Tag Archives: GE

GE Geriatric Gentleman and Power Plant Transformers

Originally Posted May 17, 2013:

I remember the day when I walked into the Electric Shop office to begin the lunch break, and four guys from the T&D department (Transmission and Distribution) came in from the door leading to the Main Switchgear. They were obviously worn out, and were complaining. The first one said that he couldn’t believe that the guy from GE had made them work through morning break. The second guy called him a slave driver. The third guy replied that he couldn’t believe how that GE guy just kept on working from the crack of dawn without stopping all morning without even coming up for air. The fourth guy just collapsed on one of the chairs.

I remember the name of the last guy. His name was Foote. I remember him because he was real proud of his heritage. The first time I had met him, I asked him his name twice, because when he told me it was “Foote”, I wasn’t sure I heard correctly, so I asked him again. I guess that he must has guessed what was going through my mind because he must have had the same reaction from a thousand other people in the past. I figure that because my last name is Breazile (pronounced “Brazil”) and I have had many conversations with people explaining the origin of my name.

Anyway. I don’t remember Foote’s first name because I think he only had initials for his first name on his hard hat, and I’m more of a visual person when it comes to memories. I clearly remember his last. If I remember correctly, one of his ancestors was a naval officer in the Civil War, though, I don’t remember for which side. I guess it doesn’t really matter much now, since both sides were Americans, and both sides loved their country and the lives they knew — that they were fighting to hold onto or to change.

This reminds me of a side story that I must tell…. Years and years later in 1997, when I was on the Confined Space Rescue Team, one guy that was from North Dakota named Brent Kautzman was constantly being “harassed” for being a Yankee, because he came from a Northern State. This was kind of a mute (or is it “moot”) point to me, because I knew that North Dakota didn’t become a state until well after the Civil War.

Anyway, one day when Brent was trying to defend himself from the hardcore confederates of the group, he pointed out that the North won the Civil war. A couple of other members disagreed, claiming that the South was going to “rise again”. One of those that believed in the Confederate resurrection turned to me and asked me, as if I was the resident historian (well… I did have a college degree… and I did have a minor in History…. and I was known for telling the truth when it really came down to it), “Kevin…. Did the north win the Civil War?”

Not really wanting to hurt the feelings of my southern friends, and also wanting to stand by Brent who was really correct about the outcome of the Civil War, I replied with the following explanation: “Yes. The North must have won the war. Otherwise the South never would have let all the carpetbaggers from the North come down there and steal their property and their dignity.” Brent was satisfied, and the southerners had to agree with my logic. They still insisted that the South would rise again. I couldn’t argue with them about that…. It has never ceased to amaze me how bigotry can be passed down so easily.

With that said, I would say that the Power Plant Men that I worked with that believed that the “South would rise again!” didn’t really understand what that meant. I say that because they never would have given a thought that the men that they worked with that were African American such as Floyd Coburn, or Bill Bennett, were nothing less than members of their own families. I know that they each personally loved these men with all their hearts. I thought it was more of a nostalgic feeling than a desire to see the return of slavery or even the bigotry that crippled the southern states for decades after the Civil War.

End of the Side Story…. Back to the worn out T&D workers.

By the sound of it, I figured that this guy from GE (General Electric) that had come to work on one of the Main Auxiliary Transformers on Unit 2 that had a problem with the Tap Changing Mechanism, was some kind of slave driver. Some hard line guy that wanted to work our employees to the brink of exhaustion because he wanted to be done with the repairs as quickly as possible so that he could move on to some more important work. You see. For this job, GE had called on one of the top Main Power Transformer Geniuses in all the country to work on this transformer.

The T&D guys sat there for a while and then walked out into the shop to eat their lunch. Shortly after that, the slave driver from GE came in the back door…. In stepped a man that immediately reminded me of Arthur Fielder from the Boston Pops.

Arthur Fielder from Boston Pops

Arthur Fielder from Boston Pops

He sat down…. opened his brown paper bag. Pulled out his sandwich. Carefully unwrapped it and began to eat. Charles Foster and I were sitting there watching him. After hearing the horror stories from the T&D crew, I wasn’t sure if I wanted to engage this seemingly mad man in conversation, so I waited a while. I ate some cherry tomatoes and Banana peppers that Charles brought for me each day…. and with each bite, I took a bite out of my ham sandwich. Then I looked over at “Arthur Fielder….” (I don’t remember his real name).

Finally, I decided that this slave driver in sheep’s clothing (well, an old frail man costume really), might come up with some interesting conversation so I asked him…. “Say, old man…. how old are you anyway?” He looked up from the total enjoyment of his sandwich, and with food still un-swallowed said, “I’m 83.”

“83?” — Either I said that or Charles did… because we were both stunned by his answer….. “Yep… They called me out of retirement to work on this transformer. Seems I’m the only one that knows how to fix ’em. But I’m teachin’ your fellows how to do it so they don’t have to call me again.”

Charles and I were so flabbergasted by his reply that we couldn’t leave it alone. One of us (Charles and I were always on the same wavelength, so usually when one of us spoke, it was what we were both thinking)… So, one of us asked…. “You’re retired and they called you up to work on this transformer!?!? Are you such a Transformer guru that you were the only one they could send?” (hmm… must have been me…. I don’t think Charles would have used the word “Guru”. He would have used something like “expert” or “talented” or maybe “genius”). He said, “Yep. They paid me enough that I agreed to take a week away from my wife to come here to take care of business. It would have to take a lot to take me away from my Jenny.”

Then this feeble old man with the white moustache explained that he didn’t like to be away from home. Every night since when he was young he has played the piano for two hours. — Wait… I wasn’t sure if I heard that right, so I asked him…. “What? You play the piano for two hours… every night!?!?” (notice… already I have used “!?!?” twice in one post… just goes to show you how surprised I was to run across this man). He reaffirmed what he said, “Yeah. I had to find a hotel that had a piano, so I could sit in the lobby and play it before I go to bed. I can’t sleep well unless I have played the piano first.

After that, he began to tell us about his career in the Music Industry. He had played for many Big Band orchestras in the past. He talked about playing with Tommy Dorsey and Benny Goodman. Names that I had learned from my Aunt Pam Sorisso in Kansas City that gave me an Eight Track Tape of Big Band music when I was in College that I used to listen to often. I had become a fan of Big Band and had a great respect for these Big Band Leaders.

Benny Goodman

Benny Goodman

Tommy Dorsey

Tommy Dorsey

Here sitting in front of me was one of the geniuses of the Big Band era in the electric shop at a Coal-fired Power Plant in the middle of North Central Oklahoma. All I could think of was, “Who woulda thought it?” Though I was impressed as all get out… I tried to act calm….. I wanted to jump up with a piece of paper and ask him for his autograph….

This old guy suddenly had all my respect. It cracked me up to think that this 83 year old man was out performing the younger T&D workers. He was running them ragged (pronounced “rag ed”). He explained that he didn’t like to stop for break. It made the day go a lot faster if he just kept working until he had to stop. He wouldn’t have stop for lunch if all the workers hadn’t just dropped all their tools and left.

It amazed me even more that this man who was a big band musician of the highest caliber had ended up working for GE Not only had he worked for GE, but he had become the ultimate authority in large transformer repair. I mean…. How cool is that?

I can’t tell you how much I instantly fell in love with this guy. He had talked and talked about his days as a big band piano player. What really came out of his conversation what just how much he loved his wife. The two things he loved in the entire world was his wife and to play the piano. He said there was nothing more soothing than playing the piano. As he walked off to go back to work at the end of lunch… the only thing I could think of was one of my Big Band favorites…. Louis Armstrong….

For those people who stopped to really think about it…. This truly is….. A Wonderful World!

Comment from the Original Post

Ron Kilman May 18, 2013:

  1. Great story. I met a lot of really neat guys at the Power Plant – experts in their fields – bladers, winders, crack-checkers, boiler gurus, balancers, . . . I remember making a factory “balance expert” really mad. He was sent to balance the Buffalo Forge FD fans at Seminole. He was the “lead” and I was just “checking” him. We used a modern IRD balance analyzer with a Teflon shaft rider and he used a pencil! When we both had taken our “readings” we shut the fan down. When it coasted to a stop, he began yelling “My marks – my marks – you wiped out my marks!” (with a German accent). On the next balance run, I took my readings first, then he put his pencil marks on the rotating fan shaft. We got the fan smooth. He was a cool guy, but used 19th century “technology”. I never asked him if he played the piano too.

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Moon Walk in a Power Plant Precipitator

Originally Posted May 25, 2013;

Just because there isn’t any smoke pouring out of the smoke stacks at a Coal-fired Power Plant, it doesn’t mean that the plant is offline.  The power plant where I worked as an electrician in north central Oklahoma had two large Buell (later GE) electrostatic precipitators.  This is what takes the smoke out of the exhaust.  The smoke is referred to as “Fly Ash”.  The electrostatic precipitator when running efficiently should take out 99.98% of the ash in the exhaust.  When running with excellent efficiency, the exhaust can have less ash than dust in the air (or 99.999%).

Sonny Kendrick, the electric specialist and Bill Rivers an electronics whiz were my mentors when I joined the electric shop.  These two Power Plant Men taught me how to maintain the precipitator.  I wrote about the interaction between these two men in the post:  Resistance in a Coal-Fired Power Plant.  It is funny to think, 30 years later that the skills they were teaching me would determine my career for the next 18 years.  You see….. I later became the Precipitator guru of the power plant.  I once thought it was sort of a curse to become good at one thing, because then you were kind of expected to do that the rest of your life.

When I first joined the electric shop and they were deciding who was going to fix all the manhole pumps, the electrical A Foreman replied by saying, “Let Kevin do it.  He likes to get dirty.”  At that point… I think I understood why they really wanted me in the electric shop.  Charles Foster had mentioned to me when I was a janitor and he had asked me if I would consider being an electrician because I cleaned things so well, and a lot of being a Power Plant electrician involved cleaning…  Now those words took on their full meaning.

I knew I was destined to work on the precipitator from the beginning.  Sonny had been banished to work on only the precipitator, as Bill Rivers had made clear to me when I was still a janitor (see the power plant post:  Singing’ Along with Sonny Kendrick).  I was his chance to be lifted from the curse that had been placed on him by our Electrical Supervisor, Leroy Godfrey.  I had accepted that.  I knew that I would eventually be the one to maintain the precipitators from day one.

So, here I was…  One month before becoming an electrician, I had a near death experience inside the precipitator (See the post:  Angel of Death Passes by the Precipitator Door).  Now I was going into the precipitator again with Bill Rivers.  I think at that time we were just wearing half-faced respirators and no fly ash suit.  Just a rain suit.

A man wearing a half faced respirator -- not me... just an image I found on Google Images

A man wearing a half faced respirator — not me… just an image I found on Google Images

Not a lot of protection….

I followed Bill Rivers into the precipitator while it was offline for overhaul.  I had my flashlight securely strapped around my neck with a string.  I had  a small notepad with a pen tied to it also around my neck for taking notes.

A notepad like this

A notepad like this

So, as Bill entered the dark cavern of the precipitator, I found that we had just entered a new world.  It was dark… Like the dark side of the moon.  We were at the intake of the precipitator and we were walking on top of the ash as it was more like sand at this point.  We just left footprints where we only sank about 2 inches into the pile of ash that had built up there.

Bill took his flashlight and shined it up between two sets of plates that are exactly 9 inches apart.  He swung the light up toward the top of the precipitator 70 feet above.  At first as the light was reflecting on all the white ash, I was blinded to the detail that Bill was trying to show me.  Eventually I realized that he was pointing his flashlight at a clip.  There was some kind of a clip that held one plate in line with the next.

Once I had confirmed to Bill that I saw where he was looking, he lowered the flashlight to about 45 feet above us, where there was another clip.  Then even lower.  About 10 feet above us.  A third clip.  — Now at this point… I was almost ready to resign myself to another lesson like the one I had learned from Ken Conrad as he had poured his heart and soul into his description of how to lay the irrigation hose and position the water gun 3 years earlier (See, “When a Power Plant Man Talks, It pays to Listen“),  then I remembered…. “I know this is boring… but you have to learn it….”  A Phrase that I made good use of 15 years later when I was teaching switching to a group of True Power Plant Men that would find themselves equally bored with the necessary material they had to learn.

Bill explained….. Each clip must (and he emphasized “Must’) be aligned with the next plate.  Every clip must be in their place.  Don’t start up this precipitator until this is so.  Ok.  I understood…. Let’s see… there are three clips between each of the four plates… or 9 clips per row…. and there were 44 rows of plates for each section…. and there were 6 sections across the precipitator, and  7 sections…. hmmm… that added up to oh… only 16,632 clips that I needed to check during each overhaul… ok… I took a note on my notepad…

Bill explained….. Clean each insulator.  there is one on the side of each bottle rack holding all the wires in place.There were only 4 for each 2 hoppers.  there were 84 hoppers,   Great.  Only 168 insulators on the bottle racks….  Then he pointed out that there were also insulators on the precipitator roof.  two on each section over each pair of hoppers… One on the tension house on one connected to the transformer, or 336 more… making a total of 504 insulators that need to be inspected and cleaned during each overhaul.

Bill explained…. you need to check each of the wires to make sure they aren’t caught on a clip or broken.  Let’s see…. there were 44 rows of wires in each section… with 16 wires in each row…. and there were 6 sections across each set of hoppers…. that came out to exactly 29568 wires that needed to be inspected during each overhaul.

Bill explained…. each rapper on the roof needs to be tested to make sure they are rapping with the correct force.  That meant that they each needed to lift at least 6 inches before they dropped the 15 pound slug (to knock the ash off of the plates into the hoppers below.  Hmm… For each 4 hoppers, there were 6 rows of 12 rappers each.  There were two sets across the precipitator and there were 7 sets of rappers.  In other words…. there were 672 rappers on the roof of the precipitator.

Bill explained…. each vibrator on the roof needs to be calibrated to provide the maximum vibration to the wires inside the precipitator in order to make sure they cleaned the wires of any ash buildup as they are responsible for delivering the static electricity to the precipitator that collects the ash on the plates.  In order to calibrate them, you had to adjust the gap between the main bracket and the magnetic coil to within a few thousands of an inch… I don’t remember the exact setting now… but we used a set of shims to set them correctly.  There were 12 vibrators for each of the two sides of each of the seven sections of hoppers.   This came out to 168 vibrators that need to be adjusted during each overhaul.  Oh.  And each vibrator had an insulator connected to the wire rack…adding 168 more insulators.

So, we had 16,632 clips, 672 insulators, 29568 wires, 672 rappers and 168 vibrators that all needed to be in good working order at the end of each overhaul (on each of the two units).  Throughout the years that I worked inspecting, adjusting and wrestling with plates, clips and wires, I became personally attached to each wire, insulator, clip, rapper and vibrator. For a number of my 18 years as an electrician, I was the only person that entered the precipitator to inspect the plates, wires, clips and internal insulators.  Some of my closest friends were precipitator components.  Each diligently performing their tasks of cleaning the environment so that millions of people wouldn’t have to breathe the toxins embedded in the ash particles.

We hired contractors to go into the precipitator to help me.  I would spend an entire day teaching them how to wear their full face respirator and fly ash suit…. How to inspect the clips and wires…. how to walk along the narrow beams along the edge of each row of 84 hoppers on each unit to find and repair the things that were not in proper alignment.  I would check out all their equipment and give them their safety training only to have them not show up for work the next day.

Contractors would gladly be paid to weld in the boiler hanging from a sky climber in the middle of space 200 feet above the bottom ash hopper, but give them one day in the precipitator and they would rather be thumbing a ride to Texas….  I should have felt insulted… after all this was my home…. Mark Fielder the head of the welders once called it my “baby”.  I knew he had never had to endure the walk on the moon when you entered the tail end of the precipitator and found yourself buried waste deep in light fly ash.  I told Mark Fielder to not call the precipitator my baby…  Not until he could find a contractor that was willing to work alongside me inside it.  He apologized.  He explained that he meant it with affection.

At the back end of the precipitator, you just sank to the bottom of a pile of fly ash when you stepped into it.  The fly ash particles there are less than 2 microns in diameter.  That meant that they would infiltrate your filter and bounce around inside your respirator on their way down into your lungs.  Building up a permanent wall of silicon in your innards that will be there until the day you die.

I noticed that after a few days of working in the precipitator that I would feel like I had the flu.  This would happen after I would smell this certain scent in the precipitator that would develop after the unit had been offline for a week or so.  I noticed that when I burped, I could taste that smell in my mouth.  I also noticed that if I had to pass some gas, that the smell would also include the smell that I was experiencing in the precipitator.

I didn’t think much about it until one day when I went to the tool room and Bud Schoonover told me that they were out of the regular hepa-filters for my respirator.  So, instead he gave me a pair of organic filters.  They had a different carbon filter that absorbed organic particles.  I said, “Thanks Bud.” and I headed out to climb into the precipitator to continue my inspection of some 30,000 wires, and 16,000 clips.

To my astonishment, when I used the carbon filters right away, I didn’t smell the acrid smell.  The flu symptoms went away, as well as the smelly burping flavors.  Not to mention (oh.. but I am) the passing of gas without the additional smell of precipitator internals….  Crazy as these seems… I became obsessed with finding out why.

You see… at the same time that this particular smell arose in the precipitator, any ash that was built up on the plates would clump up and with a simple bang on the plates with a rubber mallet would cause all the ash to fall off leaving a perfectly clean plate.  Before this smell was there, you could bang on the plates all day, and the ash would remain stuck to the plates like chalk on a chalkboard.

I had our famous chemist (well…. he was famous to me… see the post:  A Power Plant Doctor Does a Jig in a Puddle of Acid), come out to the precipitator to give it a whiff.  He said it had some kind of  a sewer smell to it…. I didn’t expand on my personal sewer experience I had had with it, though I did tell him about the burping….

He encouraged me to have the safety department come out and test it to see if they could identify the chemical that was causing this smell.  You see…. It was important to me because if we could pin this down, then we might be able to inject a substance into the precipitator while it was online to clean it without having to bring the unit offline if the precipitator was to become fouled up.

There was a young lady from the safety department (I think her name was Julia, but I can’t remember her full name).  She came from Oklahoma City and gave me some monitors to put in the precipitator while the smell was present to try to track down the chemical.  Unfortunately, we never found out what it was.  In the meantime, I had learned all I could about Van Der Waals forces.  This is the week molecular force that would cause the ash to stick to the plate.

I studied the chemical makeup of the ash to see if I could identify what chemical reactions could take place… Unfortunately, though I knew the chemical makeup of the ash, the chemicals were bound in such a way from the high temperatures of the boiler, that I couldn’t tell exactly how they were arranged without the use of  an electron microscope.  I wasn’t about to go to Ron Kilman (who was the plant manager at the time) and ask him for one.  I had already upset him with another matter as you will learn in a much later post.

So, I just continued wearing the organic filters.  This gave me the strength to continue my inspections without the flu-like symptoms.  Later on, I taught Charles Foster and Scott Hubbard how to maintain the precipitator.  When I finally left in 2001, I know I left the precipitators in competent hands.  They knew everything I did.

One main lesson I learned from my experience as the precipitator guru is this….. You can be a genius like Bill Rivers or Sonny Kendrick….. when you are given a particular job to do and you do it well, you are usually pigeon-holed into that job.  One of the main reasons I write about Power Plant Men is because they are for the most part a group of geniuses. At least they were at the plant where I worked in North Central Oklahoma.  They just happened to stumble onto the jobs that they had.  They would probably spend the rest of their working career doing what they did best…. never moving onto something where their genius would shine and others would know about them… That is why I write about them.

Do a job well, and you will be doing it until the day you die…. that’s what it seemed to be.  I didn’t feel like I was banished to the precipitator as Sonny Kendrick was by Leroy Godfrey, who did it consciously.  No.  I was “banished” to the precipitator for the next 18 years because I was good at it.  I loved it.   I may have mentioned before, but I had a personal relationship with the 168 precipitator control cabinets.

I had carefully re-written the programs on each of the eprom chips on the Central Processing Unit in each cabinet to fit the personality of each section of the precipitator.  I had spend hours and hours standing in front of each cabinet talking to them.  Coaxing them.  Telling them that they could do it with my handheld programmer in hand…. helping them along by adjusting their programming ever so slightly to give them the freedom that they needed to do their job.  If they had been human……. I would have given them names like “Mark”, or “Thomas”, or “Millie”.  Instead, I knew them as 2E11 or 1B7.  But they were each my friends in their own way.

You see… I look at friends like this…. It’s not what they can do for me…. It’s “what can I do for them?”  I have had some precipitator cabinets that I have given extra attention because they seemed to need it more than the others, only to have them crap out on me.  I wouldn’t have done anything different if I had known all along that they wouldn’t pull through.

I have my own understanding of who I should be.  My wife may call it “stubbornness”, and that may be what it is.  I would try and try to coax a control cabinet to do what it was created to do, only to have it fail over and over again….  What was I going to do?  Give up?  How could I do that to a friend?  I would tell the cabinets that were especially difficult (when I was alone with them – which was usually), “You create your own Karma.  That isn’t going to change who I am.”

Today I am called an IT Business Analyst.  I work for Dell  Computers (now I work for General Motors).  It is an honor to work for a company that serves the entire world.  I see the same pattern.  When you do something well, when you love your work and become attached to it, you become pigeon-holed into a particular job.  You become invaluable.  Almost irreplaceable.  People look to you for answers.  They are comforted to know that someone who cares is taking care of business.  I am glad to be able to serve them.

Weeks before I left the power plant, Bill Green, the plant manager asked Jim Arnold (the supervisor over maintenance) again….. “What degree is Kevin getting again?”  Arnold replied, “Oh.  nothing anyone wants.”  (an MIS degree from the college of business at Oklahoma State University). Bill was concerned that if I left they wouldn’t have anyone to take care of the precipitators.  No.  I wouldn’t do that.  Like I said… Each of the 168 precipitator control cabinets were my friends…. I had given them the best guardians I could find… Scott Hubbard and Charles Foster.

Scott Hubbard

Charles Foster

Recently Charles Foster has retired from the plant, and his health is not good.  His son, Tim Foster has taken his place.  One of the last things Tim has told me recently was that he was going with Scott Hubbard to work on the precipitator.  I wanted to reply back to his e-mail… take care of my friends Tim….  I know Scott understands….

Each clip, each wire… I often dream about them….  Row after row….. looking 70 feet up, then down… swinging my flashlight in the darkness.   Betty, Tom, Martin…. all the clips on this plate are in their place…. Sandy, David, Sarah… lined up correctly…  Fred, Chuck, Bill…. good… good…  next row….

A Slap in the Face at a Gas-fired Power Plant

Originally posted June 21, 2013:

Archimedes once said, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world.”  Thanks to my high school math teacher Robert Burns, I have always admired Archimedes.  I remember the day he was talking about him in class, and he was explaining how Archimedes had sat down in the bathtub and when the water overflowed, and he suddenly realized how to calculate the volume of the king’s crown, he jumped out of the tub and ran down the street in his birthday suit yelling “Eureka!  Eureka!”  Meaning… I have found it!  I have found it!  I especially remember Mr. Burn’s eyes tearing up as he told this story.  To Mr. Burns, mathematics was an adventure.  He instilled this love into me.

So, how does a discussion about Archimedes tie into a story about a Gas-fired Power Plant in central Oklahoma?  Well it does, or it did, on December 19, 1985.

The day began with my drive from Oklahoma City, where I was staying, to Harrah, Oklahoma where I was on overhaul at a power plant called Horseshoe Lake Plant.  The lake must have been named Horseshoe Lake for the obvious reason that it was shaped like a Horseshoe as it wrapped around the north part of the plant.

I suppose this lake was originally used to cool the condenser water once the steam had been used to turn the turbine, but it was much too small to be used by the units that were in operation when I was at the plant.  Instead it was a Fish farm where Tilapia were raised.

A Power Plant Tilapia

A Power Plant Tilapia

I wrote about working at this plant on this overhaul in an earlier post called “Bobbin’ Along with Bob Kennedy“.  This morning when I arrived, I figured I would be working in the shop repairing more of the older open-faced motors with their sleeve bearing and cambric insulation.  It started out that way.

An example of an old GE open-faced motor

An example of an old GE open-faced motor

One time during the morning, Ellis Rook, the electrical Supervisor came up to me and started talking to me about the ROLM phone computer.  He knew I had experience working on the Phone system.  I had been trained by the best even before I had gone to Muskogee to take a class.  Bill Rivers at our plant had taught me how to make “moves and changes” and how to troubleshoot the entire plant’s phone system without ever leaving the lab.

A ROLM Phone Computer

A ROLM Phone Computer

Anyway.  Ellis Rook told me about the problem they were having with the phone system that day.  He told me what had been done to try to fix the problem.  I was thinking of a few things I would try (even though I was still more of a Rookie than Ellis Rook — ok.  I couldn’t resist that one).  I had been an electrician in training for just over 2 years, which still made me a rookie.

I originally thought Ellis had approached me for ideas on how to fix the problem, so I was formulating some answers in my mind while he was going on… then he said, “What I do every time to fix any problem is just reboot the computer.” — ok.  He wasn’t seeking advice.  He was seeking approval.  So, I looked at him with as blank of a stare I could and just nodded and replied, “Well, that usually does it.”  — Nevermind that it took about 25 minutes for one of these old ROLM computers to reboot and during that time all communication with the outside world was cut-off.

This was when I remembered a story that Bob Kennedy had told me about Ellis Rook.

One day, he took another electrician with him to inspect the exciter collector rings on one of the units.  The exciter is connected to one end of the generator usually (though if I’m not mistaken, the exciter house was off to one side), and it spins at 3600 rpm.  It is not coincidental that this is 60 cycles per second, which is how fast the electricity alternates between positive and negative in your house.  This is exactly why the electricity alternates that fast.  Because that is how fast the turbine-generator is spinning.

Anyway, Ellis had taken a strobe light with him to go inspect the collector rings on the exciter because there was some indication that a fuse had blown on one of the collectors.  Using the strobe light, you could set it to blink at 3600 times per minute and the collector rings spinning at 3600 rpm would appear to stand still.

A typical strobe light

A typical strobe light

By slowly adjusting the rate that the strobe light was flashing, you could rotate the shaft slowly and inspect it just as if it was standing still, even though in reality it was still spinning at 3600 rpms (the same speed as the lawn mower in the post:  “Something is in the Water at the Muskogee Power Plant“).

After examining the shaft for a bit, they located the blown fuse.  When the fuse blew, a little indicator would stick out so it could easily be seen.  Ellis Rook slowly rotated the shaft around until the fuse was in a good position and then stopped the shaft from rotating by setting the strobe light to the exact same rate that the shaft was rotating.

Then Ellis said something that would go down in the Annals of History at Horseshoe Lake.  He told the electrician to change out the fuse.  —  Ok.  Stop and think about this for a minute.  The room where the collector rings are is normally dark, so all they can see is this turbine shaft in front of them and it looked like it was standing still.  Forget the roar of the spinning turbine and just chalk it up to a loud fan running.

Luckily the electrician wasn’t lulled into a false sense of security and didn’t put his hand forward to remove the fuse.  That would have  easily have been the last thing he would have ever done (as a live human being).  — There has to be a good murder mystery plot involving a strobe light.  I’m sure one of the great writers at WordPress can come up with one.  I can think of a couple myself.

Anyway, when Ellis Rook told me how he fixed the telephone computer problems by rebooting the computer, this story flashed through my mind for about 3 seconds.  I think I put my hands in my back pocket just for safe keeping.

Anyway.  I ate lunch in the electric shop office with my ol’ “Roomie” Steven Trammell, (We have called each other roomie from the time we were in Muskogee on overhaul in 1984.  See the post about Muskogee in the link above.  To this day, we call each other roomie, as we have kept in touch throughout the years).  While I was sitting there arguing with Art Hammond about something (See the post:  “Power Plant Arguments with Arthur Hammond“) I was reading an instruction manual about some electronic sensor that could tell you the percentage open a series of valves all in one little box.

Reggie Deloney had been working with the engineer on this valve detecting device for the past 4 weeks, and couldn’t get it to work.  The engineer asked me if I would look at it to see if I could figure out what was wrong with it, because it wasn’t working at all…. It would work every now and then, but then it would stop.

When I read the manual I noticed that there was a “common” in the circuitry and that Reggie and the engineer had assumed that the common was the same as the “ground”.  This usually isn’t true in electronic circuits as it is in regular electrical wiring.  So, I stood up from where I was lounging back reading the pamphlet and lifted the common wire up so that it wasn’t touching the metal cart, and suddenly the valve indicator worked.

When Reggie returned from lunch, I excitedly told him what I had found.  He looked a little astonished, so I showed him.  He had only spent the last 4 weeks working on this.  So, I went into the shop and worked on another motor.

Later I walked into the office figuring that Reggie had told the good news to the engineer.  He was sitting there with the engineer scratching their heads still trying to figure out why the instrument still wasn’t working.  So, I picked up the wire so it wasn’t touching the cart, and said.  “See?  Works.”  Reggie with a very irritated voice said, “Yes!  You figured it out!”  He looked at me with a look that said, “Get out of here!”  So, I left.

Art, who was listening said, “I don’t think Reggie is ready to figure it out yet.”  Then I got it.  Oh.  I see…  It is nice and cool and clean in the office.  The engineer wasn’t going to figure it out on his own….   Just a week or so left of overhaul….

About that time, Bob Kennedy, my acting Foreman told me to go with Bill Thomas and help him out.  Bill was from our plant and was a welder.  He was working out of our shop to help us out with any mechanical needs we had from welding to uncoupling pumps and fans and realigning motors and any other stuff.  Now… I know that Bill Thomas had a nickname.  But I usually called people by their real names, so I only remember him as Bill Thomas.  Maybe a Power Plant Man reading this post will remind me of Bill’s nickname.

This is where Archimedes comes into the story.

So, Bill Thomas had been working on a cooling water fan structure all morning single-handed lifting it up.  It weighed somewhere between 50 to 75 tons.  um… yes…. I think that is about it… about 100,000 pounds.  yet, Bill using nothing but the muscles in his arms and back had been lifting this monstrosity off of the ground.  Like Archimedes who lifted an entire ship out of the water once using a lever.

Bill was lifting the top round part off of the ground so that he could work under it.

Bill was lifting the top round part off of the ground so that he could work under it.

You see.  With True Power Plant Men, you really don’t ever hear that something “can’t” be done.  Bill had to work under this large round hunk of metal, so he had to pick it up. After spending two hours lifting it with only his two arms spinning a huge chain-fall, he had managed to lift the structure 2 inches from the ground. — well.  No one said anything about tossing it in the air… just lifting it off the ground.  He still had about 22 inches more to go.

This is a 3 ton chain-fall. The one we were using was more than 10 times bigger

This is a 3 ton chain-fall. The one we were using was more than 10 times bigger

This was where I came in.  Did I tell you this plant was old?  Well it was.  They didn’t have a lot of electricity in this building we were in, and there wasn’t an electric hoist, so Bill had to pull a chain that went around a pulley that turned a shaft to a gearbox that would slowly (real slowly) lift something huge.  So, the Power Plant Men from this plant had created a “tool” to make this job faster.

Bill had pulled an air compressor over to the building and had hooked the air hose up to the special tool.

This is the exact size and type of air compressor

This is the exact size and type of air compressor

This was going to make his job much faster.  There was only once catch.  He needed an extra weight.  I was the extra weight that he needed.

You see.  The special tool was an air powered grinder.

An air powered grinder. Only the one we used was much bigger

An air powered grinder. Only the one we used was much bigger

And it was mounted to a piece of plywood.  the grinding wheel had been replaced with a pulley.  The idea was to stand on the plywood and step on the lever that operated the grinder so that it would spin the pulley.  The chain for the chain-fall would fit through the pulley assembly.

Bill had asked the person that gave him this special tool what happens when the chain snags.  They said, that’s when you need the extra weight.  They explained to Bill that when two people are standing on the plywood, they will be able to overpower the grinder so that it can’t pull itself out from under them.  If there isn’t enough weight on the plywood, then if the chain snags, the special tool will slide across the floor and attempt to climb up to the top of the chain-fall until someone lets off of the lever that operates the grinder.

So.  I was the extra weight.  Not that I was all that big at the time.

Anyway.  The next thing I knew, I was standing on the plywood, and Bill was operating the large grinder with his foot and we were lifting the large cylinder off of the ground.  Before long we had it at least a foot up.  Bill had put some stops under the cylinder in case we had to set it down for some reason, it wouldn’t have to go all the way to the ground.

That’s when it hit me….  No.  I didn’t suddenly remember that I hadn’t had any chocolate for lunch (though, that would have been a tragedy).  No.  That is when as I was watching the chain spin through the pulley at breakneck speed, the chain suddenly went taut.  As the chain became snagged in the chain-fall, the chain whipped up, and before I could perceive what had happened I found myself lifted off of the ground and being thrown backward.

The chain had flown back and slapped me across the face, sending my hardhat flying and shattering my safety glasses.  I ended up on my back about 5 feet from where I had been standing.  Bill rushed to my side to check if I was all right.  I checked myself out and decided that I was going to be all right.

I told him I needed to go get another pair of safety glasses from the tool room.  he looked at my eyes and said.  “Boy.  That is really going to be a shiner tomorrow.”  Evidently, I was developing a black eye.  I was thinking… “Great!  And I’m getting married in two days.  I can just see my wedding pictures.”  (I can see myself trying to explain to my children in the future that  – “No. Your mother didn’t sock me in the eye during the wedding”).

I went to the tool room and checked out a new pair of safety glasses:

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

The one on the bottom is the kind of safety glasses we had at the time

When I returned to the electric shop, Bill Thomas and Arthur were there.  Everyone was saying the same thing.  “Boy!  That is sure going to be a shiner tomorrow.”

A little while later, Ellis Rook came in the shop and said that Larry Hatley (the plant manager) wanted to talk to me.  So, I followed Ellis to the Plant Manager’s office.  Larry asked me if I was ok.  He wanted to know if I needed medical attention.  I assured him that I was all right.  My safety glasses had protected me.  They had been destroyed in the process, but I was just fine.  I think as I left I heard Larry say under his breath, “boy… that is going to be a shiner tomorrow.”

Well.  The next day (December 20, 1985)  when I showed up at work (my last day there for overhaul before leaving to be married the following day), everyone came around to look at my eye.  There wasn’t anything to see really.  Any swelling had gone down over the night, and my face was back to it’s regular… um…. tolerable self.

The people I worked with the fall of 1985 at Horseshoe Power Plant treated me like family while I was there.  That was the way it was when you worked with True Power Plant Men.  I cherish their memory.

Comment from original post:

  1. Ron Kilman June 22, 2013:

    Great story! The manager at HLS was Hatley (with a “t”). Larry and I were good friends. He had flown airplanes some (as had I) so we swapped piloting adventures, some of which were actually true. Larry was a good guy.

Sky Climbing in the Dark with Power Plant Boiler Rats

Originally Posted July 26, 2013:

I suppose everyone at some point in their life wishes they could work at Disney World or some other place where there is one wonder after another throughout their day. Working in the Power Plant was a lot like that…. sometimes….. I have mentioned a few times that when you drove through the gate to the coal-fired Power Plant in North Central Oklahoma each morning, you never knew what was in store for that day. It was often a surprise. Sometimes the surprise was a wonder. Sometimes it was well…. surreal.

This is a story about one day in October 1986 during an overhaul while I was a plant electrician, where I entered a world totally foreign to just about anything I had encountered before. You may think this is an odd statement if you have read some of my other posts where I have found myself in oddly dangerous situations and my life was in the balance. Well…. this is one of those stories, with a new twist.

As I said, we were on overhaul. This meant that one of the two units was offline and major repairs were taking place to fix things that can only be done when the unit isn’t running. The two major areas of repair are the Turbine Generator and the Boiler. People come from the other plants to help out and get paid a lot of overtime working long hours to complete this feat.

At this time I was working on motors in the electric shop. I had been removing the fan motors from the large General Electric Transformer for Unit 1. Changing their bearings and testing them. Then putting them back in place. The transformer had 24 of these motors, so after the first few, the work was becoming pretty routine.

A Main Power Transformer

A Main Power Transformer

Somewhere between the 11th or 12th motor David McClure came into the shop. I think he may have been on the labor crew at the time. He had only been working at the plant for about 8 months. He was a welder, so I think if he had been on labor crew, they had quickly moved him into the welding shop because anybody with welding skills were always in high demand.

David told me that Bill Bennett had told him to ask me to help out with a problem in the boiler. Now. when I was on the labor crew, I had been in the boiler during an overhaul. I had worked on shaking tubes in the reheat section and cleaning the clinkers out of the economizer section. You can read about these moments of mania in the posts: “Bob Lillibridge Meets the Boiler Ghost” and “Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back“.

During those times I knew that something was taking place in the superheat section of the boiler, but I wasn’t exactly sure what it was. You see, even when I was in the bottom ash hopper when it was being sandblasted, there was a wooden floor that had been put in above the hopper so that you couldn’t see the boiler overhead. This was the first time I was going to go into the boiler to actually work on something other than laying down the floor (which I had been lucky enough to do once when I was working on the labor crew).

Diagram of a boiler

Diagram of a boiler

So, I grabbed my tool bucket and David took me up to the main entrance into the boiler which was next to the door where Chuck Ross and Cleve Smith had been blown off of the landing by the Boiler Dragon six years earlier when I was a summer help (see the post: “Where Do Knights of the Past go to Fight Dragons Today?“). About 40 feet up from the concrete floor we climbed into the boiler.

This is where I first came face to face with Boiler Rats. These rats live in a boiler when it is taken offline. Shortly after the boiler is cooled down, these “boiler rats” move in and they spend the next 4 or 10 weeks (depending on the length of the overhaul), roaming around the boiler sniffing out boiler tubes that are in need of repair.

Some lights had been placed around the bottom of the boiler to shine up the 200 feet to the top of the boiler. That is the height of a 20 story building. Yes. That’s right. The inside of the boiler is as tall as a 20 story building. I couldn’t really see what was going on up there toward the top, but there was a boiler rat standing right there in the middle of the wooden floor staring at me with the grin (or snarl) that is typical of a rat. Not a cute rat like this:

Rat from the Movie Ratatouille

Rat from the Movie Ratatouille

Or even a normal rat like this:

Normal looking rat

Normal looking rat

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

rat from kootation

rat picture taken from kootation.com

Yep. Red eyes and all, only the whiskers were longer. I would go into how the boiler rats smelled, but I didn’t want to get too personal….

Anyway, this one boiler rat that had been waiting for me said that he had just finished rigging up this sky climber so that he could take me up into the upper reaches of the dark to work on a sky climber that was stuck. He had rigged this sky climber up so that it would pull up next to the one that was hung up by the bottom of the high pressure boiler tubes that were hanging out over the top of the boiler.

If you have ever seen Window washers going up and down the side of a building washing windows, then you know what a sky climber is.

A sky climber

A sky climber

You see, the boiler rats would ride these sky climbers up from the wooden floor to the boiler tubes hanging down from the ceiling of the boiler. One had stopped working and they needed an electrician to go up and fix it so that they could continue working. That was my job…. I carry a badge…. oh… wait… that’s Sergeant Friday on Dragnet… I carry a tool bucket that doubles as a trash can and triples as a stool.

So, I climbed into the sky climber and up we went. I could see faint lights up above me where boiler rats were working away cutting and welding boiler tubes. As we took off, one of the boiler rats said that a little while just before I had arrived, someone from above had dropped a tool that came flying down and stuck right into the wooden plank floor. It had landed about 10 feet from another boiler rat. This answered a question that I had for some time…. it turned out to be true… Boiler Rats do have Guardian Angels too.

Anyway, Up into the darkness we went. The boiler rat (I believe this one was called Rodney… as in Rodney Meeks) operated the sky climber as I just enjoyed the ride. Looking down, I saw the spot lights getting smaller and dimmer. Looking up, I saw us approaching a group of hanging boiler rats, all doing their stuff. Some were resting. Some were welding. Some were looking off into space in a daze after having been in the boiler for so long they had forgotten their name.

There were names for these rats. One was called T-Bone. Another was called ET. There was a guy there called Goosman. Another boiler rat was called Frazier. I think it was John Brien that was staring off into space at the time, or was it Butch Ellis. Oh. Now I remember. Butch was on one sky climber staring off into space at the other sky climber where John Brien was staring back at him.

There were many other boiler rats there from other plants. They were all hanging down from the top of the boiler on these sky climbers like fruit hanging from a tree in the dark. Most of them paid no attention to my arrival.

We pulled up to the sky climber that was broken. I swung over the couple of feet from the one climber to the other, with a straight drop of about 160 feet down to the floor. I looked below so that I could calculate that in case I slipped and fell, how I would try to swing my body just as I fell so as to miss any boiler rats below. I wouldn’t have wanted to upset any boiler rat families by falling on their boiler rat breadwinners.

By Swinging my tool bucket toward the other sky climber, I followed the momentum so that it carried me over to the other platform, where I swung my bucket over the railing and climbed in. Once settled, I took out my flashlight so that I could look around my new six or eight foot world.

I tried the controls, and sure enough… nothing happened. Remembering my dropped flashlight almost exactly three years earlier that had almost cost me my life (see post: “Angel of Death Passes By The Precipitator Door“), I took extra care not to drop any tools on some unsuspecting souls below.

I took out my multimeter and checked the voltage coming into the main junction box and found that the problem was in the connect where the cable came into the box. So, this turned out to be a fairly easy fix. The cord had been pulled by something (geez. It was only hanging down 200 feet. I don’t know what might have been pulling on it) and had worked its way out of the connections.

I told Rod that I would be able to fix this quickly and went to work removing the connector from the cable, cutting off the end and preparing it to be reconnected to the connector. It was about that time that I became aware of something that had been going on since I had arrived, I just hadn’t noticed it. Maybe it was a remark one of the boiler rats had said. I think it was Goosman talking to Opal. He said something like “That George Jones can sure sing.”

That was it. That was the extra amount of strangeness that I had been experiencing since I had arrived. Someone had a radio that was playing country music. The music was echoing throughout the boiler so that all the hanging boiler rats could listen to it. I realized that Butch and Brien weren’t just staring off into space at each other. They were experiencing a moment of country music meditational bliss. The moment the current song was over someone off in the distance that I couldn’t see in the dark or because they were stuck up inside a rack of boiler tubes, let out a hoot of satisfaction. Butch and Brien rose and went back to work.

I have heard that it takes a village to raise a child…. Hillary Clinton even wrote a children’s book with that title once. I experienced something similar but strangely different that day in October 1986. A village of raised boiler rats, who for a moment, it seemed, some had stopped to sit by the welder’s campfire to listen to the tales being woven by the country music singer on the radio.

There was a sincere camaraderie between these individual boiler rats. A culture had grown inside this boiler that was completely foreign to me. I suppose the same thing happens to soldiers who put their lives on the line to protect our country. When you are in a position where one wrong step and someone dies. You bond to those around you in a unique way.

I am grateful for my brief encounter with the boiler rats that day. They had invited me into their lair because they needed my help. I was glad to have been able to fix there problem and be quickly on my way.

Though I never had a desire to become a boiler rat myself, during the many years where I walked alone throughout the inside of the precipitator I would sometimes hear the sounds coming down through the economizer from the Superheat section of the boiler. Maybe a faint hint of country music. I knew that the boiler rat village had come together again like a group of nomads that meet every winter to share stories. Sometimes I would take the plate straightening tool I carried and banged on the plates wondering if any of them would hear me way back up in the boiler. I doubt anyone ever did.

Comment from previous post:

  1. A.D. Everard August 3, 2014

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

GE Geriatric Gentleman and Power Plant Transformers

Originally Posted May 17, 2013:

I remember the day when I walked into the Electric Shop office to begin the lunch break, and four guys from the T&D department (Transmission and Distribution) came in from the door leading to the Main Switchgear. They were obviously worn out, and were complaining. The first one said that he couldn’t believe that the guy from GE had made them work through morning break. The second guy called him a slave driver. The third guy replied that he couldn’t believe how that GE guy just kept on working from the crack of dawn without stopping all morning without even coming up for air. The fourth guy just collapsed on one of the chairs.

I remember the name of the last guy. His name was Foote. I remember him because he was real proud of his heritage. The first time I had met him, I asked him his name twice, because when he told me it was “Foote”, I wasn’t sure I heard correctly, so I asked him again. I guess that he must has guessed what was going through my mind because he must have had the same reaction from a thousand other people in the past. I figure that because my last name is Breazile (pronounced “Brazil”) and I have had many conversations with people explaining the origin of my name.

Anyway. I don’t remember Foote’s first name because I think he only had initials for his first name on his hard hat, and I’m more of a visual person when it comes to memories. I clearly remember his last. If I remember correctly, one of his ancestors was a naval officer in the Civil War, though, I don’t remember for which side. I guess it doesn’t really matter much now, since both sides were Americans, and both sides loved their country and the lives they knew — that they were fighting to hold onto or to change.

This reminds me of a side story that I must tell…. Years and years later in 1997, when I was on the Confined Space Rescue Team, one guy that was from North Dakota named Brent Kautzman was constantly being “harassed” for being a Yankee, because he came from a Northern State. This was kind of a mute (or is it “moot”) point to me, because I knew that North Dakota didn’t become a state until well after the Civil War.

Anyway, one day when Brent was trying to defend himself from the hardcore confederates of the group, he pointed out that the North won the Civil war. A couple of other members disagreed, claiming that the South was going to “rise again”. One of those that believed in the Confederate resurrection turned to me and asked me, as if I was the resident historian (well… I did have a college degree… and I did have a minor in History…. and I was known for telling the truth when it really came down to it), “Kevin…. Did the north win the Civil War?”

Not really wanting to hurt the feelings of my southern friends, and also wanting to stand by Brent who was really correct about the outcome of the Civil War, I replied with the following explanation: “Yes. The North must have won the war. Otherwise the South never would have let all the carpetbaggers from the North come down there and steal their property and their dignity.” Brent was satisfied, and the southerners had to agree with my logic. They still insisted that the South would rise again. I couldn’t argue with them about that…. It has never ceased to amaze me how bigotry can be passed down so easily.

With that said, I would say that the Power Plant Men that I worked with that believed that the “South would rise again!” didn’t really understand what that meant. I say that because they never would have given a thought that the men that they worked with that were African American such as Floyd Coburn, or Bill Bennett, were nothing less than members of their own families. I know that they each personally loved these men with all their hearts. I thought it was more of a nostalgic feeling than a desire to see the return of slavery or even the bigotry that crippled the southern states for decades after the Civil War.

End of the Side Story…. Back to the worn out T&D workers.

By the sound of it, I figured that this guy from GE (General Electric) that had come to work on one of the Main Auxiliary Transformers on Unit 2 that had a problem with the Tap Changing Mechanism, was some kind of slave driver. Some hard line guy that wanted to work our employees to the brink of exhaustion because he wanted to be done with the repairs as quickly as possible so that he could move on to some more important work. You see. For this job, GE had called on one of the top Main Power Transformer Geniuses in all the country to work on this transformer.

The T&D guys sat there for a while and then walked out into the shop to eat their lunch. Shortly after that, the slave driver from GE came in the back door…. In stepped a man that immediately reminded me of Arthur Fielder from the Boston Pops.

Arthur Fielder from Boston Pops

Arthur Fielder from Boston Pops

He sat down…. opened his brown paper bag. Pulled out his sandwich. Carefully unwrapped it and began to eat. Charles Foster and I were sitting there watching him. After hearing the horror stories from the T&D crew, I wasn’t sure if I wanted to engage this seemingly mad man in conversation, so I waited a while. I ate some cherry tomatoes and Banana peppers that Charles brought for me each day…. and with each bite, I took a bite out of my ham sandwich. Then I looked over at “Arthur Fielder….” (I don’t remember his real name).

Finally, I decided that this slave driver in sheep’s clothing (well, an old frail man costume really), might come up with some interesting conversation so I asked him…. “Say, old man…. how old are you anyway?” He looked up from the total enjoyment of his sandwich, and with food still un-swallowed said, “I’m 83.”

“83?” — Either I said that or Charles did… because we were both stunned by his answer….. “Yep… They called me out of retirement to work on this transformer. Seems I’m the only one that knows how to fix ’em. But I’m teachin’ your fellows how to do it so they don’t have to call me again.”

Charles and I were so flabbergasted by his reply that we couldn’t leave it alone. One of us (Charles and I were always on the same wavelength, so usually when one of us spoke, it was what we were both thinking)… So, one of us asked…. “You’re retired and they called you up to work on this transformer!?!? Are you such a Transformer guru that you were the only one they could send?” (hmm… must have been me…. I don’t think Charles would have used the word “Guru”. He would have used something like “expert” or “talented” or maybe “genius”). He said, “Yep. They paid me enough that I agreed to take a week away from my wife to come here to take care of business. It would have to take a lot to take me away from my Jenny.”

Then this feeble old man with the white moustache explained that he didn’t like to be away from home. Every night since when he was young he has played the piano for two hours. — Wait… I wasn’t sure if I heard that right, so I asked him…. “What? You play the piano for two hours… every night!?!?” (notice… already I have used “!?!?” twice in one post… just goes to show you how surprised I was to run across this man). He reaffirmed what he said, “Yeah. I had to find a hotel that had a piano, so I could sit in the lobby and play it before I go to bed. I can’t sleep well unless I have played the piano first.

After that, he began to tell us about his career in the Music Industry. He had played for many Big Band orchestras in the past. He talked about playing with Tommy Dorsey and Benny Goodman. Names that I had learned from my Aunt Pam Sorisso in Kansas City that gave me an Eight Track Tape of Big Band music when I was in College that I used to listen to often. I had become a fan of Big Band and had a great respect for these Big Band Leaders.

Benny Goodman

Benny Goodman

Tommy Dorsey

Tommy Dorsey

Here sitting in front of me was one of the geniuses of the Big Band era in the electric shop at a Coal-fired Power Plant in the middle of North Central Oklahoma. All I could think of was, “Who woulda thought it?” Though I was impressed as all get out… I tried to act calm….. I wanted to jump up with a piece of paper and ask him for his autograph….

This old guy suddenly had all my respect. It cracked me up to think that this 83 year old man was out performing the younger T&D workers. He was running them ragged. He explained that he didn’t like to stop for break. It made the day go a lot faster if he just kept working until he had to stop. He wouldn’t have stop for lunch if all the workers hadn’t just dropped all their tools and left.

It amazed me even more that this man who was a big band musician of the highest caliber had ended up working for GE Not only had he worked for GE, but he had become the ultimate authority in large transformer repair. I mean…. How cool is that?

I can’t tell you how much I instantly fell in love with this guy. He had talked and talked about his days as a big band piano player. What really came out of his conversation what just how much he loved his wife. The two things he loved in the entire world was his wife and to play the piano. He said there was nothing more soothing than playing the piano. As he walked off to go back to work at the end of lunch… the only thing I could think of was one of my Big Band favorites…. Louis Armstrong….

For those people who stopped to really think about it…. This truly is….. A Wonderful World!

Comment from the Original Post

Ron Kilman May 18, 2013:

  1. Great story. I met a lot of really neat guys at the Power Plant – experts in their fields – bladers, winders, crack-checkers, boiler gurus, balancers, . . . I remember making a factory “balance expert” really mad. He was sent to balance the Buffalo Forge FD fans at Seminole. He was the “lead” and I was just “checking” him. We used a modern IRD balance analyzer with a Teflon shaft rider and he used a pencil! When we both had taken our “readings” we shut the fan down. When it coasted to a stop, he began yelling “My marks – my marks – you wiped out my marks!” (with a German accent). On the next balance run, I took my readings first, then he put his pencil marks on the rotating fan shaft. We got the fan smooth. He was a cool guy, but used 19th century “technology”. I never asked him if he played the piano too.

Moon Walk in a Power Plant Precipitator

Originally Posted May 25, 2013;

Just because there isn’t any smoke pouring out of the smoke stacks at a Coal-fired Power Plant, it doesn’t mean that the plant is offline.  The power plant where I worked as an electrician in north central Oklahoma had two large Buell (later GE) electrostatic precipitators.  This is what takes the smoke out of the exhaust.  The smoke is referred to as “Fly Ash”.  The electrostatic precipitator when running efficiently should take out 99.98% of the ash in the exhaust.  When running with excellent efficiency, the exhaust can have less ash than dust in the air (or 99.999%).

Sonny Kendrick, the electric specialist and Bill Rivers an electronics whiz were my mentors when I joined the electric shop.  These two Power Plant Men taught me how to maintain the precipitator.  I wrote about the interaction between these two men in the post:  Resistance in a Coal-Fired Power Plant.  It is funny to think, 30 years later that the skills they were teaching me would determine my career for the next 18 years.  You see….. I later became the Precipitator guru of the power plant.  I once thought it was sort of a curse to become good at one thing, because then you were kind of expected to do that the rest of your life.

When I first joined the electric shop and they were deciding who was going to fix all the manhole pumps, the electrical A Foreman replied by saying, “Let Kevin do it.  He likes to get dirty.”  At that point… I think I understood why they really wanted me in the electric shop.  Charles Foster had mentioned to me when I was a janitor and he had asked me if I would consider being an electrician because I cleaned things so well, and a lot of being a Power Plant electrician involved cleaning…  Now those words took on their full meaning.

I knew I was destined to work on the precipitator from the beginning.  Sonny had been banished to work on only the precipitator, as Bill Rivers had made clear to me when I was still a janitor (see the power plant post:  Singin’ Along with Sonny Kendrick).  I was his chance to be lifted from the curse that had been placed on him by our Electrical Supervisor, Leroy Godfrey.  I had accepted that.  I knew that I would eventually be the one to maintain the precipitators from day one.

So, here I was…  One month before becoming an electrician, I had a near death experience inside the precipitator (See the post:  Angel of Death Passes by the Precipitator Door).  Now I was going into the precipitator again with Bill Rivers.  I think at that time we were just wearing half-faced respirators and no fly ash suit.  Just a rain suit.

A man wearing a half faced respirator -- not me... just an image I found on Google Images

A man wearing a half faced respirator — not me… just an image I found on Google Images

Not a lot of protection….

I followed Bill Rivers into the precipitator while it was offline for overhaul.  I had my flashlight securely strapped around my neck with a string.  I had  a small notepad with a pen tied to it also around my neck for taking notes.

A notepad like this

A notepad like this

So, as Bill entered the dark cavern of the precipitator, I found that we had just entered a new world.  It was dark… Like the dark side of the moon.  We were at the intake of the precipitator and we were walking on top of the ash as it was more like sand at this point.  We just left footprints where we only sank about 2 inches into the pile of ash that had built up there.

Bill took his flashlight and shined it up between two sets of plates that are exactly 9 inches apart.  He swung the light up toward the top of the precipitator 70 feet above.  At first as the light was reflecting on all the white ash, I was blinded to the detail that Bill was trying to show me.  Eventually I realized that he was pointing his flashlight at a clip.  There was some kind of a clip that held one plate in line with the next.

Once I had confirmed to Bill that I saw where he was looking, he lowered the flashlight to about 45 feet above us, where there was another clip.  Then even lower.  About 10 feet above us.  A third clip.  — Now at this point… I was almost ready to resign myself to another lesson like the one I had learned from Ken Conrad as he had poured his heart and soul into his description of how to lay the irrigation hose and position the water gun 3 years earlier (See, “When a Power Plant Man Talks, It pays to Listen“),  then I remembered…. “I know this is boring… but you have to learn it….”  A Phrase that I made good use of 15 years later when I was teaching switching to a group of True Power Plant Men that would find themselves equally bored with the necessary material they had to learn.

Bill explained….. Each clip must (and he emphasized “Must’) be aligned with the next plate.  Every clip must be in their place.  Don’t start up this precipitator until this is so.  Ok.  I understood…. Let’s see… there are three clips between each of the four plates… or 9 clips per row…. and there were 44 rows of plates for each section…. and there were 6 sections across the precipitator, and  7 sections…. hmmm… that added up to oh… only 16,632 clips that I needed to check during each overhaul… ok… I took a note on my notepad…

Bill explained….. Clean each insulator.  there is one on the side of each bottle rack holding all the wires in place.There were only 4 for each 2 hoppers.  there were 84 hoppers,   Great.  Only 168 insulators on the bottle racks….  Then he pointed out that there were also insulators on the precipitator roof.  two on each section over each pair of hoppers… One on the tension hosue on one connected to the transformer, or 336 more… making a total of 504 insulators that need to be inspected and cleaned during each overhaul.

Bill explained…. you need to check each of the wires to make sure they aren’t caught on a clip or broken.  Let’s see…. there were 44 rows of wires in each section… with 16 wires in each row…. and there were 6 sections across each set of hoppers…. that came out to exactly 29568 wires that needed to be inspected during each overhaul.

Bill explained…. each rapper on the roof needs to be tested to make sure they are rapping with the correct force.  That meant that they each needed to lift at least 6 inches before they dropped the 15 pound slug (to knock the ash off of the plates into the hoppers below.  Hmm… For each 4 hoppers, there were 6 rows of 12 rappers each.  There were two sets across the precipitator and there were 7 sets of rappers.  In other words…. there were 672 rappers on the roof of the precipitator.

Bill explained…. each vibrator on the roof needs to be calibrated to provide the maximum vibration to the wires inside the precipitator in order to make sure they cleaned the wires of any ash buildup as they are responsible for delivering the static electricity to the precipitator that collects the ash on the plates.  In order to calibrate them, you had to adjust the gap between the main bracket and the magnetic coil to within a few thousands of an inch… I don’t remember the exact setting now… but we used a set of shims to set them correctly.  There were 12 vibrators for each of the two sides of each of the seven sections of hoppers.   This came out to 168 vibrators that need to be adjusted during each overhaul.  Oh.  And each vibrator had an insulator connected to the wire rack…adding 168 more insulators.

So, we had 16,632 clips, 672 insulators, 29568 wires, 672 rappers and 168 vibrators that all needed to be in good working order at the end of each overhaul (on each of the two units).  Throughout the years that I worked inspecting, adjusting and wrestling with plates, clips and wires, I became personally attached to each wire, insulator, clip, rapper and vibrator. For a number of my 18 years as an electrician, I was the only person that entered the precipitator to inspect the plates, wires, clips and internal insulators.  Some of my closest friends were precipitator components.  Each diligently performing their tasks of cleaning the environment so that millions of people wouldn’t have to breathe the toxins embedded in the ash particles.

We hired contractors to go into the precipitator to help me.  I would spend an entire day teaching them how to wear their full face respirator and fly ash suit…. How to inspect the clips and wires…. how to walk along the narrow beams along the edge of each row of 84 hoppers on each unit to find and repair the things that were not in proper alignment.  I would check out all their equipment and give them their safety training only to have them not show up for work the next day.

Contractors would gladly be paid to weld in the boiler hanging from a sky climber in the middle of space 200 feet above the bottom ash hopper, but give them one day in the precipitator and they would rather be thumbing a ride to Texas….  I should have felt insulted… after all this was my home…. Mark Fielder the head of the welders once called it my “baby”.  I knew he had never had to endure the walk on the moon when you entered the tail end of the precipitator and found yourself buried waste deep in light fly ash.  I told Mark Fielder to not call the precipitator my baby…  Not until he could find a contractor that was willing to work alongside me inside it.  He apologized.  He explained that he meant it with affection.

At the back end of the precipitator, you just sank to the bottom of a pile of fly ash when you stepped into it.  The fly ash particles there are less than 2 microns in diameter.  That meant that they would infiltrate your filter and bounce around inside your respirator on their way down into your lungs.  Building up a permanent wall of silicon in your innards that will be there until the day you die.

I noticed that after a few days of working in the precipitator that I would feel like I had the flu.  This would happen after I would smell this certain scent in the precipitator that would develop after the unit had been offline for a week or so.  I noticed that when I burped, I could taste that smell in my mouth.  I also noticed that if I had to pass some gas, that the smell would also include the smell that I was experiencing in the precipitator.

I didn’t think much about it until one day when I went to the tool room and Bud Schoonover told me that they were out of the regular hepa-filters for my respirator.  So, instead he gave me a pair of organic filters.  They had a different carbon filter that absorbed organic particles.  I said, “Thanks Bud.” and I headed out to climb into the precipitator to continue my inspection of some 30,000 wires, and 16,000 clips.

To my astonishment, when I used the carbon filters right away, I didn’t smell the acrid smell.  The flu symptoms went away, as well as the smelly burping flavors.  Not to mention (oh.. but I am) the passing of gas without the additional smell of precipitator internals….  Crazy as these seems… I became obsessed with finding out why.

You see… at the same time that this particular smell arose in the precipitator, any ash that was built up on the plates would clump up and with a simple bang on the plates with a rubber mallet would cause all the ash to fall off leaving a perfectly clean plate.  Before this smell was there, you could bang on the plates all day, and the ash would remain stuck to the plates like chalk on a chalkboard.

I had our famous chemist (well…. he was famous to me… see the post:  A Power Plant Doctor Does a Jig in a Puddle of Acid), come out to the precipitator to give it a whiff.  He said it had some kind of  a sewer smell to it…. I didn’t expand on my personal sewer experience I had had with it, though I did tell him about the burping….

He encouraged me to have the safety department come out and test it to see if they could identify the chemical that was causing this smell.  You see…. It was important to me because if we could pin this down, then we might be able to inject a substance into the precipitator while it was online to clean it without having to bring the unit offline if the precipitator was to become fouled up.

There was a young lady from the safety department (I think her name was Julia, but I can’t remember her full name).  She came from Oklahoma City and gave me some monitors to put in the precipitator while the smell was present to try to track down the chemical.  Unfortunately, we never found out what it was.  In the meantime, I had learned all I could about Van Der Waals forces.  This is the week molecular force that would cause the ash to stick to the plate.

I studied the chemical makeup of the ash to see if I could identify what chemical reactions could take place… Unfortunately, though I knew the chemical makeup of the ash, the chemicals were bound in such a way from the high temperatures of the boiler, that I couldn’t tell exactly how they were arranged without the use of  an electron microscope.  I wasn’t about to go to Ron Kilman (who was the plant manager at the time) and ask him for one.  I had already upset him with another matter as you will learn in a much later post.

So, I just continued wearing the organic filters.  This gave me the strength to continue my inspections without the flu-like symptoms.  Later on, I taught Charles Foster and Scott Hubbard how to maintain the precipitator.  When I finally left in 2001, I know I left the precipitators in competent hands.  They knew everything I did.

One main lesson I learned from my experience as the precipitator guru is this….. You can be a genius like Bill Rivers or Sonny Kendrick….. when you are given a particular job to do and you do it well, you are usually pigeon-holed into that job.  One of the main reasons I write about Power Plant Men is because they are for the most part a group of geniuses. At least they were at the plant where I worked in North Central Oklahoma.  They just happened to stumble onto the jobs that they had.  They would probably spend the rest of their working career doing what they did best…. never moving onto something where their genius would shine and others would know about them… That is why I write about them.

Do a job well, and you will be doing it until the day you die…. that’s what it seemed to be.  I didn’t feel like I was banished to the precipitator as Sonny Kendrick was by Leroy Godfrey, who did it consciously.  No.  I was “banished” to the precipitator for the next 18 years because I was good at it.  I loved it.   I may have mentioned before, but I had a personal relationship with the 168 precipitator control cabinets.

I had carefully re-written the programs on each of the eprom chips on the Central Processing Unit in each cabinet to fit the personality of each section of the precipitator.  I had spend hours and hours standing in front of each cabinet talking to them.  Coaxing them.  Telling them that they could do it with my handheld programmer in hand…. helping them along by adjusting their programming ever so slightly to give them the freedom that they needed to do their job.  If they had been human……. I would have given them names like “Mark”, or “Thomas”, or “Millie”.  Instead, I knew them as 2E11 or 1B7.  But they were each my friends in their own way.

You see… I look at friends like this…. It’s not what they can do for me…. It’s “what can I do for them?”  I have had some precipitator cabinets that I have given extra attention because they seemed to need it more than the others, only to have them crap out on me.  I wouldn’t have done anything different if I had known all along that they wouldn’t pull through.

I have my own understanding of who I should be.  My wife may call it “stubbornness”, and that may be what it is.  I would try and try to coax a control cabinet to do what it was created to do, only to have it fail over and over again….  What was I going to do?  Give up?  How could I do that to a friend?  I would tell the cabinets that were especially difficult (when I was alone with them – which was usually), “You create your own Karma.  That isn’t going to change who I am.”

Today I am called an IT Business Analyst.  I work for Dell  Computers.  It is an honor to work for a company that serves the entire world.  I see the same pattern.  When you do something well, when you love your work and become attached to it, you become pigeon-holed into a particular job.  You become invaluable.  Almost unreplaceable.  People look to you for answers.  They are comforted to know that someone who cares is taking care of business.  I am glad to be able to serve them.

Weeks before I left the power plant, Bill Green, the plant manager asked Jim Arnold (the supervisor over maintenance) again….. “What degree is Kevin getting again?”  Arnold replied, “Oh.  nothing anyone wants.”  (an MIS degree from the college of business at Oklahoma State University). Bill was concerned that if I left they wouldn’t have anyone to take care of the precipitators.  No.  I wouldn’t do that.  Like I said… Each of the 168 precipitator control cabinets were my friends…. I had given them the best guardians I could find… Scott Hubbard and Charles Foster.

Scott Hubbard

Charles Foster

Recently Charles Foster has retired from the plant, and his health is not good.  His son, Tim Foster has taken his place.  One of the last things Tim has told me recently was that he was going with Scott Hubbard to work on the precipitator.  I wanted to reply back to his e-mail… take care of my friends Tim….  I know Scott understands….

Each clip, each wire… I often dream about them….  Row after row….. looking 70 feet up, then down… swinging my flashlight in the darkness.   Betty, Tom, Martin…. all the clips on this plate are in their place…. Sandy, David, Sarah… lined up correctly…  Fred, Chuck, Bill…. good… good…  next row….

A Slap in the Face at a Gas-fired Power Plant

Originally posted June 21, 2013:

Archimedes once said, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world.”  Thanks to my high school math teacher Robert Burns, I have always admired Archimedes.  I remember the day he was talking about him in class, and he was explaining how Archimedes had sat down in the bathtub and when the water overflowed, and he suddenly realized how to calculate the volume of the king’s crown, he jumped out of the tub and ran down the street in his birthday suit yelling “Eureka!  Eureka!”  Meaning… I have found it!  I have found it!  I especially remember Mr. Burn’s eyes tearing up as he told this story.  To Mr. Burns, mathematics was an adventure.  He instilled this love into me.

So, how does a discussion about Archimedes tie into a story about a Gas-fired Power Plant in central Oklahoma?  Well it does, or it did, on December 19, 1985.

The day began with my drive from Oklahoma City, where I was staying, to Harrah, Oklahoma where I was on overhaul at a power plant called Horseshoe Lake Plant.  The lake must have been named Horseshoe Lake for the obvious reason that it was shaped like a Horseshoe as it wrapped around the north part of the plant.

I suppose this lake was originally used to cool the condenser water once the steam had been used to turn the turbine, but it was much too small to be used by the units that were in operation when I was at the plant.  Instead it was a Fish farm where Tilapia were raised.

A Power Plant Tilapia

A Power Plant Tilapia

I wrote about working at this plant on this overhaul in an earlier post called “Bobbin’ Along with Bob Kennedy“.  This morning when I arrived, I figured I would be working in the shop repairing more of the older open-faced motors with their sleeve bearing and cambric insulation.  It started out that way.

An example of an old GE open-faced motor

An example of an old GE open-faced motor

One time during the morning, Ellis Rook, the electrical Supervisor came up to me and started talking to me about the ROLM phone computer.  He knew I had experience working on the Phone system.  I had been trained by the best even before I had gone to Muskogee to take a class.  Bill Rivers at our plant had taught me how to make “moves and changes” and how to troubleshoot the entire plant’s phone system without ever leaving the lab.

A ROLM Phone Computer

A ROLM Phone Computer

Anyway.  Ellis Rook told me about the problem they were having with the phone system that day.  He told me what had been done to try to fix the problem.  I was thinking of a few things I would try (even though I was still more of a Rookie than Ellis Rook — ok.  I couldn’t resist that one).  I had been an electrician in training for just over 2 years, which still made me a rookie.

I originally thought Ellis had approached me for ideas on how to fix the problem, so I was formulating some answers in my mind while he was going on… then he said, “What I do every time to fix any problem is just reboot the computer.” — ok.  He wasn’t seeking advice.  He was seeking approval.  So, I looked at him with as blank of a stare I could and just nodded and replied, “Well, that usually does it.”  — Nevermind that it took about 25 minutes for one of these old ROLM computers to reboot and during that time all communication with the outside world was cut-off.

This was when I remembered a story that Bob Kennedy had told me about Ellis Rook.

One day, he took another electrician with him to inspect the exciter collector rings on one of the units.  The exciter is connected to one end of the generator usually (though if I’m not mistaken, the exciter house was off to one side), and it spins at 3600 rpm.  It is not coincidental that this is 60 cycles per second, which is how fast the electricity alternates between positive and negative in your house.  This is exactly why the electricity alternates that fast.  Because that is how fast the turbine-generator is spinning.

Anyway, Ellis had taken a strobe light with him to go inspect the collector rings on the exciter because there was some indication that a fuse had blown on one of the collectors.  Using the strobe light, you could set it to blink at 3600 times per minute and the collector rings spinning at 3600 rpm would appear to stand still.

A typical strobe light

A typical strobe light

By slowly adjusting the rate that the strobe light was flashing, you could rotate the shaft slowly and inspect it just as if it was standing still, even though in reality it was still spinning at 3600 rpms (the same speed as the lawn mower in the post:  “Something is in the Water at the Muskogee Power Plant“).

After examining the shaft for a bit, they located the blown fuse.  When the fuse blew, a little indicator would stick out so it could easily be seen.  Ellis Rook slowly rotated the shaft around until the fuse was in a good position and then stopped the shaft from rotating by setting the strobe light to the exact same rate that the shaft was rotating.

Then Ellis said something that would go down in the Annals of History at Horseshoe Lake.  He told the electrician to change out the fuse.  —  Ok.  Stop and think about this for a minute.  The room where the collector rings are is normally dark, so all they can see is this turbine shaft in front of them and it looked like it was standing still.  Forget the roar of the spinning turbine and just chalk it up to a loud fan running.

Luckily the electrician wasn’t lulled into a false sense of security and didn’t put his hand forward to remove the fuse.  That would have  easily have been the last thing he would have ever done (as a live human being).  — There has to be a good murder mystery plot involving a strobe light.  I’m sure one of the great writers at WordPress can come up with one.  I can think of a couple myself.

Anyway, when Ellis Rook told me how he fixed the telephone computer problems by rebooting the computer, this story flashed through my mind for about 3 seconds.  I think I put my hands in my back pocket just for safe keeping.

Anyway.  I ate lunch in the electric shop office with my ol’ “Roomie” Steven Trammell, (We have called each other roomie from the time we were in Muskogee on overhaul in 1984.  See the post about Muskogee in the link above.  To this day, we call each other roomie, as we have kept in touch throughout the years).  While I was sitting there arguing with Art Hammond about something (See the post:  “Power Plant Arguments with Arthur Hammond“) I was reading an instruction manual about some electronic sensor that could tell you the percentage open a series of valves all in one little box.

Reggie Deloney had been working with the engineer on this valve detecting device for the past 4 weeks, and couldn’t get it to work.  The engineer asked me if I would look at it to see if I could figure out what was wrong with it, because it wasn’t working at all…. It would work every now and then, but then it would stop.

When I read the manual I noticed that there was a “common” in the circuitry and that Reggie and the engineer had assumed that the common was the same as the “ground”.  This usually isn’t true in electronic circuits as it is in regular electrical wiring.  So, I stood up from where I was lounging back reading the pamplet and lifted the common wire up so that it wasn’t touching the metal cart, and suddenly the valve indicator worked.

When Reggie returned from lunch, I excitedly told him what I had found.  He looked a little astonished, so I showed him.  He had only spent the last 4 weeks working on this.  So, I went into the shop and worked on another motor.

Later I walked into the office figuring that Reggie had told the good news to the engineer.  He was sitting there with the engineer scratching their heads still trying to figure out why the instrument still wasn’t working.  So, I picked up the wire so it wasn’t touching the cart, and said.  “See?  Works.”  Reggie with a very irritated voice said, “Yes!  You figured it out!”  He looked at me with a look that said, “Get out of here!”  So, I left.

Art, who was listening said, “I don’t think Reggie is ready to figure it out yet.”  Then I got it.  Oh.  I see…  It is nice and cool and clean in the office.  The engineer wasn’t going to figure it out on his own….   Just a week or so left of overhaul….

About that time, Bob Kennedy, my acting A Foreman told me to go with Bill Thomas and help him out.  Bill was from our plant and was a welder.  He was working out of our shop to help us out with any mechanical needs we had from welding to uncoupling pumps and fans and realigning motors and any other stuff.  Now… I know that Bill Thomas had a nickname.  But I usually called people by their real names, so I only remember him as Bill Thomas.  Maybe a Power Plant Man reading this post will remind me of Bill’s nickname.

This is where Archimedes comes into the story.

So, Bill Thomas had been working on a cooling water fan structure all morning single-handed lifting it up.  It weighed somewhere between 50 to 75 tons.  um… yes…. I think that is about it… about 100,000 pounds.  yet, Bill using nothing but the muscles in his arms and back had been lifting this monstrosity off of the ground.  Like Archimedes who lifted an entire ship out of the water once using a lever.

Bill was lifting the top round part off of the ground so that he could work under it.

Bill was lifting the top round part off of the ground so that he could work under it.

You see.  With True Power Plant Men, you really don’t ever hear that something “can’t” be done.  Bill had to work under this large round hunk of metal, so he had to pick it up. After spending two hours lifting it with only his two arms spinning a huge chain-fall, he had managed to lift the structure 2 inches from the ground. — well.  No one said anything about tossing it in the air… just lifting it off the ground.  He still had about 22 inches more to go.

This is a 3 ton chain-fall.  The one we were using was more than 10 times bigger

This is a 3 ton chain-fall. The one we were using was more than 10 times bigger

This was where I came in.  Did I tell you this plant was old?  Well it was.  They didn’t have a lot of electricity in this building we were in, and there wasn’t an electric hoist, so Bill had to pull a chain that went around a pulley that turned a shaft to a gearbox that would slowly (real slowly) lift something huge.  So, the Power Plant Men from this plant had created a “tool” to make this job faster.

Bill had pulled an air compressor over to the building and had hooked the air hose up to the special tool.

This is the exact size and type of air compressor

This is the exact size and type of air compressor

This was going to make his job much faster.  There was only once catch.  He needed an extra weight.  I was the extra weight that he needed.

You see.  The special tool was an air powered grinder.

An air powered grinder.  Only the one we used was much bigger

An air powered grinder. Only the one we used was much bigger

And it was mounted to a piece of plywood.  the grinding wheel had been replaced with a pulley.  The idea was to stand on the plywood and step on the lever that operated the grinder so that it would spin the pulley.  The chain for the chain-fall would fit through the pulley assembly.

Bill had asked the person that gave him this special tool what happens when the chain snags.  They said, that’s when you need the extra weight.  They explained to Bill that when two people are standing on the plywood, they will be able to overpower the grinder so that it can’t pull itself out from under them.  If there isn’t enough weight on the plywood, then if the chain snags, the special tool will slide across the floor and attempt to climb up to the top of the chain-fall until someone lets off of the lever that operates the grinder.

So.  I was the extra weight.  Not that I was all that big at the time.

Anyway.  The next thing I knew, I was standing on the plywood, and Bill was operating the large grinder with his foot and we were lifting the large cylinder off of the ground.  Before long we had it at least a foot up.  Bill had put some stops under the cylinder in case we had to set it down for some reason, it wouldn’t have to go all the way to the ground.

That’s when it hit me….  No.  I didn’t suddenly remember that I hadn’t had any chocolate for lunch (though, that would have been a tragedy).  No.  That is when as I was watching the chain spin through the pulley at breakneck speed, the chain suddenly went taut.  As the chain became snagged in the chain-fall, the chain whipped up, and before I could perceive what had happened I found myself lifted off of the ground and being thrown backward.

The chain had flown back and slapped me across the face, sending my hardhat flying and shattering my safety glasses.  I ended up on my back about 5 feet from where I had been standing.  Bill rushed to my side to check if I was all right.  I checked myself out and decided that I was going to be all right.

I told him I needed to go get another pair of safety glasses from the tool room.  he looked at my eyes and said.  “Boy.  That is really going to be a shiner tomorrow.”  Evidently, I was developing a black eye.  I was thinking… “Great!  And I’m getting married in two days.  I can just see my wedding pictures.”  (I can see myself trying to explain to my children in the future that  – “No. Your mother didn’t sock me in the eye during the wedding”).

I went to the tool room and checked out a new pair of safety glasses:

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

The one on the bottom is the kind of safety glasses we had at the time

When I returned to the electric shop, Bill Thomas and Arthur were there.  Everyone was saying the same thing.  “Boy!  That is sure going to be a shiner tomorrow.”

A little while later, Ellis Rook came in the shop and said that Larry Hatley (the plant manager) wanted to talk to me.  So, I followed Ellis to the Plant Manager’s office.  Larry asked me if I was ok.  He wanted to know if I needed medical attention.  I assured him that I was all right.  My safety glasses had protected me.  They had been destroyed in the process, but I was just fine.  I think as I left I heard Larry say under his breath, “boy… that is going to be a shiner tomorrow.”

Well.  The next day (December 20, 1985)  when I showed up at work (my last day there for overhaul before leaving to be married the following day), everyone came around to look at my eye.  There wasn’t anything to see really.  Any swelling had gone down over the night, and my face was back to it’s regular… um…. tolerable self.

The people I worked with the fall of 1985 at Horseshoe Power Plant treated me like family while I was there.  That was the way it was when you worked with True Power Plant Men.  I cherish their memory.

Comment from original post:

  1. Ron Kilman June 22, 2013:

    Great story! The manager at HLS was Hatley (with a “t”). Larry and I were good friends. He had flown airplanes some (as had I) so we swapped piloting adventures, some of which were actually true. Larry was a good guy.

Sky Climbing in the Dark with Power Plant Boiler Rats

Originally Posted July 26, 2013:

I suppose everyone at some point in their life wishes they could work at Disney World or some other place where there is one wonder after another throughout their day. Working in the Power Plant was a lot like that…. sometimes….. I have mentioned a few times that when you drove through the gate to the coal-fired Power Plant in North Central Oklahoma each morning, you never knew what was in store for that day. It was often a surprise. Sometimes the surprise was a wonder. Sometimes it was well…. surreal.

This is a story about one day in October 1986 during an overhaul while I was a plant electrician, where I entered a world totally foreign to just about anything I had encountered before. You may think this is an odd statement if you have read some of my other posts where I have found myself in oddly dangerous situations and my life was in the balance. Well…. this is one of those stories, with a new twist.

As I said, we were on overhaul. This meant that one of the two units was offline and major repairs were taking place to fix things that can only be done when the unit isn’t running. The two major areas of repair are the Turbine Generator and the Boiler. People come from the other plants to help out and get paid a lot of overtime working long hours to complete this feat.

At this time I was working on motors in the electric shop. I had been removing the fan motors from the large General Electric Transformer for Unit 1. Changing their bearings and testing them. Then putting them back in place. The transformer had 24 of these motors, so after the first few, the work was becoming pretty routine.

A Main Power Transformer

A Main Power Transformer

Somewhere between the 11th or 12th motor David McClure came into the shop. I think he may have been on the labor crew at the time. He had only been working at the plant for about 8 months. He was a welder, so I think if he had been on labor crew, they had quickly moved him into the welding shop because anybody with welding skills were always in high demand.

David told me that Bill Bennett had told him to ask me to help out with a problem in the boiler. Now. when I was on the labor crew, I had been in the boiler during an overhaul. I had worked on shaking tubes in the reheat section and cleaning the clinkers out of the economizer section. You can read about these moments of mania in the posts: “Bob Lillibridge Meets the Boiler Ghost” and “Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back“.

During those times I knew that something was taking place in the superheat section of the boiler, but I wasn’t exactly sure what it was. You see, even when I was in the bottom ash hopper when it was being sandblasted, there was a wooden floor that had been put in above the hopper so that you couldn’t see the boiler overhead. This was the first time I was going to go into the boiler to actually work on something other than laying down the floor (which I had been lucky enough to do once when I was working on the labor crew).

Diagram of a boiler

Diagram of a boiler

So, I grabbed my tool bucket and David took me up to the main entrance into the boiler which was next to the door where Chuck Ross and Cleve Smith had been blown off of the landing by the Boiler Dragon six years earlier when I was a summer help (see the post: “Where Do Knights of the Past go to Fight Dragons Today?“). About 40 feet up from the concrete floor we climbed into the boiler.

This is where I first came face to face with Boiler Rats. These rats live in a boiler when it is taken offline. Shortly after the boiler is cooled down, these “boiler rats” move in and they spend the next 4 or 10 weeks (depending on the length of the overhaul), roaming around the boiler sniffing out boiler tubes that are in need of repair.

Some lights had been placed around the bottom of the boiler to shine up the 200 feet to the top of the boiler. That is the height of a 20 story building. Yes. That’s right. The inside of the boiler is as tall as a 20 story building. I couldn’t really see what was going on up there toward the top, but there was a boiler rat standing right there in the middle of the wooden floor staring at me with the grin (or snarl) that is typical of a rat. Not a cute rat like this:

Rat from the Movie Ratatouille

Rat from the Movie Ratatouille

Or even a normal rat like this:

Normal looking rat

Normal looking rat

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

rat from kootation

rat picture taken from kootation.com

Yep. Red eyes and all, only the whiskers were longer. I would go into how the boiler rats smelled, but I didn’t want to get too personal….

Anyway, this one boiler rat that had been waiting for me said that he had just finished rigging up this sky climber so that he could take me up into the upper reaches of the dark to work on a sky climber that was stuck. He had rigged this sky climber up so that it would pull up next to the one that was hung up by the bottom of the high pressure boiler tubes that were hanging out over the top of the boiler.

If you have ever seen Window washers going up and down the side of a building washing windows, then you know what a sky climber is.

A sky climber

A sky climber

You see, the boiler rats would ride these sky climbers up from the wooden floor to the boiler tubes hanging down from the ceiling of the boiler. One had stopped working and they needed an electrician to go up and fix it so that they could continue working. That was my job…. I carry a badge…. oh… wait… that’s Sergeant Friday on Dragnet… I carry a tool bucket that doubles as a trash can and triples as a stool.

So, I climbed into the sky climber and up we went. I could see faint lights up above me where boiler rats were working away cutting and welding boiler tubes. As we took off, one of the boiler rats said that a little while just before I had arrived, someone from above had dropped a tool that came flying down and stuck right into the wooden plank floor. It had landed about 10 feet from another boiler rat. This answered a question that I had for some time…. it turned out to be true… Boiler Rats do have Guardian Angels too.

Anyway, Up into the darkness we went. The boiler rat (I believe this one was called Rodney… as in Rodney Meeks) operated the sky climber as I just enjoyed the ride. Looking down, I saw the spot lights getting smaller and dimmer. Looking up, I saw us approaching a group of hanging boiler rats, all doing their stuff. Some were resting. Some were welding. Some were looking off into space in a daze after having been in the boiler for so long they had forgotten their name.

There were names for these rats. One was called T-Bone. Another was called ET. There was a guy there called Goosman. Another boiler rat was called Frazier. I think it was John Brien that was staring off into space at the time, or was it Butch Ellis. Oh. Now I remember. Butch was on one sky climber staring off into space at the other sky climber where john Brien was staring back at him.

There were many other boiler rats there from other plants. They were all hanging down from the top of the boiler on these sky climbers like fruit hanging from a tree in the dark. Most of them paid no attention to my arrival.

We pulled up to the sky climber that was broken. I swung over the couple of feet from the one climber to the other, with a straight drop of about 160 feet down to the floor. I looked below so that I could calculate that in case I slipped and fell, how I would try to swing my body just as i fell so as to miss any boiler rats below. I wouldn’t have wanted to upset any boiler rat families by falling on their boiler rat breadwinners.

By Swinging my tool bucket toward the other sky climber, I followed the momentum so that it carried me over to the other platform, where I swung my bucket over the railing and climbed in. Once settled, I took out my flashlight so that I could look around my new six or eight foot world.

I tried the controls, and sure enough… nothing happened. Remembering my dropped flashlight almost exactly three years earlier that had almost cost me my life (see post: “Angel of Death Passes By The Precipitator Door“), I took extra care not to drop any tools on some unsuspecting souls below.

I took out my multimeter and checked the voltage coming into the main junction box and found that the problem was in the connect where the cable came into the box. So, this turned out to be a fairly easy fix. The cord had been pulled by something (geez. It was only hanging down 200 feet. I don’t know what might have been pulling on it) and had worked its way out of the connections.

I told Rod that I would be able to fix this quickly and went to work removing the connector from the cable, cutting off the end and preparing it to be reconnected to the connector. It was about that time that I became aware of something that had been going on since I had arrived, I just hadn’t noticed it. Maybe it was a remark one of the boiler rats had said. I think it was Goosman talking to Opal. He said something like “That George Jones can sure sing.”

That was it. That was the extra amount of strangeness that I had been experiencing since I had arrived. Someone had a radio that was playing country music. The music was echoing throughout the boiler so that all the hanging boiler rats could listen to it. I realized that Butch and Brien weren’t just staring off into space at each other. They were experiencing a moment of country music meditational bliss. The moment the current song was over someone off in the distance that I couldn’t see in the dark or because they were stuck up inside a rack of boiler tubes, let out a hoot of satisfaction. Butch and Brien rose and went back to work.

I have heard that it takes a village to raise a child…. Hillary Clinton even wrote a children’s book with that title once. I experienced something similar but strangely different that day in October 1986. A village of raised boiler rats, who for a moment, it seemed, some had stopped to sit by the welder’s campfire to listen to the tales being woven by the country music singer on the radio.

There was a sincere camaraderie between these individual boiler rats. A culture had grown inside this boiler that was completely foreign to me. I suppose the same thing happens to soldiers who put their lives on the line to protect our country. When you are in a position where one wrong step and someone dies. You bond to those around you in a unique way.

I am grateful for my brief encounter with the boiler rats that day. They had invited me into their lair because they needed my help. I was glad to have been able to fix there problem and be quickly on my way.

Though I never had a desire to become a boiler rat myself, during the many years where I walked alone throughout the inside of the precipitator I would sometimes hear the sounds coming down through the economizer from the Superheat section of the boiler. Maybe a faint hint of country music. I knew that the boiler rat village had come together again like a group of nomads that meet every winter to share stories. Sometimes I would take the plate straightening tool I carried and banged on the plates wondering if any of them would hear me way back up in the boiler. I doubt anyone ever did.

Comment from previous post:

  1. A.D. Everard August 3, 2014

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

Sky Climbing in the Dark with Power Plant Boiler Rats

Originally Posted July 26, 2013:

I suppose everyone at some point in their life wishes they could work at Disney World or some other place where there is one wonder after another throughout their day. Working in the Power Plant was a lot like that…. sometimes….. I have mentioned a few times that when you drove through the gate to the coal-fired Power Plant in North Central Oklahoma each morning, you never knew what was in store for that day. It was often a surprise. Sometimes the surprise was a wonder. Sometimes it was well…. surreal.

This is a story about one day in October 1986 during an overhaul while I was a plant electrician, where I entered a world totally foreign to just about anything I had encountered before. You may think this is an odd statement if you have read some of my other posts where I have found myself in oddly dangerous situations and my life was in the balance. Well…. this is one of those stories, with a new twist.

As I said, we were on overhaul. This meant that one of the two units was offline and major repairs were taking place to fix things that can only be done when the unit isn’t running. The two major areas of repair are the Turbine Generator and the Boiler. People come from the other plants to help out and get paid a lot of overtime working long hours to complete this feat.

At this time I was working on motors in the electric shop. I had been removing the fan motors from the large General Electric Transformer for Unit 1. Changing their bearings and testing them. Then putting them back in place. The transformer had 24 of these motors, so after the first few, the work was becoming pretty routine.

A Main Power Transformer

A Main Power Transformer

Somewhere between the 11th or 12th motor David McClure came into the shop. I think he may have been on the labor crew at the time. He had only been working at the plant for about 8 months. He was a welder, so I think if he had been on labor crew, they had quickly moved him into the welding shop because anybody with welding skills were always in high demand.

David told me that Bill Bennett had told him to ask me to help out with a problem in the boiler. Now. when i was on the labor crew, I had been in the boiler during an overhaul. I had worked on shaking tubes in the reheat section and cleaning the clinkers out of the economizer section. You can read about these moments of mania in the posts: “Bob Lillibridge Meets the Boiler Ghost” and “Cracking a Boiled Egg in the Boiler and Other Days You Wish You Could Take Back“.

During those times I knew that something was taking place in the superheat section of the boiler, but I wasn’t exactly sure what it was. You see, even when I was in the bottom ash hopper when it was being sandblasted, there was a wooden floor that had been put in above the hopper so that you couldn’t see the boiler overhead. This was the first time I was going to go into the boiler to actually work on something other than laying down the floor (which I had been lucky enough to do once when I was working on the labor crew).

Diagram of a boiler

Diagram of a boiler

So, I grabbed my tool bucket and David took me up to the main entrance into the boiler which was next to the door where Chuck Ross and Cleve Smith had been blown off of the landing by the Boiler Dragon six years earlier when I was a summer help (see the post: “Where Do Knights of the Past go to Fight Dragons Today?“). About 40 feet up from the concrete floor we climbed into the boiler.

This is where I first came face to face with Boiler Rats. These rats live in a boiler when it is taken offline. Shortly after the boiler is cooled down, these “boiler rats” move in and they spend the next 4 or 10 weeks (depending on the length of the overhaul), roaming around the boiler sniffing out boiler tubes that are in need of repair.

Some lights had been placed around the bottom of the boiler to shine up the 200 feet to the top of the boiler. That is the height of a 20 story building. Yes. That’s right. The inside of the boiler is as tall as a 20 story building. I couldn’t really see what was going on up there toward the top, but there was a boiler rat standing right there in the middle of the wooden floor staring at me with the grin (or snarl) that is typical of a rat. Not a cute rat like this:

Rat from the Movie Ratatouille

Rat from the Movie Ratatouille

Or even a normal rat like this:

Normal looking rat

Normal looking rat

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

rat from kootation

rat picture taken from kootation.com

Yep. Red eyes and all, only the whiskers were longer. I would go into how the boiler rats smelled, but I didn’t want to get too personal….

Anyway, this one boiler rat that had been waiting for me said that he had just finished rigging up this sky climber so that he could take me up into the upper reaches of the dark to work on a sky climber that was stuck. He had rigged this sky climber up so that it would pull up next to the one that was hung up by the bottom of the high pressure boiler tubes that were hanging out over the top of the boiler.

If you have ever seen Window washers going up and down the side of a building washing windows, then you know what a sky climber is.

A sky climber

A sky climber

You see, the boiler rats would ride these sky climbers up from the wooden floor to the boiler tubes hanging down from the ceiling of the boiler. One had stopped working and they needed an electrician to go up and fix it so that they could continue working. That was my job…. I carry a badge…. oh… wait… that’s Sergeant Friday on Dragnet… I carry a tool bucket that doubles as a trash can and triples as a stool.

So, I climbed into the sky climber and up we went. I could see faint lights up above me where boiler rats were working away cutting and welding boiler tubes. As we took off, one of the boiler rats said that a little while just before I had arrived, someone from above had dropped a tool that came flying down and stuck right into the wooden plank floor. It had landed about 10 feet from another boiler rat. This answered a question that I had for some time…. it turned out to be true… Boiler Rats do have Guardian Angels too.

Anyway, Up into the darkness we went. The boiler rat (I believe this one was called Rodney… as in Rodney Meeks) operated the sky climber as I just enjoyed the ride. Looking down, I saw the spot lights getting smaller and dimmer. Looking up, I saw us approaching a group of hanging boiler rats, all doing their stuff. Some were resting. Some were welding. Some were looking off into space in a daze after having been in the boiler for so long they had forgotten their name.

There were names for these rats. One was called T-Bone. Another was called ET. There was a guy there called Goosman. Another boiler rat was called Frazier. I think it was John Brien that was staring off into space at the time, or was it Butch Ellis. Oh. Now I remember. Butch was on one sky climber staring off into space at the other sky climber where john Brien was staring back at him.

There were many other boiler rats there from other plants. They were all hanging down from the top of the boiler on these sky climbers like fruit hanging from a tree in the dark. Most of them paid no attention to my arrival.

We pulled up to the sky climber that was broken. I swung over the couple of feet from the one climber to the other, with a straight drop of about 160 feet down to the floor. I looked below so that I could calculate that in case I slipped and fell, how I would try to swing my body just as i fell so as to miss any boiler rats below. I wouldn’t have wanted to upset any boiler rat families by falling on their boiler rat breadwinners.

By Swinging my tool bucket toward the other sky climber, I followed the momentum so that it carried me over to the other platform, where I swung my bucket over the railing and climbed in. Once settled, I took out my flashlight so that I could look around my new six or eight foot world.

I tried the controls, and sure enough… nothing happened. Remembering my dropped flashlight almost exactly three years earlier that had almost cost me my life (see post: “Angel of Death Passes By The Precipitator Door“), I took extra care not to drop any tools on some unsuspecting souls below.

I took out my multimeter and checked the voltage coming into the main junction box and found that the problem was in the connect where the cable came into the box. So, this turned out to be a fairly easy fix. The cord had been pulled by something (geez. It was only hanging down 200 feet. I don’t know what might have been pulling on it) and had worked its way out of the connections.

I told Rod that I would be able to fix this quickly and went to work removing the connector from the cable, cutting off the end and preparing it to be reconnected to the connector. It was about that time that I became aware of something that had been going on since I had arrived, I just hadn’t noticed it. Maybe it was a remark one of the boiler rats had said. I think it was Goosman talking to Opal. He said something like “That George Jones can sure sing.”

That was it. That was the extra amount of strangeness that I had been experiencing since I had arrived. Someone had a radio that was playing country music. The music was echoing throughout the boiler so that all the hanging boiler rats could listen to it. I realized that Butch and Brien weren’t just staring off into space at each other. They were experiencing a moment of country music meditational bliss. The moment the current song was over someone off in the distance that I couldn’t see in the dark or because they were stuck up inside a rack of boiler tubes, let out a hoot of satisfaction. Butch and Brien rose and went back to work.

I have heard that it takes a village to raise a child…. Hillary Clinton even wrote a children’s book with that title once. I experienced something similar but strangely different that day in October 1986. A village of raised boiler rats, who for a moment, it seemed, some had stopped to sit by the welder’s campfire to listen to the tales being woven by the country music singer on the radio.

There was a sincere camaraderie between these individual boiler rats. A culture had grown inside this boiler that was completely foreign to me. I suppose the same thing happens to soldiers who put their lives on the line to protect our country. When you are in a position where one wrong step and someone dies. You bond to those around you in a unique way.

I am grateful for my brief encounter with the boiler rats that day. They had invited me into their lair because they needed my help. I was glad to have been able to fix there problem and be quickly on my way.

Though I never had a desire to become a boiler rat myself, during the many years where I walked alone throughout the inside of the precipitator I would sometimes hear the sounds coming down through the economizer from the Superheat section of the boiler. Maybe a faint hint of country music. I knew that the boiler rat village had come together again like a group of nomads that meet every winter to share stories. Sometimes I would take the plate straightening tool I carried and banged on the plates wondering if any of them would hear me way back up in the boiler. I doubt anyone ever did.

Comment from previous post:

  1. A.D. Everard August 3, 2014

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

A Slap in the Face at a Gas-fired Power Plant

Originally posted June 21, 2013:

Archimedes once said, “Give me a lever long enough and a fulcrum on which to place it, and I shall move the world.”  Thanks to my high school math teacher Robert Burns, I have always admired Archimedes.  I remember the day he was talking about him in class, and he was explaining how Archimedes had sat down in the bathtub and when the water overflowed, and he suddenly realized how to calculate the volume of the king’s crown, he jumped out of the tub and ran down the street in his birthday suit yelling “Eureka!  Eureka!”  Meaning… I have found it!  I have found it!  I especially remember Mr. Burn’s eyes tearing up as he told this story.  To Mr. Burns, mathematics was an adventure.  He instilled this love into me.

So, how does a discussion about Archimedes tie into a story about a Gas-fired Power Plant in central Oklahoma?  Well it does, or it did, on December 19, 1985.

The day began with my drive from Oklahoma City, where I was staying, to Harrah, Oklahoma where I was on overhaul at a power plant called Horseshoe Lake Plant.  The lake must have been named Horseshoe Lake for the obvious reason that it was shaped like a Horseshoe as it wrapped around the north part of the plant.

I suppose this lake was originally used to cool the condenser water once the steam had been used to turn the turbine, but it was much too small to be used by the units that were in operation when I was at the plant.  Instead it was a Fish farm where Tilapia were raised.

A Power Plant Tilapia

A Power Plant Tilapia

I wrote about working at this plant on this overhaul in an earlier post called “Bobbin’ Along with Bob Kennedy“.  This morning when I arrived, I figured I would be working in the shop repairing more of the older open-faced motors with their sleeve bearing and cambric insulation.  It started out that way.

An example of an old GE open-faced motor

An example of an old GE open-faced motor

One time during the morning, Ellis Rook, the electrical Supervisor came up to me and started talking to me about the ROLM phone computer.  He knew I had experience working on the Phone system.  I had been trained by the best even before I had gone to Muskogee to take a class.  Bill Rivers at our plant had taught me how to make “moves and changes” and how to troubleshoot the entire plant’s phone system without ever leaving the lab.

A ROLM Phone Computer

A ROLM Phone Computer

Anyway.  Ellis Rook told me about the problem they were having with the phone system that day.  He told me what had been done to try to fix the problem.  I was thinking of a few things I would try (even though I was still more of a Rookie than Ellis Rook — ok.  I couldn’t resist that one).  I had been an electrician in training for just over 2 years, which still made me a rookie.

I originally thought Ellis had approached me for ideas on how to fix the problem, so I was formulating some answers in my mind while he was going on… then he said, “What I do every time to fix any problem is just reboot the computer.” — ok.  He wasn’t seeking advice.  He was seeking approval.  So, I looked at him with as blank of a stare I could and just nodded and replied, “Well, that usually does it.”  — Nevermind that it took about 25 minutes for one of these old ROLM computers to reboot and during that time all communication with the outside world was cut-off.

This was when I remembered a story that Bob Kennedy had told me about Ellis Rook.

One day, he took another electrician with him to inspect the exciter collector rings on one of the units.  The exciter is connected to one end of the generator usually (though if I’m not mistaken, the exciter house was off to one side), and it spins at 3600 rpm.  It is not coincidental that this is 60 cycles per second, which is how fast the electricity alternates between positive and negative in your house.  This is exactly why the electricity alternates that fast.  Because that is how fast the turbine-generator is spinning.

Anyway, Ellis had taken a strobe light with him to go inspect the collector rings on the exciter because there was some indication that a fuse had blown on one of the collectors.  Using the strobe light, you could set it to blink at 3600 times per minute and the collector rings spinning at 3600 rpm would appear to stand still.

A typical strobe light

A typical strobe light

By slowly adjusting the rate that the strobe light was flashing, you could rotate the shaft slowly and inspect it just as if it was standing still, even though in reality it was still spinning at 3600 rpms (the same speed as the lawn mower in the post:  “Something is in the Water at the Muskogee Power Plant“).

After examining the shaft for a bit, they located the blown fuse.  When the fuse blew, a little indicator would stick out so it could easily be seen.  Ellis Rook slowly rotated the shaft around until the fuse was in a good position and then stopped the shaft from rotating by setting the strobe light to the exact same rate that the shaft was rotating.

Then Ellis said something that would go down in the Annals of History at Horseshoe Lake.  He told the electrician to change out the fuse.  —  Ok.  Stop and think about this for a minute.  The room where the collector rings are is normally dark, so all they can see is this turbine shaft in front of them and it looked like it was standing still.  Forget the roar of the spinning turbine and just chalk it up to a loud fan running.

Luckily the electrician wasn’t lulled into a false sense of security and didn’t put his hand forward to remove the fuse.  That would have  easily have been the last thing he would have ever done (as a live human being).  — There has to be a good murder mystery plot involving a strobe light.  I’m sure one of the great writers at WordPress can come up with one.  I can think of a couple myself.

Anyway, when Ellis Rook told me how he fixed the telephone computer problems by rebooting the computer, this story flashed through my mind for about 3 seconds.  I think I put my hands in my back pocket just for safe keeping.

Anyway.  I ate lunch in the electric shop office with my ol’ “Roomie” Steven Trammell, (We have called each other roomie from the time we were in Muskogee on overhaul in 1984.  See the post about Muskogee in the link above.  To this day, we call each other roomie, as we have kept in touch throughout the years).  While I was sitting there arguing with Art Hammond about something (See the post:  “Power Plant Arguments with Arthur Hammond“) I was reading an instruction manual about some electronic sensor that could tell you the percentage open a series of valves all in one little box.

Reggie Deloney had been working with the engineer on this valve detecting device for the past 4 weeks, and couldn’t get it to work.  The engineer asked me if I would look at it to see if I could figure out what was wrong with it, because it wasn’t working at all…. It would work every now and then, but then it would stop.

When I read the manual I noticed that there was a “common” in the circuitry and that Reggie and the engineer had assumed that the common was the same as the “ground”.  This usually isn’t true in electronic circuits as it is in regular electrical wiring.  So, I stood up from where I was lounging back reading the pamplet and lifted the common wire up so that it wasn’t touching the metal cart, and suddenly the valve indicator worked.

When Reggie returned from lunch, I excitedly told him what I had found.  He looked a little astonished, so I showed him.  He had only spent the last 4 weeks working on this.  So, I went into the shop and worked on another motor.

Later I walked into the office figuring that Reggie had told the good news to the engineer.  He was sitting there with the engineer scratching their heads still trying to figure out why the instrument still wasn’t working.  So, I picked up the wire so it wasn’t touching the cart, and said.  “See?  Works.”  Reggie with a very irritated voice said, “Yes!  You figured it out!”  He looked at me with a look that said, “Get out of here!”  So, I left.

Art, who was listening said, “I don’t think Reggie is ready to figure it out yet.”  Then I got it.  Oh.  I see…  It is nice and cool and clean in the office.  The engineer wasn’t going to figure it out on his own….   Just a week or so left of overhaul….

About that time, Bob Kennedy, my acting A Foreman told me to go with Bill Thomas and help him out.  Bill was from our plant and was a welder.  He was working out of our shop to help us out with any mechanical needs we had from welding to uncoupling pumps and fans and realigning motors and any other stuff.  Now… I know that Bill Thomas had a nickname.  But I usually called people by their real names, so I only remember him as Bill Thomas.  Maybe a Power Plant Man reading this post will remind me of Bill’s nickname.

This is where Archimedes comes into the story.

So, Bill Thomas had been working on a cooling water fan structure all morning single-handed lifting it up.  It weighed somewhere between 50 to 75 tons.  um… yes…. I think that is about it… about 100,000 pounds.  yet, Bill using nothing but the muscles in his arms and back had been lifting this monstrosity off of the ground.  Like Archimedes who lifted an entire ship out of the water once using a lever.

Bill was lifting the top round part off of the ground so that he could work under it.

Bill was lifting the top round part off of the ground so that he could work under it.

You see.  With True Power Plant Men, you really don’t ever hear that something “can’t” be done.  Bill had to work under this large round hunk of metal, so he had to pick it up. After spending two hours lifting it with only his two arms spinning a huge chain-fall, he had managed to lift the structure 2 inches from the ground. — well.  No one said anything about tossing it in the air… just lifting it off the ground.  He still had about 22 inches more to go.

This is a 3 ton chain-fall.  The one we were using was more than 10 times bigger

This is a 3 ton chain-fall. The one we were using was more than 10 times bigger

This was where I came in.  Did I tell you this plant was old?  Well it was.  They didn’t have a lot of electricity in this building we were in, and there wasn’t an electric hoist, so Bill had to pull a chain that went around a pulley that turned a shaft to a gearbox that would slowly (real slowly) lift something huge.  So, the Power Plant Men from this plant had created a “tool” to make this job faster.

Bill had pulled an air compressor over to the building and had hooked the air hose up to the special tool.

This is the exact size and type of air compressor

This is the exact size and type of air compressor

This was going to make his job much faster.  There was only once catch.  He needed an extra weight.  I was the extra weight that he needed.

You see.  The special tool was an air powered grinder.

An air powered grinder.  Only the one we used was much bigger

An air powered grinder. Only the one we used was much bigger

And it was mounted to a piece of plywood.  the grinding wheel had been replaced with a pulley.  The idea was to stand on the plywood and step on the lever that operated the grinder so that it would spin the pulley.  The chain for the chain-fall would fit through the pulley assembly.

Bill had asked the person that gave him this special tool what happens when the chain snags.  They said, that’s when you need the extra weight.  They explained to Bill that when two people are standing on the plywood, they will be able to overpower the grinder so that it can’t pull itself out from under them.  If there isn’t enough weight on the plywood, then if the chain snags, the special tool will slide across the floor and attempt to climb up to the top of the chain-fall until someone lets off of the lever that operates the grinder.

So.  I was the extra weight.  Not that I was all that big at the time.

Anyway.  The next thing I knew, I was standing on the plywood, and Bill was operating the large grinder with his foot and we were lifting the large cylinder off of the ground.  Before long we had it at least a foot up.  Bill had put some stops under the cylinder in case we had to set it down for some reason, it wouldn’t have to go all the way to the ground.

That’s when it hit me….  No.  I didn’t suddenly remember that I hadn’t had any chocolate for lunch (though, that would have been a tragedy).  No.  That is when as I was watching the chain spin through the pulley at breakneck speed, the chain suddenly went taut.  As the chain became snagged in the chain-fall, the chain whipped up, and before I could perceive what had happened I found myself lifted off of the ground and being thrown backward.

The chain had flew back and slapped me across the face, sending my hardhat flying and shattering my safety glasses.  I ended up on my back about 5 feet from where I had been standing.  Bill rushed to my side to check if I was all right.  I checked myself out and decided that I was going to be all right.

I told him I needed to go get another pair of safety glasses from the tool room.  he looked at my eyes and said.  “Boy.  That is really going to be a shiner tomorrow.”  Evidently, I was developing a black eye.  I was thinking… “Great!  And I’m getting married in two days.  I can just see my wedding pictures.”

I went to the tool room and checked out a new pair of safety glasses:

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

The first safety glasses we had at the time

When I returned to the electric shop, Bill Thomas and Arthur were there.  Everyone was saying the same thing.  “Boy!  That is sure going to be a shiner tomorrow.”

A little while later, Ellis Rook came in the shop and said that Larry Hatley (the plant manager) wanted to talk to me.  So, I followed Ellis to the Plant Manager’s office.  Larry asked me if I was ok.  He wanted to know if I needed medical attention.  I assured him that I was all right.  My safety glasses had protected me.  They had been destroyed in the process, but I was just fine.  I think as I left I heard Larry say under his breath, “boy… that is going to be a shiner tomorrow.”

Well.  The next day (December 20, 1985)  when I showed up at work (my last day there for overhaul before leaving to be married the following day), everyone came around to look at my eye.  There wasn’t anything to see really.  Any swelling had gone down over the night, and my face was back to it’s regular… um…. tolerable self.

The people I worked with the fall of 1985 at Horseshoe Power Plant treated me like family while I was there.  That was the way it was when you worked with True Power Plant Men.  I cherish their memory.

Comment from original post:

  1. Ron Kilman June 22, 2013:

    Great story! The manager at HLS was Hatley (with a “t”). Larry and I were good friends. He had flown airplanes some (as had I) so we swapped piloting adventures, some of which were actually true. Larry was a good guy.