Tag Archives: Jimmy Moore

Suppressing the Truth about Power Plant Coal Dust Collection

Some of you may be aware that an empty grain silo can explode if the dust from the grain is allowed to build up and an ignition source begins a chain reaction that causes the entire grain silo to explode like a bomb.  I haven’t heard about a grain explosion for a few years.  Maybe that is because a lot of effort is put into keeping the silo clean.  Think of how much easier it would be for a coal dust explosion.  After all… we know that coal when turned into a fine powder is highly combustible.

When you are covered in coal dust from head-to-toe day after day you seem to forget just how explosive the coal dust you are washing down can be.  Our coal-fired Power Plant in North Central Oklahoma was concerned after our downsizing in 1994 that by eliminating the labor crew from the roster of available Power Plant Jobs, that the operators may not be able to keep the entire coal handling system free from coal dust.

The plant had already experienced a major explosion the year before (in 1996) the “Dust Collector Task Force” was formed (See the post: “Destruction of a Power Plant God“).  It was clear that the question had been asked by those concerned, “Are there any other areas in the plant that could suddenly explode?”  Two electricians were asked to be on the Dust Collection Task Force. Jimmy Moore and myself.

Jimmie Moore

Jimmie Moore

We had a salesman of our Dust Collector come to the plant and train us on the proper maintenance of the dust collectors that were already in place. When he arrived he showed us a video that showed examples of plants that had explosions caused by coal dust.  Here is a picture I found on Google of a coal dust explosion at a power plant:

Power Plant after a coal dust explosion

Power Plant after a coal dust explosion

We heard a story about a coal plant where the explosion began at the coal yard, worked its way up the conveyor system, blew up the bowl mills and threw debris onto the main power transformer, which also blew up.  Ouch.  We thought it would be a good idea to do something about our coal dust problems.  Stopping an ounce of coal dust is worth a pound of explosives… as the saying goes.

The Instrument and Controls person on our team was Danny Cain.  He had become a Power Plant employee a year before the downsizing and had been at the plant for about four years at this point.

Danny Cain

Danny Cain

When we began looking at our dust collectors, we found that the dust collectors on the dumper had been rusted out over the past 18 years since they were first put into operation.  the reason was that they were located down inside the dumper building below ground where they were constantly exposed to coal and water.  I hadn’t seen them actually running for years.  They were definitely going to have to be replaced with something.

Okay class… I know this is boring, but you have to learn it!

We had some fairly new dust collectors on the crusher tower and the coal reclaim, but they didn’t seem to be doing their job.  They used instrument air (which is clean, dehumidified air) in order to flush the coal off of some bags inside.  When they were installed, new instrument air compressors were installed in the coal yard just to handle the extra “instrument air” load for the dust collectors.  The very expensive and large dust collectors just didn’t seem to be doing anything to “collect” the dust.

Dust Collector System

Dust Collector System

You can see that the dust collector is very large.  You actually have to climb on top of them to change out the bags inside.

When the dust collector sales man came to talk to us about dust collection, in the middle of his “Proper Maintenance” speech he happened to mention something about…. “…and of course, if you don’t have the air pulse set at exactly 32 milliseconds, the dust collector isn’t going to work at all.”  “Wait!  What did he say?”  What pulse?”

He explained that Instrument air is puffed through the collector bags with exactly a 32 millisecond pulse at a predetermined interval.  If the pulse is longer or shorter, then it doesn’t work as well.  The idea is that it creates a ripple down the bag which shakes the dust free.  We had been studying our dust collectors in the coal yard, and the interval had been completely turned off and the instrument air was constantly blowing through the dust collectors.  This guy was telling us that it was just supposed to be a quick pulse.

Everyone in the room looked at each other with stunned silence.  The salesman just looked at us and said…. “It’s right there in the instruction manual….”  pointing his finger at the page.   We thought (or said)… “Instruction manual?  We have an instruction manual?”

We said,  “Class dismissed!  Let’s go to the coalyard after lunch and see about adjusting the “pulse” on the dust collectors.

In order to measure a pulse of 32 milliseconds, I needed the oscilloscope that I kept out at the precipitator control room to measure the “Back Corona” when trying to adjust the cabinets to their optimal voltage.  I ran out to the precipitator and retrieved it and brought it with me to the coal yard along with my tool bucket and my handy dandy little screwdriver in my pocket protector:

A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.

A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.

When we arrived at the crusher tower where the two long belts sent coal to the Power Plant 1/2 mile away, one of the belts was running.  coal dust was puffing around the equipment making the room hazy, which was normal.  Water hoses were kept running on the floor trying to wash at least some of the dust down the drain.  This was a typical day in the coal handling system.  Coal dust everywhere.

I opened the control cabinet for the dust collector and hooked up the oscilloscope.

I used an Analog oscilloscope like this until we were given a new Digital one where you could zoom in and do all sorts of neat things.

I used an Analog oscilloscope like this until we were given a new Digital one where you could zoom in and do all sorts of neat things.

When we arrived there was no pulsing.  The instrument air was on all the time.  So, I flipped a switch which put it in a pulse mode.  The pulse time was set up to the maximum setting of about a minute (that meant that when the pulse turned on, it stayed on for a minute).  As I was playing with the controls, three of the task force members were standing up on the walkway between the two belts watching the discharge from the dust collector (you see, after the dust collector collected the dust, it dropped it back onto the conveyor belt just up the belt from where the coal dropped onto the belt).  Nothing was coming out of the chute.

As I adjusted the setting down from one minute to one second, I had to keep changing settings on the oscilloscope to measure how long the air took to turn on and off.  When I finally had the pulse down within 1/10 of a second (which is 100 milliseconds), then I could easily measure the 32 millisecond interval that we needed.  I was beginning to think that this wasn’t going to really do anything, but I remembered that I had seen stranger things on the precipitator controls where the difference between a couple of milliseconds is like night and day.

When the pulse was down to 35 milliseconds I looked up toward the conveyor system because I heard a couple of people yelling.  They were running down the walkway as coal dust came pouring out of the dust collector chute causing a big cloud of dust to puff up.  We all ran outside and waited for the dust to settle.  We felt like cheering!

We were practically in disbelief that all we had to do was adjust the pulse of air to the right millisecond pulse and the dust collector began working.  This meant a lot more than a working dust collector.  This also meant that we needed only a fraction of the instrument air (literally about 1/20,000) than we had been using.

In other words.  The new Instrument Air Compressors at the coal yard that had been installed to help boost air pressure at the coal yard since the installation of the dust collectors were really never needed.  And all this was done by turning a screwdriver on a small potentiometer in a control cabinet.  It pays to read the manual.

a small Power Plant potentiometer like this

a small Power Plant potentiometer like this

Along with some rewiring of the controls to the dust collector system, and a redesign of the apron around the dust chutes by Randy Dailey and Tim Crain, the coal handling areas became practically dust free as long as regular preventative maintenance was performed.

Tim Crain

Tim Crain

Randy Dailey, known as Mr. Safety to Real Power Plant Men

Randy Dailey, known as Mr. Safety to Real Power Plant Men

That is, everywhere except for the coal dumper.  This is where the coal trains dump their coal into a hopper which is then carried on three conveyors out to the coal pile.

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

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

You can see the conveyor going up to the building right next to the coal pile.  That is from the dumper which is the small off white building next to the fly ash silos.  The crusher tower is the tall thin building at the end of the long belts going up to the plant.

We still had a problem with the dumper.  The cost of buying new dust collectors and putting them outside where they wouldn’t be so quickly corroded by the harsh environment was “too costly”.  Jim Arnold, the maintenance Supervisor made that clear.  We had to come up with another solution.

Without a dust collector, the solution was “Dust Suppression”.  That is, instead of collecting the dust when it is stirred up, spray the coal with a chemical that keeps the dust down in the first place.  This was a good idea, except that it had to be turned off for three months during the winter months when it could freeze up.

A company called Arch Environmental Equipment came and talked to us about their dust suppression system.

Arch Environmental

Arch Environmental

They showed us something called:  The “Dust Shark”.

Dust Shark by Arch Environmental

Dust Shark by Arch Environmental

The dust shark sprayed the belt on the side with the coal and scraped the bottom side in order to make sure it was clean when it passed through.  This was the solution for the dumper.  It also worked well at other locations in the plant where you could use it to keep the area clean from coal when the coal was wet from the rain and would stick to the belt.

The task force was considered a success.  I have two side stories before I finish with this post.

The first is about Danny Cain.

Danny was a heavy smoker.  He had a young look so that he looked somewhat younger than he was. He had been born in July, 1964 (just ask the birthday phantom), so he was 33 during July 1997 when we were working on the task force, but he looked like someone still in college.  Whenever he would pull out a cigarette and put it in his mouth, he suddenly looked like he was still in High School.

I told Danny that one day.  I was always one to discourage people from smoking….  He seemed a little hurt, and I said I was just calling it like I saw it.  He was standing outside the electric shop smoking one day, so I took the air monitor that I used when I had to go in the precipitator and asked Danny if I could borrow his lit cigarette for a moment.

Confined Space Air Monitor

Confined Space Air Monitor

I put the butt of the cigarette up to the intake hose for the monitor about long enough for a puff and then I handed it back to him.  The monitor measures the amount of Oxygen in the air, the amount of explosive gases, the amount of Carbon Monoxide and the amount of H2S gas (Hydrogen Sulfide, an extremely toxic gas).  The monitor, as expected began beeping…

What we didn’t expect to see was that not only did the Carbon Monoxide peg out at 999 parts per million, but the H2S went out the roof as well.  In fact, everything was bad. The Percent explosive was at least 50% and the oxygen level was low.  It took about 5 minutes before the meter measured everything clean again.  Danny didn’t want to see that.

I said, “Danny?  Carbon Monoxide Poisoning!  Hello???!!!”

When we were on the Dust Collector Task Force, at one point we had to program “Programmable Logic Controllers” (or PLCs).  I had been to an Allen Bradley school a few years earlier where we had learned the basics for this.  Here is my certificate from 9 years earlier…

PLC Training Certificate

PLC Training Certificate

When Danny and I sat down to program the controller, it became clear that he expected the programming task to take a couple of weeks.  He started out by drawing some high level logic on the white board.  I said… “wait… wait…  let’s just start programming the thing.”  He told me that wasn’t the way we did things.  First we had to figure out the entire program, then we would program it.

The PLCs we were going to program were just some small ones we had bought to run the dust sharks and the dust collectors… Here’s one like it.

MicroLogix PLC like we were programming

MicroLogix PLC like we were programming

I told Danny when I program something I find that its a lot easier and quicker if we just program it as we understand the requirements and then that way we can test it as we go.  Then when we figure out what we need, we will be done.  In fact… it took us 4 hours and we were done… not two weeks.

End of the Danny Cain Side Story…. On to the second side story… much shorter….

I think it was March 2003 (the power plant men can remind me)…. a year and a half after I had left the plant, the Coal Dumper blew up.  It was the middle of the night, a coal train had finished dumping the coal about an hour earlier.  No one was in the dumper at the time and the entire dumper exploded.    The roof of the dumper, as I was told, was blown off of the building.  No injuries or deaths.  The “Dust Shark” Dust Suppression system had been turned off because it was winter.

I suppose that the insurance company ended up paying for that one.  I don’t know.  This is what happens when you say that it is too expensive to replace the dust collectors and instead you buy one of these:

Power Plant Feather Duster

Power Plant Feather Duster

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Mr. Frog’s Wild Power Plant Ride

I woke up from a dream this past Wednesday where I had just insulted a young lady who had cancer treatment by calling her “baldy”. In the dream I was attempting to be funny, but as soon as I said it, I knew I had crossed the line of common courtesy. I acknowledged right away that “I shouldn’t have said that”, and rose from my chair to go find whoever it was so that I could apologize. In my dream I was never able to find the person, though I thoroughly searched whatever restaurant-factory-office building we were in. You know how thing are in dreams.

I preface this post with that thought because someone may take offense to the title I have chosen today. So, let me just say that this is a story about someone that has been the source of constant conversation in my family for the past 30 years. Though I never refer to him as “Frog”, that is a title reserved for one of this man’s best friends. It is an expression of friendship bestowed upon Walt Oswalt by Ray Eberle.

Walt Oswalt

Walt Oswalt

Ray Eberle is the most amazing storyteller of our time.  He captivated Power Plant audiences for the past 40 years up until the day he recently retired.  I have heard hundreds of stories by Ray, but none of them were ever said with more compassion and humor than the stories that Ray Eberle would tell me about our fellow Power Plant Man, Walt Oswalt.

Ray Eberle

Ray Eberle

I used to think that Walt’s parents name him Walt so that it would be easy for him to spell his entire name.  Once he learned his first name, he just had to add an OS to it, and he could spell his last name.  Well, actually, his full name was Walter Lee Oswalt.  But whose counting?  I also thought that OD McGaha (prounounced Muh Gay Hay) was in a similar situation, because OD simply stood for OD  (prounounced O-D or Oh Dee).   Not to forget Dee Ball.  I’ll bet all of these guys could spell their names by the time they graduated the third grade.

Look closely at Ray Eberle’s picture above, because if you look closely into his eyes you can see that back behind those orbs, thousands of wonderful stories are packed in there waiting to be told.  I don’t know if I have mentioned this in a post before, but Ray looks just like my grandfather when he was younger.  I think I mentioned that to Ray one day.  Since those days when we used to sit side-by-side working on the computers in the Coal-fired Power Plant in North Central Oklahoma, I have loved Ray with all my heart as if he is a member of my family (see the post:  “Tales of Power Plant Prowess by Ray Eberle“).

Even though this post is about Walt Oswalt, I am spending an unusual amount of time talking about Ray, because the stories I am about to relay are told through the eyes of Ray.  I have already passed on some stories about Walt in other posts, so I will focus on those stories about Walt experienced by Ray.  I will only scratch the surface today, as it takes some time to absorb the universal significance of each story.  If I flood you with too many  Walt Oswalt stories at once it may cause confusion.  I appreciated the fact that Ray didn’t lay all his Walt Oswalt stories on me in one sitting for this very reason.

Ray Eberle began his stories about Walt by telling me about going over to Jimmy Moore’s new house.  Jimmy had just moved into a new house outside Morrison Oklahoma not too far from Ray.  Ray described how nice the property was at the time.  It was a picture perfect piece of property.  The surrounding fields were pristine giving the feeling of peace when you looked around.

Jimmie Moore

Jimmie Moore expression after moving into his nice house

Note the Sparco notepad in Jimmy’s pocket.   A Power Plant Electrician Necessity, just like the notepads I always used:

My Power Plant Sparco Wirebound Memo Book

One of My Power Plant Sparco Wirebound Memo Books

Just when Ray was soaking in the perfection of Jimmy’s new property, dreaming that he could have found such a great spot, Jimmy mentioned that Walt Oswalt bought the property across the road.  Ray’s response was “Frog bought the land across the road?  Oh no!”  Not wanting to upset Jimmy, he didn’t say anything else, but he was thinking it….  You see, Walt is sort of a “junk collector”.

I have always been a junk collector myself, as you may have figured out by the fact that I still have a notepad left over from Christmas 1995.  Actually, I could take a picture of the Sparco notepads I have kept from my time at the power plant and it would look like this:

My personal collection of used Power Plant Sparco Notepads

My personal collection of used Power Plant Sparco Notepads

So, I was a note taker…  Each page of these notepads are filled with work order numbers, part numbers, phrases I heard, Things Gone Right, Things Gone Wrong meeting notes, Meeting schedules, tools needed, and sometimes just thoughts that came to my mind.  I am mentioning this because I have this common bond with Walt.  We both like to collect things that others see as “junk”.

Ray was worried that after Walt moved in across the road that the Beatrice Potter Meadow was going to change into Fallout 3  terrain (well, my phrases, not his, but I think you can picture what I am saying).  From what I understand, this is what happened.  — This by the way is not a Walt Oswalt Story.  This has been more of a Jimmy Moore story.

I have been waiting so long to actually write down a Walt Oswalt Story that I actually find it hard to bring myself to put it down on virtual paper, but here goes….

Here begins the first Walt Oswalt Story:

In the mid-90s the Internet was something of a new phenomenon.  I had taught most of the Power Plant Men how to use the Internet (excluding upper management)  as you can read in the post:  “Power Plant Quest for the Internet“.  One person who immediately saw the benefit of using the Internet beyond looking up indecent pictures or connecting with clandestine online “Match.com” experiences was Walt Oswalt.  Walt saw “business opportunity”!

So, follow me on this story, because Walt stories can become complicated on paper because I can’t talk using my hands.  I may need some help from Walt’s son Edward, since he played a major role in this one…

One day, Walt and Ray were talking and Walt told Ray that he was looking at buying a dump truck.  Let me just show a picture of a dump truck, even though I don’t know the specific truck Walt had in mind.  I just know the approximate size:

A Ford Dump Truck

A Ford Dump Truck

Let’s just suppose that it is a truck like this….  anyway, Walt explained to Ray that he could buy the truck he wanted up in Wichita one hundred miles away.  However, Walt wasn’t going to do that.  He had found the same truck on the Internet for sale for $500 cheaper near Virginia Beach, Virginia, 1,400 miles away.

Ray asked, “But isn’t it going to cost you more than that to have the truck shipped to Oklahoma?”  “Oh, I have that all figured out.  I’m going to go pick it up myself.”  He went on to explain that he and his son (this is where Edward enters the story) were going to drive non-stop to Virginia Beach and pick it up.  They won’t have to stop because they can trade off driving while the other rests.

A Flat Bed Trailer

A Flat Bed Trailer

So, a marathon trip for 2,800 miles was planned.  Walt had a trailer attached to his truck to bring the new truck back… Though I’m not sure why the thought that they could just drive the new truck home wasn’t considered (or flying out there and driving the truck back, but then, that would cost more than the $500 they were saving by buying the truck)….  The plan was that they would load the truck on the trailer and haul it home.  Maybe it was so that they didn’t have to stop because they could swap off driving if they were only driving one of the two trucks.

Two members of the Oswalt family took off for the East Coast one Friday evening.  They arrived early Sunday morning at the place of business where they were going to purchase the truck.  From what I understand, the business was closed, (being Sunday, and all), so they called the owner and told him they were there to pick up the truck.  After waiting a few hours, the truck was purchased, and Walt and Edward were on their way back home.

A couple of days later, Ray noticed that Walt had made it back home, so he went over to his house to see how he managed.  Obviously, after travelling 2,800 miles in four days, the two were bushed, but the new truck was finally home.  While Ray was talking to Walt about his trip, he happened to notice that the back of the dump truck was loaded with blown out tires.

“Hey Walt, what’s up with all the tires?” Ray asked.  “Oh.  Those.” Walt replied….  “Well, the trailer wasn’t really big enough to carry this much weight, so we kept blowing out tires on the trailer when we were coming home.”  They must have blown out more than 20 tires driving home.  So, it seems to me that this turned out to be a pretty costly savings of $500.

I would leave this story at that, but after a couple of trips to Los Angeles and back from Round Rock, TX, I have to say that spending countless hours with your family in the car where there is nothing to do but to talk to each other is an incredibly priceless experience.  Once, my son Anthony and I drove the same distance, 1400 miles non-stop from Los Angeles to Round Rock without stopping and we talked the entire time.  I would say it is an experience worth a million bucks.

The night before last, I received a message on Facebook from a Power Plant Technician, Doug Black.  He wrote:  Sooner retiree, Walter Oswalt passed away on September 30, 2015.  Walter will be laid to rest at Yukon Cemetery with a grave service on October 23, at 2 p.m.

Doug Black

Doug Black

I looked up Walt’s Obituary, and it seemed to me that there was one phrase missing from the description.  It said that “Walt had went to work for OG&E in Mustang Oklahoma and later retired from the OG&E plant in Redrock…”  I didn’t see the words, “Power Plant Legend” mentioned anywhere in the Obituary.  It should be mentioned, because that’s exactly who Walt Oswalt is.

I may not have had the benefit of sitting in a truck with Walt for 20 hours at a time, but I was able to work one-on-one with Walt one day for 19 hours straight on a Saturday when we were on “Coal Cleanup” that had turned into a job repairing conveyor belt rollers.  During that day, while I was a young man of 20, I went through the motions directed by Walt to remove and install rollers on the number 10 belt up toward the top.

Coal conveyor carrying coal to the coal silos from the coalyard

Coal conveyor carrying coal to the coal silos from the coalyard

I didn’t have much of a clue about what I was doing, but I had placed all my confidence in Walt.  I felt the entire time as if Walt was keeping me safe in a potentially unsafe situation even after being awake for 19 hours.  So, I have a little knowledge of what the road trip was like that Walt and his son Edward took “There and Back Again.”

It may seem that Walt had made a bad decision to make the Internet Purchase of a truck 1,400 miles away in order to save $500, but I think that God helps us along some times by sending us down a path that seems a little foolish, only to force us into a benefit we would not otherwise encounter.  I keep Walt in mind whenever things like that happen to me today and I thank him for keeping me from being disappointed with those times in my life.

Now that Walt has met his maker, I’m sure that Walt is sitting there with Jesus Christ reviewing not only Walt’s life, but also Ray Eberle’s retelling of Walt’s story.  Walt may now be surprised to find that moments that he thought were rather insignificant to anyone but himself have actually been spread to others across the world.  As I mentioned in the post about Ray Eberle, a few years ago, CEOs of large companies across the U.S. were all learning about the “Wisdom of Walt”.  Some day I wouldn’t be surprised to find that the Walt Oswalt Stories have become required reading in Oklahoma Schools.

Rest in Peace Walt Oswalt.  We all love you.

Walt Oswalt

Walt Oswalt

Mr. Frog’s Wild Power Plant Ride

I woke up from a dream this past Wednesday where I had just insulted a young lady who had cancer treatment by calling her “baldy”. In the dream I was attempting to be funny, but as soon as I said it, I knew I had crossed the line of common courtesy. I acknowledged right away that “I shouldn’t have said that”, and rose from my chair to go find whoever it was so that I could apologize. In my dream I was never able to find the person, though I thoroughly searched whatever restaurant-factory-office building we were in. You know how thing are in dreams.

I preface this post with that thought because someone may take offense to the title I have chosen today. So, let me just say that this is a story about someone that has been the source of constant conversation in my family for the past 30 years. Though I never refer to him as “Frog”, that is a title reserved for one of this man’s best friends. It is an expression of friendship bestowed upon Walt Oswalt by Ray Eberle.

Walt Oswalt

Walt Oswalt

Ray Eberle is the most amazing storyteller of our time.  He captivated Power Plant audiences for the past 40 years up until the day he recently retired.  I have heard hundreds of stories by Ray, but none of them were ever said with more compassion and humor than the stories that Ray Eberle would tell me about our fellow Power Plant Man, Walt Oswalt.

Ray Eberle

Ray Eberle

I used to think that Walt’s parents name him Walt so that it would be easy for him to spell his entire name.  Once he learned his first name, he just had to add an OS to it, and he could spell his last name.  Well, actually, his full name was Walter Lee Oswalt.  But whose counting?  I also thought that OD McGaha (prounounced Muh Gay Hay) was in a similar situation, because OD simply stood for OD  (prounounced O-D or Oh Dee).   Not to forget Dee Ball.  I’ll bet all of these guys could spell their names by the time they graduated the third grade.

Look closely at Ray Eberle’s picture above, because if you look closely into his eyes you can see that back behind those orbs, thousands of wonderful stories are packed in there waiting to be told.  I don’t know if I have mentioned this in a post before, but Ray looks just like my grandfather when he was younger.  I think I mentioned that to Ray one day.  Since those days when we used to sit side-by-side working on the computers in the Coal-fired Power Plant in North Central Oklahoma, I have loved Ray with all my heart as if he is a member of my family (see the post:  “Tales of Power Plant Prowess by Ray Eberle“).

Even though this post is about Walt Oswalt, I am spending an unusual amount of time talking about Ray, because the stories I am about to relay are told through the eyes of Ray.  I have already passed on some stories about Walt in other posts, so I will focus on those stories about Walt experienced by Ray.  I will only scratch the surface today, as it takes some time to absorb the universal significance of each story.  If I flood you with too many  Walt Oswalt stories at once it may cause confusion.  I appreciated the fact that Ray didn’t lay all his Walt Oswalt stories on me in one sitting for this very reason.

Ray Eberle began his stories about Walt by telling me about going over to Jimmy Moore’s new house.  Jimmy had just moved into a new house outside Morrison Oklahoma not too far from Ray.  Ray described how nice the property was at the time.  It was a picture perfect piece of property.  The surrounding fields were pristine giving the feeling of peace when you looked around.

Jimmie Moore

Jimmie Moore expression after moving into his nice house

Note the Sparco notepad in Jimmy’s pocket.   A Power Plant Electrician Necessity, just like the notepads I always used:

My Power Plant Sparco Wirebound Memo Book

One of My Power Plant Sparco Wirebound Memo Books

Just when Ray was soaking in the perfection of Jimmy’s new property, dreaming that he could have found such a great spot, Jimmy mentioned that Walt Oswalt bought the property across the road.  Ray’s response was “Frog bought the land across the road?  Oh no!”  Not wanting to upset Jimmy, he didn’t say anything else, but he was thinking it….  You see, Walt is sort of a “junk collector”.

I have always been a junk collector myself, as you may have figured out by the fact that I still have a notepad left over from Christmas 1995.  Actually, I could take a picture of the Sparco notepads I have kept from my time at the power plant and it would look like this:

My personal collection of used Power Plant Sparco Notepads

My personal collection of used Power Plant Sparco Notepads

So, I was a note taker…  Each page of these notepads are filled with work order numbers, part numbers, phrases I heard, Things Gone Right, Things Gone Wrong meeting notes, Meeting schedules, tools needed, and sometimes just thoughts that came to my mind.  I am mentioning this because I have this common bond with Walt.  We both like to collect things that others see as “junk”.

Ray was worried that after Walt moved in across the road that the Beatrice Potter Meadow was going to change into Fallout 3  terrain (well, my phrases, not his, but I think you can picture what I am saying).  From what I understand, this is what happened.  — This by the way is not a Walt Oswalt Story.  This has been more of a Jimmy Moore story.

I have been waiting so long to actually write down a Walt Oswalt Story that I actually find it hard to bring myself to put it down on virtual paper, but here goes….

Here begins the first Walt Oswalt Story:

In the mid-90s the Internet was something of a new phenomenon.  I had taught most of the Power Plant Men how to use the Internet (excluding upper management)  as you can read in the post:  “Power Plant Quest for the Internet“.  One person who immediately saw the benefit of using the Internet beyond looking up indecent pictures or connecting with clandestine online “Match.com” experiences was Walt Oswalt.  Walt saw “business opportunity”!

So, follow me on this story, because Walt stories can become complicated on paper because I can’t talk using my hands.  I may need some help from Walt’s son Edward, since he played a major role in this one…

One day, Walt and Ray were talking and Walt told Ray that he was looking at buying a dump truck.  Let me just show a picture of a dump truck, even though I don’t know the specific truck Walt had in mind.  I just know the approximate size:

A Ford Dump Truck

A Ford Dump Truck

Let’s just suppose that it is a truck like this….  anyway, Walt explained to Ray that he could buy the truck he wanted up in Wichita one hundred miles away.  However, Walt wasn’t going to do that.  He had found the same truck on the Internet for sale for $500 cheaper near Virginia Beach, Virginia, 1,400 miles away.

Ray asked, “But isn’t it going to cost you more than that to have the truck shipped to Oklahoma?”  “Oh, I have that all figured out.  I’m going to go pick it up myself.”  He went on to explain that he and his son (this is where Edward enters the story) were going to drive non-stop to Virginia Beach and pick it up.  They won’t have to stop because they can trade off driving while the other rests.

A Flat Bed Trailer

A Flat Bed Trailer

So, a marathon trip for 2,800 miles was planned.  Walt had a trailer attached to his truck to bring the new truck back… Though I’m not sure why the thought that they could just drive the new truck home wasn’t considered (or flying out there and driving the truck back, but then, that would cost more than the $500 they were saving by buying the truck)….  The plan was that they would load the truck on the trailer and haul it home.  Maybe it was so that they didn’t have to stop because they could swap off driving if they were only driving one of the two trucks.

Two members of the Oswalt family took off for the East Coast one Friday evening.  They arrived early Sunday morning at the place of business where they were going to purchase the truck.  From what I understand, the business was closed, (being Sunday, and all), so they called the owner and told him they were there to pick up the truck.  After waiting a few hours, the truck was purchased, and Walt and Edward were on their way back home.

A couple of days later, Ray noticed that Walt had made it back home, so he went over to his house to see how he managed.  Obviously, after travelling 2,800 miles in four days, the two were bushed, but the new truck was finally home.  While Ray was talking to Walt about his trip, he happened to notice that the back of the dump truck was loaded with blown out tires.

“Hey Walt, what’s up with all the tires?” Ray asked.  “Oh.  Those.” Walt replied….  “Well, the trailer wasn’t really big enough to carry this much weight, so we kept blowing out tires on the trailer when we were coming home.”  They must have blown out more than 20 tires driving home.  So, it seems to me that this turned out to be a pretty costly savings of $500.

I would leave this story at that, but after a couple of trips to Los Angeles and back from Round Rock, TX, I have to say that spending countless hours with your family in the car where there is nothing to do but to talk to each other is an incredibly priceless experience.  Once, my son Anthony and I drove the same distance, 1400 miles non-stop from Los Angeles to Round Rock without stopping and we talked the entire time.  I would say it is an experience worth a million bucks.

The night before last, I received a message on Facebook from a Power Plant Technician, Doug Black.  He wrote:  Sooner retiree, Walter Oswalt passed away on September 30, 2015.  Walter will be laid to rest at Yukon Cemetery with a grave service on October 23, at 2 p.m.

Doug Black

Doug Black

I looked up Walt’s Obituary, and it seemed to me that there was one phrase missing from the description.  It said that “Walt had went to work for OG&E in Mustang Oklahoma and later retired from the OG&E plant in Redrock…”  I didn’t see the words, “Power Plant Legend” mentioned anywhere in the Obituary.  It should be mentioned, because that’s exactly who Walt Oswalt is.

I may not have had the benefit of sitting in a truck with Walt for 20 hours at a time, but I was able to work one-on-one with Walt one day for 19 hours straight on a Saturday when we were on “Coal Cleanup” that had turned into a job repairing conveyor belt rollers.  During that day, while I was a young man of 20, I went through the motions directed by Walt to remove and install rollers on the number 10 belt up toward the top.

Coal conveyor carrying coal to the coal silos from the coalyard

Coal conveyor carrying coal to the coal silos from the coalyard

I didn’t have much of a clue about what I was doing, but I had placed all my confidence in Walt.  I felt the entire time as if Walt was keeping me safe in a potentially unsafe situation even after being awake for 19 hours.  So, I have a little knowledge of what the road trip was like that Walt and his son Edward took “There and Back Again.”

It may seem that Walt had made a bad decision to make the Internet Purchase of a truck 1,400 miles away in order to save $500, but I think that God helps us along some times by sending us down a path that seems a little foolish, only to force us into a benefit we would not otherwise encounter.  I keep Walt in mind whenever things like that happen to me today and I thank him for keeping me from being disappointed with those times in my life.

Now that Walt has met his maker, I’m sure that Walt is sitting there with Jesus Christ reviewing not only Walt’s life, but also Ray Eberle’s retelling of Walt’s story.  Walt may now be surprised to find that moments that he thought were rather insignificant to anyone but himself have actually been spread to others across the world.  As I mentioned in the post about Ray Eberle, a few years ago, CEOs of large companies across the U.S. were all learning about the “Wisdom of Walt”.  Some day I wouldn’t be surprised to find that the Walt Oswalt Stories have become required reading in Oklahoma Schools.

Rest in Peace Walt Oswalt.  We all love you.

Walt Oswalt

Walt Oswalt

Suppressing the Truth about Power Plant Coal Dust Collection

Some of you may be aware that an empty grain silo can explode if the dust from the grain is allowed to build up and an ignition source begins a chain reaction that causes the entire grain silo to explode like a bomb.  I haven’t heard about a grain explosion for a few years.  Maybe that is because a lot of effort is put into keeping the silo clean.  Think of how much easier it would be for a coal dust explosion.  After all… we know that coal when turned into a fine powder is highly combustible.

When you are covered in coal dust from head-to-toe day after day you seem to forget just how explosive the coal dust you are washing down can be.  Our coal-fired Power Plant in North Central Oklahoma was concerned after our downsizing in 1994 that by eliminating the labor crew from the roster of available Power Plant Jobs, that the operators may not be able to keep the entire coal handling system free from coal dust.

The plant had already experienced a major explosion the year before (in 1996) the “Dust Collector Task Force” was formed (See the post: “Destruction of a Power Plant God“).  It was clear that the question had been asked by those concerned, “Are there any other areas in the plant that could suddenly explode?”  Two electricians were asked to be on the Dust Collection Task Force. Jimmy Moore and myself.

Jimmie Moore

Jimmie Moore

We had a salesman of our Dust Collector come to the plant and train us on the proper maintenance of the dust collectors that were already in place. When he arrived he showed us a video that showed examples of plants that had explosions caused by coal dust.  Here is a picture I found on Google of a coal dust explosion at a power plant:

Power Plant after a coal dust explosion

Power Plant after a coal dust explosion

We heard a story about a coal plant where the explosion began at the coal yard, worked its way up the conveyor system, blew up the bowl mills and threw debris onto the main power transformer, which also blew up.  Ouch.  We thought it would be a good idea to do something about our coal dust problems.  Stopping an ounce of coal dust is worth a pound of explosives… as the saying goes.

The Instrument and Controls person on our team was Danny Cain.  He had become a Power Plant employee a year before the downsizing and had been at the plant for about four years at this point.

Danny Cain

Danny Cain

When we began looking at our dust collectors, we found that the dust collectors on the dumper had been rusted out over the past 18 years since they were first put into operation.  the reason was that they were located down inside the dumper building below ground where they were constantly exposed to coal and water.  I hadn’t seen them actually running for years.  They were definitely going to have to be replaced with something.

Okay class… I know this is boring, but you have to learn it!

We had some fairly new dust collectors on the crusher tower and the coal reclaim, but they didn’t seem to be doing their job.  They used instrument air (which is clean, dehumidified air) in order to flush the coal off of some bags inside.  When they were installed, new instrument air compressors were installed in the coal yard just to handle the extra “instrument air” load for the dust collectors.  The very expensive and large dust collectors just didn’t seem to be doing anything to “collect” the dust.

Dust Collector System

Dust Collector System

You can see that the dust collector is very large.  You actually have to climb on top of them to change out the bags inside.

When the dust collector sales man came to talk to us about dust collection, in the middle of his “Proper Maintenance” speech he happened to mention something about…. “…and of course, if you don’t have the air pulse set at exactly 32 milliseconds, the dust collector isn’t going to work at all.”  “Wait!  What did he say?”  What pulse?”

He explained that Instrument air is puffed through the collector bags with exactly a 32 millisecond pulse at a predetermined interval.  If the pulse is longer or shorter, then it doesn’t work as well.  The idea is that it creates a ripple down the bag which shakes the dust free.  We had been studying our dust collectors in the coal yard, and the interval had been completely turned off and the instrument air was constantly blowing through the dust collectors.  This guy was telling us that it was just supposed to be a quick pulse.

Everyone in the room looked at each other with stunned silence.  The salesman just looked at us and said…. “It’s right there in the instruction manual….”  pointing his finger at the page.   We thought (or said)… “Instruction manual?  We have an instruction manual?”

We said,  “Class dismissed!  Let’s go to the coalyard after lunch and see about adjusting the “pulse” on the dust collectors.

In order to measure a pulse of 32 milliseconds, I needed the oscilloscope that I kept out at the precipitator control room to measure the “Back Corona” when trying to adjust the cabinets to their optimal voltage.  I ran out to the precipitator and retrieved it and brought it with me to the coal yard along with my tool bucket and my handy dandy little screwdriver in my pocket protector:

A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.

A pocket protector is a must for electricians and computer nerds who need a place to keep their small tools.

When we arrived at the crusher tower where the two long belts sent coal to the Power Plant 1/2 mile away, one of the belts was running.  coal dust was puffing around the equipment making the room hazy, which was normal.  Water hoses were kept running on the floor trying to wash at least some of the dust down the drain.  This was a typical day in the coal handling system.  Coal dust everywhere.

I opened the control cabinet for the dust collector and hooked up the oscilloscope.

I used an Analog oscilloscope like this until we were given a new Digital one where you could zoom in and do all sorts of neat things.

I used an Analog oscilloscope like this until we were given a new Digital one where you could zoom in and do all sorts of neat things.

When we arrived there was no pulsing.  The instrument air was on all the time.  So, I flipped a switch which put it in a pulse mode.  The pulse time was set up to the maximum setting of about a minute (that meant that when the pulse turned on, it stayed on for a minute).  As I was playing with the controls, three of the task force members were standing up on the walkway between the two belts watching the discharge from the dust collector (you see, after the dust collector collected the dust, it dropped it back onto the conveyor belt just up the belt from where the coal dropped onto the belt).  Nothing was coming out of the chute.

As I adjusted the setting down from one minute to one second, I had to keep changing settings on the oscilloscope to measure how long the air took to turn on and off.  When I finally had the pulse down within 1/10 of a second (which is 100 milliseconds), then I could easily measure the 32 millisecond interval that we needed.  I was beginning to think that this wasn’t going to really do anything, but I remembered that I had seen stranger things on the precipitator controls where the difference between a couple of milliseconds is like night and day.

When the pulse was down to 35 milliseconds I looked up toward the conveyor system because I heard a couple of people yelling.  They were running down the walkway as coal dust came pouring out of the dust collector chute causing a big cloud of dust to puff up.  We all ran outside and waited for the dust to settle.  We felt like cheering!

We were practically in disbelief that all we had to do was adjust the pulse of air to the right millisecond pulse and the dust collector began working.  This meant a lot more than a working dust collector.  This also meant that we needed only a fraction of the instrument air (literally about 1/20,000) than we had been using.

In other words.  The new Instrument Air Compressors at the coal yard that had been installed to help boost air pressure at the coal yard since the installation of the dust collectors were really never needed.  And all this was done by turning a screwdriver on a small potentiometer in a control cabinet.  It pays to read the manual.

a small Power Plant potentiometer like this

a small Power Plant potentiometer like this

Along with some rewiring of the controls to the dust collector system, and a redesign of the apron around the dust chutes by Randy Dailey and Tim Crain, the coal handling areas became practically dust free as long as regular preventative maintenance was performed.

Tim Crain

Tim Crain

Randy Dailey, known as Mr. Safety to Real Power Plant Men

Randy Dailey, known as Mr. Safety to Real Power Plant Men

That is, everywhere except for the coal dumper.  This is where the coal trains dump their coal into a hopper which is then carried on three conveyors out to the coal pile.

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

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

You can see the conveyor going up to the building right next to the coal pile.  That is from the dumper which is the small off white building next to the fly ash silos.  The crusher tower is the tall thin building at the end of the long belts going up to the plant.

We still had a problem with the dumper.  The cost of buying new dust collectors and putting them outside where they wouldn’t be so quickly corroded by the harsh environment was “too costly”.  Jim Arnold, the maintenance Supervisor made that clear.  We had to come up with another solution.

Without a dust collector, the solution was “Dust Suppression”.  That is, instead of collecting the dust when it is stirred up, spray the coal with a chemical that keeps the dust down in the first place.  This was a good idea, except that it had to be turned off for three months during the winter months when it could freeze up.

A company called Arch Environmental Equipment came and talked to us about their dust suppression system.

Arch Environmental

Arch Environmental

They showed us something called:  The “Dust Shark”.

Dust Shark by Arch Environmental

Dust Shark by Arch Environmental

The dust shark sprayed the belt on the side with the coal and scraped the bottom side in order to make sure it was clean when it passed through.  This was the solution for the dumper.  It also worked well at other locations in the plant where you could use it to keep the area clean from coal when the coal was wet from the rain and would stick to the belt.

The task force was considered a success.  I have two side stories before I finish with this post.

The first is about Danny Cain.

Danny was a heavy smoker.  He had a young look so that he looked somewhat younger than he was. He had been born in July, 1964 (just ask the birthday phantom), so he was 33 during July 1997 when we were working on the task force, but he looked like someone still in college.  Whenever he would pull out a cigarette and put it in his mouth, he suddenly looked like he was still in High School.

I told Danny that one day.  I was always one to discourage people from smoking….  He seemed a little hurt, and I said I was just calling it like I saw it.  He was standing outside the electric shop smoking one day, so I took the air monitor that I used when I had to go in the precipitator and asked Danny if I could borrow his lit cigarette for a moment.

Confined Space Air Monitor

Confined Space Air Monitor

I put the butt of the cigarette up to the intake hose for the monitor about long enough for a puff and then I handed it back to him.  The monitor measures the amount of Oxygen in the air, the amount of explosive gases, the amount of Carbon Monoxide and the amount of H2S gas (Hydrogen Sulfide, an extremely toxic gas).  The monitor, as expected began beeping…

What we didn’t expect to see was that not only did the Carbon Monoxide peg out at 999 parts per million, but the H2S went out the roof as well.  In fact, everything was bad. The Percent explosive was at least 50% and the oxygen level was low.  It took about 5 minutes before the meter measured everything clean again.  Danny didn’t want to see that.

I said, “Danny?  Carbon Monoxide Poisoning!  Hello???!!!”

When we were on the Dust Collector Task Force, at one point we had to program “Programmable Logic Controllers” (or PLCs).  I had been to an Allen Bradley school a few years earlier where we had learned the basics for this.  Here is my certificate from 9 years earlier…

PLC Training Certificate

PLC Training Certificate

When Danny and I sat down to program the controller, it became clear that he expected the programming task to take a couple of weeks.  He started out by drawing some high level logic on the white board.  I said… “wait… wait…  let’s just start programming the thing.”  He told me that wasn’t the way we did things.  First we had to figure out the entire program, then we would program it.

The PLCs we were going to program were just some small ones we had bought to run the dust sharks and the dust collectors… Here’s one like it.

MicroLogix PLC like we were programming

MicroLogix PLC like we were programming

I told Danny when I program something I find that its a lot easier and quicker if we just program it as we understand the requirements and then that way we can test it as we go.  Then when we figure out what we need, we will be done.  In fact… it took us 4 hours and we were done… not two weeks.

End of the Danny Cain Side Story…. On to the second side story… much shorter….

I think it was March 2003 (the power plant men can remind me)…. a year and a half after I had left the plant, the Coal Dumper blew up.  It was the middle of the night, a coal train had finished dumping the coal about an hour earlier.  No one was in the dumper at the time and the entire dumper exploded.    The roof of the dumper, as I was told, was blown off of the building.  No injuries or deaths.  The “Dust Shark” Dust Suppression system had been turned off because it was winter.

I suppose that the insurance company ended up paying for that one.  I don’t know.  This is what happens when you say that it is too expensive to replace the dust collectors and instead you buy one of these:

Power Plant Feather Duster

Power Plant Feather Duster