Originally Posted April 18, 2014:
When I was an electrician at the coal-fired Power Plant in North Central Oklahoma I inherited working on the Precipitators from Sonny Kendrick, the Electrical Specialist in the electric shop. One time after I had been struggling with the performance of the precipitator trying to lower the emissions of Fly Ash going out of the smoke stacks, I encountered a very odd situation.
One morning as I was walking out to the precipitator as I passed the Unit 1 boiler I noticed that a couple of tanker trailers were sitting outside the bottom ash area. Hoses had been attached to one of them and were running up the side of the boiler. What looked like a pump was running. I didn’t have a clue what was in the tanker. I figured it was just some routine thing that power plants did every so often to make things more interesting. You wouldn’t believe how many times Power Plant Men would come up with new and interesting things just to keep me in awe. (Of course, I am easily amazed).
Anyway, I didn’t really pay much attention to the tanker on the way to the precipitator. I just walked around the tankers that were there and entered the precipitator switchgear and up the stairs to the Precipitator control room where 84 control cabinets were waiting for my attention. On the way into the switchgear I had glanced up at the smoke stacks and noticed that the exhaust from the boiler was looking pretty good.
As I walked passed the control cabinets that controlled the back of the precipitator, I was surprised to find that they were powered up all the way and there wasn’t any sparking happening. Well. I thought. Maybe they are at low load and not much is happening inside the precipitator this morning.
As I walked between the two rows of cabinets toward the cabinets that controlled the transformers near the intake of the precipitator, my surprise turned into astonishment. I had never seen the front cabinets powered up to such a high level with no sparking. Everything was 180 degrees from the way I had left the cabinets the evening before when I was struggling to adjust the power to lower the emissions.
After going through each of the cabinets adjusting the power levels higher only to find that I was able to easily increase the performance even further, I returned to the electric shop for break. When I arrived in the electric shop office I told Charles that something very strange had happened this morning and I’m trying to figure it out, because all of the sudden the precipitator was operating at maximum efficiency.
After break I walked back out to the precipitator control room past the tanker trailers and found that everything was still running smoothly. “My work is done” I thought. I decided to go to the top of the precipitator and start working on fixing malfunctioning vibrators for the rest of the day.
I worked on the precipitator roof until noon, and then went back to the shop for lunch. I sat with Charles as we talked about movies we had seen. Charles was telling me about how the song for Ghostbusters had been on the radio. When the song said,
“If there’s something strange
in your neighborhood
Who ya gonna call?
Charles’ son Tim (not having seen the movie) thought that instead of saying “Ghostbusters” they were saying “Who ya gonna call? Charles Foster!” Besides being exceptionally cute, it was also an honor for Charles for him to hear Tim sing, “Who ya gonna call? Charles Foster!”
After lunch was over I went back out to the precipitator control room to check on the cabinets one more time. To my surprise when I walked through the row of cabinets, they were sparking again as they had been the day before! Not quite as bad, but bad enough that I had to go through the cabinets and adjust them back down almost to the levels where I had them before.
It took longer to adjust the cabinets down than it did to raise them in the morning. When break time came along, I was too engrossed in adjusting the cabinets to notice, so I continued working through break. It must have taken me close to three hours. At that time I was still using a small screwdriver on some potentiometers inside each of the cabinets to make the adjustments.
About the time I finished, all the sudden something happened. The cabinets began acting the way I had seen them in the morning! All the sparking stopped and the cabinets began powering up to the highest point they could go based on where I had set them. Ok. Now I needed to find out what was going on!
I walked out of the precipitator and headed for the Control Room. I walked past the tanker trailers and noticed that the pump was running again. I hadn’t thought about it, but when I had walked by them a few hours earlier they had been turned off. This was curious. I figured that it was more than a coincidence.
Pat Quiring was the Unit 1 Control Room operator when I arrived. I asked him what has been going on with Unit 1. I explained to him that when I arrived in the morning I found the precipitator running smoothly, then later it wasn’t, and just a few minutes ago, something happened again and there it was. Pat said two things were going on that day.
One thing was that we had been burning a pile of sand that had been soaked with oil. They had been mixing it with the coal at the coalyard and blowing it into the boiler with the pulverized coal in order to dispose of the hazardous waste. Hmm.. This was a possibility. I couldn’t see how the sand would make a difference, but maybe the mixture of the chemicals in the oil had something to do with it.
Then I asked him. “What about those tankers on the side of the boiler? Why are they there?” Pat said that we were also burning Vertan. Well, not “burning” exactly. We were destroying it in the boiler, because it was chemical waste that needed to be disposed and it is easily destroyed into it’s chemical components in the heat of the boiler.
“Vertan? What’s Vertan?” I asked Pat. He said it was some chemical used to clean boiler tubes. These tankers had been sent to our plant from another plant that had just had the boiler tubes cleaned, and we were just burning it off to get rid of it. They had a schedule they were using to burn the Vertan. They couldn’t just get rid of it all at once because it caused a buildup in the economizer that caused the airflow to be affected through the tail end of the boiler.
So, I wondered, maybe this has to do with airflow. Diverting the airflow to different parts of the precipitator could definitely affect things. The cabinets out in the middle of the precipitator definitely had different electrical properties than those out on the edge.
I suddenly realized that this was 1988 and the Internet was not readily available to the typical user, and the World Wide Web still had a few years before it was widely going to be used. Frustrated that I couldn’t just go “Google” something for another ten years, I did the next best thing that I could do. I decided to pay a visit to our Power Plant Doctor! I wrote about Doctor George Pepple in the post “Power Plant Doctor Does a Jig in a Puddle of Acid“. He was the head Power Plant Chemist.
I went to the Chemistry Lab and found George working away on some diabolical experiment. No. Not really, he was probably just testing some water samples. When Dr. Pepple was working on any kind of chemical test, he did it with such mastery and grace that it always reminded me of a mad scientist.
I asked George about Vertan. He explained to me that it was a chemical that was mixed in water and pumped through the boiler tubes to clean out calcium buildup and the like. I mentioned to him that I thought it may be affecting the operation of the precipitator and I was curious to know more about it.
Professor Pepple then explained to me that Vertan was called TetraAmmonia EDTA. EDTA? Yeah, he said, “Ethylenediaminetetraacetic Acid”. He said this just like my Animal Learning Professor, Dr. Anger used to say “Scopalamine” (See the Post “Poison Pill for Power Plant Pigeons“).
I wrote down this information and I continued monitoring the progress of the precipitator throughout the rest of the week. Each time the pumps were running on the Vertan trailers, the precipitator operated as if it was new and completely clean. Each time the pumps turned off, the precipitator reverted back to the regular mode of operation, only it would be a little better each time. By the time all the Vertan had been destroyed in the boiler, the precipitator was running very well on it’s own.
Over the weekend I went to the University Library at Oklahoma State University in Stillwater and Looked up TetraAmmonia EDTA. Not much had been written about it. I was able to find an article about it in a Journal. It had the chemical composition.
A few years later when the Internet became available I was able to find a better model of the Vertan molecule:
I mentioned that at the same time that the Vertan was being burned in the boiler, we were also blowing contaminated sand into the boiler in order to burn off oil that had soaked into the sand. At one point, I had to go work on the head end of the number 10 long belt to find a 480 volt ground in a circuit. When I arrived, I could see where the oil from the sand had caused the coal to cake up on the belt and cause a big mess where the conveyor dumped the coal onto the belt 12.
There didn’t seem to be any correlation between the times that sand was being burned. The process for burning the sand lasted a lot longer than burning off the Vertan. By the time that the sand was burned off, the precipitator was humming away operating at near maximum efficiency. So, it seemed as if the sand didn’t have anything to do with the increase in performance.
I was convinced that burning Vertan in the boiler was more convincing. If not Vertan, then just injecting water could have been a factor. Since the Vertan was in water and they were pumping large amounts of water into the fireball in order to destroy the Vertan. Maybe the increase in Humidity had something to do with the improvement.
A couple of years later when the “We’ve Got The Power” Program was underway (See the Post, “Power Plant ‘We’ve Got The Power’ Program“). Terry Blevins and I were investigating the idea that Vertan could be used to improve the performance of the precipitator. We found that Ammonia Injection was used to treat Precipitators.
This is done by injecting ammonia into the intake of the precipitator to treat it when it was performing poorly. This reinforced our idea that Vertan was the main reason that the precipitator had responded favorably during that time since Vertan broke down into Ammonia at high temperatures. Even then, we didn’t exclude the possibility that the increase of humidity may have also played a role.
Another team had the idea that injecting sand into the intake of the precipitator would improve the performance of the precipitator by sandblasting the ash off of the plates. They had seen this happen when sand had been burned earlier. I had rejected this idea as being viable. I knew that the velocity of the airflow in the precipitator was no faster than 4 miles an hour. Hardly fast enough to keep grains of sand airborne.
It was worth a try though, and the other team pursued the idea and ran a test by injecting the sand. It definitely wouldn’t hurt anything to try. The idea was rejected by the Steering Committee (Ron Kilman), based on my input, even though something extraordinary happened during the test. When this happened, I became the instant enemy of the team leader.
I will cover this dilemma in a later post (possibly next week). For now I will just leave you with the knowledge that because I had chosen Vertan over Sand, I had definitely made an enemy of a True Power Plant Man.
I don’t know if they called them “Black Ops” in 1994, but when the control room operator David Evans answered the phone that day in October, I don’t think he ever expected to have the person on the other end of the line tell him that a military special forces unit was going to stage a mock raid on the coal-fired power plant in North Central Oklahoma some time that night. I’m sure Jack Maloy, the shift supervisor, was equally surprised when David told him about the phone call. I heard later that Jack was pretty upset to find out that a military force was going to be attacking our plant in the middle of the night without his permission!
The first we heard about the call was when Jasper Christensen called a meeting of the entire maintenance department on the spur of the moment in the main break room. He told us about the phone call. He said we didn’t have any more information than that. Though the maintenance department shouldn’t be working that night, Jasper said that just in case we were called out for something, we should know that a group of commandos were going to be performing some sort of mock raid on our plant. If we encountered any soldiers sneaking around the plant in the middle of the night in full military gear, not to be alarmed. Just go on doing what you’re doing and don’t bother them.
Now that it is 21 years later (well, almost) the truth can finally come out…. Isn’t that how it goes? When we are sworn to secrecy, isn’t it 21 years before we can finally speak out? (That’s what Shadow Warriors always told me). I don’t remember us taking an oath or anything, but that’s the way it is with Power Plant Men. They just assume that if the military is staging a mock raid on our plant, it is a matter of national security. It seemed as if our plant sort of matched the layout of a power plant somewhere in Central America where the real raid was going to take place.
The main difference between our Power Plant and the one in Honduras, or wherever it was, is that our plant had recently gone through a downsizing. So, our operators at night now had to perform the duties that had before been done by the labor crew. They had to do coal cleanup throughout the conveyor system.
This meant that if one of our auxiliary operators happened to run across someone dressed in the outfit above, they would have naturally handed him either a water hose or a shovel and pointed to the nearest conveyor and said something like, “I’ll start on this end, and you can start over there.” After all. He would already be wearing his respirator.
That day on the way home, Scott Hubbard and I discussed the significance of such a raid on our Power Plant. A year and a half earlier, Janet Reno had really messed up the raid on the Branch Davidian compound in Texas when it burned down and burned everyone to death including women and children. So, it would be good to go into a situation like this more prepared.
I had often thought about the steps that could covertly be taken to single-handed destroy the power plant without using any kind of explosives. Those who understood how all the systems worked together could do it if they really wanted to. Of course, that was just how I might occupy my mind when I was doing a repetitive job, like sweeping out the main switchgear. What better place for those thoughts to drift into your mind.
Actually, now that I think about it, instead of sending in the Special Forces, just send in a few Plant Operators, Electricians and Instrument and Controls guys and they could totally destroy the plant in a matter of hours if that was their intent. The same thing could be said about putting a few incompetent people in upper management even if it isn’t their intent, only it takes longer than a couple of hours to destroy the plant in that case.
The next morning when we arrived at the plant, our foreman Alan Kramer told us the stories about the raid that happened the night before. This is what I can remember about it (if any Power Plant Men want to correct me, or add some more stories, please do in the comments below).
First he said that it appeared as if the commandos had landed in some kind of stealth helicopter out on the north side of the intake because later when the power plant men had investigated the site they could see where two wheels on the helicopter had left an impression in the mud. Dan Landes had been keeping a lookout from the top of the Unit 1 boiler, and he thought for a moment that he saw the flash of a red light…. which… thinking about it now, could have been one of those laser sites taking aim at him and mock assassinating him by shooting him in the eye from about 1/2 mile. You know how good American Snipers can be (my plug for the new movie). Good thing he was wearing his auto-tinting safety glasses.
We also heard that one of the operators, Maybe Charles Peavler (Charles is standing next to Dan wearing the pink shirt and carrying something in his lower lip) had stepped out of the office elevator on the ground floor only to come face-to-face with a soldier. When the soldier was seen by the operator, he just turned around and walked out of the door… he evidently was considered a casualty if he was seen by anyone. Either that, or he had to go do coal cleanup the rest of the night.
I think it was Jeff Meyers (front row, left in the picture above) who told us later that the Special Ops forces had left a present for the operators on the Turbine-Generator Room floor. Tracked across the clean shiny red T-G floor were muddy boot prints leading from the Unit 1 boiler entrance to the door to the control room. The tracks ended at the control room door.
The tracks were extra muddy as if someone had intentionally wanted us to see that someone had walked right up to the control room door. The tracks did not lead away from the door. They just ended right there.
So, we did have proof that the commandos had actually visited our plant that night, only because one of the operators had come face-to-face with one in the main lobby. If that hadn’t happened, then they would have come and gone and we would have been none-the-wiser… other than wondering about the strange muddy footprints and the impression left in the mud by the stealth helicopter.
I suppose it was easy for the Power Plant operators to ignore the commandos since for the most part, they never saw them coming or going. The Power Plant Men were happy to play their part in the mock raid. Of all that has been asked of these Power Plant Men over the years, this was one of the more “unique” events. How many Power Plant Men across the country can say that they took part in a Special Ops Commando Raid on their Power Plant?
All I can say is that the commandos sure picked a great bunch of Power Plant Men and Women to attack. We were all honored (even those of us who were at home in bed asleep at the time) to be able to help out the military any way we could.
I woke up from a dream this past Wednesday where I had just insulted a young lady who had cancer treatment by calling her “baldy”. In the dream I was attempting to be funny, but as soon as I said it, I knew I had crossed the line of common courtesy. I acknowledged right away that “I shouldn’t have said that”, and rose from my chair to go find whoever it was so that I could apologize. In my dream I was never able to find the person, though I thoroughly searched whatever restaurant-factory-office building we were in. You know how thing are in dreams.
I preface this post with that thought because someone may take offense to the title I have chosen today. So, let me just say that this is a story about someone that has been the source of constant conversation in my family for the past 30 years. Though I never refer to him as “Frog”, that is a title reserved for one of this man’s best friends. It is an expression of friendship bestowed upon Walt Oswalt by Ray Eberle.
Ray Eberle is the most amazing storyteller of our time. He captivated Power Plant audiences for the past 40 years up until the day he recently retired. I have heard hundreds of stories by Ray, but none of them were ever said with more compassion and humor than the stories that Ray Eberle would tell me about our fellow Power Plant Man, Walt Oswalt.
I used to think that Walt’s parents name him Walt so that it would be easy for him to spell his entire name. Once he learned his first name, he just had to add an OS to it, and he could spell his last name. Well, actually, his full name was Walter Lee Oswalt. But whose counting? I also thought that OD McGaha (prounounced Muh Gay Hay) was in a similar situation, because OD simply stood for OD (prounounced O-D or Oh Dee). Not to forget Dee Ball. I’ll bet all of these guys could spell their names by the time they graduated the third grade.
Look closely at Ray Eberle’s picture above, because if you look closely into his eyes you can see that back behind those orbs, thousands of wonderful stories are packed in there waiting to be told. I don’t know if I have mentioned this in a post before, but Ray looks just like my grandfather when he was younger. I think I mentioned that to Ray one day. Since those days when we used to sit side-by-side working on the computers in the Coal-fired Power Plant in North Central Oklahoma, I have loved Ray with all my heart as if he is a member of my family (see the post: “Tales of Power Plant Prowess by Ray Eberle“).
Even though this post is about Walt Oswalt, I am spending an unusual amount of time talking about Ray, because the stories I am about to relay are told through the eyes of Ray. I have already passed on some stories about Walt in other posts, so I will focus on those stories about Walt experienced by Ray. I will only scratch the surface today, as it takes some time to absorb the universal significance of each story. If I flood you with too many Walt Oswalt stories at once it may cause confusion. I appreciated the fact that Ray didn’t lay all his Walt Oswalt stories on me in one sitting for this very reason.
Ray Eberle began his stories about Walt by telling me about going over to Jimmy Moore’s new house. Jimmy had just moved into a new house outside Morrison Oklahoma not too far from Ray. Ray described how nice the property was at the time. It was a picture perfect piece of property. The surrounding fields were pristine giving the feeling of peace when you looked around.
Note the Sparco notepad in Jimmy’s pocket. A Power Plant Electrician Necessity, just like the notepads I always used:
Just when Ray was soaking in the perfection of Jimmy’s new property, dreaming that he could have found such a great spot, Jimmy mentioned that Walt Oswalt bought the property across the road. Ray’s response was “Frog bought the land across the road? Oh no!” Not wanting to upset Jimmy, he didn’t say anything else, but he was thinking it…. You see, Walt is sort of a “junk collector”.
I have always been a junk collector myself, as you may have figured out by the fact that I still have a notepad left over from Christmas 1995. Actually, I could take a picture of the Sparco notepads I have kept from my time at the power plant and it would look like this:
So, I was a note taker… Each page of these notepads are filled with work order numbers, part numbers, phrases I heard, Things Gone Right, Things Gone Wrong meeting notes, Meeting schedules, tools needed, and sometimes just thoughts that came to my mind. I am mentioning this because I have this common bond with Walt. We both like to collect things that others see as “junk”.
Ray was worried that after Walt moved in across the road that the Beatrice Potter Meadow was going to change into Fallout 3 terrain (well, my phrases, not his, but I think you can picture what I am saying). From what I understand, this is what happened. — This by the way is not a Walt Oswalt Story. This has been more of a Jimmy Moore story.
I have been waiting so long to actually write down a Walt Oswalt Story that I actually find it hard to bring myself to put it down on virtual paper, but here goes….
Here begins the first Walt Oswalt Story:
In the mid-90s the Internet was something of a new phenomenon. I had taught most of the Power Plant Men how to use the Internet (excluding upper management) as you can read in the post: “Power Plant Quest for the Internet“. One person who immediately saw the benefit of using the Internet beyond looking up indecent pictures or connecting with clandestine online “Match.com” experiences was Walt Oswalt. Walt saw “business opportunity”!
So, follow me on this story, because Walt stories can become complicated on paper because I can’t talk using my hands. I may need some help from Walt’s son Edward, since he played a major role in this one…
One day, Walt and Ray were talking and Walt told Ray that he was looking at buying a dump truck. Let me just show a picture of a dump truck, even though I don’t know the specific truck Walt had in mind. I just know the approximate size:
Let’s just suppose that it is a truck like this…. anyway, Walt explained to Ray that he could buy the truck he wanted up in Wichita one hundred miles away. However, Walt wasn’t going to do that. He had found the same truck on the Internet for sale for $500 cheaper near Virginia Beach, Virginia, 1,400 miles away.
Ray asked, “But isn’t it going to cost you more than that to have the truck shipped to Oklahoma?” “Oh, I have that all figured out. I’m going to go pick it up myself.” He went on to explain that he and his son (this is where Edward enters the story) were going to drive non-stop to Virginia Beach and pick it up. They won’t have to stop because they can trade off driving while the other rests.
So, a marathon trip for 2,800 miles was planned. Walt had a trailer attached to his truck to bring the new truck back… Though I’m not sure why the thought that they could just drive the new truck home wasn’t considered (or flying out there and driving the truck back, but then, that would cost more than the $500 they were saving by buying the truck)…. The plan was that they would load the truck on the trailer and haul it home. Maybe it was so that they didn’t have to stop because they could swap off driving if they were only driving one of the two trucks.
Two members of the Oswalt family took off for the East Coast one Friday evening. They arrived early Sunday morning at the place of business where they were going to purchase the truck. From what I understand, the business was closed, (being Sunday, and all), so they called the owner and told him they were there to pick up the truck. After waiting a few hours, the truck was purchased, and Walt and Edward were on their way back home.
A couple of days later, Ray noticed that Walt had made it back home, so he went over to his house to see how he managed. Obviously, after travelling 2,800 miles in four days, the two were bushed, but the new truck was finally home. While Ray was talking to Walt about his trip, he happened to notice that the back of the dump truck was loaded with blown out tires.
“Hey Walt, what’s up with all the tires?” Ray asked. “Oh. Those.” Walt replied…. “Well, the trailer wasn’t really big enough to carry this much weight, so we kept blowing out tires on the trailer when we were coming home.” They must have blown out more than 20 tires driving home. So, it seems to me that this turned out to be a pretty costly savings of $500.
I would leave this story at that, but after a couple of trips to Los Angeles and back from Round Rock, TX, I have to say that spending countless hours with your family in the car where there is nothing to do but to talk to each other is an incredibly priceless experience. Once, my son Anthony and I drove the same distance, 1400 miles non-stop from Los Angeles to Round Rock without stopping and we talked the entire time. I would say it is an experience worth a million bucks.
The night before last, I received a message on Facebook from a Power Plant Technician, Doug Black. He wrote: Sooner retiree, Walter Oswalt passed away on September 30, 2015. Walter will be laid to rest at Yukon Cemetery with a grave service on October 23, at 2 p.m.
I looked up Walt’s Obituary, and it seemed to me that there was one phrase missing from the description. It said that “Walt had went to work for OG&E in Mustang Oklahoma and later retired from the OG&E plant in Redrock…” I didn’t see the words, “Power Plant Legend” mentioned anywhere in the Obituary. It should be mentioned, because that’s exactly who Walt Oswalt is.
I may not have had the benefit of sitting in a truck with Walt for 20 hours at a time, but I was able to work one-on-one with Walt one day for 19 hours straight on a Saturday when we were on “Coal Cleanup” that had turned into a job repairing conveyor belt rollers. During that day, while I was a young man of 20, I went through the motions directed by Walt to remove and install rollers on the number 10 belt up toward the top.
I didn’t have much of a clue about what I was doing, but I had placed all my confidence in Walt. I felt the entire time as if Walt was keeping me safe in a potentially unsafe situation even after being awake for 19 hours. So, I have a little knowledge of what the road trip was like that Walt and his son Edward took “There and Back Again.”
It may seem that Walt had made a bad decision to make the Internet Purchase of a truck 1,400 miles away in order to save $500, but I think that God helps us along some times by sending us down a path that seems a little foolish, only to force us into a benefit we would not otherwise encounter. I keep Walt in mind whenever things like that happen to me today and I thank him for keeping me from being disappointed with those times in my life.
Now that Walt has met his maker, I’m sure that Walt is sitting there with Jesus Christ reviewing not only Walt’s life, but also Ray Eberle’s retelling of Walt’s story. Walt may now be surprised to find that moments that he thought were rather insignificant to anyone but himself have actually been spread to others across the world. As I mentioned in the post about Ray Eberle, a few years ago, CEOs of large companies across the U.S. were all learning about the “Wisdom of Walt”. Some day I wouldn’t be surprised to find that the Walt Oswalt Stories have become required reading in Oklahoma Schools.
Rest in Peace Walt Oswalt. We all love you.
Since this was originally posted, Jimmie Moore has also passed away. I visited his grave this past summer in Morrison, Oklahoma on July 17, 2018. Jimmie was always a steady presence in the Electric Shop when I worked there. He was the more “grown-up” member of the family. Now that he has joined many of his Power Plant friends in heaven I’m sure his steady presence is much appreciated.
Comments from previous post
this was originally posted on January 7, 2012. Added a picture of Sonny Karcher:
When I heard the sad news of the death of Sonny Karcher on 11/11/11, I wished I had been able to attend his funeral. I did reserve some amount of time that night when I heard about his death to remember the times I have spent with Sonny. All of them good, as Sonny was always pleasant to be with even when he was mad about something. Here are some of the first and last things I remember:
When I first worked at the Sooner power plant the summer of 1979, Sonny and Larry Riley were the first two mechanics I was assigned to work with. They taught me how things were at the plant at that time. Both of the units were still under construction, so there was no electricity being generated.
The first job we were to work on (my second day at the plant, since the first day was taking a safety class, and getting my hard hat and safety glasses and getting fitted for ear plugs) was a stuck check valve in the dumper sump pump pit (Not only did I not know what a check valve was, I wasn’t too sure what was meant by a dumper sump, though I did know “pump”).
It took us about an hour to take the truck to the coal yard, as a coal yard foreman Richard Nix had the key and wasn’t going to give it to us until one of his hands was ready to go with us. So we sat in the truck parked in the north entrance of the maintenance shop for almost an hour. When the guy was finally ready, and he had climbed in the back of the pickup, it turned out that he only needed to go as far as the parking lot… about 200 yards away (as the parking lot was at the Engineer’s shack at the time). We dropped him off and drove up to the coal yard, and made our way down belt 2 to the sump pump pit at the tail end of the belt.
We tested the pump and saw that the water would run back into the sump once the pump stopped running. So, it was determined that the check valve was stuck. We drove back to the plant and took the morning break.
About an hour later, Sonny told me to go to the tool room and get the following items (which I thought was a joke, because he gave me such a strange list of tools that I didn’t recognize): Two ¾ box ends, One four foot soft choker, a ¾ come-along, a ¾ shackle, a two foot steel choker a flat bastard file, a large channel lock, and two pry bars (I did recognize Pry Bars and shackle, which I believed was thrown in there just to make it sound legitimate). – I wrote down the list, because I recognized right away that a joke was being played on me and I was going to play right along.
So, I went to the tool room and I asked Bud Schoonover (a very large tall and easy going man at the time), “I need a ¾ come-along (I thought I would choose the most ridiculous item on the list first, just to get on with the joke…). Well. Bud turned around, walked to the back wall, took a come-along off the top of a pallet full of what appeared to be a bunch of junk, and laid it across the tool room gate window (The tool room was still being “organized” at the time).
So, I asked for two ¾ box ends (this was before anyone had been issued toolboxes by the way, that’s why we had to go to the tool room for these things). Well, you know the rest of this part of the story. These are all legitimate items, and I learned a lot that day and the next few weeks about the names of various tools. I kept that list in my wallet for over 10 years as a reminder to myself of when I first came to the plant, and how much I didn’t know then.
So, Larry, Sonny and I went up to the coal yard, and went down to the tail end of #2 belt and removed the check valve from the discharge pipe and brought it back to the maintenance shop to repair. When we returned, we went to lunch. During lunch Sonny told me about how he was hired at Sooner plant.
He said he lived a few miles down the road and had heard that someone was building a lake up on top of the hill he could see from his property. So, he went on over to see who was dumb enough to build a lake on top of a hill, and while he was looking around Orville Ferguson came up to him and asked him if he was looking for a job. Sonny said that he liked to mow grass, and Orville said that he would hire him to mow grass then. Sonny said, if I remember correctly, that he was hired at the same time that Linda Shiever, the timekeeper, was hired and that they were the first two new hires at the plant. The rest were already company employees that had transferred there.
After lunch we went down to the shop and took the check valve apart and what do you know…. There was a piece of coal stuck in the check valve keeping it open. We cleaned it up and put it back together. When we were finished, we took our afternoon break. After break we drove back up to the coal yard and went down to the tail end of #2 Conveyor belt and put the check valve back in the discharge pipe. When we returned to the maintenance shop, we returned the tools to the tool room and filled out our time cards. A day’s worth of work cleaning a check valve.
I did many other things that first summer, since Sooner Plant didn’t have a yard crew yet, I worked most of the time in the maintenance shop bouncing around from crew to crew helping out. I also did a lot of coal cleanup (especially on weekends), since the conveyor system didn’t work correctly when they started it up when they were starting to fire up unit 1.
The second day before I left at the end of the summer to go back to school, I worked again with Larry Riley and Sonny Karcher to fix the exact same check valve. This time we jumped in a truck (we had a lot more trucks now…. Which is another story), went to the coal yard, went down #2 tunnel to the tail end of #2 Conveyor, pulled out the check valve, removed the piece of coal, put the check valve back in, went back up to the truck and back to the maintenance shop just in time for morning break. Sooner Plant had improved a lot in the short three months I worked that summer.
I worked many years with Sonny Karcher in the garage, and fixing coal handling equipment, and just about anything else. He finally left the plant to go mow grass, when after a battle to move to the garage from coal yard maintenance to mow grass, he was told that he was going to have to go back to the coal yard to be a coal yard mechanic, because he was real good at that and they just needed him up there. So he left.
He talked to me about it before he went, that’s how I know what was on his mind. He said, “Kev, you remember when you first came here and I told you how they hired me to mow grass? Well, that’s what I want to do. Mow grass. So I’m going to have to go back home and do just that.”
After that, the only times I remember seeing Sonny was when he was mowing grass down at Bill’s corner, with a smile on his face waving at the Sooner plant employees on their way home from work.
I can see Sonny talking to St. Peter at the gates of heaven now….. The only words I can hear Sonny saying is, “I like to mow grass”… and St. Peter nodding with approval as he lets him through the gates.
Originally posted on: June 1, 2012
The first couple of years while I worked as a summer help at the Coal-Fired Power Plant Coal Cleanup was performed on weekends by volunteer He-Men that wanted to make a few extra dollars. As a summer help, I needed all the extra money I could get. My wages during the first year (1979) were $3.89 an hour.
This jumped to $5.84 an hour when I worked on the weekend, so you can imagine the thrill I had at receiving a paycheck that included the extra money made by doing “Coal Cleanup”. Another great advantage to doing coal cleanup on the weekends was that I was able to carpool with different people. So, during the first summer instead of just riding to work with Steve Higginbotham (See the post “Steve Higginbotham’s Junky Jalopy late for the Boiler Blowdown“), I caught a lot of rides with real Power Plant Men like Dale Hull, David Hankins, Jerry Mitchell, Preston Jenkins and Marlin McDaniel (Yeah. Marlin McDaniel as an A Foreman would volunteer for coal cleanup some times. Maybe it was when we were short a few people).
Coal Cleanup really became important during the second half of the first summer because Unit 1 was getting ready to go online. There was a major flaw in the Coal Conveyor logic when the conveyors first started conveying coal from the coal pile to the coal silos just above the bowl mills. What would happen was the same thing that happens if someone were to fall down at the top of a crowded escalator going up. Everyone behind that person would be shoved right on top of them if there wasn’t an emergency stop button to stop the escalator.
All the conveyors had a safety cord alongside the entire length that could be pulled to stop the conveyor in an emergency, but this was something different.
To give you an idea… once the coal on the coal pile has been fed onto either Belts 4, 5, 6 or 7, from there the coal is dropped onto either belt 8 or 9. That carries the coal up to the coal Crusher which has a bin above the crusher that can be filled with coal. If the bin gets too full, then conveyor 8 and/or 9 would stop. When that happens, belts 4, 5, 6 or 7 should stop also…. only they didn’t. Belts 8 and 9 continued dumping coal into the crusher bin until it filled up and then coal fell out all over the top of the crusher tower around belts 8 and 9 until the coal tripped the belt by hitting the safety cord on the side of the belt. Belts 4, 5, 6 and 7 continued dumping coal onto belts 8 and 9, which caused the coal to backup and spill out all over the floor until the coal piled up high enough to trip the safety cord on the side of the belt.
In the picture of the power plant on the side of this post, there is one long conveyor that goes from the coalyard to the plant. It is about 1/2 mile long. This is where belts 10 and 11 carry the coal from the crusher, which crushes the coal down from big pieces the size of baseballs down to the size of walnuts.
At the top of the Transfer tower the coal from belts 10 and 11 are dumped onto belts 12 and 13 which carry the coal up to the Surge Bin Tower where the coal is dumped into the Surge bin. Now when the Surge Bin fills up, it stops belts 12 and/or 13 and it should also stop belts 10 and 11 and the feeders that feed the coal into the crusher at the bottom of the crusher bin… only they didn’t.
They continued dumping coal into the Surge bin, which filled up and spilled coal all over the surge bin until belts 12 and 13 tripped, at which point, coal began spilling out all over the transfer tower filling up both floors of the transfer tower with tons of coal. The same thing would happen at the bottom of Belt 10 and 11, where the crusher feeders kept feeding coal down to belts 10 and 11, which spilled out all over the bottom floor of the crusher tower.
I have worked in the transfer tower where the coal was higher than the windows and you had to bend over because your head would hit the ceiling on the floor at the foot of belt 12 and 13. It was almost dangerous enough to picture yourself sliding down the pile of coal and slipping right out one of the windows (which had been broken out by the pile of coal). To give you an idea of what this felt like, it was then a straight drop of 150 feet to the concrete below.
If that doesn’t seem like enough coal spills, then picture this… The coal from the Surge Bin tower fed onto belts 14, 15, 18 and 19 which in turn fed onto belts 16 and 17, 20 and 21. These last 4 belts were in what was called the “Tripper Gallery”. These 4 belts would dump coal into 12 coal silos (6 on each unit) that would feed the bowl mills. These are big silos about 5 stories tall.
The same thing would happen to these belts leaving piles of coal at the bottom of the surge bin in the surge bin tower and all along the tripper gallery because when the coal silos were full, the tripper was supposed to move to the next silo and dump coal until it was full, and keep moving until all the silos were full. Only, the tripper wasn’t working correctly, so it wouldn’t detect that the silo was full so the belt would keep dumping coal and would end up spilling coal all over the entire tripper gallery which runs about 100 feet or so.
So, our first experience with doing coal cleanup was like being on a chain gang where we shoveled coal from morning until night trying to clean up these 15 or so major coal spills by shoveling the coal back onto the conveyor while it was running. In some cases, we had to shovel the coal away from the belt before the belt could even run (as was the case with belts 12 and 13). So, you can imagine how shoveling coal one scoop at a time made it seem like you were not getting anywhere fast. 3 or 4 men could all be shoveling on one pile of coal for 30 minutes and not even make a noticeable dent in the pile. That is why when I went to the tool room to choose a shovel, instead of picking a regular shovel, I picked a large scoop shovel used to scoop grain.
Even though each scoop of coal was heavier, it seemed more satisfying to see the bigger dent in the pile of coal with each shovelful. I remember one day after we had shoveled coal all day from morning until late at night only to come back into work the next morning to the new piles of coal just as big as the ones we had shoveled the day before.
After 2 years of volunteer coal cleanup which was becoming less volunteer and more rotational since the list of volunteers was growing smaller, Ray Butler pointed out that it didn’t make much sense to pay a first class machinist overtime to shovel coal when you could create a labor crew and pay them bottom dollar to do coal cleanup all the time, as well as other dirty jobs that no one really wanted to do (such as suck out sewage pits and other sump pits around the plant).
That was when the Labor crew was formed. While I was in my 3rd year as a summer help (1981). Bill Cook was a summer help then that stayed on as a labor crew hand at the end of the summer. By the 4th summer as summer help, the only time we did coal cleanup was when there was a major spill, which was only a couple of times all summer.
I will write later about coal cleanup with Dale Hull. I also remember doing coal-cleanup with Preston Jenkins one weekend. I hadn’t carpooled with him to work, but I caught a ride back to Stillwater with him because my ride left at the end of a full day, and I decided to stay behind to add a few extra dollars to my bank account. We left a couple of hours later around seven o’clock.
I climbed into the back of Preston’s Camaro. I apologized for being so dirty, as I was covered from head-to-toe in coal-dust and my clothes were soaked with coal-dust permeated sweat. Preston said that he didn’t mind. I soon found out why.
When I climbed into the backseat of his car, I noticed that the upholstery that covered the seat back of the back seat was stained with some blackish-brownish um…. something. Anyway. I decided to sit on the passenger side of the back seat instead of behind the driver side because that side wasn’t nearly as stained. As we drove down the highway toward home, I quickly learned why the seat back was so stained.
Being the “good-ol’ boy” that Preston was, when he climbed into the car, he took out his can of Skoal and put a pinch between his cheek and gums:
As we flew down the highway like a Texan heading for Stillwater, Preston would lean his head out the window and squirt out a wad of spit. It would dance in the air like a little fairy just before it would be sucked into the back window of his car and splat against the seat back of the back seat. Yep that explained it all right. I always wondered if he knew, never having to sit in the back seat of his own car.
During the first summer when I was able to catch a ride with David Hankins a couple of times. He was the crane operator at the time and drove a black Trans Am. He was a black man with a very broad chest that never seemed to tire while doing coal cleanup. From the first day he always treated me with great respect which in turn gave me a great respect for him. I had him classified as a true Power Plant Man.
The second summer when I had been back at the plant for a couple of weeks, one day when Jim Heflin and I were going somewhere in a yellow Cushman cart, I asked Jim why I hadn’t seen David Hankins around.
Jim (who hadn’t been at the plant the first summer) stopped the cart in the middle of the road and looked at me very solemnly and told me that David Hankins had died in a car accident in the spring. He had been going home from a Men’s Club event when he was killed. Because of this, alcoholic beverages were no longer allowed at Men’s Club events. As with all the people I have worked with at the power plant, I keep David Hankins in my memory and I often think about him to this day. David Hankins was a True Power Plant Man.
Comments from the original Post:
neenergyobserver June 1, 2012 as 6:28 pm
We’ve lost so many friends over the years, in the plants and on the line, especially when they were relaxing on their way home. You, and David’s family have my very belated condolences.
Somebody, somewhere, needs to teach engineers a course on Conveyor Logic 101, I’ve seen the same thing happen in nearly every plant (from automotive, rarely, to meat packing, often) I’ve been in. Or they could, just for once in their life, shut their pie-hole and listen to people like you and me.
Plant Electrician June 1, 2012 at 11:39 pm
We were often exhausted while driving home from work when we had been working a lot of overtime. It was a wonder sometimes that we were able to keep the car on the road.
My uncle Bill Breazile worked for the Utility company in Nebraska City where someone closed a breaker while he was working on a line. He was in the hospital for about 6 months healing from his burns. This was about 30 years ago. He has since passed away. It takes a special person to be a lineman. Putting their life on the line every time they reach out to do their job.
neenergyobserver June 2, 2012 at 10:42 am
Not that different from you. It’s all about planning your work, and doing it right, and safely. You and I know that 480 will kill you just as quick as 7200 if you get careless. That’s why almost all (old) linemen and electricians are in some sense stolid and unexcitable.
jackcurtis July 14, 2012 at 12:59 pm
Industrial America returns in stories and comments in places like this, from the only place it still exists: the minds of those who were part of it. Industrial America was a giant; those who manned it were giant tamers and it seems to me, very much the special breed illuminated in these posts…
Comment from last repost:
Originally Posted on August 3, 2012 (I added a picture of Walt Oswalt):
The second summer as Summer Help at the Coal-fired Power Plant, was when I first worked out of the Automotive garage. It wasn’t finished during the first summer. The second summer when I began working in the garage, Jim Heflin, Larry Riley, Doug House and Ken Conrad were the regular workers that mowed the fields using tractors with brush hogs, as I have explained in previous posts. A summer help that also worked with us from Ponca City named David Foster was also able to mow grass using one of the new Ford tractors that we painted Orange to easily identify them as belonging to the Electric Company in Oklahoma.
I learned to drive the tractors later in the summer when I worked irrigating the fields in our attempt to grow grass (as told in the post “When a Power Plant Man Talks, It Pays To Listen“). The next summer I was able to mow grass using a Brush Hog pulled behind a tractor:
It didn’t take long before I had to mow grass on the side of the dam (and other levies). The side of the dam has a very sharp incline, so while mowing grass on the side of the dam you sat more on the side of the tractor seat than on the seat itself. Heavy weights were put on the front of the tractor and the back tires on the tractor were turned around so that they were farther apart than they would be otherwise. This gave the tractor a lower, wider profile and a lower center of gravity helping to keep it from rolling over sideways down the slope.
I had watched Jim, Larry, Ken and David mow grass along some very steep inclines the summer before without any tractors tumbling over, so I felt like it must be safe, even though looking at the tractors they still seemed a little “top heavy”.
It was quite an eerie feeling the first time I actually mowed a slope this steep. I experienced the same feeling as you have on a roller coaster when it hits the top of the hill and flings you down real fast when the tractor tire on the downhill side of the tractor rolls into a washed out spot on the dam causing the tractor to roll over just a little farther than you are used to. It was definitely an adrenaline rush each time this happened, because it felt like the tractor was going to roll over.
That is when I remembered the story about the little engine that was trying to pull the train over the steep mountain, and he kept chanting, “I think I can, I think I can” over and over. So, between each decade of the Rosary that I was saying while counting Hail Mary’s on my fingers, I added in an “I Think I can…” as an added prayer before the next “Our Father”.
In the time that I worked as a summer help we never turned over a tractor while mowing on a slope. That isn’t to say that the tractors didn’t start to tip over. It’s just that if you realize that the large back tractor tire has left the ground and is spinning freely, you could quickly turn the steering wheel downhill so that the tractor would turn downhill preventing it from rolling completely over. The weight of the brush hog on the back helped to keep the tractor snug against the sloping dam.
Years later, after I left the Power Plant, in 2006, my father’s best friend, Tom Houghton, a Veterinarian in Lakeland, Florida was killed in a tractor accident at his family’s farm in Polo, Missouri. This greatly effected my father. He has not recovered from the loss of his friend still today. As I was mowing grass and picturing my sudden demise if a tractor were to roll down the hill, my main concern was the sorrow my family would have felt by my death. Needless to say… I never toppled a tractor.
It was during that same summer in 1981 that I first worked with the Power Plant Icon Walt Oswalt. Every plant must have at least one person like Walt. He is the type of person that once he has something in his mind about how to do something, nothing is going to change it. I know many different stories about Walt Oswalt that have been shared with me, but this is one of my own. Walt is a sandy-haired Irish-looking man that always reminded me of the little old man, Jackie Wright, on the Benny Hill Show.
I now have an actual picture of Walt that I found laying around….
One Saturday while I had caught a ride to the Power Plant to do “coal cleanup” the crew was asked who would like to wash down belts 10 and 11. These are the 1/2 mile long belts that go from the coalyard all the way up to the plant. You can see them on the left side of the picture of the plant on the side of this post. Finding the opportunity for a challenge, I volunteered.
I made my way up to the top of the Transfer tower where I found Walt Oswalt. He was working out of the coalyard at the time and was helping us wash down 10 and 11 belt. Wearing rainsuits and rubber boots we began at the top and worked our way down. It didn’t look like this belt had been washed down for a while. We could blast the tin enclosure with the high pressure hoses we were using to completely wash off all the coal dust that had built up over time. This looked like it was going to be a fun job.
Then Walt pointed out to me that most of our work was under the belt where the coal had built up almost solid up to the belt itself so that the coal was rubbing on the rubber Uniroyal conveyor belt. Remember, if the conveyor belt goes up, it has to go back down also. So underneath the conveyor is where the belt returns. it is a big loop.
So, Walt Oswalt and I spent the rest of the day laying on the grating so we could see under the belts washing the coal down the slope of belt 10 and 11. Under the conveyor is another set of rollers that the rubber conveyor belt rides on it’s return trip to the Crusher Tower. During this time there were two chants that came to my mind…. One was, “Whistle While you Work”, since we seemed to be in some kind of coal mine working away like the Seven Dwarfs (you know… Walt Disney… Walt Oswalt). The other one was the song, “Workin’ In a Coal Mine” (…goin’ down down).
At one particular spot the coal had built up and packed itself in there so much that one of the rollers wasn’t able to turn and the belt was just rubbing on the roller. After we had washed the coal away we could see that the roller was not able to turn still because the belt had worn it flat on one side.
Walt called the Control Room to shutdown the belt so that we could look at it. We could see that the roller was bad. For some reason the other belt (11) was out of commission so without this belt running, no coal was being sent up to the plant. The coal silos and the surge bin hold enough coal for a while but not for too long during the summer when the units need to run at their maximum rate to supply the electricity needed by the customers. We could have the belt shutdown for a while, but not for too long.
I followed Walt down the belt to the Crusher Tower wondering what he had in mind. He didn’t tell me what we were going to do, so I just gathered my clues by watching what he did. When we came out of the belt and left the Crusher I was surprised that it was already dark outside. When I had left the Maintenance Shop it had been morning. Now it was dark. We had spent the entire day (12 hours at this point) in Belt 10 and 11. I didn’t remember ever taking a break or eating lunch or even going to the bathroom. Just holding the high pressure water hose, directing the stream down under the belt… all day.
We walked over to a new building that was still being built called the Coalyard Maintenance Building. This was the new building that was going to be used by the new Labor Crew in a few months. Outside the building to one side was a Conex Box, as I have described before. This is the kind of large box that you see on the CSX train commercials that are being transported by trains.
We used them to store equipment used for specific jobs or crews. In this case, the Conex box had conveyor equipment in it. Walt found a long straight roller that is used under the Number 10 and 11 belts and tied it to a 2 wheel dolly. We rolled it back to the Crusher Tower and began the long trek back up the belt. I was pulling the dolly and Walt was carrying some large wrenches.
When we arrived at the spot where the roller had been worn, Walt called the control room to let them know we were beginning to work. We pulled the safety cords on the side of the conveyor to ensure that the belt would not start, even though we were assured that a Clearance had been placed on the breaker in the Main Switchgear (where I began my first war with the spiders a year later. See the post “Power Plant Spider Wars and Bugs in the Basement“).
Walt climbed over the belt and I stayed on the main walkway. We worked upside down for a while unbolting the roller. At one point we decided we needed some more suitable tools and headed back down the belt to the Coalyard Garage where the heavy equipment is serviced and brought back some large ratchet wrenches and sockets with an extension.
I think the chant, “I think I can, I think I can” was running through my head on our second trip back up the conveyor belt. I think it was around 10pm. We finished changing the roller and decided to leave the old one laying in the walkway for the night. Walt said he would bring it back to the coalyard on Monday morning.
We made our way back to the Maintenance shop where I took off the rain suit and rubber boots that I had been wearing all day and put my regular boots back on. I went up to the control room and asked if anyone could give me a ride to Stillwater since the evening shift of operators were just getting off at 11pm. I believe it was Charles Buchanan that gave me a ride home that night in his little beat up pickup truck.
I never worked directly with Charles Buchanan since he was an operator. The first impression that one may have is that he looks like a caricature of a construction worker in a comic strip.
Charles reaffirmed my belief that Power Plant Men are some of the nicest people you will ever meet. There were a few times when I caught a ride with Charles to or from the plant. Each time I felt honored to ride in his truck. If I think about what chant was running through my mind as we were on our way home at night, I think it would be something like the song “You’ve Got a Friend”: “Winter, spring, summer, or fall, all you have to do is call, Lord, I’ll be there, yeah, yeah, you’ve got a friend….”
That is what all real Power Plant men and linemen are like. Wherever you look in the United States, these great men and women work tirelessly to keep you safe by providing electricity to your homes. Something we take for granted until the power goes out.
Recently when the power went out in the east, the linemen from this electric company drove with pride, eager to help those in need:
Below I have included the lyrics for the song “You’ve Got a Friend” by Carole King and her husband James Taylor. See how well it fits those people that work around the clock bringing the power to your home:
You just call out my name, and you know where ever I am
I’ll come running to see you again.
Winter, spring, summer, or fall, all you have to do is call and I’ll be there, yeah, yeah,
you’ve got a friend.
If the sky above you should turn dark and full of clouds
and that old north wind should begin to blow,
keep your head together and call my name out loud.
Soon I will be knocking upon your door.
You just call out my name, and you know where ever I am
I’ll come running to see you again.
Winter, spring, summer, or fall, all you have to do is call and I’ll be there.
Hey, ain’t it good to know that you’ve got a friend? People can be so cold.
They’ll hurt you and desert you. Well, they’ll take your soul if you let them,
oh yeah, but don’t you let them.
You just call out my name, and you know where ever I am
I’ll come running to see you again.
Winter, spring, summer, or fall, all you have to do is call, Lord, I’ll be there, yeah, yeah,
you’ve got a friend. You’ve got a friend.
Ain’t it good to know you’ve got a friend. Ain’t it good to know you’ve got a friend.
Oh, yeah, yeah, you’ve got a friend.
Here is a YouTube video of James Taylor singing this song:
If your aren’t able to play youtube videos directly from the picture… here is the link: “You’ve got a Friend“
Originally Posted October 5, 2012:
The Coal Fired Power Plant where I worked first as a summer help, then as a janitor, a labor crew hand and finally as an Electrician is located about 20 miles north of Stillwater, Oklahoma. It just so happened that Oklahoma State University in Stillwater has one of the leading Fire Protection and Safety schools in the country. They offer Fire Service Training for companies who need to train their employees how to fight fires. As a summer help I was fortunate enough to take the onsite training that they provided at the power plant about every other summer to train the employees how to put out difficult fires.
It does sound like a good idea considering that there was all this coal laying around that had the habit of spontaneously igniting into smouldering embers that could easily lead to a large raging ball of flames. In fact, the Coal Yard heavy equipment operators had to drive their large dirt movers over and over the coal on the coal pile to pack it down because if it was exposed to too much air, it would develop hot spots that would turn into smoldering piles of coal that were nearly impossible to put out.
I have seen a spot smoldering on the coal pile where a water wagon would drench it with water over and over. That only seemed to keep it from spreading as fast. The only way to deal with it was to drag the burning coal off of the pile and let it burn itself out.
You would think that the OSU Fire Training Service would do a good job of teaching the employees the proper use of the fire extinguishers, and they did. The plant was loaded with Fire Extinguishers. As a summer help and labor crew hand, we would have to do a monthly inspection of all the plant extinguishers to check their pressures and initial the inspection sticker showing that we had been by to check it. This was a practice that would later change to once each quarter when the Power Plant Men were strung out too thin and the labor crew no longer existed. Even later, the operators inspected them as they made their rounds, since they walked by them during their shifts anyway.
The plant had more than just the regular chemical fire extinguishers, it had the larger roll-around type in a few places as well:
The Fire Training Service trained us to use this as well. Actually, they motivated us to go out and buy fire extinguishers to put in our own homes. Which came in handy for me one year when an air condition repairman was using a blow torch in my house to cut out the cooling coils but forgot to take out the filter first.
The moment I saw him light up his torch, I pulled out the extinguisher from under the sink and set it on the counter. As I watched him, he suddenly started jerking back and forth. I figured something was up, so I pulled the pin, and when he was finally able to pull the burning filter out of the air duct, I was ready to blast it with the extinguisher. So, I gratefully thank the electric company for properly training us to use the handy dandy fire extinguishers that you might use around the house.
One important thing that you learn about the little extinguishers in your house is that they don’t really go very far before they run out of chemicals. So, you have to get the job done quickly while the fire is still small and manageable.
When I first heard that we were going to be trained to fight fires the second summer I was at the plant as a summer help, I was pretty excited. Wow… Great!!! Fight Fires! That sounds fun. A day of watching safety videos and playing with fire extinguishers. I didn’t realize at the time that there was a reason why OSU Fire Training Service was the best fire training school in the radius of about 1,000 miles.
Sure. We watched the training videos. We learned all about proper fire extinguisher care and maintenance. We heard stories about how small fires turned into raging infernos that burned companies right out of business. One thing I remember is that some large percentage of companies that have a major fire are never able to recover to the point that they go completely out of business.
If you need the exact percentage, I suggest you call up the OSU School of Fire Protection and Safety. They probably have the latest statistic printed on their school lunch napkins, because these guys eat, drink and sleep fire safety.
Then, after they had impressed us with their Fire Safety Prowess, they said, “Let’s take about a 15 minute break, and we will meet outside just north of the water treatment plant where we will resume your lessons. Oh, and bring your rubber boots and maybe a rain suit.” Rain Suit? What? It’s about 100 degrees outside. “I wouldn’t mind getting a little wet”, I thought to myself. — The simpleminded summer help that I was at the time.
I would describe in detail to you how they had this obstacle course of staircases and pipes and other metal structures all sitting in a big tray. It’s enough to say that it was quite a tangled mess of a contraption.
“Interesting.” I thought… Are we going to climb the staircase and shoot the fire from up above with our handy dandy fire extinguishers which were lined up in a row off to one side? Climbing over pipes to fight a fire under the stairs maybe… Do we get to use the big roll around fire extinguisher that was there too? This looks like it might be fun.
That was when the fun began. One of the trainers turned a valve, and then I noticed that there was a fairly large tank there also that was hooked up to the pipes that wound around the mocked up structure of a stairway and other obstacles in the large tray. As he turned the valve, what looked like diesel or kerosene like petroleum product came spraying out of various holes in the piping spraying everything in the tray drenching it with fuel.
This other guy had a long rod that he had lit like a large lighter only it was giant size, and after the fuel had been spraying out for a while, he lowered the flame down into the tray that now was beginning to fill up with some kind of oily substance. He lit it and the flames quickly spread over the entire structure. He had us go in groups of 4 people with fire extinguishers to try to put out the fire. As their extinguishers ran out of fuel, others waiting behind would take their place trying to put out the fire.
We would chase the fire around the structure trying to put it out, but it wasn’t as easy as you would think. If you didn’t completely suffocate it by hitting it from many different directions and in a pattern from one end to the other just right, the fire would dodge around the spray from the extinguishers to be right back where you started. By the time we had used up all the extinguishers, we may have put the fire out about 3 times.
Rubber boots… I kept thinking…. my feet are getting hot… You couldn’t hardly get close enough to the fire to use your fire extinguisher without getting your eyebrows singed. I was always known for having long eyelashes, and I thought I could hear them sizzle as they brushed against my safety glasses.
That’s when they pulled the fire hose out of the fire box that was there next to the fire hydrant. All over the plant grounds there were these red boxes. They are lined up alongside the long conveyor belt from the coal yard to the plant (about 1/2 mile). They were also lined up around the two silver painted million gallon number 2 Diesel tanks. They were just about everywhere you looked (come to think of it).
I remember Summer Goebel when she was a new plant engineer one time asked me when she had first arrived, “What are all those red boxes out there?” (she was pointing out the window of the Engineer’s office). I told her they each contained fire hose and a valve wrench to open up the fire hydrant. I neglected to add that they also provided great shade for all the Jack and Jill rabbits that inhabited the plant grounds, which doubled as a wild life preserve.
So, we were going to use the fire hose! That sounded like more fun. That is until the one guy said to the other guy (more using hand and face signals — like putting his thumb up and winking) “open ‘er up” — so, he was using “slang” hand and face signals…
That’s when the real training began. First of all, we all backed up because as the flames grew on their structure, the heat literally talked directly to your legs and magically told them…. “back up, or else…” so, now that we were standing a good 50 feet away from the fire, we lined up in a row on the fire hose.
4 of us. Four hefty Brawny Power Plant men… (well, 3 hefty brawny power plant men, and one scrawny little runt of a summer help who actually thought he could be measured alongside them), Isn’t that a bit much for this one 4 inch fire hose? (or was it just 3 inches?). There were two hoses actually being used. One to create a wide barrier of water to protect us from the heat, and another hose to shoot water through the barrier into the fire.
A couple of guys manned the large roll around fire extinguisher. Here is an actual picture of the OSU Training Service training a group of employees at a work site to fight fires to give you a picture of what we faced:
Notice the two different types of sprays in the picture. I very wide spray and a narrow spray.
Like I said, these guys aren’t called the best Fire Trainers because they have pretty pamplets. so, the first time I slipped in the mud, I thought… hmm… I suppose the rainsuit would have kept all that mud from coming into contact with my jeans, and my shirt and my ego.
Well, the most fascinating thing was that we could walk up real close to this intense fire and the wide spray of water sheltered us from the heat.
Then with the large fire extinguisher on wheels, you could open it up on the fire by standing behind this barrier and shoot the chemicals right through the water onto the fire, and it would quickly and incredibly put out that tremendous fire when it was done right. The other fire hose that was spraying through the barrier of water was used to cool everything down so that the fire didn’t spring right back up. the water wasn’t going to put out an oil fire.
Anyway, not long after our first of many fire fighting training sessions that we had throughout the years, the night that we were actually fighting the dragon in the boiler (See the Post, “Where do Knights of the Past go to Fight Dragons Today“), the Control Room came over the gray phone (PA system) saying that there was a fire on the turbine room floor.
A bunch of power plant he-men dropped the lance they were using to pierce the dragon and ran off to fight the fire. It turned out to be a barrel full of oily rags that had spontaneously combusted. The fire refused to go out for a long time. It kept re-igniting until the contents had completely burned up.
I remained in the bottom ash area as I was still reeling from the steaming hot water that had been spewed all over me. A little while later the men were back ready to grab the lance and go back to work on the boiler around 10pm (this after a full day of coal cleanup from 8am that morning).
The one important topic that they ingrained into our minds while we were taking the training was that you have to know when the fire is too big to fight. We had learned what our equipment could do and what it couldn’t do. So, we had the knowledge to realize that if the fire is too big, then it is time to get out of there and call the professionals. The only problem was that the nearest professionals were about 20 minutes away. A lot can burn down in that amount of time…. but that is a story for another time. I see the grin on the power plant men’s faces. They know what I am talking about.
Comments from Previous Repost:
Originally posted December 14, 2012:
I have heard the relationship between Bill Rivers and Sonny Kendrick referred to as the “Punch and Judy Show”. Ok. I thought. Punch and Judy. Sounds like a show from the early 50’s. Must have been a comedy. I thought that for a long time until one day I ran across a brief history of the Punch and Judy Show. It turned out that Punch and Judy was a puppet show from the time of Queen Anne of England. She was queen of England from 1702 to 1714. I could only find a painting of Queen Anne. Didn’t anyone ever think about taking her photograph?
Anyway, once I learned more about Punch and Judy, I realized that this was probably a better description of the Rivers – Sonny relationship than those people realized. It turns out in the first version of the Punch and Judy show, Punch actually strangles his child and beats his wife Judy to death and beats up on other people as well. I suppose that was “entertainment” back then. Now we only have things like “The Terminator”!
I carpooled with Bill Rivers at this particular time when I was a janitor and while I was on labor crew (except during the summer when I carpooled with my summer help buddies). Each day Bill Rivers would explain about some trick he had played on Sonny that day. The one thing that amazed Bill the most was that every day he could play a joke on Sonny, and each day, Sonny would fall for it.
This reminded me of when I was in Rockbridge High School in Columbia, Missouri and I used to borrow a pencil from my friend Bryan Treacy each day and each day I would chew it up to the point where it was practically useless. I had to come up with different diversionary tactics each day, but somehow I was able to coax a wooden pencil from my friend. Before he would realize what he had done, I had already chewed it up from one end to the next. I liked to think that I was tricking Bryan each day, but I also thought that it was odd that Bryan would have a new pencil every time, and he probably made sure that his mom kept a full stock of pencils just for my enjoyment in eating them (I also wondered if I was getting lead poisoning from all the yellow paint I was ingesting).
Bryan Treacy today is a doctor living in Moore Oklahoma. I would like to drop by his office without seeing him some time just to see if he has any wooden pencils laying about that I could leave all chewed up. I wonder if he would realize I had been there. He might read this blog from time-to-time, so I may have just blown my cover.
I mentioned Bill Rivers and Sonny Kendrick because they were the first two electricians that I worked for before becoming an electrician. I worked on the precipitator while I was on the Labor Crew. See the Post:
I also mentioned before that I owe my decision to become a Power Plant Electrician to Charles Foster an Electrical B Foreman at the time. I was a janitor and cleaning the electric shop office and lab were part of my duty. How I came to be the janitor of the electric shop is explained further in the post:
I had found the floor scrubbing machine in ill repair. Charles helped me put it back in running condition. He explained how to take care of the batteries and to keep them properly charged.
When the electric shop had an opening they tried to recruit me while I was still a janitor, but the Evil Plant Manager had a rule at the time that when you were a janitor, the only place you could go from there was onto the Labor Crew. That was when Mike Rose was hired to become a backup for Jim Stevenson that worked on the air conditioning and freeze protection. I knew about the janitor ruling so I didn’t have my hopes up. Besides, at the time I didn’t have any electrical background.
Charles asked me to take the electrical courses that were offered by the company. The company offered correspondence courses, and in about 3 weeks, I had signed up for them, read the books, and taken the tests. While I was on the labor crew I signed up for a House wiring course at the Vo-Tech. I was taking that course when I learned that Larry Burns was moving from our electric shop to go to another plant. It was then that I applied for the job as a plant electrician.
The main power transformer for Unit 1 had been destroyed by the heat wave that summer (1983) when the plant had tested it’s durability on the hottest day. The unit was offline for a couple of months while GE created a new transformer and shipped it to us.
After the main power transformer was destroyed and it took so long to ship in a new one, it was decided that we would keep a spare on hand. That way if it went bad again, we could swap them out quickly. That is probably the best assurance that we wouldn’t lose that transformer again. We had that spare transformer sitting around for years collecting taxes. I’m sure we must have paid for it a few times over again.
During the time that the unit was offline, and we weren’t shaking boiler tubes or cutting the ash out of the economizer tubes, I was working with Bill Rivers and Sonny Kendrick on the precipitator. The precipitator (by the way), is what takes the smoke (ash) out of the exhaust, so you don’t see smoke coming out of the smokestacks.
Bill and Sonny were pretty well sure that I was going to be selected to fill the opening in the Electric Shop, so they were already preparing me to work on the precipitator. Of all the jobs in the electric shop, this one had more to do with electronics than any of the others. That gave “being an electrician” a whole new dimension. I was even looking forward to taking an Electronics course at the Vo-Tech in the spring.
I was getting updates from Bill and Sonny about the progress of the job opening and they were telling me about the battle that was going on between the Evil Plant Manager and the Electrical Supervisor. Eldon Waugh, the plant manager at the time wanted Charles Peavler to be chosen as the electrician. He had an electrical background, because he had wired his barn once.
The ultimate reason why the plant manager wanted Charles Peavler to be the new electrician was because I had been placed on the blacklist due to the incident that took place earlier that I had described in the post:
Thanks to Larry Riley’s performance review, and his purposeful procrastination of the Plant Manager’s request to modify my performance review, and Charles Foster’s insistence that they follow the procedures that were laid out in the new Employee Application Program (known as the EAP), the argument stopped with Charles Foster’s statement: “Let’s just take whoever has the best performance rating as it is laid out in the company policy and leave it at that.” I was chosen to fill the position for the opening in the Electric Shop.
I was actually called to Eldon Waugh’s office while I was sandblasting the Sand Filter Tank. See Post:
When I arrived in Eldon’s office I was covered from head to toe in sandblast dust. My hair was all disheveled and my shirt was soaked with sweat. Jack Ballard (the head of HR) was sitting there along with Leroy Godfrey and Charles Foster. I knew what it was about because according to Bill Rivers on the way home the day before, they had already decided that they were going to accept me for the position.
Eldon Waugh explained that I was being offered the job that I had applied for in the electric shop. I felt really humbled at the time. Even though I was expecting it, I felt surprised that it was actually happening. To me, being an electrician was like the greatest job in the world. The electricians were like an elite team of super heroes.
I had the occasion to watch the electricians while I was a janitor in their shop and many of them were like these super intelligent beings that could quickly look at a blueprint and grab their tool bucket and head out to fix the world. I was very grateful for the opportunity, and at the same time apprehensive. I wasn’t sure if I had the quality of character and intelligence to become a part of this team. This was truly a dream come true for me.
Few times in my life has this happened to me. The day I was married. The day I became a Father. The day I drove to Dell to begin my first day as a Programmer Analyst. These were all major milestones in my life. The first major milestone was the day I became an electrician. Because of the way that I am (I don’t know…. maybe it’s because I’m half Italian), I just wanted to break out in tears and hug Eldon Waugh and cry on his shoulder. Instead, I just managed to crack a small smile.
I thanked them and started to leave. Then Jack Ballard said something interesting. As I was leaving he asked, “Uh…. Do you accept the offer?” Oh. In my surprise and elation, I hadn’t said anything but “Thank You”. Jack’s expression was that it wasn’t official until it was official. So, I replied, “Yes. I accept the offer”. “Ok then,” Jack replied. And I left to go crawl back in my hole and continue sandblasting the Sand Filter tank.
My last day on the Labor Crew was on November 4, 1983. I was leaving my Labor Crew Family behind and moving onto a new life in the electric shop. This was hard for me because I really did consider most of the people on the Labor Crew as family. Fred Crocker, Ron Luckey, Jim Kanelakos, and Ronnie Banks. Curtis Love and Chuck Moreland. Doretta Funkhouser and Charles Peavler. Jody Morse and Bob Lillibridge.
Most of all, I knew I was going to miss Larry Riley. I had worked with Larry from the day I had first arrived as a summer help in 1979. Now it was November, 1983. Larry was a hero to me. I love him dearly and if I had ever had an older brother I would have liked someone with the character and strength of Larry Riley. He remains in my prayers to this day.
The last day on the labor crew I suspected foul play. Mainly because the last day that Bill Cook was on the Labor Crew, he had asked us if we would throw Larry in the intake as a going away gift. I had worked with Bill when we were summer help together and I felt like I owed him one, so I told him I would help.
As we were driving from the Coalyard Maintenance building (the home of the labor crew) to the plant maintenance shop that day, Bill Cook, who was driving, suddenly turned toward the intake pumps and stopped the truck. By the time Larry had figured out what was going on, we had dragged Larry out of the truck and I was carrying him over to the Intake and getting ready to throw him in.
Larry had worked with me long enough to know that once I had set my mind on something, there was no turning back. He had tried to escape from my grip, but I had him where he couldn’t escape. As I climbed with him over the guard rail and headed toward the edge of the water, Larry said the only possible thing that could make me stop in my tracks. He said, “Please Kevin. Don’t do this.”
I was paralyzed. Stuck between my word with Bill Cook that I would help him throw Larry in the brink, and a plea from someone who meant the world to me. There wasn’t but one choice to make. I set Larry down. I walked back to the truck and I told Bill, “I’m sorry. I can’t do it.” I returned to my seat in the back of the crew cab. Without my help, no one else had the resolve and strength to follow through with Bill’s wish. We drove on to the Maintenance Shop.
So, on my last day on the Labor Crew, I thought that something similar might be planned for me. As soon as we left to go to work that morning, I headed up Belt 10 and 11. That is the long belt on the left side of the power Plant picture on the upper right side of this post…. Ok. I’ll post it here:
Once up 10 & 11 and 12 & 13, I was in the Surge bin tower. (The Surge Bin Tower is the white building you can see between the two boilers near the top that has the conveyor belt entering it from the left). From there, I roamed around looking for some coal to clean up. I figured I would stay far away from my labor crew buddies that day.
At the end of the day, I traveled back down belts 10 & 11 and headed into the office in the Coalyard Maintenance building to fill out my last timecard as a Laborer. Beginning next Monday on November 7, I would be an “Electrician.” Along with the empty feeling at the bottom of my heart was a feeling of excitement for the new adventure that awaited me.