Tag Archives: feeder

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.

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Angel of Death Passes by the Precipitator Door

Originally published on May 25, 2012:

Either this was the luckiest day of my life, or a day where stupidity seemed to be my natural state of mind. This particular day occurred sometime during September 1983. The Main Power transformer for Unit 1 had  shutdown because of an internal fault during an exceptionally hot day during the summer and was being replaced.

While the unit was offline, while I was on the labor crew, I was asked to help out the electricians who were doing an overhaul on the Precipitator. The Precipitator takes the ash out of the boiler exhaust before it goes up the smoke stack. Without it, you would see thick smoke, instead, you see only clear exhaust. At the time the electricians I worked with were Sonny Kendrick and Bill Rivers. I had already applied for a job in the electric shop and was waiting to see if I was going to be offered the job. This gave me the chance to show the electricians what a brilliant worker I was.

Bill Rivers told me to go in the precipitator and wipe down the insulators that held the wire racks in place. He showed me where they were. I wore a regular half-face respirator because the fly ash is harmful to inhale.

Half-face respirator

Just before I went in the precipitator door to begin wiping down the insulators using a Scotch Brite Pad, Bill Rivers pointed to my flashlight and said, “Don’t drop your flashlight in a hopper otherwise you will have to make sure that you get it out of the hopper before we go back online.” I told him I would be sure to hold onto my flashlight (noticing that Bill had a string tied to his flashlight which was slung over his shoulder) and I entered the precipitator door.

Yellow Flashlight similar to the one I carried

The inside of the precipitator was dark. 70 foot tall plates are lined up 9 inches apart. Wires hang down between the plates and when the precipitator is turned on, the wires are charged up to around 45,000 volts of electricity. The wires each have a 30 pound weight on the bottom to keep the wires straight, and the wires are kept apart and lined up by a rack at the bottom. One end of the rack which is about 25 feet long is held in place by an electrical insulator about 3 feet long. This is what I was supposed to clean. The light from the flashlight lit up the area around me because everything was covered with the fine white powder reflecting the light.

The first hopper I came to was full of ash up to the top of the hopper, but just below where the insulator was mounted to the edge of the hopper. So, I worked my way down to the ledge along the edge of the hopper and dangled my feet down into the ash as I prepared to wipe down the first of the four insulators on this particular hopper. Just as I began, the precipitator suddenly went dark as my flashlight fell from my hand and down into the hopper. — Oh boy, that didn’t take long.

Fly Ash Hoppers. Our hoppers were 12 foot by 12 foot at the top.

I sat there for a minute in the dark as my eyes grew accustomed to the small amount of light that was coming through the doors. After I could see again, I reached my hand into the ash to feel for my flashlight. The ash was very fluffy and there was little or no resistance as I flailed my hand around searching for it. I leaned over farther and farther to reach down deeper into the ash. I was at the point where I was laying down flat on the ledge trying to find the flashlight, and it was no where to be found.

I pulled myself over to the side edge of the hopper and dropped myself down into the ash so that I could reach over where I had dropped the light, but I was still not able to find it. At that point, I was leaning out into the hopper with only my one index finger gripping the ledge around the hopper. I had a decision to make… I thought I would just bail off into the ash to see if I could find the flashlight, or I could give up and go tell Bill Rivers that I had done the one thing that he told me not to do, and in record time.

I don’t usually like to give up until I have exhausted every effort, so here was my dilemma. Do I let go and dive into this ash to retrieve my flashlight? Or do I leave the hopper and go tell Bill? I regretfully decided to go tell Bill. So, I climbed up out of the hopper, with my clothes covered with Ash (as we did not have fly ash suits at the time and I was wearing my coveralls). I made my way to the precipitator door and once I was outside, I determined which hopper I had been in when I dropped my flashlight.

I found Bill and told him that I had dropped my flashlight in a hopper full of ash. He told me to get the key for that hopper and open the door at the bottom and see if I could find the flashlight. Unlike the picture of the hoppers above, we had a landing around the base of the hoppers by the access door so you didn’t need a ladder to reach them.

Curtis Love had been watching the door of the precipitator for me while I was supposed to be wiping off the insulators. He came down with me, and we proceeded to open the access door at the bottom on the side of the hopper. When I opened the door both Curtis and I were swept backward as a stream of fly ash shot from the door. The ash fell through the grating to the ground below. We regained our footing and watched as a tremendous pile of ash grew below us. If the flashlight had come out of the doorway, it would have remained on the landing since it was too big to go through the grating, but it never came out.

After the ash had finished pouring out of the hopper as if it were water, I reached down into the remaining ash to see if I could feel the flashlight. Still I was unable to find it. There was about 4 more feet from the doorway to the bottom of the hopper, so I emptied out as much ash as I could using my hard hat for a shovel. Then I pulled my body head first into the hopper and I reached down as far as I could in the bottom of the hopper, but I couldn’t find the flashlight.

So, in my infinite wisdom, I asked Curtis Love to hold onto my legs as I lowered myself down to the throat at the bottom of the hopper. I lowered myself down until I had half of my face laying in the ash. At this point only one of the two filters on my respirator was able to function as the other one was down in the ash. I reached my hand into the top of the feeder at the bottom of the hopper and with my finger tips I could just feel the flashlight. I had reached as far as I could, but I couldn’t reach far enough to grip the flashlight.

All of the sudden my head dipped down into the ash and my hand went around the flashlight. I was not able to breathe as my respirator (and my entire head) was entirely immersed in ash. Everything went dark. I struggled to get up, as Curtis had let go of my legs and I had plunged head first into the bottom of the hopper. I had one hand free as the other one held the flashlight. I used it to push against the opposite wall of the hopper to raise my head up out of the ash. I still couldn’t breathe as my respirator was now clogged solid with ash. When I tried to inhale, the respirator just gripped my face tighter. Finally with my one free hand pushing against the hopper wall to hold my head out of the ash, I reached up with the hand that held the flashlight and pushed against my respirator enough to break the seal around my face so that I was able to get a breath of air.

Then I quickly pulled myself out of the precipitator as I heard Curtis saying the mantra that I had heard one other time (as I indicated in the post about Power Plant Safety as Interpreted by Curtis Love). He was saying over and over again, “I’mSorry,I’mSorry, KevinI’mSorry, ThoseGuysWereTicklingMe. I’mSorry,IDidn’tMeanToLetGo,ITriedToHoldOn, butThoseGuysWereTicklingMe.”

Looking around I spied a few Labor Crew hands sneaking away. As this happened before when I was sandblasting in the sand filter tank when Curtis Love had turned off my air, this wasn’t the first encounter I had with Power Plant Men In-Training playing a Power Plant joke on me. I told Curtis to forget it. I had retrieved my flashlight and everything was all right. I was covered from head-to-toe with fly ash, but that washes off pretty easily.

It dawned on me then that when I had dropped the flashlight, it had sunk clear to the bottom of the hopper and down into the throat of the feeder at the bottom. If I had dived into the ash in the hopper from up above, I would have fallen right down to the bottom of the hopper and been engulfed in ash. My feet would have been pinned down in the feeder pipe, and that would have been the end of me. It probably would have taken many hours to figure out where I was, and they would have found only a corpse.

While I was hanging on the edge of the hopper with only the tip of my index finger gripping the ledge, I was actually considering letting go. There never would have been an electrician at the power Plant named Kevin Breazile. I never would have married my wife Kelly, and had my two children Elizabeth and Anthony. I would not be writing this story right now. If it had been left to my own stupidity, none of those things would have happened.

I believe it was my guardian angel that had talked me out of letting go (or had actually been standing on my finger). As stubborn as I was, and against my nature, that day I had decided to give up searching for my flashlight and seek help. That one momentary decision has made all the difference in my life.

Since that day I have had a certain appreciation for the things that happen to me even when they seem difficult at the time. I have lived a fairly stress-free life because each day is a gift. Currently I work in a stress-filled job where individual accomplishments are seldom rewarded. From one day to the next I may be laid off at any time. I still find a lot of satisfaction in what I do because it was possible that it never would have happened. I have been kept alive for a purpose so I might as well enjoy the ride.

I find a special love for the people I work with today, because they are all gifts to me. I try to pay them back with kindness… when that doesn’t work.. I try to annoy them with my presence… Just to say….. — I am still here!

Comments from previous repost:

  1. Dan Antion May 27, 2014

    Scary thought there at the end. Sounds like quick sand.

  2. Ron May 27, 2014

    I’m glad you chose to “give up” on going after a flashlight! There is a Proverb that says “There is a way which seems right to a man, but the end thereof is the way death.” Sounds like you found one of those “ways”. To choose to find your flashlight and lose your life would be the ultimate bad choice. God, give us the wisdom to choose the way of life.

  3. A.D. Everard August 4, 2014

    Wow. So close! You have a book with all these adventures, you really do. I’m enjoying reading these pages very much. I’m so glad you survived to write them!

  4. inmytwisteddreams August 17, 2014

    You are a very good story teller! I was drawn in from the first sentence, and engulfed in your words until the last. Great Story! I mean, not so great at the time, but glad you brought it full circle in the end! I always say, “You must never hesitate” – a simple statement, whose words most might take for granted. As humans, it’s typically against our nature to trust our first (or gut) instinct, but as you know, it is there for a reason! Good story! 🙂

    ~Nikki

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.

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 his 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 memerable 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 pullcord 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.

Angel of Death Passes by the Precipitator Door

Originally published on May 25, 2012:

Either this was the luckiest day of my life, or a day where stupidity seemed to be my natural state of mind. This particular day occurred sometime in September 1983. The Main Power transformer for Unit 1 had  shutdown because of an internal fault during an exceptionally hot day during the summer and was being replaced. While the unit was offline, while I was on the labor crew, I was asked to help out the electricians who were doing an overhaul on the Precipitator. The Precipitator takes the ash out of the boiler exhaust before it goes up the smoke stack. Without it, you would see thick smoke, instead, you see only clear exhaust. At the time the electricians I worked with were Sonny Kendrick and Bill Rivers. I had already applied for a job in the electric shop and was waiting to see if I was going to be offered the job. This gave me the chance to show the electricians what a brilliant worker I was.

Bill Rivers told me to go in the precipitator and wipe down the insulators that held the wire racks in place. He showed me where they were. I wore a regular half-face respirator because the fly ash is harmful to inhale.

Half-face respirator

Just before I went in the precipitator door to begin wiping down the insulators using a Scotch Brite Pad, Bill Rivers pointed to my flashlight and said, “Don’t drop your flashlight in a hopper otherwise you will have to make sure that you get it out of the hopper before we go back online.” I told him I would be sure to hold onto my flashlight (noticing that Bill had a string tied to his flashlight which was slung over his shoulder) and I entered the precipitator door.

Yellow Flashlight similar to the one I carried

The inside of the precipitator was dark. 70 foot tall plates are lined up 9 inches apart. Wires hang down between the plates and when the precipitator is turned on, the wires are charged up to around 45,000 volts of electricity. The wires each have a 30 pound weight on the bottom to keep the wires straight, and the wires are kept apart and lined up by a rack at the bottom. One end of the rack which is about 25 feet long is held in place by an electrical insulator about 3 feet long. This is what I was supposed to clean. The light from the flashlight lit up the area around me because everything was covered with the fine white powder reflecting the light.

The first hopper I came to was full of ash up to the top of the hopper, but just below where the insulator was mounted to the edge of the hopper. So, I worked my way down to the ledge along the edge of the hopper and dangled my feet down into the ash as I prepared to wipe down the first of the four insulators on this particular hopper. Just as I began, the precipitator suddenly went dark as my flashlight fell from my hand and down into the hopper. — Oh boy, that didn’t take long.

Fly Ash Hoppers. Our hoppers were 12 foot by 12 foot at the top.

I sat there for a minute in the dark as my eyes grew accustomed to the small amount of light that was coming through the doors. After I could see again, I reached my hand into the ash to feel for my flashlight. The ash was very fluffy and there was little or no resistance as I flailed my hand around searching for it. I leaned over farther and farther to reach down deeper into the ash. I was at the point where I was laying down flat on the ledge trying to find the flashlight, and it was no where to be found.

I pulled myself over to the side edge of the hopper and dropped myself down into the ash so that I could reach over where I had dropped the light, but I was still not able to find it. At that point, I was leaning out into the hopper with only my one index finger gripping the ledge around the hopper. I had a decision to make… I thought I would just bail off into the ash to see if I could find the flashlight, or I could give up and go tell Bill Rivers that I had done the one thing that he told me not to do, and in record time.

I don’t usually like to give up until I have exhausted every effort, so here was my dilemma. Do I let go and dive into this ash to retrieve my flashlight? Or do I leave the hopper and go tell Bill? I regretfully decided to go tell Bill. So, I climbed up out of the hopper, with my clothes covered with Ash (as we did not have fly ash suits at the time and I was wearing my coveralls). I made my way to the precipitator door and once I was outside, I determined which hopper I had been in when I dropped my flashlight.

I found Bill and told him that I had dropped my flashlight in a hopper full of ash. He told me to get the key for that hopper and open the door at the bottom and see if I could find the flashlight. Unlike the picture of the hoppers above, we had a landing around the base of the hoppers by the access door so you didn’t need a ladder to reach them.

Curtis Love had been watching the door of the precipitator for me while I was supposed to be wiping off the insulators. He came down with me, and we proceeded to open the access door at the bottom on the side of the hopper. When I opened the door both Curtis and I were swept backward as a stream of fly ash shot from the door. The ash fell through the grating to the ground below. We regained our footing and watched as a tremendous pile of ash grew below us. If the flashlight had come out of the doorway, it would have remained on the landing since it was too big to go through the grating, but it never came out.

After the ash had finished pouring out of the hopper as if it were water, I reached down into the remaining ash to see if I could feel the flashlight. Still I was unable to find it. There was about 4 more feet from the doorway to the bottom of the hopper, so I emptied out as much ash as I could using my hard hat for a shovel. Then I pulled my body head first into the hopper and I reached down as far as I could in the bottom of the hopper, but I couldn’t find the flashlight.

So, in my infinite wisdom, I asked Curtis Love to hold onto my legs as I lowered myself down to the throat at the bottom of the hopper. I lowered myself down until I had half of my face laying in the ash. At this point only one of the two filters on my respirator was able to function as the other one was down in the ash. I reached my hand into the top of the feeder at the bottom of the hopper and with my finger tips I could just feel the flashlight. I had reached as far as I could, but I couldn’t reach far enough to grip the flashlight.

All of the sudden my head dipped down into the ash and my hand went around the flashlight. I was not able to breathe as my respirator (and my entire head) was entirely immersed in ash. Everything went dark. I struggled to get up, as Curtis had let go of my legs and I had plunged head first into the bottom of the hopper. I had one hand free as the other one held the flashlight. I used it to push against the opposite wall of the hopper to raise my head up out of the ash. I still couldn’t breathe as my respirator was now clogged solid with ash. When I tried to inhale, the respirator just gripped my face tighter. Finally with my one free hand pushing against the hopper wall to hold my head out of the ash, I reached up with the hand that held the flashlight and pushed against my respirator enough to break the seal around my face so that I was able to get a breath of air.

Then I quickly pulled myself out of the precipitator as I heard Curtis saying the mantra that I had heard one other time (as I indicated in the post about Power Plant Safety as Interpreted by Curtis Love). He was saying over and over again, “I’mSorry,I’mSorry, KevinI’mSorry, ThoseGuysWereTicklingMe. I’mSorry,IDidn’tMeanToLetGo,ITriedToHoldOn, butThoseGuysWereTicklingMe.”

Looking around I spied a few Labor Crew hands sneaking away. As this happened before when I was sandblasting in the sand filter tank when Curtis Love had turned off my air, this wasn’t the first encounter I had with Power Plant Men In-Training playing a Power Plant joke on me. I told Curtis to forget it. I had retrieved my flashlight and everything was all right. I was covered from head-to-toe with fly ash, but that washes off pretty easily.

It dawned on me then that when I had dropped the flashlight, it had sunk clear to the bottom of the hopper and down into the throat of the feeder at the bottom. If I had dived into the ash in the hopper from up above, I would have fallen right down to the bottom of the hopper and been engulfed in ash. My feet would have been pinned down in the feeder pipe, and that would have been the end of me. It probably would have taken many hours to figure out where I was, and they would have found only a corpse.

While I was hanging on the edge of the hopper with only the tip of my index finger gripping the ledge, I was actually considering letting go. There never would have been an electrician at the power Plant named Kevin Breazile. I never would have married my wife Kelly, and had my two children Elizabeth and Anthony. I would not be writing this story right now. If it had been left to my own stupidity, none of those things would have happened. I believe it was my guardian angel that had talked me out of letting go (or had actually been standing on my fingers). As stubborn as I was, and against my nature, that day I had decided to give up searching for my flashlight and seek help. That one momentary decision has made all the difference in my life.

Since that day I have had a certain appreciation for the things that happen to me even when they seem difficult at the time. I have lived a fairly stress-free life because each day is a gift. Currently I work in a stress-filled job where individual accomplishments are seldom rewarded. From one day to the next I may be laid off at any time. I still find a lot of satisfaction in what I do because it was possible that it never would have happened. I have been kept alive for a purpose so I might as well enjoy the ride.

I find a special love for the people I work with today, because they are all gifts to me. I try to pay them back with kindness… when that doesn’t work.. I try to annoy them with my presence… Just to say….. — I am still here!

Comments from previous repost:

  1. Dan Antion May 27, 2014

    Scary thought there at the end. Sounds like quick sand.

  2. Ron May 27, 2014

    I’m glad you chose to “give up” on going after a flashlight! There is a Proverb that says “There is a way which seems right to a man, but the end thereof is the way death.” Sounds like you found one of those “ways”. To choose to find your flashlight and lose your life would be the ultimate bad choice. God, give us the wisdom to choose the way of life.

  3. A.D. Everard August 4, 2014

    Wow. So close! You have a book with all these adventures, you really do. I’m enjoying reading these pages very much. I’m so glad you survived to write them!

  4. inmytwisteddreams August 17, 2014

    You are a very good story teller! I was drawn in from the first sentence, and engulfed in your words until the last. Great Story! I mean, not so great at the time, but glad you brought it full circle in the end! I always say, “You must never hesitate” – a simple statement, whose words most might take for granted. As humans, it’s typically against our nature to trust our first (or gut) instinct, but as you know, it is there for a reason! Good story! 🙂

    ~Nikki

Lifecycle of a Power Plant Lump of Coal — Repost

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 them 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 file 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 his 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.

Angel of Death Passes by the Precipitator Door — Repost

Originally published on May 25, 2012:

Either this was the luckiest day of my life, or a day where stupidity seemed to be my natural state of mind. This particular day occurred sometime in September 1983. The Main Power transformer for Unit 1 had  shutdown because of an internal fault during an exceptionally hot day during the summer and was being replaced. While the unit was offline, while I was on the labor crew, I was asked to help out the electricians who were doing an overhaul on the Precipitator. The Precipitator takes the ash out of the boiler exhaust before it goes up the smoke stack. Without it, you would see thick smoke, instead, you see only clear exhaust. At the time the electricians I worked with were Sonny Kendrick and Bill Rivers. I had already applied for a job in the electric shop and was waiting to see if I was going to be offered the job. This gave me the chance to show the electricians what a brilliant worker I was.

Bill Rivers told me to go in the precipitator and wipe down the insulators that held the wire racks in place. He showed me where they were. I wore a regular half-face respirator because the fly ash is harmful to inhale.

Half-face respirator

Just before I went in the precipitator door to begin wiping down the insulators using a Scotch Brite Pad, Bill Rivers pointed to my flashlight and said, “Don’t drop your flashlight in a hopper otherwise you will have to make sure that you get it out of the hopper before we go back online.” I told him I would be sure to hold onto my flashlight (noticing that Bill had a string tied to his flashlight which was slung over his shoulder) and I entered the precipitator door.

Yellow Flashlight similar to the one I carried

The inside of the precipitator was dark. 70 foot tall plates are lined up 9 inches apart. Wires hang down between the plates and when the precipitator is turned on, the wires are charged up to around 45,000 volts of electricity. The wires each have a 30 pound weight on the bottom to take out the tension, and the wires are kept apart and lined up by a rack at the bottom. One end of the rack which is about 25 feet long is held in place by an electrical insulator about 3 feet long. This is what I was supposed to clean. The light from the flashlight lit up the area around me because everything was covered with the fine white powder reflecting the light.

The first hopper I came to was full of ash up to the top of the hopper, but just below where the insulator was mounted to the edge of the hopper. So, I worked my way down to the ledge along the edge of the hopper and dangled my feet down into the ash as I prepared to wipe down the first of the four insulators on this particular hopper. Just as I began, the precipitator suddenly went dark as my flashlight fell from my hand and down into the hopper. — Oh boy, that didn’t take long.

Fly Ash Hoppers. Our hoppers were 12 foot by 12 foot at the top.

I sat there for a minute in the dark as my eyes grew accustomed to the small amount of light that was coming through the doors. After I could see again, I reached my hand into the ash to feel for my flashlight. The ash was very fluffy and there was little or no resistance as I flailed my hand around searching for it. I leaned over farther and farther to reach down deeper into the ash. I was at the point where I was laying down flat on the ledge trying to find the flashlight, and it was no where to be found.

I pulled myself over to the side edge of the hopper and dropped myself down into the ash so that I could reach over where I had dropped the light, but I was still not able to find it. At that point, I was leaning out into the hopper with only my one index finger gripping the ledge around the hopper. I had a decision to make… I thought I would just bail off into the ash to see if I could find the flashlight, or I could give up and go tell Bill Rivers that I had done the one thing that he told me not to do, and in record time. I don’t usually like to give up until I have exhausted every effort, so here was my dilemma. Do I let go and dive into this ash to retrieve my flashlight? Or do I leave the hopper and go tell Bill? I regretfully decided to go tell Bill. So, I climbed up out of the hopper, with my clothes covered with Ash (as we did not have fly ash suits at the time and I was wearing my coveralls). I made my way to the precipitator door and once I was outside, I determined which hopper I had been in when I dropped my flashlight.

I found Bill and told him that I had dropped my flashlight in a hopper full of ash. He told me to get the key for that hopper and open the door at the bottom and see if I could find the flashlight. Unlike the picture of the hoppers above, we had a landing around the base of the hoppers by the access door so you didn’t need a ladder to reach them.

Curtis Love had been watching the door of the precipitator for me while I was supposed to be wiping off the insulators. He came down with me, and we proceeded to open the access door at the bottom on the side of the hopper. When I opened the door both Curtis and I were swept backward as a stream of fly ash shot from the door. The ash fell through the grating to the ground below. We regained our footing and watched as a tremendous pile of ash grew below us. If the flashlight had come out of the doorway, it would have remained on the landing since it was too big to go through the grating, but it never came out.

After the ash had finished pouring out of the hopper as if it were water, I reached down into the remaining ash to see if I could feel the flashlight. Still I was unable to find it. There was about 4 more feet from the doorway to the bottom of the hopper, so I emptied out as much ash as I could using my hard hat for a shovel. Then I pulled my body head first into the hopper and I reached down as far as I could in the bottom of the hopper, but I couldn’t find the flashlight.

So, in my infinite wisdom, I asked Curtis Love to hold onto my legs as I lowered myself down to the throat at the bottom of the hopper. I lowered myself down until I had half of my face laying in the ash. At this point only one of the two filters on my respirator was able to function as the other one was down in the ash. I reached my hand into the top of the feeder at the bottom of the hopper and with my finger tips I could just feel the flashlight. I had reached as far as I could, but I couldn’t reach far enough to grip the flashlight.

All of the sudden my head dipped down into the ash and my hand went around the flashlight. I was not able to breathe as my respirator (and my entire head) was entirely immersed in ash. Everything went dark. I struggled to get up, as Curtis had let go of my legs and I had plunged head first into the bottom of the hopper. I had one hand free as the other one held the flashlight. I used it to push against the opposite wall of the hopper to raise my head up out of the ash. I still couldn’t breathe as my respirator was now clogged solid with ash. When I tried to inhale, the respirator just gripped my face tighter. Finally with my one free hand pushing against the hopper wall to hold my head out of the ash, I reached up with the hand that held the flashlight and pushed against my respirator enough to break the seal around my face so that I was able to get a breath of air.

Then I quickly pulled myself out of the precipitator as I heard Curtis saying the mantra that I had heard one other time (as I indicated in the post about Power Plant Safety as Interpreted by Curtis Love). He was saying over and over again, “I’mSorry,I’mSorry, KevinI’mSorry, ThoseGuysWereTicklingMe. I’mSorry,IDidn’tMeanToLetGo,ITriedToHoldOn, butThoseGuysWereTicklingMe.”

Looking around I spied a few Labor Crew hands sneaking away. As this happened before when I was sandblasting in the sand filter tank when Curtis Love had turned off my air, this wasn’t the first encounter I had with Power Plant Men In-Training playing a Power Plant joke on me. I told Curtis to forget it. I had retrieved my flashlight and everything was all right. I was covered from head-to-toe with fly ash, but that washes off pretty easily.

It dawned on me then that when I had dropped the flashlight, it had sunk clear to the bottom of the hopper and down into the throat of the feeder at the bottom. If I had dived into the ash in the hopper from up above, I would have fallen right down to the bottom of the hopper and been engulfed in ash. My feet would have been pinned down in the feeder pipe, and that would have been the end of me. It probably would have taken many hours to figure out where I was, and they would have found only a corpse.

While I was hanging on the edge of the hopper with only the tip of my index finger gripping the ledge, I was actually considering letting go. There never would have been an electrician at the power Plant named Kevin Breazile. I never would have married my wife Kelly, and had my two children Elizabeth and Anthony. I would not be writing this story right now. If it had been left to my own stupidity, none of those things would have happened. I believe it was my guardian angel that had talked me out of letting go (or had actually been standing on my fingers). As stubborn as I was, and against my nature, that day I had decided to give up searching for my flashlight and seek help. That one momentary decision has made all the difference in my life.

Since that day I have had a certain appreciation for the things that happen to me even when they seem difficult at the time. I have lived a fairly stress-free life because each day is a gift. Currently I work in a stress-filled job where individual accomplishments are seldom rewarded. From one day to the next I may be laid off at any time. I still find a lot of satisfaction in what I do because it was possible that it never would have happened. I have been kept alive for a purpose so I might as well enjoy the ride.

I find a special love for the people I work with today, because they are all gifts to me. I try to pay them back with kindness… when that doesn’t work.. I try to annoy them with my presence… Just to say….. — I am still here!

Lifecycle of a Power Plant Lump of Coal

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 them 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 file 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 his 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.

Angel of Death Passes by the Precipitator Door — Repost

Originally published on May 25, 2012:

Either this was the luckiest day of my life, or a day where stupidity seemed to be my natural state of mind. This particular day occurred sometime in September 1983. The Main Power transformer for Unit 1 had  shutdown because of an internal fault during an exceptionally hot day during the summer and was being replaced. While the unit was offline, while I was on the labor crew, I was asked to help out the electricians who were doing an overhaul on the Precipitator. The Precipitator takes the ash out of the boiler exhaust before it goes up the smoke stack. Without it, you would see thick smoke, instead, you see only clear exhaust. At the time the electricians I worked with were Sonny Kendrick and Bill Rivers. I had already applied for a job in the electric shop and was waiting to see if I was going to be offered the job. This gave me the chance to show the electricians what a brilliant worker I was.

Bill Rivers told me to go in the precipitator and wipe down the insulators that held the wire racks in place. He showed me where they were. I wore a regular half-face respirator because the fly ash is harmful to inhale.

Half-face respirator

Just before I went in the precipitator door to begin wiping down the insulators using a Scotch Brite Pad, Bill Rivers pointed to my flashlight and said, “Don’t drop your flashlight in a hopper otherwise you will have to make sure that you get it out of the hopper before we go back online.” I told him I would be sure to hold onto my flashlight (noticing that Bill had a string tied to his flashlight which was slung over his shoulder) and I entered the precipitator door.

Yellow Flashlight similar to the one I carried

The inside of the precipitator was dark. 70 foot tall plates are lined up 9 inches apart. Wires hang down between the plates and when the precipitator is turned on, the wires are charged up to around 45,000 volts of electricity. The wires each have a 30 pound weight on the bottom to take out the tension, and the wires are kept apart and lined up by a rack at the bottom. One end of the rack which is about 25 feet long is held in place by an electrical insulator about 3 feet long. This is what I was supposed to clean. The light from the flashlight lit up the area around me because everything was covered with the fine white powder reflecting the light.

The first hopper I came to was full of ash up to the top of the hopper, but just below where the insulator was mounted to the edge of the hopper. So, I worked my way down to the ledge along the edge of the hopper and dangled my feet down into the ash as I prepared to wipe down the first of the four insulators on this particular hopper. Just as I began, the precipitator suddenly went dark as my flashlight fell from my hand and down into the hopper. — Oh boy, that didn’t take long.

Fly Ash Hoppers. Our hoppers were 12 foot by 12 foot at the top.

I sat there for a minute in the dark as my eyes grew accustomed to the small amount of light that was coming through the doors. After I could see again, I reached my hand into the ash to feel for my flashlight. The ash was very fluffy and there was little or no resistance as I flailed my hand around searching for it. I leaned over farther and farther to reach down deeper into the ash. I was at the point where I was laying down flat on the ledge trying to find the flashlight, and it was no where to be found.

I pulled myself over to the side edge of the hopper and dropped myself down into the ash so that I could reach over where I had dropped the light, but I was still not able to find it. At that point, I was leaning out into the hopper with only my one index finger gripping the ledge around the hopper. I had a decision to make… I thought I would just bail off into the ash to see if I could find the flashlight, or I could give up and go tell Bill Rivers that I had done the one thing that he told me not to do, and in record time. I don’t usually like to give up until I have exhausted every effort, so here was my dilemma. Do I let go and dive into this ash to retrieve my flashlight? Or do I leave the hopper and go tell Bill? I regretfully decided to go tell Bill. So, I climbed up out of the hopper, with my clothes covered with Ash (as we did not have fly ash suits at the time and I was wearing my coveralls). I made my way to the precipitator door and once I was outside, I determined which hopper I had been in when I dropped my flashlight.

I found Bill and told him that I had dropped my flashlight in a hopper full of ash. He told me to get the key for that hopper and open the door at the bottom and see if I could find the flashlight. Unlike the picture of the hoppers above, we had a landing around the base of the hoppers by the access door so you didn’t need a ladder to reach them.

Curtis Love had been watching the door of the precipitator for me while I was supposed to be wiping off the insulators. He came down with me, and we proceeded to open the access door at the bottom on the side of the hopper. When I opened the door both Curtis and I were swept backward as a stream of fly ash shot from the door. The ash fell through the grating to the ground below. We regained our footing and watched as a tremendous pile of ash grew below us. If the flashlight had come out of the doorway, it would have remained on the landing since it was too big to go through the grating, but it never came out.

After the ash had finished pouring out of the hopper as if it were water, I reached down into the remaining ash to see if I could feel the flashlight. Still I was unable to find it. There was about 4 more feet from the doorway to the bottom of the hopper, so I emptied out as much ash as I could using my hard hat for a shovel. Then I pulled my body head first into the hopper and I reached down as far as I could in the bottom of the hopper, but I couldn’t find the flashlight.

So, in my infinite wisdom, I asked Curtis Love to hold onto my legs as I lowered myself down to the throat at the bottom of the hopper. I lowered myself down until I had half of my face laying in the ash. At this point only one of the two filters on my respirator was able to function as the other one was down in the ash. I reached my hand into the top of the feeder at the bottom of the hopper and with my finger tips I could just feel the flashlight. I had reached as far as I could, but I couldn’t reach far enough to grip the flashlight.

All of the sudden my head dipped down into the ash and my hand went around the flashlight. I was not able to breathe as my respirator (and my entire head) was entirely immersed in ash. Everything went dark. I struggled to get up, as Curtis had let go of my legs and I had plunged head first into the bottom of the hopper. I had one hand free as the other one held the flashlight. I used it to push against the opposite wall of the hopper to raise my head up out of the ash. I still couldn’t breathe as my respirator was now clogged solid with ash. When I tried to inhale, the respirator just gripped my face tighter. Finally with my one free hand pushing against the hopper wall to hold my head out of the ash, I reached up with the hand that held the flashlight and pushed against my respirator enough to break the seal around my face so that I was able to get a breath of air.

Then I quickly pulled myself out of the precipitator as I heard Curtis saying the mantra that I had heard one other time (as I indicated in the post about Power Plant Safety as Interpreted by Curtis Love). He was saying over and over again, “I’mSorry,I’mSorry, KevinI’mSorry, ThoseGuysWereTicklingMe. I’mSorry,IDidn’tMeanToLetGo,ITriedToHoldOn, butThoseGuysWereTicklingMe.”

Looking around I spied a few Labor Crew hands sneaking away. As this happened before when I was sandblasting in the sand filter tank when Curtis Love had turned off my air, this wasn’t the first encounter I had with Power Plant Men In-Training playing a Power Plant joke on me. I told Curtis to forget it. I had retrieved my flashlight and everything was all right. I was covered from head-to-toe with fly ash, but that washes off pretty easily.

It dawned on me then that when I had dropped the flashlight, it had sunk clear to the bottom of the hopper and down into the throat of the feeder at the bottom. If I had dived into the ash in the hopper from up above, I would have fallen right down to the bottom of the hopper and been engulfed in ash. My feet would have been pinned down in the feeder pipe, and that would have been the end of me. It probably would have taken many hours to figure out where I was, and they would have found only a corpse.

While I was hanging on the edge of the hopper with only the tip of my index finger gripping the ledge, I was actually considering letting go. There never would have been an electrician at the power Plant named Kevin Breazile. I never would have married my wife Kelly, and had my two children Elizabeth and Anthony. I would not be writing this story right now. If it had been left to my own stupidity, none of those things would have happened. I believe it was my guardian angel that had talked me out of letting go (or had actually been standing on my fingers). As stubborn as I was, and against my nature, that day I had decided to give up searching for my flashlight and seek help. That one momentary decision has made all the difference in my life.

Since that day I have had a certain appreciation for the things that happen to me even when they seem difficult at the time. I have lived a fairly stress-free life because each day is a gift. Currently I work in a stress-filled job where individual accomplishments are seldom rewarded. From one day to the next I may be laid off at any time. I still find a lot of satisfaction in what I do because it was possible that it never would have happened. I have been kept alive for a purpose so I might as well enjoy the ride.

I find a special love for the people I work with today, because they are all gifts to me. I try to pay them back with kindness… when that doesn’t work.. I try to annoy them with my presence… Just to say….. — I am still here!

Angel of Death Passes by the Precipitator Door (or Almost Dying Twice in One Day)

Either this was the luckiest day of my life, or a day where stupidity seemed to be my state of mind.  This particular day occurred sometime in September 1983.  The Main Power Transformer for Unit 1 had shorted out during an exceptionally hot day during the summer and was being replaced.  While the unit was offline, while I was on the labor crew, I was asked to help out the electricians who were doing an overhaul on the Precipitator.  The Precipitator takes the ash out of the boiler exhaust before it goes up the smoke stack.  Without it, you would see thick smoke, instead, you see only clear exhaust.  At the time that was Sonny Kendrick and Bill Rivers.  I had already applied for a job in the electric shop and was waiting to see if I was going to be offered the job.  This gave me the chance to show the electricians what a brilliant worker I was.

Bill Rivers told me to go in the precipitator and wipe down the insulators that held the wire racks in place.  He showed me where they were.  I wore a regular half-face respirator because the fly ash is harmful to inhale.

Half-face respirator

Just before I went in the precipitator door to begin wiping down the insulators using a Scotch Brite Pad, Bill Rivers pointed to my flashlight and said, “Don’t drop your flashlight in a hopper otherwise you will have to make sure that you get it out of the hopper before we go back online.”  I told him I would be sure to hold onto my flashlight (noticing that Bill had a string tied to his flashlight which was slung over his head) and I entered the precipitator door.

Yellow Flashlight similar to the one I carried

The inside of the precipitator was dark.  70 foot tall plates are lined up 9 inches apart.  Wires hang down between the plates and when the precipitator is turned on, the wires are charged up to around 45,000 volts of electricity.  The wires each have a 30 pound weight on the bottom to take out the tension, and the wires are kept apart and lined up by a rack at the bottom.  One end of the rack which is about 25 feet long is held in place by an electrical insulator about 3 feet long.  This is what I was supposed to clean.  The light from the flashlight lit up the area around me because everything was covered with the fine white powder reflecting the light.

The first hopper I came to was full of ash up to the top of the hopper, but just below where the insulator was mounted to the edge of the hopper.  So, I worked my way down to the ledge along the edge of the hopper and dangled my feet down into the ash as I prepared to wipe down the first of the four insulators on this particular hopper.  Just as I began, the precipitator suddenly went dark as my flashlight fell from my hand and down into the hopper.  —  Oh boy, that didn’t take long.

Fly Ash Hoppers.  Our hoppers were 12 foot by 12 foot at the top.

I sat there for a minute in the dark as my eyes grew accustomed to the small amount of light that was coming through the doors.  After I could see again, I reached my hand into the ash to feel for my flashlight.  The ash was very fluffy and there was little or no resistance as I flailed my hand around searching for it.  I leaned over farther and farther to reach down deeper into the ash.  I was at the point where I was laying down flat on the ledge trying to find the flashlight, and it was no where to be found.

I pulled myself over to the side edge of the hopper and dropped myself down into the ash so that I could reach over where I had dropped the light, but I was still not able to find it.  At that point, I was leaning out into the hopper with only my one index finger gripping the ledge around the hopper.  At this point, I had a decision to make…  I thought I would just bail off into the ash to see if I could find the flashlight, or I could give up and go tell Bill Rivers that I had done the one thing that he told me not to do, and in record time.  I don’t usually like to give up until I have exhausted every effort, so here was my dilemma.  Do I let go and dive into this ash to retrieve my flashlight?  Or do I leave the hopper and go tell Bill?  I regretfully decided to go tell Bill.  So, I climbed up out of the hopper, with my clothes covered with Ash (as we did not have fly ash suits at the time and I was wearing my coveralls).  I made my way to the precipitator door and once I was outside, I determined which hopper I had been in when I dropped my flashlight.

I found Bill and told him that I had dropped my flashlight in a hopper full of ash.  He told me to get the key for that hopper and open the door at the bottom and see if I could find the flashlight.  Unlike the picture of the hoppers above, we had a landing around the base of the hoppers by the access door so you didn’t need a ladder to reach them.

Curtis Love had been watching the door of the precipitator for me while I was supposed to be wiping off the insulators.  He came down with me, and we proceeded to open the access door at the bottom on the side of the hopper.  When I opened the door both Curtis and I were swept backward as a stream of fly ash shot from the door.  The ash fell through the grating to the ground below.  We regained our footing and watched as a tremendous pile of ash grew below us.  If the flashlight had come out of the doorway, it would have remained on the landing since it was too big to go through the grating, but it never came out.

After the ash had finished pouring out of the hopper as if it were water, I reached down into the remaining ash to see if I could feel the flashlight.  Still I was unable to find it.  There was about 4 more feet from the doorway to the bottom of the hopper, so I emptied out as much ash as I could using my hard hat for a shovel.  Then I pulled my body head first into the hopper and I reached down as far as I could in the bottom of the hopper, but I couldn’t find the flashlight.  So, in my infinite wisdom, I asked Curtis Love to hold onto my legs as I lowered myself down to the throat at the bottom of the hopper.  I lowered myself down until I had half of my face laying in the ash.  At this point only one of the two filters on my respirator was able to function as the other one was down in the ash.  I reached my hand into the top of the feeder at the bottom of the hopper and with my finger tips I could just feel the flashlight.  I had reached as far as I could, but I couldn’t reach far enough to grip the flashlight.

All of the sudden my head dipped down into the ash and my hand went around the flashlight.  I was not able to breathe as my respirator (and my entire head) was entirely immersed in ash.  I struggled to get up, as Curtis had let go of my legs and I had plunged head first into the bottom of the hopper.  I had one hand free as the other one held the flashlight.  I used it to push against the opposite wall of the hopper to raise my head up out of the ash.  I still couldn’t breathe as my respirator was now clogged solid with ash.  When I tried to inhale, the respirator just gripped my face tighter.  Finally with my one free hand pushing against the hopper wall to hold  my head out of the ash, I reached up with the hand that held the flashlight and pushed against my respirator enough to open the seal around my face so that I was able to get a breath of air.

Then I quickly pulled myself out of the precipitator as I heard Curtis saying the mantra that I had heard one other time (as I indicated in the post about Power Plant Safety as Interpreted by Curtis Love).  He was saying over and over again, “I’mSorry,I’mSorry, KevinI’mSorry, ThoseGuysWereTicklingMe. I’mSorry,IDidn’tMeanToLetGo,ITriedToHoldOn, butThoseGuysWereTicklingMe.”  Looking around I spied a few Labor Crew hands sneaking away.  As this happened before I was sandblasting in the sand filter tank when Curtis Love had turned off my air, this was the first encounter I had with Power Plant Men In-Training playing a Power Plant joke on me.  I told Curtis to forget it.  I had retrieved my flashlight and everything was all right.  I was covered from head-to-toe with fly ash, but that washes off pretty easily.

It dawned on me then that when I had dropped the flashlight, it had sunk clear to the bottom of the hopper and down into the throat of the feeder at the bottom.  If I had dived into the ash in the hopper from up above, I would have shot right down to the bottom of the hopper and been engulfed in ash.  My feet would have been pinned down in the feeder pipe, and that would have been the end of me.  It probably would have taken many hours to figure out where I was, and they would have found only a corpse.

While I was hanging on the edge of the hopper with only the tip of my index finger gripping the ledge, I was actually considering letting go.  There never would have been an electrician at the power Plant named Kevin Breazile.  I never would have married my wife Kelly, and had my two children Elizabeth and Anthony.  I would not be writing this story right now.  If I had been left to my own stupidity, none of those things would have happened.  I believe it was my guardian angel that had talked me out of letting go.  As stubborn as I was, and against my nature, that day I had decided to give up searching for my flashlight and seek help.  That one momentary decision has made all the difference in my life.

Since that day I have had a certain appreciation for the things that happen to me even when they seem difficult at the time.   I have lived a fairly stress-free life because each day is a gift.  Currently I work in a stress-filled job where individual accomplishments are seldom rewarded.  From one day to the next I may be laid off at any time.  I still find a lot of satisfaction in what I do because it was possible that it never would have happened.  I have been kept alive for a purpose so I might as well enjoy the ride.