Tag Archives: Floor drain cover

Back to Plain Ol’ Power Plant Back Pain

Does anyone know where the phrase, “Step on a Crack, Break Your Mother’s Back” came from? I’m sure there is a story behind that one. Maybe even a lot of different origins. I can distinctly remember a day in the Power Plant when a Power Plant Man stepped on a crack and broke his own back.

I remember looking out of the seventh floor window of my friends dorm room when I was a freshman in college watching students returning from classes about 6 months before the Power Plant Man broke his back. I was watching closely to see if any of them were purposely missing the cracks as they walked down the sidewalk toward the entrance. Out of about 20 people two of them purposely stepped over every crack in the sidewalk.

In the post “Power Plant Safety is Job Number One” I told the story about four of us were carrying a very long extension ladder through the maintenance shop at the Coal-fired Power Plant in North Central Oklahoma one summer morning in 1979 when Tom Dean stepped on a crack (well, it was a cracked piece of plywood that had been placed over a floor drain because the floor grate was missing), and when as he stepped on it, he lost his balance enough to twist himself around. By the time he stopped twirling, he was in immense pain as he had destroyed any chance for comfort for the next 6 months.

A Cast Iron Floor drain cover similar to this

A Cast Iron Floor drain cover was missing from the drain

So, I could understand the dangers of stepping on cracks even when they appear to be insignificant. What that has to do with my mom I’m not sure. However, one day when my sister was walking with my mom on the campus of Oklahoma State University, my sister may have stepped on a crack at that time, as well as my mom, which sent her plummeting the five feet to the ground resulting in a broken hip.

This makes me wonder that since the times have changed, it may be time to change the saying to something else. Maybe something like “Smoke some crack, break your parent’s piggy bank” would be more appropriate for these times. Oh well, I’ve never been much of a poet.

Anyway, back to the subject of back pain.

The number one favorite topic during Safety Meetings at the Power Plant was Back Safety. We were told (and rightly so) that accidents where the back is injured cost the company and the employee more than any other injury. Once you really hurt your back, you can expect to have back pain the rest of your life. It only takes one time. — Times may have changed since 1979, so that now you can have some excellent back surgeries to help correct your back injuries. Even with these, you will never be completely free from back pain.

In the Power Plant Post, “When Power Plant Competition Turns Terribly Safe” I told a story about how our team came up with hundreds of safety slogans in an attempt to win the coveted Power Plant Safety Award Pizza at the end of the year. A Pizza that continued to allude us for 2 and a half years. During our meetings to invent the most catchy safety slogans, Andy Tubbs (or was it Ben Davis) came up with a slogan that said, “Lift with your legs, not your back. Or you may hear a lumbar crack”. — See. I wish I could come up with doozies like that! This takes the idea of a crack and a back and turns it around, if you think about it. Now instead of a crack hurting your back, its about a strain on your back creating a crack. — I know… probably just a coincidence….

Lumbars don't really crack. The discs indicated in blue become damaged

Lumbars don’t really crack. The discs indicated in blue become damaged

One morning Sonny Kendrick, our electric specialist at the time, while sitting in the electric lab during break, let out a whopper of a sneeze. When he did, he suddenly knew what it felt like to experience tremendous back pain. One sneeze and he was out of commission for many weeks.

Sonny as he is today

Sonny Kendrick as he is today or… yesterday…

One day, when Charles Foster, my very close friend, and electric foreman, were talking about back pain, I realized that a good portion of Power Plant Men suffered with back pain. — At the risk of sounding like Randy Dailey teaching our Safety Class, I’m going to repeat myself, “You only have to hurt your back one time to have a lifetime of back pain.”

The company would focus a lot of their safety training around the importance of proper lifting techniques in order to prevent back accidents (not to be confused with backing accidents which is when you back out of a parking space — which is also a common accident — though usually less severe — unless you happen to be a Ford Truck). We would learn how to lift with our legs and not with our back.

You see, it wasn’t just that one sneeze that caused Sonny’s plunge into Back Pain Hell, and it wasn’t just stepping on the cracked plywood floor drain cover that broke Tom’s back (I know “Broke Back” is a misnomer since the back isn’t exactly broke). The problem is more systemic than that. This is just the final result of maybe years of neglecting your back through various unsafe activities.

The two important points I remember from watching the safety videos during our monthly safety meetings was that when you slouch while sitting, you put a needless strain on your lower back. So, by sitting with good posture, you help prevent a future of pain. The second point I remember is that you need to keep your stomach muscles strong. Strong stomach muscles take the weight off of your back when you’re just doing your regular job.

The big problem that finally causes the disc in your lumbar region of your spine to break after neglecting it through these other means is to lift a heavy object by bending over to pick it up instead of lifting the load with your legs. So, the phrase that we always heard was “Lift with your Legs. Not your Back”. You do this by bending your knees instead of just your hips.

Ok. I know you are all thinking the same thing I am thinking (right? Yeah. You are). Bending both your knees and hips saves your back. Isn’t there another word for when you bend your knees and hips at the same time? — Yeah. Yet, I don’t remember hearing it during any of our Safety Videos. — Oh. It was implied, they just never came out and said it…. What they really mean to say is, “Squat”. Yeah. “Squat”. When you bend your knees and hips, isn’t that “Squatting?”

Times have changed…. I mean….. Doesn’t everyone today have a “Squatty Potty”?

The Squatty Potty Logo

The Squatty Potty Logo

Don’t we all have “I ‘heart’ 2 Squat” tee-shirts?

See how happy you can be to Squat?

See how happy you can be to Squat?

To learn more, you can watch this video:

This doesn’t just work with the Squatty Potty to help you drop your loads, it also works when lifting heavy loads. So, remember the next time you are going to bend over to pick something up…. Squat instead.

Other lifting tips include keeping the load close to your body and not holding your breath but tightening your stomach muscles, and don’t lift something too bulky by yourself. Don’t twist your body when picking something up, face the load directly. A weightlifter once told me that when you lift, feel the weight on the heel of your feet, not on the balls of your feet.

Randy Dailey, the Safety Guru of our Power Plant, and an expert machinist invented a pen that you could put in your pocket protector in your shirt pocket that would alert you by beeping if you leaned over too far. It was an ingenious device to remind you to lift with your legs instead of your back.

In one of the safety videos we watched about back safety, there was a short stalky scientist that explained the dynamics of lifting and how easy it was to put a tremendous strain on your back by leaning over and picking something up. He said that “People choose the more simple way to pick something up. Not the easiest way.”

Doesn’t that sound like the same thing? Isn’t the simplest way the easiest way? Well. You would think so, but it isn’t always the case. This Doctor of Back-ology went on to explain his statement. He explained that the simplest way to pick up an object on the floor is to bend at the hip. It is one movement. Bend at the hip. — However…. The easiest way to pick up the object is to bend both your knees and your hips to pick up the object. Since you keep your back straight and you lift with your leg muscles that are the most powerful muscles in your body. He avoided using the word, “Squat”, but that’s what he meant.

In order to reduce back injuries at the plant, the company made back belts available at the plant.

A Back Support Belt

A Back Support Belt

Note that this picture not only shows a Power Plant Man wearing a Back Support Belt, but he also is wearing the right kind of Tee-Shirt. It has a vest pocket where you can put a Pocket Protector for your little screwdriver and your Back Alert Pen created by Randy Dailey.

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

The use of back belts was new around the late 1980’s. Even though we had them available through the tool room when we wanted them, few people wore them. The warehouse team wore them a lot. I suppose that is because they were lifting and moving things all day long.

In the warehouse Bob Ringwall, Darlene Mitchell and Dick Dale used to have back belts on when I would visit the warehouse to pick up a part, or to visit my friends. I don’t remember if Bud Schoonover would wear a back belt. How’s this for a slogan…. “Be a Safety Black Belt…. When Lifting, wear your Back Belt.” I know. I should stop when I’m ahead, only I’m so far behind now I may never catch up.

There was a question about whether wearing a back belt was really a good idea. It was thought that people might tend to substitute using their stomach muscles while lifting with the back belt, resulting in weaker stomach muscles. So we were cautioned not to go around wearing back belts all day long. Only when we were going to be doing a job where we had to do a lot of lifting. I suppose now, after years of research, there is a lot more data to tell us one way or the other. I haven’t heard what the latest injury jury has said on this subject.

Even though I titled this post “…Plain Ol’ Power Plant Back Pain”, there is nothing plain about back pain. I just thought it sounded like a catchy title.

I was lucky enough that during the 20 years I spent working at the Power Plant, I never really hurt my back. To this day, I have been able to avoid living with perpetual pain in my back. — I have been accused of causing pain in other people’s necks. Also, I don’t think the many times that people told me I was a pain in their back side, they were referring to the Lumbar region. I think they meant an area just below the tailbone. I hope that by bringing to their attention the benefits of the Squatty Potty that I have been able to relieve (or prevent) a little of that lower lumbar pain.

Now when someone says, “You don’t know Squat”, you can correct them!

Comments from the original post:

    1. tellthetruth1 Ocotber 18, 2014

      I can remember getting into a taxi whilst in my late teens, turning in the seat to sling a bag in the back seat, only to pull something in my back. The pain lasted for ages.

      These days, it’s arthritis being the culprit. Back pain is as bad as everybody says it is.

      Good page 🙂

  1. Scott Hubbard October 21, 2014

    Wasn’t the back alert pen given to someone in the garage to try out. Rumor is they didn’t like it because it kept going off all day every time they bent over.
    Hmmmmmm

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Power Plant Farm Fixing and Risk Management

We were told at the coal-fired Power Plant in North Central Oklahoma that we were going to have to stop doing the excellent job we were used to doing.  We no longer had time to make everything perfect.  We just had to patch things together enough so that it was fixed and leave it at that.  Jasper Christensen told us that we were going to have to “Farm Fix” things and work harder because we now only had half the employees.

Jasper Christensen

Jasper Christensen

Two things bothered me right away….

First, “Work Harder.”  What exactly does that mean?  How does one work harder?  When I pick up my tool bucket to go work on a job, should I put some extra bricks in it so that it is harder to carry?  What then?  Think about it… Shouldn’t we be working “Smarter” instead of “Harder”?  We were all hard workers (if that means, spending a good 8 hour day doing your job).  Any slackers were laid off 7 years earlier.

When I heard “Farm Fixing” I took offense to the reference.  Jasper had mentioned using baling wire to hold something up instead of taking the time to make our jobs look pretty.  As if baling wire was somehow synonymous with “Farm Fixing”.  My grandfather was a farmer….  I’ll talk about that in a bit….

Jasper also informed us that we were no longer stuck doing only our own trade.  So, an electrician should expect to help out as a mechanic or a welder as long as it wasn’t too involved.  Certain welding jobs, for instance, require a certified welder.  If the job was just to tack weld up a bracket somewhere, then I, as an electrician, could wheel a welding machine over there and weld it up.

After that initial meeting after we had been downsized to pint-sized, we met with our own teams.  Alan Kramer was my new foreman.  He encouraged us to learn the different skills from our teammates.

Alan Kramer

Alan Kramer

I asked Ed Shiever to teach me how to weld.  After about an hour, I decided I wasn’t too interested in melting metal using electricity.  I would leave it to the experts.  I was left with a sunburned chest, as I usually wore a V-Neck Tee Shirt in the summer.

Ed Shiever 15 years later

Ed Shiever Welder Extraordinaire

Jody Morse was a mechanic on our team, who had been a friend of mine since I was a janitor.  We had been on the labor crew together.  He asked me if he could do some electrical work with me.  He thought it would be a useful skill to learn.  I happily agreed to let him work alongside me running conduit and pulling wire around the precipitator hoppers.

Jody Morse

Jody Morse

It wouldn’t include working on any circuits where he might accidentally come into contact with anything live.  So, I thought this was a good starting point.  That was one of the first skills I learned as an electrician-in-training when I was taught by Gene Roget, a master of conduit bending.

I showed Jody how to bend the conduit and have it end up being the right length with the curves in the right place (which is a little tricky at first).  Then I showed Jody where the conduit needed to go, and where the wire needed to end up.  He said he wanted to do this all by himself, so I left him to it and left to do something else.

A little while later, Jody came back and said he had a slight problem.  He had cut the cable just a little bit too short (Yeah.  I had done that myself, see the post: “When Enough Power Plant Stuff Just Ain’t Enough“).  I looked at the problem with him, and he was about six inches too short.

Jody looked the job over and decided he had two options.  Pull some new longer cable, or try to make the existing cable work.He figured out that if he cut off 6 inches of the conduit, and sort of bent it out so that it was no longer exactly at 90 degrees, then it would still reach where it needed to go, only the conduit wouldn’t look so pretty because the conduit would appear a little cockeyed.  We figured this would be all right because Jasper had just finished telling us that we needed to make things not so pretty anymore.  Jody finished the job, and filled out the Maintenance Order indicating that the job was done.

The cable and conduit job had been requested by Ron Madron, one of the Instrument and Controls guys on our team.  When he went out and looked at the conduit, let’s just say that he wasn’t too impressed.  He went to Alan Kramer and complained that the conduit job was disgraceful.  I don’t remember his exact words, but when I heard about it, it sounded to me like he said “It was an abomination to all things electrical”.

I had always taken pride in my work, and doing a “sloppy” job was not normal for me.  I didn’t want Jody to feel bad about this because he was pretty proud of having completed the job all by himself without my help.  So I went and had a one-on-one with Ron and explained the situation to him.  I also told him that the next time he has  problem with something I did, come directly and talk to me about it instead of our foreman.  We’re all on the same team now.

I think once he realized the situation, he was more receptive.  Jody and I did go back out there and fix the issue by running a new cable that was long enough, with a new piece of conduit that was installed with the best of care so that it looked pretty.  — None of us informed Jasper that behind his back we were still performing our jobs with great care and precision.

 

Conduit Bending Basics

Conduit Bending Basics

The more I thought about the idea of “Farm Fixing” and “Risk Management” and how it was being applied at our plant, after about a year, I wrote a letter to the Superintendent over all the Power Plants, Jack Coffman.

Here is the letter I wrote (It was titled “Farm Fixing and Risk Management” — appropriate, don’t you think?):

Dear Jack Coffman,

I went through the Root Learning Class on Friday, September 6.  After the class our table remained to discuss with Bruce Scambler the situation that exists at the power plants concerning the way we maintain our equipment.  We attempted to discuss our concerns with our facilitator, however, the canyon depicted in the first visual became more and more evident the further we discussed it.

Roo-Learning-Canyon

The Canyon Root Learning Map

My two concerns are the terms “Farm Fixing” and “Risk Management”.  These are two good processes which I believe must be employed if we are to compete in an open market.  I do believe, however, that our management has misunderstood their true meaning and has turned them into catch phrases that are something totally different than they were originally intended.

I come from a family of farmers.  My father and grandfather were farmers.  I was concerned about our use of the term “Farm-fixed”, so I discussed the way we were using it in our company with my father and I have confirmed my understanding of the term.

My grandfather as a farmer was a Welder, a Blacksmith, a Carpenter, and an Engine Mechanic.  When a piece of machinery broke down while he was out harvesting or plowing a field, it is true that baling wire and a quick fix was needed to continue the work for the day.  There is a small window of opportunity when harvesting and the equipment had to be running during this time or the farmer’s livelihood was at stake.

That evening, however, the piece that broke was reworked and re-machined until it was better than the original store bought item.  Thus guaranteeing that it wouldn’t break down the following day.  If the repairs took all night to make it right, they would stay up all night repairing it correctly.  It was vital to their livelihood to have their machinery running as well as possible.

A Ford Tractor soon became my grandfather’s tractor as the original factory parts were replaced with more sturdy parts.  It wasn’t repainted (gold-plated), because they weren’t planning on selling their equipment.  The tractors and plows would last years longer than originally designed.  All this was before farming became a subsidized industry.

We need to “Farm-Fix” our equipment.  Our management however, focuses on the use of baling wire during an emergency and replaces the true meaning of Farm-Fixing with the meaning of “Jerry-Rigging”.  Which is merely a temporary fix while farming and is NOT farm-fixing something.  We have been maintaining our plant with quick fixes and have not been farm-fixing them.  If so, our equipment would be more reliable, and would last longer than originally intended.

Risk Management is another area that has been misunderstood by our management.  They have gone to school and have been trained in Risk Management.  I don’t believe they are using their tools in the way that they were taught.  They have taken the underlying idea that we may not need to make a change or repair a certain piece of equipment at this particular time and have made it the center of their idea of Risk Management.  Risk Management is more than that.  It is weighing the consequences of both actions against the cost and making an informed decision to determine the timing of maintenance.

Risk Management at our plant has become nothing more than speculation, or what I call “Wish Management”.  The decision is often made based on the immediate cost and downtime to delay maintenance without properly identifying the possible damage that could occur and the cost of that scenario.

The phrase “It’s run that way this long, it will probably be all right” is used to justify not repairing the equipment.  No real analysis is done.  Then we cross our fingers and “Wish” that it will continue running forever.

I believe in the concepts of Risk Management and Farm-fixing.  I think they are processes that should be used in our company to achieve and maintain “Best-In-Class”.  I am concerned, however, that if we continue on the course that we are on where “Wishing” and “Jerry-rigging” are our processes, it will only be a matter of time before our workers get killed and our plants melt down around us.

Kevin Breazile

Sooner Station

— End of the letter.  See?  I was always trying to stir things up.

The first summer I worked at the Power Plant as a summer help, we had a couple of floor drain covers in the maintenance shop that were missing from the floor drains.  Plywood had been used to cover the drains, which had been smashed down by the heavy equipment that traveled in and out of the shop.  One day during lunch I wrote a Maintenance Order to have the floor drain covers replaced and placed it on Marlin McDaniel’s (the only A Foreman at the time) desk.  I was only an 18 year old kid that was just learning my way around in the world and already stirring things up, but I figured this was an accident waiting to happen.

The very next day, a plant mechanic, Tom Dean stepped onto one of those floor drains while carrying a heavy ladder and seriously hurt his back.  It was a life changing event for Tom that immediately changed his career.  The next day, the drains had new covers.  I talked about this in the post:  “Power Plant Safety is Job Number One

Approximately one year after I wrote the Farm-fixing and Risk Management letter to Jack Coffman, we had a major incident at the power plant that was directly caused by the decision not to replace a coupling when it was known to be faulty (risk management, they called it).  It would have required extending an overhaul a day or two.  Instead, after half of the T-G floor burned to the ground and the plant was offline for about 3 months.  Millions of dollars of damage.  That is a story for another post.

Back to Plain Ol’ Power Plant Back Pain

Originally posted October 18, 2014.

Does anyone know where the phrase, “Step on a Crack, Break Your Mother’s Back” came from? I’m sure there is a story behind that one. Maybe even a lot of different origins. I can distinctly remember a day in the Power Plant when a Power Plant Man stepped on a crack and broke his own back.

I remember looking out of the seventh floor window of my friends dorm room when I was a freshman in college watching students returning from classes about 6 months before the Power Plant Man broke his back. I was watching closely to see if any of them were purposely missing the cracks as they walked down the sidewalk toward the entrance. Out of about 20 people two of them purposely stepped over every crack in the sidewalk.

In the post “Power Plant Safety is Job Number One” I told the story about four of us were carrying a very long extension ladder through the maintenance shop at the Coal-fired Power Plant in North Central Oklahoma one summer morning in 1979 when Tom Dean stepped on a crack (well, it was a cracked piece of plywood that had been placed over a floor drain because the floor grate was missing), and when as he stepped on it, he lost his balance enough to twist himself around. By the time he stopped twirling, he was in immense pain as he had destroyed any chance for comfort for the next 6 months.

A Cast Iron Floor drain cover similar to this

A Cast Iron Floor drain cover was missing from the drain

So, I could understand the dangers of stepping on cracks even when they appear to be insignificant. What that has to do with my mom I’m not sure. However, one day when my sister was walking with my mom on the campus of Oklahoma State University, my sister may have stepped on a crack at that time, as well as my mom, which sent her plummeting the five feet to the ground resulting in a broken hip.

This makes me wonder that since the times have changed, it may be time to change the saying to something else. Maybe something like “Smoke some crack, break your parent’s piggy bank” would be more appropriate for these times. Oh well, I’ve never been much of a poet.

Anyway, back to the subject of back pain.

The number one favorite topic during Safety Meetings at the Power Plant was Back Safety. We were told (and rightly so) that accidents where the back is injured cost the company and the employee more than any other injury. Once you really hurt your back, you can expect to have back pain the rest of your life. It only takes one time. — Times may have changed since 1979, so that now you can have some excellent back surgeries to help correct your back injuries. Even with these, you will never be completely free from back pain.

In the Power Plant Post, “When Power Plant Competition Turns Terribly Safe” I told a story about how our team came up with hundreds of safety slogans in an attempt to win the coveted Power Plant Safety Award Pizza at the end of the year. A Pizza that continued to allude us for 2 and a half years. During our meetings to invent the most catchy safety slogans, Andy Tubbs (or was it Ben Davis) came up with a slogan that said, “Lift with your legs, not your back. Or you may hear a lumbar crack”. — See. I wish I could come up with doozies like that! This takes the idea of a crack and a back and turns it around, if you think about it. Now instead of a crack hurting your back, its about a strain on your back creating a crack. — I know… probably just a coincidence….

Lumbars don't really crack. The discs indicated in blue become damaged

Lumbars don’t really crack. The discs indicated in blue become damaged

One morning Sonny Kendrick, our electric specialist at the time, while sitting in the electric lab during break, let out a whopper of a sneeze. When he did, he suddenly knew what it felt like to experience tremendous back pain. One sneeze and he was out of commission for many weeks.

Sonny as he is today

Sonny Kendrick as he is today or… yesterday…

One day, when Charles Foster, my very close friend, and electric foreman, were talking about back pain, I realized that a good portion of Power Plant Men suffered with back pain. — At the risk of sounding like Randy Dailey teaching our Safety Class, I’m going to repeat myself, “You only have to hurt your back one time to have a lifetime of back pain.”

The company would focus a lot of their safety training around the importance of proper lifting techniques in order to prevent back accidents (not to be confused with backing accidents which is when you back out of a parking space — which is also a common accident — though usually less severe — unless you happen to be a Ford Truck). We would learn how to lift with our legs and not with our back.

You see, it wasn’t just that one sneeze that caused Sonny’s plunge into Back Pain Hell, and it wasn’t just stepping on the cracked plywood floor drain cover that broke Tom’s back (I know “Broke Back” is a misnomer since the back isn’t exactly broke). The problem is more systemic than that. This is just the final result of maybe years of neglecting your back through various unsafe activities.

The two important points I remember from watching the safety videos during our monthly safety meetings was that when you slouch while sitting, you put a needless strain on your lower back. So, by sitting with good posture, you help prevent a future of pain. The second point I remember is that you need to keep your stomach muscles strong. Strong stomach muscles take the weight off of your back when you’re just doing your regular job.

The big problem that finally causes the disc in your lumbar region of your spine to break after neglecting it through these other means is to lift a heavy object by bending over to pick it up instead of lifting the load with your legs. So, the phrase that we always heard was “Lift with your Legs. Not your Back”. You do this by bending your knees instead of just your hips.

Ok. I know you are all thinking the same thing I am thinking (right? Yeah. You are). Bending both your knees and hips saves your back. Isn’t there another word for when you bend your knees and hips at the same time? — Yeah. Yet, I don’t remember hearing it during any of our Safety Videos. — Oh. It was implied, they just never came out and said it…. What they really mean to say is, “Squat”. Yeah. “Squat”. When you bend your knees and hips, isn’t that “Squatting?”

Times have changed…. I mean….. Doesn’t everyone today have a “Squatty Potty”?

The Squatty Potty Logo

The Squatty Potty Logo

Don’t we all have “I ‘heart’ 2 Squat” tee-shirts?

See how happy you can be to Squat?

See how happy you can be to Squat?

To learn more, you can watch this video:

This doesn’t just work with the Squatty Potty to help you drop your loads, it also works when lifting heavy loads. So, remember the next time you are going to bend over to pick something up…. Squat instead.

Other lifting tips include keeping the load close to your body and not holding your breath but tightening your stomach muscles, and don’t lift something too bulky by yourself. Don’t twist your body when picking something up, face the load directly. A weightlifter once told me that when you lift, feel the weight on the heel of your feet, not on the balls of your feet.

Randy Dailey, the Safety Guru of our Power Plant, and an expert machinist invented a pen that you could put in your pocket protector in your shirt pocket that would alert you by beeping if you leaned over too far. It was an ingenious device to remind you to lift with your legs instead of your back.

In one of the safety videos we watched about back safety, there was a short stalky scientist that explained the dynamics of lifting and how easy it was to put a tremendous strain on your back by leaning over and picking something up. He said that “People choose the more simple way to pick something up. Not the easiest way.”

Doesn’t that sound like the same thing? Isn’t the simplest way the easiest way? Well. You would think so, but it isn’t always the case. This Doctor of Back-ology went on to explain his statement. He explained that the simplest way to pick up an object on the floor is to bend at the hip. It is one movement. Bend at the hip. — However…. The easiest way to pick up the object is to bend both your knees and your hips to pick up the object. Since you keep your back straight and you lift with your leg muscles that are the most powerful muscles in your body. He avoided using the word, “Squat”, but that’s what he meant.

In order to reduce back injuries at the plant, the company made back belts available at the plant.

A Back Support Belt

A Back Support Belt

Note that this picture not only shows a Power Plant Man wearing a Back Support Belt, but he also is wearing the right kind of Tee-Shirt. It has a vest pocket where you can put a Pocket Protector for your little screwdriver and your Back Alert Pen created by Randy Dailey.

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

The use of back belts was new around the late 1980’s. Even though we had them available through the tool room when we wanted them, few people wore them. The warehouse team wore them a lot. I suppose that is because they were lifting and moving things all day long.

In the warehouse Bob Ringwall, Darlene Mitchell and Dick Dale used to have back belts on when I would visit the warehouse to pick up a part, or to visit my friends. I don’t remember if Bud Schoonover would wear a back belt. How’s this for a slogan…. “Be a Safety Black Belt…. When Lifting, wear your Back Belt.” I know. I should stop when I’m ahead, only I’m so far behind now I may never catch up.

There was a question about whether wearing a back belt was really a good idea. It was thought that people might tend to substitute using their stomach muscles while lifting with the back belt, resulting in weaker stomach muscles. So we were cautioned not to go around wearing back belts all day long. Only when we were going to be doing a job where we had to do a lot of lifting. I suppose now, after years of research, there is a lot more data to tell us one way or the other. I haven’t heard what the latest jury has said on this subject.

Even though I titled this post “…Plain Ol’ Power Plant Back Pain”, there is nothing plain about back pain. I just thought it sounded like a catchy title.

I was lucky enough that during the 20 years I spent working at the Power Plant, I never really hurt my back. To this day, I have been able to avoid living with perpetual pain in my back. — I have been accused of causing pain in other people’s necks. Also, I don’t think the many times that people told me I was a pain in their back side, they were referring to the Lumbar region. I think they meant an area just below the tailbone. I hope that by bringing to their attention the benefits of the Squatty Potty that I have been able to relieve (or prevent) a little of that lower lumbar pain.

Now when someone says, “You don’t know Squat”, you can correct them!

Comments from the original post:

    1. tellthetruth1 Ocotber 18, 2014

      I can remember getting into a taxi whilst in my late teens, turning in the seat to sling a bag in the back seat, only to pull something in my back. The pain lasted for ages.

      These days, it’s arthritis being the culprit. Back pain is as bad as everybody says it is.

      Good page 🙂

  1. Scott Hubbard October 21, 2014

    Wasn’t the back alert pen given to someone in the garage to try out. Rumor is they didn’t like it because it kept going off all day every time they bent over.
    Hmmmmmm

Power Plant Farm Fixing and Risk Management

We were told at the coal-fired Power Plant in North Central Oklahoma that we were going to have to stop doing the excellent job we were used to doing.  We no longer had time to make everything perfect.  We just had to patch things together enough so that it was fixed and leave it at that.  Jasper Christensen told us that we were going to have to “Farm Fix” things and work harder because we now only had half the employees.

Jasper Christensen

Jasper Christensen

Two things bothered me right away….

First, “Work Harder.”  What exactly does that mean?  How does one work harder?  When I pick up my tool bucket to go work on a job, should I put some extra bricks in it so that it is harder to carry?  What then?  Think about it… Shouldn’t we be working “Smarter” instead of “Harder”?  We were all hard workers (if that means, spending a good 8 hour day doing your job).  Any slackers were laid off 7 years earlier.

When I heard “Farm Fixing” I took offense to the reference.  Jasper had mentioned using baling wire to hold something up instead of taking the time to make our jobs look pretty.  As if baling wire was somehow synonymous with “Farm Fixing”.  My grandfather was a farmer….  I’ll talk about that in a bit….

Jasper also informed us that we were no longer stuck doing only our own trade.  So, an electrician should expect to help out as a mechanic or a welder as long as it wasn’t too involved.  Certain welding jobs, for instance, require a certified welder.  If the job was just to tack weld up a bracket somewhere, then I, as an electrician, could wheel a welding machine over there and weld it up.

After that initial meeting after we had been downsized to pint-sized, we met with our own teams.  Alan Kramer was my new foreman.  He encouraged us to learn the different skills from our teammates.

Alan Kramer

Alan Kramer

I asked Ed Shiever to teach me how to weld.  After about an hour, I decided I wasn’t too interested in melting metal using electricity.  I would leave it to the experts.  I was left with a sunburned chest, as I usually wore a V-Neck Tee Shirt in the summer.

Ed Shiever 15 years later

Ed Shiever Welder Extraordinaire

Jody Morse was a mechanic on our team, who had been a friend of mine since I was a janitor.  We had been on the labor crew together.  He asked me if he could do some electrical work with me.  He thought it would be a useful skill to learn.  I happily agreed to let him work alongside me running conduit and pulling wire around the precipitator hoppers.

Jody Morse

Jody Morse

It wouldn’t include working on any circuits where he might accidentally come into contact with anything live.  So, I thought this was a good starting point.  That was one of the first skills I learned as an electrician-in-training when I was taught by Gene Roget, a master of conduit bending.

I showed Jody how to bend the conduit and have it end up being the right length with the curves in the right place (which is a little tricky at first).  Then I showed Jody where the conduit needed to go, and where the wire needed to end up.  He said he wanted to do this all by himself, so I left him to it and left to do something else.

A little while later, Jody came back and said he had a slight problem.  He had cut the cable just a little bit too short (Yeah.  I had done that myself, see the post: “When Enough Power Plant Stuff Just Ain’t Enough“).  I looked at the problem with him, and he was about six inches too short.

Jody looked the job over and decided he had two options.  Pull some new longer cable, or try to make the existing cable work.He figured out that if he cut off 6 inches of the conduit, and sort of bent it out so that it was no longer exactly at 90 degrees, then it would still reach where it needed to go, only the conduit wouldn’t look so pretty because the conduit would appear a little cockeyed.  We figured this would be all right because Jasper had just finished telling us that we needed to make things not so pretty anymore.  Jody finished the job, and filled out the Maintenance Order indicating that the job was done.

The cable and conduit job had been requested by Ron Madron, one of the Instrument and Controls guys on our team.  When he went out and looked at the conduit, let’s just say that he wasn’t too impressed.  He went to Alan Kramer and complained that the conduit job was disgraceful.  I don’t remember his exact words, but when I heard about it, it sounded to me like he said “It was an abomination to all things electrical”.

I had always taken pride in my work, and doing a “sloppy” job was not normal for me.  I didn’t want Jody to feel bad about this because he was pretty proud of having completed the job all by himself without my help.  So I went and had a one-on-one with Ron and explained the situation to him.  I also told him that the next time he has  problem with something I did, come directly and talk to me about it instead of our foreman.  We’re all on the same team now.

I think once he realized the situation, he was more receptive.  Jody and I did go back out there and fix the issue by running a new cable that was long enough, with a new piece of conduit that was installed with the best of care so that it looked pretty.  — None of us informed Jasper that behind his back we were still performing our jobs with great care and precision.

 

Conduit Bending Basics

Conduit Bending Basics

The more I thought about the idea of “Farm Fixing” and “Risk Management” and how it was being applied at our plant, after about a year, I wrote a letter to the Superintendent over all the Power Plants, Jack Coffman.

Here is the letter I wrote (It was titled “Farm Fixing and Risk Management” — appropriate, don’t you think?):

Dear Jack Coffman,

I went through the Root Learning Class on Friday, September 6.  After the class our table remained to discuss with Bruce Scambler the situation that exists at the power plants concerning the way we maintain our equipment.  We attempted to discuss our concerns with our facilitator, however, the canyon depicted in the first visual became more and more evident the further we discussed it.

Roo-Learning-Canyon

The Canyon Root Learning Map

My two concerns are the terms “Farm Fixing” and “Risk Management”.  These are two good processes which I believe must be employed if we are to compete in an open market.  I do believe, however, that our management has misunderstood their true meaning and has turned them into catch phrases that are something totally different than they were originally intended.

I come from a family of farmers.  My father and grandfather were farmers.  I was concerned about our use of the term “Farm-fixed”, so I discussed the way we were using it in our company with my father and I have confirmed my understanding of the term.

My grandfather as a farmer was a Welder, a Blacksmith, a Carpenter, and an Engine Mechanic.  When a piece of machinery broke down while he was out harvesting or ploughing a field, it is true that baling wire and a quick fix was needed to continue the work for the day.  There is a small window of opportunity when harvesting and the equipment had to be running during this time or the farmer’s livelihood was at stake.

That evening, however, the piece that broke was reworked and re-machined until it was better than the original store bought item.  Thus guaranteeing that it wouldn’t break down the following day.  If the repairs took all night to make it right, they would stay up all night repairing it correctly.  It was vital to their livelihood to have their machinery running as well as possible.

A Ford Tractor soon became my grandfather’s tractor as the original factory parts were replaced with more sturdy parts.  It wasn’t repainted (gold-plated), because they weren’t planning on selling their equipment.  The tractors and plows would last years longer than originally designed.  All this was before farming became a subsidized industry.

We need to “Farm-Fix” our equipment.  Our management however, focuses on the use of baling wire during an emergency and replaces the true meaning of Farm-Fixing with the meaning of “Jerry-Rigging”.  Which is merely a temporary fix while farming and is NOT farm-fixing something.  We have been maintaining our plant with quick fixes and have not been farm-fixing them.  If so, our equipment would be more reliable, and would last longer than originally intended.

Risk Management is another area that has been misunderstood by our management.  They have gone to school and have been trained in Risk Management.  I don’t believe they are using their tools in the way that they were taught.  They have taken the underlying idea that we may not need to make a change or repair a certain piece of equipment at this particular time and have made it the center of their idea of Risk Management.  Risk Management is more than that.  It is weighing the consequences of both actions against the cost and making an informed decision to determine the timing of maintenance.

Risk Management at our plant has become nothing more than speculation, or what I call “Wish Management”.  The decision is often made based on the immediate cost and downtime to delay maintenance without properly identifying the possible damage that could occur and the cost of that scenario.

The phrase “It’s run that way this long, it will probably be all right” is used to justify not repairing the equipment.  No real analysis is done.  Then we cross our fingers and “Wish” that it will continue running forever.

I believe in the concepts of Risk Management and Farm-fixing.  I think they are processes that should be used in our company to achieve and maintain “Best-In-Class”.  I am concerned, however, that if we continue on the course that we are on where “Wishing” and “Jerry-rigging” are our processes, it will only be a matter of time before our workers get killed and our plants melt down around us.

Kevin Breazile

Sooner Station

— End of the letter.  See?  I was always trying to stir things up.

The first summer I worked at the Power Plant as a summer help, we had a couple of floor drain covers in the maintenance shop that were missing from the floor drains.  Plywood had been used to cover the drains, which had been smashed down by the heavy equipment that traveled in and out of the shop.  One day during lunch I wrote a Maintenance Order to have the floor drain covers replaced and placed it on Marlin McDaniel’s (the only A Foreman at the time) desk.  I was only an 18 year old kid that was just learning my way around in the world and already stirring things up, but I figured this was an accident waiting to happen.

The very next day, a plant mechanic, Tom Dean stepped onto one of those floor drains while carrying a heavy ladder and seriously hurt his back.  It was a life changing event for Tom that immediately changed his career.  The next day, the drains had new covers.  I talked about this in the post:  “Power Plant Safety is Job Number One

Approximately one year after I wrote the Farm-fixing and Risk Management letter to Jack Coffman, we had a major incident at the power plant that was directly caused by the decision not to replace a coupling when it was known to be faulty (risk management, they called it).  It would have required extending an overhaul a day or two.  Instead, after half of the T-G floor burned to the ground and the plant was offline for about 3 months.  Millions of dollars of damage.  That is a story for another post.

Back to Plain Ol’ Power Plant Back Pain

Originally posted October 18, 2014.

Does anyone know where the phrase, “Step on a Crack, Break Your Mother’s Back” came from? I’m sure there is a story behind that one. Maybe even a lot of different origins. I can distinctly remember a day in the Power Plant when a Power Plant Man stepped on a crack and broke his own back.

I remember looking out of the seventh floor window of my friends dorm room when I was a freshman in college watching students returning from classes about 6 months before the Power Plant Man broke his back. I was watching closely to see if any of them were purposely missing the cracks as they walked down the sidewalk toward the entrance. Out of about 20 people two of them purposely stepped over every crack in the sidewalk.

In the post “Power Plant Safety is Job Number One” I told the story about four of us were carrying a very long extension ladder through the maintenance shop at the Coal-fired Power Plant in North Central Oklahoma one summer morning in 1979 when Tom Dean stepped on a crack (well, it was a cracked piece of plywood that had been placed over a floor drain because the floor grate was missing), and when as he stepped on it, he lost his balance enough to twist himself around. By the time he stopped twirling, he was in immense pain as he had destroyed any chance for comfort for the next 6 months.

A Cast Iron Floor drain cover similar to this

A Cast Iron Floor drain cover was missing from the drain

So, I could understand the dangers of stepping on cracks even when they appear to be insignificant. What that has to do with my mom I’m not sure. However, one day when my sister was walking with my mom on the campus of Oklahoma State University, my sister may have stepped on a crack at that time, as well as my mom, which sent her plummeting the five foot to the ground resulting in a broken hip.

This makes me wonder that since the times have changed, it may be time to change the saying to something else. Maybe something like “Smoke some crack, break your parent’s piggy bank” would be more appropriate for these times. Oh well, I’ve never been much of a poet.

Anyway, back to the subject of back pain.

The number one favorite topic during Safety Meetings at the Power Plant was Back Safety. We were told (and rightly so) that accidents where the back is injured cost the company and the employee more than any other injury. Once you really hurt your back, you can expect to have back pain the rest of your life. It only takes one time. — Times may have changed since 1979, so that now you can have some excellent back surgeries to help correct your back injuries. Even with these, you will never be completely free from back pain.

In the Power Plant Post, “When Power Plant Competition Turns Terribly Safe” I told a story about how our team came up with hundreds of safety slogans in an attempt to win the coveted Power Plant Safety Award Pizza at the end of the year. A Pizza that continued to allude us for 2 and a half years. During our meetings to invent the most catchy safety slogans, Andy Tubbs (or was it Ben Davis) came up with a slogan that said, “Lift with your legs, not your back. Or you may hear a lumbar crack”. — See. I wish I could come up with doozies like that! This takes the idea of a crack and a back and turns it around, if you think about it. Now instead of a crack hurting your back, its about a strain on your back creating a crack. — I know… probably just a coincidence….

Lumbars don't really crack. The discs indicated in blue become damaged

Lumbars don’t really crack. The discs indicated in blue become damaged

One morning Sonny Kendrick, our electric specialist at the time, while sitting in the electric lab during break, let out a whopper of a sneeze. When he did, he suddenly knew what it felt like to experience tremendous back pain. One sneeze and he was out of commission for many weeks.

Sonny as he is today

Sonny Kendrick as he is today or… yesterday…

One day, when Charles Foster, my very close friend, and electric foreman, were talking about back pain, I realized that a good portion of Power Plant Men suffered with back pain. — At the risk of sounding like Randy Dailey teaching our Safety Class, I’m going to repeat myself, “You only have to hurt your back one time to have a lifetime of back pain.”

The company would focus a lot of their safety training around the importance of proper lifting techniques in order to prevent back accidents (not to be confused with backing accidents which is when you back out of a parking space — which is also a common accident — though usually less severe — unless you happen to be a Ford Truck). We would learn how to lift with our legs and not with our back.

You see, it wasn’t just that one sneeze that caused Sonny’s plunge into Back Pain Hell, and it wasn’t just stepping on the cracked plywood floor drain cover that broke Tom’s back (I know “Broke Back” is a misnomer since the back isn’t exactly broke). The problem is more systemic than that. This is just the final result of maybe years of neglecting your back through various unsafe activities.

The two important points I remember from watching the safety videos during our monthly safety meetings was that when you slouch while sitting, you put a needless strain on your lower back. So, by sitting with good posture, you help prevent a future of pain. The second point I remember is that you need to keep your stomach muscles strong. Strong stomach muscles take the weight off of your back when you’re just doing your regular job.

The big problem that finally causes the disc in your lumbar region of your spine to break after neglecting it through these other means is to lift a heavy object by bending over to pick it up instead of lifting the load with your legs. So, the phrase that we always heard was “Lift with your Legs. Not your Back”. You do this by bending your knees instead of just your hips.

Ok. I know you are all thinking the same thing I am thinking (right? Yeah. You are). Bending both your knees and hips saves your back. Isn’t there another word for when you bend your knees and hips at the same time? — Yeah. Yet, I don’t remember hearing it during any of our Safety Videos. — Oh. It was implied, they just never came out and said it…. What they really mean to say is, “Squat”. Yeah. “Squat”. When you bend your knees and hips, isn’t that “Squatting?”

Times have changed…. I mean….. Doesn’t everyone today have a “Squatty Potty”?

The Squatty Potty Logo

The Squatty Potty Logo

Don’t we all have “I ‘heart’ 2 Squat” tee-shirts?

See how happy you can be to Squat?

See how happy you can be to Squat?

To learn more, you can watch this video:

This doesn’t just work with the Squatty Potty to help you drop your loads, it also works when lifting heavy loads. So, remember the next time you are going to bend over to pick something up…. Squat instead.

Other lifting tips include keeping the load close to your body and not holding your breath but tightening your stomach muscles, and don’t lift something too bulky by yourself. Don’t twist your body when picking something up, face the load directly. A weightlifter once told me that when you lift, feel the weight on the heel of your feet, not on the balls of your feet.

Randy Dailey, the Safety Guru of our Power Plant, and an expert machinist invented a pen that you could put in your pocket protector in your shirt pocket that would alert you by beeping if you leaned over too far. It was an ingenious device to remind you to lift with your legs instead of your back.

In one of the safety videos we watched about back safety, there was a short stalky scientist that explained the dynamics of lifting and how easy it was to put a tremendous strain on your back by leaning over and picking something up. He said that “People choose the more simple way to pick something up. Not the easiest way.”

Doesn’t that sound like the same thing? Isn’t the simplest way the easiest way? Well. You would think so, but it isn’t always the case. This Doctor of Back-ology went on to explain his statement. He explained that the simplest way to pick up an object on the floor is to bend at the hip. It is one movement. Bend at the hip. — However…. The easiest way to pick up the object is to bend both your knees and your hips to pick up the object. Since you keep your back straight and you lift with your leg muscles that are the most powerful muscles in your body. He avoided using the word, “Squat”, but that’s what he meant.

In order to reduce back injuries at the plant, the company made back belts available at the plant.

A Back Support Belt

A Back Support Belt

Note that this picture not only shows a Power Plant Man wearing a Back Support Belt, but he also is wearing the right kind of Tee-Shirt. It has a vest pocket where you can put a Pocket Protector for your little screwdriver and your Back Alert Pen created by Randy Dailey.

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

The use of back belts was new around the late 1980’s. Even though we had them available through the tool room when we wanted them, few people wore them. The warehouse team wore them a lot. I suppose that is because they were lifting and moving things all day long.

In the warehouse Bob Ringwall, Darlene Mitchell and Dick Dale used to have back belts on when I would visit the warehouse to pick up a part, or to visit my friends. I don’t remember if Bud Schoonover would wear a back belt. How’s this for a slogan…. “Be a Safety Black Belt…. When Lifting, wear your Back Belt.” I know. I should stop when I’m ahead, only I’m so far behind now I may never catch up.

There was a question about whether wearing a back belt was really a good idea. It was thought that people might tend to substitute using their stomach muscles while lifting with the back belt, resulting in weaker stomach muscles. So we were cautioned not to go around wearing back belts all day long. Only when we were going to be doing a job where we had to do a lot of lifting. I suppose now, after years of research, there is a lot more data to tell us one way or the other. I haven’t heard what the latest jury has said on this subject.

Even though I titled this post “…Plain Ol’ Power Plant Back Pain”, there is nothing plain about back pain. I just thought it sounded like a catchy title.

I was lucky enough that during the 20 years I spent working at the Power Plant, I never really hurt my back. To this day, I have been able to avoid living with perpetual pain in my back. — I have been accused of causing pain in other people’s necks. Also, I don’t think the many times that people told me I was a pain in their back side, they were referring to the Lumbar region. I think they meant an area just below the tailbone. I hope that by bringing to their attention the benefits of the Squatty Potty that I have been able to relieve (or prevent) a little of that lower lumbar pain.

Now when someone says, “You don’t know Squat”, you can correct them!

Comments from the original post:

    1. tellthetruth1 Ocotber 18, 2014

      I can remember getting into a taxi whilst in my late teens, turning in the seat to sling a bag in the back seat, only to pull something in my back. The pain lasted for ages.

      These days, it’s arthritis being the culprit. Back pain is as bad as everybody says it is.

      Good page 🙂

  1. Scott Hubbard October 21, 2014

    Wasn’t the back alert pen given to someone in the garage to try out. Rumor is they didn’t like it because it kept going off all day every time they bent over.
    Hmmmmmm

Power Plant Farm Fixing and Risk Management

We were told at the coal-fired Power Plant in North Central Oklahoma that we were going to have to stop doing the excellent job we were used to doing.  We no longer had time to make everything perfect.  We just had to patch things together enough so that it was fixed and leave it at that.  Jasper Christensen told us that we were going to have to “Farm Fix” things and work harder because we now only had half the employees.

Jasper Christensen

Jasper Christensen

Two things bothered me right away….

First, “Work Harder.”  What exactly does that mean?  How does one work harder?  When I pick up my tool bucket to go work on a job, should I put some extra bricks in it so that it is harder to carry?  What then?  Think about it… Shouldn’t we be working “Smarter” instead of “Harder”?  We were all hard workers (if that means, spending a good 8 hour day doing your job).  Any slackers were laid off 7 years earlier.

When I heard “Farm Fixing” I took offense to the reference.  Jasper had mentioned using bailing wire to hold something up instead of taking the time to make our jobs look pretty.  As if bailing wire was somehow synonymous with “Farm Fixing”.  My grandfather was a farmer….  I’ll talk about that in a bit….

Jasper also informed us that we were no longer stuck doing only our own trade.  So, an electrician should expect to help out as a mechanic or a welder as long as it wasn’t too involved.  Certain welding jobs, for instance, require a certified welder.  If the job was just to tack weld up a bracket somewhere, then I, as an electrician, could wheel a welding machine over there and weld it up.

After that initial meeting after we had been downsized to pint-sized, we met with our own teams.  Alan Kramer was my new foreman.  He encouraged us to learn the different skills from our teammates.

Alan Kramer

Alan Kramer

I asked Ed Shiever to teach me how to weld.  After about an hour, I decided I wasn’t too interested in melting metal using electricity.  I would leave it to the experts.  I was left with a sunburned chest, as I usually wore a V-Neck Tee Shirt in the summer.

Ed Shiever 15 years later

Ed Shiever Welder Extraordinaire

Jody Morse was a mechanic on our team, who had been a friend of mine since I was a janitor.  We had been on the labor crew together.  He asked me if he could do some electrical work with me.  He thought it would be a useful skill to learn.  I happily agreed to let him work alongside me running conduit and pulling wire around the precipitator hoppers.

Jody Morse

Jody Morse

It wouldn’t include working on any circuits where he might accidentally come into contact with anything live.  So, I thought this was a good starting point.  That was one of the first skills I learned as an electrician-in-training when I was taught by Gene Roget, a master of conduit bending.

I showed Jody how to bend the conduit and have it end up being the right length with the curves in the right place (which is a little tricky at first).  Then I showed Jody where the conduit needed to go, and where the wire needed to end up.  He said he wanted to do this all by himself, so I left him to it and left to do something else.

A little while later, Jody came back and said he had a slight problem.  He had cut the cable just a little bit too short (Yeah.  I had done that myself, see the post: “When Enough Power Plant Stuff Just Ain’t Enough“).  I looked at the problem with him, and he was about six inches too short.

Jody looked the job over and decided he had two options.  Pull some new longer cable, or try to make the existing cable work.He figured out that if he cut off 6 inches of the conduit, and sort of bent it out so that it was no longer exactly at 90 degrees, then it would still reach where it needed to go, only the conduit wouldn’t look so pretty because the conduit would appear a little cockeyed.  We figured this would be all right because Jasper had just finished telling us that we needed to make things not so pretty anymore.  Jody finished the job, and filled out the Maintenance Order indicating that the job was done.

The cable and conduit job had been requested by Ron Madron, one of the Instrument and Controls guys on our team.  When he went out and looked at the conduit, let’s just say that he wasn’t too impressed.  He went to Alan Kramer and complained that the conduit job was disgraceful.  I don’t remember his exact words, but when I heard about it, it sounded to me like he said “It was an abomination to all things electrical”.

I had always taken pride in my work, and doing a “sloppy” job was not normal for me.  I didn’t want Jody to feel bad about this because he was pretty proud of having completed the job all by himself without my help.  So I went and had a one-on-one with Ron and explained the situation to him.  I also told him that the next time he has  problem with something I did, come directly and talk to me about it instead of our foreman.  We’re all on the same team now.

I think once he realized the situation, he was more receptive.  Jody and I did go back out there and fix the issue by running a new cable that was long enough, with a new piece of conduit that was installed with the best of care so that it looked pretty.  — None of us informed Jasper that behind his back we were still performing our jobs with great care and precision.

 

Conduit Bending Basics

Conduit Bending Basics

The more I thought about the idea of “Farm Fixing” and “Risk Management” and how it was being applied at our plant, after about a year, I wrote a letter to the Superintendent over all the Power Plants, Jack Coffman.

Here is the letter I wrote (It was titled “Farm Fixing and Risk Management” — appropriate, don’t you think?):

Dear Jack Coffman,

I went through the Root Learning Class on Friday, September 6.  After the class our table remained to discuss with Bruce Scambler the situation that exists at the power plants concerning the way we maintain our equipment.  We attempted to discuss our concerns with our facilitator, however, the canyon depicted in the first visual became more and more evident the further we discussed it.

My two concerns are the terms “Farm Fixing” and “Risk Management”.  These are two good processes which I believe must be employed if we are to compete in an open market.  I do believe, however, that our management has misunderstood their true meaning and has turned them into catch phrases that are something totally different than they were originally intended.

I come from a family of farmers.  My father and grandfather were farmers.  I was concerned about our use of the term “Farm-fixed”, so I discussed the way we were using it in our company with my father and I have confirmed my understanding of the term.

My grandfather as a farmer was a Welder, a Blacksmith, a Carpenter, and an Engine Mechanic.  When a piece of machinery broke down while he was out harvesting or ploughing a field, it is true that baling wire and a quick fix was needed to continue the work for the day.  There is a small window of opportunity when harvesting and the equipment had to be running during this time or the farmer’s livelihood was at stake.

That evening, however, the piece that broke was reworked and re-machined until it was better than the original store bought item.  Thus guaranteeing that it wouldn’t break down the following day.  If the repairs took all night to make it right, they would stay up all night repairing it correctly.  It was vital to their livelihood to have their machinery running as well as possible.

A Ford Tractor soon became my grandfather’s tractor as the original factory parts were replaced with more sturdy parts.  It wasn’t repainted (gold-plated), because they weren’t planning on selling their equipment.  The tractors and plows would last years longer than originally designed.  All this was before farming became a subsidized industry.

We need to “Farm-Fix” our equipment.  Our management however, focuses on the use of baling wire during an emergency and replaces the true meaning of Farm-Fixing with the meaning of “Jerry-Rigging”.  Which is merely a temporary fix while farming and is NOT farm-fixing something.  We have been maintaining our plant with quick fixes and have not been farm-fixing them.  If so, our equipment would be more reliable, and would last longer than originally intended.

Risk Management is another area that has been misunderstood by our management.  They have gone to school and have been trained in Risk Management.  I don’t believe they are using their tools in the way that they were taught.  They have taken the underlying idea that we may not need to make a change or repair a certain piece of equipment at this particular time and have made it the center of their idea of Risk Management.  Risk Management is more than that.  It is weighing the consequences of both actions against the cost and making an informed decision to determine the timing of maintenance.

Risk Management at our plant has become nothing more than speculation, or what I call “Wish Management”.  The decision is often made based on the immediate cost and downtime to delay maintenance without properly identifying the possible damage that could occur and the cost of that scenario.

The phrase “It’s run that way this long, it will probably be all right” is used to justify not repairing the equipment.  No real analysis is done.  Then we cross our fingers and “Wish” that it will continue running forever.

I believe in the concepts of Risk Management and Farm-fixing.  I think they are processes that should be used in our company to achieve and maintain “Best-In-Class”.  I am concerned, however, that if we continue on the course that we are on where “Wishing” and “Jerry-rigging” are our processes, it will only be a matter of time before our workers get killed and our plants melt down around us.

Kevin Breazile

Sooner Station

— End of the letter.  See?  I was always trying to stir things up.

The first summer I worked at the Power Plant as a summer help, we had a couple of floor drain covers in the maintenance shop that were missing from the floor drains.  Plywood had been used to cover the drains, which had been smashed down by the heavy equipment that traveled in and out of the shop.  One day during lunch I wrote a Maintenance Order to have the floor drain covers replaced and placed it on Marlin McDaniel’s (the only A Foreman at the time) desk.  I was only an 18 year old kid that was just learning my way around in the world and already stirring things up, but I figured this was an accident waiting to happen.

The very next day, a plant mechanic, Tom Dean stepped onto one of those floor drains while carrying a heavy ladder and seriously hurt his back.  It was a life changing event for Tom that immediately changed his career.  The next day, the drains had new covers.  I talked about this in the post:  “Power Plant Safety is Job Number One

Approximately one year after I wrote the Farm-fixing and Risk Management letter to Jack Coffman, we had a major incident at the power plant that was directly caused by the decision not to replace a coupling when it was known to be faulty (risk management, they called it).  It would have required extending an overhaul a day or two.  Instead, after half of the T-G floor burned to the ground and the plant was offline for about 3 months.  Millions of dollars of damage.  That is a story for another post.

Back to Plain Ol’ Power Plant Back Pain

Does anyone know where the phrase, “Step on a Crack, Break Your Mother’s Back” came from?  I’m sure there is a story behind that one.  Maybe even a lot of different origins.  I can distinctly remember a day in the Power Plant when a Power Plant Man stepped on a crack and broke his own back.

I remember looking out of the seventh floor window of my friends dorm room when I was a freshman in college about 6 months before the Power Plant Man broke his back watching students returning from classes.  I was watching closely to see if any of them were purposely missing the cracks as they walked down the sidewalk toward the entrance.  Out of about 20 people two of them purposely stepped over every crack in the sidewalk.

In the post “Power Plant Safety is Job Number One” I told the story of how while four of us were carrying a very long extension ladder through the maintenance shop at the Coal-fired Power Plant in North Central Oklahoma one summer morning in 1979 when Tom Dean stepped on a crack (well, it was a cracked piece of plywood that had been placed over a floor drain because the floor grate was missing), and when as he stepped on it, he lost his balance enough to twist himself around.  By the time he stopped twirling, he was in immense pain as he had destroyed any chance for comfort for the next 6 months.

A Cast Iron Floor drain cover similar to this

A Cast Iron Floor drain cover was missing from the drain

So, I could understand the dangers of stepping on cracks even when they appear to be insignificant.  What that has to do with my mom I’m not sure.  However, one day when my sister was walking with my mom on the campus of Oklahoma State University, my sister may have stepped on a crack at that time, as well as my mom, which sent her plummeting the five foot to the ground resulting in a broken hip.

This makes me wonder that since the times have changed, it may be time to change the saying to something else.  Maybe something like “Smoke some crack, break your parent’s piggy bank” would be more appropriate for these times.  Oh well, I’ve never been much of a poet.

Anyway, back to the subject of back pain.

The number one favorite topic during Safety Meetings at the Power Plant was Back Safety.  We were told (and rightly so) that accidents where the back is injured cost the company and the employee more than any other injury.  Once you really hurt your back, you can expect to have back pain the rest of your life.  It only takes one time.  — Times may have changed since 1979, so that now you can have some excellent back surgeries to help correct your back injuries.  Even with these, you will never be completely free from back  pain.

In the Power Plant Post, “When Power Plant Competition Turns Terribly Safe” I told a story about how our team came up with hundreds of safety slogans in an attempt to win the coveted Power Plant Safety Award Pizza at the end of the year.  A Pizza that continued to allude us for 2 and a half years.  During our meetings to invent the most catchy safety slogans, Andy Tubbs (or was it Ben Davis) came up with a slogan that said, “Lift with your legs, not your back.  Or you may hear a lumbar crack”.  — See.  I wish I could come up with doozies like that!  This takes the idea of a crack and a back and turns it around, if you think about it.  Now instead of a crack hurting your back, its about a strain on your back creating a crack.  — I know… probably just a coincidence….

Lumbars don't really crack.  The discs indicated in blue become damaged

Lumbars don’t really crack. The discs indicated in blue become damaged

One morning Sonny Kendrick, our electric specialist at the time, while sitting in the electric lab during break, let out a whopper of a sneeze.  When he did, he suddenly knew what it felt like to experience tremendous back pain.  One sneeze and he was out of commission for many weeks.

Sonny as he is today

Sonny Kendrick as he is today or… yesterday…

One day, when Charles Foster, my very close friend, and electric foreman, were talking about back pain, I realized that a good portion of Power Plant Men suffered with back pain.  — At the risk of sounding like Randy Dailey teaching our Safety Class, I’m going to repeat myself, “You only have to hurt your back one time to have a lifetime of back pain.”

The company would focus a lot of their safety training around the importance of proper lifting techniques in order to prevent back accidents (not to be confused with backing accidents which is when you back out of a parking space — which is also a common accident — though usually less severe  — unless you happen to be a Ford Truck).  We would learn how to lift with our legs and not with our back.

You see, it wasn’t just that one sneeze that caused Sonny’s plunge into Back Pain Hell, and it wasn’t just stepping on the cracked plywood floor drain cover that broke Tom’s back (I know “Broke Back” is a misnomer since the back isn’t exactly broke).  The problem is more systemic than that.  This is just the final result of maybe years of neglecting your back through various unsafe activities.

The two important points I remember from watching the safety videos during our monthly safety meetings was that when you slouch while sitting, you put a needless strain on your lower back.  So, by sitting with good posture, you help prevent a future of pain.   The second point I remember is that you need to keep your stomach muscles strong.  Strong stomach muscles take the weight off of your back when you’re just doing your regular job.

The big problem that finally causes the disc in your lumbar region of your spine to break after neglecting it through these other means is to lift a heavy object by bending over to pick it up instead of lifting the load with your legs.  So, the phrase that we always heard was “Lift with your Legs.  Not your Back”.  You do this by bending your knees instead of just your hips.

Ok.  I know you are all thinking the same thing I am thinking (right?  Yeah.  You are).  Bending both your knees and hips saves your back.  Isn’t there another word for when you bend your knees and hips at the same time?  — Yeah.  Yet, I don’t remember hearing it during any of our Safety Videos.  — Oh.  It was implied, they just never came out and said it….  What they really mean to say is, “Squat”.  Yeah.  “Squat”.  When you bend your knees and hips, isn’t that “Squatting?”

Times have changed…. I mean….. Doesn’t everyone today have a “Squatty Potty”?

The Squatty Potty Logo

The Squatty Potty Logo

Don’t we all have “I ‘heart’ 2 Squat” tee-shirts?

See how happy you can be to Squat?

See how happy you can be to Squat?

To learn more, you can watch this video:

This doesn’t just work with the Squatty Potty to help you drop your loads, it also works when lifting heavy loads.  So, remember the next time you are going to bend over to pick something up…. Squat instead.

Other lifting tips include keeping the load close to your body and not holding your breath but tightening your stomach muscles, and don’t lift something too bulky by yourself.  Don’t twist your body when picking something up, face the load directly.  A weightlifter once told me that when you lift, feel the weight on the heel of your feet, not on the balls of your feet.

Randy Dailey, the Safety Guru of our Power Plant, and an expert machinist invented a pen that you could put in your pocket protector in your shirt pocket that would alert you by beeping if you leaned over too far.  It was an ingenious device to remind you to lift with your legs instead of your back.

In one of the safety videos we watched about back safety, there was a short stalky scientist that explained the dynamics of lifting and how easy it was to put a tremendous strain on your back by leaning over and picking something up.  He said that “People choose the more simple way to pick something up.  Not the easiest way.”

Doesn’t that sound like the same thing?  Isn’t the simplest way the easiest way?  Well.  You would think so, but it isn’t always the case.  This Doctor of Back-ology went on to explain his statement.  He explained that the simplest way to pick up an object on the floor is to bend at the hip.  It is one movement.  Bend at the hip.  — However…. The easiest way to pick up the object is to bend both your knees and your hips to pick up the object.  Since you keep your back straight and you lift with your leg muscles that are the most powerful muscles in your body.  He avoided using the word, “Squat”, but that’s what he meant.

In order to reduce back injuries at the plant, the company made back belts available at the plant.

A Back Support Belt

A Back Support Belt

Note that this picture not only shows a Power Plant Man wearing a Back Support Belt, but he also is wearing the right kind of Tee-Shirt.  It has a vest pocket where you can put a Pocket Protector for your little screwdriver and your Back Alert Pen created by Randy Dailey.

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

Our Pocket Protectors were freebies given to us by vendors so they would have advertisements on them like these

The use of back belts was new around the late 1980’s.  Even though we had them available through the tool room when we wanted them, few people wore them.  The warehouse team wore them a lot.   I suppose that is because they were lifting and moving things all day long.

In the warehouse Bob Ringwall, Darlene Mitchell and Dick Dale used to have back belts on when I would visit the warehouse to pick up a part, or to visit my friends.  I don’t remember if Bud Schoonover would wear a back belt.  How’s this for a slogan…. “Be a Safety Black Belt…. When Lifting, wear your Back Belt.”   I know.  I should stop when I’m ahead, only I’m so far behind now I may never catch up.

There was a  question about whether wearing a back belt was really a good idea.  It  was thought that people might tend to substitute using their stomach muscles while lifting with the back belt, resulting in weaker stomach muscles.  So we were cautioned not to go around wearing back belts all day long.  Only when we were going to be doing a job where we had to do a lot of lifting.  I suppose now, after years of research, there is a lot more data to tell us one way or the other.  I haven’t heard what the latest jury has said on this subject.

Even  though I titled this post “…Plain Ol’ Power Plant Back Pain”, there is nothing plain about back pain.  I just thought it sounded like a catchy title.

I was lucky enough that during the 20 years I spent working at the Power Plant, I never really hurt my back.  To this day, I have been able to avoid living with perpetual pain in my back.  — I have been accused of causing pain in other people’s necks. Also, I don’t think the many times that people told me I was a pain in their back side, they were referring to the Lumbar region.  I think they meant an area just below the tailbone.  I hope that by bringing to their attention the benefits of the Squatty Potty that I have been able to relieve (or prevent) a little of that lower lumbar pain.

Now when someone says, “You don’t know Squat”, you can correct them!