Tag Archives: Floor drain

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.

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Power Plant Safety is Job Number One

Originally posted September 14, 2012:

I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One.  I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back.  I thought the hard hat made me look really cool.  Especially with the safety glasses that looked like someone wore as a scientist during the 1950s.  Dark and square.

The first safety glasses we had didn’t have side shields

I used to keep a pair with me when I went back to school.  When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).

A hat just like this.  An Inspector Clouseau hat.

That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent.  Anyway…. I diverse.  I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.

The yellow hard hat made me confident that I was part of the blue collar working class.  Hard hats have a suspension system in them that make them look like it is riding too high on your head.  You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.

See? The hardhat looks like it is floating above this man’s head

This is this because of this great suspension system that causes the hat to ride so high on someone’s head.  I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.

Ok. Not this big, but pretty large

While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground.  At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast.  It seemed that my legs had just buckled under me.

I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat.  I was surprised by the force of the cable and how little I had felt.  I became a true believer in wearing my hardhat whenever I was working.  The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.

Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere.  Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.

During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back.  I mean… really hurt their back.  I was helping to carry a very large 30 foot long section of a wooden extension ladder.  There were four of us.  Each on one corner.  I know that Tom Dean was behind me carrying one side of the back end.  I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.

As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office.  The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.

A Cast Iron Floor drain cover similar to this was missing

Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.

When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder.  By doing this, he became slightly twisted, and at once he was in terrible pain.  Back pain.  I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant.  He was pretty well out the rest of the summer recuperating from the back injury.

The next summer when I returned to the plant, Tom was working in the tool room.  Obviously a step down from being a mechanic.  He was also very unhappy.  You could tell by looking at him that he had lost the proud expression that he had wore the summer before.

I don’t remember how long Tom worked at the plant after that.  I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth.  Hurting your back is one of the most common and most serious injuries in an industrial setting.  It is definitely a life changing event.

There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work.  One summer there was a young man working in the warehouse and tool room.  His name was Bill Engleking (thanks Fred.  I didn’t remember his name in the original post).  The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind.  It turned out that he had a very serious case of diabetes.  The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.

Then there was one of the Electricians, Bill Ennis.  He would say that he was “Blind in one eye and couldn’t see out of the other one.”  He was actually blind in one eye completely, and the other eye he was color blind.  So, what he said was actually true.

It happened on occasion that people visiting the plant would be seriously hurt.  Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.

One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse.  While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.

An example of a PTO shaft on a brush hog

I remember Mickey Postman explaining what happened.  His crew was eating lunch in the garage when they heard someone yelling for help.  When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air.  They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.

It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do.  This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew.  I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins.  Mickey would know for sure.  I’ll leave it up to him to remind me.

Mickey Postman

I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One.  The Power Plant Men didn’t have to be told by a safety video to know how important it was.  They all knew examples of tragedies such as these.

Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting.  Safety pamphlets would be read, safety videos would be watched.  Campaigns would be waged to re-emphasize the importance of proper lifting techniques.  Everyone in the plant had to take the Defensive Driving course.

The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course.  The course was being given by Nancy Brien, Nick Gleason and Ken Couri.  We learned a lot of defensive driving slogans like, “Is the Pass really necessary?”  “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time).  “Do a Circle For Safety” etc….

The Defensive Driving Course we took when I was a summer help

The Defensive Driving Course we took when I was a summer help

My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them.  Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.

That was when I began wearing my seat belt all the time.  Before that, it was not common for people to wear seat belts.  They only had the lap belt before that, and those weren’t the safest things in the world.  Especially since they would get lost inside the seat.  I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver.  There were a number of tips that I learned then, that I still use all the time today.

There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head.  Whenever you are outside at the plant, you always wear your hardhat and safety glasses.  When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.

During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me.  Not until I had a sunburn on the top of my head.  I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat.  Oh, and a pair of super stylish safety glasses like those shown at the top of this post.

You know when you are young, and I’m sure this has happened to all of you at one point in your life,  you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas.  — Yeah.  I thought you would remember that one.  Well.  I still have dreams of showing up at my desk job wearing a hardhat and safety glasses.  I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.

Comment from previous post:

Jack Curtis January 22, 2014:

The safety meetings, Defensive Driving, safety glasses… it was the same way for telephone men, too. And they jumped in whenever there were problems as well. It is striking to me, to see the differences in attitudes from one generation to another…

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.

Power Plant Safety is Job Number One

Originally posted September 14, 2012:

I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One.  I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back.  I thought the hard hat made me look really cool.  Especially with the safety glasses that looked like someone wore as a scientist during the 1950s.  Dark and square.

The first safety glasses we had didn’t have side shields

I used to keep a pair with me when I went back to school.  When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).

A hat just like this.  An Inspector Clouseau hat.

That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent.  Anyway…. I diverse.  I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.

The yellow hard hat made me confident that I was part of the blue collar working class.  Hard hats have a suspension system in them that make them look like it is riding too high on your head.  You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.

See? The hardhat looks like it is floating above this man’s head

This is this because of this great suspension system that causes the hat to ride so high on someone’s head.  I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.

Ok. Not this big, but pretty large

While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground.  At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast.  It seemed that my legs had just buckled under me.

I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat.  I was surprised by the force of the cable and how little I had felt.  I became a true believer in wearing my hardhat whenever I was working.  The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.

Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere.  Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.

During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back.  I mean… really hurt their back.  I was helping to carry a very large 30 foot long section of a wooden extension ladder.  There were four of us.  Each on one corner.  I know that Tom Dean was behind me carrying one side of the back end.  I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.

As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office.  The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.

A Cast Iron Floor drain cover similar to this was missing

Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.

When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder.  By doing this, he became slightly twisted, and at once he was in terrible pain.  Back pain.  I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant.  He was pretty well out the rest of the summer recuperating from the back injury.

The next summer when I returned to the plant, Tom was working in the tool room.  Obviously a step down from being a mechanic.  He was also very unhappy.  You could tell by looking at him that he had lost the proud expression that he had wore the summer before.

I don’t remember how long Tom worked at the plant after that.  I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth.  Hurting your back is one of the most common and most serious injuries in an industrial setting.  It is definitely a life changing event.

There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work.  One summer there was a young man working in the warehouse and tool room.  His name was Bill Engleking (thanks Fred.  I didn’t remember his name in the original post).  The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind.  It turned out that he had a very serious case of diabetes.  The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.

Then there was one of the Electricians, Bill Ennis.  He would say that he was “Blind in one eye and couldn’t see out of the other one.”  He was actually blind in one eye completely, and the other eye he was color blind.  So, what he said was actually true.

It happened on occasion that people visiting the plant would be seriously hurt.  Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.

One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse.  While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.

An example of a PTO shaft on a brush hog

I remember Mickey Postman explaining what happened.  His crew was eating lunch in the garage when they heard someone yelling for help.  When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air.  They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.

It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do.  This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew.  I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins.  Mickey would know for sure.  I’ll leave it up to him to remind me.

I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One.  The Power Plant Men didn’t have to be told by a safety video to know how important it was.  They all knew examples of tragedies such as these.

Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting.  Safety pamphlets would be read, safety videos would be watched.  Campaigns would be waged to re-emphasize the importance of proper lifting techniques.  Everyone in the plant had to take the Defensive Driving course.

The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course.  The course was being given by Nancy Brien, Nick Gleason and Ken Couri.  We learned a lot of defensive driving slogans like, “Is the Pass really necessary?”  “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time).  “Do a Circle For Safety” etc….

The Defensive Driving Course we took when I was a summer help

The Defensive Driving Course we took when I was a summer help

My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them.  Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.

That was when I began wearing my seat belt all the time.  Before that, it was not common for people to wear seat belts.  They only had the lap belt before that, and those weren’t the safest things in the world.  Especially since they would get lost inside the seat.  I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver.  There were a number of tips that I learned then, that I still use all the time today.

There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head.  Whenever you are outside at the plant, you always wear your hardhat and safety glasses.  When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.

During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me.  Not until I had a sunburn on the top of my head.  I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat.  Oh, and a pair of super stylish safety glasses like those shown at the top of this post.

You know when you are young, and I’m sure this has happened to all of you at one point in your life,  you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas.  — Yeah.  I thought you would remember that one.  Well.  I still have dreams of showing up at my desk job wearing a hardhat and safety glasses.  I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.

Comment from previous post:

Jack Curtis January 22, 2014:

The safety meetings, Defensive Driving, safety glasses… it was the same way for telephone men, too. And they jumped in whenever there were problems as well. It is striking to me, to see the differences in attitudes from one generation to another…

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.

Power Plant Safety is Job Number One — Repost

Originally posted September 14, 2012:

I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One.  I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back.  I thought the hard hat made me look really cool.  Especially with the safety glasses that looked like someone wore as a scientist during the 1950s.  Dark and square.

The first safety glasses we had didn’t have side shields

I used to keep a pair with me when I went back to school.  When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).

A hat just like this.  An Inspector Clouseau hat.

That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent.  Anyway…. I diverse.  I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.

The yellow hard hat made me confident that I was part of the blue collar working class.  Hard hats have a suspension system in them that make them look like it is riding too high on your head.  You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.

See? The hardhat looks like it is floating above this man’s head

This is this because of this great suspension system that causes the hat to ride so high on someone’s head.  I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.

Ok. Not this big, but pretty large

While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground.  At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast.  It seemed that my legs had just buckled under me.

I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat.  I was surprised by the force of the cable and how little I had felt.  I became a true believer in wearing my hardhat whenever I was working.  The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.

Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere.  Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.

During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back.  I mean… really hurt their back.  I was helping to carry a very large 30 foot long section of a wooden extension ladder.  There were four of us.  Each on one corner.  I know that Tom Dean was behind me carrying one side of the back end.  I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.

As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office.  The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.

A Cast Iron Floor drain cover similar to this was missing

Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.

When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder.  By doing this, he became slightly twisted, and at once he was in terrible pain.  Back pain.  I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant.  He was pretty well out the rest of the summer recuperating from the back injury.

The next summer when I returned to the plant, Tom was working in the tool room.  Obviously a step down from being a mechanic.  He was also very unhappy.  You could tell by looking at him that he had lost the proud expression that he had wore the summer before.

I don’t remember how long Tom worked at the plant after that.  I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth.  Hurting your back is one of the most common and most serious injuries in an industrial setting.  It is definitely a life changing event.

There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work.  One summer there was a young man working in the warehouse and tool room.  His name was Bill Engleking (thanks Fred.  I didn’t remember his name in the original post).  The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind.  It turned out that he had a very serious case of diabetes.  The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.

Then there was one of the Electricians, Bill Ennis.  He would say that he was “Blind in one eye and couldn’t see out of the other one.”  He was actually blind in one eye completely, and the other eye he was color blind.  So, what he said was actually true.

It happened on occasion that people visiting the plant would be seriously hurt.  Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.

One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse.  While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.

An example of a PTO shaft on a brush hog

I remember Mickey Postman explaining what happened.  His crew was eating lunch in the garage when they heard someone yelling for help.  When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air.  They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.

It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do.  This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew.  I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins.  Mickey would know for sure.  I’ll leave it up to him to remind me.

I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One.  The Power Plant Men didn’t have to be told by a safety video to know how important it was.  They all knew examples of tragedies such as these.

Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting.  Safety pamphlets would be read, safety videos would be watched.  Campaigns would be waged to re-emphasize the importance of proper lifting techniques.  Everyone in the plant had to take the Defensive Driving course.

The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course.  The course was being given by Nancy Brien (I think that was her last name) and Ken Couri.  We learned a lot of defensive driving slogans like, “Is the Pass really necessary?”  “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time).  “Do a Circle For Safety” etc….

My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them.  Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.

That was when I began wearing my seat belt all the time.  Before that, it was not common for people to wear seat belts.  They only had the lap belt before that, and those weren’t the safest things in the world.  Especially since they would get lost inside the seat.  I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver.  There were a number of tips that I learned then, that I still use all the time today.

There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head.  Whenever you are outside at the plant, you always wear your hardhat and safety glasses.  When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.

During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me.  Not until I had a sunburn on the top of my head.  I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat.  Oh, and a pair of super stylish safety glasses like those shown at the top of this post.

You know when you are young, and I’m sure this has happened to all of you at one point in your life,  you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas.  — Yeah.  I thought you would remember that one.  Well.  I still have dreams of showing up at my desk job wearing a hardhat and safety glasses.  I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.

2 Comment from previous post:

Jack Curtis January 22, 2014:

The safety meetings, Defensive Driving, safety glasses… it was the same way for telephone men, too. And they jumped in whenever there were problems as well. It is striking to me, to see the differences in attitudes from one generation to another…

Power Plant Safety is Job Number One — Repost

Originally posted September 14, 2012:

I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One.  I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back.  I thought the hard hat made me look really cool.  Especially with the safety glasses that looked like someone wore as a scientist during the 1950s.  Dark and square.

The first safety glasses we had didn’t have side shields

I used to keep a pair with me when I went back to school.  When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).

A hat just like this.  An Inspector Clouseau hat.

That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent.  Anyway…. I diverse.  I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.

The yellow hard hat made me confident that I was part of the blue collar working class.  Hard hats have a suspension system in them that make them look like it is riding too high on your head.  You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.

See? The hardhat looks like it is floating above this man’s head

This is this because of this great suspension system that causes the hat to ride so high on someone’s head.  I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.

Ok. Not this big, but pretty large

While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground.  At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast.  It seemed that my legs had just buckled under me.

I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat.  I was surprised by the force of the cable and how little I had felt.  I became a true believer in wearing my hardhat whenever I was working.  The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.

Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere.  Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.

During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back.  I mean… really hurt their back.  I was helping to carry a very large 30 foot long section of a wooden extension ladder.  There were four of us.  Each on one corner.  I know that Tom Dean was behind me carrying one side of the back end.  I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.

As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office.  The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.

A Cast Iron Floor drain cover similar to this was missing

Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.

When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder.  By doing this, he became slightly twisted, and at once he was in terrible pain.  Back pain.  I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant.  He was pretty well out the rest of the summer recuperating from the back injury.

The next summer when I returned to the plant, Tom was working in the tool room.  Obviously a step down from being a mechanic.  He was also very unhappy.  You could tell by looking at him that he had lost the proud expression that he had wore the summer before.

I don’t remember how long Tom worked at the plant after that.  I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth.  Hurting your back is one of the most common and most serious injuries in an industrial setting.  It is definitely a life changing event.

There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work.  One summer there was a young man working in the warehouse and tool room.  His name was Bill Engleking (thanks Fred.  I didn’t remember his name in the original post).  The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind.  It turned out that he had a very serious case of diabetes.  The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.

Then there was one of the Electricians, Bill Ennis.  He would say that he was “Blind in one eye and couldn’t see out of the other one.”  He was actually blind in one eye completely, and the other eye he was color blind.  So, what he said was actually true.

It happened on occasion that people visiting the plant would be seriously hurt.  Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.

One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse.  While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.

An example of a PTO shaft on a brush hog

I remember Mickey Postman explaining what happened.  His crew was eating lunch in the garage when they heard someone yelling for help.  When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air.  They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.

It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do.  This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew.  I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins.  Mickey would know for sure.  I’ll leave it up to him to remind me.

I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One.  The Power Plant Men didn’t have to be told by a safety video to know how important it was.  They all knew examples of tragedies such as these.

Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting.  Safety pamphlets would be read, safety videos would be watched.  Campaigns would be waged to re-emphasize the importance of proper lifting techniques.  Everyone in the plant had to take the Defensive Driving course.

The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course.  The course was being given by Nancy Brien (I think that was her last name) and Ken Couri.  We learned a lot of defensive driving slogans like, “Is the Pass really necessary?”  “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time).  “Do a Circle For Safety” etc….

My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them.  Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.

That was when I began wearing my seat belt all the time.  Before that, it was not common for people to wear seat belts.  They only had the lap belt before that, and those weren’t the safest things in the world.  Especially since they would get lost inside the seat.  I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver.  There were a number of tips that I learned then, that I still use all the time today.

There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head.  Whenever you are outside at the plant, you always wear your hardhat and safety glasses.  When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.

During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me.  Not until I had a sunburn on the top of my head.  I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat.  Oh, and a pair of super stylish safety glasses like those shown at the top of this post.

You know when you are young, and I’m sure this has happened to all of you at one point in your life,  you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas.  — Yeah.  I thought you would remember that one.  Well.  I still have dreams of showing up at my desk job wearing a hardhat and safety glasses.  I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.

Power Plant Safety is Job Number One

I found out soon after I arrived at the Coal-fired power plant in Oklahoma the first summer I worked as a summer help that Safety was Job Number One.  I was given a hard hat and safety glasses the first day I was there, and I watched a safety film on how to lift with my legs and not with my back.  I thought the hard hat made me look really cool.  Especially with the safety glasses that looked like someone wore as a scientist during the 1950s.  Dark and square.

The first safety glasses we had didn’t have side shields

I used to keep a pair with me when I went back to school.  When I was a senior at the University of Missouri, Columbia, while working at the Bakery on Broadway, I kept a pair with me at all times, along with a hat that I had stol…um…. borrowed from my dad and always forgot to return. (In fact, I still have that hat to this day).

A hat just like this.  An Inspector Clouseau hat.

That way, whenever someone suspected who I was, I would put on my glasses and hat and people would think I was Clark Kent.  Anyway…. I diverse.  I never thought about it being an Inspector Clouseau hat until one winter morning in the parking lot at the plant Louise Gates (later Louise Kalicki) called me Inspector Clouseau.

The yellow hard hat made me confident that I was part of the blue collar working class.  Hard hats have a suspension system in them that make them look like it is riding too high on your head.  You soon get used to it, but for the first couple of weeks I kept bumping into things because my hardhat made me taller than I was used to being.

See? The hardhat looks like it is floating above this man’s head

This is this because of this great suspension system that causes the hat to ride so high on someone’s head.  I learned about this not long after I arrived and Marlin McDaniel the A Foreman at the time told me to sort out of bunch of large steel chokers (or slings) in a wooden shack just inside the Maintenance shop by the door to the office elevator.

Ok. Not this big, but pretty large

While I was bending over picking up the chokers (I mean…. While I was lifting with my legs and not my back…) and hanging them on pegs I suddenly found myself laying on the ground.  At first I wasn’t sure what had happened because I hadn’t felt anything and it happened so fast.  It seemed that my legs had just buckled under me.

I soon realized that one of the large chokers that I had just hung on a peg a couple of feet above my head had fallen off and struck me square in the middle of the hard hat.  I was surprised by the force of the cable and how little I had felt.  I became a true believer in wearing my hardhat whenever I was working.  The steel rope had left a small gash across the hardhat that remained as a reminder to me of the importance of wearing my hardhat at all times.

Larry Riley used to comment to me that I didn’t need to wear it when we were in the truck driving somewhere.  Especially when I was sitting in the middle in the back seat of the crew cab and it made it hard for him to see anything through the rear view mirror other than a yellow hard hat sticking up to the top of the cab.

During my first summer at the plant (1979), I did witness how easy it was for someone to hurt their back.  I mean… really hurt their back.  I was helping to carry a very large 30 foot long section of a wooden extension ladder.  There were four of us.  Each on one corner.  I know that Tom Dean was behind me carrying one side of the back end.  I believe that Ben Hutchinson and Aubrey Cargill were on the other side of the ladder.

As we were walking through the shop, Tom stepped on the floor drain just outside of the A Foreman’s office.  The drain cover was missing and a wooden piece of plywood had been put in its place to cover the hole.

A Cast Iron Floor drain cover similar to this was missing

Large equipment had driven over the plywood and it was smashed down into the drain making a slight indention in the middle of the floor.

When Tom stepped on the piece of wood, he lost his balance, and ended up spinning himself around as he tried to remain holding onto the ladder.  By doing this, he became slightly twisted, and at once he was in terrible pain.  Back pain.  I didn’t realize it at the time, but this one event was a critical turning point in Tom Dean’s career at the power plant.  He was pretty well out the rest of the summer recuperating from the back injury.

The next summer when I returned to the plant, Tom was working in the tool room.  Obviously a step down from being a mechanic.  He was also very unhappy.  You could tell by looking at him that he had lost the proud expression that he had wore the summer before.

I don’t remember how long Tom worked at the plant after that.  I just know that it really made me sad to see someone’s life deteriorate during the snapshots that I had in my mind from the summer before to when I returned to see a man tortured not only by back pain, but by a feeling of inadequate self worth.  Hurting your back is one of the most common and most serious injuries in an industrial setting.  It is definitely a life changing event.

There were other tragedies during my time as a summer help and they didn’t necessarily have to do with something dangerous at work.  One summer there was a young man working in the warehouse and tool room.  I don’t remember his name.  The next summer I asked where he had gone, and I learned that one morning he had woke up and found that he had become completely blind.  It turned out that he had a very serious case of diabetes.  The sugar levels in his blood had reached such dangerous levels that it destroyed his optic nerves overnight.

Then there was one of the Electricians, Bill Ennis.  He would say that he was “Blind in one eye and couldn’t see out of the other one.”  He was actually blind in one eye completely, and the other eye he was color blind.  So, what he said was actually true.

It happened on occasion that people visiting the plant would be seriously hurt.  Everyone at the plant was trained in first aid, and Power Plant Men, being the way that they are, are always willing to do whatever it takes to help someone out in time of trouble.

One day during lunch, a man came to the plant to fill the unleaded gas tank on the side of the garage in front of the warehouse.  While he was reaching over the PTO (Power Take Off), His shirt sleeve caught in the spinning PTO shaft and broke his arm.

An example of a PTO shaft on a brush hog

I remember Mickey Postman explaining what happened.  His crew was eating lunch in the garage when they heard someone yelling for help.  When they ran out to see what had happened, they found the man tied up in the PTO with one bone from his arm sticking straight out in the air.  They quickly took care of him and treated him for shock as they waited for the Ambulance from Ponca City to arrive.

It is times like this that you wish would never happen, but you are glad that you had first aid training and you know what to do.  This person could easily have died from this injury if not for the quick action of Mickey Postman and the rest of his crew.  I believe other Power Plant Men that were there to help was Dale Mitchell, George Alley, Don Timmons and Preston Jenkins.  Mickey would know for sure.  I’ll leave it up to him to remind me.

I have illustrated these tragic events to demonstrate the importance of making Safety Job Number One.  The Power Plant Men didn’t have to be told by a safety video to know how important it was.  They all knew examples of tragedies such as these.

Each month the plant would have the Monthly Safety Meeting, and every Monday morning each crew would have their own safety meeting.  Safety pamphlets would be read, safety videos would be watched.  Campaigns would be waged to re-emphasize the importance of proper lifting techniques.  Everyone in the plant had to take the Defensive Driving course.

The last summer I worked as a summer help in 1982 was the first summer that everyone was required to take the Defensive Driving course.  The course was being given by Nancy Brien (I think that was her last name) and Ken Couri.  We learned a lot of defensive driving slogans like, “Is the Pass really necessary?”  “Slow down, ride to the right, ride off the road” (when an emergency vehicle is approaching), “Use the Two Second Rule” (Only, I think it was 3 seconds at that time).  “Do a Circle For Safety” etc….

My friend Tim Flowers and another summer help were carpooling during that time and we made signs with those slogans on them.  Then when we were driving home in my little Honda Civic, we would hold one of those signs up in the back window so that the Power Plant person that was following us home (Usually Dick Dale and Mike Gibbs) would wonder what it said, and would pull up closer to read the sign, and it would say, “Use the 3 second rule”, or “If you can read this, you are too close”.

That was when I began wearing my seat belt all the time.  Before that, it was not common for people to wear seat belts.  They only had the lap belt before that, and those weren’t the safest things in the world.  Especially since they would get lost inside the seat.  I attribute the Defensive Driving Course that I took while I was a summer help at the plant for my safe record as a driver.  There were a number of tips that I learned then, that I still use all the time today.

There is one advantage to wearing a hardhat that I didn’t realize until I left the power plant in 2001. It is that you never have to worry about hair loss on the top of your head.  Whenever you are outside at the plant, you always wear your hardhat and safety glasses.  When I changed jobs to become a software developer at Dell, I would find that just by walking down the street in the neighborhood in Texas, I would quickly develop a sunburn on the top of my head.

During the years of wearing a hardhat, I may have been losing my hair, but it never occurred to me.  Not until I had a sunburn on the top of my head.  I wondered at times if people would look at me funny if I showed up for work in my cubicle at Dell (when we had cubicles) wearing a yellow hardhat.  Oh, and a pair of super stylish safety glasses like those shown at the top of this post.

You know when you are young, and I’m sure this has happened to all of you at one point in your life,  you dream that you get off of the school bus at your school in the morning only to find that you are still wearing your pajamas.  — Yeah.  I thought you would remember that one.  Well.  I still have dreams of showing up at my desk job wearing a hardhat and safety glasses.  I don’t realize it until I lift my hardhat up to wipe the sweat off of my brow, then I quickly look around to see if anyone noticed as I stuff the hardhat under the desk.