Tag Archives: Electric Shop

Importance of Power Plant Backup Battery Preventative Maintenance

The very last thing I ever learned in High School was the importance of Backup Battery Preventative Maintenance. In fact, the entire senior class of 1978 at Rockbridge High School in Columbia, Missouri learned this lesson at the same time. It was during the graduation ceremony in May while the students were walking across the stage to receive their diplomas.

I had already received mine and I was back in my seat sitting between Tracy Brandecker and Patrick Brier (we were sitting alphabetically. My last name is Breazile). Pat was sitting on my left and Tracy was on my right. We were grinning from ear-to-ear to be graduating. My friends from the second grade, Mark Schlemper, Russell Somers and Brent Stewart had just walked across the stage in the gymnasium while a storm raged outside. As my friend from the fifth grade forward, Matt Tapley was walking across the stage there was a loud crack of thunder and the sound of an explosion as the lights went out.

Matt Tapley has albinism, giving him white hair and skin. In his black robe, the entire class witnessed Matt’s head bobbing up and down in the faint light given off from the emergency lights to either side of the stage as he was bowing to his classmates. We all clapped. The clapping soon turned to laughter as the emergency lights quickly dimmed and went entirely out within a minute.

An emergency light

An emergency light

As we sat in total darkness waiting for some resourceful faculty member to make their way to the hidden fallout shelter in the basement of the school to retrieve the portable generator and a spotlight, I was amazed by how quickly the emergency lighting had failed. The transformer to the school had been destroyed by the lightning strike so we finished the ceremony by the light of the large spotlight from the back of gym. My thought was that the school is only 4 years old and already the emergency lighting is too old to stay lit long enough to even begin evacuating the building, if that was what we had intended to do.

Fast forward to the spring of 1984. I had become an electrician a few months earlier. As I was learning the electrical ropes, I learned the importance of Preventative Maintenance in a power plant setting. The majority of an electrician’s job when I first joined the electric shop was doing “Preventative Maintenance”. I have some horror stories of bad preventative maintenance that I will share much later. I will point out now that most Americans know of some stories themselves, they just don’t realize that the root cause of these major failures were from a lack of preventative maintenance.

A power plant, like the emergency lights in the High School, has a battery backup system, only it is on a grand scale. There are backup batteries for every system that needs to remain online when there is a total blackout of power. These batteries needed to be inspected regularly. We inspected them monthly.

At first, I had done battery inspections with various electricians. Some people didn’t seem to take this task very seriously. I remember that when I did the inspections with Mike Rose, he usually finished by taking a gallon of soda water (a gallon of water with a box of baking soda dissolved into it) and pouring it all over the batteries.

My bucket buddy, Diana Lucas (Dee), on the other hand, took a different approach. We carefully filled each cell with just the right amount of distilled water. Then she showed me how to meticulously clean any corrosion from the battery posts using a rag soaked in the soda water, and then she would paint the area on the post where the corrosion was with No-Ox grease.

A jar of No-Ox Grease (No-Ox means No Oxide)

A jar of No-Ox Grease (No-Ox means No Oxide)

When I say batteries, you may think that I’m talking about batteries like you have in your car, or even in a large piece of equipment like a big dirt mover. Some of the batteries were the size of a battery used in a large dozer or dirt mover:

A battery used in a large dozer

A battery used in a large dozer

Some of the batteries that we inspected were of this type. They were usually hooked up to generators that could be started up in case all the power was out and we needed to start up a diesel generator. However, this was just the puppies when it came to the Station Power Batteries. These were some serious batteries:

The battery shown on the left is about the size of a small file cabinet

These are the type of UPS Station batteries used at the plant. The battery shown on the left is about the size of a small file cabinet

As big as these batteries are, it takes 58 of them for each system to come up with a 130 volt circuit. That’s right. 58 of these batteries all in a series. The station batteries are all in rooms by themselves known as…. “Unit 1 and Unit 2 Battery rooms”. Smaller station battery sets are found at different locations. Today, those places include the relay house in the main substation, the Microwave room on the roof of #1 boiler. The River pumps, the radio tower building, the coalyard switchgear, Enid Turbine Generators and the Co-Generation plant in Ponca City. I’m sure I’m leaving some out. Maybe a current electrician at the plant can remind me of the others in a comment below. Each of these locations have approximately 58 station batteries.

While I was still a novice electrician, one morning in May I was told that I was going with Dee and Ben Davis to Enid to a Battery training class at an electric company office where the manufacturer (C&D) was going to go over the proper maintenance of the station batteries. Ben drove the pickup. I remember sitting in the middle between Dee and Ben both going and coming back from our lesson on Battery Preventative Maintenance….

Interesting that Ben was sitting to my left and Dee to my right that day… just like Pat and Tracy during the graduation ceremony 6 years earlier to the month when we first learned the impact of bad preventative maintenance on backup batteries. This time we were learning how to prevent the problem I had witnessed years before. I don’t know why I draw parallels like that. It just seem to make life a little neater when that happens. I don’t remember Ben and Dee grinning ear-to-ear like Pat and Tracy were the night we graduated from High School, but I can assure you, I was grinning the entire 45 minutes going to Enid and the 45 minutes going back to the plant.

Since I had been trained for battery maintenance, I suppose it was like Andy Griffith becoming the Permanent Latrine Orderly (PLO) in the movie “No Time For Sergeants”. I was able to go to town inspecting all kinds of backup batteries.

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Gene Roget (pronounced with a french accent as “Row Jay” with a soft J) was a contract electrician when I first became an electrician in the shop. I wrote about him in the post New Home in the Power Plant Electric Shop. He was a great mentor that taught me a lot about how to be an electrician. He taught me how to use all the different tools in my tool bucket. He taught me how to bend conduit and make it come out the right length on both ends…

He especially taught me the importance of doing a “pretty” job when running wire or conduit or just rewiring a motor. I remember Gene stopping one day when we were walking to the precipitator and he paused to look up at the transfer tower. I asked him where he was looking. He said, “I’m just admiring the wonderful job someone did bending that set of conduit. that’s a perfect job! Just perfect!”

Anyway, Gene and I were given the task of checking all the batteries in the emergency lights throughout the plant. It happened that the emergency lights at the plant were all about 5 years old. Probably about the same age as the lights were in the high school the night of our graduation. The lights in the plant had wet cells. Which meant that you had to add distilled water to them like you do in your car, or in the station batteries. This amounted to a pretty large task as there were emergency lights stationed throughout the plant.

We found many of the lights that would never have been able to light up enough to cause a cockroach to run for cover. We took the bad ones back to the shop to work on them. A lot of the batteries had gone bad because they had never been checked. They have a built-in battery charger, and some of the chargers were not working. I drew a wiring diagram of the charger so that we could troubleshoot them and replace components that had gone bad.

All of this was like a dream to me. At the time I couldn’t think of any other place I would rather be. I loved taking things that were broken and fixing them and putting them back into operation. Eventually we decided to change the emergency light batteries to dry batteries. Those didn’t need water. We could pull out the six wet cells from each emergency light box and just plug the new batteries in place. This made a lot more sense. Who has time to go around regularly and check 50 or 60 emergency lights every 3 months? Not us. Not when we were trying to save the world.

Back to the Station Batteries:

Just to give you an idea of how important these batteries are, let me tell you what they are used for…. Suppose the power plant is just humming along at full power, and all of the sudden, the power goes out. It doesn’t matter the reason. When there is a blackout in a city, or a state, be assured, the power plant itself is in a blackout state as well. After all, the power plant is where the electricity is being created.

In the plant there is large equipment running. The largest and most valuable piece of equipment by far in a power plant is the Turbine Generator. The entire plant exists to spin this machine. As big as it is, it spins at 3600 revolutions per minute, or 60 times each second. In order to do that, oil has to be flowing through the bearings otherwise they would burn up almost instantly. This would cause the generator to come to a screeching halt — and I mean “screeching!”

A turbine Generator Room at a nuclear plant with a waxed floor!

A turbine Generator Room at a nuclear power plant with a waxed floor!  When I was a janitor I would wax the T-G floor.

So, in order to stop a turbine generator properly, when a unit is taken offline, once it has coasted to a smooth stop, the turbine has to be engaged to something called a “Turning Gear” which slowly rotates the turbine generator. This is turned off only when the shaft has cooled down. Without this, you might as well call General Electric and order a new one.

So, one of the most important things the station batteries do is run emergency oil pumps that engage immediately when the power is cutoff from the plant. This allows the turbine generator and other important equipment throughout the plant to slowdown and come to a stop gracefully in case the power is instantly gone.

I will write a story later about a day when this happened at our plant. The moments of confusion, and the quick decisions that had to be made to keep the unit 1 boiler from melting to the ground. Rest assured that throughout this time, the emergency oil pumps had kicked in. The station batteries did their job when they were called upon. While the control room operators were performing their emergency tasks to the letter and the electricians were scrambling to come up with a workable solution to an unforeseen problem, the turbine-generator, the PA (Primary Air) fans, the FD (Forced Draft) Fans, the ID (Induction) fans were all coasting down as the groundwork was being laid to quickly restore power.

Someone in an office in the middle of Oklahoma City may have noticed their lights flicker for a moment. Maybe they dimmed slightly…

If not for the proper maintenance of the power plant station batteries, the lights would have possibly gone dark. Someone would have had to go looking for the portable generator and the spotlight. Ceremonies in progress may have to continued under candlelight.

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Working Power Plant Wonders with Willard Stark

Originally posted on July 6, 2013:

Ted Riddle and I were working for an “Acting” foreman named Willard Stark during an overhaul at the plant outside Mustang, Oklahoma the spring of ’86.  Willard seemed much older than he was.  I would have guessed he was in his late 60’s or early 70’s, but it turned out he was only in his mid to lower 50’s.  I found out why he had aged as the overhaul unfolded.

I heard some slight grumblings from a few in the shop when Bill Bennett told me that I was going to the plant near Mustang, Oklahoma that spring.  I suppose it was because since I had become an electrician in the Fall of 1983, this was already going to be my third overhaul away from our plant, and all of them ended up being major overhauls.

The reason others were grumbling about this was because when you were able to go on an extended overhaul at another plant, it meant that you were going to earn not only a lot of extra overtime, but you also received travel time, mileage and a per diem (a daily amount of money for expenses).  I believe at the time the Per Diem rate was $32.00 each day.  This was supposed to pay for your hotel room and your meals while you were away from your family.  We lived in trailers to cut down on costs.

Others believed that I had received more than my share of the piece of this pie.  I had been sent on every available overhaul since just before I had reached my first year as an electrician.  So, by this time, most people would have saved up quite a sum of money.  I, however, was making around $7.50 my first year, and by the time 1986 had rolled around, I was still making just under $10.00 an hour.  So, overtime amounted to $14.50 an hour.

When you compared this to the first class electricians that were making around $19.00 an hour at the time, they would have been making $28.50 an hour overtime.  This was about twice what I was making.  So, I was a cheap date.

On December 21, 1985 I had been married (the day following my last day at Horseshoe Lake overhaul — see the post:  A Slap in the Face at a Gas-Fired Power Plant), and I had used every cent I had in the world to pay for our honeymoon.  I was even relying on paychecks I was receiving while I was away to finish paying for it.

So, it helped to come back and find that we were on a major overhaul at our plant on Unit 1 doing the 5 year checkout.  Then finding that I was going to a major overhaul at the plant in Mustang, Oklahoma where I could live with my wife in her apartment in Oklahoma City while she finished her last semester to obtain her nursing degree from Oklahoma University.  I went on the overhaul with Ted Riddle.

Ted was hired into the electric shop the previous summer.  He wasn’t on my crew so I hadn’t worked much with him.  He was a farmer that had an electric background.  He was a bigger man than I was and had a good sense of humor.  He had a steady temper and didn’t let much bother him.  He would laugh at things that might bother others.

I appreciated working with Ted, because his steady mood helped to teach me that blowing my top about little things did little to help the situation.  So, for this overhaul, I decided that I would try to emulate Ted Riddle by keeping up with his easy-going-ness (I know…. the dictionary couldn’t find that one).

Bob Kennedy was on this overhaul as well.  He had been my acting foreman during the  overhaul at Horseshoe Lake.  I had described our relationship in the post:  “Bobbin’ Along with Bob Kennedy“.  I was glad to be working with Bob again. As I mentioned, Willard Stark was our acting foreman.

For those that don’t know…. an acting foreman is someone that normally isn’t a foreman, but is appointed to lead a crew for a particular job.  These men usually are the best foremen to work for, because they haven’t attended any official “manager training”.  This usually made them better foremen, as the manager training had a tendency to destroy one’s character and moral integrity.  — I never could figure that one out.  Some people came back unscathed, but others came back with PTMD (Post-Traumatic Manager Disorder).

The plant at Mustang was the smallest gas-fired power plant that had people permanently working there.  It had some smaller units that they wouldn’t run when the newer larger units weren’t running because the water treatment plant (that creates the boiler water) used more power than the small units could generate.  — That amazed me.  So, while we were there, I don’t think any of the units were running so they didn’t have to run the water treatment plant.

Willard Stark had spent a good portion of his life working at the plant and had a lot of stories about the plant manager and assistant manager at our plant.  He had been an electrician when Bill Moler had first come to the plant as a new green electrician like me.  I enjoyed sitting during lunch in Mark Thomas’s electric lab as Willard told us stories.

Willard had an incredible memory.  He could remember what he was doing on any specific day decades before. We would listen to Paul Harvey on the radio during lunch, and whenever Paul would say, “….noon news and comment.”  Willard would always finish the sentence by saying “…mostly comment.” I had spent a good part of my childhood listening to Paul Harvey on the radio because when I was young, we always had a radio playing in the house and the car.  So, Paul Harvey’s voice was always a comfort to me.  I was saddened a few years ago when he passed away.

Paul Harvey was one of a kind radio personality. No one will ever fill his shoes.

Paul Harvey was one of a kind radio personality. No one will ever fill his shoes.

Working with Ted Riddle cracked me up.  He would notice things that I was totally oblivious to (yeah.  I see it.  A preposition at the end of a sentence).  For instance, one day while we were working, Ted asked me if I ever noticed how Bob Kennedy drinks water out of his jar.  I told him I hadn’t noticed.

You see, Bob had this jar that looked like a pickle jar that he brought to work each day filled with water.  During lunch, he would drink out of this jar.  Ted said, “Watch Bob during lunch today.  Tell me what you think.” So as I was sitting next to Bob during lunch listening to Paul Harvey, and Willard Stark telling us what he did on any particular date in the past that Paul Harvey might mention, I kept one eye on Bob.

As Bob lifted his jar to his mouth I watched as he began to drink.  I immediately knew what Ted had wanted me to see. As Bob took a drink, he  slowly tilted the jar up until the water reached his mouth.  As the jar was being tilted, Bob’s upper lip would reach way into the jar as far as it could, quivering in anticipation of a cool drink of fresh water.  The upper lip of a camel came to my mind.

Bob Kennedy's upper lip reaching into the water jar...

Bob Kennedy’s upper lip reaching into the water jar…

With all my might, I struggled to keep a straight face as I turned my head slowly to look over at Ted who had a grin from ear-to-ear….. ok.  I’ll show you the picture of Andy Griffith again that I included in my post from last week, just so you can see what I saw when I looked over at Ted:

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

Andy Griffith as Permanent Latrine Orderly in No Time for Sergeants grinning ear-to-ear

I think I almost choked on my ham sandwich as I swallowed while trying to keep my composure.

Another day while Ted and I were cleaning ignitors on the shop work bench Ted asked me if I had noticed what Randy Oxley and Jimmy Armafio were working on.  I told him I hadn’t noticed.  Ted said that if he’s not mistaken Randy Oxley has been coming into the shop all morning with the same piece of conduit.  He bends it, then cuts a little off the end and re-threads it.

So, the next time Randy came into the shop I noticed he had a piece of one and a half inch conduit in his hand.  It was about 3 1/2 feet long and had a couple of bends in it.  Randy hooked the conduit up in the large conduit bender and using his measuring tape carefully lined it up as Armafio stood back and watched.  He bent the conduit a little, then put it in the bandsaw and cut off a few inches.  Then he put it in the vice on the work bench and proceeded to thread the end of the conduit.

Then Jimmy and Randy left. Ted said that if he wasn’t mistaken, that’s the same piece of conduit Randy has been working on all morning.  So, as we continued the boring job of cleaning the 30 or so ignitors piled on our workbench, I told Ted about the time I was at the plant at Horseshoe Lake and Randy had told a Mechanical A foreman Joe Balkenbush (I think his first name was Joe), who was Randy’s uncle on his mom’s side, that Randy was the best electrician at the plant at Mustang, only he was the only one that knew it.

I mentioned this meeting and the reason for it in the post:  “Bobbin Along with Bob Kennedy” (See the link above). Sure enough, a little while later, Randy came back to the shop with the same piece of conduit and performed the same procedure of bending, cutting and threading and scadoodling.

A little while later the electrical B foremen came out into the shop (I can’t remember his name for the life of me… I can see his face – maybe something Campbell), and asked us if we knew how to run conduit.  We assured him that we did.  I had been thoroughly trained by Gene Roget and Ted, well, as it turned out, Ted was a crackerjack conduit hand.

The foremen took us up onto the boiler and asked us if we could run some conduit from one place to another.  He sounded apologetic when he asked if that would be all right.  We assured him it was no problem.  We would get right on it.

On the way back to the shop, as we were coming down from the boiler, Ted tapped my shoulder and pointed down to the bottom of a light fixture.  He said, “Hey!  Isn’t that the piece of conduit that Randy has been working on all morning?”  Sure enough.  There is was.  He finally bent it and cut it to fit! Well… The rest of this part of the story is that instead of running back and forth to the shop to bend and cut and thread conduit, Ted and I grabbed a conduit stand, and the appropriate tools and hauled them up on the boiler.

Conduit threader stand

Rigid Conduit threader stand

We carried about 40 foot of conduit up there and began bending, cutting and threading and mounting the conduit.  We finished just before lunch.  As I mentioned above, Ted was a heck of a conduit person.  He knew exactly what he was doing.  We carried all the equipment back to the shop.

After lunch Ted and I went back to cleaning ignitors.  The foreman saw us out of the window of the office and came out and asked us why we weren’t working on the conduit.  When we told him we were done, he had a look of disbelief.  He left the shop (to go check out our work).  Ted and I smiled at each other.

A little while later the foreman returned with the electric supervisor. The electric supervisor asked us if we wouldn’t mind working on some more jobs to run conduit.  Ted told him that we were there to do whatever they needed.  I nodded in agreement.

During the rest of the overhaul we worked to repair broken conduit, pull wire and install new conduit where needed. Mark Thomas, the electric specialist, that was about my age, asked if he could use us to pull and mount some new controls.  He said he wouldn’t let the others in the shop touch it because he would just have to follow through and redo it when they were done.  So, we did that also.

We did get in trouble one day when we went to install some conduit over a control room just off of the T-G floor.  We noticed that all of the lights were out except a couple, so we found a couple of large boxes of light bulbs and replaced the burned out bulbs.  The Electric Foreman came running up to us a little while later and said, “What are you trying to do?  Run us out of business?”

With looks on our faces that conveyed that we didn’t understand what he meant, he explained that in small plants like this one, they don’t have a budget like the bigger plants.  They can’t afford to keep the lights burning all over the plant all the time.  So, we were only supposed to replace lights in the immediate area where we had to work.  Now the foreman had to figure out where he was going to find the money to buy another box of light bulbs.  — These were incandescent bulbs that don’t have a long life span.

I had mentioned in an earlier post called Resistance in a Coal-fire Power Plant that Bill Rivers had been given a bum deal when another person had accused him of cutting off the leads of electronic components so that no one could check them to see if they were really bad (which doesn’t make any sense given that you could still check them no matter how short the leads are).  Well, I found that the same situation had existed in this plant.

There was this one guy that sat in the electric shop Lab (not the same electric shop lab where Willard and Mark Thomas hung out), working on Gray Phones all day.  Ted had asked me if I had noticed how many gray phone boxes were missing gray phones (gray phones are the PA system in a plant.  You could go to any one of them and page someone).

Gaitronics Gray Phone

Gaitronics Gray Phone

Ted would point to empty gray phone boxes as we walked through the plant.  He told me that they have one electrician that doesn’t do anything else but sit in the electric lab working on gray phones.  That is all he does.  When we asked Willard about it, he told us this story.

Mark Thomas used to work on all the gray phones, and kept them all running in good order.  When Mark worked on a gray phone, sometimes to make sure it is working, he would page himself.  Just to make sure that part worked.  I understood this.  When I was working on gray phones with Bill Rivers, he would page me, or I would page him, just to test it.

If you were working by yourself, it would make sense that you would page yourself instead of bugging someone else several times a day while you went from one gray phone to the next. Anyway, people accused Mark Thomas of trying to make himself more important by making others think that he was being paged all the time by paging himself.

Now, anyone with any sense would know how lame of an idea that is.  I mean, anyone would recognize Mark Thomas’s voice.  The plant wasn’t that big.  There weren’t that many people working there.  Everyone knew everyone else.  Mark was obviously just working on gray phones.

So, after the foreman accused him of trying to promote his self importance by paging himself several times a day, Mark said, “Fine!  Let someone else work on the gray phones!”  Mark was by far the most intelligent person at the plant.  He obviously didn’t need to artificially promote his reputation by making a fool of himself.

So, they gave the job of gray phone maintenance to someone that didn’t understand electronics.  They even bought an expensive gray phone test set to help him out.  So each day he would sit in the lab smoking his pipe staring at an ever-growing pile of gray phones.  At one point, Ted and I offered to fix them all for him.  He said, “That’s ok.  It keeps me in the air conditioning.

I know in later times, Mark Thomas went on to greater successes within the company.  I believe that Willard stayed around until there was a downsizing and he was able to early retire. I mentioned at the beginning that Willard looked a lot older than he really was.  Willard brought this to my attention.  He showed me a picture of himself a few years earlier.  It was of him standing by a car wearing a suit.

He reminded me of an actor from an old movie, though, I can’t remember the actor’s name at the moment. Willard said that in the past few years he aged rapidly.  It happened when the previous foreman had retired.  Willard had seniority in the shop and had been at the plant most of his life.  He knew what he was doing, and had filled in as foreman many times.  He really expected to become the foreman.

Nevertheless, they gave the job to someone from somewhere else who didn’t know the plant, or even much about being a foreman. This upset Willard so much that he said he just gave up.  He said the stress from that experience aged him.  Mark Thomas agreed.

Mark had his own encounter with this attitude when he decided to retreat to his lab off and away from the electric shop.  Willard and Mark, the two electricians that really knew what they were doing at the plant had sequestered themselves in their own hideaway where they would sit each day listening to Paul Harvey at lunch and biding their time until the next phase of their life came around.

Power Plant Lock Out – Tag Out or Just Tag Out

Originally Posted July 12, 2013:

All safe electricians worth their salt know about OSHA regulation 1910.147(c)(3). Only Power Plant electricians have learned more about OSHA regulation 1910.147(a)(1)(ii)(C). Section 147 has to do with locking out and tagging a power source in order to protect the employees working on the circuit. 147(a)(1)(ii) says that Power plants are exempt from section 147. In other words, if you are working in a power plant it is all right to have a less stringent lock-out/tag-out procedure in place than if you didn’t work in a power plant.

One of the first things I learned from Charles Foster, my foreman when I became an electrician was how to remove the “heaters” from a breaker relay in order to protect myself from an “unauthorized” operation of the breaker. That means…. in case someone accidentally turned on the breaker and started up the motor or whatever else I was working on. “Heaters” are what we called the overloads that trip a 480 volt breaker when the circuit uses more power than it is supposed to be using. They are called heaters, because they literally “heat up” in order to trip the breaker.

typical 480 volt overload heaters

typical 480 volt overload heaters

Charles Foster told me the following story about my bucket buddy Diana Lucas (later Diana Brien):

Dee was wiring up a sump pump at the bottom of the coal dumper. The motor had been taken out while the pump had been repaired. Once back in place Dee was sent to wire it back up. The proper clearance had been taken to work on the motor. That is, she had gone to the Shift Supervisor’s office in the Control Room to request a clearance on the motor. Then later she had witnessed the operator opening the 480 volt breaker and place the clearance tag on the breaker.

A typical Clearance Tag. Our tags had the word

A typical Clearance Tag. Our tags had the word “Clearance” at the top. We called them a “Hold Tag”

The tag is signed by the Shift Supervisor and is only to be removed by an operator sent by the Shift Supervisor. It is placed through a slot in the handle on the breaker that keeps the breaker from closing unless the tag is removed first…. well… that’s the theory anyway.

Dee had just finished hooking the three leads in the junction box together with the cable coming into the box using two wrenches. She reached down into her tool bucket that she was using as her stool to get some rubber tape to begin wrapping the connections. The three bare connections were sticking out in front of her face.

A large vertical pump motor

A large vertical pump motor

The Junction box is the box on the right side of this motor. At this point the cover would be off and the wires would be sticking straight out. As she reached into the bucket, the motor turned on and began running.

Startled, Dee stopped what she was doing. I suppose she also pinched herself to make sure she wasn’t dreaming. Then I suppose she checked her diaper to make sure it was still dry. Then I suppose she may have said a few choice words whether anyone was around to hear them or not. Maybe not all in that order.

For those of you who don’t realize what this meant. It meant that if the motor had started running about 5 to 10 seconds later, someone, some time later may have made their way down to the west end of the dumper sump only to find one charred Diana Lucas (who never would have later become Diana Brien). They might not have recognized her at first. I can assure you. It wouldn’t have been pretty.

You see… someone had removed the Hold Tag and purposely started up the motor totally disregarding the clearance. I won’t mention any names, but his initials were Jerry Osborn.

So, after Charles told me this story, he showed me what to do to prevent this from ever happening to me.

Charles and I went to the Shift Supervisor’s office to take a clearance on a motor. Then we followed the operator to the breaker and watched him open the breaker and put the tag on the handle. Then we signed something and the operator left.

After the operator left, Charles told me to open the breaker and slip the hold tag through the slot in the door so that the door could open without removing the tag. I followed his directions.

Once the door was open, he told me to remove the three heaters on the bottom of the relay and hide them at the bottom of the breaker box.

480 volt relay with the 3 heaters at the bottom. That white square is an overload reset button. in front of the first heater

480 volt relay with the 3 heaters at the bottom. That white square is an overload reset button. in front of the first heater.  The black squares with the W 34 on them are the heaters.

You see… with the heaters removed, even if someone were to close the breaker and try to start the motor, the electricity would never leave the breaker box because I had just created an open circuit between the relay and the wires going to the motor.

Well… If you don’t learn from history you are bound to repeat it. No. I’m not going to change subjects and start talking about making it illegal to own guns.

Anyway, there is always a chance for something to go wrong. The Peter Principle demands it. So, at one point, someone forgot to replace the heaters in the relay before returning their clearance. When the motor was tested for rotation, it didn’t work. At that point the electrician knew that they had forgotten to re-insert the heaters. So, they had to return to the breaker to install the heaters before the motor would run.

This didn’t set well with the Shift Supervisor, who has supreme power at the power plant…. well… besides the janitor who had total control over the toilet paper supply.

Technically we were not going around the hold tag by removing the heaters because they were downstream from the breaker handle which cut off the power to the relay. The Shift Supervisor on the other hand believed that the hold tag included everything in the breaker box, including the relay and heaters (which really was stretching it).

An argument ensued that pitted the shift supervisors and the supervisor of operations, Ted Holdges with the electricians. Ted argued that we should not be removing the heaters to keep ourselves from becoming electrocuted accidentally when someone inadvertently removes a hold tag and turns the breaker on and starts up a motor. Electricians on the other hand argued that if we were going to be exposed to the possibility of being electrocuted, we would rather not work on any circuit. Without being completely assured that we would not occasionally be blown to pieces when someone or something accidentally caused the circuit to become hot, we concluded it wasn’t worth it.

So, a compromise was reached. We could remove the heaters, but they had to be put in a plastic bag and attached to the hold tag on the outside of the breaker. That way, when the clearance was returned, not only were the heaters readily available the operator would know to contact the electrician to re-install the heaters. The electricians didn’t really like this alternative, but we agreed. We were assured that there wasn’t any way that a breaker was going to be turned on and operated with the heaters in them when someone was actually working on a circuit.

Fast forward three years. 1992.

Bill Ennis and Ted Riddle were working on replacing a large electric junction box on the stack out tower. The Stack Out Tower is the tower that pours the coal out on the coal pile. Halfway up this tower there is a large junction box where most of the electric cables passed through going to the top of the tower. Bill Ennis had taken a clearance on a number of motor and control breakers.

Bill returned from lunch one day to work on the junction box, removing the old cables. Putting new lugs on them and placing them in the new junction box. As he began working, he decided to take out his multimeter and check the wires he was about to work on….

We had a couple of these Simpson Analog Multimeters in the shop

We had a couple of these Simpson Analog Multimeters in the shop

Bill was surprised to find that one set of cables were hot. They had 480 volts on them. Everything in this box should have been dead. I suppose he pinched himself to make sure he wasn’t dreaming. Then I suppose he checked his diaper to make sure it was still dry. Then I suppose he said a few choice words that Ted may have heard if he was standing close by.  Maybe not all in that order.

What had happened was that there had been two clearances on this one particular motor. One of the electricians had returned his clearance, and had installed the heaters that were in the plastic bag on the front of the breaker and the motor had been tested for rotation and put back in service. The operator had taken both clearances off of the breaker by mistake.

Ok. It was time for another meeting. Something had gone wrong. If it had not been for the guardian angels of both Diana Brien and Bill Ennis, at this point we would have had at least two dead electricians, and believe me…. I know that when an operator had later climbed the stack out tower to check the equipment, if he had run across the body of Bill Ennis… it definitely wouldn’t have been pretty (even on a good day).

I attended this meeting with Ted Holdges as did most of the electricians. I began by telling Ted that when we had met three years earlier I was newly married and wouldn’t have minded so much if I was killed by being electrocuted because I was young and only had a wife who knew how to take care of herself. But now it was different. I had a little girl at home and I need to be around to help her grow up.

Ted looked surprised by my remark. I had just told him the way I felt about this whole situation. The argument that we were making was that we should be able to place locks on the breakers just like OSHA demanded from the other industries. We had demonstrated that we didn’t have a system that would protect us from human error. We needed something that definitely kept us safe.

We told Ted that even if we had locks, and for some reason the breaker just had to be closed and the electrician had forgotten to remove his lock, the shift supervisor could keep a master key in his office to remove the lock. He finally agreed. His problem was a loss of control. The thought was that the Shift Supervisor had ultimate power.

If you don’t learn from history you are bound to repeat it. No. I’m not going to change subjects and talk about socialized healthcare and how it destroys all concepts of quality and privacy.

So, as electricians, we weren’t really happy with this situation. We had a secret weapon against human error. Sure we would place a lock on the breaker. But after the operator would leave, before we placed our lock on the breaker, we might just open up the breaker box and remove the entire face off of the relay. It was similar to removing the heaters only it was bigger. It completely opened the circuit no matter what.

I hadn’t really planned on talking about this next story for a couple more years, but I’ll tell it now because it fits with this story.

In the month of May, 2001. I had already given my notice to leave the plant to work for Dell as a software developer. I was asked to work on a job with my old bucket buddy Diana Brien.

Diana-Brien

My Bucket Buddy Diana Brien

The problem was that there was a grounded three phase circuit up on the Surge Bin tower. It had been tracked down to the dust collectors located below the surge bin conveyor floor.

Dee and I walked up to the Gravimetric feeder deck to look at the breaker to make sure it was turned off. It had a Danger tag on it that had been placed by the Shift Supervisor.

A typical Danger tag used at the plant

A typical Danger tag used at the plant

The breaker was open and the message on the tag said “Do not close this breaker. The circuit is grounded”.

Ok. We walked up to the surge bin tower through the counter weight room for belts 18 and 19. We opened up the big junction box that fed the power to the two large dust collector motors on the landing behind us. After taking the cover off of the box, I took out my multimeter and checked the circuit.

Like this. Ok. So the multimeters had become more sophisticated over the years.

Like this. Ok. So the multimeters had become more sophisticated over the years.

The big copper bus was dead (that means, there was no electricity present).

So, Dee and I worked on locating the grounded circuit. I had just removed the cover to the junction box on one of the motors while Dee was removing some wires from the control panel when Larry Tapp arrived on the landing through the same route we had taken from the gravimetric feeder deck.

Larry asked us what we were doing. We told him we were tracking down the ground on the Dust Collectors. Larry looked surprised.

You see… Larry explained that he had just come from the Gravimetric feeder deck where he had just closed the breaker for the dust collectors. This particular breaker didn’t have a relay, as it was controlled by the control panel where Dee had been working.

So, I rechecked the copper bus with my multimeter and it was hot. 480 volts hot.

I had just been looking through my tool bucket for two wrenches to remove a piece of the bus work just to make sure the ground wasn’t in the box itself when Larry had arrived. In other words, if Larry had arrived 5 to 10 seconds later, he would have probably arrived to find Dee looking down at my body, stunned that I had just been electrocuted by a circuit that we had just tested and found dead.

If you don’t learn by history you are bound to repeat it.

You see… there is a difference between a Hold Tag and a Danger Tag. A hold tag is placed on a breaker after someone has requested a clearance by signing a form in the Shift Supervisor’s office in the control room. A Danger tag can be placed and removed at anytime by the person that placed the tag on the breaker.

So, I personally wrote this up as a “near” accident. We could have wiped our brow, pinched ourselves to make sure we weren’t dreaming. We could have checked our diaper to make sure it was still dry and then Dee could have said a few choice words that Larry Tapp would have agreed with (I have always had a mental block against expressing myself in that manner…. I found other ways). And we could have left this incident as a secret between Larry, Dee and I.

I thought it was a good time to remind the electricians throughout power production to follow the clearance procedures when working on high voltage circuits. Sure. Dee, Bill Ennis and I have powerful guardian Angels looking out for us…. but gee… I think we should be expected to look out for ourselves. So, I wrote up this incident to warn the rest of the team….. If we don’t learn from history, we are bound to repeat it.

I met with my roomie Steven Trammell, a month and a half later in Perkins Restaurant in Stillwater, Oklahoma to discuss his performance plan. I was a 360 Degree Assessment Counselor and my favorite roommate from 17 years earlier had chosen me to review his performance appraisal. During this meeting I asked Steven, who had driven from Harrah, Oklahoma from another power plant to meet with me, if he had read the near accident report about the dust collector at our plant.

My roomie told me that he had, and that he thought it seemed to unduly blame the electrician. I told him I was the electrician and that I wrote the report. After 18 years of being an electrician, I had become so relaxed in my job that I had become dangerous to myself and others. So, after I did a cause-effect analysis of the near accident, most of the cause had come from my own belief that I could circumvent clearance procedures and save time and still believe that I was being safe.

On my drive back to the plant after the meeting with my favorite roomie of all time, I had time to think about this…. I was going to be leaving the power plant in a little over a month to work for Dell as a programmer. I knew this when I had been negligent with the Danger tag. I could have caused the death of both Dee and I. I will sure be glad to be in Texas. — Only.. I will miss my friends most of all.

I leave the Power Plant with this one thought…. If you don’t learn from history, you are bound to repeat it. I mean it… This time I really do.

Comments from the previous posts:

  1. Ron Kilman July 13, 2013:

    This is a great story. I thank God for His guardian angels and I thank you for taking responsibility. It was always difficult investigating accidents because people are a little reluctant to share their mistakes with the world. But a wise man knows it’s better to have a bruised ego than a fried friend.

Larry McCurry July 13, 2013:

Kevin,

  1. As an old time operator and having follows in my fathers footsteps as a Shift Supervisor, The answer to all of these problems to add steps to the clearance procedure to make sure the heaters were removed and then replaced. The second was definitely an operator error, and I agree with you about it, The Shift supervisors did argue for it however the hubris of certain power hungry people managed to intimidate and control the situation. You do not ever work on equipment without your own clearance or a plan that includes the SS, as you mentioned He is the operating authority, or was until a person by the initials of Jim Arnold rewrote the procedures and made himself the Authority.

Jack Curtis August 12, 2013:
Good Story Indeed.
There is, I’m sure, a gene in human DNA labeled: “Murphy” that assures that anything that can happen, does. And in total ignorance, I’ll bet that some constant percentage of plant electricians were fried. I suppose the onset of computer controls has reduced that but that it still happens at a lower rate. The way you and your friends sort of automatically reached for your multimeters is a clue! These are shocking, highly-charged stories…
NEO July 16, 2014
Yep, and even c.3 rules fail on occasion. Most places I’ve worked the other key was at superintendent level, and required a veritable mountain of paperwork to acquire. G-d help anybody who lost his key! 🙂
Traditionally on distribution lines, we left our shotgun hanging on the (grounded) stinger to notify everyone since there is no (effective) way to LOTO a power line. Imagine my vocabulary one fine day up in Montana when I drove up to reenergize a tap to find it energized and a crew I had never seen putting my shotgun in their truck. That day, I got a profuse apology (and assurances) from the line superintendent in person, 50 miles from the office. I never worked dead again without three point grounding, and I require my people to use it as well, I don’t like funerals. Hot line is actually safer for most operations.
Dan Antion July 17, 2014
I have great respect for electricity, power tools and the threat of human error. That was a close call. Glad you had the presence of mind and experience to think to check again.

Placed on Light Duty at the Power Plant

Originally posted July 19, 2013:

In another profession being put on light duty may mean that you don’t have to work as hard as everyone else.  When an electrician is put on light duty it means something else entirely.  I think I calculated the number of lights and it was well over 10,000 light bulbs in the coal-fired power plant in North Central Oklahoma.  Ideally you would think that every one of the lights should be in good working order.

Electricians don’t call a light bulb a light.  The light is the fixture.  The bulb is called a “lamp”.  So, for the rest of this post I’ll call the light bulbs “lamps”.

You may think that it’s pretty straight forward to go change out lights (oh.  I mean… lamps), but it’s not.  You see, it isn’t like in your house where you have the regular light bulbs everywhere with just different shapes and wattage.  Sure, there were different Watts for the different lamps, but for a good number of the lights, they varied by voltage as well.

Not only that, but these lamps were different types of lights.  Most of which are not incandescent (well… now that the government has seen fit to force the lighting industry to stop making incandescent lamps altogether, I guess it wouldn’t seem odd to the younger folks).

A descriptive picture of an Incandescent lamp found at www.techlinea.com

A descriptive picture of an Incandescent lamp found at http://www.techlinea.com

In the office areas and places like the main switchgear 4 foot fluorescent lamps were used.  Each 4 foot fluorescent lamp is 40 watts.  Just because it is 40 watts, it doesn’t mean that the voltage is low.  It can take up to 650 volts to start up a fluorescent lamp.  A Fluorescent lamp actually has a gas in it that causes a coating on the glass to glow when a current flows across the gas.

A fluorescent Lamp

A fluorescent Lamp

Besides the typical fluorescent lamps, the majority of the rest of the lamps in the plant were various sizes of Mercury Vapor lamps.  (now replaced with Sodium Vapor).

Before you become all twisted about using Mercury Vapor to light up a power plant because of the environmental impact, I think I should point out that even though a fluorescent lamp is filled with an inert gas like argon, it is mixed with Mercury vapor as well, and the phosphorous coating on the glass has mercury in it also.

So, if you have fluorescent lamps in your house…. Well, there you go.  And you know those lamps that are used to replace your old incandescent light bulbs….. Yep… and they have other kinds of hazardous metals as well.  I suppose it is good for the environment to take those hazardous materials out of the earth and put them in lamps in your houses.  Isn’t that improving the environment?

The thing about using Fluorescent lamps and Mercury Vapors and Sodium Vapor lamps is that they all use different voltages.  So, in order for them to start up and stay running, the voltages have to change from the start up voltage to the operating voltage.  Each lamp has it’s own transformer designed just for that one type of lamp.  It is placed in the light fixture for the lamp.

You can tell this is a 100 Watt Mercury Vapor lamp because of the 10. If it had a 25, then it would be a 250 watt lamp. Following the same logic if it has a 75 on it, then it is a 75 watt lamp..... oh...well.. the logic is there somewhere

You can tell this is a 100 Watt Mercury Vapor lamp because of the 10. If it had a 25, then it would be a 250 watt lamp. Following the same logic if it has a 75 on it, then it is a 75 watt lamp….. oh…well.. the logic is there somewhere

If the light glows blue, then it is mercury vapor.  If it is orange then it is a sodium light.  Your street lights are the same way.  Well.  Now there is also Halogen lamps which shine white.

Besides these different type lamps, we also had some super special lights.  We have the flashing lights on the smoke stack and the red blinking light on the top of the radio tower.  The lights that flash on the smoke stacks are really flashbulbs.

A flash tube used in a smoke stack beacon that can easily be seen 50 miles away at night. Especially when the day time setting is still on

A flash tube used in a smoke stack beacon that can easily be seen 50 miles away at night. Especially when the day time setting is still on

Our smoke stacks are 500 feet tall with beacons at the 250 foot level and the 500 foot level.  Not only did you have to change out the bulb, but you often had to change out the large capacitors and the circuit boards that had been fried by a passing lightning storm.

You may have heard that with the older style Television sets that had a picture tube (before the flat screen TVs came around), that you could electrocute yourself by taking the cover off the back of the TV and working on it, even though you unplugged the set from the wall before you started.  A few movies used this in the plot.  Robert T. Ironside even used it once in an episode during the first season.

Robert T. Ironside played by Raymond Burr

Robert T. Ironside played by Raymond Burr

Well.  The Stack lights are like that.  When we opened up the light fixture to work on the flash tube or the circuits inside the first thing you did was take a metal rod with a wooden handle and a wire attached with a clip on the end and clipped the wire to the handrail.  Then turning your head the other way, you placed the metal rod across each of the large capacitors in the box.   Invariably, one of the capacitors would let out a loud pop (or should I spell that “pow!”) that would echo across the lake…. oh, and leave your ears ringing.

Once the voltage was discharged from all the capacitors, you knew it was safe to go to work fixing the light.  The lights had a day and a night mode, and the difference was how many times the flash tube flashed when it discharged.  What I mean to say is that it wasn’t just one flash.  It is really a series of flashes closely timed to look like one flash.  The number of flashes and the timing between the flashes determine how bright the flash is.

At night the flash was much dimmer because it didn’t need to be so bright.  When it was stuck in the day mode at night the farmers for a 30 mile radius would be calling saying they can’t sleep because every 6 seconds their bedroom would light up as the smoke stack lights would blink.

The Lake on a hill with the power plant in the distance at sunset

The Lake on a hill with the power plant in the distance at sunset

I thought I would just put that picture in there so you could see how pretty the plant looked from across the lake at sunset.  To me it looked like a big ship on the horizon.

I mentioned above that there was a radio tower that had a light on it that needed to be changed when it burned out.  The actual lamp looked a lot like a regular incandescent bulb in your house, but it was different.  It was designed just for this job.  It didn’t burn out very often.  Ok.  I can see your look of disbelief, so here is a picture of one:

A radio tower light bulb

A radio tower light bulb

Yeah, looks just like something in your house.  Doesn’t it?

Anyway.  I changed out the light at the top of our radio tower which is only about 200 feet tall.  It looked like the following picture:

Our tower was like this only it didn't have a safety pole up the side for a lanyard.

Our tower was like this only it didn’t have a safety pole up the side for a lanyard.

I had to climb to the top of this tower to replace the red flashing light.  I was by myself when I did it.  Bill Bennett handed me the bulb that had been specially ordered and asked me if I would do it.  If not, they could call Oklahoma City and have the line crew come down and change it.  I told him I could do it.  The tower wasn’t that tall, and I had shimmied around the top of the smoke stack before at 500 feet with only a slight urge to panic.

I changed the lamp out without incident.  I know that some people have a much more interesting job changing these lights out than I had.  Our radio tower was only 200 feet tall.  Here is a video of someone that had to climb a tower 1768 feet high.  You can see the beacon when they reach the top of this radio tower:

if your browser doesn’t play the video from the picture try this link:  “Climbing a 1768 foot tower“.

Ok.  That is crazy!  Wouldn’t dropping someone from a helicopter onto the tower using a safety line be safer?

My last story about being on light duty at a power plant is about when Ted Riddle and I were working at the gas-fired power plant near Mustang, Oklahoma.  I talked about the time that Ted and I worked at this plant in the post “Working Power Plant Wonders with Willard Stark

While we were there after they found out that we were electric conduit running fools, they gave us all sorts of jobs running conduit all over the plant.  One job they showed us was in an area that was dark.  All the lights were out in this area.  The foreman explained where the light bulbs were kept.  They were just the regular incandescent lights like the normal lights you would have in your house.

Well… Ted and I had both been put on Light Duty at our plant, and we knew that when we went to change out one light, we were supposed to change out all the lights that were out.  So, Ted and I each grabbed a box and a ladder and headed up to the boiler enclosure to change lights.

After lunch, the foreman came running up to us yelling, “What did you do?  You used up all of the light bulbs!”  Well.  Yes.  We had used up the lights, but now when you go up on the boiler you can see where you are going.  The foreman then explained to us  that this little plant didn’t have the same kind of budget that the new big plants had.  They couldn’t afford to just go around replacing all the lights whenever they burned out.  They only put in a light when someone has to work in that area.  We had lit the entire place up like a Christmas tree.

Ok.  Take a note Jan… Don’t replace all the lights if they are incandescent.

Ok (again), that wasn’t quite the last story.  Let me tell you some more about replacing Fluorescent lamps in our Coal-fired power plant.  When we were placed on Light Duty, we would grab a couple of boxes of 30 lamps from the pallet in the main switchgear and go to work.

In the main switchgear the lights were up high, so we used a 10 foot ladder with a stand on the top of it (No.  I don’t mean like a Deer stand…. geez… Power Plant men…. always thinkin’ ’bout huntin’).  Actually it is called a Platform ladder:

This is a 6 foot platform ladder. Ours was 10 foot and very wobbly

This is a solid 6 foot platform ladder. Ours was 10 foot and very wobbly

I didn’t like using this wobbly ladder when I was by myself.  besides being wobbly, the thing weighed a ton.  So, I would take a smaller ladder and put it on top of the breaker cabinets and climb on top of them.  The only problem here was that I couldn’t get directly under the lights, so I would end up reaching out to one side to change a light while I was standing on a ladder on top of a seven foot cabinet.  Not a pretty sight if someone safety minded walked in.

I felt safer doing this than standing way up in the air on a 10 foot wobbly platform ladder.  I always had the feeling that if I sneezed, the ladder would topple over.  The rule of thumb was to keep your belt buckle within the rungs on the ladder.

When we were done changing out fluorescent lamps, we usually had a stack of boxes of burned out lamps.  We couldn’t just throw them in the dumpster because they were a safety hazard as they were.  We had to break each bulb.  We found that we could take a box of 4 foot fluorescent lamps and back the truck over it and it would let out a low but loud boom that sounded like a cannon going off.

The ingenious electricians invented a bulb busting barrel where you slid one 4 foot bulb into a tube and then lifted a handle quickly, and it would explode the lamp in the safe confines of the metal barrel.  The end of the lamp may at times come shooting out the end of the tube, so you never wanted to be standing to that side of the barrel.  I would show you a picture of one, but I’ve never found another one like it.

So, if you were into breaking glass, this was the best part of being placed on Light Duty.  After a hard day of changing out lamps all over the plant, you could stand around in front of the electric shop and slide the lamps down a tube like mortar shell and pull the rod and…. Boom! A puff of Mercury Vapor released into the atmosphere a small cloud of dust…. repeat.

Comment from original post:

  1. Ron Kilman July 24, 2014

    I remember being on “Light Duty” at the Mustang Power Plant as a summer student in 1967. We changed the 1000 watt bulbs in the top of the turbine room. It was so hot, we had to wear gloves.

Sky Climbing in the Dark with Power Plant Boiler Rats

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.

A Main Power Transformer

A Main Power Transformer

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).

Diagram of a boiler

Diagram of a boiler

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:

Rat from the Movie Ratatouille

Rat from the Movie Ratatouille

Or even a normal rat like this:

Normal looking rat

Normal looking rat

No. These rats looked like Ron Hunt wearing his hillbilly teeth. More like this:

rat from kootation

rat picture taken from kootation.com

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.

A sky climber

A sky climber

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:

  1. A.D. Everard August 3, 2014

    You tell a wonderful story and keep the reader spellbound. I love this sort of inside information!
    Coming to your blog has given me the same rush of excitement I get when I’m researching something and find a gem! Now I want to write about boiler rats! 🙂

Not a Fan of French Power Plant Fan Filters

Originally posted August 2, 2013:

I had only been an electrician a couple of months before I heard about Power Plant Louvers. My first thought was that this was a mispronunciation of the word “Louvre”. I remembered how Marland McDaniel would pronounce the word “Italian”. He pronounced it “It-lee-un”. The first time he said that I asked him what he had said, and he said, “So, You’re an It Lee Un Huh? An It-Lee-Un from It-Lee. Meaning “An Italian from Italy”.

So, when I heard the word Louver, I immediately said to myself “ok. They are probably trying to say the word “Louvre” (pronounced “Loove” which rhymes with “move”). Why shouldn’t they be trying to say the name of the most famous museum in the world. After all. When Sonny Karcher wanted to say there were a lot of things, he would say that there were “boo-coos” of them, When I asked him what “Boo-coos” meant he explained that it was French for “A lot”. Then I understood that he was mispronouncing the word “Beau-coup” (pronounced: “Bo Coo”). I suspected that everyone knew about the Louvre in Paris, France. I had first visited the Louvre in 1974 when I was 13 with my father on our way from Rome to Liverpool which I mentioned in the post “Power Plant Snitch“.

The Louvre in Paris France. The home of the Mona Lisa and the Venus De-Milo.

The Louvre in Paris France. The home of the Mona Lisa and the Venus De-Milo.

It didn’t surprise me that they may have named a motor after the Louvre (as we were told to go replace a Louver Motor when we were doing filters). I half expected it. I figured it was somewhere up in the Tripper Gallery which is where the coal feeds into the coal silos above the bowl mills. I explained about the Tripper Gallery in the post “Power Plant Painting Lessons with Aubrey Cargill“. I have expected to see paintings lining the walls when I first entered the Tripper Gallery.

So. I mentioned that we were supposed to replace a Louver Motor while we were “Doing Filters”. As a new electrician (which in my head an electrician was a vision of “elitism” going about the plant fixing electric circuits and running conduit and pulling wire), I soon learned from my foreman Charles Foster that as an electrician we were responsible for anything that had a wire going to it. That meant… well. Just about anything, one way or another. From water fountains, to elevators, to air filters.

Air Filters? Really? Not that I minded changing out air filters. It was just the connection to being an electrician that was confusing me. Ok. I could understand the filters that were on motors. Since motors were something we worked on all the time. It was the air handling filters that I was having a trouble connecting. Needless to say. within a few months my expectations of what an “electrician” meant was much more down to earth.  Like climbing in a precipitator.

Even though we were the “elite” group of magical maintenance men (and woman), we were also the team that was looked to for all sorts of other tasks that was too involved for the labor crew, and too vague to fit under Mechanical Maintenance, because somewhere, there was a wire attached. God forbid if a labor crew hand was electrocuted while changing out a bank of paper air filters. — Ok. It’s not like me to complain… — or maybe in my old age, it is becoming more common… I’m not sure.

So. In most houses there are two types of filters. There is what I would call a “Paper Filter”, and there is a “Metal Filter”. The paper filter is found in the air conditioner intake. You probably don’t change it out as often as you should, but you know what I’m talking about. The metal filter is probably over your stove in your oven vent. — Oh…. You didn’t think about that one? Better go clean it then….

The Power Plant is the same. There are both paper filters and metal filters, and things we would call “Bag Filters”. — Oh.. yes. and coffee filters… but I’m not going to talk about Coffee filters in this post other than to say that, “yes. We did have coffee filters also.”

Power Plant Coffee Maker Coffee Filter

Power Plant Coffee Maker Coffee Filter

Ok. A short side story… The person that was appointed to drive the truck was responsible for making sure the coffee maker was ready to go by break time. Only, when I was the designated truck driver I told everyone that I was not going to make the coffee. My reason was that I don’t drink coffee, and I wouldn’t know how to make a good cup of coffee and they could be sure that if I made it, it was going to be as thick as syrup. — The rest of the Electric shop agreed that it would not be a good idea for me to make their coffee, so either Andy or Dee made the coffee when I was on Truck Driver Duty. — End of side story.

So, when we were placed on Filter Duty… That meant that we went around the plant and changed out filters for air handlers, and we cleaned and coated the metal filters that were used on motors. This task took about a week. “A week?” you say? Yep. I don’t remember the exact numbers, though at one point in my career I had counted everyone of the them just to amuse my self… but just one air handler for the main switchgear had about 50 large paper filters and if I remember correctly had another 50 bag filters behind them.

Industrial Paper Air Handling Unit Filter

Industrial Paper Air Handling Unit Filter. They kind of look like Modern Art I suppose

Here is the bag filters that usually were attached to the back side of the paper filters:

Industrial Air Handler Bag Filter

Industrial Air Handler Bag Filter. Except ours weren’t pink and they weren’t on a beach.

First we had to remove the old filters that were often crawling with various kinds of flying insects that had been stuck to the filters since they flew too close and were sucked onto the filter. Then we installed the new filters in their place on a wall made of a large metal frame designed specifically for these filters. I think the reason they have a picture of the beach with this bag filter is because usually when you are trying to fit the bag filter into the basket you often thought that you would rather be at the beach than doing this task.

So. In the coal-fired power plant in North Central Oklahoma, there were a set of very large motors that spun the large fans that blew air into the boiler and that blew the exhaust up the smoke stack. Each of these motors (and we have two of each kind on each unit), had a set of large metal filters on them. You had to remove a large panel bolted to the side of the motors to remove the filters. — The motors were almost always running when this was being done. After all. We can’t stop lighting Oklahoma City just because it’s time to clean the motor filters on the fans on the boilers….

The metal filters reminded me of the filters over the stove when I was a cook at Sirloin Stockade. We would have to take them out each night and run them through the dishwasher after all the dishes had been washed after closing. Then the dishwasher was put in a self-cleaning mode to clean out all the gunk from the filters.

Galvanized, Stainless Steel Framed Air Filter used in large motors. This is a about 2 feet by 2 feet square.

Galvanized, Stainless Steel Framed Air Filter used in large motors. ours is a about 2-1/2 feet by 2 feet in the largest motors.

Then we had pump motors around the plant and down at the river that had smaller versions of these metal filters. Each of these metal filters were taken to the shop where we used a high pressure washer (one that would take the paint off of your car), and we would disintegrate the bugs that were stuck to these filters using the high pressure washer until the filters were cleaned. Then after letting them dry, we would coat them with a “filter coat” that would collect dust so that we wouldn’t have to wait too long before they were dirty again.

Well. There were some that didn’t like using the filter coat. Especially if they thought they might have to be cleaning the same filters themselves the next time. This happened when we decided to split the Filter Duty up between teams once. We decided that one team was going to be responsible for Unit 1 and the other team was going to be responsible for Unit 2, and we split up the air filters so that they were pretty evenly divided.

When we did this, an incredible thing happened. Each time we had to clean our filters, they were really dirty. Half the time the other team cleaned their filters they were not very dirty. It was obvious what was happening…. someone wasn’t using the filter coat. We all knew that it was “Ain’t My Mota” (translated “not my motor) Michael Rose. There was nothing anyone could really do about it. His foreman tried and tried to reform him, but there was really only one cure.

Talking about “Ain’t My Mota” Michael reminds me of one guy that was on our crew, Gary Wehunt. It wasn’t that he cut corners. It’s just that he always wanted to do the easiest jobs first and work his way up to the worse jobs. I was the other way around. I always wanted to get the tough jobs over with right away, and then cruise on down to the easier jobs.

So, when I was working with Dee (Diana Brien) cleaning motor filters, we would start with the bowl mill motors and then work our way over to the big fan motors. Then we would end up down at the river cleaning the river pump motor filters. When I was working with Gary, he always wanted to go straight to the river pumps. I always had the feeling that he thought that there might be a chance that by the time the Bowl Mill motors (which were always caked with Coal Dust) he would be called off to go work on an air conditioner instead. To each their own.

So. What is a Louver? I guess I forgot to mention that. A Louver is the metal flap that opens to let the air in. When the air handler is off, the louver closes. Before it starts up, the Louver opens so the air can pass through the filters. It is like a set of blinds on a window. The Louver Motor opens and closes the Louvers:

Large Metal Louvers for an Industrial Air Handler

Large Metal Louvers for an Industrial Air Handler

Today I am not able to change out the filter for my air conditioner in my house without having a flashback to the time I spent replacing filters at the plant covered with dirt, coal dust, fly ash and bugs. I had reminded myself often early on after I joined the electric shop as an electrician what Charles Foster had told me when I was still a janitor.

In my new job I sit in a clean office area with people sitting all around typing away on their computers or talking to one another. But out of the corner of my ear I can hear the noise every so often up in the ceiling above the false ceiling of the air handler louvers adjusting the air flow as the climate control detects that more air is needed in another area.

My coworkers may think I’m sort of strange (for a lot of reasons, but one of them may be) because as I’m working away on the computer apparently oblivious to what is going on around me, I may suddenly break out in a big smile. Why? They may wonder. Because I can hear that louver slowly changing position. They sound like they are pneumatically controlled, but there is no mistaking the distinct low grind of the flaps as they slowly change. So, without stopping what I’m doing, a grin may appear on my face.

Charles had come up to me when I was a janitor while I was working on the floor scrubber in the main switchgear and asked me if I would think about becoming an electrician. He said that a lot of being an electrician was cleaning things. He had noticed that I took a lot of pride in the way I cleaned and that he thought I would make a good electrician.

I did enjoy being a Janitor and having someone encourage me to become an electrician was all I needed to pursue the honorable trade of “Electrician”. It didn’t take me long once I joined the shop to learn that Charles wasn’t stretching the truth when he said that a lot of what an electrician does is clean things.

I spent 18 years as an electrician at the Power Plant before moving on. Throughout that time, my wife never knew what to expect when I came home from work. My clothes could be just as clean as when I left in the morning, or (most likely), they would be covered with Soot or Coal Dust from the Coal-Fired Power Plant in North Central Oklahoma. One thing she could usually count on when I walked in the door was that I would have a smile on my face for having the privilege to spend a day at work with such a great group of Power Plant Heroes.

What do Power Plant Men in North Central Oklahoma Do For Recreation

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.

The Evil Knievel Pinball machine was one of the many I had mastered. By the way, why isn't his last name pronounced: "Nee-vel"? Just wondering.

The Evel Knievel Pinball machine was one of the many I had mastered. By the way, why isn’t his last name pronounced: “Nee-vel”? Just wondering.

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.

Beehives like this only lined up on a trailer

Power Plant Beehives

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 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?

Marlin McDaniel always reminded me of Spanky from Little Rascals

Marlin McDaniel always reminded me of Spanky from Little Rascals

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…..

Gene Day's truck was similar to this only different, with a different pattern of flames and a newer type of truck

Gene Day’s truck was similar to this only different, with a different pattern of flames and it wasn’t a low rider

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.

A couple of Rodeo Clowns

A couple of Rodeo Clowns

Sure they stand around in bright colored clothes. These two guys aren’t just there for laughs. Here is a rodeo clown at work.

Rodeo Clown at Work

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.

A Rodeo Clown Hard at Work

A Rodeo Clown Hard at Work

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 (or one of our fingers). 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 deer 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.

A Deer and a raccoon fighting over who gets first dibs on the deer feeder. My money is on the raccoon.

A Deer and a raccoon fighting over who gets first dibs on the deer feeder. My money is on the raccoon.

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.

Pawnee Lake Oklahoma. Photo taken by John Brumfield

Pawnee Lake Oklahoma. Photo taken by John Brumfield

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.

This isn't Trail Boss, but you get the idea. This guy is wearing a Trail Boss Hat

This isn’t Trail Boss, but you get the idea. This guy is wearing a Trail Boss Hat

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.

Comments from the previous repost:

    1. Ron Kilman August 14, 2014

      My hobby was astronomy. I built an 8″ telescope when I lived in Ada (worked at the Seminole Plant in Konawa). I remember telling my Plant Manager (Jim Gist – lived in Konawa) about all the things I could see with my telescope. When I told him that I could see Uranus (I used the long “a” pronunciation), he got a real surprised look on his face – and finally said “All the way from Ada?” He was a real hoot!

  1. Citizen Tom August 14, 2014

    Good story! That’s the kind of experience most people can relate to, getting to know ones coworkers. And the interesting facts and pictures just make it more interesting.
    Never occurred to me a raccoon would take on a deer.

Lifecycle of a Power Plant Lump of Coal

Originally posted August 16, 2013:

Fifty Percent of our electricity is derived from coal. Did you ever wonder what has to take place for that to happen? I thought I would walk through the lifecycle of a piece of coal to give you an idea. I will not start back when the it was still a tree in a prehistoric world where dinosaurs grew long necks to reach the branches. I will begin when the large scoop shovel digs it out of the ground and loads it onto a coal truck.

The coal is loaded onto trucks like these before it is dumped onto the train cars. This photo was found at http://www.gillettechamber.com/events/eventdetail.aspx?EventID=2827

The coal is loaded onto trucks like these before it is dumped onto the train cars. This photo was found at http://www.gillettechamber.com/events/eventdetail.aspx?EventID=2827

The coal for the power plant in North Central Oklahoma came from Wyoming. There were trains from the Black Thunder Mine and the Powder River Basin.

Coal Trains on their way to power plants

Coal Trains on their way to power plants

It’s a long ride for the lump of coal sitting in the coal train on it’s way to Oklahoma. Through Nebraska and Kansas. It’s possible for the coal to be visited by a different kind of traveler. One that we may call “A tramp.” Someone that catches a ride on a train without paying for the ticket.

One time a tramp (or a hobo, I don’t remember which), caught a ride on one of our coal trains. They forgot to wake up in time, and found their self following the lumps of coal on their next phase of the journey. You see. Once the coal reached the plant, one car at a time enters a building called the “Rotary Dumper”.

A rotary dumper much like the one that was at our Power Plant

A rotary dumper much like the one that was at our Power Plant

As each train car enters the dumper four clamps come done on the car and it rolls upside down dumping the coal into a bin below. Imagine being a tramp waking up just in time to find yourself falling into a bin full of coal. with a car full of coal dumping coal on top of you. One coal car contained 102 tons of coal (today they carry 130 tons). Today one train contains 13,300 tons of coal. This is over 26 million pounds of coal per train.

Miraculously, this passenger survived the fall and was able to call for help or someone saw him fall. He was quickly rescued and brought to safety. Needless to say, the tramp went from being penniless to being, “comfortable” very quickly. I don’t know that it made the news at the time. I think the electric company didn’t want it to become “viral” that they had dumped a hobo into a coal bin by accident. Well. They didn’t know what “going viral” meant at the time, but I’m sure they had some other phrase for it then.

Ok. Time for a Side Story:

Since I’m on the subject of someone catching a clandestine ride on a train, this is as good of a place as any to sneak in the tragic story of Mark Meeks. Well. I say it was tragic. When Mark told the story, he seemed rather proud of his experience. You see. Mark was a construction electrician. He hired on as a plant electrician in order to settle down, but in his heart I felt like he was always a construction electrician. That is, he didn’t mind moving on from place to place. Doing a job and then moving on.

Mark explained that when he was working at a construction job in Chicago where he worked for 2 years earning a ton of overtime, he figured that by the time he finished he would have saved up enough to buy a house and settle down. He was married and living in an apartment in Chicago. He didn’t spend much time at home as he was working 12 hour days at least 6 days each week. He figured that was ok, because when he was done, he would be set for life.

Unknown to him at the time, each morning when he woke up before the crack of dawn to go to work, his wife would drive to O’Hara airport and catch a plane to Dallas, Texas where she was having an affair with some guy. By the time Mark returned from work 14 hours later, she was back home. Each day, Mark was earning a ton of overtime, and his wife was burning it on airline tickets.

When the two years were over, Mark came home to his apartment to collect his wife and his things and go live in peace in some small town some where. That was when he learned that his wife had been having the affair and using all his money to do it. She was leaving him. Penniless.

Completely broke, Mark drifted around for a while. Finally one day he saw a train that was loaded down with wooden electric poles. Mark figured that wherever those poles were going, there was going to be work. So, he hopped on the train and traveled all the way from Minneapolis Minnesota riding in the cold, wedged between some wooden poles on one of the cars on the train.

The train finally arrived at its destination somewhere at a port in the Gulf of Mexico. I don’t remember if it was Mississippi or Louisiana. He watched as they unloaded the poles, waiting to see what jobs were going to be needed for whatever the poles were for. He watched as they took the large wooden poles and piled them up in the ocean. They were using them to build up the shoreline. There were no jobs.

It is when you have been beaten down to the point of breaking when you reach a very important point in your life. Do you give up, or do you pick yourself up and make something of yourself? Mark chose the latter. He was a natural fighter. He eventually ended up at our plant as contract help, and then was hired as a plant electrician.

End of side story.

Let’s follow the lump of coal after it is poured out of the coal train in the dumper…

The coal is fed onto a conveyor belt. Let’s call this Conveyor 1, (because that is what we called it in the plant). This has a choice to feed it onto belt 2 which leads up to the stack out tower, or it can feed the other way to where some day it was planned to add another conveyor with another stackout tower. This was going to go to a pile of coal for two other units that were never built.

Anyway, when the coal drops down on Conveyor 2, way under ground, it travels up to the ground level, and continues on its way up to the top of the stackout tower where it feeds onto Belt 3. Belt 3 is a short belt that is on an arm that swings out over the coal pile. The coal is fed onto the coal pile close to the stack out tower. I suppose it is called stack out, because the coal is stacked up next to the tower.

A view of the coalyard from the top of the Smoke Stack

A view of the coalyard from the top of the Smoke Stack. The tower with the conveyor running up to the top is the stack out tower. Belt 3 is the arm pointing to the right in this picture

Anyway, there are large dozers (bulldozers) and dirt movers that pickup the coal and spread it out to make room for more coal from more coal trains. As mentioned above. One train now carries 26 million pounds of coal.

Dirt Mover full of coal

Dirt Mover full of coal

the coal that is spread out on the coal pile has to stay packed down otherwise it would spontaneously combust. That is, it would catch on fire all by itself. Once coal on a coal pile catches on fire it is impossible to “reasonably” put out. You can spray all the water on it you want and it won’t go out. When a fire breaks out, you just have to drag the burning coal off of the pile and let it burn out.

In order to keep the coal from performing spontaneous combustion, the dirt movers kept it packed down. As long as the coal is packed tight, air can’t freely reach the buried coal, and it doesn’t catch fire. So, dirt movers were constantly driving back and forth on the coal pile to keep the coal well packed. Even on the picture of the coalyard above from the smoke stack, you can see two pieces of heavy equipment out on the coal pile traveling back and forth packing the coal.

Anyway, the next phase in the life of the lump of coal happens when it finds itself directly under the stack out tower, and it is fed down by a vibratory feeder onto a conveyor. In our plant, these belts were called, Belts 4, 5, 6 and 7. Belts 4 and 5 fed onto Belt 8 and belts 6 and 7 fed onto belt 9.

Belts 8 and 9 brought the coal up from under the coal pile to the top of the Crusher tower. In the picture above you can see that tower to the right of the stack out tower with the long belts coming from the bottom of the tower toward the plant. The crusher tower takes the large lumps of coal that can be the size of a baseball or a softball and crushes it down to the size of marbles and large gumballs.

Coal conveyor carrying coal to the coal silos from the coalyard

Coal conveyor carrying coal to the coal silos from the coalyard. This is the size of the coal after it has been crushed by the crusher

From the crusher tower the lump of coal which is now no more than a nugget of coal travels from the coal yard up to the plant on belts 10 and 11.

conveyor 10 and 11 are almost 1/2 mile long

conveyor 10 and 11 are almost 1/2 mile long

Up at the top of this belt in the distance you can see another tower. This tower is called the Transfer tower. Why? Well, because it transfers the coal to another set of belts, Belt 12 and 13. You can see them going up to the right to that tower in the middle between the two boilers.

The tower between the two boilers is called the Surge Bin tower. That basically means that there is a big bin there that can hold a good amount of coal to feed to either unit. At the bottom of the white part of the tower you can see that there is a section on each side. This is where the tripper galleries are located. There are two belts in each tripper, and two belts that feed to each tripper belt from the surge bin. So, just to keep counting, Belts 14 and 15 feed to unit one and belts 16 and 17 feed to unit 2 from the surge bin. then Belts 18 and 19 are the two tripper belts that dump coal into the 6 silos on unit one, while belts 20 and 21 feed the silos on unit 2.

Once in the Coal silos, the coal is through traveling on belts. The silos are positioned over things called bowl mills. The coal is fed from the silo into the bowl mill through something called a Gravimetric feeder, which is able to feed a specific amount of coal into the bowl mill. This is the point that basically decides how hot the boiler is going to be.

Once the coal leaves the gravimetric feeder and drops down to the bowl mill, it is bound for the boiler. The gravimetric feeder is tied right to the control room. When they need to raise load more than just a minimal amount, a control room operator increases the amount of coal being fed from these feeders in order to increase the flow of coal into the boiler….. I don’t know… maybe it’s more automatic than that now…. The computer probably does it these days.

When the nugget of coal falls into the bowl mill the long journey from the coal mine in Wyoming is almost complete. Its short life as a nugget is over and it is pulverized into powder. The powder is finer than flour. Another name for a bowl mill is “Pulverizer”. The coal comes from the Powder River Basin in Wyoming and just before it is consumed in Oklahoma it really does become powder.

Big rollers are used to crush the coal into fine particles. The pulverized coal is blown up pipes by the primary air fans and blown directly into the boiler where they burst into flames. A bright orange flame. The color reminds me of orange sherbet Ice cream.

The color of the fireball in the boiler

The color of the fireball in the boiler

At this point an incredible thing happens to the coal that so many years ago was a part of a tree or some other plant. The chemical process that trapped the carbon from the carbon dioxide millions of years earlier is reversed and the carbon is once again combined to the oxygen as it was many millennium ago. A burst of heat is released which had been trapped after a cooling effect below the tree as it sucked the carbon out of the environment way back then.

The heat is transferred to the boiler tubes that line the boiler. The tubes heat the water and turn it into steam. The steam shoots into the turbine that turns a generator that produces the electricity that enters every house in the country. The solar power from eons ago that allowed the tree to grow is being used today to power our world. What an amazing system.

To take this one step further, the carbon dioxide that is released into the atmosphere today is replenishing the lost carbon dioxide from many years ago. Back when plants could breathe freely. Back before the carbon dioxide level was depleted almost to the point of the extinction of plant life on this planet. Remember, what we look on as a pollutant and a poison, to a plant is a chance to grow. The Sahara desert used to be a thriving forest. Maybe it will be again some day.

So, there is the question of global warming. We humans are so short sighted sometimes. We want to keep everything the same way we found it when we were born. We try desperately to keep animals from becoming extinct. We don’t think about the bazillions (ok, so I exaggerate) of animals that were extinct long before man arrived. It is natural for extinction to occur. That is how things evolve. We are trying to keep a system the same when it has always been changing.

Years from now we may develop ways to harness the energy from the sun or even from the universe in ways that are unimaginable today. When that time arrives, let’s just hope that we remain good stewards of the world so that we are around to see it. I believe that the use of fossil fuels, (as odd as that may seem) is a major step in reviving our planet’s natural resources.

Comments from the previous repost:

twotiretirade  August 20, 2014

Glad Mark fought the good fight, still a sad story.


Antion August 21, 2014
Great read. I love knowing how things work. As I read the sad story of the traveling electrician, I kept wondering if she could have pulled that off in today’s world of air travel.


hiwaychristian August 22, 2014
when I went to the Christian College in Eugene Oregon, they forced me to take a course in biology at the University of Oregon. I willingly sat and listened to the mix of science and evolution. I admit their perspective was intriguing.
at the end of the class, the last day, the instructor asked each one of her students to tell how the class had affected their thinking.
each one gave the politically correct answer in a variety of form. all the while I sat joyfully waiting my turn.
my response hushed the class for a moment. (it’s been some decades ago so I have to paraphrase but let it be sufficient) “I’m impressed with all the material you’ve covered. it’s astounding to think of all the things that were. but for me this class has only glorified my God. because I realize that in his wisdom he created gasoline for my car.”
you’ve covered a lot of material in your post. and I’m impressed at your diligence to complete it. I thank God for His faithfulness that he has put into you. may He prosper your testimony for the glory of His Holy Son.
By His Grace
(please overlook the syntax errors in this reply it was generated on a mobile device)

Monty Hansen November 4, 2014

We processed several hobo’s through our coal system, & injured a few, but none ever got anything from the power company. I remember we would always worried about finding a chunk of scalp or something in the grating where the tripper car drops coal down into the silo. One especially memorable event was when a coal yard operator found a down vest jacket on the coal pile and bragged about how lucky he was to find this jacket, the size even fit, but the jacket did smell a little funny. yes it was ripped off the body of a hobo by the plow above conveyor one & shot out onto the coal pile by the stackout conveyor.

It was always unnerving to have a pull cord go down in the middle of the night deep down in the coal trestle, while the belts were shut down. You’d have to go down there alone, in the dark & reset the pull cords, so the belts could be started later when needed. You knew it wasn’t a trick because the whole crew had been up in the control room together eating dinner or something. You always wondered if you might run into a real hobo – or the ghost of one.

Power Plant Cajun and the Hatchet Man

Originally Posted August 30, 2013:

During the 18 years I worked as an electrician at the coal-fired Power Plant in North Central Oklahoma, we often had contractors working from our shop. I have mentioned that from the moment that I first entered the electric shop the first day I was an electrician, one of the first two people I met was a contract electrician. (See the post: “New Home in the Power Plant Electric Shop“).

Gene Roget (pronounced, “Row Jay” with a soft J) was originally from Louisiana.

A Cajun I found on Google Images that slightly resembles Gene Roget

A Cajun I found on Google Images (this is actually the actor Shia Lebeouf) that slightly resembles Gene Roget

Gene had spent the first 10 to 12 years of his adult life as a construction electrician. Charles Foster told him to be my mentor. At first Gene was shocked to find out that instead of hiring him to be a Plant Electrician along with his best buddy, Arthur Hammond, they had hired a young kid who didn’t know squat about being a real Power Plant Electrician. Yeah…. that was me.

I felt sorry for Gene because he obviously was the better candidate. The only saving grace for my mind was the knowledge that I was hired through the internal job program and that if they hadn’t taken me into the electric shop, they were going to be stuck with Charles Peavler. Charles was… well… he was somewhat older, but, well….. he couldn’t get around the fact that no matter what he did, he was always still Charles Peavler.

The day I entered the electric shop, I was 23 years and about 3 weeks old. Charles Peavler was 43. However, Charles might remind you of someone more around the age of 65. Not because he looked quite that old. He looked more like, well… um….. I guess he did look like he was about 65. I couldn’t tell if it was just the way he walked or stood, or the way his lip curled around the wad of skoal between his front lower lip and gums.

Just a pinch between your cheek and gums.... Never tried it myself.

Just a pinch between your cheek and gums…. Never tried it myself.

I know… I’m being a little hard on Charles. I just like to tease him. I could be worse. I could tell you that his first name was really Amos. But I wouldn’t stoop that low. That would be like saying that Andy Tubb’s first name is really Carl, only worse, so I won’t go there. Actually, Peavler looks more like an Amos than a Charles. (Oh. That paragraph was about Amos and Andy!).

Anyway, by hiring me instead of Charles Peavler off of the labor crew I figured that even though I was dumb as dirt as far as being an electrician, I was more apt to learn new things than Charles. So in the long run I was probably the better candidate. Gene Roget wouldn’t have been able to be hired even if they hadn’t chosen me.

There were two openings for electrician when I was hired. Arthur Hammond (Art) was able to be hired by the electric shop was because they convinced the higher-ups that they needed someone with a background in electronics and there weren’t any internal candidates that fit that bill. So Charles Foster, the foreman, made the case that they needed an experienced electrician with electronics background and they needed someone dumb as dirt, but able to learn something more than just how to lace up their steel-toed boot. — That was where I came in.

I figured that Gene Roget would hold a grudge against me for taking the job that he wanted. This is where the true quality of a person may shine through. When you are involved in making someone upset, even though it wasn’t your decision to make, the way a person reacts to you will tell you a lot about that person’s character.

When Charles Foster told Gene Roget to be my mentor and show me the ropes to being an electrician I suspected that I was being setup for failure. “Ok…” I thought, “I’ll watch what he does instead of what he tells me…” I’ll also watch my back to make sure I don’t end up being electrocuted or knocked off of a ledge or some other accident that would create a new opening in the electric shop.

As it turned out Gene Roget was a man of great quality. Not once in the year and a half that I worked with him did I ever have the feeling that Gene wasn’t doing his best to teach me the skills of being the best electrician I could be. It also turned out that Gene was not only eager to teach me, but he was a highly skilled electrician. So, I felt like I was being taught by one of the best.

Gene Roget (I always liked calling him Gene Roget instead of just Gene… I’m not sure why, but I suppose I can blame it on Gene Day. I never could just call him Gene. And Gene Day and Gene Roget rhymed), carpooled with Art Hammond (I always liked calling Art, Arthur, but I’ll call him Art in this post just to make it shorter… except that I just used all these words explaining it that now it’s longer).

Gene and Art were like best buddies. I carpooled with them a couple of times when I had to catch a ride because I had to stay late and my carpooling ride had to leave (that would have been Rich Litzer, Yvonne Taylor and Bill Rivers). During the drive home, I came to learn that Art and Gene had worked with each other on construction jobs for quite a while and their families were close in some ways.

I also learned that there was another activity that they did together that was not all together kosher (I don’t mean in a Jewish way). They asked me on the way into Stillwater one day if I wanted to take a “hit” on the small rolled cigarette they were taking turns taking tokes from. I had spent 4 years prior to this time in college in a dorm where smoking marijuana was more common than cigarettes and the idea didn’t phase me.

I declined, because I had no desire to go down that route. I told them that I wished that they didn’t do that while I was in the car because then my clothes would smell like I had been living in the dorm again, where your clothes were going to smell like that just going from your room to the elevator… At least it was that way my second year in college.

I’m only talking about this now because it was 29 years ago, and by now if Gene Roget wanted to set his grandchildren on his knee and tell them about the times he was a younger construction electrician, he can mention that he had a shady past at one point, but now he’s just a kind old man. So, I’m going to go on with a story that up to now I have only shared with Arthur Hammond.

One day I went into the main switchgear to find some parts in the parts cage behind the electric shop. When I went back there, an operator Dan Landes was in the switchgear with another operator. They were looking for something by the ladders, so I walked over to see if I could help. Maybe they needed the key to unlock the ladders, I thought.

I don’t remember what they wanted, but I do remember that when I walked up to them I immediately smelled the aroma of marijuana being smoked somewhere. We had just recently lost an electrician in our shop when the snitch tricked him into trading some marijuana for a supposedly stolen knife set (see the post “Power Plant Snitch“).

I asked Dan if he smelled that smell. It was pretty strong. I told him that was marijuana, and I could tell him what type it was. You see, even though I had never smoked the stuff, the drug dealer for the entire dorm used to share the bathroom with our room, and three nights each week he held parties in his room. He had high quality stuff and low. There was a definite difference in the smell. So, I would ask my roommate Mark Sarmento about it and he explained it to me.

So, I told Dan that someone had just been smoking marijuana somewhere right there. It would have definitely been a dumb thing to do. Eventually Dan and the other operator (I can’t remember who) left the switchgear to continue on with their switching. So I returned to the rack where the ladders were.

As I stood there alone I realized that the aroma was pouring down from on top of the battery rooms. So I yelled out, “Hey! You better stop that right now! Don’t you know that the smoke is coming right down here in the switchgear?!?! Put that out and come on down from there!” I stood there for a few minutes and then I walked back into the electric shop.

I laid my parts on the workbench where I was repairing something, and then I walked back over to where I could look through the window in the door into the main switchgear. I finally saw someone climb down one of the ladders from the top of the battery rooms. So, I confronted him.

Yep. It was Gene Roget. I had been working with him for a year and a half at this time and I considered him a very good friend. I told him, “Gene! How could you do that? You know if they catch you they will fire you right away. No questions asked!” He said he was sorry, he didn’t think about the smell coming down into the switchgear and he would make sure it never happened again. I told him that he was lucky that I had found him and not Dan Landes. Dan’s nickname was Deputy Dan. He was a deputy in Perry, Oklahoma.

Well. as it turned out a few weeks later, Gene Roget was let go. I hadn’t told a soul about our encounter, but I wondered if he thought I had. Later I found out that he was let go so suddenly because he had confronted Leroy Godfrey about how Craig Jones had been fired because he had done something wrong. He didn’t know all the details about the snitch, but he did know that they said he was part of a (non-existent) Drug and Theft Ring.

No one tells Leroy Godfrey how to do his job, and in this case, Leroy had nothing to do with it. As a matter of fact, Leroy’s best buddy Jim Stevenson had been unjustly fingered by the snitch just because he was Leroy’s friend. So, Leroy had Gene Roget fired. I barely had time to say goodbye to Gene as he was led out the door to the parking lot and escorted out the gate by the highway patrolman who doubled as a security guard.

One time a year later, when I was carpooling with Art Hammond once again, I talked to Arthur about that day in the switchgear. I knew he was best friends with Gene Roget. So I told him about that instance. He told me that Gene had told him the whole story on the way home that day. Gene had just about had a heart attack when I had yelled up there for him to come down. He had swore to Arthur that he was never going to be that stupid again.

I made it clear to Arthur that I hadn’t told a soul about that day. And up until now, I still hadn’t. That was when Art explained to me the real reason that Gene had been fired. That made total sense. I knew how Leroy Godfrey was. He was an “old school” Power Plant Supervisor.

This is where the short story of the Hatchet Man comes up. He was another contract electrician. I think he was hired to help Jim Stevenson and Bill Ennis with the freeze protection. They were preparing for the coming winter and they needed a little extra help. I call this guy the “Hatchet Man” not because he was a hatchet man for the “Tong”, but because the only tool he used was a hatchet.

A Detective holding aTong War Hatchet

A Detective holding a Tong War Hatchet

He didn’t have a tool bucket. He just used this one tool. A Hatchet. As it turned out, he was missing two fingers on one hand and three fingers on the other hand. Hmmm… what came first? I wondered… the hatchet or the lost fingers? It seemed comical that a person missing half of all his fingers used only a hatchet as his only tool as an electrician. — how would he screw in a screw? Electricians had to work with screws all the time. Maybe he had a pocket knife for that.

I figured he probably lost his fingers working in the oil fields, since a lot of people lost fingers doing that. This guy definitely didn’t look much like a rodeo rider, which was the other group of people that would lose fingers.

One day, while sitting in the electrical lab during break time or lunch the subject of an upcoming job opening in the shop came up. The Hatchet Man made the mistake of saying that since he was handicapped, they had to give him the job. All he had to do was apply. They couldn’t turn him down. His missing fingers was his ticket.

Well. It didn’t take long before word of this conversation made its way up to the one good ear that Leroy Godfrey used to hear. The other one was out of commission. As I mentioned before. No one told Leroy what to do. He was supreme leader of the electric shop domain. By the end of the day, the Hatchet Man was given the Ax.

Ted Riddle was hired instead. Now you know the rest of the story.

Prolonged Power Plant Pause Before the Panic

Originally posted September 6, 2013:

Today when I attend meetings while on the job at Dell (and now at GM) and the discussion is about something new, and the manager is looking for input from the team, I usually sit there quietly while the others share their thoughts. This is not my usual behavior in other settings as I am usually quick to respond with a quip or something sarcastic.

Later, after everyone else has given their two cents, then if asked, I will wade in with both feet. This hasn’t always been the course of action I would have taken. Actually, I used to be pretty hot-headed. I was usually the first person to respond when someone asked a question. I already had my mind made up about just about everything.

My wife began noticing a change in my behavior a few years after we were married. She would ask me a simple question, like, “Would you like a piece of gum.” I would suddenly go into a momentary comatose state where I would stare off into space and think about it. She would say something like, “The answer doesn’t need a lot of thought. It is either ‘yes’ or ‘no’.”

After careful analysis, I finally figured out what happened. The transformation began the day I entered the electric shop at the coal-fired power plant as an electrician. I described that first day in the post “New Home in the Power Plant Electric Shop“. In that post I described my first job as an electrician when I went to the coalyard with my foreman Charles Foster to fix a room heater that wasn’t working.

The first time I used my new tools, Charles told me to remove a screw from a fuse block so that we could lift a wire in order to replace the fuse block.

A small fuse block like this.

A small fuse block like this.

When I was removing the wire (with one hand, as Charles had warned me that an electrician never uses two hands to do this), the screwdriver slipped and shorted out on the mounting screw which caused a brief flash. In the millisecond that the flash occurred, it cut a notch in the tip of my new Stanley screwdriver.

A Stanley screwdriver used by electgricians because of the rubber on the handle

A Stanley screwdriver used by electricians because of the rubber on the handle

This was the beginning of my 18 year career of various minor electrocutions and small explosions. We did things to minimize the chances of shorting out your screwdriver when working on a hot circuit (that means a circuit that has the electricity still turned on). One thing we would do is wrap rubber tape up the metal shank so that if it leaned against something metal with it while the tip was touching something hot, it wouldn’t short out the circuit.

Inevitably, something would happen every now and then and something was going to explode. So you just had to be prepared for that. This is where the “Prolonged Pause” comes in.

Sometimes there is nothing you can do. Let me give you a “For Instance”. One time when we had an overhaul on Unit 1 (we had 2 units at our Power Plant in North Central Oklahoma), Richard Moravek was visiting from the Power Plant in Muskogee, Oklahoma. I have written about him in the Post “Lap o’ Luxury at the Muskogee Power Plant“. Each morning at Muskogee, he and Jay Harris would sing the song, “Nestle’s makes the very best Chocolate”, with Richard whistling as he sang like the Nestle’s rabbit with a whistle in his voice.

The Nestle's Rabbit

The Nestle’s Rabbit

On one particular day, Richard and I were sent to perform a “quick and dirty” elevator inspection on the Unit 1 elevator. It received a lot of wear and tear during overhaul with everyone riding up and down from the 9th floor where you could reach the upper echelons of the boiler. If things didn’t work perfectly every time, then the work would be slowed, and schedules wouldn’t be met.

During our elevator inspection we decided that we needed to change out some lights on the push buttons, because…. well… because some of them were burned out. Which caused them to not light up when they were supposed to, causing some Power Plant workers to become confused because they would forget which button they had pushed when they entered the elevator, thus, allowing them to forget which floor they were supposed to get off (working long hours will do that to you).

Anyway, Richard had taken the screws out of the push button panel and had swung the door on the panel open so that the wiring inside was all exposed. He reached in to pulled out one of the push button assemblies so that he could remove the bulb (oh… electricians call bulbs, Lamps… I mentioned that in the post “Place On Light Duty at the Power Plant“, if you recall).

I had reached down into my tool bucket and pulled out a box of special elevator lamps….. Actually, I think it was a standard 6S6 lamp, but it looked like a bulb to me:

A 12 Volt 6S6 bulb

A 12 Volt 6S6 bulb (or is it a lamp?)

Richard had put his hand out to receive the bulb I had in my hand, so I handed it to him. At that point, a funny thing happened. You see, my other hand was on the elevator scissor gate.

An Elevator Scissor Gate

An Elevator Scissor Gate

As I placed the lamp into Richard’s hand, he suddenly twitched and sort of jumped at the same time. When he did, he pushed into me and he began doing a jig. My legs were twitching and I was sort of doing a jig myself, or maybe a jog.

It became apparent right away what had happened. While Richard’s one hand was in the elevator push button panel taking out the bulb, he had come in contact with the electric circuit. This was fine as long as he wasn’t grounded. That is, he wasn’t touching anything else metal, like the front of the panel.

Being a good electrician, Richard had kept his other hand at his side like Charles Foster had taught me my first day as an electrician. That is, until he raised that hand for me to give him a lamp. When my fingers touched his palm, and my other hand was holding the elevator gate, we suddenly made a circuit to ground. From Richard, to me, to the gate, to the ground, and back to the the main power generator through various grounds and circuits and transformers….

About the time that I realized what was happening, we had separated from each other, and were no longer dancing. It cracked us up and we stood there laughing about it for a minute because both of us had just been dancing in the elevator.

As I explained in the post about being on light duty that I mentioned above, when you went to work on the stack lights, you carried metal prod with you that you used to ground the large capacitors before you worked on the circuit. When you did this, there would be a bright flash and a loud explosion.

If a noise or a flash like that made you jump, you may end up going over the handrail and falling 500 feet to the ground. So, you learned that in the event of a flash, your first reaction is to freeze. Then assess the situation, and then if necessary, Panic.

Many years later (like 16), I became very aware of how well trained we were when something like this happened when I was once again working with Charles Foster in a junction box on the 11 landing of Unit 1 on the west side. We were standing side-by-side and we were working on something hot.

Suddenly there was a bright flash and a loud boom as something shorted out. By that time in our history, we had learned all about wearing fire resistant clothing, so that even though what we were wearing wasn’t fire proof, it also wasn’t going to melt to our skin.

What amazed me about this moment was that we both stood there still for a moment before we panicked. There was about a one second pause where we both restrained ourselves from jumping back. I chalked this up to our years of being around explosive situations. Jumping back as the first reaction can often lead to other injuries.

I took this resistance to panic with me into other situations. Before 1994 when OSHA added a bunch of new laws protecting people in confined spaces, I was crawling inside the main generator bus that goes out to the main power transformer. No hole watch. No one watching me outside that could grab me and pull me out if something went wrong.

A Main Power Transformer

A Main Power Transformer. The bus piping are those three pipes going into the building at the top in the back

I had squeezed myself into one of these pipes to clean the insulators that held the bus in place in the middle of the pipe. This meant that I was crammed into the pipe under the bus bar that ran through the middle of the pipe.

I had made it to the insulator that I needed to clean and wiped it down with the rag I had taken with me. Then I decided I couldn’t go forward anymore to look at any more of the insulators because it was too tight of a fit. So, I started to back myself out.

As I went to push myself back I suddenly realized that I was stuck. It was easy moving forward because I was using the soles of my sneakers to push on the pipe, but as soon as I wanted to go back, there didn’t seem to be anyway to maneuver my body in a way that would back myself out. My arms were stretched out in front of me.  This was one of a few times when I began to feel the panicky feeling of claustrophobia.

I had seen claustrophobia in others and I knew that when you are gripped with it, you can hurt yourself, or even Bob Lillibridge if he happened to be the one grabbing your legs at the time (see the post: Bob Lillibridge Meets the Power Plant Ghost for an explanation.

Here it came… I felt myself swelling up tight in the pipe as the panic was gripping me. I knew I had to do something quickly or it wasn’t going to be pretty…. Well, either way… nothing about this was pretty. So, I forced myself to calm down. I told myself to breathe out, and slowly back in.

Then I decided to use the palms of my hands that were stretched out straight in front of me to push against the pipe to move me back. With that effort, I could see (in the darkness) that I had moved myself back about 1/2 inch. I thought. “Ok, 1/2 inch is something. If I did that 100 more times, that would be more than 4 feet. 200 times and I would be out of this pipe.”

Realizing I could move myself at least a little bit allowed me to calm down and quell the panic. I did nothing but concentrate on pushing with my palms 1/2 inch at a time and eventually, I did climb out of that pipe (What?  You expected me to say I was still in there?).

I don’t know how many times over the years I have woken up in the middle of the night and swung my feet over the side of the bed and taken a few large breaths because I had been dreaming about being in that pipe again. I will discuss the topic of claustrophobia in a later post, but this example fit the topic of training yourself not to panic so I thought I would use it here.

If you ever end up talking to someone that doesn’t quite look at you when they look like they are trying to look at you, then you may think that they are a welder. There are some welders that seem to look at you from the corner of their eye. I suppose it was because the middle of their vision has been burned out because they have looked at the welding arc too many times without their visor down.  Or maybe they had just learned to look away from whatever they are seeing just as a safety habit.

Similarly, if you ever encounter someone that momentarily goes into a comatose state for a few moments when you ask them a simple question, you may now think that maybe this person was a Power Plant Electrician that has learned to have a Prolonged Pause before they Panic… or… respond to your question. If they aren’t from a power plant, then they probably were just trying to ignore you.

Comments from previous repost:

    1. Dan Antion September 11, 2014

      Good advice for anyone in similar situations.

    1. Slowmoto September 11, 2014

      Pause before panic is my response to most stressors perceived by a presenter or an emerging reality. You hit the mark!

  1. Monty Hansen November 26, 2014

    Excellent writing! I felt myself getting panicky with you! As a control room operator I had an electrician drop a screwdriver & blow the unit out from under me at full load + 5% overpressure (2520#)-(It caused a false boiler feedpump saturation temp trip). The power plant has trained me not to startle as well, inside I may be screaming like a schoolgirl, but outside I am calm and handling emergencies as though routine.