work.
You see. When a contestant is riding a bull and they fall off, in order to keep the bull from turning around and goring the poor guy to death, a rodeo clown jumps into action and distracts the bull while the contestant is quickly spirited away to safety.
Jerry Mitchell had told me when I was still a summer help that you could tell who liked to participate in rodeos. They were usually missing one or more fingers. One of the rodeo hands explained it to me like this. When you lasso the cow, you quickly wrap the rope around the saddle horn. Just as you are doing that, the cow hits the end of the rope and goes flying back. This means that if you don’t get your fingers out of the way when you are wrapping the rope around the saddle horn, the rope will snap it right off.
January 1997 a new Instrument and Controls person came to work at the plant. Brent Kautzman was a rodeo person. We were sitting in a Confined Space Rescue team meeting once and Randy Dailey was espousing the dangers of roping cows in a rodeo when Brent said that he had his thumb cut off in a rodeo once. At first we looked at him as if he was just pulling our leg. He had all of his fingers.
Someone asked if they sewed his thumb back on. He said they weren’t able to do that. Instead they took one of his big toes and sewed it on his hand where his thumb had been. We were surprised when he showed us his thumb and sure enough. There was a big toe in place of his thumb.
Brent said that if he knew at the time how important a big toe is, he never would have done it. He said that he was young at the time, and he wanted to continue participating in rodeos, so he had them cut off his big toe and sew it on his hand. Anyway. Later, Brent returned to where he had come from, Richardton, North Dakota. He was a great guy, and a hard worker, but like myself, he wasn’t a True Power Plant Man.
The biggest source of recreation for Power Plant Men was Hunting. I would hear stories about how the hunters would send in their name for a drawing to be able to take part in the annual Elk Hunt in Montana. It was a lottery and they only picked so many people. So, the hunters would wait patiently each year to see if they were going to be able to make a trip to Montana.
Corporate Headquarters and the Evil Plant Manager wanted to make sure that not too many took off for Christmas because they wanted to ensure that enough people stayed in town in case there was an emergency at the plant and they needed to call everyone out. Christmas wasn’t really the problem at the plant as was “Hunting Season”.
There were two parts to deer hunting. The first few weeks it was bow season. You could go hunting for dear with a bow and arrows. Later you could hunt with a rifle. This was serious business in North Central Oklahoma. The Deer Hunters would prepare for this season all summer long. They would build their tree stands, and they would put out deer feeders to fatten up the deer.
People would become pretty sparse around when deer hunting season opened. At least or a few days. You could usually only kill one or two deer and that was your limit. Each year the number was decided by the population of deer.
If there were too many deer running around then the deer hunters could kill more. The whole idea of Deer Hunting from a Wildlife perspective was for population control. When there were too many deer, they would start passing around diseases and then all end up dying off anyway. So, this was a way of controlling the population.
A few times I was invited to join the Power Plant Men in their recreation. It was always a learning experience for both of us.
I was invited to Charles Foster’s house one summer to make pickles. We picked the cucumbers from Charles garden. Charles’ garden was the pride of Pawnee. I spent some time with his family that day, cleaning and boiling the cucumbers in vinegar in the pickle jars with the dill we had picked from his garden. I think often of the day I spent with Charles in his garden picking the cucumbers and in his house that evening.
I was also invited once to go to the Resort just outside of Pawnee known as “Pawnee Lake”. Diana Brien and Gary Wehunt and their spouses were camping out there and they invited me to join them the following morning. I showed up in the morning where we cooked breakfast, then they taught me the art of flying across the lake on a jet ski.
To me, this was sheer madness, but I bucked up and did it anyway. If I was going to die, doing it on a jet ski was as good of a place as any.
Then they invited me to play horseshoes. Well. I kindly declined saying that they didn’t really want me to play horseshoes. They said that they needed two teams of two, and they would really appreciate it if I joined them. So, I succumbed.
My first throw was very impressive as it bumped right up against the stake. I knew that this was just beginner’s luck, I really wasn’t a beginner. I had played a lot of horseshoes as a kid. Only, I had lost any sort of self-control when it came to letting lose of the horseshoe. I think it was my third throw that did it. The horseshoe literally ended up behind me. I think I almost hit Tek’s pickup. (Tek was Dee’s husband’s nickname or was it Tex?). When I let go of the horseshoe and it went flying through the air, everyone scattered.
There was an interesting character that came by when we were at the Pawnee Lake. His name was Trail Boss. He was a larger sociable person. Someone that you would think would come from a town called Pawnee, Oklahoma. There was another guy that was there that scattered when Trail Boss showed up. So, I made a comment to the Boss that he seemed to have quite an influence on people. I figured that was why they called him Trail Boss.
Anyway. There were a lot of other things that the Power Plant Men did for recreation. I could go on and on. Maybe some of the Power plant that read this blog will post some of them in the comments. I purposely didn’t mention anything about “Noodling” (except for just now). I think I’ll do that in another post some time later.
Though I was like a fish out of water when I was with the Power Plant Men enjoying their time off, I was always treated as if I belonged. No one made fun of me even when they were scattering to dodge a rogue horseshoe. When I went fishing with them as a new summer help when I was 18 years old, I was never shunned and no one ever looked down on me. I have to give them this: True Power Plant are patient people. They put up with me for 20 years. I can’t ask for more than that.